Especificaciones 416c#2

Engine Design
SMCS - 1201
Type 1 Engines and 9RM Engines
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Illustration 1 g00296342
Cylinder and valve location for Type 1 engines and 9RM engines
(A) Exhaust valves
(B) Inlet valves
Note: Type 1 engines can be identified in two ways. The first method refers to Illustration 1. When the valve cover is
removed, look at the cylinder head valves. Type 1 engines have two exhaust valves in a row and two inlet valves that
are in a row.
The second method does not require the removal of the valve cover. Refer to the inlet manifold and the exhaust
manifold. Type 1 engines have two exhaust ports in a row and two inlet ports that are in a row.
Type ... Four cylinder and four stroke
Combustion system ... Direct injection
Nominal Bore ... 100 mm (3.937 inch)
Stroke ... 127 mm (5.00 inch)
Capacity ... 4 liters (243 in3)
Compression Ratio ... 16:1
Number of cylinders ... 4

Arrangement of cylinders ... in-line
Firing Order ... 1, 3, 4, 2
Valve Lash
Inlet valve ... 0.20 mm (.008 inch)

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

Exhaust valve ... 0.45 mm (.018 inch)
When the crankshaft is viewed from the front of the engine the crankshaft rotates in the following direction: ...
Clockwise
When the camshaft is viewed from the front of the engine the camshaft rotates in the following direction: ... Clockwise
Note: The front end of the engine is opposite the flywheel end. The left side and the right side of the engine are viewed
from the flywheel end. The No. 1 cylinder is the front cylinder.
Fuel Injection Pump
SMCS - 1251; 1290Various Fuel Injection Pumps may be equipped to the engine. Bosch, Delphi, or Stanadyne
fuel injection pumps may be equipped to the engine.
Bosch Fuel Injection Pump (EPVE
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Note: Parts that are inside of the fuel injection pump are only serviceable by an authorized Bosch dealer. Please consult
your parts book for availability of parts on the outside of the pump that are not related to the settings of the fuel pump
and for the possibility of remanufacturing options.
Hub nut (not shown)
Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is positioned to the pump shaft in
order to ensure that the fuel pump is in the correct position for timing. If the hub is removed, the hub will need to be
accurately positioned to the pump shaft. Accurate positioning requires the use of special equipment by a Caterpillar
Dealer.
(1) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in)
(2) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to 6 Nm (44 to 53 lb in)
(3) Tighten the fitting for the fuel supply connection to the following torque. ... 22 Nm (16 lb ft)
(4) Boost control (if equipped)

(5) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in)
(6) Tighten the nuts for the high pressure fuel line connection to the following torque. ... 22 Nm (16 lb ft)
(7) Tighten the flange nuts to the following torque. ... 22 Nm (16 lb ft)
(8) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to 81.4 Nm (52 to 60 lb ft)
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(9) Locking spacer (If equipped)
Note: The drive shaft of the fuel injection pump must not be turned without the spacer in position under the locking
screw (10) .
(10) Tighten the locking screw to the following torque. ... 27 Nm (20 lb ft)
(11) Tighten the nut for the drive gear to the following torque. ... 80 Nm (59 lb ft)
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Note: Before the crankshaft is turned or the fuel injection pump is installed, move the locking spacer (9) under the
locking screw (10). Refer to position (A) that is in Illustration 3. This position ensures that the pump drive shaft is
released.
Timing Information for the Bosch Fuel Injection Pump
Table 1
Early Bosch Fuel Injection Pump Without Locking Screw
Code Letters on Engine Check Fuel Injection Pump Static Timing

Piston
Fuel Injection Angle (degrees) (1) Mark Angle Position Before TC
Displacement (1)
Pump (degrees) (1) Position (degrees)
"BK" 308 314 12 1.78 mm (0.070

inch)
"CK" 308 314 12 1.78 mm (0.070

inch)
"DK" 306 313 14 2.42 mm (0.095

inch)
"EK" 308.5 315.5 14 2.42 mm (0.095

inch)
"EK" (2) 306.5 315.5 18 3.99 mm (0.157

inch)
"EM" 288.5 295.5 14 2.42 mm (0.095
inch)
"FM" 289 295 12.5 1.93 mm (0.076

inch)
"JM" - - 6 -
"JM" (3) - - 2 -
"JM" (4) - - TDC -
"KC" (5) - - TDC -
"KL" (5) - - TDC -
"ML" (5) - - TDC -

"PM" - - 12 -
"SK" - - 9 -
"TL" (5) - - TDC -
VM - - 2 ATDC -
(1) The engine must be set at the TC position on the compression stroke for the number 1 piston. The fuel injection pump mark angle
and the displacement of the piston can be checked when the plunger for the fuel injection pump is set at 1.00 mm (0.039 inch).
(2) The information plate on the fuel injection pump is stamped "J609".
(3) "AD70229" and "AD702230" only
(4) "AD80643" only
(5) The cold start advance (KSB) must be energized before the timing is set.
Note: Later Bosch Fuel Injection Pumps use a pin to time the pump.
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Note: Parts that are inside of the fuel injection pump are only serviceable by an authorized Stanadyne dealer. Please
consult your parts book for availability of parts on the outside of the pump that are not related to the settings of the
fuel pump and for the possibility of remanufacturing options.
Hub nut (not shown)
Dealer.
(1) Electrical connection for the stop solenoid
(3) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in)
(4) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in)
(6) Adjustment screw for advance timing
(7) Tighten the fittings for the fuel discharge to the following torque. ... 70.5 to 81.4 Nm (52 to 60 lb ft)
(8) Tighten the nuts for the high pressure fuel injection line to the following torque. ... 22 Nm (16 lb ft)
(9) Tighten the nut for the end cap to the following torque. ... 22 Nm (16 lb ft)
NOTICE
The No. 1 cylinder must be at the top center position on the compression stroke before the fuel injection pump is
installed. If the crankshaft needs to be rotated, the fuel injection pump must be mounted temporarily or the loose gear
could cause damage to the front housing.
Timing Information for the Stanadyne Fuel Injection Pump

Table 2
Stanadyne Fuel Injection Pump
Code Letters on Fuel Injection Engine Check Angle Fuel Injection Pump Mark Angle
Pump (degrees) (degrees)
"AC" 282 291
"AL" 326 336
"BL" 326 336

"CL" 327 333
"CL" (1) - 247.5
"DL" 332 338

"FL" 326 333
"GL" 326 332
"HC" 282 290.5
"JL" 325 334.5
"KM" 282 290
"LM" 282 287
"LM" (2) 288.5 295
"MM" 282 287
"MM" (3) 288.5 295

"NC" 282 294
"SL" 331.5 338
"SM" 282 291
"TC" 282 290
"TM" 282 290.5
"UC" 228.5 296

"VL" 326 389
"XK" 325 331.5
"YK" 325 334.5
"YL" 330 338
"ZK" 326 334
"ZM" (4) 282 287
"ZM" (5) 282 289

(1) The fuel injection pump is timed with a pin.
(2) The fuel injection pump is coded "2643U211" or "2643U213".
(3) The fuel injection pump is coded "2643U214".
(4) The values are for the fuel injection pumps with a serial number up to "7665964".
(5) The values are for the fuel injection pump with a serial number that includes "7665965". The values are also for the fuel injection
pumps with serial numbers that are higher than "7665965".
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Note: Parts that are inside of the fuel injection pump are only serviceable by an authorized Delphi dealer. Please consult
your parts book for availability of parts on the outside of the pump that are not related to the settings of the fuel pump
and for the possibility of remanufacturing options.
(1) Hub nut
Dealer.
(2) O-ring
(3) Locking spacer
The drive shaft of the fuel injection pump must not be turned without the spacer in position under the locking screw (4)
.
(4) Tighten the locking screw to the following torque. ... 10 Nm (7 lb ft)
The locking screw prevents the rotation of the drive shaft.

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Before the crankshaft is turned or the fuel injection pump is installed, move the locking spacer (3) under the locking
screw (4). Refer to position (A) that is in Illustration 6. This position ensures that the pump drive shaft is released.
(6) Tighten the adjustment screw for low idle to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in)
(7) Tighten the adjustment screw for high idle to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in)
(8) Electrical connection for the stop solenoid
(9) Tighten the fitting for the fuel supply connection to the following torque. ... 22 Nm (16 lb ft)
(10) Tighten the nuts for the fuel line to the following torque. ... 22 Nm (16 lb ft)
(12) Electrical connection for cold starting aid
(13)Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to 81.4 Nm (52 to 60 lb ft)
(14)
timing Information for the Delphi Fuel Injection Pump

Table 3
Delphi Fuel Injection Pump
Code that is on the Fuel Injection Engine Check Angle Fuel Injection Pump Mark Angle
Pump (degrees) (degrees)
"AK" 325.5 336
"AM" 282 290.5
"BF" 326 334
"BM" 281 291
"CM" 282.5 291.5
"DM" 282.25 290.5
"FK" 325.5 336

"GK" 325 336
"GM" 282 290.5
"HK" 326 336
"HM" 282 291
"JK" 325 334
"KK" 325 334

"LK" 327 337.5
"LK" (1) 328 337.5
"MK" 326 336
"MK" (2) 325 336

"PK" 326 334
"RK" 328 336
"RM" 282.5 290.5
"TK" 327 334

"UK" 326 334
"XM" 282 291
(1) "YA31257" only
(2) "YA50532" only
Table 4
Dephi Fuel Injection Pump With Locking Screw

Code Letters on Fuel Injection Pump Locking Angle (degrees)
"BC" 336.5
"CC" 338.5
"DC" 337.5
"EC" 337.5
"FC" 335.5
"GC" 337
"PC" 339
"RC" 339
"SC" 341
"XL" 22
Note: Later Delphi Fuel Injection Pumps are timed with a pin.
Fuel Injection Nozzles
SMCS - 1254

Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine
Design" for more information.
Fuel injection nozzle
(1) Connection for the union nut of the fuel supply line
(2) Threaded hole for the banjo bolt of the leak off line
(3) Clamp
(4) Seal
(5) Spacer
(6) Fuel injector assembly
(7) Seat washer
(1) Tighten the union nut of the high pressure fuel line (not shown) to the following torque: ... 18 Nm (13.3 lb ft)
(2) Tighten the banjo bolts of the leak off tubing (not shown) to the following torque: ... 9.5 Nm (84 lb in)
(3) Tighten the flange bolts (not shown) for the clamp to the following torque: ... 12 Nm (9 lb ft)
Note: Remove the original seat washer from the threaded hole for the fuel injection nozzle which is located in the
cylinder head. If the original seat washer is not removed, the projection of the nozzle will be incorrect when a new seat
washer is installed. Do not reuse the seal (4) and the seat washer (7) .
Bench test the fuel injection nozzles at a temperature of 18 to 20 °C (64 to 70 °F).
Note: Use clean SAE J-967 oil (ISO 4113) when you are conducting the test. The oil is available in 5 gallon containers
( 6V-6068 Calibration Fluid ) and 55 gallon containers ( 6V-6067 Calibration Fluid ). If dirty oil is used for the test, the
components of the fuel injection nozzle will be damaged.
Refer to Testing And Adjusting, "Pressure Adjustment, Back Leakage Test, Nozzle and Seat Test".
Table 1
Pressure Settings for the Fuel Injection Nozzles for the Type 1 Engines and 9RM Engines
Code (1) Pressure Setting

"HU"
22291 kPa (3233 psi)
"HV"
25331 kPa (3674 psi)
"HZ"
22291 kPa (3233 psi)
"JA"
25331 kPa (3674 psi)
"JB"
25331 kPa (3674 psi)
"JE"
22291 kPa (3233 psi)
"JF"
25331 kPa (3674 psi)
"JG"
23304 kPa (3380 psi)
"JH"
25331 kPa (3674 psi)
"JJ"
25331 kPa (3674 psi)
"JK"
22291 kPa (3233 psi)
"JL"
25331 kPa (3674 psi)
"JR"
25331 kPa (3674 psi)
"JS"
25331 kPa (3674 psi)
"JT"
25331 kPa (3674 psi)
"JU"
22291 kPa (3233 psi)
"JY"
25331 kPa (3674 psi)
"NJ"
22291 kPa (3233 psi)
"NK"
22801 kPa (3307 psi)
"NL"
22801 kPa (3307 psi)
"NM"
23304 kPa (3380 psi)
"NN"
23304 kPa (3380 psi)
"NP"
22291 kPa (3233 psi)
"NR"
23304 kPa (3380 psi)
"NS"
25331 kPa (3674 psi)
"NT"
23304 kPa (3380 psi)
"NU"
22291 kPa (3233 psi)
"NV"
22291 kPa (3233 psi)
"NW"
22291 kPa (3233 psi)
"RD"
25028 kPa (3630 psi)
"RE"
25028 kPa (3630 psi)
"RF"
25028 kPa (3630 psi)
"RH"
25028 kPa (3630 psi)
"RK"
26903 kPa (3902 psi)
"RM"
25028 kPa (3630 psi)
"RN"
25028 kPa (3630 psi)
"RP"
25028 kPa (3630 psi)
"RR"
25028 kPa (3630 psi)
"RS"
25028 kPa (3630 psi)
"RT"
25028 kPa (3630 psi)
"RU"
25028 kPa (3630 psi)
"RV"
25028 kPa (3630 psi)
(1) The code letters are stamped on the side of the fuel injector body. The code letters are located below the connection for the nut of
the high pressure fuel line.
Note: Ensure that the new fuel injection nozzles have the same identification code as the nozzles which were originally
installed in the cylinder head.
Leakage in 10 seconds ... 0 drops

Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for
more information.
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Fuel injection nozzle
(1) Connection for the union nut of the fuel supply line
(2) Threaded hole for the banjo bolt of the leak off line
(3) Nut of the fuel injection nozzle
(4) Wire clip
(5) Seat washer
(1) Tighten the union nut of the high pressure fuel line (not shown) to the following torque: ... 22 Nm (16 lb ft)
(2) Tighten the banjo bolts of the leak off tubing (not shown) to the following torque: ... 9.5 Nm (84 lb in)
(3) Tighten the nut of the fuel injection nozzle to the following torque: ... 30 Nm (22 lb ft)
Note: When the fuel injection nozzle is installed, put a 2.0 mm (.08 inch) bead of 4C-5591 Anti-Seize Compound on the
first two threads of the gland nut. Do not rotate the fuel injection nozzle after installation. The seal which is made by
the anti-seize compound may break. A broken seal may allow leakage past the seat of the fuel injection nozzle.
(4) Wire clip
(5) Seat washer
Note: Remove the original seat washer from the threaded hole for the fuel injection nozzle which is located in the
cylinder head. If the original seat washer is not removed, the projection of the nozzle will be incorrect when a new seat
washer is installed. Do not reuse the seat washer (5) .
Bench test the fuel injection nozzles at a temperature of 18 to 20 °C (64 to 70 °F).
Note: Use clean SAE J-967 oil (ISO 4113) when you are conducting the test. The oil is available in 5 gallon containers
( 6V-6068 Calibration Fluid ) and 55 gallon containers ( 6V-6067 Calibration Fluid ). If dirty oil is used for the test, the
components of the fuel injection nozzle will be damaged.
Refer to Testing And Adjusting, "Pressure Adjustment, Back Leakage Test, Nozzle and Seat Test".
Table 2
Pressure Settings for the Fuel Injection Nozzles for the Type 2 Engines and 7BJ Engines
Code (1) Pressure Setting
"KB"
30406 kPa (4410 psi)
"KC"
28979 kPa (4203 psi)
"KD"
29385 kPa (4262 psi)
"KE"
29385 kPa (4262 psi)
"KF"
29385 kPa (4262 psi)
"KG"
29385 kPa (4262 psi)
"KH"
29392 kPa (4263 psi)
"KJ"
25338 kPa (3675 psi)
"KK"
30406 kPa (4410 psi)
"KL"
30406 kPa (4410 psi)
"KM"
30406 kPa (4410 psi)
"KN"
29385 kPa (4262 psi)
"KP"
29385 kPa (4262 psi)
"KR"
29392 kPa (4263 psi)
"KT"
29392 kPa (4263 psi)
"KS"
29392 kPa (4263 psi)
"KU"
29385 kPa (4262 psi)
"KV"
25338 kPa (3675 psi)
"KW"
29385 kPa (4262 psi)
"NX"
29385 kPa (4262 psi)
"NY"
29392 kPa (4263 psi)
"NZ"
29392 kPa (4263 psi)
"PA"
29392 kPa (4263 psi)
"PB"
29392 kPa (4263 psi)
"PC"
29385 kPa (4262 psi)
"PD"
27862 kPa (4041 psi)
"PE"
28372 kPa (4115 psi)
"RZ"
25338 kPa (3675 psi)
"SA"
25338 kPa (3675 psi)
"SB"
25338 kPa (3675 psi)
"SC"
25338 kPa (3675 psi)
(1) The code letters are stamped on the side of the fuel injector body. The code letters are located below the connection for the nut of
the high pressure fuel line.
Note: Ensure that the new fuel injection nozzles have the same identification code as the nozzles which were
originally installed in the cylinder head.
Leakage in 10 seconds ... 0 drops
Fuel Transfer Pump
SMCS - 1256
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Typical example of the fuel transfer pump
Method of drive ... Camshaft
Output pressure during the first ten seconds of cranking:
Normal pressure ... 42 to 70 kPa (6 to 10 psi)

Minimum pressure ... 30 kPa (4.4 psi)
The engine may be equipped with four mounting bolts or four mounting studs with nuts. Tighten to the following
torque: ... 22 Nm (16 lb ft)
Apply 4C-4030 Thread Lock Compound to the first three threads of the mounting bolts or the mounting studs.
Refer to the Systems Operation, Testing and Adjusting Module, "Fuel System Pressure - Test" topic in order to test the
operation of the fuel transfer pump.
Note: When the fuel transfer pump is installed on the engine, ensure that the camshaft is on minimum lobe lift and that
the bolts are evenly tightened. Failure to follow this procedure can cause the following conditions: loss of maximum
engine power and damage to the fuel transfer pump.
Rocker Shaft
SMCS - 1102
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(1) Rocker arm
Diameter of the rocker arm bore for the bushing ... 22.23 to 22.26 mm (0.8750 to 0.8762 inch)
(2) Rocker arm bushing
Outside diameter of the rocker arm bushing ... 22.28 to 22.31 mm (0.8770 to 0.8785 inch)
Inside diameter of the rocker arm bushing ... 19.06 to 19.10 mm (0.7505 to 0.7520 inch)
Clearance between the rocker arm bushing and the rocker shaft ... 0.03 to 0.09 mm (0.001 to 0.0035 inch)
Maximum permissible clearance between the rocker arm bushing and the rocker shaft ... 0.13 mm (0.005 inch)
(3) Tighten the bolts evenly. Begin in the center and work toward the outside. Tighten the bolts to the following torque.
Cast iron or steel rocker shaft brackets ... 88 Nm (65 lb ft)
Aluminum rocker shaft brackets ... 40 Nm (30 lb ft)
(4) Diameter of the rocker shaft ... 19.01 to 19.04 mm (0.7485 to 0.7495 inch)
(5) Tighten the bolt to the following torque. ... 4 Nm (35 lb in)
Valve Mechanism Cover
SMCS - 1107
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(1) Tighten the nut to the following torque.
Composite cover ... 20 Nm (15 lb ft)

Aluminum cover ... 30 Nm (22 lb ft)
Cylinder Head Valves
SMCS - 1105

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Inlet valves and exhaust valves
Double valve springs:
(1) Outer spring
Length under test force ... 35.8 mm (1.41 inch)

Test force ... 176 to 195 N (40 to 44 lb)
(2) Inner spring

Single valve springs (not shown)
Free length after test ... 53.4 mm (2.10 inch)
(3) Valve spring recess for the valve spring
(4) Valve guides for the inlet and exhaust valves
Inside diameter ... 9.51 to 9.56 mm (0.374 to 0.376 inch)

Outside diameter ... 15.900 to 15.910 mm (0.6260 to 0.6265 inch)
Bore diameter in cylinder head for valve guide ... 15.87 to 15.89 mm (0.625 to 0.626 inch)
Interference fit of valve guide in cylinder head ... 0.03 to 0.07 mm (0.001 to 0.003 inch)
Overall length of valve guide
Inlet ... 57.94 mm (2.281 inch)
Exhaust ... 61.1 mm (2.406 inch)
Projection of valve guide above valve spring recess (3) ... 15.1 mm (0.595 inch)
Note: When new valve guides are installed, new valves and new valve seat inserts must be installed. The valve guides
and the valve seat inserts are supplied as partially finished parts. The unfinished valve guides and unfinished valve seat
inserts are installed in the cylinder head. Then, the guides and inserts are cut and reamed in one operation with special
tooling. This procedure ensures the concentricity of the valve seat to the valve guide in order to create a seal that is
tight. Refer to the Disassembly and Assembly Manual for removal and installation procedures.
(5) Diameter of the exhaust valve stem ... 9.43 to 9.46 mm (0.371 to 0.372 inch)
Clearance of valve in valve guide ... 0.05 to 0.13 mm (0.002 to 0.005 inch)
Maximum permissible clearance of valve in valve guide ... 0.15 mm (0.006 inch)
Overall length of the exhaust valve ... 123.07 to 123.57 mm (4.845 to 4.865 inch)
(6) Diameter of the inlet valve stem ... 9.460 to 9.490 mm (0.3724 to 0.3735 inch)
Clearance of valve in the valve guide ... 0.02 to 0.10 mm (0.001 to 0.004 inch)
Overall length of the inlet valve ... 122.66 to 123.07 mm (4.829 to 4.845 inch)
(7) Exhaust valve face angle ... 45 degrees
Valve seat angle ... 46 degrees
(8) Diameter of the exhaust valve ... 37.26 to 37.52 mm (1.467 to 1.477 inch)
Valve depth below the cylinder head face
Minimum ... 1.28 mm (0.050 inch)
Maximum ... 1.83 mm (0.072 inch)
Service wear limit ... 2.08 mm (0.082 inch)
(9) Diameter of the inlet valve ... 44.86 to 45.11 mm (1.766 to 1.776 inch)
(10) Inlet valve face angle ... 45 degrees
Note: Some engines may have valve face angles of 30 degrees and valve seat angles of 31 degrees.
The valve lash is the following value when the engine is hot or cold:
Inlet valves ... 0.20 mm (0.008 inch)
Exhaust valves ... 0.45 mm (0.018 inch)
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Recess for a valve insert
(11) Machine the recess in the head for valve seat inserts to the following dimensions:
Inlet
(A) ... 7.19 to 7.32 mm (0.283 to 0.288 inch)
(B) ... 51.220 to 51.240 mm (2.0167 to 2.0175 inch)
(C) Maximum radius ... 0.38 mm (0.015 inch)
Exhaust
(A) ... 9.52 to 9.65 mm (0.375 to 0.380 inch)
(B) ... 42.620 to 42.650 mm (1.6779 to 1.6790 inch)
Note: When a new valve seat insert is installed, a new valve and valve guide must be installed. Refer to the
Disassembly and Assembly for removal and installation procedures.
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Angles and dimensions of the valve seat insert
(12) Valve seat insert
(D) Included angle of the faces
(E) Dimension of chamfer
(F) Vertical angle of chamfer
(D) Included angle of the faces of the valve seat insert

Engines with 46 degree valve seats ... 88 degrees
(E) Dimension of chamfer for all engines ... 1.10 ± 0.20 mm (0.043 ± 0.008 inch)
(F) Angle of chamfer from the vertical for all engines ... 30 degrees

more information.
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Inlet valves and exhaust valves
(1) Single valve springs

(2) Valve spring insert for the valve spring
(3) Valve guides
Inside diameter of finished valve guide ... 9.00 to 9.02 mm (0.354 to 0.355 inch)
Outside diameter of inlet valve ... 13.03 to 13.05 mm (0.513 to 0.514 inch)
Outside diameter of exhaust valve ... 14.03 to 14.05 mm (0.552 to 0.553 inch)
Bore diameter in the cylinder head for the inlet valve guide ... 13.00 to 13.03 mm (0.512 to 0.513 inch)
Bore diameter in the cylinder head for the exhaust valve guide ... 14.000 to 14.027 mm (0.5512 to 0.5522 inch)
Interference fit of valve guide in the cylinder head ... 0.007 to 0.047 mm (0.0003 to 0.0019 inch)
Overall length of inlet and exhaust valve guides ... 51.25 mm (2.012 inch)
Projection of valve guide above the valve spring recess (2) ... 14.85 to 15.15 mm (0.585 to 0.596 inch)
Note: When new valve guides are installed, new valves and new valve seat inserts must be installed. The valve guides
and the valve seat inserts are supplied as partially finished parts. The unfinished valve guides and unfinished valve seat
inserts are installed in the cylinder head. Then, the guides and inserts are cut and reamed in one operation with special
tooling. This procedure ensures the concentricity of the valve seat to the valve guide in order to create a seal that is
tight. Refer to the Disassembly and Assembly Manual for removal and installation procedures.
(4) Diameter of the exhaust valve stem ... 8.94 to 8.96 mm (0.352 to 0.353 inch)
Clearance of valve in valve guide ... 0.040 to 0.084 mm (0.0026 to 0.0033 inch)
Overall length of the exhaust valve ... 122.65 to 123.30 mm (4.829 to 4.854 inch)
(5) Diameter of the inlet valve stem ... 8.953 to 8.975 mm (0.3525 to 0.3533 inch)
Clearance of valve in the valve guide ... 0.025 to 0.069 mm (0.001 to 0.003 inch)
Overall length of the inlet valve ... 122.65 to 123.30 mm (4.829 to 4.854 inch)
(6) Exhaust valve face angle ... 45 degrees
(7) Exhaust valve head diameter ... 40.88 to 41.12 mm (1.609 to 1.619 inch)

(8) Diameter of the inlet valve ... 42.88 to 43.12 mm (1.688 to 1.698 inch)

(9) Inlet valve face angle ... 45 degrees
The valve lash is the following value when the engine is hot or cold:
Inlet valves ... 0.20 mm (0.008 inch)

Exhaust valves ... 0.45 mm (0.018 inch)
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Recess for a valve insert
(11) Machine the recess in the head for valve seat inserts to the following dimensions.
Inlet
(A) ... 10.585 to 10.715 mm (0.4167 to 0.4219 inch)
(B) ... 45.535 to 45.560 mm (1.7927 to 1.7937 inch)
Exhaust
(A) ... 10.585 to 10.715 mm (0.4167 to 0.4219 inch)
(B) ... 43.535 to 43.560 mm (1.7140 to 1.7150 inch)
Note: When a new valve seat insert is installed, a new valve and valve guide must be installed. Refer to Disassembly
and Assembly for removal and installation procedures.
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Angles and dimensions of the valve seat insert
(D) Included angle of the faces
(E) Dimension of chamfer
(F) Vertical angle of chamfer
(D) Included angle of the faces of the valve seat insert

(E) Dimension of chamfer for all engines ... 1.10 ± 0.20 mm (0.043 ± 0.008 inch)
(F) Angle of chamfer from the vertical for all engines ... 30 degrees
Cylinder Head
SMCS - 1100

Bolt tightening sequence for the cylinder head
Use the following procedure in order to tighten the cylinder head bolts:
Put engine oil on the threads of the bolts and the nuts. Tighten bolts (1) through bolts (22) in a numerical sequence in
Illustration 1.
Torque for the bolts ... 110 Nm (81 lb ft)
Tighten bolts (1) through bolts (22) again in a numerical sequence.

Torque for bolts ... 110 Nm (81 lb ft)
Rotate bolts (1) through bolts (22) in a numerical sequence to the following values:
Tighten the bolts of short length "S" to the following value.

Rotate the bolts in a clockwise direction: ... 150 degrees
Tighten the bolts of medium length "M" to the following value.

Tighten the bolts of long length "L" to the following value.

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

Aluminum bracket ... 40 Nm (30 lb ft)
(4) Valve lash
Inlet ... 0.20 mm (.008 inch)

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

A ... 0.08 mm (.003 inch)
B ... 0.15 mm (.006 inch)
C ... 0.15 mm (.006 inch)
Turbocharged engines
A ... 0.13 mm (.005 inch)
B ... 0.25 mm (.010 inch)
C ... 0.25 mm (.010 inch)
Tighten the bolts of the inlet manifold (not shown) to the following torque: ... 44 Nm (32 lb ft)
Tighten exhaust manifold nuts (not shown) to the following torque:
Plated ... 44 Nm (32 lb ft)

Plain ... 50 Nm (37 lb ft)

more information.
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Bolt tightening sequence for the cylinder head
Use the following procedure in order to tighten the cylinder head bolts:
Put engine oil on the threads of bolts. Tighten bolts (1) through bolts (22) in a numerical sequence in Illustration 4.
Tighten bolts (1) through bolts (22) again in a numerical sequence.

Rotate bolts (1) through bolts (26) in a numerical sequence to the following values:
Tighten the bolts of short length "S" to the following value.

Tighten the bolts of medium length "M" to the following value.

Tighten the bolts of long length "L" to the following value.

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Bolts, nuts, and components of the cylinder head
Note: When the fuel injection nozzle is removed, the following items must be replaced: dust seal and seat washer.
(1) Tighten the bolts that hold the rocker shaft to the cylinder head to the following torques:
Begin tightening the inner bolts. Then tighten the bolts by working toward the end of the shaft.
Cast iron or steel bracket ... 75 Nm (55 lb ft)
Aluminum bracket ... 40 Nm (30 lb ft)
(2) Valve lash
Inlet ... 0.20 mm (.008 inch)

Exhaust ... 0.45 mm (.018 inch)
(3) Maximum permissible nozzle projection below cylinder head face after resurfacing ... 4.45 mm (.175 inch)
Maximum allowance for resurfacing ... 0.30 mm (.012 inch)
(4) Depth of new cylinder head ... 102.79 to 103.59 mm (4.047 to 4.078 inch)
Minimum depth of cylinder head after resurfacing ... 102.48 mm (4.035 inch)
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Positions for measuring the bow of the cylinder head (typical example)
Maximum permissible amount of bow (curve of the cylinder head)
A ... 0.08 mm (.003 inch)

B ... 0.15 mm (.006 inch)
C ... 0.15 mm (.006 inch)
Tighten the bolts for the inlet manifold (not shown) to the following torque: ... 44 Nm (32 lb ft)
Tighten the nuts for the exhaust manifold (not shown) to the following torque:
Plated ... 44 Nm (32 lb ft)

Plain ... 50 Nm (37 lb ft)
Turbocharger
SMCS - 1052
Turbocharger
(1) Put oil on the threads of the nut and put oil on the seat face.
Tighten the impeller nut to the following torque: ... 2 to 2.3 Nm (18 to 20 lb in)
Tighten the nut again to the following value: ... 110 degrees
Note: Do not bend or add stress to the shaft when the nut is tightened.
(2) Tighten the bolts, which hold the back plate, to the following torque: ... 8.5 to 10.2 Nm (75 to 90 lb in)
(3) Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the compressor housing to the
center section, to the following torque: ... 15.3 to 18.7 Nm (12 to 14 lb ft)
(4) Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the turbine housing to the center
section, to the following torque: ... 18.6 to 20.4 Nm (14 to 15 lb ft)
(5) Turbine wheel assembly
Minimum journal outside diameter ... 10.152 mm (.3997 inch)

Ring groove diameter (minimum) ... 14.401 mm (.5670 inch)
Ring groove width (maximum) ... 1.740 mm (.0685 inch)
Hub outside diameter (minimum) ... 17.323 mm (.6820 inch)
(6) End play for shaft
Minimum permissible end play ... .03 mm (.001 inch)

Maximum permissible end play ... .10 mm (.004 inch)
(7) Compressor wheel
Bore inside diameter (maximum) ... 6.353 mm (.2501 inch)

(8) Backplate assembly
Seal inside diameter (maximum) ... 12.713 mm (.5005 inch)
Flatness from the backplate to the mating surface of the center housing is within the following value: ... .013 mm
(.0005 inch)
(9) Thrust collar
Thickness (maximum) ... 18.339 mm (0.7220 inch)

Thrust bearing groove width (maximum) ... 4.440 mm (.1748 inch)
Thrust bearing groove diameter (minimum) ... 9.398 mm (.3700 inch)
Piston ring groove width (maximum) ... 1.659 mm (.0653 inch)
(10) Thrust bearing
Thickness (minimum) ... 4.359 mm (0.1716 inch)

(11) Radial play (side to side movement) for shaft
Minimum permissible radial play (side to side movement) ... .08 mm (.003 inch)
Maximum permissible radial play (side to side movement) ... .15 mm (.0059 inch)
(12) Center housing
Bearing inside diameter (maximum) ... 15.806 mm (.6223 inch)

Seal inside diameter (maximum) ... 17.805 mm (.7010 inch)
Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the turbocharger to the manifold (not
shown), to the following torque: ... 55 ± 5 Nm (40 ± 4 lb ft)
Air Inlet Heater
Ver imagen
(1) Electrical connection
(2) Fuel inlet
(3) Ball valve
(4) Valve holder
(5) Wire coil
(6) Ignition coil
Voltage ... 12 volts
Current draw ... 13.5 amperes
Tighten the air inlet heater to the inlet manifold to the following torque: ... 31 ± 8 Nm (23 ± 6 lb ft)
Exhaust Manifold
SMCS - 1059
Ver imagen
The cylinder head is shown.
Refer to Illustration 1 for the tightening sequence. Tighten the plated nuts for the exhaust manifold to the following
torque. ... 44 Nm (33 lb ft)
Refer to Illustration 1 for the tightening sequence. Tighten the nuts that are not plated for the exhaust manifold to the
following torque. ... 50 Nm (37 lb ft)
Ver imagen
Apply 4C-9507 Retaining Compound to the stud threads.
Refer to Illustration 2 for the tightening sequence. Tighten the exhaust manifold nuts or bolts gradually to the following
torque. ... 44 Nm (33 lb ft)
Muffler
SMCS - 1062
Ver imagen
(1) Tighten the nuts to the following torque. ... 30 ± 7 Nm (22 ± 5 lb ft)
(2) Tighten the bolts and the nuts to the following torque. ... 55 ± 10 Nm (41 ± 7 lb ft)
Camshaft
SMCS - 1210
Ver imagen
End play of a new camshaft ... 0.10 to 0.41 mm (0.004 to 0.016 inch)
Maximum permissible end play of a worn camshaft ... 0.53 mm (0.021 inch)
(1) Locating pin
(2) Camshaft thrust washer
Thickness of thrust washer ... 5.49 to 5.54 mm (0.216 to 0.218 inch)

Cylinder block recess depth for thrust washer ... 5.46 to 5.54 mm (0.215 to 0.218 inch)
Relationship of thrust washer to cylinder block front face ... -0.05 to +0.08 mm (-0.002 to +0.003 inch)
(3) Woodruff key
(4) Diameter of camshaft journals
Table 1
Diameters of Camshaft Journals
Camshaft Journal Standard Diameter Service Limit Diameter (1)
1
50.710 to 50.740 mm (1.9965 to 1.9975 inch) 50.660 mm (1.9945 inch)
2
3
Internal clearance of the journal ... 0.06 to 0.14 mm (0.002 to 0.006 inch)
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Camshaft lobe lift
To determine lobe lift, use the procedure that follows:
Measure the height (B) of the camshaft lobe.
Measure the base circle (C) .
Subtract the base circle (C) from the height (B) of the lobe. The difference is the actual lobe lift (A) .
Specified camshaft lobe lift (A)

Inlet ... 7.62 to 7.69 mm (0.300 to 0.303 inch)
Exhaust ... 7.71 to 7.79 mm (0.304 to 0.307 inch)
Minimum permissible height of lobes ... 7.37 mm (0.290 inch)

Engine Oil Filter Base
SMCS - 1306
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(1) Engine oil filter base
The bypass valve in the engine oil filter opens at the following pressure difference: ... 55 to 83 kPa (8 to 12 psi)
(2) Engine oil cooler
The bypass valve in the engine oil cooler opens at the following pressure: ... 172 kPa (25 psi)
Tighten the threaded adapter that fastens the engine oil cooler to the engine oil filter base to the following torque: ...
37 Nm (27 lb ft)
Engine Oil Relief Valve
SMCS - 1315
Ver imagen
The relief valve for the engine oil pressure should open at the following pressure setting:
Engines that are not equipped with piston cooling jets ... 340 to 395 kPa (49 to 57 psi)
Engines that are equipped with piston cooling jets ... 415 to 470 kPa (60 to 68 psi)
Engines that are equipped with counter balancer ... 523 kPa (76 psi)
(1) Spring
Length under test force for engines that are equipped with counter balancer ... 42.7 mm (1.681 inch)
Test force ... 15.9 to 23.1 N (3.6 to 5.2 lb)
Test force with engines that are equipped with counter balancer ... 34 to 38 N (7.6 to 8.5 lb)
(2) Outside diameter of plunger ... 18.16 to 18.18 mm (.715 to .716 inch)
Outside diameter of plunger with engines that are equipped with counter balancer ... 15.95 to 15.98 mm (.628 to .629
inch)
Clearance of plunger in bore ... 0.06 to 0.11 mm (.002 to .004 inch)
Clearance of plunger in bore with engines that are equipped with counter balancer ... 0.02 to 0.08 mm (.0008 to .0031
inch)
(3) Diameter of the bore in the valve housing ... 18.24 to 18.27 mm (.718 to .719 inch)
Diameter of the bore in the valve housing with engines that are equipped with counter balancer ... 16.00 to 16.03 mm
(.630 to .631 inch)
(4) Tighten the bolt to the following torque: ... 44 ± 5 Nm (32 ± 4 lb ft)
Engine Oil Pump
SMCS - 1304
Ver imagen
Oil pump cover
(1) Bolt
Tighten the cover bolts to the following torque: ... 28 Nm (21 lb ft)
When the oil pump is mounted to a balancer unit, tighten the single bolt on the oil pump cover (not shown) to the
following torque: ... 22 Nm (16 lb ft)
Type ... Gerotor pump
Number of lobes
Inner rotor ... 6

Outer rotor ... 7
Ver imagen
Clearance for the outer rotor body
Clearance of the outer rotor to the body
The balancer unit is not installed. ... 0.15 to 0.34 mm (0.006 to 0.013 inch)
The balancer unit is installed. ... 0.31 to 0.45 mm (0.012 to 0.018 inch)
Ver imagen
Clearance for the inner rotor body

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

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

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

SMCS - 1302
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Typical engine oil pan
(1) Bolt
Tighten the bolts and the nuts that fasten the engine oil pan to the cylinder block to the following torque. ... 22 Nm (16
lb ft)
Note: The engine may be equipped with an oil drain plug or the engine may be equipped with a drain valve.
(2) Drain plug
Tighten the drain plug for the engine oil pan to the following torque. ... 34 ± 5 Nm (25 ± 4 lb ft)
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(3) Drain valve
Tighten the drain valve into the adapter to the following torque. ... 34 ± 5 Nm (25 ± 4 lb ft)
(4) Adapter
Tighten the adapter into the engine oil pan to the following torque. ... 34 ± 5 Nm (25 ± 4 lb ft)
Crankcase Breather
SMCS - 1317
Closed Crankcase Ventilation
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(1) Apply 9S-3263 Thread Lock Compound to the threads of the bolts that secure the crankcase breather to the engine.
(2) Breather Tube
Tighten the breather tube to the following torque. ... 34 ± 5 Nm (25 ± 4 lb ft)
Crankcase Breather
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Disassembled view of the crankcase breather
(1) Crankcase breather
Tighten the bolts that fasten the cover for the crankcase breather to the following torque. ... 3 Nm (27 lb in)
Water Temperature Regulator
SMCS - 1355
Ver imagen
Opening temperature ... 77 to 85 °C (171 to 185 °F)
Full open temperature ... 92 to 98 °C (198 to 208 °F)
Minimum stroke at full open temperature ... 9 mm (0.35 inch)

Water Pump
SMCS - 1361

more information.
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Ver imagen
(1) Outside diameter of shaft for drive gear ... 15.91 to 15.92 mm (.626 to .627 inch)
(2) Diameter of bore of drive gear ... 15.86 to 15.88 mm (.624 to .625 inch)
Interference fit of drive gear on shaft ... 0.03 to 0.06 mm (.001 to .002 inch)
(3) Diameter of bore of impeller ... 15.87 to 15.89 mm (.625 to .626 inch)
Outside diameter of shaft for impeller ... 15.91 to 15.92 mm (.626 to .627 inch)
Interference fit of impeller on shaft ... 0.02 to 0.05 mm (.001 to .002 inch)
(4) Diameter of bearing ... 29.990 to 30.000 mm (1.1807 to 1.1811 inch)
Diameter of bore for bearing ... 29.960 to 29.980 mm (1.1795 to 1.1803 inch)
Interference fit of bearing in pump body ... 0.010 to 0.040 mm (.0004 to .0016 inch)
(5) The water pump must be assembled in order to correctly measure the distance from the impeller boss to the front
face of the pump body. Distance ... 8.1 to 8.5 mm (.32 to .34 inch)
(6) The water pump must be assembled in order to correctly measure the distance of the gear from the rear face of the
pump body. Distance ... 0.6 to 2.6 mm (.02 to .10 inch)

more information.
Note: The water pump for Type 2 engines and 7BJ engines is not serviceable. Contact your Caterpillar dealer for more
replacement information.
Cylinder Block
SMCS - 1201
Ver imagen
Typical example
(1) Cylinder liner
Outside diameter of cylinder liner ... 104.25 to 104.28 mm (4.105 to 4.106 inch)
Inside diameter of cylinder liner ... 100.00 to 100.03 mm (3.937 to 3.938 inch)
Maximum permissible wear of cylinder liner bore ... 0.25 mm (0.010 inch)
Interference fit of cylinder liner in cylinder block ... 0.03 to 0.08 mm (0.001 to 0.003 inch)
Flange thickness of cylinder liner ... 3.81 to 3.86 mm (0.150 to 0.152 inch)
The projection of the liner flange can be 0.10 mm (0.004 inch) above to 0.10 mm (0.004 inch) below the top face of
the cylinder block.
(2) Plug with baffle plates (if equipped)
Orientation of baffle plates to the vertical plane ... +/- 5 degrees

Depth of plug from face of cylinder block ... 3 mm (0.12 inch)
(3) Cylinder block
Diameter of the bore for the cylinder liner ... 104.20 to 104.23 mm (4.103 to 4.104 inch)
Depth of the recess for the cylinder liner flange ... 3.81 to 3.91 mm (0.150 to 0.154 inch)
Diameter of the recess for the cylinder liner flange ... 107.82 to 107.95 mm (4.245 to 4.250 inch)
(4) Tighten the bolts that fasten the housing for the crankshaft rear seal to the cylinder block to the following torque. ...
22 Nm (16 lb ft)
(5) Tighten the bolts that fasten the housing for the crankshaft rear seal to the bridge to the following torque.
M6 ... 13 Nm (10 lb ft)

M8 ... 22 Nm (16 lb ft)
(6) Bridge bolt
Use the following procedure in order to install the bridge bolts.
Use a straight edge in order to ensure that the bridge is aligned with the front face of the cylinder block.
Evenly tighten the bridge bolts to a torque of 16 Nm (12 lb ft).
When the bridge is installed on the cylinder block, apply a thin bead of 8T-9013 Silicone Sealant into the groove at each
end of the bridge.
(7) Main bearing cap bolts
Use the following procedure in order to install the main bearing cap bolts.
Apply clean engine oil to the threads of the main bearing cap bolts.
Put the main bearing caps in the correct position that is indicated by a number on the top of the main bearing cap.
Install the main bearing caps with the locating tabs in correct alignment with the recess in the cylinder block.
Evenly tighten the main bearing cap bolts to a torque of 265 Nm (195 lb ft).
(8) Bore in the cylinder block for the main bearings ... 80.416 to 80.442 mm (3.1660 to 3.1670 inch)
(9) Camshaft bearing
Inside diameter of the camshaft bearing for the number 1 camshaft journal ... 50.79 to 50.85 mm (2.000 to 2.002
inch)
Bore diameter in the cylinder block for the number 1 camshaft bearing ... 55.56 to 55.59 mm (2.187 to 2.189 inch)
Bore diameter in the cylinder block for the number 2 camshaft journal ... 50.55 to 50.60 mm (1.990 to 1.992 inch)
Bore diameter in the cylinder block for the number 3 camshaft journal ... 50.04 to 50.09 mm (1.970 to 1.972 inch)
Total height of cylinder block between the top and the bottom faces. ... 441.12 to 441.33 mm (17.367 to 17.375 inch)
Piston Cooling Jets (If Equipped)
Ver imagen
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(1) Tighten the piston cooling jets to the following torque. ... 27 Nm (20 lb ft)
(2) Diameter of rod ... 1.70 mm (0.067 inch)
(3) Cylinder block
Note: Ensure that the piston cooling jet is positioned correctly on the dowel in the cylinder block (not shown).
Use the following procedure in order to ensure the correct alignment of the piston cooling jet.
Insert rod (2) into the end of the piston cooling jet. Rod (2) should protrude out of the top of the cylinder block.
Use the following dimensions to locate the center point of diameter (C) .
Dimension (A) ... 33 mm (1.3 inch)
Dimension (B) ... 21 mm (0.8 inch)
Diameter (C) ... 14 mm (0.6 inch)
Note: Dimension (A) and dimension (B) are tangent to the cylinder bore.
Position rod (2) within diameter (C) .

Crankshaft
SMCS - 1201
Ver imagen
Crankshaft and main bearing journals
Note: If a crankshaft that was not originally induction hardened has been remachined, then the crankshaft must be
rehardened. Use one of the process that follow for 20 hours in order to reharden the crankshaft: nitrocarburizing
process and nitriding process
(1) Connecting rod bearing
(2) Top and bottom thrust washer thickness
Standard ... 2.26 to 2.31 mm (0.089 to 0.091 inch)

Oversize ... 2.45 to 2.50 mm (0.096 to 0.098 inch)
(3) Main bearing
Clearance for main bearings ... 0.057 to 0.117 mm (0.0022 to 0.0046 inch)
Bearing width
Center bearing ... 36.32 to 36.70 mm (1.430 to 1.445 inch)
All other bearings ... 31.62 to 31.88 mm (1.245 to 1.255 inch)
Thickness of the bearing at the center
All bearings ... 2.083 to 2.086 mm (0.0820 to 0.0821 inch)
(4) Crankshaft gear
(5) End play of the crankshaft ... 0.05 to 0.38 mm (0.002 to 0.015 inch)
Maximum permissible end play ... 0.51 mm (0.020 inch)
(6) Width of the connecting rod journal ... 40.35 to 40.42 mm (1.589 to 1.591 inch)
Connecting rod journal diameter of flange ... 133.27 to 133.37 mm (5.247 to 5.251 inch)
Depth of recess for connecting rod bearing ... 20.22 to 20.98 mm (0.796 to 0.826 inch)
Bore of recess for connecting rod bearing ... 46.96 to 46.99 mm (1.849 to 1.850 inch)
Measure the connecting rod journals on the crankshaft. See the following chart for the dimensions.
Table 1
Connecting Rod Bearing Journal

If the bearing journal has been ground beyond this size, then regrind the
bearing journals to the next undersize journal. 63.43 mm (2.497 inch)
Original Size Journal
63.47 to 63.49 mm (2.499 to
2.500 inch)
Undersize Journal
0.25 mm (0.010 inch) 63.22 to 63.24 mm (2.489 to
2.490 inch)
Undersize Journal
0.51 mm (0.020 inch) 62.96 to 62.98 mm (2.479 to
2.480 inch)
Undersize Journal
0.76 mm (0.030 inch) 62.71 to 62.73 mm (2.469 to
2.470 inch)
Connecting rod bearings are available for remachined journals with the following undersize dimensions:
Undersize ... 0.25 (0.010)

Undersize ... 0.51 (0.020)
Undersize ... 0.76 (0.030)
(7) Dimensions of main journals which are the standard, original size
Width of front journal ... 36.93 to 37.69 mm (1.454 to 1.484 inch)

Width of center journal ... 44.15 to 44.22 mm (1.738 to 1.741 inch)
Width of all other journals ... 39.24 to 39.35 mm (1.545 to 1.549 inch)
Measure the main bearing journals on the crankshaft. See the following chart for dimensions.
Table 2
Main Bearing Journal
If the bearing journal has been ground beyond this size, then regrind the
bearing journals to the next undersize journal. 76.12 mm (2.996 inch)
Original Size Journal
76.16 to 76.18 mm (2.998 to
2.999 inch)
Undersize Journal
0.25 mm (0.010 inch) 75.91 to 75.93 mm (2.988 to
2.989 inch)
Undersize Journal
0.51 mm (0.020 inch) 75.65 to 75.67 mm (2.978 to
2.979 inch)
Undersize Journal
0.76 mm (0.030 inch) 75.40 to 75.42 mm (2.968 to
2.969 inch)
Tighten the bolts for the main bearing journal to the following torque: ... 265 Nm (195 lb ft)
Main bearings are available for remachined journals with the following undersize dimensions:
Undersize ... 0.25 (0.010)

Undersize ... 0.51 (0.020)
Undersize ... 0.76 (0.030)
Tighten the retaining bolts of the crankshaft pulley (not shown) to the following torque: ... 115 Nm (85 lb ft)
Apply 9S-3263 Thread Lock Compound to the bolts of the crankshaft damper. Tighten the bolts (not shown) to the
following torque:
M8 bolts ... 35 Nm (26 lb ft)

M12 bolts ... 75 Nm (55 lb ft)
Tighten the bolts that fasten the rear oil seal housing to the cylinder block (not shown) to the following torque: ... 22
Nm (16 lb ft)
Tighten the bolts that fasten the rear oil seal housing to the bridge (not shown) to the following torque:
M6 ... 13 Nm (10 lb ft)

M8 ... 18 Nm (13 lb ft)
Crankshaft Seals
SMCS - 1160; 1161
Crankshaft Front Seal
Ver imagen
The front oil seal (2) is normally installed to a depth of 7.00 ± 0.25 mm (0.2756 ± 0.0098 inch) (A) from the face of
the front oil seal housing (6). The oil seal may cause wear on the hub of crankshaft pulley (3). This wear may allow oil
leakage past the oil seal. If this situation occurs, the front oil seal can be installed to a depth of 9.3 mm (0.37 inch)
from the face of the front oil seal housing.
If a wear sleeve (4) is installed, the front oil seal is installed to a depth of 9.30 mm (0.366 inch) from the face of the
front oil seal housing. When the wear sleeve is installed, the flange of the wear sleeve does not require removal. If a
wear sleeve is installed, a new front oil seal must be installed.
(5) Tighten three bolts for the crankshaft pulley to the following torque. ... 115 Nm (85 lb ft)
Crankshaft Rear Seal

Engines with 14 Bolt Housing Assembly
Ver imagen
Positions of the crankshaft seal
Position (1) is 0 mm (0.0 inch) from the face of the rear housing.
Position (2) is 4.6 mm (0.18 inch) from the face of the rear housing. Use position (2) if the crankshaft surface is worn in
position (1) .
Position (3) is 6.9 mm (0.27 inch) from the face of the rear housing. Use position (3) if the crankshaft surface is worn in
both of the other positions.
Engines with 10 Bolt Housing Assembly

The 10 bolt housing assembly is manufactured as a one-piece assembly. There is no adjustment of the position from
the face of the rear housing.
Note: If a wear groove on the crankshaft flange has occurred, use a 209-8228 Sleeve to renew the sealing surface
when you replace the housing assembly.
Tighten the bolts that fasten the rear housing for the crankshaft rear seal to the cylinder block to the following torque.
... 22 Nm (16 lb ft)
Connecting Rod
SMCS - 1218
more information.
Ver imagen
Connecting Rod And Bearings
Naturally Aspirated Engines

(1) Inside diameter of rod for bearing ... 38.89 to 38.92 mm (1.531 to 1.532 inch)
(2) Outside diameter of bearing for piston pin ... 38.94 to 39.03 mm (1.535 to 1.536 inch)
Inside diameter of bearing for piston pin after reaming ... 34.940 to 34.960 mm (1.3758 to 1.3765 inch)
Clearance between small end bearing and piston pin ... 0.020 to 0.043 mm (.0008 to .0017 inch)
(3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to 219.10 mm (8.624 to 8.626
inch)
(4) Bearings are available for remachined journals of the crankshaft which have the following undersize dimensions:
0.25 mm (.010 inch)
0.51 mm (.020 inch)
0.76 mm (.030 inch)

Shell thickness ... 1.835 to 1.842 mm (.0723 to .0726 inch)
Width of connecting rod bearing ... 31.62 to 31.88 mm (1.245 to 1.255 inch)
Bearing clearance ... 0.035 to 0.081 mm (.0014 to .0032 inch)
(6) Connecting rod cap with nuts and bolts
Tighten the nuts for the connecting rod to the following torque: ... 125 Nm (92 lb ft)
Connecting rod cap with bolts only
Tighten the bolts for the connecting rod to the following torque: ... 155 Nm (114 lb ft)
Turbocharged Engines
inch)
(4) Bearings are available for remachined journals of the crankshaft which have the following undersize dimensions:
0.25 mm (.010 inch)
0.51 mm (.020 inch)
0.76 mm (.030 inch)
Note: If piston cooling jets are installed, the piston and the connecting rod assembly must be turned when the piston
and rod assembly are installed. Turning the piston and connecting rod assembly will prevent the connecting rod from
hitting and damaging the piston cooling jet. When the connecting rod has passed the piston cooling jet, turn the
connecting rod until the arrow or "Front" mark on the top of the piston is toward the front of the engine.

more information.
The piston height is controlled by the length of the connecting rod. Connecting rods are supplied in six grades of length.
The different grades of length are manufactured by machining the hole in the piston pin bearing in an off-center
position. The different grades of length are created by the following method:
Machining the center of the hole in the piston pin
Machining the center of the hole in the bearing
If the connecting rod is replaced, ensure that the same grade of length as the original connecting rod is used.
However, if the crankshaft or the cylinder block is replaced, the required grade of length of the connecting rods may
change.
A correct grade of length of a connecting rod can be ordered for replacement. The connecting rod includes the piston
pin bearing. The piston pin bearing is machined in order to create the correct grade of length. The piston pin is installed
in the connecting rod at the factory. Table 2 provides the specifications for the grade of length.
Note: The length of the connecting rod is determined by the following method: The bearing for the crankshaft journal
must be removed and the piston pin must be installed. The original grade of length of the connecting rod is determined
when the original piston pin is installed.
Connecting rods are color coded. The color code is a reference for the length (Y) of the connecting rod. Refer to Table 2
for the different lengths of connecting rods.
--------------------------------------------------------------------------------
Ver imagen
--------------------------------------------------------------------------------
Table 1
Grade of Length Color Length of the Connecting Rod
"F" Red
165.728 to 165.761 mm (6.5247 to 6.5265 inch)
"G" Orange
165.682 to 165.715 mm (6.5229 to 6.5247 inch)
"H" White
165.637 to 165.670 mm (6.5211 to 6.5229 inch)
"J" Green
165.591 to 165.624 mm (6.5193 to 6.5211 inch)
"K" Purple
165.545 to 165.578 mm (6.5175 to 6.5193 inch)
"L" Blue
165.499 to 165.532 mm (6.5157 to 6.5175 inch)
If a piston pin bearing requires replacement but the connecting rod does not require replacement, a new piston pin
bearing can be ordered. This bearing is partially finished. The hole in the bearing must be machined off-center to the
correct distance in order to create a connecting rod assembly that is the correct grade of length.
Refer to the Testing and Adjusting manual for the following procedures:
Determine the length of the connecting rod.
Determine the distortion of a connecting rod.
Replace the piston pin bearing.
Serrated Connecting Rods and Flat Connecting Rods
Ver imagen
Connecting Rod And Bearings
inch)
(4) Bearing for connecting rod journal

Note: If piston cooling jets are installed, the piston and the connecting rod assembly must be turned when the piston
and rod assembly are installed. Turning the piston and connecting rod assembly will prevent the connecting rod from
hitting and damaging the piston cooling jet. When the connecting rod has passed the piston cooling jet, turn the
connecting rod until the arrow or "Front" mark on top of the piston is toward the front of the engine.
Hydraulically Fractured Connecting Rods
Ver imagen
Note: The caps and rods must stay together as a pair.
Note: When the connecting rods are replaced, do not reuse the connecting rod bolts. New connecting rod bolts must be
used.
The mating surfaces of the connecting rod are produced by hydraulically fracturing the forged connecting rod.
(7) Tighten the connecting rod bolts to the following torque. ... 18 Nm (13 lb ft)
Tighten the connecting rod bolts again to the following torque. ... 70 Nm (52 lb ft)
Tighten the connecting rod bolt for an additional 120 degrees.
(8) Connecting rod bearing
Ver imagen
(9) Diameter of the bore for the piston pin ... 43.01 to 43.04 mm (1.693 to 1.694 inch)
(10) Distance between bearing centers ... 219.05 to 219.10 mm (8.624 to 8.626 inch)
(11) Diameter for the bore for the connecting rod bearing ... 67.21 to 67.22 mm (2.6460 to 2.6465 inch)
Piston and Rings
SMCS - 1214; 1215

more information.
--------------------------------------------------------------------------------
Ver imagen
--------------------------------------------------------------------------------
Piston and rings
Note: The word "Front" or an arrow which is marked on the piston crown must be toward the front of the engine. If the
piston crown is not marked, put the narrowest side of the piston crater toward the side of the engine with the fuel
injection pump. The shortest distance between the edge of the piston crater and the edge of the piston is the narrowest
side of the piston crater.
Note: Be sure that the ring end gaps of all the piston rings have 120 degrees spacing from each other.
Note: Refer to Systems Operation, "General Information" for the location of the serial number.
Naturally Aspirated Engines

(1) Width of groove in piston for top ring ... 2.57 to 2.59 mm (.101 to .102 inch)
Thickness of top ring ... 2.48 to 2.49 mm (.097 to .098 inch)
Clearance between groove and piston ring ... 0.08 to 0.11 mm (.003 to .004 inch)
Clearance between the ends of the top ring with a cylinder liner without any wear ... 0.40 to 0.85 mm (.016 to .033
inch)
(2) Width of groove in piston for intermediate ring ... 2.55 to 2.57 mm (.100 to .101 inch)
Thickness of intermediate ring ... 2.48 to 2.49 mm (.097 to .098 inch)
Clearance between groove and intermediate ring ... 0.06 to 0.09 mm (.002 to .003 inch)
Clearance between the ends of the intermediate ring with a cylinder liner without any wear ... 0.30 to 0.76 mm (.012 to
.030 inch)
(3) Width of groove in piston for oil control ring ... 4.030 to 4.060 mm (.1587 to .1598 inch)
Thickness of oil control ring ... 3.980 to 3.990 mm (.1566 to .1571 inch)
Clearance between groove and oil control ring ... 0.04 to 0.08 mm (.002 to .003 inch)
Clearance between the ends of oil control ring with a cylinder liner without any wear ... 0.38 to 0.84 mm (.015 to .033
inch)
(4) Diameter of new piston pin ... 34.920 to 34.925 mm (1.3748 to 1.3750 inch)
Bore for piston pin ... 34.928 to 34.934 mm (1.3751 to 1.3754 inch)
(1) Shape of groove in piston for top ring ... Taper
Shape of top ring ... Taper
Clearance between the ends of top ring in a cylinder liner without any wear ... 0.35 to 0.75 mm (.014 to .030 inch)
(2) Width of groove in piston for intermediate ring ... 2.56 to 2.58 mm (.101 to .102 inch)
Thickness of intermediate ring ... 2.48 to 2.49 mm (.097 to .098 inch)
Clearance between the ends of an intermediate ring in a cylinder liner without any wear ... 0.30 to 0.76 mm (.012 to
.030 inch)
(3) Width of groove in piston for oil control ring ... 4.040 to 4.060 mm (.1591 to .1598 inch)
Clearance between the ends of an oil control ring in a cylinder liner without any wear ... 0.38 to 0.84 mm (.015 to .033
inch)
Piston Height
--------------------------------------------------------------------------------
Ver imagen
--------------------------------------------------------------------------------
Quadram piston
There are two different designs for the crown of the piston. One design is the Quadram piston. There is only one grade
of piston for the replacement of a Quadram piston.
Grade of piston for service ... L
Height of a Quadram piston above the top face of the cylinder block ... 0.14 to 0.36 mm (0.005 to 0.014 inch)
--------------------------------------------------------------------------------
Ver imagen
--------------------------------------------------------------------------------
Fastram piston
The other style of piston is the Fastram piston. The piston height above the top face of the cylinder block is controlled
by different grades of height of the piston. Identification of the height grade is by the letter that is stamped on the top
of each piston. The height grade can be checked by measuring from the center of the piston pin to the top of the piston.
The difference between each grade of height is 0.045 mm (0.0018 inch). Table 1 provides the specifications for the
grade of height for a Fastram piston.
Table 1
Height Grades for the Piston

Letter on top of Piston Height Dimension Latest Equivalent Grade
A (1) G
70.334 mm (2.7690 inch)
B (1) H
70.289 mm (2.7673 inch)
C (1) J
70.244 mm (2.7655 inch)
D (1) K
70.199 mm (2.7637 inch)
E (1) L
70.154 mm (2.7620 inch)
F -
70.391 mm (2.7713 inch)
G -
70.345 mm (2.7695 inch)
H -
70.299 mm (2.7677 inch)
J -
70.253 mm (2.7659 inch)
K -
70.207 mm (2.7640 inch)
L -
70.161 mm (2.7622 inch)
(1) Earlier engines
Height of a Fastram piston above the top face of the cylinder block ... 0.38 to 0.50 mm (0.015 to 0.020 inch)

more information.
Ver imagen
--------------------------------------------------------------------------------
Note: The word "Front" or an arrow which is marked on the piston crown must be toward the front of the engine. If the
piston crown is not marked, put the narrowest side of the piston crater toward the side of the engine with the fuel
injection pump. The shortest distance between the edge of the piston crater and the edge of the piston is the narrowest
side of the piston crater.
Note: Be sure that the ring end gaps of all the piston rings have 120 degrees spacing from each other.
Note: Refer to Systems Operation, "General Information" for the location of the serial number.
(1) Top piston ring
Shape of groove in piston for top ring ... Taper

Shape of top ring ... Taper
Clearance between the ends of the top ring in a cylinder liner without any wear ... 0.28 to 0.63 mm (.011 to .025 inch)
Note: Install the word "TOP" toward the top of the piston. New top rings have a red identification mark which must be
on the left of the ring gap when the intermediate ring is installed on an upright piston.
(2) Intermediate ring
Width of groove in piston for intermediate ring ... 2.56 to 2.58 mm (0.101 to 0.102 inch)
Thickness of intermediate ring ... 2.48 to 2.49 mm (0.097 to 0.098 inch)
Clearance between the ends of an intermediate ring in a cylinder liner without any wear ... 0.40 to 0.65 mm (.016 to
.026 inch)
Note: Install the word "TOP" toward the top of the piston. New intermediate rings have a green identification mark
which must be on the left of the ring gap when the intermediate ring is installed on an upright piston.
(3) Oil control ring
Width of groove in piston for oil control ring ... 3.54 to 3.56 mm (.139 to .140 inch)
Clearance between the ends of an oil control ring in a cylinder liner without any wear ... 0.38 to 0.83 mm (.015 to .033
inch)
Note: A pin is used in order to hold both ends of the spring of the oil control ring in position. The ends of the spring of
the oil control ring must be 180 degrees opposite the end gap of the oil control ring.
Piston height above cylinder block (not shown) ... 0.36 to 0.50 mm ( .014 to .020 inch)
Housing (Front)
SMCS - 1151
Ver imagen
Front housing and front cover
Ver imagen
9U-6200 Front Cover Installer
(1) Front cover
The front cover must be centered on the front of the engine before the bolts are tightened. Use a 9U-6200 Front Cover
Installer to center the front cover before the bolts are tightened.
(2) Front housing
Tighten the M8 bolts (not shown) that fasten the front housing to the cylinder block to the following torque: ... 22 Nm
(16 lb ft)
Tighten the M10 bolts (not shown) that fasten the front housing to the cylinder block to the following torque: ... 44 Nm
(33 lb ft)
(3) Bolts
After the front cover is centered on the front of the engine, tighten the bolts and the two nuts that fasten the front
cover to the front housing. Tighten the bolts and the nuts to the following torque: ... 22 Nm (16 lb ft)
(4) 9U-6200 Front Cover Installer
The front cover installer is used to center the front cover on the front of the engine. Refer to the Disassembly and
Assembly Module, "Front Cover - Install" topic for additional information.
Gear Group (Front)
SMCS - 1206
Ver imagen
(1) Fuel injection pump gear
Bore ... 36.00 to 36.06 mm (1.417 to 1.420 inch)

Tighten the four bolts to the following torque. ... 28 Nm (21 lb ft)
Tighten the two torx screws to the following torque. ... 9 Nm (7 lb ft)
Note: The torx screws retain the timing plate on the front of the gear. This plate is installed in the factory after the fuel
injection pump timing has been accurately set to the top center position on the compression stroke of the No. 1
cylinder. If the timing plate is moved, the timing of the fuel injection pump must be set.
Note: The crankshaft must not be turned unless the fuel injection pump gear is installed.
Note: Do not remove the nut that retains the hub of the fuel injection pump to the shaft of the fuel injection pump. If
the hub is removed, the hub must be positioned by correctly trained personnel and special test equipment.
(2) Camshaft gear
Diameter of the camshaft gear bore ... 34.930 to 34.950 mm (1.3752 to 1.3760 inch)
Outside diameter of camshaft hub ... 34.900 to 34.920 mm (1.3741 to 1.3747 inch)
Clearance between the camshaft gear and the camshaft hub ... 0.008 to 0.048 mm (0.0003 to 0.0019 inch)
(3) Tighten the bolt for the camshaft gear to the following torque. ... 95 Nm (70.0682 lb ft)
(4) Idler gear and hub
Diameter of the idler gear bore ... 57.14 to 57.18 mm (2.250 to 2.251 inch)
Width of the idler gear and split bearing assembly ... 30.14 to 30.16 mm (1.186 to 1.187 inch)
Inside diameter of the idler gear bearing ... 50.78 to 50.80 mm (1.999 to 2.000 inch)
Outside diameter of the idler gear hub ... 50.70 to 50.74 mm (1.996 to 1.998 inch)
Clearance of the bearing on the idler gear hub ... 0.04 to 0.10 mm (0.002 to 0.004 inch)
Idler gear end play ... 0.10 to 0.20 mm (0.004 to 0.008 inch)
Maximum permissible end play ... 0.38 mm (0.015 inch)
Backlash (minimum) ... 0.08 mm (0.003 inch)
(5) Tighten the bolts for the idler gear to the following torque: ... 44 Nm (33 lb ft)
(6) Crankshaft gear
Diameter of the bore of the crankshaft gear ... 47.625 to 47.650 mm (1.8750 to 1.8760 inch)
Outside diameter of the crankshaft for the crankshaft gear ... 47.625 to 47.645 mm (1.8750 to 1.8758 inch)
Clearance of the crankshaft gear on the crankshaft for a press fit ... 0.015 ± 0.035 mm (0.0006 ± 0.0014 inch)
(7) Oil pump idler gear
Inside diameter of the bearing ... 22.230 to 22.260 mm (0.8750 to 0.8766 inch)
Outside diameter of the idler gear shaft ... 22.19 to 22.21 mm (0.873 to 0.874 inch)
Clearance of the gear on the shaft ... 0.020 to 0.066 mm (0.0008 to 0.0026 inch)
Idler gear end play ... 0.012 to 0.643 mm (0.0005 to 0.0253 inch)
Timing gear backlash (minimum) ... 0.08 mm (0.003 inch)

Flywheel and Flywheel Housing Runout
SMCS - 1156; 1157
Ver imagen
(1) Tighten the bolts of the flywheel housing to the following torque:
The M10 bolts for the cast iron flywheel housing ... 44 Nm (32 lb ft)
The M12 bolts that are stamped "8.8" for the cast iron flywheel housing ... 75 Nm (55 lb ft)
The M10 bolts that are for the aluminum flywheel housing ... 70 Nm (52 lb ft)
(2) The maximum temperature for heating the flywheel ring gear for installation ... 250 °C (482 °F)
(3) Tighten flywheel bolts to the following torque: ... 105 Nm (77 lb ft)
Flywheel Housing Runout

Face Runout
Ver imagen
Face Runout Check
Maximum permissible face runout of the flywheel housing ... 0.20 mm (0.008 inch)
Refer to Testing and Adjusting, "Flywheel and Flywheel Housing" for the correct procedure to measure the runout.
Bore Runout
Ver imagen
--------------------------------------------------------------------------------
Bore Runout Check
Maximum permissible bore runout of the flywheel housing ... 0.20 mm (0.008 inch)
Flywheel Runout
Face Runout
Ver imagen
Face Runout Check
Refer to Testing and Adjusting, "Flywheel and Flywheel Housing".
Outside Diameter Runout
Ver imagen
Outside Diameter Runout Check
Belt Tension Chart
SMCS - 1357
Table 1
Belt Tension Chart
Gauge Reading
Initial Belt Tension (1) Used Belt Tension (2)
400 to 489 N (90 to 110 lb)

267 to 356 N (60 to 80 lb)
(1) Initial Belt Tension refers to a new belt.
(2) Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.
Note: Use a 144-0235 Belt Tension Gauge to measure the tension of the belt
Fan Drive
SMCS - 1359
Ver imagen
(1) Fan drive bearing
Bore of housing for bearing ... 41.965 to 41.978 mm (1.6522 to 1.6537 inch)
Outside diameter of bearing ... 41.99 to 42.00 mm (1.653 to 1.654 inch)
Interference fit of bearing in housing ... 0.009 to 0.035 mm (0.0004 to 0.0014 inch)
(2) Fan drive shaft
Bore of hub on shaft ... 21.938 to 21.958 mm (0.8637 to 0.8645 inch)

Outside diameter of shaft ... 21.987 to 22.000 mm (0.8656 to 0.8661 inch)
Interference fit of shaft in hub ... 0.029 to 0.062 mm (0.0011 to 0.0024 inch)
Maximum permissible end play of shaft ... 0.20 mm (0.008 inch)
(3) Install the hub on the shaft to the following dimension: ... 115.3 mm (4.54 inch)
Tighten the bolts that fasten the fan drive to the engine to the following torque: ... 44 Nm (33 lb ft)
Tighten the bolts for the fan drive pulley (not shown) to the following torque:
M8 ... 22 Nm (16 lb ft)

M10 ... 44 Nm (33 lb ft)
Tighten the bolts for the fan (not shown) to the following torque:
M8 ... 22 Nm (16 lb ft)

Alternator and Regulator
SMCS - 1405; 1410
ver imagen
Typical alternator (side view)
Ver imagen
End view of the 12 volt alternator which shows the electrical connections
Ver imagen
End view of the 24 volt alternator which shows the electrical connections
Note: Test the battery with a carbon pile 4C-4911 Battery Load Tester in order to measure the maximum output from
the alternator.
The rotation of the alternator is clockwise when the alternator is viewed from the pulley.
The regulator of the alternator is sealed.
Polarity ... Negative ground to the case
Type of brushes ... Sealed
(1) Tighten the pulley nut to the following torque. ... 45 to 55 Nm (33 to 40 lb ft)
(2) Tighten the terminal nut "W" to the following torque. ... 2 to 2.5 Nm (17 to 22 lb in)
The "W" terminal is the source of the alternating current from the stator.
Note: The peak voltage at the "W" terminal must not be less than the output voltage at the "B+" terminal. The peak
voltage at the "W" must not be more than two volts greater than the "B+" terminal.
(3) Tighten terminal nut "D+" to the following torque. ... 1.45 to 1.95 Nm (13 to 17 lb in)
The "D+" terminal is the field excitation terminal. The battery must be connected in order to energize the circuit.
(4) Tighten terminal nut "B+" to the following torque. ... 5.9 to 9.8 Nm (52 to 87 lb in)
(5) Tighten terminal nut "B-" on the 24 volt alternator to the following torque: ... 3.6 ± 0.8 Nm (32 ± 7 lb in)
12 Volt Alternator at 25°C (77°F)
Rpm ... 1500 to 8000 rpm

Positive terminal load ... 2 amperes to maximum output
Minimum full load current at 5000 rpm ... 48.6 amperes
Output voltage ... 14 ± .5 volts
Rated voltage ... 12 volts
Maximum leakage current with load of 18000 ohm ... 220 microamperes
Load range ... 0 to 1 ampere
24 Volt Alternator at 25°C (77°F)
Rpm ... 1500 to 8000 rpm

Positive terminal load ... 2 amperes to maximum output
Minimum full load current at 5000 rpm ... 47 amperes
Output voltage ... 28 ± 1 volts
Maximum leakage current with load of 18000 ohm ... 220 microamperes
Load range ... 0 to 1 ampere
Alignment of the alternator pulley to the crankshaft pulley ... ± 2.4 mm (0.095 inch)
Electric Starting Motor
SMCS - 1453
12 Volt Starting Motor
Ver imagen
Starting Motor (Side View)
Ver imagen
End view of the starting motor which shows the electrical connections
No load conditions at 25 °C (77 °F)
Rpm of shaft ... 7000 minimum

Current draw ... 130 amperes maximum
Voltage ... 11.5 volts
(1) Tighten the battery terminal nut to the following torque: ... 24 to 32 Nm (18 to 24 lb ft)
(2) Tighten the nut for the switch terminal to the following torque: ... 1.0 to 1.3 Nm (9 to 12 lb in)
Tension of the spring for the motor brush ... 8.34 to 11.00 N (1.9 to 2.5 lb)
Minimum resistance of the starter cable at 200 °C (392 °F) and at 12 volts ... 0.0017 ohms
Start Relays
9G-4368 Relay
Ver imagen
Voltage ... 12 VDC
Resistance between "W1" terminal and "W2" terminal ... 15 ± 1.5 ohms
069-5466 Relay
Ver imagen
Voltage ... 6 VDC
Resistance between terminal "A" and terminal "B" ... 30 to 34 ohms
24 Volt Starting Motor

No load conditions at 25 °C (77 °F)
Rpm of shaft ... 7000 minimum

Current draw ... 85 amperes maximum
Voltage ... 23 volts
Minimum pull-in voltage ... 18 volts
Brush length:
Minimum brush length ... 15.5 mm (0.61 inch)

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

Minimum diameter ... 42.5 mm (1.67 inch)

Especificaciones 416c#2

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Engine Design

Type 1 Engines and 9RM Engines

(A) Exhaust valves

(B) Inlet valves

Type ... Four cylinder and four stroke

Combustion system ... Direct injection

Nominal Bore ... 100 mm (3.937 inch)

Stroke ... 127 mm (5.00 inch)

Capacity ... 4 liters (243 in3)

Compression Ratio ... 16:1

Number of cylinders ... 4

Firing Order ... 1, 3, 4, 2

Inlet valve ... 0.20 mm (.008 inch)

Type 2 Engines and 7BJ Engines

(A) Exhaust valves

(B) Inlet valves

Combustion system ... Direct injection

Nominal Bore ... 100 mm (3.937 inch)

Stroke ... 127 mm (5.00 inch)

Capacity ... 4 liters (243 in3)

Compression Ratio ... 17.25:1

Number of cylinders ... 4

Arrangement of cylinders ... in-line

Firing Order ... 1, 3, 4, 2

Inlet valve ... 0.20 mm (.008 inch)

Hub nut (not shown)

(4) Boost control (if equipped)

(9) Locking spacer (If equipped)

Timing Information for the Bosch Fuel Injection Pump

Code Letters on Engine Check Fuel Injection Pump Static Timing

"BK" 308 314 12 1.78 mm (0.070

"CK" 308 314 12 1.78 mm (0.070

"DK" 306 313 14 2.42 mm (0.095

"EK" 308.5 315.5 14 2.42 mm (0.095

"EK" (2) 306.5 315.5 18 3.99 mm (0.157

"FM" 289 295 12.5 1.93 mm (0.076

"JM" (4) - - TDC -

"KC" (5) - - TDC -

"KL" (5) - - TDC -

"ML" (5) - - TDC -

"TL" (5) - - TDC -

Hub nut (not shown)

(1) Electrical connection for the stop solenoid

(6) Adjustment screw for advance timing

Timing Information for the Stanadyne Fuel Injection Pump

"BL" 326 336

"CL" (1) - 247.5

"DL" 332 338

"LM" (2) 288.5 295

"MM" 282 287

"MM" (3) 288.5 295

"UC" 228.5 296

"ZM" (4) 282 287

"ZM" (5) 282 289

(1) Hub nut

(3) Locking spacer

The locking screw prevents the rotation of the drive shaft.

(8) Electrical connection for the stop solenoid

(12) Electrical connection for cold starting aid

timing Information for the Delphi Fuel Injection Pump

"FK" 325.5 336

"KK" 325 334

"LK" (1) 328 337.5

"MK" 326 336

Composite cover ... 20 Nm (15 lb ft)