RENR9337-00 Specification Manual

RENR9337 July 2006

Specifications Preliminary Preliminary Information Information

C175-16 Generator Set Engine WYB1-Up (Generator Set)

i01658146

Important Safety Information Most accidents that t hat involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary necess ary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or or perform any lubrication, maintenance or repair on this product, until you have read and understood understood the operation, operation, lubrication, maintenance and repair information. information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, heeded , bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Attention! Become Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations Operations that that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar Caterpillar cannot anticipate every possible possible circumstance that might involve a potential potential hazard. hazard. The warnings warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will w ill not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was availabl available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. job. Caterpillar dealers have the most current information available.

When replacemen replacementt parts parts are requir required ed for this product Caterpillar recommends using Caterpilementt parts parts or parts parts with equival equivalent ent lar replac replacemen specifications specifications including, including, but not limited to, physical dimensions, type, strength and material. material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

i01658146

Important Safety Information Most accidents that t hat involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary necess ary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or or perform any lubrication, maintenance or repair on this product, until you have read and understood understood the operation, operation, lubrication, maintenance and repair information. information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, heeded , bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Attention! Become Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations Operations that that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar Caterpillar cannot anticipate every possible possible circumstance that might involve a potential potential hazard. hazard. The warnings warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will w ill not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was availabl available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. job. Caterpillar dealers have the most current information available.

When replacemen replacementt parts parts are requir required ed for this product Caterpillar recommends using Caterpilementt parts parts or parts parts with equival equivalent ent lar replac replacemen specifications specifications including, including, but not limited to, physical dimensions, type, strength and material. material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

RENR9337

Table of Contents Specifications Section Engine Design ...................... .................................. ........................ ..................... ......... 4 Fuel Filter (Primary) ........................ .................................... ........................ ............ 4 Fuel Filter (Secondary) (Secondary) ...................... .................................. ..................... ......... 5 Fuel Transfer Transfer Pump Pump ........................ .................................... ....................... ........... 5 Fuel Injector Injector ........................ .................................... ........................ ........................ ............ 6 Fuel Lines ........................ .................................... ........................ ........................ ............... ... 7 Fuel Lines ........................ .................................... ........................ ........................ ............... ... 8 Camshaft Camshaft ........................ .................................... ........................ ........................ .............. .. 11 Lifter Group ...................... .................................. ........................ ........................ .............. 12 Valve Mechanism Mechanism ........................ .................................... ........................ .............. 13 Cylinder Cylinder Head ....................... ................................... ........................ ................... ....... 13 Cylinder Cylinder Head Valves Valves ........................ ................................... ................... ........ 15 Turbocharg Turbocharger er ........................ .................................... ....................... ................... ........ 16 Air Lines ............. ............ ............ ............. ............ .. 17 Exhaust Exhaust Manifold ....................... .................................. ....................... ............... ... 17 Exhaust Exhaust Manifold ....................... .................................. ....................... ............... ... 18 Exhaust Exhaust Fitting ...................... .................................. ....................... .................... ......... 18 Exhaust Exhaust Fitting ...................... .................................. ....................... .................... ......... 19 Air Cleaner ........... ............ ............ ............. ........... 19 Engine Oil Pump ....................... ................................... ........................ ............... ... 19 Pressure Control Valve (Oil Regulator Valve and Oil Bypass Valve) Valve) ...................... .................................. ........................ ................... ....... 20 Engine Oil Pan ...................... .................................. ........................ ................... ....... 21 Water Water Pump ....................... ................................... ........................ ...................... .......... 21 Auxiliary Water Pump ............. ............ ............. .... 23 Cylinder Cylinder Block ..................... ................................. ........................ ..................... ......... 24 Cylinder Cylinder Liner ........................ .................................... ....................... ................... ........ 27 Piston and Rings ....................... ................................... ........................ ............... ... 28 Connecting Connecting Rod ....................... ................................... ........................ ................ .... 30 Connecting Rod and Main Bearing Journals ........ 31 Crankshaft Crankshaft ...................... .................................. ........................ ........................ .............. 32 Crankshaft Crankshaft Wear Wear Sleeves Sleeves and Seals Seals ................... ................... 33 Gear Group (Front) ................................. ............................................. .............. .. 35 Gear Group (Front) ................................. ............................................. .............. .. 37 Gear Group (Rear) ...................... .................................. ........................ .............. .. 38 Fan Drive Drive ........................ .................................... ........................ ........................ .............. 39 Flywheel Flywheel ........................ .................................... ........................ ........................ ............... ... 40 Flywheel Flywheel Housing Housing ....................... ................................... ........................ .............. 40 Vibration Vibration Damper ....................... ................................... ....................... .............. ... 41 Fastener Group (Vibration Damper) ..................... 42 Fastener Group (Vibration Damper) ..................... 42 Belt Tension Tension Chart Chart ........................ .................................... ....................... ........... 42 Belt Tensioner ensioner ........................ .................................... ........................ ................... ....... 44 Alternator and Regulator ............. ............ ............. 44 Electric Starting Motor ...................... .................................. ................... ....... 45 Engine Harness ....................... ................................... ........................ ................. ..... 46 Engine Speed Sensor ........................ ................................... ................... ........ 47 Engine Speed Sensor ........................ ................................... ................... ........ 47 Pressure Pressure Sensor ....................... ................................... ....................... ................ ..... 47 Pressure Pressure Sensor ....................... ................................... ....................... ................ ..... 48 Temperature emperature Sensor ........................ .................................... ..................... ......... 48 Temperature emperature Sensor ........................ .................................... ..................... ......... 48

Index Section Index ....................... ................................... ........................ ........................ ...................... .......... 50

3 Table of Contents Contents

4 Specifications Specifications Section Section

RENR9337

Specifications Specifications Section

i02525081

Fuel Filter (Primary) i02524923

Engine Design

SMCS Code: 1260 Part No.:

247-2696

SMCS Code: 1000

Illustration 1

g01262912

Cylinder and valve location (A) Inlet valves va lves (B) Exhaust valves

Number Number and arrange arrangement ment of cylinders ............................................ 60 60 degree V-16 Valves per cylinder cylinder ...................... ................................. ....................... ................. ..... 4 Displacement ................................. 85 L (5187 cu in) Bore ............................................. 175 mm (6.7 (6.7 inch)

Illustration 2

g01262978

Stroke .......................................... 220 mm (7.5 inch)

(1) O-ring O-ring

Compression Compression ratio ................................. ............................................ ............. .. 14:1

Lubricate the O-ring with clean diesel fuel prior to installation.

.................................. .................. ...... Direct injection injection Combustion ...................... When the crankshaft is viewed from the flywheel end the crankshaft cran kshaft rotates in the following direction. direction. ....................... ................................... ................ .... Counterclockw Counterclockwise ise (injection sequence) sequence) Firing order order (injection Standard Standard rotation 5,16, 11, 12, 12, 13, 14,7, 8 CCW CCW .. 1, 1, 2, 5, 6, 3, 4, 9, 10, 15,16, Note: The front end of the engine is opposite the flywheel flywheel end of the engine. The left and the right side of the engine are determined from the flywheel end. The number 1 cylinder is the front cylinder on the right side. side. The number 2 cylinder is the front cylinder on the left side.

(2) Element (3) Filter housing housing Do not use an air wrench. Torque ............. ......................... ............... ... 55 ± 5 N·m (41 ± 4 lb ft)

RENR9337

5 Specifications Specifications Section

i02525340

i02525379

Fuel Filter (Secondary)

Fuel Transfer Pump

SMCS Code: 1261

SMCS Code: 1256

Part No.:

Part No.:

249-2345

286-4580

Illustration 4

g01263179

(1) Inlet Inlet port (2) Outlet Outlet port Illustration 3

g01263123

(1) O-ring O-ring Lubricate the O-ring with clean diesel fuel prior to installation. (2) Element Element (3) Filter housing housing Do not use an air wrench. Torque .............. .......................... .............. .. 55 ± 5 N·m (41 ± 4 lb ft)

(3) Priming port Minimum requirements Volume per minute at 650 kPa (94 psi) and 2860 RPM ...................... .................................. .................... ........ 36 L (10 US gal) Volume per minute at 650 kPa (94 psi) and 2412 RPM ...................... .................................. ...................... .......... 34 L (9 US gal) Volume per minute at 650 kPa (94 psi) and 1740 RPM ...................... .................................. ...................... .......... 21 L (6 US gal) Volume per minute at 450 kPa (65 psi) and 108 RPM ...................... .................................. .............. .. 0.6 L (0.159 US gal) The setting for the cracking pressure for the bypass valve is the following value: ....... 793 kPa (115 psi) The setting for the full open pressure for the bypass valve is the following value: ....... 862 kPa (125 psi)

6 Specifications Section

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i02525593

Fuel Injector

Note: As the stud is removed, the stud will extract the fuel injector.


6. Remove hold-down stud (1) for the fuel injector.

Fuel injector installation

239-6105

1. For lubrication of the O-ring seals, lightly coat 1P-0808 Multipurpose Grease in the bore of the cylinder head. 2. Seat the fuel injector and tighten the hold down clamp nut (2). 3. Tighten bolts (A) and bolts (B) hand tight. 4. Tighten hold down clamp nut (2). Torque .......................................... 5 N·m (44 lb in) 5. Evenly tighten bolts (A) from the fuel line to the cylinder head. Torque ........................................ 20 N·m (15 lb ft) 6. Evenly tighten bolts (B) from fuel line to the fuel supply rail. Illustration 5

g01263277

(1) Stud Torque .......................... 60 ± 12 N·m (44 ± 9 lb ft) (2) Nut (3) Fuel injector (4) Fuel injector tip ........................ Protect the spray tip from debris and from damage. (A) Bolts (B) Bolts Fuel injector removal 1. Loosen bolts (A) from the fuel line to the cylinder head. 2. Loosen bolts (B) from the fuel line to the fuel supply rail. 3. Ensure that bolts (A) and bolts (B) are completely loose. 4. Retract the fuel line from cylinder head approximately 8 mm (0.315 inch). 5. Remove the hold-down nut (2) for the fuel injector.

Torque ........................................ 20 N·m (15 lb ft) 7. Tighten clamp nut (4) for the fuel injector. Torque ........................... 100 ± 2 N·m (74 ± 1 lb ft) 8. Again, evenly tighten bolts (A) and bolts (B) in pairs. Torque ........................................ 40 N·m (30 lb ft)

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i02564673

Fuel Lines SMCS Code: 1274 Part No.:

284-8351

Illustration 6

g01283929

(1) O-ring seal Lubricate the bore for the O-ring seal lightly with 5P-3975 Rubber Lubricant. (2) Connector Torque ............................ 40 ± 4 N·m (30 ± 3 lb ft) (3) Tube


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i02564838

Fuel Lines SMCS Code: 1274 Part No.:

Illustration 7

286-4595

g01284044

RENR9337


Illustration 10

g01284193

Figure C

Note: Ensure that all parts are extremely clean. All of the parts must not be contaminated with any dirt or debris. Illustration 8

g01284189

Reference: Reuse and Salvage Guidelines, SEBF9109, “Cleaning and Handling Procedures for the Common Rail Fuel System Components”

Figure A

Procedure for the installation of the rails and the quill tubes 1. Tighten the bolts that hold rail (1) and rail (7) to the cylinder block in the following order: A1, A2, B1, B2, D1, D2, C1, and C2 Again tighten the bolts that hold rail (1) and rail (7) to the cylinder block in the following order. A1, A2, B1, B2, C1, C2, D1, and D2 2. If the bolts are already installed, remove the bolts that attach quill tubes (5) to the rails. If the bolts are already installed, remove the bolts that attach the quill tubes to the cylinder head.

Illustration 9 Figure B

g01284191

3. Apply clean engine oil to joint (13) at the collar to quill tube. Refer to Illustration 8. Slide the collar away from the cylinder head and the rail prior to disassembly. 4. Apply clean engine oil to O-rings (14). Refer to Illustration 8. 5. Lubricate both ends of quill tube (12) with 10 cu cm (0.61 cu in) 6V-4876 Lubricant prior to assembly. Refer to Illustration 8. Assemble the quill tubes into the cylinder head and the rail. 6. Evenly hand tighten the bolts into the cylinder head.


7. Evenly hand tighten the bolts into the rail. 8. Evenly tighten the bolts into the cylinder head. Torque ........................................ 20 N·m (15 lb ft) 9. Evenly tighten the bolts into the rail. Torque ........................................ 20 N·m (15 lb ft) 10. Evenly tighten the bolts into the cylinder head.

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12. Install adjustable bracket (11) and tighten adjustable bracket (11) by using the adjustable bracket’s mounting hardware. 13. Lubricate the O-ring that seals the collar of the line (9) with clean engine oil. Refer to Illustration 9. Lubricate the end of line (10) with 10 cu cm (0.61 cu in) 6V-4876 Lubricant prior to assembly. Refer to Illustration 10. 14. Evenly hand tighten line (9) to the pump with the washers and the bolts.

Torque ........................................ 40 N·m (30 lb ft) 11. Evenly tighten the bolts into the rail. Torque ........................................ 40 N·m (30 lb ft) Procedure for the installation of the lines 1. Lubricate the O-ring that seals the collar of the line (10) with clean engine oil. Refer to Illustration 9. Lubricate the end of line (10) with 10 cu cm (0.61 cu in) 6V-4876 Lubricant prior to assembly. Refer to Illustration 10. 2. Off the engine, insert line (10) into block (6). 3. Evenly tighten line (10) to block (6) with the washers and the bolts.

15. Evenly hand tighten line (9) to block (6) with the washers and the bolts. 16. Evenly tighten line (9) to the pump. Torque ........................................ 20 N·m (15 lb ft) 17. Evenly tighten line (9) to block (6). Torque ........................................ 20 N·m (15 lb ft) 18. Evenly tighten line (9) to the pump. Torque ........................................ 40 N·m (30 lb ft) 19. Evenly tighten line (9) to block (6) to the pump adapter.

Torque ........................................ 10 N·m (89 lb in)

Torque ........................................ Standard torque

4. Lubricate the O-ring that seals the collar of the line (10) with clean engine oil. Lubricate the end of line (10) with 10 cu in in cm (0.61 cu in) 6V-4876 Lubricant prior to assembly. Refer to Illustration 9.

20. Lubricate the O-ring that seals the collar of the line (4) with clean engine oil. Refer to Illustration 9. Lubricate the end of line (4) with 10 cu cm (0.61 cu in.) 6V-4876 Lubricant prior to assembly. Refer to Illustration 10.

5. On the engine, insert line (10) into rail (1). 21. Insert line (4) into rail (1) and into rail (7). 6. Evenly hand tighten line (10) to rail (1) with the washers and the bolts. 7. Evenly hand tighten block (6) to the pump adapter.

22. Evenly hand tighten line (4) to rail (1). 23. Evenly hand tighten line (4) to rail (7) with the washers and the bolts.

8. Evenly tighten line (10) to rail (1). Torque ........................................ 20 N·m (15 lb ft)

24. Install the low pressure fuel line and the mounting hardware for the low pressure fuel line that connects to rail (1) and to rail (7).

9. Evenly tighten block (6) to the pump adapter. Torque ........................................ 20 N·m (15 lb ft) 10. Evenly tighten line (10) to rail (1).

25. Evenly hand tighten clamps (3) and hardware to line (4). 26. Evenly hand tighten clamps (2) and hardware to line (4).

Torque ........................................ 40 N·m (30 lb ft) 27. Evenly tighten line (4) to rail (1). 11. Evenly tighten block (6) to the pump adapter. Torque ........................................ 20 N·m (15 lb ft) Torque ........................................ Standard torque 28. Evenly tighten line (4) to rail (7).

RENR9337


Torque ........................................ 20 N·m (15 lb ft) 29. Evenly tighten clamps (3) and hardware to line (4).

(1) Front camshaft (2) Inlet lobe (odd number’s cylinders) (3) Exhaust lobe (odd number’s cylinders)

Torque ........................................ 20 N·m (15 lb ft) (4) Exhaust lobe (even number’s cylinders) 30. Evenly tighten clamps (2) and hardware to line (4). Torque ........................................ 20 N·m (15 lb ft) 31. Evenly tighten line (4) to rail (1). Torque ........................................ 40 N·m (30 lb ft) 32. Evenly tighten line (4) to rail (7). Torque ........................................ 40 N·m (30 lb ft) 33. Evenly tighten clamps (3) and hardware to line (4). Torque ........................................ Standard torque 34. Evenly tighten clamps (2) and hardware to line (4). Torque ........................................ Standard torque i02527814

Camshaft

Diameter of surface (journals) for new camshaft bearings .. 91.88 ± 0.02 mm (3.617 ± 0.001 inch) Bore in bearings for camshafts after assembly ............................. 92.152 ± 0.015 mm (3.628 ± 0.0006 inch) (7) Rear camshaft (8) Thrust washer Thickness of a new thrust washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch) Thickness of the groove in a new camshaft ... 8.75 ± 0.05 mm (0.344 ± 0.002 inch) End play for new camshafts ..... 0.15 to 0.35 mm (0.006 to 0.014 inch) (9) Dowel The dowel extends from the end of the front camshaft by the following distance: .... 11.5 ± 0.5 mm (0.453 ± 0.0197 inch)

Torque ............................ 35 ± 5 N·m (26 ± 4 lb ft)

274-7725

Illustration 11

(6) Journal surface

(10) Studs


(5) Inlet lobe (even number’s cylinders)

g01264753

Illustration 13

Illustration 12

g01265223

(12) Camshaft lobe height

g01265150


RENR9337

In order to determine the height, use the following procedure: 1. Measure camshaft lobe height (12). 2. Measure base circle (13). 3. Subtract the base circle (Step 2) from the lobe height (Step 1). The difference is the actual lobe lift. 4. Specified camshaft lobe lift (11) Inlet lobe ................ 12.447794 mm (0.4901 inch) Exhaust lobe .......... 17.183920 mm (0.6765 inch) i02563171

Lifter Group SMCS Code: 1209 Part No.:

Illustration 15

g01283285

(4) Bolts

283-9354

(4) Bolt Torque .......................... 55 ± 10 N·m (41 ± 7 lb ft)

Illustration 16

Illustration 14

g01283284

(1) Bolts (2) Housing As (3) Lifter As

(1) Bolt Torque .......................... 55 ± 10 N·m (41 ± 7 lb ft)

g01283372

(A) Hollow dowel .. Install the hollow dowel to 8 ± 0.5 from the top of the dowel to the housing surface. (B) Hollow dowel .. Install the hollow dowel to 7.5 ± 1 from the top of the dowel to the housing surface.

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i02530414

i02531323

Valve Mechanism

Cylinder Head

SMCS Code: 1102

SMCS Code: 1100

Part No.:

Part No.:

273-1225

Illustration 17

g01265938

(1) Bolt Torque .................... 240 ± 40 N·m (177 ± 30 lb ft) (2) Locknut Torque ...................... 120 ± 15 N·m (89 ± 11 lb ft) (3) Valve lash Inlet ................................... 0.8 mm (0.0315 inch) Exhaust ............................. 1.3 mm (0.0512 inch) (4) Rocker arm shaft Bore in the bearings for the rocker arm shaft After the 254-5922 Bushing is installed in the rocker arm the bearing must be machined to size. .. 50.086 ± 0.015 mm (1.972 ± 0.0006 inch) Maximum roughness average (Ra) ...................... 0.8 micrometer (32 microinch) Diameter of the rocker arm shaft .. 50 ± 0.013 mm (1.9685 ± 0.0005 inch) Maximum roughness average (Ra) ............. 0.125 micrometer (4.875 microinch)

273-1221

Illustration 18

g01266761

Use the following procedure to tighten cylinder head bolts (1). 1. Coat the threads of the cylinder head bolts with clean engine oil. 2. Tighten bolts A through F in the lettered sequence that is pictured in Illustration 18. Torque ............................. 30 ± 5 N·m (22 ± 4 lb ft) 3. Tighten bolts A through F again in the lettered sequence. Torque ..................... 190 ± 15 N·m (140 ± 11 lb ft) 4. Tighten bolts A through F again in the lettered sequence. Torque ..................... 190 ± 15 N·m (140 ± 11 lb ft) 5. Tighten bolts A through F again to the following rotation. Rotation for bolts ........................ 180 ± 5 degrees


RENR9337

Apply 6V-6640 Sealant to the outside of injector sleeve (2) within area (A). (3) O-rings ... Coat the O-rings with clean engine oil. (4) Plugs Use 6V-6640 Sealant in the plug bores prior to assembly. Two plugs are installed in the top of the cylinder head to the following depth: ....... 1.25 ± 0.25 mm (0.0492 ± 0.0098 inch) (5) Plugs Use 6V-6640 Sealant in the plug bores prior to assembly. Two plugs are installed in the top of the cylinder head to the following depth: ................ 0.750 mm (0.0295 inch) (6) Height of new cylinder head ............. 208.00 mm (8.1890 inch)

Illustration 19

Illustration 20

(2) Injector sleeve

g01266843

g01266856

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i02532590

Cylinder Head Valves SMCS Code: 1105 Part No.:

273-1221, 274-7704, 283-1684,

283-1686

g01267114

Illustration 21

(1) Valve stem diameter and valve guide bore Diameter of the new valve stems in the area of the valve guide ...................... 12.573 ± 0.01 mm (0.4950 ± 0.0004 inch) When the valve guides are installed in the cylinder head the bore in the valve guides is the following value: .................... 12.626 ± 0.020 mm (0.4971 ± 0.0008 inch) When the valve guides are installed in the cylinder head the maximum bore that can be used again in the valve guides is the following value: ............................ 13.16 mm (0.5181 inch) (2)

236-0550

Spring

Length under test force ...... 66 mm (2.5984 inch) Test force ...................... 900 ± 45 N (202 ± 10 lb) Free length after test .. 109.06 mm (4.2937 inch) Outside diameter .......... 48.91 mm (1.9256 inch)

(3)

256-5986

Spring

Length under test force ...... 55 mm (2.1654 inch) Test force ........................ 450 ± 22 N (101 ± 5 lb) Free length after test .... 97.12 mm (3.8236 inch) Outside diameter ........ 34.398 mm (1.3542 inch) (4) Height to the top of the valve guides ... 42.0 ± 0.50 mm (1.6535 ± 0.0197 inch) (5) Diameter of the valve heads Inlet ....... 58.5 ± 0.15 mm (2.3031 ± 0.0059 inch) Exhaust .. 56.5 ± 0.15 mm (2.2244 ± 0.0059 inch) (6) Angle of the valve faces: Inlet ................................... 70.75 ± 0.25 degrees Exhaust ............................. 45.60 ± 0.25 degrees


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i02535620

Turbocharger SMCS Code: 1052 Part No.:

Illustration 22

254-6777, 263-1454

g01267505

(7) Depth of bore in head for valve seat inserts ..... 16.00 ± 0.15 mm (0.630 ± 0.006 inch) (8) Diameter of valve seat inserts: Inlet ..... 62.1 ± 0.013 mm (2.4449 ± 0.0005 inch) Exhaust .................................. 61.12 ± 0.013 mm (2.4063 ± 0.0005 inch) Bore in head for valve seat inserts Inlet ..... 62.0 ± 0.025 mm (2.4409 ± 0.0010 inch) Exhaust .................................... 61.0 ± 0.025 mm (2.4016 ± 0.0010 inch) (9) Angle of face of valve seat inserts Inlet ........................................ 20 ± 0.25 degrees Exhaust .................................. 45 ± 0.25 degrees (10) Outside diameter of the face of the valve seat inserts ... 55.0 ± 0.25 mm (2.1654 ± 0.0098 inch)

Illustration 23

g01269136

(1) V-band clamp 1. Tighten the V-band clamp. Torque ........................................ 20 N·m (15 lb ft) 2. Loosen the V-band clamp by 2 to 3 turns. 3. Tighten the V-band clamp again. Torque ............................. 19 ± 1 N·m (14 ± 1 lb ft) (2) Bolts Torque ............................ 40 ± 3 N·m (29 ± 2 lb ft)

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i02564541

i02536571

Air Lines

Exhaust Manifold

SMCS Code: 1058; 1071

SMCS Code: 1059

Part No.:

Part No.:

283-9364

g01283877

Illustration 24

(1) Clamps

Illustration 26

g01269432

(1) V-band clamps

Lubricate the nut face and threads 5P-3931 Anti-Seize Compound before assembly. Torque .............................. 12 ± 2 N·m (9 ± 1 lb ft)

Torque .............................. 12 ± 2 N·m (9 ± 1 lb ft) (2) Washers Lubricate the washers with 5P-3931 Anti-Seize Compound before assembly.

(2) O-ring Lubricate the bore lightly with Lubricant.

243-2972, 253-7723, 282-8533

5P-3975

Rubber

(3) Bolts Lubricate the bolts with 5P-3931 Anti-Seize Compound before assembly. Torque ............................ 65 ± 5 N·m (49 ± 4 lb ft)

Illustration 25

g01283879

(3) Bolts Torque ...................... 100 ± 20 N·m (74 ± 15 lb ft)


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i02536701

i02536935

Exhaust Manifold

Exhaust Fitting

SMCS Code: 1059

SMCS Code: 1061-X6

Part No.:

Part No.:

254-2062, 254-2063, 282-8534

Illustration 27

g01269497

(1) V-band clamps Torque .............................. 12 ± 2 N·m (9 ± 1 lb ft) (2) Washers

269-2551

Illustration 28

g01269830

(1) V-band clamp 1. Tighten all the V-band clamps. Torque ................................. 8.5 ± 1 N·m (6 ± 1 ft)

Lubricate the washers with 5P-3931 Anti-Seize Compound before assembly.

2. Gently tap around the V-band clamps with a soft faced hammer.

(3) Bolts

3. Tighten all the V-band clamps again.

Lubricate the bolts with 5P-3931 Anti-Seize Compound before assembly. Torque ............................ 65 ± 5 N·m (49 ± 4 lb ft)

Torque ................................. 8.5 ± 1 N·m (6 ± 1 ft)

RENR9337


i02536750

i02537004

Exhaust Fitting

Air Cleaner

SMCS Code: 1061-X6

SMCS Code: 1051

Part No.:

Part No.:

245-4875

Illustratio n 29

276-5929

g01269533

(1) V-band clamp 1. Tighten all the V-band clamps. Torque ............................... 12 ± 2 N·m (9 ± 1 lb ft) 2. Gently tap around the V-band clamps with a soft faced hammer . 3. Tighten all the V-band clamps again.

Illustration 30

g01269901

(1) Clamp Torque .......................... 4 ± 0.6 N·m (35 ± 5 lb in)

Torque ............................... 12 ± 2 N·m (9 ± 1 lb ft)

i02537201

Engine Oil Pump SMCS Code: 1304 Part No.:

255-4846

Illustration 31

g01270117


RENR9337

(6) The bearings are installed in the housing at the following depth. .. 1.5 ± 0.5 mm (0.06 ± 0.02 inch) (7) Distance from the end of the idler shafts to gear faces ....... 41.5 ± 0.5 mm (1.6339 ± 0.0197 inch) (8) The location of each bearing joint is shown. Position the bearing joint from the centerline through the bearing bores to the following angle. ................................................ 30 degrees Bench test specifications Unrestricted flow rate per minute at 2394 rpm ..................................... 1296 L (342 US gal) Note: Before you install the pump, lubricate the moving parts with engine oil. Rotate the pump by hand in order to ensure that the pump rotates freely.

Illustration 32

i02538181

g01270121

Pressure Control Valve (Oil Regulator Valve and Oil Bypass Valve) SMCS Code: 1315; 1319-VL Part No.:

Illustration 33

274-2148

g01270122

(1) Distance from the end of the drive shaft to gear face ......... 47.9 ± 0.5 mm (1.8858 ± 0.0197 inch) (2) Length of new gears ..... 121.92 mm (4.800 inch) Depth of bores for new gears ............... 122.055 mm (4.8053 inch) (3) The dowels (not shown) extend from the cover by the following distance. ................... 8.0 ± 0.5 mm (0.3150 ± 0.0197 inch) (4) The bearings are installed in the cover at the following depth. .. 1.5 ± 0.5 mm (0.06 ± 0.02 inch) (5) Diameter of new gear shafts ............. 50.795 mm (1.9998 inch) Bore in bearings for gear shafts after assembly ............................ 55.655 mm (2.1911 inch)

g01270636

Illustration 34

(1) Shim Thickness ......................... 1.0 mm (0.0394 inch) Used with the

288-4597

Spring

Pressure change with one shim ... 21 kPa (3 psi)

RENR9337


Used with the

285-6589

Spring

Pressure change with one shim ... 14 kPa (2 psi) (2)

288-4597

Apply 5P-3975 Rubber Lubricant to the bore for the O-ring prior to assembly.

Spring for the oil regulator valve

Length under test force ... 85.5 mm (3.3661 inch) Test force .................. 1871 ± 126 N (421 ± 28 lb) Free length after test .... 105.4 mm (4.1496 inch) Outside diameter .......... 48.20 mm (1.8976 inch)

i02544912

Water Pump SMCS Code: 1361 Part No.:

(3)

285-6589

248-4129

Spring for the oil bypass valve

Length under test force ... 87.6 mm (3.4488 inch) Test force .................... 1669 ± 83 N (375 ± 19 lb) Free length after test .... 148.3 mm (5.8386 inch) Outside diameter .......... 48.20 mm (1.8976 inch) i02539560

Engine Oil Pan SMCS Code: 1302 Part No.:

256-5970, 274-7697, 281-9400,

288-8770 Illustration 36

Illustration 37

Illustration 35

(1) O-ring

g01271269

g01274088

g01274062


RENR9337

Torque .... 4 ± 1.25 N·m (35.4030 ± 11.0634 lb in) Follow this procedure for assembly: 1. Install bearing assembly (5) onto the shaft. 2. Tighten locknut (6) according to the specified torque. Note: The seal installation tool is part of the replacement seal assembly. Install the oil seal within two minutes of the removal from the tube for shipping. 3. Install oil seal (7) into the pump housing. Install the oil seal dry. Do not lubricate the sealing lip. Use the correct installation tool and use a slow, even motion to press the seal into the pump housing. 4. Install shaft (3) through the oil seal. 5. Install retainer plate (4). Illustration 38

g01274086

View A-A

(1) O-ring seal Lubricate the bore for the O-ring seal with clean engine oil prior to assembly. (2) Stud Torque ............................ 35 ± 5 N·m (26 ± 4 lb ft) (3) Shaft Shaft’s outer diameter for impeller ... 25.4 ± 0.01 mm (1.000 ± 0.0004 inch) (4) Retainer (5) Bearing assembly (6) Oil seal (7) Locknut Torque .................... 300 ± 30 N·m (221 ± 22 lb ft) (8) O-ring seal Lubricate the O-ring with 1U-6396 O-Ring Assembly Compound prior to assembly. (9) Seal assembly (10) Impeller Diameter of impeller’s bore .... 25.35 ± 0.012 mm (0.9980 ± 0.0005 inch) (11) Setscrew

6. Tighten setscrews (11) according to the specified torque. 7. Install seal assembly (9). Use the seal installation tool and hand pressure to install the seal assembly onto the shaft. 8. Lubricate the shaft with clean engine oil. Place the shaft onto a fixture that will absorb the load and press impeller (10) onto the shaft until the face of the impeller is flush with the face of the shaft. Maximum leakage per minute for the water seal at 138 kPa (20 psi) of air pressure ..... 20 cc (1.22 cu in) Maximum leakage per minute for the oil seal at 138 kPa (20 psi) of air pressure ..... 24 cc (1.46 cu in)

RENR9337


i02547236

Auxiliary Water Pump SMCS Code: 1371 Part No.:

250-6720

g01275298

Illustration 39

Diameter of impeller’s bore .. 25.342 ± 0.013 mm (0.9977 ± 0.0005 inch) (4) Shaft Shaft’s outer diameter for impeller ................................ 25.400 ± 0.013 mm (1.0000 ± 0.0005 inch) Width of shaft’s groove for thrust washer ...... 8.75 ± 0.05 mm (0.345 ± 0.002 inch) (5) Stud Torque ............................ 35 ± 5 N·m (26 ± 4 lb ft) Illustr ation 40

g01275612

Area B

(1) Stud Torque ............................ 35 ± 5 N·m (26 ± 4 lb ft) (2) O-ring seal (3) Impeller

(6) Nut Torque ............................ 27 ± 4 N·m (20 ± 3 lb ft) (7) Thrust washer Thickness .................................. 8.50 ± 0.05 mm (0.3346 ± 0.0020 inch) (8) O-ring seal (9) Oil seal


(10) Ring assembly

RENR9337

Maximum leakage per minute for the water seal at 138 kPa (20 psi) of air pressure ..... 20 cc (1.22 cu in)

(11) Ceramic ring and rubber seal (12) Seal assembly

Maximum leakage per minute for the oil seal at 138 kPa (20 psi) of air pressure ..... 24 cc (1.46 cu in)

(13) Spring

i02550794

Follow this procedure for assembly:

Cylinder Block

Note: The seal installation tool is part of the replacement seal assembly.


283-9344

1. Install ring assembly (10) and oil seal (9) into the pump housing. Install the oil seal dry. Do not lubricate the sealing lip. Use the correct installation tool and use a slow, even motion to press the seal into the pump housing. 2. Install shaft (4) through the oil seal and through the ring assembly. 3. Install thrust washer (7). 4. Lubricate the outside diameter of the ceramic ring and rubber seal (11) with clean water or with 207-1600 Rubber Lubricant. 5. Orient the polished face of the ceramic ring toward seal assembly (12). Use the installation tool and hand pressure to seat the ceramic ring and the rubber seal into the pump housing. 6. Remove spring (13) from the seal assembly. Lubricate the inside diameter of the seal assembly with clean water or with 207-1600 Rubber Lubricant. 7. Use the seal installation tool and hand pressure to install the seal assembly onto the shaft until the face of the seal assembly makes light contact with the face of the ceramic ring and rubber seal.

Illustration 41 Pictorial view

8. Install the spring onto the seal assembly. 9. Lubricate the shaft with clean engine oil. Place the shaft onto a fixture that will absorb the load and press impeller (3) onto the shaft until the face of the impeller is flush with the face of the shaft. 10. Lubricate the bore for O-ring seal (2) with clean engine oil. 11. Lubricate the bore for O-ring seal (8) with clean engine coolant. 12. Tighten studs (5) according to the specified torque. 13. Tighten nuts (6) according to the specified torque.

g01277012

RENR9337

Illustration 42


g01276834

Front view

Illustration 43

Illustration 44

g01276824

Rear view

g01276831

Right side view

Illustr ation 45 Front view

g01276830


RENR9337

(10) Cylinder 2 (11) O-ring seal Lubricate the O-ring seal with clean engine oil prior to assembly. (12) Dowel The dowels extend from the face by the following distance: ....... 16 ± 1 mm (0.6299 ± 0.0394 inch) (13) Centerline through the oil holes in the camshaft bearings Install the camshaft bearings so the oil holes are horizontal. (14) O-ring seal

g01276840

Illustration 46 Right side view

(1)

248-7585

Lubricate the O-ring seal with clean engine oil prior to assembly. (15) Dowel

Orifice

Orifice (1) must be fully seated in the bore and flush with the head face of the cylinder block. After you start the orifice into the bores, apply 4C-9507 Retaining Compound to the outside diameter of the orifice. Install the outside diameter of the orifice’s chamfer toward the cylinder block. Orifice (1) is only for the number eight cylinder (2) through the number three cylinder (6).

The dowels extend from the face by the following distance: ....... 19 ± 1 mm (0.7480 ± 0.0394 inch) (16) Cup Plug Apply 6v-6640 Sealant to the outside diameter of the cup plug prior to assembly. (17) New dimension from centerline of crankshaft bearing bore to the top of the block ....... 650 mm (25.5905 inch)

(2) Cylinder 8 (18) Depth of all cup plugs from the face of the holes for the cup plugs. ........................... 3.4 ± 1.8 mm (0.1339 ± 0.0709 inch)

(3) Cylinder 7 (4) Cylinder 4

(19) Main bearing cap (5) Cylinder 6 (20) Washer (6) Cylinder 3 (21) Bolt (7) Cylinder 4 (22) Nut (8)

248-7584

Orifice (23) Stud

Orifice (8) must be fully seated in the bore and flush with the head face of the cylinder block. After you start the orifice into the bores, apply 4C-9507 Retaining Compound to the outside diameter of the orifice. Install the outside diameter of the orifice’s chamfer toward the cylinder block. Orifice (8) is only for the number one cylinder (9) and for the number two cylinder (10). (9) Cylinder 1

(24) Bore in the block for the main bearings Standard, original new size ........ 210 ± 0.02 mm (8.2677 ± 0.0008 inch) Use the following procedure to tighten the main bearing cap bolts: 1. Tighten studs (23) again. Torque ....................... 100 ± 20 N·m (74 ± 15 lb ft)

RENR9337


2. Assemble main bearing caps (19) with the part number toward the front of the cylinder block. 3. Lubricate the treads of studs (23) and the face of nuts (22). Assemble and hand tighten the nuts. 4. Lubricate the threads of bolts (21) and both sides of washers (20). Assemble and hand tighten the bolts and the washers in the side of the cylinder block.

i02550061

Cylinder Liner SMCS Code: 1216 Part No.:

286-4564

5. Start at the front of the engine (number one main bearing cap). Tighten all the side bolts on the right hand side (same side as the bearing tab slots) of the cylinder block. Torque ....................... 100 ± 20 N·m (74 ± 15 lb ft) 6. Use the

249-6717

Stud Tensioner Tool Group.

Start at the front of the engine (number one main bearing cap). Tension both studs (23) simultaneously. Pressure ... 135000 ± 1000 kPa (19580 ± 145 psi) 7. Hand tighten both nuts (22) with the use of the gear drives on the tensioner. 8. Release the hydraulic pressure on the tensioner. 9. Repeat Step 6 through Step 8 for main bearing caps 2 through 9. 10. Repeat Step 6 through Step 8 again for all the main bearing caps. 11. Start at the front of the engine (number one main bearing). Tighten all the side bolts on the left hand side (opposite side as the bearing tab slots) of the cylinder block. Illustration 47

Torque ....................... 100 ± 20 N·m (74 ± 15 lb ft) 12. Start at the front of the engine (number one main bearing cap). Tighten all the side bolts on the right hand side (same side as the bearing tab slots) of the cylinder block. Torque ... 530 ± 70 N·m (390.9068 ± 51.6292 lb ft) 13. Start at the front of the engine (number one main bearing). Tighten all the side bolts on the left hand side (opposite side as the bearing tab slots) of the cylinder block. Torque ... 530 ± 70 N·m (390.9068 ± 51.6292 lb ft)

g01276565


RENR9337

i02558469

Piston and Rings SMCS Code: 1214 Part No.:

270-6823

g01276570

Illustration 48

(1) Cylinder liner (2)

246-7264

O-Ring Seal

(3)

253-9950

O-Ring Seal

Illustration 49

g01280888

(4) Thickness of flange on liner ........ 114.7 ± 0.1 mm (4.5157 ± 0.0039 inch) (5) Diameter for the sleeve ............. 184.5 ± 0.2 mm (7.2638 ± 0.0079 inch) (6) Bore in new liner .................. 175.025 ± 0.08 mm (6.8907 ± 0.0031 inch) (7) Sleeve (8) Outside diameter of the sleeve .................................. 185.45 ± 0.025 mm (7.3012 ± 0.0010 inch) (9) Inside diameter of the sleeve .................................. 174.025 ± 0.25 mm (6.8514 ± 0.0098 inch) (10) Thickness of the sleeve .......... 23.1 ± 0.25 mm (0.9094 ± 0.0098 inch) Illustration 50

Cylinder Liner Installation 1. Put liquid soap on the cylinder block liner bore surface. Also, put liquid soap on the O-ring seals. 2. Install the liner in the cylinder block immediately, before the O-ring seals expand.

g01280890

RENR9337


After all of the piston rings have been installed, rotate the rings so that the end gaps are separated by 120 degrees. The ring gap for the oil ring must be aligned in the plane of the pin bore. (4) Pin Outside diameter ........................... 75.0 ± 0.005 mm (2.9527 ± 0.0002 inch) Inside diameter .................................. 31.0 ± 0.3 mm (1.2205 ± 0.0118 inch) Length ....... 102.0 ± 0.25 mm (4.0157 ± 0.0098 inch) (5) Piston pin bore Diameter ............................... 75.113 ± 0.008 mm (2.9572 ± 0.0003 inch) (6) Retainer Illustration 51

g01138425

(1) Top ring Install the top ring with the “Up-1” side toward the top of the piston. When the piston ring is installed in a cylinder liner with a bore size of 175 mm (6.8898 inch), the clearance between the ends of the piston ring is the following value. ...... 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch) (2) Intermediate ring Install the intermediate ring with the “Up-2” side toward the top of the piston. When the piston is installed in a cylinder liner with a bore size of 175 mm (6.8898 inch), the clearance between the ends of the piston ring is the following value. .......... 1.0 ± 0.125 mm (0.0394 ± 0.0049 inch) (3) Oil control ring Width of groove in piston for the new oil control ring ................ 4.06 ± 0.1 mm (0.1598 ± 0.0039 inch) Maximum thickness of new oil control ring ...................................... 4.0 − 0.01 to − 0.03 mm (0.1575 − 0.0004 to − 0.0012 inch) When the oil control ring is installed in a cylinder liner with a bore size of 175 mm (6.8898 inch), the clearance between the ends of the piston ring is the following value. ................................... 0.5 to 0.8 mm (0.0197 to 0.0315 inch) Install the oil control ring so that the gap in the spring is 180 degrees away from the gap in the ring. The white portion of the spring must be visible at the ring gap.

(7) Area A Assemble the retainer with the opening within area A. Refer to Table 1 for the part numbers of the tools that are used in servicing the piston. Table 1

Service Tools Pt. No.

Description

271-0504

Piston Ring Expander Gp

255-8897

Piston Ring Compressor Gp

1P-1861

Retaining Ring Pliers


RENR9337

i02557016

Connecting Rod

Deburr the connecting rod around the very edge of the bore for the rod eye bushing prior to assembly.


Diameter of new piston pin ............ 75.0 ± 0.005 mm (2.9527 ± 0.0002 inch)

293-2260

The rod eye bushing must be cooled for the installation of the rod eye bushing. Cool the rod eye bushing with the use of liquid nitrogen to the following temperature. ......... −195 °C (−319 °F) After assembly, the rod eye bushing can not cover the oil hole in the connecting rod. The oil hole must be completely open. The ends of the rod eye bushing must not extend more than the connecting rod by the following value: .................................... 0.25 mm (0.0098 inch) (2) Distance between center of bearings .... 420 mm (16.5354 inch) (3) Bore in bearing for crankshaft .......................... 150.197 ± 0.016 mm (5.9133 ± 0.0006 inch) (4) After the bolts are tightened, the bore in the connecting rod for the bearing is the following dimension. ................................ 157 ± 0.013 mm (6.1811 ± 0.0005 inch) (5) Spacer (6) Bolt Clearance between bearing and new crankshaft ................................... 0.181 to 0.213 mm (0.0071 to 0.0084 inch)

Illustration 52

g01280244

The side clearance between two connecting rods on the same new crankshaft pin is the following value. ...... 0.850 ± 0.332 mm (0.0335 ± 0.0131 inch) The word “FRONT” on the shank of the connecting rod must f ace the front of the engine in the cylinder bank with an odd number in a standard rotation engine. The word “FRONT” on the shank of the connecting rod must face the rear of the engine in the cylinder bank with an odd number in a reverse rotation engine.

Illustration 53

g01280245

(1) Bore in bearing for new piston pin ..... 75.04 ± 0.008 mm (2.9543 ± 0.0003 inch)

RENR9337

Careful handling of the connecting rod is required at all times. The fracture face of the connecting rod and the fracture face of the connecting rod cap must not make contact with any surface. The connecting rod and the connecting rod cap must be laid flat on the sides. When possible, the rod assembly should be kept together in order to protect the fracture face when the connecting rod is out of the engine.


i02560298

Connecting Rod and Main Bearing Journals SMCS Code: 1230 Part No.:

286-5799, 286-5801

The connecting rod and the connecting rod cap must be marked only with a mechanical etcher with the number of the cylinder. The cylinder number must be etched on the same surface as the part number and the serial number for the connecting rod.

Refer to Guidelines For Reusable Parts, SEBF8009, “Main Bearings And Connecting Rod Bearings” for more information.

Procedure f or Tightening Connecting Rod Bolts

Table 2

1. Before assembly, put 6V-4876 Lubricant on the threads of bolt (5), spacer (6) and all surfaces that make contact between the bolt and the cap. 2. Install the spacers and the bolts. Hand tighten the bolts. 3. Tighten bolts A and B.

Connecting Rod Bearing Journals

Diameter Of Crankshaft Journal (Bearing Surface) For Connecting Rod Bearings Original Size Journal

150 mm (5.9055 inch)

Undersize Journal 0.63 mm (0.025 inch)

149.37 mm (5.8807 inch)


148.73 mm (5.8555 inch)

Clearance between bearing and new journal .... 0.172 to 0.295 mm (0.0068 to 0.0116 inch)

Torque ............................. 80 ± 5 N·m (59 ± 4 lb ft) Main Bearing Journals 4. Tighten bolts C and D. Table 3

Torque ............................. 80 ± 5 N·m (59 ± 4 lb ft) 5. Tighten bolts E and F. Torque ............................. 80 ± 5 N·m (59 ± 4 lb ft) 6. Repeat Step 9 through Step 6. 7. Tighten bolts C and D. Torque ........................................ 180± 5 degrees 8. Tighten bolts E and F. Torque ........................................ 180 ± 5 degrees 9. Tighten bolts A and B. Torque ........................................ 180 ± 5 degrees

Diameter Of Crankshaft Journal (Bearing Surface) For Main Bearings Original Size Journal

200 mm (7.8740 inch)


199.37 mm (7.8492 inch)


198.73 mm (7.8240 inch)

Clearance between bearing and new journal ... 0.145 to 0.262 mm (0.0057 to 0.0103 inch)


RENR9337

i02559833

Crankshaft SMCS Code: 1202 Part No.:

285-3719

g01281321

Illustration 54

Refer to Specifications, “Connecting Rod And Main Bearing Journals”. (2) Main bearing journal Refer to Specifications, “Connecting Rod And Main Bearing Journals”. (3) Bolt Note: Do not reuse counterweight bolts. (4) Thrust plates for the rear main bearing (5) End play for a new crankshaft End play .. 0.17 to 0.63 mm (0.007 to 0.025 inch) (6) Plug Torque ............................ 50 ± 7 N·m (37 ± 5 lb ft) Illustration 55

(1) Connecting rod journal

g01281755

Use the following procedure to tighten the counterweight bolts:

RENR9337


1. Prior to assembly, put 6V-4876 Lubricant on the bolt threads, on the shank, and on the underside of the bolt head. 2. Tighten the bolts evenly. Torque ..................... 220 ± 20 N·m (162 ± 15 lb ft) 3. Tighten each bolt again to the following rotation. Rotation ........................................ 90 ± 5degrees i02560387

Crankshaft Wear Sleeves and Seals SMCS Code: 1160 Part No.:

248-4115 g01281911

Illustration 57

(1)

245-3574

Crankshaft Seal Gp

Install the245-3574 Crankshaft Seal Gp in the front housing on a standard rotation engine. Install the 245-3574 Crankshaft Seal Gp in the flywheel housing on a reverse rotation engine. (2)

245-3575

Crankshaft Seal Gp

Install the 245-3575 Crankshaft Seal Gp in the flywheel housing on a standard rotation engine. Install the 245-3575 Crankshaft Seal Gp in the front housing on a reverse rotation engine. (3) Flywheel housing Illustration 56

g01281910

(4) Front housing Make sure that the correct seal is installed on each end of the crankshaft. (5) Depth of the crankshaft seal and the wear sleeve The crankshaft seal and the wear sleeve is installed from both ends of the crankshaft at the following distance. ......................... 0.5 ± 0.5 mm (0.0197 ± 0.0197 inch) (6) Crankshaft Removal 1. Remove the seal from each end of the engine. Note: Seals and wear sleeves cannot be used again, after the seals and the wear sleeves are separated.


RENR9337

2. Remove the wear sleeves with the 5P-7409 Sleeve Distorter and the 6V-3143 Distorter Adapter. Installation 1. DO NOT separate the wear sleeves from the crankshaft seals. Once the wear sleeves and crankshaft seals are separated, the crankshaft seals cannot be used again. Note: For a complete procedure with illustrations, refer to the Disassembly And Assembly Manual. 2. Install the sleeve and the seal assembly with the correct tools. 3. Clean the outer surface of the crankshaft and the inner surface of the wear sleeve with 169-5464 Quick Cure Pr imer (Aerosol Spray). 4. Carefully, put a thin coat of 4C-9507 Retaining Compound on the inner surface of the wear sleeve and on the crankshaft surface. 5. Install the crankshaft seals and the wear sleeves as a unit. Install the unit on the end of the crankshaft with the correct tools. Refer to Table 4. Table 4

Tools for the Installation of the Crankshaft Seal Part Number

quantity

250-4586

Seal Locator

1

250-4587

Seal Installer

1

Bolt

2

Nut

2

258-0933 9S-8858

RENR9337


i02563409

Gear Group (Front) SMCS Code: 1206 Part No.:

250-9959

g01283463

Illustration 58

(1) Shaft Diameter of new shaft .......... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) (2) Idler gear After the bearing is installed in the gear the bearing must be machined to size. Bore in bearings after assembly .. 90.0 ± 0.01 mm (3.5433 ± 0.0004 inch) (3) Crankshaft gear (4) Adapter

After the bearing is installed in the gear the bearing must be machined to size. Bore in bearings after assembly ............................. 75.000 ± 0.055 mm (2.9528 ± 0.0022 inch) (5) O-ring Lubricate the bore for all O-rings with clean engine oil prior to assembly. (6) Drive gear (7) Bolt Torque ...................... 120 ± 20 N·m (89 ± 15 lb ft) (8) Bolt Torque .................... 190 ± 30 N·m (140 ± 22 lb ft)


(9) Shaft Diameter of new shaft .......... 89.880 ± 0.020 mm (3.5386 ± 0.0008 inch) Note: (10) Adapter After the bearing is installed in the gear the bearing must be machined to size. Bore in bearings after assembly ............................. 75.000 ± 0.055 mm (2.9528 ± 0.0022 inch) Maximum roughness average (Ra) for all bearings that are machined to size .................. 0.8 micrometer (32 microinch)

RENR9337

RENR9337


i02564515

Gear Group (Front) SMCS Code: 1206 Part No.:

277-6909, 282-8771

g01283826

Illustration 59

(1) Shaft Diameter of new shaft .......... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) (2) Idler gear After the bearing is installed in the gear the bearing must be machined to size. Bore in bearings after assembly .. 90.0 ± 0.01 mm (3.5433 ± 0.0004 inch) (3) Crankshaft gear (4) Adapter

After the bearing is installed in the gear the bearing must be machined to size. Bore in bearings after assembly ............................. 75.000 ± 0.055 mm (2.9528 ± 0.0022 inch) (5) O-ring Lubricate the bore for all O-rings with clean engine oil prior to assembly. (6) Drive gear (7) Bolt Torque ...................... 100 ± 20 N·m (74 ± 15 lb ft) (8) Bolt Torque .................... 190 ± 30 N·m (140 ± 22 lb ft)


RENR9337

(9) Shaft Diameter of new shaft .......... 89.880 ± 0.020 mm (3.5386 ± 0.0008 inch) Note: (10) Adapter After the bearing is installed in the gear the bearing must be machined to size. Bore in bearings after assembly ............................. 75.000 ± 0.055 mm (2.9528 ± 0.0022 inch) Maximum roughness average (Ra) for all bearings that are machined to size .................. 0.8 micrometer (32 microinch) i02562764

Gear Group (Rear) SMCS Code: 1206 Part No.:

254-2074

Illustration 60

g01283065

(1) Shaft Diameter .................................. 74.99 ± 0.01 mm (2.9524 ± 0.0004 inch) Maximum roughness average (Ra) ...................... 0.4 micrometer (16 microinch) (2) Camshaft drive gear (3) Camshaft idler gear

After the bearing is installed in the gear the bearing must be machined to size. The bore in the bearings after machining is the following value: ........................ 75.06 ± 0.01 mm (2.9551 ± 0.0004 inch) Maximum roughness average (Ra) ...................... 0.8 micrometer (32 microinch) (4) Alignment mark The mark on the cluster idler gear must be in alignment with the mark on the crankshaft gear. (5) Crankshaft gear

RENR9337


i02563615

Fan Drive SMCS Code: 1359 Part No.:

259-9221

g01283594

Illustration 61 (1) Key (2) Yoke end (3) Set screw

(4) Bearing cap (5) Joint group (6) Bolts

1. Install yoke adapter (7) prior to installing joint group (5). 2. Bearing caps (4) need to be removed from yoke end (2) in order to allow the joint group to be installed. 3. Install the yoke end onto the pulley shaft. 4. Turn the fan in order to provide proper alignment between the bearing cross and the yoke. 5. Install the bearing caps. Tighten the bolts that support the cover for the bearing cap. Torque ............................. 28 ± 7 N·m (21 ± 5 lb ft) 6. Apply 4C-9506 Retaining Compound to the set screw (3). 7. Install the set screw.

(7) Yoke adapter


RENR9337

i02550818

i02564826

Flywheel

Flywheel Housing

SMCS Code: 1156

SMCS Code: 1157

Part No.:

Part No.:

282-8773

Illustration 62

g01276832

Refer to Testing And Adjusting, “Flywheel - Inspect” for the correct method of flywheel inspection. (1) Flywheel (2) Gear (3) Bolts Use clean unused engine oil on the bolt threads and the bolt seats before assembly. Torque .................. 1100 ± 60 N·m (811 ± 44 lb ft)

287-7079

Illustration 63

g01284043

(1) Joint surface for the flywheel housing

For information on inspecting the flywheel housing, refer to Systems Operation/Testing and Adjusting. Note: Before installation of the flywheel housing, inspect the front face of the flywheel housing and the rear face of the cylinder block. The components must be free of the following substances: oil, fuel, water, gasket adhesive, assembly compounds, and any other foreign material. To seal the joint between the flywheel housing and the cylinder block, apply a 6 mm (0.250 inch) of 4C-5300 Gasket Sealant or 185-3984 Gasket Sealant to the mating surface of the flywheel housing.

RENR9337


i02550922

Vibration Damper SMCS Code: 1205 Part No.:

283-1678

g01284018

Illustration 64

(X)

6V-3532

Bolts

(Y)

259-9148

Bolts

Apply 4C-5300 Gasket Sealant uniformly to the surface that joins with the engine block.

Illustration 66

g01277026

Note: Apply 9S-3263 Thread Lock Compound to the bolt threads. (1) Tighten the bolts to the following torque. ........................... 55 ± 7 N·m (40 ± 5 lb ft) (2) Damper Illustration 65

g01284019

View A-A

(A) Dowel pins ... 5 ± 0.5 mm (0.1969 ± 0.0197 inch)


RENR9337

i02550925

i02550951

Fastener Group (Vibration Damper)

Fastener Group (Vibration Damper)

SMCS Code: 1205-FG

SMCS Code: 1205-FG

Part No.:

Part No.:

266-2193, 270-6862, 283-1676, 288-9940

249-6399

Illustration 67

g01276986

Illustration 68

g01277000

(1) Damper (1) Damper (2) Spacer (2) Spacer (3) Bolts Torque .................... 625 ± 50 N·m (461 ± 37 lb ft)

(3) Bolts lubricate the bolt threads, bolt head and the spacer plate with clean engine oil. Torque .................... 700 ± 50 N·m (516 ± 37 lb ft) i01617888

Belt Tension Chart SMCS Code: 1357 Note: Do not use the belt tension charts for belts with tensioners that are spring loaded.

RENR9337


Table 5

Belt Tension Chart Kent-Moore Gauge Numbers

Gauge Reading Size of Belt

Width of Belt

3/8

Belt Tension “Initial”(1)

Belt Tension “Used”(2)(3)

Number of the Old Gauge

Number of the New Gauge

10.72 mm (0.422 inch)

534 ± 111 N (120 ± 25 lb)

400 ± 22 N (90 ± 5 lb)

BT-33-97

BT 3397

1/2

13.89 mm (0.547 Inch)

578 ± 111 N (130 ± 25 lb)

445 ± 44 N (100 ± 10 lb)

BT-33-97

BT 3397

5V

15.88 mm (0.626 Inch)

712 ± 111 N (160 ± 25 lb)

445 ± 44 N (100 ± 10 lb)

BT-3372C

BT 3372C

11/16

17.48 mm (0.688 Inch)

712 ± 111 N (160 ± 25 lb)

445 ± 44 N (100 ± 10 lb)

BT-3372C

BT 3372C

3/4

19.05 mm (0.750 Inch)

712 ± 111 N (160 ± 25 lb)

445 ± 44 N (100 ± 10 lb)

BT-3372C

BT 3372C

15/16

23.83 mm (0.938 Inch)

712 ± 111 N (160 ± 25 lb)

445 ± 44 N (100 ± 10 lb)

BT-33-77

BT 3372C

8PK

27.82 mm (1.095 inch)

1068 ± 111 N (240 ± 25 lb)

890 ± 44 N (200 ± 10 lb)

BT-33109

BT 33109

6PK

20.94 mm (0.824 Inch)

801 ± 111 N (180 ± 25 lb)

667 ± 44 N (150 ± 10 lb)

BT-33109

BT 33109

Measure the tension of the belt that is farthest from the engine. (1) (2) (3)

Belt tension “Initial” is for a new belt. Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed. If a belt falls below the “Used” belt tension, the belt should be tightened again to the high side of the “Used” belt tension.

Table 6

For DAYCO Supplied Belts Only

(1) (2) (4)

Size of Belt

Belt Tension “Initial”(1)

Belt Tension “Used”(2)(4)

.380 (V-Belt)

623 ± 22 N (140 ± 5 lb)

245 - 534 N (100 ± 5 lb)

.440 (V-Belt)

667 ± 22 N (150 ± 5 lb)

245 - 534 N (100 ± 5 lb)

.500 (V-Belt)

712 ± 22 N (160 ± 5 lb)

245 - 534 N (100 ± 5 lb)

.600 (V-Belt)

779 ± 22 N (175 ± 5 lb)

245 - 534 N (100 ± 5 lb)

.660 (V-Belt)

890 ± 22 N (200 ± 5 lb)

245 - 534 N (100 ± 5 lb)

.790 (V-Belt)

890 ± 22 N (200 ± 5 lb)

245 - 534 N (100 ± 5 lb)

4 - RIB PVK

623 ± 22 N (140 ± 5 lb)

267 - 445 N (90 ± 5 lb)

5 - RIB PVK

779 ± 22 N (175 ± 5 lb)

334 - 556 N (100 ± 5 lb)

6 - RIB PVK

934 ± 22 N (210 ± 5 lb)

400 - 667 N (130 ± 5 lb)

8 - RIB PVK

1157 ± 22 N (260 ± 5 lb)

534 - 890 N (180 ± 5 lb)

10 - RIB PVK

1557 ± 22 N (350 ± 5 lb)

667 - 1112 N (230 ± 5 lb)

12 - RIB PVK

1869 ± 22 N (420 ± 5 lb)

800 - 1335 N (270 ± 5 lb)

15 - RIB PVK

2336 ± 22 N (525 ± 5 lb)

1000 - 1669 N (350 ± 5 lb)

Belt tension “Initial” is for a new belt. Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed. If a belt falls below the “Used” belt tension, the belt should be tightened again to the “Initial” belt tension.


RENR9337

i02561293

Belt Tensioner SMCS Code: 1358 Part No.:

190-0642

Illustratio n 69

g01282318

Illustration 71

g01282267

(1) Limited travel .................. 71 degrees (minimum)

Voltage ............................................................... 24 V

(2) Spring force at assembly 25.4 ± 2.6 N·m (19 ± 2 lb ft) at 30 degrees from the free arm stop

Amperage ..................................................... 75 Amp

i02561119

Alternator and Regulator

Polarity ............................................ Negative ground


Note: Load the battery with a carbon pile 4C-4911 Battery Load Tester in order to get the maximum alternator output.

Rotation ............................................ Either direction

276-8899

The minimum full load current at 5000 rpm is the following value: .......................................... 67.5 Amp The minimum full load current at 2000 rpm is the following value: ............................................. 26 Amp Output voltage .......................................... 28 ± 1.0 V (1) Bolt Torque ....................... 6.2 ± 0.6 N·m (55 ± 5 lb in) (2) Shaft nut Torque .......................... 102 ± 7 N·m (75 ± 5 lb ft) Illustration 70

g01282265

(3) Positive terminal nut Torque ....................... 6.2 ± 0.6 N·m (55 ± 5 lb in) (4) “R” terminal ............................................ Optional alternating current from the stator (5) “I” terminal Torque ............. 2.25 ± 0.25 N·m (20.0 ± 2.2 lb in)

RENR9337


i02100780

Electric Starting Motor SMCS Code: 1453 Part No.:

276-8900, 276-8901

g01093018

Illustration 72 Typical example

Rotation of the starting motor when viewed from the pinion end ................................................. Clockwise The following performance specifications are rated at no load at 25 °C (77 °F): Speed ............................................ 6950 ± 1650 rpm Current draw ....................................... 115 ± 25 Amp

Current consumption (draw) at 20 V Pull-in windings ........................... 49.3 ± 3.3 Amp Hold-in windings ............................ 6.8 Amp max (B) Allowable range from the horizontal plane for the position of the solenoid (3) Small terminal nut (ground) Torque ................... 2.25 ± 0.25 N·m (20 ± 2 lb in)

Voltage ............................................................... 23 V (4) Small terminal nut (switch) (1) Large terminal nuts Torque ...................... 30.5 ± 3.5 N·m (22 ± 3 lb ft) (2) Solenoid

Heat shrink tubes must be used to insulate terminals for the switch terminal. Do not use molded terminals. Torque ................... 2.25 ± 0.25 N·m (20 ± 2 lb in) (5) Large terminal nut


RENR9337

There can be no more than three cable or wire terminals between nuts. Only two of the cable or wire terminals can be larger than 0 AWG. Torque ...................... 30.5 ± 3.5 N·m (22 ± 3 lb ft) (6) Clearance between the pinion and the housing with the pinion in the extended position .. 9.1 mm (0.36 inch) Note: Twelve point bolts are required for the mounting of the starting motor. i02580020

Engine Harness SMCS Code: 1408 Part No.:

285-3991, 285-3993

Illustration 73

(4) Nuts M40 Torque ......................... 15 ± 1 N·m (132 ± 9 lb in) (1) Nuts M20 Torque ............................. 5 ± 1 N·m (45 ± 9 lb in) (3) Nuts M12 Torque ............................ 1 ± 0.5 N·m (9 ± 5 lb in) (2) Nuts M16 Torque .......................... 3 ± 0.5 N·m (27 ± 5 lb in) (5) Connector Torque ............................. 6 ± 1 N·m (53 ± 9 lb in)

g01292329

RENR9337


i02425985

Engine Speed Sensor

Torque ............................ 28 ± 7 N·m (21 ± 5 lb ft) (2) Clearance between the sensor and the gear tooth ........................... 0.5 mm (0.0197 inch)


(1) Bolt

191-8304, 191-8305

Note: The wiring harness must be tied down and supported less than 102 mm (4 inches) from the sensor. Twisting of the wires minimizes the effect of the electrical noise. i02577495

Pressure Sensor SMCS Code: 7400-NS; 7450-NS Part No.:

Illustration 74

287-1866

g01075831

(1) Sensor assembly Torque ............................ 25 ± 5 N·m (18 ± 4 lb ft) Clearance between the sensor and the gear tooth ................ 1.0 ± 0.4 mm (0.04 ± 0.016 inch)

Illustration 76

g01291168

(1) Sensor assembly i02562514

Torque .......... 45 ± 6 N·m (33.1902 ± 4.4254 lb ft)

Engine Speed Sensor

Supply voltage ....................................... 5 ± 0.5 volts

SMCS Code: 1907

Output signal ................................................. Voltage

Part No.:

244-5544

Operating temperature ...................... − 40 ° ± 150 °C (− 40 ° ± 270 °F) Sensed media ......................... Engine oil, and diesel

Illustration 75

g01282732

Note: Lubricate the O-ring with clean unused engine oil.


RENR9337

i02562825

i02562983

Pressure Sensor

Temperature Sensor

SMCS Code: 7400-NS; 7450-NS

SMCS Code: 7400

Part No.:

Part No.:

241-1798, 274-6721

Illustratio n 77

g01282909

(1) Sensor assembly Torque ........................ 10 ± 2 N·m (90 ± 18 lb in) Operating temperature ...................... − 40 ° ± 125 °C (− 40 ° ± 225 °F) Supply voltage ....................................... 5 ± 0.5 volts

238-0112

Illustratio n 78

g01283059

Note: Do not connect the sensor directly to battery voltage. (1) Sensor assembly Torque ............................ 20 ± 3 N·m (15 ± 2 lb ft) Operating temperature ...................... − 40 ° ± 150 °C (− 40 ° ± 270 °F)

Sensed media ................... Engine oil and diesel fuel Note: Install the sensor so that the input pressure port is lower than the connector end and as close to the vertical position as possible. This reduces the possibility of ice that forms on the diaphragm in the sensor.

Sensed media .................................. Engine coolant, engine oil, fuel, air, and hydraulic oil i02576336

Temperature Sensor SMCS Code: 7400 Part No.:

247-7635

Illustration 79

(1) Fitting

g01291434

RENR9337

Torque ............................ 45 ± 5 N·m (33 ± 4 lb ft) Operating temperature ........................ −40 to 850 °C (−40 to 1562 °F) Supply voltage .................................... 8.0 ± 0.5 volts Output type ............... Pulse width modulated (PWM) Output frequency ................................. 500 ± 100 Hz Sensed media .............................................. Exhaust


50 Index Section

RENR9337

Index A Air Cleaner............................................................. Air Lines....................... .......................................... Alternator and Regulator ....................................... Auxiliary Water Pump ............................................

I 19 17 44 23

Important Safety Information ................................... 2 L Lifter Group............................................................ 12

B Belt Tension Chart ................................................. 42 Belt Tensioner........................................................ 44 C Camshaft ................................................................ 11 Connecting Rod..................................................... 30 Procedure for Tightening Connecting Rod Bolts ................................................................. 31 Connecting Rod and Main Bearing Journals......... 31 Crankshaft ............................................................ 32 Crankshaft Wear Sleeves and Seals ..................... 33 Cylinder Block........................................................ 24 Cylinder Head........................................................ 13 Cylinder Head Valves ............................................ 15 Cylinder Liner ........................................................ 27

P Piston and Rings ................................................... 28 Pressure Control Valve (Oil Regulator Valve and Oil Bypass Valve)...................................................... 20 Pressure Sensor.............................................. 47–48

S Specifications Section ............................................. 4

T Table of Contents..................................................... 3 Temperature Sensor.............................................. 48 Turbocharger ......................................................... 16

E V Electric Starting Motor ........................................... 45 Engine Design ......................................................... 4 Engine Harness ..................................................... 46 Engine Oil Pan....................................................... 21 Engine Oil Pump.................................................... 19 Engine Speed Sensor............................................ 47 Exhaust Fitting................................................. 18–19 Exhaust Manifold ............................................. 17–18

F Fan Drive............................................................... 39 Fastener Group (Vibration Damper) ...................... 42 Flywheel ................................................................ 40 Flywheel Housing .................................................. 40 Fuel Filter (Primary)................................................. 4 Fuel Filter (Secondary)............................................ 5 Fuel Injector............................................................. 6 Fuel Lines............................................................ 7–8 Fuel Transfer Pump ................................................. 5 G Gear Group (Front).......................................... 35, 37 Gear Group (Rear) ................................................ 38

Valve Mechanism .................................................. 13 Vibration Damper................................................... 41

W Water Pump........................................................... 21

RENR9337

51 Index Section

RENR9337-00 Specification Manual

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