H ENGINE ASSEMBLY PROCESS

Ascepts to be checked :

NUMBERING & PUNCHING: Punch the engine number and model as

per the sequence. Fit expansion plug and steel ball on IP face. Screw
dummy plug on sump face and torque to 450-550 kg cm
FILAMENT OF CRANKSHAFT: Ensure cleanliness of cylinder block,
crank shaft & brg shells. Ensure oil groove coincidence, with oil hole
on cylindrical block.
AUTO STN: torque crank shaft brg cap bolts to 140+-15nm & check
free rotation & end float to be within 0.050 to 0.265 mm
FILAMENT OF CAM SHAFT SUB ASSEMBLY: Torque thrust plate bolts
to 190-260 kg cm . match number mark (1,1) between cam and oil
pump gears.
FITMENT OF IDLER GEAR: Application of oil on bolt thread ad face .
Torque bolt to 100+-10 nm & 120+-5 deg(A & B P Form)
AUTOSTN: Check rear oil seal leak .
FITMENT OF FLYWHEEL S/ASSY: set the o mark on flywheel & fit FW
on crank shaft collar. Torque bolts to 100+-10nm & 60+-5 deg (A & B-
P) form as per sequence . fitament of drive plate adaptor for TDC
setting and flip-up. Pre fitment of FIP support bracket
TDC SETTING (AUTO): Ensure gear train matching. Fitment of FIP sub
assembly . fitment of TG case cover S/assy. Torque bolts to 190-260 kg
cm . ensure dolley fitment befro TG case fitment. Fitment of FIP
support bracket. Torque FIP Bracket mtg. bolts to 380-500kgcm on
cylindrical block . fitment of oil pipes to the fuel pump & compressor .
Torque FIP banjo bolt to 100-150 kg cm .
FITMENT OF PISTON ASSEMBLY: lubricate piston & linear bores.
Ensure staging of piston at 120c . position o mark on piston towards
tappet chamber side. Fitment of oil strainer sub assembly and torque
to 190-260 kg cm. Ensure matching marks on con rod& cap . Torque
con rod bolts to 4 kgm+ 68 Deg (A-P form) 100+-10nm & 60+-5 degree
(b-p). FS conrod-40Nm+120 deg. Check endplay
 SHORT BLOCK TEST : pre fit oil pan with liquid selent . fit breather
hose, bracket. Torque sump mtg bolts to 190-260 kg cm
Lift engine to next stage . ensure fitment of all sump bolts befro lifting
engine unload on to the conveyor pallet.
FITMENT OF CYLINDERS HEAD S/ ASSY: clean the head face on the
block and fit 2 dowels for cylinder head gasket & fit 12 valve lifters. Fit
cylinder head sub assembly using guide rods. Put the all mtg bolts
with two threads driven by hand. Check for O rings in gasket CRS . fill
70 ml oil in CSR pump and torque the screw to 100-150 kg cm. Apply
grease on TG case and speed sensor mtg hole.
AUTO STN: tightening of cyl. Heads bolts as per sequence torque cyl.
Head bolts to 70+2NM &150+2deg . Torque cyl. Head addl.bolts to
450-500 kg cm.
FITMENT OF PUSH RODS & ROCKER ASSEMBLY : Place valve caps on
valve stem. Fit push rods and roc.assembly. Torque bolts to 70+2NM
&180+2 Deg. Check free rotation of collars. Pre fit additional bolts and
EMF studs. Prefit cam plate bolts.
SETTING OF INJECTION TIMING: marks on flywheel & on FIP flange for
inline pumps. Torque injection pump . torque injection pump gear
bolts 300-350 kg cm. SET TIMING E2-1.30/1.35mm, E3-0.18/0.22 mm
Fitment of diesel filter and bracket and torque bolts to 450-500 kg cm .
prefit fuel hoses.
FITMENT OF THERMOSTAT CASE S/ASSEMBLY :fitment of 2 O rings
on timing gear case. Apply grease on thermostat S/ assembly and
connector stem (CRS). Fit thermostat sub assembly and torque bolts to
190-260 kg cm . fitment of dipstick guide and gauge. Torque TG case
addl. Bolts to 190-260 kg cm . fitment of breather hose and routing . fit
thermostat sensor.
FITMENT OF OIL COOLER SUB ASSEMBLY: with 4 O rings on the
cylindrical block torque bolts to 190-260 kg cm as per sequence . pre
fit EMF studs with gaskets. Prefit coolant filter with O ring.
FITMENT OF EXHAUST MANIFOLD: torque nuts with spacers to 450-
500 kg cm . ensure proper seating of gasket.
 SUB-ASSEMBLY OF TURBO CHARGER: fitment of turbo charger , oil
Drain pipe. Ensure TC model. Pre fit TC adapter. Ensure proper seating
of gasket.
Torque rocker addl. Bolts to 190-260 kg cm . tight cam plate bolts , Tc
adaptor and EMF nuts. Prefit TC inlet pipe . Fit IMP gaskets with 2
studs. Torque diesel filter hoses to 300-350 kg cm.
SETTING OF VALUE CLEARANCE : inlet value 0.30 mm. exhaust value
0.45 mm . ensure 1/6 befro tappet setting.
I cycle: 1,2,4,5,8,9 II CYLCLE: 3,6,7,10,11,12
Sub assemble air compressor torque the gear nut to 1000-1400 kg cm .
fit rocker cover gasket . sub assemble link bolt . set O mark in A/C gear
Fit inlet manifold. Torque bolts 190-260 kg cm . ensure proper seating
of gasket. Fit wiring harness bracket. Ensure application of sealent. Fit
water pump. Torque bolts to 190-260 kg cm
Fitment of studs on IMF and injector mtg studs on cyclindrical head
Fitment of nozzle with copper washer. Ensure no dirt in nozzle sleeves
befro filament . ensure injector fitment as per model . apply grease on
CRS injector O ring . Torque common rail mtg nut to 300-350kg cm
Set nozzle holder and torque holder nuts to 160-180 kg cm & 190-260
kg cm (CRS) . Ensure nozzle holder clamps are not inclined . fitment of
leak off pipes . fit and torque CRS diesel return hose to 300-350 kg cm.
Set bottom clamps to inlet manifold. Fitment of fuel injection pipes to
pump & nozzles provisionally by hand. Torque injector pipe nuts with
special spanner . tight leak off pipes .
FITMENT OF ALTERNATOR BRACKET : Coolent elbow with O ring and
drain cock . torque bolts to 450-500 kg cm . fitment of alternator .
tight coolant filter with O ring . fit speed sensor.
Pre fit exhaust elbow with gasket. Filament of water pulley. Pre fit
damper pulley as per spec..
Pre fit starter motor and coolant pipe. Fitment of injector pipe clamps
. fit coolant pipe from a/c to TG case and thermostat hsg. Fit boost pre
- sensor.
LEAK TEST: The engine water ways and oil ways.
Tight alternator mtg bolts. Fit engine support brackets and lifting
bracket . fit wiring harness.
 Fit 3 FIP banjo bolts. Tight ex elbow with support brackets. Tight
starter motor. Clamp oil separator hoses. Tag wiring harness.
Fill engine oil as per given specification . fit leak off feed through pipe.
Fit rubber connector hose with clips. Lift engine for testing . ensure
proper placing of engine hooks. Connect wiring harness to all input
points . tag wiring harness.
Engine test is on the given specification basis and if any problems , it
will be rectified by the team of members ,then again sent for the
testing .