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Engine Design

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Type 1 Engines and 9RM Engines


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Illustration 1 Cylinder and valve location for Type 1 engines and 9RM engines (A) Exhaust valves (B) Inlet valves

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Note: Type 1 engines can be identified in two ways. The first method refers to Illustration 1. When the valve cover is removed, look at the cylinder head valves. Type 1 engines have two exhaust valves in a row and two inlet valves that are in a row. The second method does not require the removal of the valve cover. Refer to the inlet manifold and the exhaust manifold. Type 1 engines have two exhaust ports in a row and two inlet ports that are in a row. Type ... Four cylinder and four stroke Combustion system ... Direct injection Nominal Bore ... 100 mm (3.937 inch) Stroke ... 127 mm (5.00 inch)

Capacity ... 4 liters (243 in3) Compression Ratio ... 16:1 Number of cylinders ... 4 Arrangement of cylinders ... in-line Firing Order ... 1, 3, 4, 2 Valve Lash Inlet valve ... 0.20 mm (.008 inch) Exhaust valve ... 0.45 mm (.018 inch) When the crankshaft is viewed from the front of the engine the crankshaft rotates in the following direction: ... Clockwise When the camshaft is viewed from the front of the engine the camshaft rotates in the following direction: ... Clockwise Note: The front end of the engine is opposite the flywheel end. The left side and the right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder.

Type 2 Engines and 7BJ Engines


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Illustration 2

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Cylinder and valve location for Type 2 engines and 7BJ engines (A) Exhaust valves (B) Inlet valves

Note: Type 2 engines can be identified in two ways. The first method refers to Illustration 2. When the valve cover is removed, look at the cylinder head valves. Type 2 engines alternate the exhaust valves and the inlet valves. Note: Some of the Type 2 7BJ engines may look like the Type 1 engines. When the valve cover is removed, these engines may have two exhaust valves in a row and two inlet valves in a row. This is only a small percentage of the Type 2 7BJ engines. The second method does not require the removal of the valve cover. Refer to the inlet manifold and the exhaust manifold. Type 2 engines alternate the exhaust ports and the inlet ports. Type ... Four cylinder and four stroke Combustion system ... Direct injection Nominal Bore ... 100 mm (3.937 inch) Stroke ... 127 mm (5.00 inch) Capacity ... 4 liters (243 in3) Compression Ratio ... 17.25:1 Number of cylinders ... 4 Arrangement of cylinders ... in-line Firing Order ... 1, 3, 4, 2 Valve Lash Inlet valve ... 0.20 mm (.008 inch) Exhaust valve ... 0.45 mm (.018 inch) When the crankshaft is viewed from the front of the engine the crankshaft rotates in the following direction: ... Clockwise When the camshaft is viewed from the front of the engine the camshaft rotates in the following direction: ... Clockwise Note: The front end of the engine is opposite the flywheel end. The left side and the right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder.
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Fuel Injection Pump


SMCS - 1251; 1290

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Various Fuel Injection Pumps may be equipped to the engine. Bosch, Delphi, or Stanadyne fuel injection pumps may be equipped to the engine.

Bosch Fuel Injection Pump (EPVE)


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Illustration 1

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Note: Parts that are inside of the fuel injection pump are only serviceable by an authorized Bosch dealer. Please consult your parts book for availability of parts on the

outside of the pump that are not related to the settings of the fuel pump and for the possibility of remanufacturing options. Hub nut (not shown) Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is positioned to the pump shaft in order to ensure that the fuel pump is in the correct position for timing. If the hub is removed, the hub will need to be accurately positioned to the pump shaft. Accurate positioning requires the use of special equipment by a Caterpillar Dealer. (1) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in) (2) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to 6 Nm (44 to 53 lb in) (3) Tighten the fitting for the fuel supply connection to the following torque. ... 22 Nm (16 lb ft) (4) Boost control (if equipped) (5) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in) (6) Tighten the nuts for the high pressure fuel line connection to the following torque. ... 22 Nm (16 lb ft) (7) Tighten the flange nuts to the following torque. ... 22 Nm (16 lb ft) (8) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to 81.4 Nm (52 to 60 lb ft)

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Illustration 2

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(9) Locking spacer (If equipped) Note: The drive shaft of the fuel injection pump must not be turned without the spacer in position under the locking screw (10) . (10) Tighten the locking screw to the following torque. ... 27 Nm (20 lb ft) (11) Tighten the nut for the drive gear to the following torque. ... 80 Nm (59 lb ft)

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Illustration 3

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Note: Before the crankshaft is turned or the fuel injection pump is installed, move the locking spacer (9) under the locking screw (10). Refer to position (A) that is in Illustration 3. This position ensures that the pump drive shaft is released.
Timing Information for the Bosch Fuel Injection Pump Table 1 Early Bosch Fuel Injection Pump Without Locking Screw Code Letters on Fuel Injection Pump Static Timing Position Before TC Position (degrees)

Engine Check Angle (degrees) (1)

Fuel Injection Pump Mark Angle (degrees) (1)

Piston Displacement (1)

"BK"

308

314

12

1.78 mm (0.070 inch)

"CK"

308

314

12

1.78 mm (0.070 inch)

"DK"

306

313

14

2.42 mm (0.095 inch)

"EK"

308.5

315.5

14

2.42 mm (0.095 inch)

"EK" (2)

306.5

315.5

18

3.99 mm (0.157 inch)

"EM"

288.5

295.5

14

2.42 mm (0.095 inch)

"FM"

289

295

12.5

1.93 mm (0.076 inch) -

"JM" "JM" (3) "JM" (4) "KC" (5) "KL" (5) "ML" (5) "PM" "SK" "TL" (5) VM

6 2 TDC TDC TDC TDC 12 9 TDC 2 ATDC

(1)

The engine must be set at the TC position on the compression stroke for the number 1 piston. The fuel injection pump mark angle and the displacement of the piston can be checked when the plunger for the fuel injection pump is set at 1.00 mm (0.039 inch). The information plate on the fuel injection pump is stamped "J609". "AD70229" and "AD702230" only "AD80643" only The cold start advance (KSB) must be energized before the timing is set.

(2)

(3)

(4)

(5)

Note: Later Bosch Fuel Injection Pumps use a pin to time the pump.

Stanadyne Fuel Injection Pump (DB2 or DB4)


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Illustration 4

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Note: Parts that are inside of the fuel injection pump are only serviceable by an authorized Stanadyne dealer. Please consult your parts book for availability of parts on the outside of the pump that are not related to the settings of the fuel pump and for the possibility of remanufacturing options. Hub nut (not shown) Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is positioned to the pump shaft in order to ensure that the fuel pump is in the correct position for timing. If the hub is removed, the hub will need to be accurately positioned to the pump shaft. Accurate positioning requires the use of special equipment by a Caterpillar Dealer. (1) Electrical connection for the stop solenoid (2) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to 6 Nm (44 to 53 lb in) (3) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in) (4) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in) (5) Tighten the flange nuts to the following torque. ... 22 Nm (16 lb ft) (6) Adjustment screw for advance timing (7) Tighten the fittings for the fuel discharge to the following torque. ... 70.5 to 81.4 Nm (52 to 60 lb ft) (8) Tighten the nuts for the high pressure fuel injection line to the following torque. ... 22 Nm (16 lb ft) (9) Tighten the nut for the end cap to the following torque. ... 22 Nm (16 lb ft)

NOTICE
The No. 1 cylinder must be at the top center position on the compression stroke before the fuel injection pump is installed. If the crankshaft needs to be rotated, the fuel injection pump must be mounted temporarily or the loose gear could cause damage to the front housing.

Timing Information for the Stanadyne Fuel Injection Pump Table 2 Stanadyne Fuel Injection Pump Code Letters on Fuel Injection Pump "AC" "AL" "BL" "CL" "CL" (1) "DL" "FL" "GL" "HC" "JL" "KM" "LM" "LM" (2) "MM" "MM" (3) Engine Check Angle (degrees) 282 326 326 327 332 326 326 282 325 282 282 288.5 282 288.5 Fuel Injection Pump Mark Angle (degrees) 291 336 336 333 247.5 338 333 332 290.5 334.5 290 287 295 287 295

"NC" "SL" "SM" "TC" "TM" "UC" "VL" "XK" "YK" "YL" "ZK" "ZM" (4) "ZM" (5)
(1)

282 331.5 282 282 282 228.5 326 325 325 330 326 282 282

294 338 291 290 290.5 296 389 331.5 334.5 338 334 287 289

The fuel injection pump is timed with a pin. The fuel injection pump is coded "2643U211" or "2643U213". The fuel injection pump is coded "2643U214". The values are for the fuel injection pumps with a serial number up to "7665964". The values are for the fuel injection pump with a serial number that includes "7665965". The values are also for the fuel injection pumps with serial numbers that are higher than "7665965".

(2)

(3)

(4)

(5)

Delphi Fuel Injection Pump (DPA or DPS)

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Illustration 5

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Note: Parts that are inside of the fuel injection pump are only serviceable by an authorized Delphi dealer. Please consult your parts book for availability of parts on the outside of the pump that are not related to the settings of the fuel pump and for the possibility of remanufacturing options. (1) Hub nut Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is positioned to the pump shaft in order to ensure that the fuel pump is in the correct position for timing. If the hub is removed, the hub will need to be accurately positioned to the pump shaft. Accurate positioning requires the use of special equipment by a Caterpillar Dealer. (2) O-ring (3) Locking spacer

The drive shaft of the fuel injection pump must not be turned without the spacer in position under the locking screw (4) . (4) Tighten the locking screw to the following torque. ... 10 Nm (7 lb ft) The locking screw prevents the rotation of the drive shaft.

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Illustration 6

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Before the crankshaft is turned or the fuel injection pump is installed, move the locking spacer (3) under the locking screw (4). Refer to position (A) that is in Illustration 6. This position ensures that the pump drive shaft is released. (5) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to 6 Nm (44 to 53 lb in) (6) Tighten the adjustment screw for low idle to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in) (7) Tighten the adjustment screw for high idle to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in) (8) Electrical connection for the stop solenoid (9) Tighten the fitting for the fuel supply connection to the following torque. ... 22 Nm (16 lb ft)

(10) Tighten the nuts for the fuel line to the following torque. ... 22 Nm (16 lb ft) (11) Tighten the flange nuts to the following torque. ... 22 Nm (16 lb ft) (12) Electrical connection for cold starting aid (13) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to 81.4 Nm (52 to 60 lb ft)
Timing Information for the Delphi Fuel Injection Pump Table 3 Delphi Fuel Injection Pump Code that is on the Fuel Injection Pump "AK" "AM" "BF" "BM" "CM" "DM" "FK" "GK" "GM" "HK" "HM" "JK" Engine Check Angle (degrees) 325.5 282 326 281 282.5 282.25 325.5 325 282 326 282 325 Fuel Injection Pump Mark Angle (degrees) 336 290.5 334 291 291.5 290.5 336 336 290.5 336 291 334

"KK" "LK" "LK" (1) "MK" "MK" (2) "PK" "RK" "RM" "TK" "UK" "XM"
(1)

325 327 328 326 325 326 328 282.5 327 326 282

334 337.5 337.5 336 336 334 336 290.5 334 334 291

"YA31257" only "YA50532" only

(2)

Table 4 Dephi Fuel Injection Pump With Locking Screw Code Letters on Fuel Injection Pump "BC" "CC" "DC" Locking Angle (degrees) 336.5 338.5 337.5

"EC" "FC" "GC" "PC" "RC" "SC" "XL"

337.5 335.5 337 339 339 341 22

Note: Later Delphi Fuel Injection Pumps are timed with a pin.
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Fuel Injection Nozzles


SMCS - 1254
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Type 1 Engines and 9RM Engines


Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information.
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Illustration 1 Fuel injection nozzle (1) Connection for the union nut of the fuel supply line (2) Threaded hole for the banjo bolt of the leak off line (3) Clamp (4) Seal (5) Spacer (6) Fuel injector assembly (7) Seat washer

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(1) Tighten the union nut of the high pressure fuel line (not shown) to the following torque: ... 18 Nm (13.3 lb ft) (2) Tighten the banjo bolts of the leak off tubing (not shown) to the following torque: ... 9.5 Nm (84 lb in) (3) Tighten the flange bolts (not shown) for the clamp to the following torque: ... 12 Nm (9 lb ft) Note: Remove the original seat washer from the threaded hole for the fuel injection nozzle which is located in the cylinder head. If the original seat washer is not removed, the projection of the nozzle will be incorrect when a new seat washer is installed. Do not reuse the seal (4) and the seat washer (7) . Bench test the fuel injection nozzles at a temperature of 18 to 20 C (64 to 70 F).

Note: Use clean SAE J-967 oil (ISO 4113) when you are conducting the test. The oil is available in 5 gallon containers ( 6V-6068 Calibration Fluid ) and 55 gallon containers ( 6V-6067 Calibration Fluid ). If dirty oil is used for the test, the components of the fuel injection nozzle will be damaged. Refer to Testing And Adjusting, "Pressure Adjustment, Back Leakage Test, Nozzle and Seat Test". Table 1 Pressure Settings for the Fuel Injection Nozzles for the Type 1 Engines and 9RM Engines Code (1) "HU" 22291 kPa (3233 psi) "HV" 25331 kPa (3674 psi) "HZ" 22291 kPa (3233 psi) "JA" 25331 kPa (3674 psi) "JB" 25331 kPa (3674 psi) "JE" 22291 kPa (3233 psi) "JF" 25331 kPa (3674 psi) "JG" 23304 kPa (3380 psi) "JH" 25331 kPa (3674 psi) "JJ" 25331 kPa (3674 psi) "JK" 22291 kPa (3233 psi) "JL" 25331 kPa (3674 psi) "JR" 25331 kPa (3674 psi) Pressure Setting

"JS" 25331 kPa (3674 psi) "JT" 25331 kPa (3674 psi) "JU" 22291 kPa (3233 psi) "JY" 25331 kPa (3674 psi) "NJ" 22291 kPa (3233 psi) "NK" 22801 kPa (3307 psi) "NL" 22801 kPa (3307 psi) "NM" 23304 kPa (3380 psi) "NN" 23304 kPa (3380 psi) "NP" 22291 kPa (3233 psi) "NR" 23304 kPa (3380 psi) "NS" 25331 kPa (3674 psi) "NT" 23304 kPa (3380 psi) "NU" 22291 kPa (3233 psi) "NV" 22291 kPa (3233 psi) "NW" 22291 kPa (3233 psi) "RD" "RE" 25028 kPa (3630 psi) 25028 kPa (3630 psi)

"RF" "RH" "RK" "RM" "RN" "RP" "RR" "RS" "RT" "RU" "RV"
(1)

25028 kPa (3630 psi) 25028 kPa (3630 psi) 26903 kPa (3902 psi) 25028 kPa (3630 psi) 25028 kPa (3630 psi) 25028 kPa (3630 psi) 25028 kPa (3630 psi) 25028 kPa (3630 psi) 25028 kPa (3630 psi) 25028 kPa (3630 psi) 25028 kPa (3630 psi)

The code letters are stamped on the side of the fuel injector body. The code letters are located below the connection for the nut of the high pressure fuel line.

Note: Ensure that the new fuel injection nozzles have the same identification code as the nozzles which were originally installed in the cylinder head. Leakage in 10 seconds ... 0 drops

Type 2 Engines and 7BJ Engines


Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information.
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Illustration 2 Fuel injection nozzle (1) Connection for the union nut of the fuel supply line (2) Threaded hole for the banjo bolt of the leak off line (3) Nut of the fuel injection nozzle (4) Wire clip (5) Seat washer

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(1) Tighten the union nut of the high pressure fuel line (not shown) to the following torque: ... 22 Nm (16 lb ft)

(2) Tighten the banjo bolts of the leak off tubing (not shown) to the following torque: ... 9.5 Nm (84 lb in) (3) Tighten the nut of the fuel injection nozzle to the following torque: ... 30 Nm (22 lb ft) Note: When the fuel injection nozzle is installed, put a 2.0 mm (.08 inch) bead of 4C5591 Anti-Seize Compound on the first two threads of the gland nut. Do not rotate the fuel injection nozzle after installation. The seal which is made by the anti-seize compound may break. A broken seal may allow leakage past the seat of the fuel injection nozzle. (4) Wire clip (5) Seat washer Note: Remove the original seat washer from the threaded hole for the fuel injection nozzle which is located in the cylinder head. If the original seat washer is not removed, the projection of the nozzle will be incorrect when a new seat washer is installed. Do not reuse the seat washer (5) . Bench test the fuel injection nozzles at a temperature of 18 to 20 C (64 to 70 F). Note: Use clean SAE J-967 oil (ISO 4113) when you are conducting the test. The oil is available in 5 gallon containers ( 6V-6068 Calibration Fluid ) and 55 gallon containers ( 6V-6067 Calibration Fluid ). If dirty oil is used for the test, the components of the fuel injection nozzle will be damaged. Refer to Testing And Adjusting, "Pressure Adjustment, Back Leakage Test, Nozzle and Seat Test". Table 2 Pressure Settings for the Fuel Injection Nozzles for the Type 2 Engines and 7BJ Engines Code (1) "KB" 30406 kPa (4410 psi) "KC" 28979 kPa (4203 psi) "KD" 29385 kPa (4262 psi) "KE" 29385 kPa (4262 psi) "KF" Pressure Setting

29385 kPa (4262 psi) "KG" 29385 kPa (4262 psi) "KH" 29392 kPa (4263 psi) "KJ" 25338 kPa (3675 psi) "KK" 30406 kPa (4410 psi) "KL" 30406 kPa (4410 psi) "KM" 30406 kPa (4410 psi) "KN" 29385 kPa (4262 psi) "KP" 29385 kPa (4262 psi) "KR" 29392 kPa (4263 psi) "KT" 29392 kPa (4263 psi) "KS" 29392 kPa (4263 psi) "KU" 29385 kPa (4262 psi) "KV" 25338 kPa (3675 psi) "KW" "NX" 29385 kPa (4262 psi) "NY" 29392 kPa (4263 psi) "NZ" 29392 kPa (4263 psi) "PA" 29385 kPa (4262 psi)

29392 kPa (4263 psi) "PB" 29392 kPa (4263 psi) "PC" "PD" "PE" "RZ" 25338 kPa (3675 psi) "SA" 25338 kPa (3675 psi) "SB" 25338 kPa (3675 psi) "SC" 25338 kPa (3675 psi)
(1)

29385 kPa (4262 psi) 27862 kPa (4041 psi) 28372 kPa (4115 psi)

The code letters are stamped on the side of the fuel injector body. The code letters are located below the connection for the nut of the high pressure fuel line.

Note: Ensure that the new fuel injection nozzles have the same identification code as the nozzles which were originally installed in the cylinder head. Leakage in 10 seconds ... 0 drops
1 1 0

Fuel Transfer Pump


SMCS - 1256
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Illustration 1 Typical example of the fuel transfer pump

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Method of drive ... Camshaft Output pressure during the first ten seconds of cranking: Normal pressure ... 42 to 70 kPa (6 to 10 psi) Minimum pressure ... 30 kPa (4.4 psi) The engine may be equipped with four mounting bolts or four mounting studs with nuts. Tighten to the following torque: ... 22 Nm (16 lb ft) Apply 4C-4030 Thread Lock Compound to the first three threads of the mounting bolts or the mounting studs. Refer to the Systems Operation, Testing and Adjusting Module, "Fuel System Pressure Test" topic in order to test the operation of the fuel transfer pump. Note: When the fuel transfer pump is installed on the engine, ensure that the camshaft is on minimum lobe lift and that the bolts are evenly tightened. Failure to follow this procedure can cause the following conditions: loss of maximum engine power and damage to the fuel transfer pump.
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Rocker Shaft
SMCS - 1102
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Illustration 1

g00876530

(1) Rocker arm Diameter of the rocker arm bore for the bushing ... 22.23 to 22.26 mm (0.8750 to 0.8762 inch) (2) Rocker arm bushing Outside diameter of the rocker arm bushing ... 22.28 to 22.31 mm (0.8770 to 0.8785 inch) Inside diameter of the rocker arm bushing ... 19.06 to 19.10 mm (0.7505 to 0.7520 inch) Clearance between the rocker arm bushing and the rocker shaft ... 0.03 to 0.09 mm (0.001 to 0.0035 inch) Maximum permissible clearance between the rocker arm bushing and the rocker shaft ... 0.13 mm (0.005 inch) (3) Tighten the bolts evenly. Begin in the center and work toward the outside. Tighten the bolts to the following torque. Cast iron or steel rocker shaft brackets ... 88 Nm (65 lb ft) Aluminum rocker shaft brackets ... 40 Nm (30 lb ft)

(4) Diameter of the rocker shaft ... 19.01 to 19.04 mm (0.7485 to 0.7495 inch) (5) Tighten the bolt to the following torque. ... 4 Nm (35 lb in)
1 0 1

Valve Mechanism Cover


SMCS - 1107
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Illustration 1

g00529181

(1) Tighten the nut to the following torque. Composite cover ... 20 Nm (15 lb ft) Aluminum cover ... 30 Nm (22 lb ft)
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Cylinder Head Valves


SMCS - 1105
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Type 1 Engines and 9RM Engines


Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information.
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Illustration 1 Inlet valves and exhaust valves

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Double valve springs: (1) Outer spring Length under test force ... 35.8 mm (1.41 inch) Test force ... 176 to 195 N (40 to 44 lb) (2) Inner spring Length under test force ... 34.0 mm (1.34 inch) Test force ... 89 to 104 N (20 to 23 lb)

Single valve springs (not shown) Length under test force ... 40.0 mm (1.57 inch) Test force ... 310 to 344 N (70 to 77 lb) Free length after test ... 53.4 mm (2.10 inch) (3) Valve spring recess for the valve spring (4) Valve guides for the inlet and exhaust valves Inside diameter ... 9.51 to 9.56 mm (0.374 to 0.376 inch) Outside diameter ... 15.900 to 15.910 mm (0.6260 to 0.6265 inch) Bore diameter in cylinder head for valve guide ... 15.87 to 15.89 mm (0.625 to 0.626 inch) Interference fit of valve guide in cylinder head ... 0.03 to 0.07 mm (0.001 to 0.003 inch) Overall length of valve guide Inlet ... 57.94 mm (2.281 inch) Exhaust ... 61.1 mm (2.406 inch) Projection of valve guide above valve spring recess (3) ... 15.1 mm (0.595 inch) Note: When new valve guides are installed, new valves and new valve seat inserts must be installed. The valve guides and the valve seat inserts are supplied as partially finished parts. The unfinished valve guides and unfinished valve seat inserts are installed in the cylinder head. Then, the guides and inserts are cut and reamed in one operation with special tooling. This procedure ensures the concentricity of the valve seat to the valve guide in order to create a seal that is tight. Refer to the Disassembly and Assembly Manual for removal and installation procedures. (5) Diameter of the exhaust valve stem ... 9.43 to 9.46 mm (0.371 to 0.372 inch) Clearance of valve in valve guide ... 0.05 to 0.13 mm (0.002 to 0.005 inch) Maximum permissible clearance of valve in valve guide ... 0.15 mm (0.006 inch) Overall length of the exhaust valve ... 123.07 to 123.57 mm (4.845 to 4.865 inch) (6) Diameter of the inlet valve stem ... 9.460 to 9.490 mm (0.3724 to 0.3735 inch) Clearance of valve in the valve guide ... 0.02 to 0.10 mm (0.001 to 0.004 inch) Maximum permissible clearance of valve in valve guide ... 0.13 mm (0.005 inch) Overall length of the inlet valve ... 122.66 to 123.07 mm (4.829 to 4.845 inch) (7) Exhaust valve face angle ... 45 degrees Valve seat angle ... 46 degrees (8) Diameter of the exhaust valve ... 37.26 to 37.52 mm (1.467 to 1.477 inch)

Valve depth below the cylinder head face Minimum ... 1.28 mm (0.050 inch) Maximum ... 1.83 mm (0.072 inch) Service wear limit ... 2.08 mm (0.082 inch) (9) Diameter of the inlet valve ... 44.86 to 45.11 mm (1.766 to 1.776 inch) Valve depth below the cylinder head face Minimum ... 1.27 mm (0.050 inch) Maximum ... 1.60 mm (0.063 inch) Service wear limit ... 1.85 mm (0.073 inch) (10) Inlet valve face angle ... 45 degrees Valve seat angle ... 46 degrees Note: Some engines may have valve face angles of 30 degrees and valve seat angles of 31 degrees. The valve lash is the following value when the engine is hot or cold: Inlet valves ... 0.20 mm (0.008 inch) Exhaust valves ... 0.45 mm (0.018 inch)
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Illustration 2

g00295327

Recess for a valve insert

(11) Machine the recess in the head for valve seat inserts to the following dimensions: Inlet (A) ... 7.19 to 7.32 mm (0.283 to 0.288 inch) (B) ... 51.220 to 51.240 mm (2.0167 to 2.0175 inch) (C) Maximum radius ... 0.38 mm (0.015 inch) Exhaust (A) ... 9.52 to 9.65 mm (0.375 to 0.380 inch) (B) ... 42.620 to 42.650 mm (1.6779 to 1.6790 inch) (C) Maximum radius ... 0.38 mm (0.015 inch) Note: When a new valve seat insert is installed, a new valve and valve guide must be installed. Refer to the Disassembly and Assembly for removal and installation procedures.
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Illustration 3 Angles and dimensions of the valve seat insert

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(12) Valve seat insert (D) Included angle of the faces (E) Dimension of chamfer (F) Vertical angle of chamfer

(12) Valve seat insert (D) Included angle of the faces of the valve seat insert Engines with 46 degree valve seats ... 88 degrees Engines with 31 degree valve seats ... 118 degrees (E) Dimension of chamfer for all engines ... 1.10 0.20 mm (0.043 0.008 inch) (F) Angle of chamfer from the vertical for all engines ... 30 degrees

Type 2 Engines and 7BJ Engines


Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information.
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Illustration 4 Inlet valves and exhaust valves

g00294082

(1) Single valve springs Length under test force ... 39.0 mm (1.54 inch) Test force ... 246 to 277 N (55 to 62 lb) (2) Valve spring insert for the valve spring (3) Valve guides Inside diameter of finished valve guide ... 9.00 to 9.02 mm (0.354 to 0.355 inch) Outside diameter of inlet valve ... 13.03 to 13.05 mm (0.513 to 0.514 inch) Outside diameter of exhaust valve ... 14.03 to 14.05 mm (0.552 to 0.553 inch) Bore diameter in the cylinder head for the inlet valve guide ... 13.00 to 13.03 mm (0.512 to 0.513 inch) Bore diameter in the cylinder head for the exhaust valve guide ... 14.000 to 14.027 mm (0.5512 to 0.5522 inch) Interference fit of valve guide in the cylinder head ... 0.007 to 0.047 mm (0.0003 to 0.0019 inch) Overall length of inlet and exhaust valve guides ... 51.25 mm (2.012 inch) Projection of valve guide above the valve spring recess (2) ... 14.85 to 15.15 mm (0.585 to 0.596 inch) Note: When new valve guides are installed, new valves and new valve seat inserts must be installed. The valve guides and the valve seat inserts are supplied as partially finished parts. The unfinished valve guides and unfinished valve seat inserts are installed in the cylinder head. Then, the guides and inserts are cut and reamed in one operation with special tooling. This procedure ensures the concentricity of the valve seat to the valve guide in order to create a seal that is tight. Refer to the Disassembly and Assembly Manual for removal and installation procedures. (4) Diameter of the exhaust valve stem ... 8.94 to 8.96 mm (0.352 to 0.353 inch) Clearance of valve in valve guide ... 0.040 to 0.084 mm (0.0026 to 0.0033 inch) Maximum permissible clearance of valve in valve guide ... 0.104 mm (0.0041 inch) Overall length of the exhaust valve ... 122.65 to 123.30 mm (4.829 to 4.854 inch) (5) Diameter of the inlet valve stem ... 8.953 to 8.975 mm (0.3525 to 0.3533 inch) Clearance of valve in the valve guide ... 0.025 to 0.069 mm (0.001 to 0.003 inch) Maximum permissible clearance of valve in valve guide ... 0.089 mm (0.0035 inch) Overall length of the inlet valve ... 122.65 to 123.30 mm (4.829 to 4.854 inch)

(6) Exhaust valve face angle ... 45 degrees Valve seat angle ... 46 degrees Note: Some engines may have valve face angles of 30 degrees and valve seat angles of 31 degrees. (7) Exhaust valve head diameter ... 40.88 to 41.12 mm (1.609 to 1.619 inch) Valve depth below the cylinder head face Minimum ... 1.50 mm (0.059 inch) Maximum ... 1.80 mm (0.071 inch) Service wear limit ... 2.05 mm (0.081 inch) (8) Diameter of the inlet valve ... 42.88 to 43.12 mm (1.688 to 1.698 inch) Valve depth below the cylinder head face Minimum ... 1.40 mm (0.055 inch) Maximum ... 1.70 mm (0.067 inch) Service wear limit ... 1.95 mm (0.077 inch) (9) Inlet valve face angle ... 45 degrees Valve seat angle ... 46 degrees Note: Some engines may have valve face angles of 30 degrees and valve seat angles of 31 degrees. The valve lash is the following value when the engine is hot or cold: Inlet valves ... 0.20 mm (0.008 inch) Exhaust valves ... 0.45 mm (0.018 inch)
Ver imagen

Illustration 5 Recess for a valve insert

g00295327

(11) Machine the recess in the head for valve seat inserts to the following dimensions. Inlet (A) ... 10.585 to 10.715 mm (0.4167 to 0.4219 inch) (B) ... 45.535 to 45.560 mm (1.7927 to 1.7937 inch) (C) Maximum radius ... 0.38 mm (0.015 inch) Exhaust (A) ... 10.585 to 10.715 mm (0.4167 to 0.4219 inch) (B) ... 43.535 to 43.560 mm (1.7140 to 1.7150 inch) (C) Maximum radius ... 0.38 mm (0.015 inch) Note: When a new valve seat insert is installed, a new valve and valve guide must be installed. Refer to Disassembly and Assembly for removal and installation procedures.
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Illustration 6 Angles and dimensions of the valve seat insert (12) Valve seat insert (D) Included angle of the faces (E) Dimension of chamfer (F) Vertical angle of chamfer

g00517019

(12) Valve seat insert (D) Included angle of the faces of the valve seat insert Engines with 46 degree valve seats ... 88 degrees Engines with 31 degree valve seats ... 118 degrees (E) Dimension of chamfer for all engines ... 1.10 0.20 mm (0.043 0.008 inch) (F) Angle of chamfer from the vertical for all engines ... 30 degrees
1 0 1

Cylinder Head

SMCS - 1100
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Type 1 Engines and 9RM Engines


Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information.
Ver imagen

Illustration 1 Bolt tightening sequence for the cylinder head

g00295370

Use the following procedure in order to tighten the cylinder head bolts: 1. Put engine oil on the threads of the bolts and the nuts. Tighten bolts (1) through bolts (22) in a numerical sequence in Illustration 1. Torque for the bolts ... 110 Nm (81 lb ft) 2. Tighten bolts (1) through bolts (22) again in a numerical sequence. Torque for bolts ... 110 Nm (81 lb ft) 3. Rotate bolts (1) through bolts (22) in a numerical sequence to the following values: a. Tighten the bolts of short length "S" to the following value. Rotate the bolts in a clockwise direction: ... 150 degrees

b. Tighten the bolts of medium length "M" to the following value. Rotate the bolts in a clockwise direction: ... 180 degrees c. Tighten the bolts of long length "L" to the following value. Rotate the bolts in a clockwise direction: ... 210 degrees
Ver imagen

Illustration 2 Bolts, nuts, and components of the cylinder head

g00295371

(1) Tighten the nuts that hold fuel injectors to the following torque: ... 12 Nm (10 lb ft) Note: When the fuel injection nozzle is removed, the following items must be replaced: dust seal and seat washer. (2) Tighten the nuts for fuel line to the following torque: ... 18 Nm (13 lb ft) (3) Tighten the bolts that hold the rocker shaft to the cylinder head to the following torque: Begin tightening the inner bolts. Then tighten the bolts by working toward the end of the shaft. Cast iron or steel bracket ... 75 Nm (55 lb ft) Aluminum bracket ... 40 Nm (30 lb ft) (4) Valve lash

Inlet ... 0.20 mm (.008 inch) Exhaust ... 0.45 mm (.018 inch) (5) Maximum permissible nozzle projection below cylinder head face after resurfacing ... 4.45 mm (.175 inch) Maximum allowance for resurfacing ... 0.30 mm (.012 inch) (6) Depth of new cylinder head ... 102.79 to 103.59 mm (4.047 to 4.078 inch) Minimum depth of cylinder head after resurfacing ... 102.48 mm (4.035 inch)
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Illustration 3 Positions for measuring the bow of the cylinder head (typical example)

g00295372

Maximum permissible amount of bow (curve of cylinder head) Naturally aspirated engines A ... 0.08 mm (.003 inch) B ... 0.15 mm (.006 inch) C ... 0.15 mm (.006 inch) Turbocharged engines A ... 0.13 mm (.005 inch) B ... 0.25 mm (.010 inch) C ... 0.25 mm (.010 inch) Tighten the bolts of the inlet manifold (not shown) to the following torque: ... 44 Nm (32 lb ft)

Tighten exhaust manifold nuts (not shown) to the following torque: Plated ... 44 Nm (32 lb ft) Plain ... 50 Nm (37 lb ft)

Type 2 Engines and 7BJ Engines


Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information.
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Illustration 4 Bolt tightening sequence for the cylinder head

g00295370

Use the following procedure in order to tighten the cylinder head bolts: 1. Put engine oil on the threads of bolts. Tighten bolts (1) through bolts (22) in a numerical sequence in Illustration 4. Torque for bolts ... 110 Nm (81 lb ft) 2. Tighten bolts (1) through bolts (22) again in a numerical sequence. Torque for bolts ... 110 Nm (81 lb ft) 3. Rotate bolts (1) through bolts (26) in a numerical sequence to the following values: a. Tighten the bolts of short length "S" to the following value. Rotate the bolts in a clockwise direction: ... 150 degrees

b. Tighten the bolts of medium length "M" to the following value. Rotate the bolts in a clockwise direction: ... 180 degrees c. Tighten the bolts of long length "L" to the following value. Rotate the bolts in a clockwise direction: ... 210 degrees
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Illustration 5 Bolts, nuts, and components of the cylinder head

g00295373

Note: When the fuel injection nozzle is removed, the following items must be replaced: dust seal and seat washer. (1) Tighten the bolts that hold the rocker shaft to the cylinder head to the following torques: Begin tightening the inner bolts. Then tighten the bolts by working toward the end of the shaft. Cast iron or steel bracket ... 75 Nm (55 lb ft) Aluminum bracket ... 40 Nm (30 lb ft)

(2) Valve lash Inlet ... 0.20 mm (.008 inch) Exhaust ... 0.45 mm (.018 inch) (3) Maximum permissible nozzle projection below cylinder head face after resurfacing ... 4.45 mm (.175 inch) Maximum allowance for resurfacing ... 0.30 mm (.012 inch) (4) Depth of new cylinder head ... 102.79 to 103.59 mm (4.047 to 4.078 inch) Minimum depth of cylinder head after resurfacing ... 102.48 mm (4.035 inch)
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Illustration 6 Positions for measuring the bow of the cylinder head (typical example)

g00295372

Maximum permissible amount of bow (curve of the cylinder head) A ... 0.08 mm (.003 inch) B ... 0.15 mm (.006 inch) C ... 0.15 mm (.006 inch) Tighten the bolts for the inlet manifold (not shown) to the following torque: ... 44 Nm (32 lb ft) Tighten the nuts for the exhaust manifold (not shown) to the following torque: Plated ... 44 Nm (32 lb ft)

Plain ... 50 Nm (37 lb ft)


1 1 0

Turbocharger
SMCS - 1052
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Turbocharger
Ver imagen

Illustration 1

g00295466

(1) Put oil on the threads of the nut and put oil on the seat face. Tighten the impeller nut to the following torque: ... 2 to 2.3 Nm (18 to 20 lb in) Tighten the nut again to the following value: ... 110 degrees Note: Do not bend or add stress to the shaft when the nut is tightened.

(2) Tighten the bolts, which hold the back plate, to the following torque: ... 8.5 to 10.2 Nm (75 to 90 lb in) (3) Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the compressor housing to the center section, to the following torque: ... 15.3 to 18.7 Nm (12 to 14 lb ft) (4) Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the turbine housing to the center section, to the following torque: ... 18.6 to 20.4 Nm (14 to 15 lb ft) (5) Turbine wheel assembly Minimum journal outside diameter ... 10.152 mm (.3997 inch) Ring groove diameter (minimum) ... 14.401 mm (.5670 inch) Ring groove width (maximum) ... 1.740 mm (.0685 inch) Hub outside diameter (minimum) ... 17.323 mm (.6820 inch) (6) End play for shaft Minimum permissible end play ... .03 mm (.001 inch) Maximum permissible end play ... .10 mm (.004 inch) (7) Compressor wheel Bore inside diameter (maximum) ... 6.353 mm (.2501 inch) (8) Backplate assembly Seal inside diameter (maximum) ... 12.713 mm (.5005 inch) Flatness from the backplate to the mating surface of the center housing is within the following value: ... .013 mm (.0005 inch) (9) Thrust collar Thickness (maximum) ... 18.339 mm (0.7220 inch) Bore inside diameter (maximum) ... 6.363 mm (.2505 inch) Thrust bearing groove width (maximum) ... 4.440 mm (.1748 inch) Thrust bearing groove diameter (minimum) ... 9.398 mm (.3700 inch) Piston ring groove width (maximum) ... 1.659 mm (.0653 inch) (10) Thrust bearing Thickness (minimum) ... 4.359 mm (0.1716 inch) Bore inside diameter (maximum) ... 10.922 mm (.4300 inch) (11) Radial play (side to side movement) for shaft Minimum permissible radial play (side to side movement) ... .08 mm (.003 inch)

Maximum permissible radial play (side to side movement) ... .15 mm (.0059 inch) (12) Center housing Bearing inside diameter (maximum) ... 15.806 mm (.6223 inch) Seal inside diameter (maximum) ... 17.805 mm (.7010 inch) Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the turbocharger to the manifold (not shown), to the following torque: ... 55 5 Nm (40 4 lb ft)

Air Inlet Heater


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Illustration 2 (1) Electrical connection (2) Fuel inlet (3) Ball valve (4) Valve holder (5) Wire coil (6) Ignition coil

g00298861

Voltage ... 12 volts

Current draw ... 13.5 amperes Tighten the air inlet heater to the inlet manifold to the following torque: ... 31 8 Nm (23 6 lb ft)
1 1 0

Exhaust Manifold
SMCS - 1059
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Type 1 Engines and 9RM Engines


Ver imagen

Illustration 1 The cylinder head is shown.

g00559857

Refer to Illustration 1 for the tightening sequence. Tighten the plated nuts for the exhaust manifold to the following torque. ... 44 Nm (33 lb ft) Refer to Illustration 1 for the tightening sequence. Tighten the nuts that are not plated for the exhaust manifold to the following torque. ... 50 Nm (37 lb ft)

Type 2 Engines and 7BJ Engines


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Illustration 2

g00501179

Apply 4C-9507 Retaining Compound to the stud threads. Refer to Illustration 2 for the tightening sequence. Tighten the exhaust manifold nuts or bolts gradually to the following torque. ... 44 Nm (33 lb ft)
1 0 1

Muffler
SMCS - 1062
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Ver imagen

Illustration 1

g00295475

(1) Tighten the nuts to the following torque. ... 30 7 Nm (22 5 lb ft) (2) Tighten the bolts and the nuts to the following torque. ... 55 10 Nm (41 7 lb ft

Camshaft
SMCS - 1210
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Ver imagen

Illustration 1

g00618583

End play of a new camshaft ... 0.10 to 0.41 mm (0.004 to 0.016 inch) Maximum permissible end play of a worn camshaft ... 0.53 mm (0.021 inch) (1) Locating pin (2) Camshaft thrust washer Thickness of thrust washer ... 5.49 to 5.54 mm (0.216 to 0.218 inch) Cylinder block recess depth for thrust washer ... 5.46 to 5.54 mm (0.215 to 0.218 inch) Relationship of thrust washer to cylinder block front face ... -0.05 to +0.08 mm (-0.002 to +0.003 inch) (3) Woodruff key (4) Diameter of camshaft journals Table 1 Diameters of Camshaft Journals Camshaft Journal 1 Standard Diameter Service Limit Diameter (1) 50.660 mm (1.9945 inch)

50.710 to 50.740 mm (1.9965 to 1.9975 inch) 50.460 to 50.480 mm (1.9865 to 1.9875 inch) 49.950 to 49.980 mm (1.9665 to 1.9675 inch)

50.410 mm (1.9845 inch)

3
(1)

49.900 mm (1.9645 inch)

The service limit is the maximum or the minimum dimension which is specified for a part. A part which has reached the service limit must be replaced.

Internal clearance of the journal ... 0.06 to 0.14 mm (0.002 to 0.006 inch)
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Illustration 2

g00295323

Camshaft lobe lift To determine lobe lift, use the procedure that follows: 1. Measure the height (B) of the camshaft lobe. 2. Measure the base circle (C) . 3. Subtract the base circle (C) from the height (B) of the lobe. The difference is the actual lobe lift (A) . 4. Specified camshaft lobe lift (A) Inlet ... 7.62 to 7.69 mm (0.300 to 0.303 inch) Exhaust ... 7.71 to 7.79 mm (0.304 to 0.307 inch) Minimum permissible height of lobes ... 7.37 mm (0.290 inch)
1 1 0

Engine Oil Filter Base


SMCS - 1306
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Ver imagen

Illustration 1

g00308804

(1) Engine oil filter base The bypass valve in the engine oil filter opens at the following pressure difference: ... 55 to 83 kPa (8 to 12 psi) (2) Engine oil cooler The bypass valve in the engine oil cooler opens at the following pressure: ... 172 kPa (25 psi) Tighten the threaded adapter that fastens the engine oil cooler to the engine oil filter base to the following torque: ... 37 Nm (27 lb ft)
0 1 1

Engine Oil Relief Valve


SMCS - 1315
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Ver imagen

Illustration 1

g00295480

The relief valve for the engine oil pressure should open at the following pressure setting: Engines that are not equipped with piston cooling jets ... 340 to 395 kPa (49 to 57 psi) Engines that are equipped with piston cooling jets ... 415 to 470 kPa (60 to 68 psi) Engines that are equipped with counter balancer ... 523 kPa (76 psi) (1) Spring Length under test force ... 59.8 mm (2.35 inch) Length under test force for engines that are equipped with counter balancer ... 42.7 mm (1.681 inch) Test force ... 15.9 to 23.1 N (3.6 to 5.2 lb) Test force with engines that are equipped with counter balancer ... 34 to 38 N (7.6 to 8.5 lb) (2) Outside diameter of plunger ... 18.16 to 18.18 mm (.715 to .716 inch)

Outside diameter of plunger with engines that are equipped with counter balancer ... 15.95 to 15.98 mm (.628 to .629 inch) Clearance of plunger in bore ... 0.06 to 0.11 mm (.002 to .004 inch) Clearance of plunger in bore with engines that are equipped with counter balancer ... 0.02 to 0.08 mm (.0008 to .0031 inch) (3) Diameter of the bore in the valve housing ... 18.24 to 18.27 mm (.718 to .719 inch) Diameter of the bore in the valve housing with engines that are equipped with counter balancer ... 16.00 to 16.03 mm (.630 to .631 inch) (4) Tighten the bolt to the following torque: ... 44 5 Nm (32 4 lb ft)
1 0 1

Engine Oil Pump


SMCS - 1304
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Illustration 1 Oil pump cover

g00295506

(1) Bolt Tighten the cover bolts to the following torque: ... 28 Nm (21 lb ft)

When the oil pump is mounted to a balancer unit, tighten the single bolt on the oil pump cover (not shown) to the following torque: ... 22 Nm (16 lb ft) Type ... Gerotor pump Number of lobes Inner rotor ... 6 Outer rotor ... 7
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Illustration 2 Clearance for the outer rotor body

g00295515

Clearance of the outer rotor to the body The balancer unit is not installed. ... 0.15 to 0.34 mm (0.006 to 0.013 inch) The balancer unit is installed. ... 0.31 to 0.45 mm (0.012 to 0.018 inch)
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Illustration 3 Clearance for the inner rotor body

g00295516

Clearance between the inner rotor and the outer rotor ... 0.040 to 0.130 mm (0.0015 to 0.0050 inch) End play of the rotor assembly. ... 0.03 to 0.10 mm (0.001 to 0.004 inch) Tighten the bolts that fasten the engine oil pump to the main bearing cap to the following torque: ... 22 Nm (16 lb ft)
1 1 0

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Engine Oil Pressure


SMCS - 1924
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The minimum oil pressure at low idle with an ambient temperature of 18 to 20 C (64 to 68 F) is the following value: ... 62 kPa (9 psi) The minimum oil pressure at high idle and at normal operating temperature is the following value: Turbocharged engine ... 280 kPa (40 psi)

Tighten the oil pressure switch, which is located on the left side of the engine block, to the following torque: ... 7 to 12 Nm (62 to 107 lb in)
0 1 1

Water Temperature Regulator


SMCS - 1355
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Illustration 1

g00877006

Opening temperature ... 77 to 85 C (171 to 185 F) Full open temperature ... 92 to 98 C (198 to 208 F) Minimum stroke at full open temperature ... 9 mm (0.35 inch)
1 0 1

Water Pump
SMCS - 1361
/sisw eb/sisw eb/m /sisw eb/mediase

Type 1 Engines and 9RM Engines

Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information.
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Illustration 1

g00295544

(1) Outside diameter of shaft for drive gear ... 15.91 to 15.92 mm (.626 to .627 inch) (2) Diameter of bore of drive gear ... 15.86 to 15.88 mm (.624 to .625 inch) Interference fit of drive gear on shaft ... 0.03 to 0.06 mm (.001 to .002 inch) (3) Diameter of bore of impeller ... 15.87 to 15.89 mm (.625 to .626 inch)

Outside diameter of shaft for impeller ... 15.91 to 15.92 mm (.626 to .627 inch) Interference fit of impeller on shaft ... 0.02 to 0.05 mm (.001 to .002 inch) (4) Diameter of bearing ... 29.990 to 30.000 mm (1.1807 to 1.1811 inch) Diameter of bore for bearing ... 29.960 to 29.980 mm (1.1795 to 1.1803 inch) Interference fit of bearing in pump body ... 0.010 to 0.040 mm (.0004 to .0016 inch) (5) The water pump must be assembled in order to correctly measure the distance from the impeller boss to the front face of the pump body. Distance ... 8.1 to 8.5 mm (.32 to .34 inch) (6) The water pump must be assembled in order to correctly measure the distance of the gear from the rear face of the pump body. Distance ... 0.6 to 2.6 mm (.02 to .10 inch)

Type 2 Engines and 7BJ Engines


Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information. Note: The water pump for Type 2 engines and 7BJ engines is not serviceable. Contact your Caterpillar dealer for more replacement information.
0 1 1

Cylinder Block
SMCS - 1201
/sisw eb/sisw eb/m /sisw eb/mediase

Ver imagen

Illustration 1 Typical example

g00892504

(1) Cylinder liner Outside diameter of cylinder liner ... 104.25 to 104.28 mm (4.105 to 4.106 inch) Inside diameter of cylinder liner ... 100.00 to 100.03 mm (3.937 to 3.938 inch) Maximum permissible wear of cylinder liner bore ... 0.25 mm (0.010 inch) Interference fit of cylinder liner in cylinder block ... 0.03 to 0.08 mm (0.001 to 0.003 inch) Flange thickness of cylinder liner ... 3.81 to 3.86 mm (0.150 to 0.152 inch) The projection of the liner flange can be 0.10 mm (0.004 inch) above to 0.10 mm (0.004 inch) below the top face of the cylinder block. (2) Plug with baffle plates (if equipped) Orientation of baffle plates to the vertical plane ... +/- 5 degrees Depth of plug from face of cylinder block ... 3 mm (0.12 inch) (3) Cylinder block Diameter of the bore for the cylinder liner ... 104.20 to 104.23 mm (4.103 to 4.104 inch)

Depth of the recess for the cylinder liner flange ... 3.81 to 3.91 mm (0.150 to 0.154 inch) Diameter of the recess for the cylinder liner flange ... 107.82 to 107.95 mm (4.245 to 4.250 inch) (4) Tighten the bolts that fasten the housing for the crankshaft rear seal to the cylinder block to the following torque. ... 22 Nm (16 lb ft) (5) Tighten the bolts that fasten the housing for the crankshaft rear seal to the bridge to the following torque. M6 ... 13 Nm (10 lb ft) M8 ... 22 Nm (16 lb ft) (6) Bridge bolt Use the following procedure in order to install the bridge bolts. 1. Use a straight edge in order to ensure that the bridge is aligned with the front face of the cylinder block. 2. Evenly tighten the bridge bolts to a torque of 16 Nm (12 lb ft). 3. When the bridge is installed on the cylinder block, apply a thin bead of 8T-9013 Silicone Sealant into the groove at each end of the bridge. (7) Main bearing cap bolts Use the following procedure in order to install the main bearing cap bolts. 1. Apply clean engine oil to the threads of the main bearing cap bolts. 2. Put the main bearing caps in the correct position that is indicated by a number on the top of the main bearing cap. Install the main bearing caps with the locating tabs in correct alignment with the recess in the cylinder block. 3. Evenly tighten the main bearing cap bolts to a torque of 265 Nm (195 lb ft). (8) Bore in the cylinder block for the main bearings ... 80.416 to 80.442 mm (3.1660 to 3.1670 inch) (9) Camshaft bearing Inside diameter of the camshaft bearing for the number 1 camshaft journal ... 50.79 to 50.85 mm (2.000 to 2.002 inch) Bore diameter in the cylinder block for the number 1 camshaft bearing ... 55.56 to 55.59 mm (2.187 to 2.189 inch) Bore diameter in the cylinder block for the number 2 camshaft journal ... 50.55 to 50.60 mm (1.990 to 1.992 inch)

Bore diameter in the cylinder block for the number 3 camshaft journal ... 50.04 to 50.09 mm (1.970 to 1.972 inch) Total height of cylinder block between the top and the bottom faces. ... 441.12 to 441.33 mm (17.367 to 17.375 inch)

Piston Cooling Jets (If Equipped)


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Illustration 2

g00631670

(1) Tighten the piston cooling jets to the following torque. ... 27 Nm (20 lb ft) (2) Diameter of rod ... 1.70 mm (0.067 inch) (3) Cylinder block Note: Ensure that the piston cooling jet is positioned correctly on the dowel in the cylinder block (not shown). Use the following procedure in order to ensure the correct alignment of the piston cooling jet.

1. Insert rod (2) into the end of the piston cooling jet. Rod (2) should protrude out of the top of the cylinder block. 2. Use the following dimensions to locate the center point of diameter (C) . Dimension (A) ... 33 mm (1.3 inch) Dimension (B) ... 21 mm (0.8 inch) Diameter (C) ... 14 mm (0.6 inch) Note: Dimension (A) and dimension (B) are tangent to the cylinder bore. 3. Position rod (2) within diameter (C) .
1 1 0

Crankshaft
SMCS - 1201
/sisw eb/sisw eb/m /sisw eb/mediase

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Illustration 1 Crankshaft and main bearing journals

g00295557

Note: If a crankshaft that was not originally induction hardened has been remachined, then the crankshaft must be rehardened. Use one of the process that follow for 20 hours in order to reharden the crankshaft: nitrocarburizing process and nitriding process (1) Connecting rod bearing (2) Top and bottom thrust washer thickness Standard ... 2.26 to 2.31 mm (0.089 to 0.091 inch) Oversize ... 2.45 to 2.50 mm (0.096 to 0.098 inch) (3) Main bearing Clearance for main bearings ... 0.057 to 0.117 mm (0.0022 to 0.0046 inch) Bearing width Center bearing ... 36.32 to 36.70 mm (1.430 to 1.445 inch) All other bearings ... 31.62 to 31.88 mm (1.245 to 1.255 inch) Thickness of the bearing at the center All bearings ... 2.083 to 2.086 mm (0.0820 to 0.0821 inch) (4) Crankshaft gear (5) End play of the crankshaft ... 0.05 to 0.38 mm (0.002 to 0.015 inch) Maximum permissible end play ... 0.51 mm (0.020 inch) (6) Width of the connecting rod journal ... 40.35 to 40.42 mm (1.589 to 1.591 inch) Connecting rod journal diameter of flange ... 133.27 to 133.37 mm (5.247 to 5.251 inch) Depth of recess for connecting rod bearing ... 20.22 to 20.98 mm (0.796 to 0.826 inch) Bore of recess for connecting rod bearing ... 46.96 to 46.99 mm (1.849 to 1.850 inch) Measure the connecting rod journals on the crankshaft. See the following chart for the dimensions. Table 1 Connecting Rod Bearing Journal If the bearing journal has been ground beyond this size, then regrind the bearing journals to the next undersize journal. 63.43 mm (2.497 inch)

Original Size Journal 63.47 to 63.49 mm (2.499 to 2.500 inch) Undersize Journal 0.25 mm (0.010 inch) Undersize Journal 0.51 mm (0.020 inch) Undersize Journal 0.76 mm (0.030 inch) 63.22 to 63.24 mm (2.489 to 2.490 inch) 62.96 to 62.98 mm (2.479 to 2.480 inch) 62.71 to 62.73 mm (2.469 to 2.470 inch)

Connecting rod bearings are available for remachined journals with the following undersize dimensions: Undersize ... 0.25 (0.010) Undersize ... 0.51 (0.020) Undersize ... 0.76 (0.030) (7) Dimensions of main journals which are the standard, original size Width of front journal ... 36.93 to 37.69 mm (1.454 to 1.484 inch) Width of center journal ... 44.15 to 44.22 mm (1.738 to 1.741 inch) Width of all other journals ... 39.24 to 39.35 mm (1.545 to 1.549 inch) Measure the main bearing journals on the crankshaft. See the following chart for dimensions. Table 2 Main Bearing Journal If the bearing journal has been ground beyond this size, then regrind the bearing journals to the next undersize journal. Original Size Journal 76.16 to 76.18 mm (2.998 to 2.999 inch) Undersize Journal 0.25 mm (0.010 inch) Undersize Journal 0.51 mm (0.020 inch) 75.91 to 75.93 mm (2.988 to 2.989 inch) 75.65 to 75.67 mm 76.12 mm (2.996 inch)

(2.978 to 2.979 inch) Undersize Journal 0.76 mm (0.030 inch) 75.40 to 75.42 mm (2.968 to 2.969 inch)

Tighten the bolts for the main bearing journal to the following torque: ... 265 Nm (195 lb ft) Main bearings are available for remachined journals with the following undersize dimensions: Undersize ... 0.25 (0.010) Undersize ... 0.51 (0.020) Undersize ... 0.76 (0.030) Tighten the retaining bolts of the crankshaft pulley (not shown) to the following torque: ... 115 Nm (85 lb ft) Apply 9S-3263 Thread Lock Compound to the bolts of the crankshaft damper. Tighten the bolts (not shown) to the following torque: M8 bolts ... 35 Nm (26 lb ft) M12 bolts ... 75 Nm (55 lb ft) Tighten the bolts that fasten the rear oil seal housing to the cylinder block (not shown) to the following torque: ... 22 Nm (16 lb ft) Tighten the bolts that fasten the rear oil seal housing to the bridge (not shown) to the following torque: M6 ... 13 Nm (10 lb ft) M8 ... 18 Nm (13 lb ft)
1 1 0

Crankshaft Seals
SMCS - 1160; 1161

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Crankshaft Front Seal


Ver imagen

Illustration 1

g00664588

The front oil seal (2) is normally installed to a depth of 7.00 0.25 mm (0.2756 0.0098 inch) (A) from the face of the front oil seal housing (6). The oil seal may cause wear on the hub of crankshaft pulley (3). This wear may allow oil leakage past the oil seal. If this situation occurs, the front oil seal can be installed to a depth of 9.3 mm (0.37 inch) from the face of the front oil seal housing. If a wear sleeve (4) is installed, the front oil seal is installed to a depth of 9.30 mm (0.366 inch) from the face of the front oil seal housing. When the wear sleeve is installed, the flange of the wear sleeve does not require removal. If a wear sleeve is installed, a new front oil seal must be installed. (5) Tighten three bolts for the crankshaft pulley to the following torque. ... 115 Nm (85 lb ft)

Crankshaft Rear Seal


Engines with 14 Bolt Housing Assembly

Ver imagen

Illustration 2

g00317365

Positions of the crankshaft seal

Position (1) is 0 mm (0.0 inch) from the face of the rear housing. Position (2) is 4.6 mm (0.18 inch) from the face of the rear housing. Use position (2) if the crankshaft surface is worn in position (1) . Position (3) is 6.9 mm (0.27 inch) from the face of the rear housing. Use position (3) if the crankshaft surface is worn in both of the other positions.
Engines with 10 Bolt Housing Assembly

The 10 bolt housing assembly is manufactured as a one-piece assembly. There is no adjustment of the position from the face of the rear housing. Note: If a wear groove on the crankshaft flange has occurred, use a 209-8228 Sleeve to renew the sealing surface when you replace the housing assembly.

Tighten the bolts that fasten the rear housing for the crankshaft rear seal to the cylinder block to the following torque. ... 22 Nm (16 lb ft)
0 1 1

Connecting Rod
SMCS - 1218

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Type 1 Engines and 9RM Engines


Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information.

Ver imagen

Illustration 1

g00295602

Connecting Rod And Bearings

Naturally Aspirated Engines

(1) Inside diameter of rod for bearing ... 38.89 to 38.92 mm (1.531 to 1.532 inch) (2) Outside diameter of bearing for piston pin ... 38.94 to 39.03 mm (1.535 to 1.536 inch) Inside diameter of bearing for piston pin after reaming ... 34.940 to 34.960 mm (1.3758 to 1.3765 inch) Clearance between small end bearing and piston pin ... 0.020 to 0.043 mm (.0008 to .0017 inch) (3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to 219.10 mm (8.624 to 8.626 inch) (4) Bearings are available for remachined journals of the crankshaft which have the following undersize dimensions: 0.25 mm (.010 inch) 0.51 mm (.020 inch) 0.76 mm (.030 inch) Shell thickness ... 1.835 to 1.842 mm (.0723 to .0726 inch) Width of connecting rod bearing ... 31.62 to 31.88 mm (1.245 to 1.255 inch) Bearing clearance ... 0.035 to 0.081 mm (.0014 to .0032 inch) (5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch) (6) Connecting rod cap with nuts and bolts Tighten the nuts for the connecting rod to the following torque: ... 125 Nm (92 lb ft) Connecting rod cap with bolts only Tighten the bolts for the connecting rod to the following torque: ... 155 Nm (114 lb ft)
Turbocharged Engines

(1) Inside diameter of rod for bearing ... 42.07 to 42.09 mm (1.656 to 1.657 inch)

(2) Outside diameter of bearing for piston pin ... 42.160 to 42.190 mm (1.6600 to 1.6613 inch) Inside diameter of bearing for piston pin after reaming ... 38.120 to 38.140 mm (1.5008 to 1.5015 inch) Clearance between small end bearing and piston pin ... 0.020 to 0.043 mm (.0008 to .0017 inch) (3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to 219.10 mm (8.624 to 8.626 inch) (4) Bearings are available for remachined journals of the crankshaft which have the following undersize dimensions: 0.25 mm (.010 inch) 0.51 mm (.020 inch) 0.76 mm (.030 inch) Shell thickness ... 1.835 to 1.844 mm (.0723 to .0726 inch) Width of connecting rod bearing ... 31.55 to 31.88 mm (1.240 to 1.255 inch) Bearing clearance ... 0.030 to 0.081 mm (.0012 to .0032 inch) (5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch) (6) Connecting rod cap with nuts and bolts Tighten the nuts for the connecting rod to the following torque: ... 125 Nm (92 lb ft) Connecting rod cap with bolts only Tighten the bolts for the connecting rod to the following torque: ... 155 Nm (114 lb ft) Note: If piston cooling jets are installed, the piston and the connecting rod assembly must be turned when the piston and rod assembly are installed. Turning the piston and connecting rod assembly will prevent the connecting rod from hitting and damaging the piston cooling jet. When the connecting rod has passed the piston cooling jet, turn the connecting rod until the arrow or "Front" mark on the top of the piston is toward the front of the engine.

Type 2 Engines and 7BJ Engines


Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information.

The piston height is controlled by the length of the connecting rod. Connecting rods are supplied in six grades of length. The different grades of length are manufactured by machining the hole in the piston pin bearing in an off-center position. The different grades of length are created by the following method:

Machining the center of the hole in the piston pin Machining the center of the hole in the bearing If the connecting rod is replaced, ensure that the same grade of length as the original connecting rod is used.

However, if the crankshaft or the cylinder block is replaced, the required grade of length of the connecting rods may change. A correct grade of length of a connecting rod can be ordered for replacement. The connecting rod includes the piston pin bearing. The piston pin bearing is machined in order to create the correct grade of length. The piston pin is installed in the connecting rod at the factory. Table 2 provides the specifications for the grade of length. Note: The length of the connecting rod is determined by the following method: The bearing for the crankshaft journal must be removed and the piston pin must be installed. The original grade of length of the connecting rod is determined when the original piston pin is installed. Connecting rods are color coded. The color code is a reference for the length (Y) of the connecting rod. Refer to Table 2 for the different lengths of connecting rods.

Ver imagen

Illustration 2

g00915056

Table 1 Grade of Length Color Length of the Connecting Rod

"F"

Red

165.728 to 165.761 mm (6.5247 to 6.5265 inch)

"G"

Orange

165.682 to 165.715 mm (6.5229 to 6.5247 inch)

"H"

White

165.637 to 165.670 mm (6.5211 to 6.5229 inch)

"J"

Green

165.591 to 165.624 mm (6.5193 to 6.5211 inch)

"K"

Purple

165.545 to 165.578 mm (6.5175 to 6.5193 inch)

"L"

Blue

165.499 to 165.532 mm (6.5157 to 6.5175 inch)

If a piston pin bearing requires replacement but the connecting rod does not require replacement, a new piston pin bearing can be ordered. This bearing is partially finished. The hole in the bearing must be machined off-center to the correct distance in order to create a connecting rod assembly that is the correct grade of length. Refer to the Testing and Adjusting manual for the following procedures:

Determine the length of the connecting rod. Determine the distortion of a connecting rod. Replace the piston pin bearing.

Turbocharged Engines Serrated Connecting Rods and Flat Connecting Rods


Ver imagen

Illustration 3

g00295602

Connecting Rod And Bearings

(1) Inside diameter of rod for bearing ... 43.01 to 43.04 mm (1.693 to 1.694 inch) (2) Outside diameter of bearing for piston pin ... 43.11 to 43.15 mm (1.697 to 1.699 inch) Inside diameter of bearing for piston pin after reaming ... 39.723 to 39.738 mm (1.5639 to 1.5645 inch) Clearance between small end bearing and piston pin ... 0.023 to 0.044 mm (.0009 to .0017 inch) (3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to 219.10 mm (8.624 to 8.626 inch) (4) Bearing for connecting rod journal Shell thickness ... 1.835 to 1.844 mm (.0723 to .0726 inch)

Width of connecting rod bearing ... 31.55 to 31.88 mm (1.240 to 1.255 inch) Bearing clearance ... 0.030 to 0.081 mm (.0012 to .0032 inch) (5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch) (6) Connecting rod cap with nuts and bolts Tighten the nuts for the connecting rod to the following torque: ... 125 Nm (92 lb ft) Connecting rod cap with bolts only Tighten the bolts for the connecting rod to the following torque: ... 155 Nm (114 lb ft) Note: If piston cooling jets are installed, the piston and the connecting rod assembly must be turned when the piston and rod assembly are installed. Turning the piston and connecting rod assembly will prevent the connecting rod from hitting and damaging the piston cooling jet. When the connecting rod has passed the piston cooling jet, turn the connecting rod until the arrow or "Front" mark on top of the piston is toward the front of the engine.
Hydraulically Fractured Connecting Rods
Ver imagen

Illustration 4

g01064497

Note: The caps and rods must stay together as a pair. Note: When the connecting rods are replaced, do not reuse the connecting rod bolts. New connecting rod bolts must be used. The mating surfaces of the connecting rod are produced by hydraulically fracturing the forged connecting rod. (7) Tighten the connecting rod bolts to the following torque. ... 18 Nm (13 lb ft) Tighten the connecting rod bolts again to the following torque. ... 70 Nm (52 lb ft) Tighten the connecting rod bolt for an additional 120 degrees. (8) Connecting rod bearing

Ver imagen

Illustration 5

g01064498

(9) Diameter of the bore for the piston pin ... 43.01 to 43.04 mm (1.693 to 1.694 inch) (10) Distance between bearing centers ... 219.05 to 219.10 mm (8.624 to 8.626 inch)

(11) DPiston and Rings


SMCS - 1214; 1215

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Type 1 Engines and 9RM Engines


Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information.

Ver imagen

Illustration 1

g00295711

Piston and rings

Note: The word "Front" or an arrow which is marked on the piston crown must be toward the front of the engine. If the piston crown is not marked, put the narrowest side of the piston crater toward the side of the engine with the fuel injection pump. The shortest distance between the edge of the piston crater and the edge of the piston is the narrowest side of the piston crater.

Note: Be sure that the ring end gaps of all the piston rings have 120 degrees spacing from each other. Note: Refer to Systems Operation, "General Information" for the location of the serial number.
Naturally Aspirated Engines

(1) Width of groove in piston for top ring ... 2.57 to 2.59 mm (.101 to .102 inch) Thickness of top ring ... 2.48 to 2.49 mm (.097 to .098 inch) Clearance between groove and piston ring ... 0.08 to 0.11 mm (.003 to .004 inch) Clearance between the ends of the top ring with a cylinder liner without any wear ... 0.40 to 0.85 mm (.016 to .033 inch) (2) Width of groove in piston for intermediate ring ... 2.55 to 2.57 mm (.100 to .101 inch) Thickness of intermediate ring ... 2.48 to 2.49 mm (.097 to .098 inch) Clearance between groove and intermediate ring ... 0.06 to 0.09 mm (.002 to .003 inch) Clearance between the ends of the intermediate ring with a cylinder liner without any wear ... 0.30 to 0.76 mm (.012 to .030 inch) (3) Width of groove in piston for oil control ring ... 4.030 to 4.060 mm (.1587 to .1598 inch) Thickness of oil control ring ... 3.980 to 3.990 mm (.1566 to .1571 inch) Clearance between groove and oil control ring ... 0.04 to 0.08 mm (.002 to .003 inch) Clearance between the ends of oil control ring with a cylinder liner without any wear ... 0.38 to 0.84 mm (.015 to .033 inch) (4) Diameter of new piston pin ... 34.920 to 34.925 mm (1.3748 to 1.3750 inch) Bore for piston pin ... 34.928 to 34.934 mm (1.3751 to 1.3754 inch)
Turbocharged Engines

(1) Shape of groove in piston for top ring ... Taper Shape of top ring ... Taper Clearance between the ends of top ring in a cylinder liner without any wear ... 0.35 to 0.75 mm (.014 to .030 inch)

(2) Width of groove in piston for intermediate ring ... 2.56 to 2.58 mm (.101 to .102 inch) Thickness of intermediate ring ... 2.48 to 2.49 mm (.097 to .098 inch) Clearance between groove and intermediate ring ... 0.07 to 0.11 mm (.003 to .004 inch) Clearance between the ends of an intermediate ring in a cylinder liner without any wear ... 0.30 to 0.76 mm (.012 to .030 inch) (3) Width of groove in piston for oil control ring ... 4.040 to 4.060 mm (.1591 to .1598 inch) Thickness of oil control ring ... 3.98 to 3.99 mm (.156 to .157 inch) Clearance between groove and oil control ring ... 0.05 to 0.08 mm (.002 to .003 inch) Clearance between the ends of an oil control ring in a cylinder liner without any wear ... 0.38 to 0.84 mm (.015 to .033 inch) (4) Diameter of new piston pin ... 38.095 to 38.100 mm (1.4998 to 1.5000 inch) Bore for piston pin ... 38.103 to 38.109 mm (1.5000 to 1.5004 inch)
Piston Height
Ver imagen

Illustration 2

g00891532

Quadram piston

There are two different designs for the crown of the piston. One design is the Quadram piston. There is only one grade of piston for the replacement of a Quadram piston. Grade of piston for service ... L Height of a Quadram piston above the top face of the cylinder block ... 0.14 to 0.36 mm (0.005 to 0.014 inch)

Ver imagen

Illustration 3

g00891548

Fastram piston

The other style of piston is the Fastram piston. The piston height above the top face of the cylinder block is controlled by different grades of height of the piston. Identification of the height grade is by the letter that is stamped on the top of each piston. The height grade can be checked by measuring from the center of the piston pin to the top of the piston. The difference between each grade of height is 0.045 mm (0.0018 inch). Table 1 provides the specifications for the grade of height for a Fastram piston.
Table 1 Height Grades for the Piston

Letter on top of Piston

Height Dimension

Latest Equivalent Grade

A (1)

70.334 mm (2.7690 inch)

B (1)

70.289 mm (2.7673 inch)

C (1)

70.244 mm (2.7655 inch)

D (1)

70.199 mm (2.7637 inch)

E (1)

70.154 mm (2.7620 inch)

70.391 mm (2.7713 inch)

70.345 mm (2.7695 inch)

70.299 mm (2.7677 inch)

70.253 mm (2.7659 inch)

70.207 mm (2.7640 inch)

70.161 mm (2.7622 inch)


Earlier engines

(1)

Height of a Fastram piston above the top face of the cylinder block ... 0.38 to 0.50 mm (0.015 to 0.020 inch)

Type 2 Engines and 7BJ Engines


Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information.

Ver imagen

Illustration 4

g00500921

Note: The word "Front" or an arrow which is marked on the piston crown must be toward the front of the engine. If the piston crown is not marked, put the narrowest side of the piston crater toward the side of the engine with the fuel injection pump. The shortest distance between the edge of the piston crater and the edge of the piston is the narrowest side of the piston crater. Note: Be sure that the ring end gaps of all the piston rings have 120 degrees spacing from each other.

Note: Refer to Systems Operation, "General Information" for the location of the serial number.
Turbocharged Engines

(1) Top piston ring


Shape of groove in piston for top ring ... Taper Shape of top ring ... Taper Clearance between the ends of the top ring in a cylinder liner without any wear ... 0.28 to 0.63 mm (.011 to .025 inch)

Note: Install the word "TOP" toward the top of the piston. New top rings have a red identification mark which must be on the left of the ring gap when the intermediate ring is installed on an upright piston. (2) Intermediate ring
Width of groove in piston for intermediate ring ... 2.56 to 2.58 mm (0.101 to 0.102 inch) Thickness of intermediate ring ... 2.48 to 2.49 mm (0.097 to 0.098 inch) Clearance between groove and intermediate ring ... 0.07 to 0.11 mm (.003 to .004 inch) Clearance between the ends of an intermediate ring in a cylinder liner without any wear ... 0.40 to 0.65 mm (.016 to .026 inch)

Note: Install the word "TOP" toward the top of the piston. New intermediate rings have a green identification mark which must be on the left of the ring gap when the intermediate ring is installed on an upright piston. (3) Oil control ring
Width of groove in piston for oil control ring ... 3.54 to 3.56 mm (.139 to .140 inch) Thickness of oil control ring ... 3.47 to 3.49 mm (.136 to .137 inch) Clearance between groove and oil control ring ... 0.05 to 0.09 mm (.002 to .004 inch) Clearance between the ends of an oil control ring in a cylinder liner without any wear ... 0.38 to 0.83 mm (.015 to .033 inch)

Note: A pin is used in order to hold both ends of the spring of the oil control ring in position. The ends of the spring of the oil control ring must be 180 degrees opposite the end gap of the oil control ring.

(4) Diameter of new piston pin ... 39.694 to 39.700 mm (1.5628 to 1.5630 inch) Bore for piston pin ... 39.703 to 39.709 mm (1.5631 to 1.5633 inch) Piston height above cylinder block (not shown) ... 0.36 to 0.50 mm ( .014 to .020 inch)
1 1 0

iameter for the bore for the connecting rod bearing ... 67.21 to 67.22 mm (2.6460 to 2.6465 inch)

Housing (Front)
SMCS - 1151
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Ver imagen

Illustration 1 Front housing and front cover Ver imagen

g00753583

Illustration 2 9U-6200 Front Cover Installer

g00753612

(1) Front cover The front cover must be centered on the front of the engine before the bolts are tightened. Use a 9U-6200 Front Cover Installer to center the front cover before the bolts are tightened. (2) Front housing Tighten the M8 bolts (not shown) that fasten the front housing to the cylinder block to the following torque: ... 22 Nm (16 lb ft) Tighten the M10 bolts (not shown) that fasten the front housing to the cylinder block to the following torque: ... 44 Nm (33 lb ft) (3) Bolts After the front cover is centered on the front of the engine, tighten the bolts and the two nuts that fasten the front cover to the front housing. Tighten the bolts and the nuts to the following torque: ... 22 Nm (16 lb ft) (4) 9U-6200 Front Cover Installer The front cover installer is used to center the front cover on the front of the engine. Refer to the Disassembly and Assembly Module, "Front Cover - Install" topic for additional information.
1 1 0

Gear Group (Front)

SMCS - 1206
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Ver imagen

Illustration 1

g00295804

(1) Fuel injection pump gear Bore ... 36.00 to 36.06 mm (1.417 to 1.420 inch) Tighten the four bolts to the following torque. ... 28 Nm (21 lb ft) Tighten the two torx screws to the following torque. ... 9 Nm (7 lb ft) Note: The torx screws retain the timing plate on the front of the gear. This plate is installed in the factory after the fuel injection pump timing has been accurately set to the top center position on the compression stroke of the No. 1 cylinder. If the timing plate is moved, the timing of the fuel injection pump must be set. Note: The crankshaft must not be turned unless the fuel injection pump gear is installed.

Note: Do not remove the nut that retains the hub of the fuel injection pump to the shaft of the fuel injection pump. If the hub is removed, the hub must be positioned by correctly trained personnel and special test equipment. (2) Camshaft gear Diameter of the camshaft gear bore ... 34.930 to 34.950 mm (1.3752 to 1.3760 inch) Outside diameter of camshaft hub ... 34.900 to 34.920 mm (1.3741 to 1.3747 inch) Clearance between the camshaft gear and the camshaft hub ... 0.008 to 0.048 mm (0.0003 to 0.0019 inch) (3) Tighten the bolt for the camshaft gear to the following torque. ... 95 Nm (70.0682 lb ft) (4) Idler gear and hub Diameter of the idler gear bore ... 57.14 to 57.18 mm (2.250 to 2.251 inch) Width of the idler gear and split bearing assembly ... 30.14 to 30.16 mm (1.186 to 1.187 inch) Inside diameter of the idler gear bearing ... 50.78 to 50.80 mm (1.999 to 2.000 inch) Outside diameter of the idler gear hub ... 50.70 to 50.74 mm (1.996 to 1.998 inch) Clearance of the bearing on the idler gear hub ... 0.04 to 0.10 mm (0.002 to 0.004 inch) Idler gear end play ... 0.10 to 0.20 mm (0.004 to 0.008 inch) Maximum permissible end play ... 0.38 mm (0.015 inch) Backlash (minimum) ... 0.08 mm (0.003 inch) (5) Tighten the bolts for the idler gear to the following torque: ... 44 Nm (33 lb ft) (6) Crankshaft gear Diameter of the bore of the crankshaft gear ... 47.625 to 47.650 mm (1.8750 to 1.8760 inch) Outside diameter of the crankshaft for the crankshaft gear ... 47.625 to 47.645 mm (1.8750 to 1.8758 inch) Clearance of the crankshaft gear on the crankshaft for a press fit ... 0.015 0.035 mm (0.0006 0.0014 inch) (7) Oil pump idler gear Inside diameter of the bearing ... 22.230 to 22.260 mm (0.8750 to 0.8766 inch) Outside diameter of the idler gear shaft ... 22.19 to 22.21 mm (0.873 to 0.874 inch) Clearance of the gear on the shaft ... 0.020 to 0.066 mm (0.0008 to 0.0026 inch)

Idler gear end play ... 0.012 to 0.643 mm (0.0005 to 0.0253 inch) Timing gear backlash (minimum) ... 0.08 mm (0.003 inch)

Balancer (If equipped)


Diameter of drive shaft for front bearing ... 28.562 to 28.575 mm (1.1245 to 1.1250 inch) Diameter of drive shaft for rear bearing ... 23.787 to 23.800 mm (0.9365 to 0.9370 inch) Number of teeth on gear of drive shaft ... 21 Backlash from gear of drive shaft to idler gear ... 0.17 to 0.29 mm (0.0067 to 0.0114 inch) End play of drive shaft ... 0.13 to 0.30 mm (0.0051 to 0.0118 inch) Diameter of bore for front bearing of drive shaft ... 34.912 to 34.937 mm (1.3745 to 1.3755 inch) Diameter of bore for rear bearing of drive shaft ... 29.972 to 29.993 mm (1.1800 to 1.1808 inch) Diameter of bore for idler gear ... 47.64 to 47.65 mm (1.8756 to 1.8760 inch) Diameter of hub of idler gear ... 38.09 to 38.10 mm (1.4996 to 1.5000 inch) End play of idler gear ... 0.07 to 0.23 mm (0.0028 to 0.0091 inch) Thickness of thrust washer for idler gear ... 4.14 to 4.29 mm (0.1630 to 0.1689 inch) Number of teeth on idler gear ... 37 Inside diameter of bushes in balancer frame and end cover ... 38.133 to 38.174 mm (1.5013 to 1.5029 inch) Diameter of spigots for balance weights ... 38.054 to 38.069 mm (1.4982 to 1.4988 inch) Fit of spigot in bush ... 0.064 to 0.120 mm (0.0025 to 0.0047 inch) End play of balance weights ... 0.19 to 0.40 mm (0.0075 to 0.0157 inch) Backlash of gears on balance weights ... 0.10 to 0.27 mm (0.0039 to 0.0106 inch) Backlash of drive gear to spline on balance weight ... 0.05 to 0.20 mm (0.0020 to 0.0079 inch)

Number of teeth on drive gear ... 24 Number of teeth on spline on balance weight ... 16
0 1 1

Flywheel and Flywheel Housing Runout


SMCS - 1156; 1157

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Ver imagen

Illustration 1

g00295950

(1) Tighten the bolts of the flywheel housing to the following torque:

The M10 bolts for the cast iron flywheel housing ... 44 Nm (32 lb ft) The M12 bolts that are stamped "8.8" for the cast iron flywheel housing ... 75 Nm (55 lb ft) The M10 bolts that are stamped "10.9" for the cast iron flywheel housing ... 63 Nm (46 lb ft) The M12 bolts that are stamped "10.9" for the cast iron flywheel housing ... 115 Nm (85 lb ft) The M10 bolts that are for the aluminum flywheel housing ... 70 Nm (52 lb ft)

(2) The maximum temperature for heating the flywheel ring gear for installation ... 250 C (482 F) (3) Tighten flywheel bolts to the following torque: ... 105 Nm (77 lb ft)

Flywheel Housing Runout


Face Runout
Ver imagen

Illustration 2

g00295952

Face Runout Check

Maximum permissible face runout of the flywheel housing ... 0.20 mm (0.008 inch) Refer to Testing and Adjusting, "Flywheel and Flywheel Housing" for the correct procedure to measure the runout.
Bore Runout
Ver imagen

Illustration 3

g00295954

Bore Runout Check

Maximum permissible bore runout of the flywheel housing ... 0.20 mm (0.008 inch)

Refer to Testing and Adjusting, "Flywheel and Flywheel Housing" for the correct procedure to measure the runout.

Flywheel Runout
Face Runout
Ver imagen

Illustration 4

g00295955

Face Runout Check

Maximum permissible bore runout of the flywheel housing ... 0.20 mm (0.008 inch) Refer to Testing and Adjusting, "Flywheel and Flywheel Housing".
Outside Diameter Runout

Ver imagen

Illustration 5

g00295956

Outside Diameter Runout Check

Maximum permissible bore runout of the flywheel housing ... 0.30 mm (0.012 inch) Refer to Testing and Adjusting, "Flywheel and Flywheel Housing" for the correct procedure to measure the runout

Electric Starting Motor


SMCS - 1453

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12 Volt Starting Motor

Ver imagen

Illustration 1

g00295928

Starting Motor (Side View) Ver imagen

Illustration 2

g00295930

End view of the starting motor which shows the electrical connections

No load conditions at 25 C (77 F)


Rpm of shaft ... 7000 minimum Current draw ... 130 amperes maximum Voltage ... 11.5 volts Rated voltage ... 12 volts

(1) Tighten the battery terminal nut to the following torque: ... 24 to 32 Nm (18 to 24 lb ft) (2) Tighten the nut for the switch terminal to the following torque: ... 1.0 to 1.3 Nm (9 to 12 lb in) Tension of the spring for the motor brush ... 8.34 to 11.00 N (1.9 to 2.5 lb)

Minimum resistance of the starter cable at 200 C (392 F) and at 12 volts ... 0.0017 ohms

Start Relays
9G-4368 Relay
Ver imagen

Illustration 3

g00731492

Voltage ... 12 VDC Resistance between "W1" terminal and "W2" terminal ... 15 1.5 ohms
069-5466 Relay
Ver imagen

Illustration 4

g00295932

Voltage ... 6 VDC Resistance between terminal "A" and terminal "B" ... 30 to 34 ohms

24 Volt Starting Motor


No load conditions at 25 C (77 F)
Rpm of shaft ... 7000 minimum Current draw ... 85 amperes maximum Voltage ... 23 volts Rated voltage ... 24 volts

Minimum pull-in voltage ... 18 volts Brush length:

Minimum brush length ... 15.5 mm (0.61 inch)

Armature end play ... 0.1 to 0.3 mm (0.004 to 0.012 inch) Install shims or remove shims in order to adjust the armature end play to the correct specification. Commutator
New diameter ... 45 mm (1.77 inch) Minimum diameter ... 42.5 mm (1.67 inch)
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