Professional Documents
Culture Documents
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Illustration 1
Cylinder and valve location for Type 1 engines and 9RM engines
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.
Valve Lash
When the crankshaft is viewed from the front of the engine the crankshaft rotates in the
following direction: ... Clockwise
When the camshaft is viewed from the front of the engine the camshaft rotates in the
following direction: ... Clockwise
Note: The front end of the engine is opposite the flywheel end. The left side and the
right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the
front cylinder.
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Illustration 2
Cylinder and valve location for Type 2 engines and 7BJ engines
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.
Valve Lash
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
1 1 0
front cylinder.
Fuel Injection Pump
SMCS - 1251; 1290
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Various Fuel Injection Pumps may be equipped to the engine. Bosch, Delphi, or
Stanadyne fuel injection pumps may be equipped to the engine.
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Illustration 1
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.
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)
(5) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5
Nm (35 to 40 lb in)
(6) Tighten the nuts for the high pressure fuel line connection to the following torque. ...
22 Nm (16 lb ft)
(7) Tighten the flange nuts to the following torque. ... 22 Nm (16 lb ft)
(8) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to
81.4 Nm (52 to 60 lb ft)
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Illustration 2
Note: The drive shaft of the fuel injection pump must not be turned without the spacer
in position under the locking screw (10) .
(10) Tighten the locking screw to the following torque. ... 27 Nm (20 lb ft)
(11) Tighten the nut for the drive gear to the following torque. ... 80 Nm (59 lb ft)
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Illustration 3
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.
"JM" - - 6 -
"JM" (3) - - 2 -
"PM" - - 12 -
"SK" - - 9 -
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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Illustration 4 g00788020
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.
Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is
positioned to the pump shaft in order to ensure that the fuel pump is in the correct
position for timing. If the hub is removed, the hub will need to be accurately positioned
to the pump shaft. Accurate positioning requires the use of special equipment by a
Caterpillar Dealer.
(2) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to
6 Nm (44 to 53 lb in)
(3) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5
Nm (35 to 40 lb in)
(4) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to
4.5 Nm (35 to 40 lb in)
(5) Tighten the flange nuts to the following torque. ... 22 Nm (16 lb ft)
(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
Code Letters on Fuel Engine Check Angle Fuel Injection Pump Mark Angle
Injection Pump (degrees) (degrees)
(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".
g00788005
Illustration 5
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.
Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is
positioned to the pump shaft in order to ensure that the fuel pump is in the correct
position for timing. If the hub is removed, the hub will need to be accurately positioned
to the pump shaft. Accurate positioning requires the use of special equipment by a
Caterpillar Dealer.
(2) O-ring
(4) Tighten the locking screw to the following torque. ... 10 Nm (7 lb ft)
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Illustration 6
Before the crankshaft is turned or the fuel injection pump is installed, move the locking
spacer (3) under the locking screw (4). Refer to position (A) that is in Illustration 6.
This position ensures that the pump drive shaft is released.
(5) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to
6 Nm (44 to 53 lb in)
(6) Tighten the adjustment screw for low idle to the following torque. ... 4 to 4.5 Nm
(35 to 40 lb in)
(7) Tighten the adjustment screw for high idle to the following torque. ... 4 to 4.5 Nm
(35 to 40 lb in)
(9) Tighten the fitting for the fuel supply connection to the following torque. ... 22 Nm
(16 lb ft)
(10) Tighten the nuts for the fuel line to the following torque. ... 22 Nm (16 lb ft)
(11) Tighten the flange nuts to the following torque. ... 22 Nm (16 lb ft)
(13) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to
81.4 Nm (52 to 60 lb ft)
Code that is on the Fuel Engine Check Angle Fuel Injection Pump Mark Angle
Injection Pump (degrees) (degrees)
(1)
"YA31257" only
(2)
"YA50532" only
Table 4
"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
1
Note: Later Delphi Fuel Injection Pumps are timed with a pin.
1 0
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Illustration 1
(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
(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) .
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
"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.
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Illustration 2
(1) Connection for the union nut of the fuel supply line
(2) Threaded hole for the banjo bolt of the leak off line
(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.
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) .
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
"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.
1 1 0
Leakage in 10 seconds ... 0 drops
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Illustration 1
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
1 1 0
damage to the fuel transfer pump.
Rocker Shaft
SMCS - 1102
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Illustration 1
Diameter of the rocker arm bore for the bushing ... 22.23 to 22.26 mm (0.8750 to
0.8762 inch)
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.
1
(5) Tighten the bolt to the following torque. ... 4 Nm (35 lb in)
1 0
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Illustration 1
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Type 1 Engines and 9RM Engines
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
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Illustration 1
Note: When new valve guides are installed, new valves and new valve seat inserts must
be installed. The valve guides and the valve seat inserts are supplied as partially finished
parts. The unfinished valve guides and unfinished valve seat inserts are installed in the
cylinder head. Then, the guides and inserts are cut and reamed in one operation with
special tooling. This procedure ensures the concentricity of the valve seat to the valve
guide in order to create a seal that is tight. Refer to the Disassembly and Assembly
Manual for removal and installation procedures.
(5) Diameter of the exhaust valve stem ... 9.43 to 9.46 mm (0.371 to 0.372 inch)
Clearance of valve in valve guide ... 0.05 to 0.13 mm (0.002 to 0.005 inch)
Maximum permissible clearance of valve in valve guide ... 0.15 mm (0.006 inch)
Overall length of the exhaust valve ... 123.07 to 123.57 mm (4.845 to 4.865 inch)
(6) Diameter of the inlet valve stem ... 9.460 to 9.490 mm (0.3724 to 0.3735 inch)
Clearance of valve in the valve guide ... 0.02 to 0.10 mm (0.001 to 0.004 inch)
Maximum permissible clearance of valve in valve guide ... 0.13 mm (0.005 inch)
Overall length of the inlet valve ... 122.66 to 123.07 mm (4.829 to 4.845 inch)
(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
(9) Diameter of the inlet valve ... 44.86 to 45.11 mm (1.766 to 1.776 inch)
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:
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Illustration 2 g00295327
Recess for a valve insert
(11) Machine the recess in the head for valve seat inserts to the following dimensions:
Inlet
(A) ... 7.19 to 7.32 mm (0.283 to 0.288 inch)
(B) ... 51.220 to 51.240 mm (2.0167 to 2.0175 inch)
(C) Maximum radius ... 0.38 mm (0.015 inch)
Exhaust
(A) ... 9.52 to 9.65 mm (0.375 to 0.380 inch)
(B) ... 42.620 to 42.650 mm (1.6779 to 1.6790 inch)
(C) Maximum radius ... 0.38 mm (0.015 inch)
Note: When a new valve seat insert is installed, a new valve and valve guide must be
installed. Refer to the Disassembly and Assembly for removal and installation
procedures.
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Illustration 3
(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
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Illustration 4
Inside diameter of finished valve guide ... 9.00 to 9.02 mm (0.354 to 0.355 inch)
Outside diameter of inlet valve ... 13.03 to 13.05 mm (0.513 to 0.514 inch)
Outside diameter of exhaust valve ... 14.03 to 14.05 mm (0.552 to 0.553 inch)
Bore diameter in the cylinder head for the inlet valve guide ... 13.00 to 13.03
mm (0.512 to 0.513 inch)
Bore diameter in the cylinder head for the exhaust valve guide ... 14.000 to
14.027 mm (0.5512 to 0.5522 inch)
Interference fit of valve guide in the cylinder head ... 0.007 to 0.047 mm (0.0003
to 0.0019 inch)
Overall length of inlet and exhaust valve guides ... 51.25 mm (2.012 inch)
Projection of valve guide above the valve spring recess (2) ... 14.85 to 15.15 mm
(0.585 to 0.596 inch)
Note: When new valve guides are installed, new valves and new valve seat inserts must
be installed. The valve guides and the valve seat inserts are supplied as partially finished
parts. The unfinished valve guides and unfinished valve seat inserts are installed in the
cylinder head. Then, the guides and inserts are cut and reamed in one operation with
special tooling. This procedure ensures the concentricity of the valve seat to the valve
guide in order to create a seal that is tight. Refer to the Disassembly and Assembly
Manual for removal and installation procedures.
(4) Diameter of the exhaust valve stem ... 8.94 to 8.96 mm (0.352 to 0.353 inch)
Clearance of valve in valve guide ... 0.040 to 0.084 mm (0.0026 to 0.0033 inch)
Maximum permissible clearance of valve in valve guide ... 0.104 mm (0.0041 inch)
Overall length of the exhaust valve ... 122.65 to 123.30 mm (4.829 to 4.854 inch)
(5) Diameter of the inlet valve stem ... 8.953 to 8.975 mm (0.3525 to 0.3533 inch)
Clearance of valve in the valve guide ... 0.025 to 0.069 mm (0.001 to 0.003 inch)
Maximum permissible clearance of valve in valve guide ... 0.089 mm (0.0035 inch)
Overall length of the inlet valve ... 122.65 to 123.30 mm (4.829 to 4.854 inch)
(6) Exhaust valve face angle ... 45 degrees
Note: Some engines may have valve face angles of 30 degrees and valve seat angles of
31 degrees.
(7) Exhaust valve head diameter ... 40.88 to 41.12 mm (1.609 to 1.619 inch)
(8) Diameter of the inlet valve ... 42.88 to 43.12 mm (1.688 to 1.698 inch)
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:
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Illustration 5
(11) Machine the recess in the head for valve seat inserts to the following dimensions.
Inlet
(A) ... 10.585 to 10.715 mm (0.4167 to 0.4219 inch)
(B) ... 45.535 to 45.560 mm (1.7927 to 1.7937 inch)
(C) Maximum radius ... 0.38 mm (0.015 inch)
Exhaust
(A) ... 10.585 to 10.715 mm (0.4167 to 0.4219 inch)
(B) ... 43.535 to 43.560 mm (1.7140 to 1.7150 inch)
(C) Maximum radius ... 0.38 mm (0.015 inch)
Note: When a new valve seat insert is installed, a new valve and valve guide must be
installed. Refer to Disassembly and Assembly for removal and installation procedures.
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Illustration 6
(E) Dimension of chamfer for all engines ... 1.10 0.20 mm (0.043 0.008 inch)
1
(F) Angle of chamfer from the vertical for all engines ... 30 degrees
1 0
Cylinder Head
SMCS - 1100
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Illustration 1
Use the following procedure in order to tighten the cylinder head bolts:
1. Put engine oil on the threads of the bolts and the nuts. Tighten bolts (1) through
bolts (22) in a numerical sequence in Illustration 1.
3. Rotate bolts (1) through bolts (22) in a numerical sequence to the following
values:
a. Tighten the bolts of short length "S" to the following value.
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Illustration 2
(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.
(5) Maximum permissible nozzle projection below cylinder head face after resurfacing
... 4.45 mm (.175 inch)
(6) Depth of new cylinder head ... 102.79 to 103.59 mm (4.047 to 4.078 inch)
Minimum depth of cylinder head after resurfacing ... 102.48 mm (4.035 inch)
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Illustration 3
Positions for measuring the bow of the cylinder head (typical example)
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:
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Illustration 4
Use the following procedure in order to tighten the cylinder head bolts:
1. Put engine oil on the threads of bolts. Tighten bolts (1) through bolts (22) in a
numerical sequence in Illustration 4.
3. Rotate bolts (1) through bolts (26) in a numerical sequence to the following
values:
a. Tighten the bolts of short length "S" to the following value.
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Illustration 5
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
(3) Maximum permissible nozzle projection below cylinder head face after resurfacing
... 4.45 mm (.175 inch)
(4) Depth of new cylinder head ... 102.79 to 103.59 mm (4.047 to 4.078 inch)
Minimum depth of cylinder head after resurfacing ... 102.48 mm (4.035 inch)
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Illustration 6
Positions for measuring the bow of the cylinder head (typical example)
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:
Turbocharger
SMCS - 1052
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Turbocharger
Ver imagen
g00295466
Illustration 1
(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)
Minimum permissible radial play (side to side movement) ... .08 mm (.003 inch)
Maximum permissible radial play (side to side movement) ... .15 mm (.0059
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)
Ver imagen
g00298861
Illustration 2
Tighten the air inlet heater to the inlet manifold to the following torque: ... 31 8 Nm
1 1 0
(23 6 lb ft)
Exhaust Manifold
SMCS - 1059
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Ver imagen
g00559857
Illustration 1
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
g00501179
Illustration 2
Refer to Illustration 2 for the tightening sequence. Tighten the exhaust manifold nuts or
1
bolts gradually to the following torque. ... 44 Nm (33 lb ft)
1 0
Muffler
SMCS - 1062
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Ver imagen
g00295475
Illustration 1
(1) Tighten the nuts to the following torque. ... 30 7 Nm (22 5 lb ft)
(2) Tighten the bolts and the nuts to the following torque. ... 55 10 Nm (41 7 lb ft
Camshaft
SMCS - 1210
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Ver imagen
g00618583
Illustration 1
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)
Table 1
Diameters of Camshaft Journals
Internal clearance of the journal ... 0.06 to 0.14 mm (0.002 to 0.006 inch)
Ver imagen
g00295323
Illustration 2
3. Subtract the base circle (C) from the height (B) of the lobe. The difference is the
actual lobe lift (A) .
1 1 0
Engine Oil Filter Base
SMCS - 1306
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Ver imagen
g00308804
Illustration 1
The bypass valve in the engine oil filter opens at the following pressure difference: ...
55 to 83 kPa (8 to 12 psi)
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
1 1
base to the following torque: ... 37 Nm (27 lb ft)
0
/sisweb/sisweb/m /sisweb/mediasea
Ver imagen
g00295480
Illustration 1
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
(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 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)
1
(4) Tighten the bolt to the following torque: ... 44 5 Nm (32 4 lb ft)
1 0
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Ver imagen
g00295506
Illustration 1
(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)
Number of lobes
Ver imagen
g00295515
Illustration 2
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
g00295516
Illustration 3
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
1 1 0
following torque: ... 22 Nm (16 lb ft)
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The minimum oil pressure at low idle with an ambient temperature of 18 to 20 C (64 to
68 F) is the following value: ... 62 kPa (9 psi)
The minimum oil pressure at high idle and at normal operating temperature is the
following value:
/sisweb/sisweb/m /sisweb/mediasea
Ver imagen
g00877006
Illustration 1
1
Minimum stroke at full open temperature ... 9 mm (0.35 inch)
1 0
Water Pump
SMCS - 1361
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Ver imagen
g00295544
Illustration 1
(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)
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)
Note: The water pump for Type 2 engines and 7BJ engines is not serviceable. Contact
1 1
your Caterpillar dealer for more replacement information.
0
Cylinder Block
SMCS - 1201
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Ver imagen
g00892504
Illustration 1
Typical example
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.
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.
1. Use a straight edge in order to ensure that the bridge is aligned with the front
face of the cylinder block.
3. When the bridge is installed on the cylinder block, apply a thin bead of 8T-9013
Silicone Sealant into the groove at each end of the bridge.
Use the following procedure in order to install the main bearing cap bolts.
1. Apply clean engine oil to the threads of the main bearing cap bolts.
2. Put the main bearing caps in the correct position that is indicated by a number on
the top of the main bearing cap. Install the main bearing caps with the locating
tabs in correct alignment with the recess in the cylinder block.
3. Evenly tighten the main bearing cap bolts to a torque of 265 Nm (195 lb ft).
(8) Bore in the cylinder block for the main bearings ... 80.416 to 80.442 mm (3.1660 to
3.1670 inch)
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)
Ver imagen
g00631670
Illustration 2
(1) Tighten the piston cooling jets to the following torque. ... 27 Nm (20 lb ft)
Note: Ensure that the piston cooling jet is positioned correctly on the dowel in the
cylinder block (not shown).
Use the following procedure in order to ensure the correct alignment of the piston
cooling jet.
1. Insert rod (2) into the end of the piston cooling jet. Rod (2) should protrude out
of the top of the cylinder block.
2. Use the following dimensions to locate the center point of diameter (C) .
Note: Dimension (A) and dimension (B) are tangent to the cylinder bore.
1 1 0
Crankshaft
SMCS - 1201
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Ver imagen
g00295557
Illustration 1
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
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)
(5) End play of the crankshaft ... 0.05 to 0.38 mm (0.002 to 0.015 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:
(7) Dimensions of main journals which are the standard, original size
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)
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:
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:
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:
Crankshaft Seals
SMCS - 1160; 1161
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Ver imagen
g00664588
Illustration 1
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)
g00317365
Illustration 2
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.
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
1 1
block to the following torque. ... 22 Nm (16 lb ft)
0
Connecting Rod
SMCS - 1218
/sisweb/sisweb/m /sisweb/mediasea
Ver imagen
Illustration 1 g00295602
Connecting Rod And Bearings
(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:
Width of connecting rod bearing ... 31.62 to 31.88 mm (1.245 to 1.255 inch)
(5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch)
Tighten the nuts for the connecting rod to the following torque: ... 125 Nm (92 lb ft)
Tighten the bolts for the connecting rod to the following torque: ... 155 Nm (114 lb ft)
Turbocharged Engines
(1) Inside diameter of rod for bearing ... 42.07 to 42.09 mm (1.656 to 1.657 inch)
(2) Outside diameter of bearing for piston pin ... 42.160 to 42.190 mm (1.6600 to
1.6613 inch)
Inside diameter of bearing for piston pin after reaming ... 38.120 to 38.140 mm (1.5008
to 1.5015 inch)
Clearance between small end bearing and piston pin ... 0.020 to 0.043 mm (.0008 to
.0017 inch)
(3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to
219.10 mm (8.624 to 8.626 inch)
(4) Bearings are available for remachined journals of the crankshaft which have the
following undersize dimensions:
Width of connecting rod bearing ... 31.55 to 31.88 mm (1.240 to 1.255 inch)
(5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch)
Tighten the nuts for the connecting rod to the following torque: ... 125 Nm (92 lb ft)
Tighten the bolts for the connecting rod to the following torque: ... 155 Nm (114 lb ft)
Note: If piston cooling jets are installed, the piston and the connecting rod assembly
must be turned when the piston and rod assembly are installed. Turning the piston and
connecting rod assembly will prevent the connecting rod from hitting and damaging the
piston cooling jet. When the connecting rod has passed the piston cooling jet, turn the
connecting rod until the arrow or "Front" mark on the top of the piston is toward the
front of the engine.
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
g00915056
Illustration 2
Table 1
"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:
Turbocharged Engines
Ver imagen
g00295602
Illustration 3
(1) Inside diameter of rod for bearing ... 43.01 to 43.04 mm (1.693 to 1.694 inch)
(2) Outside diameter of bearing for piston pin ... 43.11 to 43.15 mm (1.697 to 1.699
inch)
Inside diameter of bearing for piston pin after reaming ... 39.723 to 39.738 mm (1.5639
to 1.5645 inch)
Clearance between small end bearing and piston pin ... 0.023 to 0.044 mm (.0009 to
.0017 inch)
(3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to
219.10 mm (8.624 to 8.626 inch)
(5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch)
Tighten the nuts for the connecting rod to the following torque: ... 125 Nm (92 lb ft)
Tighten the bolts for the connecting rod to the following torque: ... 155 Nm (114 lb ft)
Note: If piston cooling jets are installed, the piston and the connecting rod assembly
must be turned when the piston and rod assembly are installed. Turning the piston and
connecting rod assembly will prevent the connecting rod from hitting and damaging the
piston cooling jet. When the connecting rod has passed the piston cooling jet, turn the
connecting rod until the arrow or "Front" mark on top of the piston is toward the front
of the engine.
Ver imagen
g01064497
Illustration 4
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)
g01064498
Illustration 5
(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)
Ver imagen
g00295711
Illustration 1
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) Width of groove in piston for top ring ... 2.57 to 2.59 mm (.101 to .102 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)
Clearance between groove and intermediate ring ... 0.06 to 0.09 mm (.002 to .003 inch)
Clearance between the ends of the intermediate ring with a cylinder liner without any
wear ... 0.30 to 0.76 mm (.012 to .030 inch)
(3) Width of groove in piston for oil control ring ... 4.030 to 4.060 mm (.1587 to .1598
inch)
Thickness of oil control ring ... 3.980 to 3.990 mm (.1566 to .1571 inch)
Clearance between groove and oil control ring ... 0.04 to 0.08 mm (.002 to .003 inch)
Clearance between the ends of oil control ring with a cylinder liner without any wear ...
0.38 to 0.84 mm (.015 to .033 inch)
(4) Diameter of new piston pin ... 34.920 to 34.925 mm (1.3748 to 1.3750 inch)
Bore for piston pin ... 34.928 to 34.934 mm (1.3751 to 1.3754 inch)
Turbocharged Engines
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)
Clearance between groove and intermediate ring ... 0.07 to 0.11 mm (.003 to .004 inch)
Clearance between the ends of an intermediate ring in a cylinder liner without any wear
... 0.30 to 0.76 mm (.012 to .030 inch)
(3) Width of groove in piston for oil control ring ... 4.040 to 4.060 mm (.1591 to .1598
inch)
Thickness of oil control ring ... 3.98 to 3.99 mm (.156 to .157 inch)
Clearance between groove and oil control ring ... 0.05 to 0.08 mm (.002 to .003 inch)
Clearance between the ends of an oil control ring in a cylinder liner without any wear ...
0.38 to 0.84 mm (.015 to .033 inch)
(4) Diameter of new piston pin ... 38.095 to 38.100 mm (1.4998 to 1.5000 inch)
Bore for piston pin ... 38.103 to 38.109 mm (1.5000 to 1.5004 inch)
Piston Height
Ver imagen
g00891532
Illustration 2
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.
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
g00891548
Illustration 3
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
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)
Type 2 Engines and 7BJ Engines
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
Ver imagen
g00500921
Illustration 4
Note: The word "Front" or an arrow which is marked on the piston crown must be
toward the front of the engine. If the piston crown is not marked, put the narrowest side
of the piston crater toward the side of the engine with the fuel injection pump. The
shortest distance between the edge of the piston crater and the edge of the piston is the
narrowest side of the piston crater.
Note: Be sure that the ring end gaps of all the piston rings have 120 degrees spacing
from each other.
Note: Refer to Systems Operation, "General Information" for the location of the serial
number.
Turbocharged Engines
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.
Width of groove in piston for intermediate ring ... 2.56 to 2.58 mm (0.101 to 0.102
inch)
Clearance between groove and intermediate ring ... 0.07 to 0.11 mm (.003 to .004
inch)
Clearance between the ends of an intermediate ring in a cylinder liner without any
wear ... 0.40 to 0.65 mm (.016 to .026 inch)
Note: Install the word "TOP" toward the top of the piston. New intermediate rings have
a green identification mark which must be on the left of the ring gap when the
intermediate ring is installed on an upright piston.
Width of groove in piston for oil control ring ... 3.54 to 3.56 mm (.139 to .140 inch)
Thickness of oil control ring ... 3.47 to 3.49 mm (.136 to .137 inch)
Clearance between groove and oil control ring ... 0.05 to 0.09 mm (.002 to .004 inch)
Clearance between the ends of an oil control ring in a cylinder liner without any wear
... 0.38 to 0.83 mm (.015 to .033 inch)
Note: A pin is used in order to hold both ends of the spring of the oil control ring in
position. The ends of the spring of the oil control ring must be 180 degrees opposite the
end gap of the oil control ring.
(4) Diameter of new piston pin ... 39.694 to 39.700 mm (1.5628 to 1.5630 inch)
Bore for piston pin ... 39.703 to 39.709 mm (1.5631 to 1.5633 inch)
Piston height above cylinder block (not shown) ... 0.36 to 0.50 mm ( .014 to .020 inch)
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iameter for the bore for the connecting rod bearing ... 67.21 to 67.22 mm (2.6460 to
2.6465 inch)
Housing (Front)
SMCS - 1151
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Illustration 1
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Illustration 2
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.
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)
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
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additional information.
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Illustration 1
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.
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)
(5) Tighten the bolts for the idler gear to the following torque: ... 44 Nm (33 lb ft)
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)
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)
Diameter of drive shaft for rear bearing ... 23.787 to 23.800 mm (0.9365 to 0.9370 inch)
Backlash from gear of drive shaft to idler gear ... 0.17 to 0.29 mm (0.0067 to 0.0114
inch)
End play of drive shaft ... 0.13 to 0.30 mm (0.0051 to 0.0118 inch)
Diameter of bore for front bearing of drive shaft ... 34.912 to 34.937 mm (1.3745 to
1.3755 inch)
Diameter of bore for rear bearing of drive shaft ... 29.972 to 29.993 mm (1.1800 to
1.1808 inch)
Diameter of bore for idler gear ... 47.64 to 47.65 mm (1.8756 to 1.8760 inch)
Diameter of hub of idler gear ... 38.09 to 38.10 mm (1.4996 to 1.5000 inch)
End play of idler gear ... 0.07 to 0.23 mm (0.0028 to 0.0091 inch)
Thickness of thrust washer for idler gear ... 4.14 to 4.29 mm (0.1630 to 0.1689 inch)
Inside diameter of bushes in balancer frame and end cover ... 38.133 to 38.174 mm
(1.5013 to 1.5029 inch)
Diameter of spigots for balance weights ... 38.054 to 38.069 mm (1.4982 to 1.4988
inch)
End play of balance weights ... 0.19 to 0.40 mm (0.0075 to 0.0157 inch)
Backlash of gears on balance weights ... 0.10 to 0.27 mm (0.0039 to 0.0106 inch)
Backlash of drive gear to spline on balance weight ... 0.05 to 0.20 mm (0.0020 to 0.0079
inch)
Number of teeth on drive gear ... 24
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Number of teeth on spline on balance weight ... 16
0
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Illustration 1
(1) Tighten the bolts of the flywheel housing to the following torque:
The M10 bolts for the cast iron flywheel housing ... 44 Nm (32 lb ft)
The M12 bolts that are stamped "8.8" for the cast iron flywheel housing ... 75 Nm (55
lb ft)
The M10 bolts that are stamped "10.9" for the cast iron flywheel housing ... 63 Nm (46
lb ft)
The M12 bolts that are stamped "10.9" for the cast iron flywheel housing ... 115 Nm
(85 lb ft)
The M10 bolts that are for the aluminum flywheel housing ... 70 Nm (52 lb ft)
(2) The maximum temperature for heating the flywheel ring gear for installation ... 250
C (482 F)
(3) Tighten flywheel bolts to the following torque: ... 105 Nm (77 lb ft)
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Illustration 2
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
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Illustration 3
Maximum permissible bore runout of the flywheel housing ... 0.20 mm (0.008 inch)
Refer to Testing and Adjusting, "Flywheel and Flywheel Housing" for the correct
procedure to measure the runout.
Flywheel Runout
Face Runout
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Illustration 4
Maximum permissible bore runout of the flywheel housing ... 0.20 mm (0.008 inch)
g00295956
Illustration 5
Maximum permissible bore runout of the flywheel housing ... 0.30 mm (0.012 inch)
Refer to Testing and Adjusting, "Flywheel and Flywheel Housing" for the correct
procedure to measure the runout
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Illustration 1
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Illustration 2
End view of the starting motor which shows the electrical connections
(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
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Illustration 3
Resistance between "W1" terminal and "W2" terminal ... 15 1.5 ohms
069-5466 Relay
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Illustration 4
Brush length:
Minimum brush length ... 15.5 mm (0.61 inch)
Install shims or remove shims in order to adjust the armature end play to the correct
specification.
Commutator
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