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Assembly QSX15
(10-001-028-shopas) Cylinder Liner (10-001-006-shopas) Bearings, Main (10-001-007-shopas) Bearing, Thrust (10-001-016-shopas) Crankshaft (10-007-031-shopas) Lubricating Oil Pump (10-001-033-shopas) Gear Housing, Front (10-016-006-shopas) Flywheel Housing (10-016-007-shopas) Flywheel Housing, REPTO (10-001-024-shopas) Crankshaft Seal, Rear (10-016-005-shopas) Flywheel (10-001-047-shopas) Piston Rings (10-001-005-shopas) Bearings, Connecting Rod (10-001-054-shopas) Piston and Connecting Rod Assembly (10-001-046-shopas) Piston Cooling Nozzle (10-001-089-shopas) Block Stiffener Plate (10-007-035-shopas) Lubricating Oil Suction Tube (Block Mounted) (10-007-025-shopas) Lubricating Oil Pan (10-001-076-shopas) Idle Gear, Lower Concept (10-016-002-shopas) Engine Support Bracket, Front (10-002-004-shopas) Cylinder Head (10-002-025-shopas) Overhead Camshaft, Injector (10-002-024-shopas) Overhead Camshaft, Valve (10-001-088-shopas) Engine Base Timing (10-012-014-shopas) Air Compressor (10-001-080-shopas) Gear Cover, Lower (10-001-023-shopas) Crankshaft Seal, Front (10-001-079-shopas) Gear Cover, Upper (10-001-052-shopas) Vibration Damper, Viscous (10-006-026-shopas) Injector (10-003-009-shopas) Rocker Lever Assembly (10-003-004-shopas) Overhead Set

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(10-008-062-shopas) Water Pump (10-008-082-shopas) Water Inlet Connection (10-007-003-shopas) Lubricating Oil Cooler

Cylinder Liner (001-028)


Install
TOC

CAUTION
Cylinder liners of different design can not be mixed within an engine. All six cylinder liners must be of the same design.
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There are two different designs of cylinder liners used. The design used in a particular engine is dependent on the engine's production vintage. Engines assembled prior to engine serial number 14022615 have groove-top cylinder liners. They are characterized by a groove machined into the top surface of the cylinder liner flange. Engines with serial number 14022615 and after are assembled with flat-top cylinder liners. They are characterized by a cylinder liner flange that is flat, except for the fire dam.

3 Make sure the cylinder block and all parts are clean before assembly. Lubricate the two cylinder liner o-ring seals with vegetable oil prior to assembly. Install the two o-ring seals onto the cylinder liner.
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CAUTION
Cylinder liners of different design can not be mixed within an engine. All six cylinder liners must be of the same design.
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Install the cylinder liner into the cylinder block. When acceptable and used cylinder liners are installed, rotate the cylinder liner 90 degrees from its original position in the engine. The thrust and antithrust surfaces must face the front and back of the cylinder block. Use cylinder liner installation kit, Part Number 3162461, to seat the liner. If the cylinder liner does not seat properly, remove it and Inspect the cylinder liner bore seat and cylinder liner for nicks, burrs, or dirt. Install the cylinder liner again.

Measure

TOC

4 Liner Protrusion Because of design differences, the cylinder liner's position (relative to the cylinder top deck) will be different. For groove-top cylinder liners, a recession measurement is taken. This measures the depth of the groove relative to the cylinder block deck regardless of the flange or fire dam height.
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For flat-top cylinder liners, a cylinder liner protrusion measurement is taken which is the height of the cylinder liner flange above the cylinder block surface regardless of the flange or fire dam height. Regardless of the cylinder liner design, the measurement technique will be the same.
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The cylinder liner measurement must be checked before installing the pistons and connecting rods. The cylinder liner measurement must be made with the cylinder liners in the clamped state. Install and tighten the cylinder liner installation tool. Torque Value: n.m 68 ft-lb ] [50
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Use depth gauge, Part Number 3823495, to measure the clamped state at the intake side three times and average the readings. Measure the clamped state of the exhaust side three times and average the readings.

5 Cylinder Liner Recession (Groove-Top Cylinder Liners) mm in 0.36 MIN 0.014 0.51 MAX 0.019 Cylinder Liner Protrusion (Flat-Top Cylinder Liners) mm in 0.18 MIN 0.007 0.33 MAX 0.014 If the cylinder liner measurement on either the intake or exhaust side is not within specifications, the cylinder liner must be replaced.
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For flat-top cylinder liners only:

The difference between the lowest cylinder liner and the highest cylinder liner can not be greater than 0.102 mm [0.004 in]. The maximum allowable difference between adjacent cylinders is 0.51 mm [0.002 in]. The protrusion must be within 0.0381 mm [0.0015 in] around any cylinder.

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Before installing the piston and connecting rod assemblies, wipe the inside of the cylinder liners using a clean cloth with 15W-40 oil.

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Bearings, Main (001-006)

Install

TOC

CAUTION
The cylinder block saddle and the cap mating surfaces must be clean and dry when the bearing shells are installed. Used bearings must be installed in their original location or engine damage can occur.

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CAUTION
The bearing tang must fit into the slot in the bearing saddle or engine damage can occur.

CAUTION
Do not use a capscrew or any hard metal object to install bearings, as this can damage the crankshaft and cause an engine failure.

Use clean Lubriplate 105 multi-purpose lubricant, or its equivalent, to lubricate the upper main bearing shell to crankshaft journal mating surface. Start the bearing into the upper saddle by hand. Slide the bearing into position. Take care to not damage the crankshaft journal while installing the bearing.

7 Use clean Lubriplate 105 multi-purpose lubricant, or its equivalent, to lubricate the inside diameter of the bearing shells and the liner side of the upper thrust bearings.

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Align the lower main bearing shell and push it into place.

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CAUTION
Make sure the bevel side is toward the crankshaft journal. Incorrect thrust bearing installation will result in engine damage.
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Use clean Lubriplate 105 multi-purpose lubricant, or its equivalent, to lubricate the liner side of the lower thrust bearings. Install the lower thrust bearings in the number four main bearing cap as shown.

CAUTION
Make sure the bevel side is toward the crankshaft journal. Incorrect thrust bearing installation will result in engine damage.
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Install the upper thrust bearings in the number four main bearing saddle. Push the crankshaft toward the rear of the engine to install the front thrust bearing and toward the front of the engine to install the rear thrust bearing.

CAUTION
Only use Loctite 518 thread sealant on the main cap joint mating surface. Other sealants can become hard, brittle, and allow oil and debris into the main bearing/block joint, causing engine damage.

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CAUTION
The bead must be 3 to 5 mm [0.12 to 0.20 in] wide and must not enter the main bearing shell inside the main bearing shell inside diameter. Sealant in the main bearing can cause engine damage.

Apply a bead of Loctite 518 thread sealant to the two main bearing cap surfaces on each main bearing cap as shown.

9 Use clean 15W-40 engine oil to lubricate the capscrew threads and flat washers (or the underside of the capscrew heads if washers are not used). Drain the excess oil from the capscrews before installing them.
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CAUTION
The main bearing caps are marked with a `V.' Position the `V' mark so that it points to the front of the engine. Incorrect positioning will result in severe engine damage.

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Align the capscrew holes in the cap with the holes in the cylinder block. Make sure the lower bearing shell is in position. Install the capscrews through the cap and into the cylinder block.

To reduce the possibility of bore size issues, clearance issues, or both, the main bearing capscrews must be tightened within 15 minutes of the Loctite 518 thread sealant application.

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10 Make sure the bearing shell does not move. Tighten the capscrews in far enough to use a heel bar to pry the caps into place.

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Tighten both of the capscrews on a main bearing cap to 203 Nm [150 ft-lb]. Loosen both capscrews completely. The remaining main bearings do not have thrust bearings.
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It is recommended to use an air impact wrench and socket, Tool Numbers 3163059 and 3163060, to rotate the capscrews an additional 180 degrees. Use the torque plus angle method to tighten the main bearing capscrews in the sequence shown. Torque Value: Step 1 Step 2 149 n.m [110 ft-lb] Rotate 180 degrees.
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To measure the end clearance of the crankshaft, install a dial indicator onto the oil pan flange. Place the tip of the gauge against the crankshaft counterweight. Push the crankshaft toward the rear of the cylinder block.
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Set the dial indicator at "0" (zero). Push the crankshaft toward the front of the cylinder block.

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If the end clearance is less than 0.10 mm [0.004 in], loosen all main bearing capscrews one turn. Push the crankshaft toward the front and then toward the rear of the cylinder block.

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Tighten the main bearing capscrews in sequence. Block Main Bearing Capscrews Step 2 Step 3 149 n.m [110 ft-lb] Rotate 180 degrees.
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12 Measure the crankshaft end clearance. Crankshaft End Clearance - New or Reground mm in 0.10 MIN 0.004 0.50 MAX 0.020
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Crankshafts that have been reground on the thrust bearing surfaces are marked for oversize thrust bearings on the rear crankshaft counterweight. If the crankshaft counterweight is marked, check the thrust ring part number to make sure the correct thrust ring size is used. Example: F0.010 = front 0.25 mm [0.010 in] Example: R0.020 = rear 0.51 mm [0.020 in]
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If the crankshaft end play is more than 0.50 mm [0.020 in], the engine must be removed to allow for replacement of the crankshaft. Refer to Procedure 000-001 (Engine Removal) in Section 0.

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Bearings, Thrust (001-007)

13

Install
Use Lubriplate 105, or equivalent, to coat the upper thrust bearings.

TOC

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Push the crankshaft toward the rear of the engine to install the rear thrust bearing, and to the front of the engine to install the front thrust bearing. Install the upper thrust bearings in the number four main bearing saddle. The bevel must be toward the crankshaft.
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Use Lubriplate 105, or equivalent, to coat the lower thrust bearings. Install the lower thrust bearings in the number four main bearing cap as shown. The bevel of the thrust bearing must be toward the crankshaft.
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Crankshaft (001-016)

14

Install

TOC

WARNING
This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

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CAUTION
Use a lifting strap that will not damage the crankshaft. Do not drop the crankshaft on the bearings.

Install the main bearings. Refer to Procedure 001006 (Bearings, Main) in Section 1. The end of the crankshaft with the smallest diameter must point toward the front of the cylinder block. Install the crankshaft.

Lubricating Oil Pump (007-031)

Install

TOC

15 Align dowels on oil pump with mounting holes in the cylinder block. Install the oil pump, shims (if they were removed), and the four capscrews. Tighten the capscrews. Torque Value: n.m 56 ft-lb ] [41
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Use a dial indicator, check the oil pump idler gear back lash. Oil Pump Idler Gear Backlash mm in 0.241 MIN 0.009 0.254 NOM 0.010 0.267 MAX 0.011

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CAUTION
Improper gear lash can cause damage to the gear train and the lubricating oil pump.
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Shims will be available in six different thicknesses in order to provide correct lash. The various thicknesses are identified by the color of the shim. Identify the number stamped on the pump (1) and the block (2). Use the following table to determine which shim should be used according to the stamped number.

If a lube pump or cylinder block is replaced, the block and pump will not be stamped. In that instance, a shim must be chosen and installed. The oil pump idler gear backlash must be checked. If the backlash is not within the specification, choose another size shim and recheck the backlash. Do this until the backlash is within specification.

16 Block Pump 1 A 0.000 mm [0.000 in]None0.45 mm [0.018 in]Black0.55 mm [0.022 in]Purple0.35 mm [0.014 in]YellowB 0.45 mm [0.018 in]Black0.65 mm [0.026 in]Red0.75 mm [0.030 in]Blue0.55 mm [0.022 in]PurpleC 0.55 mm [0.022 in]Purple0.75 mm [0.030 in]Blue0.85 mm [0.033 in]Green0.65 mm [0.026 in]RedD 0.35 mm [0.014 in]Yellow0.55 mm [0.022 in]Purple0.65 mm [0.026 in]Red0.45 mm [0.018 in]Black-

Check the oil pump idler gear backlash.

Oil Pump Idler Gear Backlash mm 0.254 0.13 NOMINAL TOLERANCE in 0.010 0.005
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If the lubricating oil pump is not within specifications the shims must be changed to proper thickness to give proper backlash.

Lubricating Oil Pump (007-031)

Install

TOC

17 Align dowels on oil pump with mounting holes in the cylinder block. Install the oil pump, shims (if they were removed), and the four capscrews. Tighten the capscrews. Torque Value: n.m 56 ft-lb ] [41
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Use a dial indicator, check the oil pump idler gear back lash. Oil Pump Idler Gear Backlash mm in 0.241 MIN 0.009 0.254 NOM 0.010 0.267 MAX 0.011

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CAUTION
Improper gear lash can cause damage to the gear train and the lubricating oil pump.
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Shims will be available in six different thicknesses in order to provide correct lash. The various thicknesses are identified by the color of the shim. Identify the number stamped on the pump (1) and the block (2). Use the following table to determine which shim should be used according to the stamped number.

If a lube pump or cylinder block is replaced, the block and pump will not be stamped. In that instance, a shim must be chosen and installed. The oil pump idler gear backlash must be checked. If the backlash is not within the specification, choose another size shim and recheck the backlash. Do this until the backlash is within specification.

18 Block Pump 1 A 0.000 mm [0.000 in]None0.45 mm [0.018 in]Black0.55 mm [0.022 in]Purple0.35 mm [0.014 in]YellowB 0.45 mm [0.018 in]Black0.65 mm [0.026 in]Red0.75 mm [0.030 in]Blue0.55 mm [0.022 in]PurpleC 0.55 mm [0.022 in]Purple0.75 mm [0.030 in]Blue0.85 mm [0.033 in]Green0.65 mm [0.026 in]RedD 0.35 mm [0.014 in]Yellow0.55 mm [0.022 in]Purple0.65 mm [0.026 in]Red0.45 mm [0.018 in]Black-

Check the oil pump idler gear backlash.

Oil Pump Idler Gear Backlash mm 0.254 0.13 NOMINAL TOLERANCE in 0.010 0.005
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If the lubricating oil pump is not within specifications the shims must be changed to proper thickness to give proper backlash.

Gear Housing, Front (001-033)

Install

TOC

19 Remove the protective plug from the cylinder block oil passage. Make sure no debris enters the lubrication system. Use a clean shop towel, carefully wipe out the oil passage and inspect to make sure no debris is left in the passages.

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Install two guide studs. Install a new gear housing mounting gasket.

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The gear housing has the words Special Capscrew cast into the housing at the number 1 mounting location (see illustration). This capscrew must be the short head capscrew to prevent contact between the capscrew and the idler gear.

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WARNING
This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.
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20 Install the gear housing.

Install the 18 mounting capscrews. Four different length capscrews are utilized on the front gear housing. Use the table below to identify the capscrews and their mounting locations.

Capscrew Mounting Location Location 14 18, 19, 20 1 All remaining Size M10 x 1.5 x 93 M10 x 1.5 x 70 M10 x 1.5 x 21.8 (Special Short Head) M10 x 1.5 x 2.5 Quantity 1 3 1

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15

Remove the guide studs and install two capscrews. Tighten the capscrews in the sequence shown. All Capscrews Except (1) Step 2 Step 3 Capscrew (1) Step 2 Step 3 20 n.m [15 ft-lb] 56 n.m [41 ft-lb] 20 n.m [15 ft-lb] 72 n.m [53 ft-lb]

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Flywheel Housing (016-006)

Install
Remove the protective plug from the block oil passages. Make sure debris does not enter the lubrication system. Use a clean shop towel to carefully wipe out the oil passage and inspect to make sure no debris is left in the passage.
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TOC

Install the cover plate and two capscrews. Tighten the capscrews. Torque Value: n.m 11 in-lb ] [97

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Install two guide studs into the cylinder block to help support and align the housing during installation. Position the flywheel housing gasket to the rear of the engine block using the guide pins.

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22 Install the flywheel housing over the guide studs. Lubricate the threads and underneath the heads of the capscrews with clean 15W-40 lubricating oil. Install capscrews 1, 2, 3, and 4, and tighten in the sequence shown. Torque Value: n.m 7 in-lb ] [62
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The flywheel housing is located on the block by two ring dowels from the factory. If a flywheel housing is removed, it can be reinstalled with the ring dowels in place, but alignment must be checked with the following alignment procedure. If the alignment does not meet specification, the ring dowels must be removed and the housing must be realigned without the ring dowels.

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CAUTION
The flywheel housing bore and surface must be in alignment with the crankshaft to prevent possible damage to the engine, the clutch, or the transmission.

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Measure the flywheel housing alignment.

Measure
Bore Alignment

TOC

23 Attach a dial indicator to the crankshaft. Use mounting tool Part Number ST-1325 and indicator Part Number 3376050. The dial indicator can be mounted by any method that holds the extension bar of the indicator rigid so it does not sag. If the bar sags or the indicator slips, the readings obtained will be inaccurate.
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Position the indicator in the 6:00 o'clock position and the gauge at zero.

Slowly rotate the crankshaft. Record the readings obtained at the 9:00 o'clock, 12:00 o'clock, and 3:00 o'clock positions as (a), (b), and (c) in the concentricity work sheet. Recheck zero at the 6:00 o'clock position. The values for (a), (b), and (c) can be positive or negative. Refer to the accompanying figure to determine the correct sign when recording these values.

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CAUTION
Do not force the crankshaft beyond the point where the bearing clearance has been removed. Do not pry against the flywheel housing. These actions can cause false bearing clearance reading.

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Rotate the crankshaft until the dial indicator is at the 12-o'clock position and zero the gauge. Use a pry bar to raise the rear of the crankshaft to its upper limit. Record the value as (d) in the concentricity work sheet. This is the vertical bearing clearance adjustment and will always be positive.

24 Use the concentricity work sheet (see the accompanying illustration) to determine the total vertical and horizontal values. The total horizontal is equal to the 9:00 o'clock reading (1) minus the 3 :00 o'clock reading (c). The total vertical is equal to the 12:00 o'clock reading (b) plus the bearing clearance (d). Example: 6:00 o'clock = reference = 0 9:00 o'clock = [a ] = 0.004 12:00 o'clock = [b ] = 0.003 3:00 o'clock =[c] = -0.002. Using the work sheet and the numbers from the example, the total horizontal value equals 0.006, and the total vertical value equals 0.005.
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Mark the total horizontal value on the horizontal side of the chart and the total vertical on the vertical side of the chart. Use a straightedge to find the intersection point of the total horizontal and total vertical values. The intersection point must fall within the shaded area for the flywheel housing concentricity to be within specification. Using the total horizontal and total vertical values from the previous example, the intersection point falls within the shaded area. Therefore, the flywheel housing concentricity is within specification. Use the accompanying chart for SAE 1, 2, and 3 flywheel housings.

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25 Use the accompanying chart for SAE 0 and flywheel housings.

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Use the accompanying chart for SAE 00 flywheel housings.

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If the intersection point falls outside the shaded area, the ring dowels must be removed and the housing repositioned. The ring dowels are not required to maintain concentricity of the housing; the clamping force of the capscrews holds the housing in place. After the ring dowels are discarded, install the flywheel housing on the engine. To position the housing, tighten the capscrews enough to hold the flywheel housing in place, but loose enough to enable small movement when struck lightly with a mallet. Recheck the concentricity. When concentricity is within specification, tighten the capscrews to the specified value. Face Alignment
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CAUTION
The dial indicator tip must not enter the capscrew holes, or the gauge will be damaged.
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Install a dial indicator as illustrated. The extension bar for the indicator must be rigid for an accurate reading. It must not sag. Position the indicator at the 12:00 o'clock position. Adjust the dial until the needle points to zero.

Slowly rotate the crankshaft. Record the readings at the 3:00 o'clock, 6:00 o'clock, and 9:00 o'clock positions. The crankshaft must be pushed toward the front of the engine to remove the crankshaft end clearance each time a position is measured.
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Continue to rotate the crankshaft until the indicator is at the 12:00 o'clock position. Check the indicator to make sure that the needle points to zero. If it does not, the readings will be incorrect.

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27 Determine the total indicator runout.

Total Indicator Runout (Example) Position 12:00 o'clock 3:00 o'clock 6:00 o'clock 9:00 o'clock Total Indicator Runout = Runout 0.00 mm [0.000 in] +0.08 mm [+0.003 in] -0.05 mm [-0.002 in] +0.08 mm [+0.003 in] 0.13 mm [0.005 in]
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The maximum allowable total indicator reading is determined by the diameter of the housing bore. If out of specifications, replace the housing.

SAE Number

Bore Diameter

Total Indicator Runout Maximum

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28 447.68 to 447.80 mm [17.652 to 17.630 in] 409.58 to 409.70 mm [16.125 to 16.130 in]

0.20 mm [0.008 in]

0.20 mm [0.008 in]

Install the remaining capscrews. Tighten all capscrews in two steps using the sequence shown. Torque Value: Step 1 Step 2 100 n.m [74 ft-lb] 197 n.m [145 ft-lb]
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Crankshaft Seal, Rear (001-024)

Install
The rear crankshaft seal must be oriented with the engine as shown in the illustration.

TOC

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29

CAUTION
Never use a hammer or mallet to install the seal. Damage to the seal can occur.
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Do not use lubricants to install the seal. Apply a 10percent soap solution to the outer-ribbed surface of the seal. Guide the rear crankshaft seal (1), spacer (2), and replacer plate (3) over the crankshaft.

NOTE: Spacer, Part Number 4918688, is used to make sure of the correct installation depth of the crankshaft seal. The flat side of the spacer should contact the crankshaft seal during installation. NOTE: Three guide pins, Part Number 3164765, are required on REPTO applications to support the REPTO crankshaft gear and the replacer plate.

CAUTION
The rear crankshaft seal must be pressed evenly into the bore. Misalignment of the seal can cause damage.
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30 Finger-tighten the three installation capscrews against the replacer plate. Tighten the screws not more than of a turn at a time, in a clockwise pattern, until the installation tool seats against the flywheel housing. Tighten the screws. Torque Value: n.m 16 in-lb ] [142

Remove the replacer plate.

Measure
Measure the protrusion of the outer rubber portion (A) of the seal relative to the inner metal portion of the seal (B). Set the dial indicator to zero on the inner metal portion of the seal. Measure and record the protrusion of the outer rubber portion of the seal. Repeat the measurement in four locations equally spaced around the crankshaft seal. The protrusion measurement at each location must be within +/- 1 mm [+/- 0.04 in]. The difference between any of the four protrusion measurements must be within +/- 0.5 mm [0.02 in]. If either of these conditions are not met, the rear crankshaft seal must be removed and a new seal installed.
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TOC

31

Flywheel (016-005)

Install
Install the pilot bearing spacer into the rear of the crankshaft with the spacer lip oriented outward.

TOC

NOTE: A small amount of clean Lubriplate 105 multi-purpose lubricant, or its equivalent, can be used to help keep the pilot bearing spacer in position until the flywheel is assembled.

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CAUTION
The flywheel mounting capscrews must be a minimum of SAE Grade 8 with rolled threads. Use identical replacements to avoid possible flywheel failure resulting in personal injury or property damage.

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Lubricate the threads and underneath the heads of the capscrews with clean 15W-40 oil. Allow the excess oil to drip off the parts. Do not lubricate the threads of the crankshaft.

32

WARNING
This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component.
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Use two M6 x 1.5 guide studs during assembly. Install the flywheel. The flywheel must be firmly against the crankshaft.

Install the ten capscrews. Remove the t-handles and the guide studs. Install the remaining two capscrews into the holes from which the guide studs were removed. Tighten the capscrews in two steps, use the sequence shown. Torque Value: Step 1 Step 2 125 n.m [92 ft-lb] 250 n.m [184 ft-lb]
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Use a mandrel and hammer to install the pilot bearing. The pilot bearing must be installed even with the pilot bore surface.

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Piston Rings (001-047)

33

Install
Articulated Piston

TOC

CAUTION
Use a copper or aluminum vise protector when installing the connecting rod in a vise to protect the connecting rod from damage.
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The ring gap of each ring must not be aligned with the piston pin or with any other ring. If the ring gaps are not aligned correctly, the rings will not seal properly. Place the connecting rod in a vise to hold the assembly in a horizontal position while installing the rings.

A cross-sectioned view of an oil control ring is shown. The two-piece oil control ring must be installed with the expander ring gap 180 degrees from the gap of the oil ring. Do not overlap the ends of the expander ring.
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34 Install the piston rings with TOP toward the top of the piston. The rings have the top marked for correct installation. The oil control ring is symmetrical and can be installed in either orientation.
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The piston must be held in a horizontal position to install the rings in order to keep the rings in the groove while installing the ring compressor. For articulated pistons, the top piston ring (1) is a keystone ring with no twist or cutback notch. The intermediate ring (2) is a positive twist design with a cutback notch (3) on the topside and a twodegree taper face. The oil control ring (4) is the bottom piston ring.
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Rotate the rings to position the ring gaps as shown. The ring gap of each ring must not be aligned with the piston pin, or with any other ring gap. If the ring gaps are not aligned correctly, the rings will not seal properly.
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Single-Piece Piston

35

CAUTION
Use a copper or aluminum vise protector when installing the connecting rod in a vise to protect the connecting rod from damage.
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The ring gap of each ring must not be aligned with the piston pin or with any other ring. If the ring gaps are not aligned correctly, the rings will not seal properly. Install the connecting rod in a vise to hold the assembly in a horizontal position while installing the rings.

A cross-sectioned view of an oil control ring is shown. The two-piece oil control ring must be installed with the expander ring gap 180 degrees from the gap of the oil ring. Do not overlap the ends of the expander ring.
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Install the piston rings with TOP toward the top of the piston. The rings have the top marked for correct installation. The oil control ring is symmetrical and can be installed in either orientation.
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For single-piece pistons, use a universal piston ring expander to install the second ring into the piston.

36 The single-piece ring set is similar to the articulated ring set, with the exception of the second ring. The second ring has a rectangular cross-section (2) with an angled cut (3) on the upper side of the inner diameter to induce a positive twist. This design improves the slobber-resistance of the ring pack. The oil control ring (4) is the bottom piston ring.
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Rotate the rings to position the ring gaps as shown. The ring gap of each ring must not be aligned with the piston pin, or with any other ring gap. If the ring gaps are not aligned correctly, the rings will not seal properly.
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If failure resulted in coolant, oil, excessive fuel or excessive black smoke entering the exhaust system, the aftertreatment system must be inspected. Refer to Procedure 014-013.

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Bearings, Connecting Rod (001-005)

37

Install

TOC

CAUTION
Connecting rod bearings must match the connecting rod design. Drilled rods must use drilled rod bearings. Non-drilled rods must use non-drilled bearings. Mismatches will cause engine damage.

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Connecting rod design must be matched with the proper connecting rod bearing. Drilled connecting rods must be fitted with drilled connecting rod bearings. Non-drilled connecting rods must be fitted with nondrilled connecting rod bearings.

Drilled and non-drilled connecting rods can be mixed in the same engine as long as the two piece piston is used. Engines using single piece pistons can not use nondrilled connecting rods.
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CAUTION
The connecting rod and bearing shell mating surfaces must be clean and dry when the bearing shells are installed. Used bearings must be
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38 installed in their original location or engine damage can occur.

Use clean Lubriplate 105 multi-purpose lubricant, or its equivalent to lubricate the crankshaft journal mating surface of the upper bearing shell. Install the upper bearing shell into the connecting rod with the tang of the bearing in the slot of the rod.

Install the bearing shell into the connecting rod cap with the tang (2) of the bearing in the slot (1) of the cap. Use clean Lubriplate 105 multi-purpose lubricant, or its equivalent to lubricate the bearing shell to crankshaft journal mating surface and the connecting rod capscrews.
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CAUTION
The rod cap alpha characters must match the alpha characters on the connecting rod and must be installed with the characters aligned to prevent damage to the connecting rods and crankshaft. The locking tang of the connecting rod cap must face toward the intake side of the cylinder block. Rod and cap mating surfaces must be clean or engine damage can occur.

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Install the cap onto the connecting rod.

39 Lubricate the threads of the capscrews with clean engine oil. Thread the capscrews into the connecting rod and hand tighten. The procedure for tightening used capscrews is different than the procedure for tightening new capscrews. For used connecting rod capscrews: Tighten Capscrews in Numerical Sequence Step 2 70 6 n.m [52 4 ftlb] Rotate capscrews in numerical sequence 60 5 degrees

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Step 3

For new connecting rod capscrews: Tighten Capscrews in Numerical Sequence Step 2 Step 3 Step 4 40 6 n.m [29 4 ftlb] Loosen capscrews in numerical sequence 70 6 n.m [52 4 ftlb] Rotate capscrews in numerical sequence 60 5 degrees

Step 5

Measure the connecting rod side clearance.

Connecting Rod Side Clearance mm in


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40 0.10 0.33 MIN MAX 0.004 0.013

NOTE: The connecting rod must move freely from side to side on the crankshaft journal. If the rod does not move freely, remove the rod cap and make sure the bearing shells are the correct size. Check for dirt or damage on the crankshaft and the bearing shells.
Repeat the above steps to install the remaining

Piston and Connecting Rod Assembly (001-054)

Install
Immerse the piston in a container of clean 15W40 oil. Remove the piston from the container. Let the excess oil drain from the piston.

TOC

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41 Use piston ring compressor, Part Number 3164846, to compress the rings. The cylinder block and all parts must be clean before assembly. Inspect the cylinder liners for reuse. Refer to Procedure 001-028.
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Use a clean, lint-free cloth to clean the connecting rods and bearing shells. Do not lubricate the backside of the bearing shells. The operating clearance of the bearing will be reduced and the bearing can be damaged during engine operation.
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If new bearings are not used, the used bearings must be installed on the same connecting rod from which they were removed. Install the upper bearing shell into the connecting rod. The tang of the bearing shell (2) must be in the slot of the cap (1). The end of the bearing shell must be even with the cap mounting surface.
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Use Lubriplate 105, Part Number 3163086, or equivalent, to coat the entire inside circumference of the bearing shell. Apply a film of clean 15W-40 oil to the cylinder liner.

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42

Install connecting rod guide pins, Part Number 3163097.

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Use the compressor drive or barring device to rotate the crankshaft so the connecting rod journal of the connecting rod being installed is at bottom dead center.

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CAUTION
Failure to align the deep valve pocket and the piston skirt cooling nozzle notch correctly will result in extensive engine damage.
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43 and assemble correctly. Insert the connecting rod through the cylinder liner until the ring compressor contacts the top of the liner.

Both articulated pistons and single-piece pistons have an arrow on the top of the piston crown, which will point to the front of the engine, when the piston is installed properly.

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CAUTION
Do not use a metal drift to push the piston into the cylinder liner. The piston rings or cylinder liner can be damaged.
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Hold the ring compressor against the cylinder liner. Push the piston through the ring compressor and into the cylinder liner. Push the piston until the top ring is completely in the cylinder liner. If the piston does not move freely, remove the piston and inspect for broken or damaged rings.

Use the nylon guide pins to align the connecting rod with the crankshaft while pushing the piston and connecting rod assembly into place. Remove the nylon guide pins.

44
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Piston Cooling Nozzle (001-046)

Install

TOC

CAUTION
Properly align the nozzles in the locator notch before tightening the capscrews. Damage to the engine can occur.
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The crankshaft must be rotated to allow access to install all the nozzles. Install the nozzle, washers, and capscrews. Tighten the capscrews. Torque Value: n.m 65 ft-lb ] [48

Block Stiffener Plate (001-089)

45

Install
Install the block stiffener plate and the 10 capscrews. Tighten the capscrews. Torque Value: n.m 137 ft-lb ] [102

TOC

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Lubricating Oil Suction Tube (Block-Mounted) (007-035)

Install
Lubricate the o-ring with clean 15W-40 engine oil. Install the new o-ring on the oil suction tube.

TOC

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46 Install the oil suction tube into the lubricating oil pump. Install the lubricating oil suction tube capscrews. Tighten capscrews. Torque Value: n.m 47 ft-lb ] [35

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Lubricating Oil Pan (007-025)

Install
Apply a 1.97 mm [1/8 in] bead of silicon sealant, Part Number 3164067, to each of the four T-joints where the front gear housing and flywheel housing gaskets intersect the oil pan gasket.

TOC

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Install a new oil pan gasket. Install the oil pan onto the cylinder block. Install one of the 13 mm oil pan mounting capscrews, hand tight, on each side of the oil pan, halfway between the front and the rear of the oil pan. Finger-tighten all or the mounting capscrews.
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47

Tighten the thirty-two 13 mm capscrews in the sequence shown. At the end of the sequence, loosen and tighten capscrew number 1again. Torque Value: Install the oil drain plug. Torque Value: n.m 47 ft-lb ] [35 n.m 55 ft-lb ] [41

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Idler Gear, Lower Concept (001-076)

General Information
Before installation or removal of any gears, read Engine Base Timing. Refer to Procedure 001-088.

TOC

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Engine Support Bracket, Front (016-002)

48

Install
Install the engine support bracket and the six mounting capscrews. Tighten the capscrews. Torque: 97 Nm + 60 deg [72 ft-lb + 60 deg] Install the rubber engine mounts into the crossmember.
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TOC

WARNING
This assembly weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this assembly.
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Lower the front of the engine to the rubber engine mounts. The capscrew holes in the support bracket must be aligned with the capscrew holes in the engine mounts. Install the two capscrews in the support bracket and engine mount. Tighten to the manufacturer's specifications. Remove the lifting fixture or the hoist from the engine.

Cylinder Head (002-004)

49

Install
Two different styles of head gaskets are used on Signature, ISX, and QSX15 engines based on the style of liner used in the engine. Refer to Procedure 001-028 (Cylinder Liner) in Section 1 to correctly identify which style of liner is used. Install the cylinder head gasket.
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TOC

WARNING
This assembly weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this assembly.
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Use engine lifting fixture, Part Number 3162996, to lift the cylinder head. Two long cylinder head capscrews placed toward each end of the cylinder head serve as convenient guides when lowering the cylinder head into place. Align the cylinder head over the dowel pins and lower into position.

Use clean 15W-40 oil to lubricate the cylinder head capscrews. Allow the excess oil to drain from the threads. Install 26 capscrews into the cylinder head.
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50

CAUTION
Make sure the four longer capscrews placed in the correct location. Engine damage can occur if these capscrews are not placed in the correct locations.
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Tighten capscrews in sequence. It is recommended to use an air impact wrench and socket, Tool Number 3163059 and 3163484, to rotate the capscrew 90 degrees. Torque Value: Step 1 Step 2 Step 3 200 n.m [148 ft-lb] 405 n.m [300 ft-lb] Rotate 90 degrees.

Overhead Camshaft, Injector (002-025)

Install

TOC

CAUTION
Use caution when installing the camshaft to avoid damaging the camshaft bushings.

51
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Coat the inside of the injector camshaft bearings with Lubriplate prior to installing camshaft. Install the injector camshaft.

Install new o-rings on the retainer plate. Install the retainer plate and capscrews. Tighten the capscrews. Torque Value: n.m 40 ft-lb ] [30

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Install the injector camshaft cover plate with new gasket. Install the capscrews. Tighten the capscrews. Torque Value: n.m 40 ft-lb ] [30
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Overhead Camshaft, Valve (002-024)

Install

TOC

52

CAUTION
Use caution when installing the camshaft to avoid damaging the camshaft bushings.
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Coat the inside of the valve camshaft bushings with Lubriplate prior to installing camshaft. Install the valve camshaft.

Install new o-rings onto the retainer plate. Install the retainer plate and capscrews. Tighten the capscrews. Torque Value: n.m 40 ft-lb ] [30

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Engine Base Timing (001-088)

Install

TOC

53 Timing Wedges: The timing code is located on the engine dataplate.


First number - injector wedge Second number - valve wedge.


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Make sure the wedges with the proper angles are used and that the wedges are properly seated in their installed position. Insert the correct timing wedge to lock the injector camshaft. Lightly tap the top of the timing wedge with a mallet to be sure it is properly seated.
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WARNING
Do not drive the wedges into place. Engine damage can occur. Make sure the wedges with the proper angles are used and that the wedges are properly seated in their installed position. Insert the correct timing wedge to lock the valve camshaft. Lightly tap the top of the timing wedge with a mallet to be sure it is properly seated. Lower Idler Scissor Gear
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54 The lower scissor idler gear must be unloaded during installation. To unload the gear, two of the gear screws must be backed out far enough to allow the teeth on the scissor gear to be aligned. Apply Lubriplate to the thrust bearing, shaft, and lower scissor idler gear. Install the thrust bearing, shaft, and lower scissor idler gear. The shaft must be installed with the word TOP (stamped on the end of the shaft) toward the top of the engine.
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The lower idler scissor gear front retainer plate is larger in diameter than the adjustable idler retainer plate. The slots in the plate go toward the scissor gear Install the retainer and capscrews. Tighten all capscrews in a star pattern.
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Torque Value:

Step 1

30 n.m [22 ft-lb] Rotate each capscrew an additional 60 degrees in the same sequence as above.

Step 2

CAUTION
Make sure all the scissor gear screws are tightened to the proper torque so that they do not back out during engine operation. Severe engine
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55 Torque Value: n.m 28 in-lb ] [248

Lower Idler Non-Scissor Gear Apply Lubriplate to the thrust bearing, shaft, and lower non-scissor idler gear. Install the thrust bearing, shaft, and lower nonscissor idler gear. The shaft must be installed with the word TOP (stamped on the end of the shaft) toward the top of the engine.
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The lower idler non-scissor gear front retainer plate is larger in diameter than the adjustable idler retainer plate. The slots in the plate go toward the scissor gear Install the retainer and capscrews. Tighten all capscrews in a star pattern.
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Torque Value:

Step 1

30 n.m [22 ft-lb] Rotate each capscrew an additional 60 degrees in the same sequence as above.

Step 2

Adjustable Idler Gear The spacer plate is doweled to the block with two standard dowels. Install the mounting spacer plate.

56
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Apply Lubriplate to the spacer, shaft, and adjustable idler gear. It is possible to install the shaft in an incorrect orientation; however, it will not be possible to set the gear backlash correctly. Install the spacer, shaft and adjustable idler gear. The shaft must be installed with the word TOP (stamped on the front face of the shaft) oriented toward the top of the engine.
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The adjustable idler front retainer plate is smaller in diameter than the lower idler scissor gear retainer plate. The slots on the retainer plate go toward the gear. The adjustable idler gear is installed loosely, because it is moved into its final position later in the timing process.
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Install the retainer and capscrews. Finger-tighten the capscrews and then loosen by one flat, which is 60 degrees. Injector Camshaft Scissor Gear Install the injector camshaft rear cover plate. Torque Value: n.m 40 ft-lb ] [30

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57

CAUTION
The injector camshaft nose and injector camshaft scissor gear must be clean and dry prior to assembly. Wipe off the taper surface with a clean lint-free cloth and apply a thin coat of Loctite 609, Part Number 3823718, to the inside diameter of the camshaft gear. Use care not to contaminate the joint with oil prior to assembly or engine damage may occur.

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The injector camshaft scissor gear must be unloaded during installation. To unload the gear, two of the gear screws must be backed out far enough to allow the teeth on the scissor gear to be aligned.

Apply a thin coat of Loctite 609, Part Number 3823718, to the inside diameter of the camshaft gear.

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The injector camshaft scissor gear needs to be fully engaged on the camshaft nose taper, yet loose enough so it can rotate on the camshaft nose. Install the injector camshaft scissor gear loosely on the camshaft nose taper. The injector camshaft scissor gear mounting washer is larger in diameter than the valve camshaft mounting washer. Install the mounting washer and capscrew.
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58 Finger-tighten the capscrew and then loosen by one flat, which is 60 degrees. The injector camshaft scissor gear is still loose at this point, to allow the adjustable idler gear to be properly positioned. Do not seat the gear.
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Injector Camshaft Non-Scissor Gear Install the injector camshaft rear cover plate. Torque Value: n.m 40 ft-lb ] [30

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CAUTION
The injector camshaft nose and injector camshaft non-scissor gear must be clean and dry prior to assembly. Wipe off the taper surface with clean a lint-free cloth and apply a thin coat of Loctite 609, Part Number 3823718, to the inside diameter of the camshaft gear. Use care not to contaminate the joint with oil prior to assembly or engine damage may occur.

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59 Apply a thin coat of Loctite 609, Part Number 3823718, to the inside diameter of the camshaft gear.

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The injector camshaft non-scissor gear needs to be fully engaged on the camshaft nose taper, yet loose enough so it can rotate on the camshaft nose. Install the injector camshaft non-scissor gear loosely on camshaft nose taper. The injector camshaft non-scissor gear mounting washer is larger in diameter than the valve camshaft mounting washer. Install the mounting washer and capscrew.
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Finger-tighten the capscrew and then loosen by one flat, which is 60 degrees. The injector camshaft non-scissor gear is still loose at this point to allow the adjustable idler gear to be properly positioned. Do not seat the gear.
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Valve Camshaft Gear

60

CAUTION
The valve camshaft nose and valve camshaft gear must be clean and dry prior to assembly. Wipe off the taper surface with a clean lint-free cloth and apply a thin coat of Loctite 609, Part Number 3823718, to the inside diameter of the camshaft gear. Use care not to contaminate the joint with oil prior to assembly or engine damage may occur.

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Apply a thin coat of Loctite 609, Part Number 3823718, to the inside diameter of the camshaft gear.

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The valve camshaft gear needs to be fully engaged on the camshaft nose taper, yet loose enough so it can rotate on the camshaft nose. Install the valve camshaft gear loosely on the camshaft nose taper. The valve camshaft mounting washer is smaller in diameter than the injector camshaft scissor gear mounting washer. Install the mounting washer and capscrew.
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61 Finger-tighten the capscrew and then loosen by one flat, which is 60 degrees. The valve camshaft gear is still loose at this point to allow the adjustable idler gear to be properly positioned. Do not seat the gear.
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Adjust
Backlash (Non Gear Combinations)

TOC

CAUTION
Do not set backlash between the adjustable idler gear and the lower scissor idler gear. Severe engine damage can occur.
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62 Shim Tolerance mm 0.225 0.275 MIN MAX in 0.009 0.011

NOTE: The gear backlash set procedure for engines that have a non-scissor injector camshaft gear and a scissor type lower idler gear is the same as that of engines that utilize two scissor type gears. Use hand pressure, only, to move the adjustable idler gear toward the center of the engine (into mesh), so there is no gap on either side of the shim. Both of the camshaft gears will rotate slightly on the camshafts during this step. Slight drag will be felt on the shim while pulling the shim in and out. Backlash (Non-Scissor Gear Combinations) Removal of the lower front cover is not required when setting the gear backlash on engines that utilize all non-scissor gears. An access hole is provided to insert a shim between the lower non-scissor idler gear and the adjustable idler gear. The access hole is sealed with a plug. The plug can be pushed out from the rear side without removing the gear cover. The following procedure will be shown with the lower gear cover removed.
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Insert, as shown, a shim (0.25 mm [0.010 in]) into the gear teeth mesh between the adjustable idler gear and the injector camshaft gear. The shim is inserted on the load side of the gear teeth. Insert, as shown, a shim (0.25 mm [0.010 in]) into the gear teeth mesh between the adjustable idler

63 inserted on the load side of the gear teeth. Use hand pressure, only, to move the adjustable idler gear so there is no gap between the teeth and either side of the shims. Both of the camshaft gears will rotate slightly on the camshafts during this step. Slight drag will be felt on the shim while pulling the shim in and out. Adjustable Idler Gear While holding the adjustable idler gear in position, tighten the adjustable idler gear mounting capscrews. Torque Value: Step 1 30 n.m [22 ft-lb] Rotate each capscrew an additional 60 degrees in the same sequence as above.
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Step 2

Remove the feeler gauge. Injector Camshaft Scissor Gear

CAUTION
Make sure all the scissor gear screws are tightened to the proper torque so that they do not back out during engine operation. Severe engine
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64 Value: 28 [248

The valve camshaft gear will rotate slightly on the valve camshaft during this step.

Tighten the injector camshaft scissor gear retaining capscrew. Torque Value: Step 1 Step 2 216 n.m [159 ft-lb] Rotate an additional 90 degrees
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Injector Camshaft Non-Scissor Gear Use hand pressure only to rotate the injector camshaft gear clockwise until the gear train backlash is taken up. Obtain tooth-to-tooth contact between the crankshaft gear and the injector camshaft gear.

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Tighten the injector camshaft non-scissor gear retaining capscrew. Torque Value: Step 1 Step 2 218 n.m [161 ft-lb] Rotate 90 degrees.
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65 Valve Camshaft Scissor Gear Tighten the valve camshaft scissor gear retaining capscrew. Torque Value: n.m 148 ft-lb ] [109

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Valve Camshaft Non-Scissor Gear Use hand pressure, only, to rotate the valve camshaft gear counterclockwise until the backlash between the injector camshaft gear is taken up. Obtain toothto-tooth contact between the injector camshaft gear and the valve camshaft gear.

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Tighten the valve camshaft non-scissor gear retaining capscrew. Torque Value: n.m 148 ft-lb ] [109

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66 Coat the entire gear train with clean 15W-40 oil.

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Use the access hole in the lower gear cover to lubricate the lower idler gear and crankshaft.

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Air Compressor (012-014)

Install

TOC

67 Pin the engine crankshaft. Refer to Procedure 001-088. Rotate the gear on the air compressor until the mark on the gear is in line with the V-notch on the air compressor housing, located at the three o'clock position as viewed from the front. Loctite, Part Number 3824040 or equivalent, must be used on the capscrews which mount the air compressor to the gear housing. This seals the threads in the housing. To evenly distribute the sealant as the capscrew is torqued, a line of sealant should be placed along the length of the capscrew. Install the air compressor and the four capscrews onto the front gear housing.
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Tighten the capscrews. Torque Value: n.m 45 ft-lb ] [33

Tighten capscrews again. Torque Value: n.m 45 ft-lb ] [33


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Install the air compressor mounting brace and four capscrews on the block beneath the air compressor. Start threading all four capscrews.

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68 Torque the capscrews on the cylinder block and air compressor. Torque Value: n.m 45 ft-lb ] [33

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Use two elbows and run the locking nuts all the way up prior to installation Start threading the elbows in the cylinder head. Use a 24 mm open-ended wrench to position the elbows.
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Install the U-shaped water inlet tube in the left elbow, start threading the compression nut. Install the other end of the water inlet tube into the grommet in the cylinder block.

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Insert the water outlet tube into the other elbow and start threading the compression nut. Install the other end of the water inlet tube into the grommet in the cylinder block.

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69

Start threading the capscrews in the two locations designated by the arrows. Torque the capscrews. Torque Value: n.m 45 ft-lb ] [33
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Tighten the compression nuts and elbow locking nuts.

Install the air discharge line. Torque Value: Install the air inlet line. Tighten the hose clamp. Torque Value: n.m 8 in-lb ] [71
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n.m 60

ft-lb ] [44

Install the air governor (if removed). Connect the air governor pressure signal line.

Gear Cover, Lower (001-080)

Install

TOC

70 Install a new strip seal. Orient the overlap joint to the upper left of the gear housing as shown. Use a small amount of RTV at the overlap joint of strip seal.
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NOTE: Do not tighten the capscrews until the new crankshaft seal is installed. The crankshaft seal must be installed first to locate the gear cover properly.
Position the lower gear cover with the 15 capscrews. Hand-tighten the capscrews.
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Install a new crankshaft seal. Refer to Procedure 001-023 (Crankshaft Seal, Front) in Section 1.

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Tighten the 15 capscrews in the sequence shown. Torque Value: n.m 28 in-lb ] [248

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71

Vibration Damper, Viscous (001-052)

Install
Automotive Applications

TOC

Make sure the mounting surfaces of the crankshaft nose, vibration damper, and the pulley are clean, dry, and free from burrs. Install two guide studs into the crankshaft nose. Align the dowel pin in the crankshaft wit the dowel hole in the vibration damper.
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Install the vibration damper, pulley, and clamping plate onto the guide plate.

Use clean 15W-40 oil to lubricate the capscrew threads. Install 10 capscrews. Remove the two guide studs and install the remaining capscrews. Tighten the capscrews in a star pattern. Torque Value: n.m 175 ft-lb ] [130
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72 Industrial and Power Generation with Crank-Driven Fan or PTO Make sure the mounting surfaces of the crankshaft nose, vibration dampers, mounting spacer, and pulley are clean, dry, and free from burrs. Install two guide studs into the crankshaft nose.

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Install one of the vibration dampers (1), mounting spacer (2), second vibration damper (3), and the pulley (4) onto the guide studs.

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Lubricate the capscrew threads with clean 15W-40 oil. Install four capscrews. Remove the two guide studs and install the remaining two capscrews. Tighten the six capscrews in a star pattern. Torque Value: n.m 175 ft-lb ] [130
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73 Install the crankshaft adapter (1). Make sure the crank shaft adapter sets flush against the pulley (2). Lubricate the capscrew threads with clean 15W-40 oil. Install the six capscrews and tighten in a star pattern. Torque Value: n.m 175 ft-lb ] [130
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Industrial and Power Generation without Crank-Driven Fan or PTO Make sure the mounting surfaces of the crankshaft nose, vibration dampers, mounting spacer, and pulley are clean, dry, and free from burrs. Install two guide studs into the crankshaft nose.

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Install one of the vibration dampers (1), mounting spacer (2), second vibration damper (3), and the pulley (4) onto the guide studs.

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74 Lubricate the capscrew threads with clean 15W-40 oil. Install 10 capscrews. Remove the two guide studs and install the two remaining capscrews. Tighten the 12 capscrews in a star pattern. Torque Value: n.m 175 ft-lb ] [130
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Eccentricity Check
All Applications Clean the outside surface of the vibration damper. To measure the vibration damper eccentricity (out of round), install a dial indicator onto the gear cover as indicated. Rotate the crankshaft with the accessory driveshaft one complete revolution (360 degrees), and record the total indicator movement. Vibration Damper Eccentricity mm in 0.28 MAX 0.011 If the vibration damper is not within specifications, it must be replaced.

TOC

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Wobble Check

TOC

75 All Applications To measure wobble (face alignment), install a dial indicator as shown. Push the crankshaft to the front or rear of the engine and set the indicator to 0 (zero). Rotate the crankshaft one complete revolution (360 degrees) while maintaining the position of the crankshaft, either toward the front or rear of the engine. Record the total indicator movement. Vibration Damper Wobble Measurement mm in 0.28 MAX 0.011 If the vibration damper is not within specifications, it must be replaced.

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Injector (006-026)

Install
Use clean 15W-40 lubricating oil. Lubricate the orings.

TOC

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76

CAUTION
Make sure the injector hold down clamp is properly aligned before tightening the capscrew. It is possible for the clamp to contact a nearby ledge, and result in low clamp load.

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Install the injector into the cylinder head. Install the injector clamp, and the capscrew with washer. Tighten the capscrew. Torque Value: Install the crossheads. n.m 80 ft-lb ] [59

Rocker Lever Assembly (003-009)

Install

TOC

77 Install the adjusting screw and locknut into each rocker lever. Do not tighten the locknuts.

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Install the injector rocker levers on the shaft. Install the exhaust (1), intake (2), and engine brake (3) rocker levers onto the shaft.

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WARNING
Clear the rocker lever assembly mounting capscrew holes of oil and debris. Extensive engine damage can result if this warning instruction is not followed. Install the valve crossheads. Position the valve/brake rocker lever assemblies onto the cylinder head.

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78

CAUTION
To reduce the possibility of valve rocker shaft damage due to inadequate brake rocker lever running clearance, follow the specified procedure to seat the valve rocker shafts on the cylinder head pedestals (1).

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Each valve rocker shaft must be seated in the cylinder head pedestals prior to tightening the rocker shaft capscrews. The front and rear rocker lever shaft assemblies will seat separately as the engine is rotated in the clockwise direction.

Use the compressor drive or barring device to bar the engine over in the direction of rotation, clockwise as viewed from the front of the engine. Align the A mark on the vibration damper with the timing mark on the gear cover.
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Either the front or the rear rocker shaft assembly will be fully seated on the cylinder head pedestals at this point. Check the position of the front and rear valve rocker shaft assemblies to determine which one is fully seated. Lubricate the capscrews of the fully seated rocker shaft with clean 15W-40 oil.
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79

CAUTION
To reduce the possibility of valve rocker shaft damage because of inadequate brake rocker lever running clearance, follow the specified capscrew torque procedure. The valve rocker lever shaft has a machined flat on the front of the shaft to provide proper brake rocker lever position. Therefore, the front rocker shaft capscrew (1) must be tightened first to control brake rocker lever position. Brake lever running clearance must always be checked after valve rocker lever shaft installation.

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Check the brake running clearance. Refer to Procedure 003-004. Tighten the front mounting capscrew for the fully seated valve rocker lever shaft to the initial torque value to locate the shaft. Torque Value: n.m 30 ft-lb ] [22

Tighten all the capscrews to the final torque value using the torque plus angle method. Tighten the capscrews from the center out. Torque Value: Step 1 Step 2 30 n.m [22 ft-lb] Rotate 60 degrees

Use the compressor drive or barring device to bar the engine over in the direction of rotation, clockwise as viewed from the front of the engine. Align the B mark on the vibration damper with the timing mark on the gear cover. The remaining rocker shaft will be fully seated at this point.
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80 point. Lubricate the capscrews of the fully seated rocker shaft with clean 15W-40 oil.

CAUTION
To reduce the possibility of valve rocker shaft damage because of inadequate brake rocker lever running clearance, follow the specified capscrew torque procedure. The valve rocker lever shaft has a machined flat on the front of the shaft to provide proper brake rocker lever position. Therefore, the front rocker shaft capscrew must be tightened first to control brake rocker lever position. Brake lever running clearance must always be checked after valve rocker lever shaft installation.

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Check the brake running clearance. Refer to Procedure 003-004. Tighten the front mounting capscrew for the remaining valve rocker lever shaft to the initial torque value to locate the shaft. Torque Value: n.m 30 ft-lb ] [22

Tighten all the capscrews to the final torque value using the torque plus angle method. Tighten the capscrews from the center out. Torque Value: Step 1 Step 2 30 n.m [22 ft-lb] Rotate 60 degrees

81 Position the injector rocker lever assemblies onto the cylinder head. Lubricate the injector rocker lever shaft capscrews with clean 15W-40 oil. Install the capscrews and washers. Tighten all the mounting capscrews.
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Torque Value:

n.m 68

ft-lb ] [50

Loosen capscrews one at a time 360 and tighten again, using the torque-plus-angle method. Tighten capscrews from center out. Torque Value: Step 1 Step 2 30 n.m [22 ft-lb] Rotate 60 degrees
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Adjust the valve, injectors, and brake. Refer to Procedure .

Overhead Set (003-004)

Measure
General Information

TOC

82 All overhead lash measurements must be made when the engine is cold. Stabilized coolant temperature must be at 60C [140F] or below.

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Remove the rocker lever cover. Refer to Procedure 003-011 (Rocker Lever Cover) in Section 3. Make sure the engine base timing is properly set before attempting to measure, adjust, or set the overhead. Refer to Procedure 001-088 (Engine Base Timing) in Section 1.
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Early engine vibration dampers are marked with BRAKE SET 1-6, BRAKE SET 2-5, or BRAKE SET 34. The engine brakes must be set at the appropriate mark on these engines. Newer engine vibration dampers are marked with only A, B, or C, and are adjusted with the valves and injector on the same cylinder. Locate the valve set marks on the outside of the vibration damper. The set marks are A, B, and C: Set to mark A to adjust cylinder 1 or 6. Set to mark B to adjust cylinder 2 or 5. Set to mark C to adjust cylinder 3 or 4. Two complete revolutions are required to set all valves, engine brakes, and injectors.
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83 If the engine is equipped with an air compressor: Remove the oil fill connector from the lower gear case cover. Insert a 3/4-inch drive ratchet and extension into the air compressor drive. Rotate the air compressor drive clockwise, as viewed from the front of the engine.
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WARNING
Do not pull or pry on the fan to manually rotate the engine. To do so can damage the fan blades. Damaged fan blades can cause premature fan failures which can result in serious personal injury or property damage. The crankshaft rotation is clockwise, as viewed from the front of the engine. The cylinders are numbered from the front of the engine (1-2-3-4-5-6). The engine firing order is 1-5-3-6-2-4.

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If the engine is not equipped with an air compressor: Loosen the cover plate capscrews and rotate the cover or remove the oil fill tube, if equipped.

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84 Use a 1 inch socket to push the barring gear into the gear mesh and rotate the barring adapter counterclockwise to bar the engine. Rock the barring device back and forth until it disengages.
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Each cylinder has four rocker levers:


The exhaust valve rocker lever (1) The injector rocker lever (2) The intake valve rocker lever (3) The engine brake rocker lever (4).
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The intake valve rocker lever is always the long lever

85 Advance to Advance to Advance to Advance to Advance to Firing Order: 1-53-6-2-4 B C A B C 5 3 6 2 4 5 3 6 2 4 5 3 6 2 4

NOTE: For illustrative purposes, position A is shown as the first step. It is not necessary to start with position A, as long as the proper sequence is followed.
Use the compressor drive or barring device to bar the engine over in the direction of engine rotation, clockwise as viewed from the front of the engine. Align the A mark on the vibration damper with the pointer on the gear cover.

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Check the valve rocker levers on the given cylinder to see if both intake and exhaust valves are closed. Both sets of valves are closed when the rocker levers and the brake lever are loose. If both sets of valves are not closed, rotate the compressor drive gear one complete revolution, and align the A mark on the front damper with the pointer again.
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86 Valve Lash Use feeler gauges to measure the amount of clearance (lash) between the crosshead and the rocker lever nose. Measure and record the intake, exhaust, and brake valve lash. If the valve lash is not within the specifications listed below, the valve must be adjusted. See the adjust step in this procedure.
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Press the brake lever down to verify the camshaft follower is in contact with the camshaft prior to measurement of the brake lash. ISX, QSX Series Valve Lash Recheck Limits Intake Intake Exhaust Exhaust Brake Brake 0.23 mm 0.48 mm 0.56 mm 0.81 mm 6.87 mm 7.13 mm minimum maximum minimum maximum minimum maximum 0.006 in 0.019 in 0.022 in 0.032 in 0.271 in 0.281 in

Brake Running Clearance Rotate the brake lever to the detent (neutral) position. Check the clearance between the engine brake actuator piston and the cross head guide pin (1). If the brake running clearance is not within the specifications listed below, the running clearance must be adjusted. See the Adjust step in this procedure.
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Brake Running Clearance mm 0.635 2.79 Injector Lash There is no service procedure to check the injector free load. Install the rocker lever cover. Refer to Procedure 003011 (Rocker Lever Cover) in Section 3. MIN MAX in 0.025 0.110

87

Adjust
Read the entire procedure for overhead adjustment before attempting to perform this operation. Valves, injectors, and engine brakes (if equipped) must be correctly adjusted for the engine to operate efficiently. Valve, injector, and engine brake adjustment must be performed using the values listed in this section.
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TOC

After an engine rebuild or any major repair where the injector and valve setting must be disturbed, set all of the valves, injectors, and brakes.

Valve, Brake, and Injector Adjustment Values Injector Adjustment is 8 Nm [70 in-lb] Intake Valve Exhaust Valve Engine Brake 0.35 mm [0.014 in] 0.68 mm [0.027 in] 7.00 mm [0.276 in]

Early engine vibration dampers are marked with BRAKE SET 1-6, BRAKE SET 2-5, or BRAKE SET 34. The engine brakes must be set at the appropriate mark on these engines. Newer engine vibration dampers are marked with only A, B, or C, and are adjusted with the valves and injector on the same cylinder. Locate the valve set marks on the outside of the
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88 Set to mark A to adjust cylinder 1 or 6. Set to mark B to adjust cylinder 2 or 5. Set to mark C to adjust cylinder 3 or 4. Two complete revolutions are required to set all valves, engine brakes, and injectors.

If the engine is equipped with an air compressor: Remove the oil fill connector from the lower gear case cover. Insert a 3/4-inch drive ratchet and extension into the air compressor drive. Rotate the air compressor drive clockwise, as viewed from the front of the engine.
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WARNING
Do not pull or pry on the fan to manually rotate the engine. To do so can damage the fan blades. Damaged fan blades can cause premature fan failures which can result in serious personal injury or property damage. The crankshaft rotation is clockwise as viewed from the front of the engine. The cylinders are numbered from the front of the engine (1-2-3-4-5-6). The engine firing order is 1-5-3-6-2-4.

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89 If the engine is not equipped with an air compressor: Loosen the capscrews and rotate the cover or remove the oil fill tube, if equipped.

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Use a 1 inch socket to push the barring gear into the gear mesh and rotate the barring adapter counterclockwise to bar the engine. Rock the barring device back and forth until it disengages.
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Each cylinder has four rocker levers:


The exhaust valve rocker lever (1) The injector rocker lever (2) The intake valve rocker lever (3) The engine brake rocker lever (4).
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The intake valve rocker lever is always the long lever

90 damper.

Injector and Valve Adjustmen t Sequence Bar Engine Set Set Set in Pulley Cylinder Cylinder Cylinder Direction Position Injector Valve Brake of Rotation Start Advance to Advance to Advance to Advance to Advance to Firing Order: 1-53-6-2-4 A B C A B C 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4

NOTE: For illustrative purposes, position A is shown as the first step. It is not necessary to start with position A, as long as the proper sequence is followed.
Use the compressor drive or barring device to bar the engine over in the direction of engine rotation, clockwise as viewed from the front of the engine. Align the A mark on the vibration damper with the pointer on the gear cover.

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91 Check the valve rocker levers on the given cylinder to see if both intake and exhaust valves are closed. Both sets of valves are closed when the rocker levers and the brake lever are loose. If both sets of valves are not closed, rotate the compressor drive gear one complete revolution, and align the A mark on the front damper with the pointer again.
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Loosen the injector adjusting screw locknut on the cylinder. Do not use a click-type torque wrench. Use a dial-type torque wrench with a range of 0 to 150 in-lb to tighten the injector rocker lever adjusting screw. If the screw chatters during setting, repair the screw and lever as required. Back out the adjusting screw one or two turns. Hold the torque wrench in a position that allows you to look in a direct line at the dial. This is to make sure the dial will be read accurately. Make sure the parts are aligned, and squeeze the oil out of the valve and injector train by tightening the adjusting screw. Use this initial adjustment to preload the valve train and injector.

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Tighten the injector lever adjusting screw. Torque Value: n.m 8 in-lb ] [71

Back the adjusting lever screw out 1 or 2 turns.


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92 Tighten the injector lever adjusting screw. Torque Value: n.m 8 in-lb ] [71

Hold the injector lever adjusting screw and tighten the adjusting screw locknut. Torque Value: n.m 75 ft-lb ] [55

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After setting the injector on a cylinder, set the valves and engine brakes on the same cylinder. Early engine vibration dampers are marked with BRAKE SET 1-6, BRAKE SET 2-5, or BRAKE SET 34. The engine brakes must be set at the appropriate mark on these engines. Newer engine vibration dampers are marked with only A, B, or C, and are adjusted with the valve and injector on the same cylinder.

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With the set mark aligned with the pointer on the gear cover and both sets of valves closed on the cylinder, loosen the locknuts on the intake and exhaust valve adjusting screws. Back out the adjusting screws one or two turns.
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93 Select a feeler gauge for the correct valve lash specification. Valve Lash Specification mm 0.36 NOM 0.69 NOM

Intake Exhaust

in 0.014 0.027
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Insert the feeler gauge between the top of the crosshead and the rocker lever nose pad. Make sure the feeler gauge is completely under the pivoting rocker lever nose pad.

Tighten the adjusting screw. Torque Value: n.m 0.6 in-lb ] [5

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Use a torque wrench and crows foot adapter to tighten the locknut. Hold the adjusting screw in this position. The adjusting screw must not turn when the locknut is tightened. Torque Value: n.m 45 ft-lb ] [33
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94 After tightening the locknut to the correct torque value, remove the feeler gauge.

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CAUTION
To get maximum brake operating efficiency and to prevent engine damage, the brake adjustment instructions must be followed.
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For older engines, locate the engine brake set marks on the outside of the vibration damper. The set marks are BRAKE SET 1-6, and BRAKE SET 2-5, and BRAKE SET 3-4. BRAKE SET 1-6: Cylinder 1 or 6 adjust BRAKE SET 2-5: Cylinder 2 or 5 adjust BRAKE SET 3-4: Cylinder 3 or 4 adjust

Use the compressor drive or barring device to bar the engine over in the direction of rotation, clockwise as viewed from the front of the engine. Align the A mark on the vibration damper with the pointer on the gear cover. For illustrative purposes, position A is shown as the first step. It is not necessary to start with position A, as long as the proper sequence is followed.

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95

Check the valve rocker levers on the given cylinder to see if both intake and exhaust valves are closed. Both sets of valves are closed when the rocker levers and the brake lever are loose. If both sets of valves are not closed, rotate the compressor drive gear one complete revolution, and align the A mark on the front damper with the pointer again.

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Press the engine brake lever down to verify the camshaft follower is in contact with the camshaft.

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Loosen the locknut on the brake lever adjusting screw, and back out the adjusting screw one turn. Insert the feeler gauge, Part Number 3163530, between the bottom of the engine brake piston and the top of the exhaust valve pin on the exhaust valve crosshead.
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Brake Lever Lash Specification mm in 7.00 NOM 0.276

96 Tighten the adjusting screw until drag on the feeler gauge is felt. Proper drag means that there is no motion of the brake lever camshaft follower against the cam lobe.

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Hold the engine brake lever adjusting screw and tighten the locknut. Torque Value: n.m 20 in-lb ] [177

Remove the feeler gauge.


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CAUTION
Engine damage can occur if the running clearance is not within specifications.
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97 2.790 MAX 0.110

If the running clearance does not meet specification, loosen, but do not remove the rocker shaft capscrews, and rotate the shaft in the direction required to bring the running clearance within the listed specification. It is critical that this clearance be set and verified on all six brake levers. Engine damage can result if this task is not completed. Check the brake running clearance. The rocker lever shafts must be adjusted so that all three engine brake levers fall within the given running clearance specification. Repeat the process to adjust all injectors, engine brakes, and valves according to the chart shown below.

Injector and Valve Adjustmen t Sequence Bar Engine Set Set Set in Pulley Cylinder Cylinder Cylinder Direction Position Injector Valve Brake of Rotation Start Advance to Advance to Advance to Advance to Advance to Firing A B C A B C 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4

98 Order: 1-53-6-2-4

Water Pump (008-062)

Install
Automotive with CM870

TOC

CAUTION
Do not use petroleum based lubricants. Petroleum based lubricants cause the o-ring seals to crack, leading to a coolant leak.
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Lubricate and install the new o-ring seal. Install the two guide studs. Install the water pump and three capscrews.

Remove the two guide studs and install the remaining mounting capscrews. Tighten the capscrews. Torque Value: n.m 72 ft-lb ] [53
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99

Automotive with CM570 Install a new o-ring seal in the water inlet. Install the two guide studs.

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CAUTION
Do not use petroleum based lubricants. Petroleum based lubricants cause the o-ring seals to crack, leading to a coolant leak.
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Install a new o-ring seal in the water pump outlet groove. Apply a thin layer of non-petroleum-based lubricant, such as vegetable oil, to both o-ring seals.

Use clean engine oil to lubricate the threads and bottom of the capscrew heads of all the water pump capscrews. Install the water pump and two lower capscrews. Tighten the capscrews to hold the pump in place.
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100

NOTE: Some configurations do not use the middle aluminum belt tensioner bracket shown. Refer to Procedure for the appropriate tensioner bracket installation.
Install the belt tensioner bracket, if equipped, and capscrews in the location shown. Finger tighten all capscrews.
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Tighten the water pump mounting capscrews in the sequence and values shown. Capscrews 1, 2, and 3 Capscrews 4 and 5 All Capscrews, Engines Without Belt Tensioner Bracket n.m n.m n.m 58 72 72 ft-lb ] ft-lb ] ft-lb ] [43 [53 [53
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Industrial CM570 and Power Generation without CM570 Install a new o-ring seal in the water inlet. Install the two guide studs.

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CAUTION
Do not use petroleum based lubricants. Petroleum based lubricants cause the o-ring seals to crack, leading to a coolant leak.

101
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Install a new o-ring seal in the water pump outlet groove. Apply a thin layer of non-petroleum-based lubricant, such as vegetable oil, to both o-ring seals.

Use clean engine oil to lubricate the threads and bottom of the capscrew heads of all the water pump capscrews. Position the water pump on the engine. Install the bottom two capscrews finger tight.
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NOTE: Some configurations do not use the middle aluminum belt tensioner bracket. Refer to Procedure 008-088 for the appropriate tensioner bracket installation. NOTE: Early engines that did not have a slotted hole on the middle aluminum belt tensioner idler bracket required the vibration dampers to be removed to remove and install the water pump.
Install the belt tensioner bracket, if equipped, and the capscrews in the locations shown. Finger tighten all capscrews.
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102 Tighten the water pump mounting capscrews in the sequence and values shown. Capscrews 1, 2, and 3 Capscrews 4 and 5 All Capscrews, Engines Without Belt Tensioner Bracket n.m n.m n.m 58 72 72 ft-lb ] ft-lb ] ft-lb ] [43 [53 [53
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Align the idler pulley (1) and the shaft of the pilot adapter (2) with the belt tensioner bracket (3) using the guide pin on the pilot adapter (4), if equipped. Install the belt idler pulley and shaft on the belt idler bracket using one washer and capscrew. Tighten the capscrew.
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Torque Value: Install the dust seal. Automotive With CM871

n.m 30

ft-lb ] [25

CAUTION
Do not use petroleum based lubricants, petroleum based lubricants cause the o-ring to crack or swell, leading to a coolant leak.
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103 Torque Value: n.m 72 ft-lb ] [53

Install the two bracket capscrews. Tighten the capscrews. Torque Value: n.m 30 ft-lb ] [25

Install the EGR tube outlet capscrew. Tighten the capscrew. Torque Value: n.m 30 ft-lb ] [25

Water Inlet Connection (008-082)

Install
Replace the o-ring and gasket. Install the gasket, water inlet connection, and the four capscrews. Tighten the capscrews. Torque Value: n.m 56 ft-lb ] [41
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TOC

Install the coolant hoses.

104

Lubricating Oil Cooler (007-003)

Install
All Applications

TOC

WARNING
This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly. When installing a new two-element oil cooler on an older engine, be sure the cooler element mounting capscrews do not interfere with the cylinder block. Install the guide pins. Remove the protective plugs from the oil passages. Make sure no debris enters the lubrication system. Using a clean shop towel, carefully wipe out the oil passages and inspect to make sure no debris is left in these passages. Install a new mounting gasket and the oil cooler housing assembly. Install the 18 capscrews.

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105 Remove the guide pins and install the two capscrews. Tighten the capscrews in a circular motion from the center out. Torque Value: n.m 47 ft-lb ] [35

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Last Modified: 21-Nov-2007


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