Motor Caterpillar 3054

8/11/2019 Motor Caterpillar 3054

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Engine Design

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Type 1 Engines and 9RM Engines

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Illustration 1 g00296342

Cylinder and valve location for Type 1 engines and 9RM engines

(A) Exhaust valves

(B) Inlet valves

Note: Type 1 engines can be identified in two ways. The first method refers toIllustration 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 inletmanifold and the exhaust manifold. Type 1 engines have two exhaust ports in a row andtwo inlet ports that are in a row.

Type ... Four cylinder and four stroke

Combustion system ... Direct injection

Nominal Bore ... 100 mm (3.937 inch)

Stroke ... 127 mm (5.00 inch)
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Capacity ... 4 liters (243 in 3)

Compression Ratio ... 16:1

Number of cylinders ... 4

Arrangement of cylinders ... in-line

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

Valve Lash

Inlet valve ... 0.20 mm (.008 inch)Exhaust valve ... 0.45 mm (.018 inch)

When the crankshaft is viewed from the front of the engine the crankshaft rotates in thefollowing direction: ... Clockwise

When the camshaft is viewed from the front of the engine the camshaft rotates in thefollowing direction: ... Clockwise

Note: The front end of the engine is opposite the flywheel end. The left side and theright side of the engine are viewed from the flywheel end. The No. 1 cylinder is thefront cylinder.

Type 2 Engines and 7BJ Engines

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Cylinder and valve location for Type 2 engines and 7BJ engines

(A) Exhaust valves

(B) Inlet valves

Note: Type 2 engines can be identified in two ways. The first method refers toIllustration 2. When the valve cover is removed, look at the cylinder head valves. Type2 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 thevalve cover is removed, these engines may have two exhaust valves in a row and twoinlet 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 inletmanifold and the exhaust manifold. Type 2 engines alternate the exhaust ports and the

inlet ports.

Type ... Four cylinder and four stroke

Combustion system ... Direct injection

Nominal Bore ... 100 mm (3.937 inch)

Stroke ... 127 mm (5.00 inch)

Capacity ... 4 liters (243 in 3)

Compression Ratio ... 17.25:1

Number of cylinders ... 4

Arrangement of cylinders ... in-line

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

Valve Lash

Inlet valve ... 0.20 mm (.008 inch)Exhaust valve ... 0.45 mm (.018 inch)

When the crankshaft is viewed from the front of the engine the crankshaft rotates in thefollowing direction: ... Clockwise

When the camshaft is viewed from the front of the engine the camshaft rotates in thefollowing 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 thefront cylinder.

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Fuel Injection Pump

SMCS - 1251; 1290


Various Fuel Injection Pumps may be equipped to the engine. Bosch, Delphi, orStanadyne fuel injection pumps may be equipped to the engine.

Bosch Fuel Injection Pump (EPVE)

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Note: Parts that are inside of the fuel injection pump are only serviceable by anauthorized Bosch dealer. Please consult your parts book for availability of parts on the


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outside of the pump that are not related to the settings of the fuel pump and for the possibility of remanufacturing options.

Hub nut (not shown)

Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is positioned to the pump shaft in order to ensure that the fuel pump is in the correct position for timing. If the hub is removed, the hub will need to be accurately positionedto the pump shaft. Accurate positioning requires the use of special equipment by aCaterpillar Dealer.

(1) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to4.5 Nm (35 to 40 lb in)

(2) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to6 Nm (44 to 53 lb in)

(3) Tighten the fitting for the fuel supply connection to the following torque. ... 22 Nm(16 lb ft)

(4) Boost control (if equipped)

(5) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in)

(6) Tighten the nuts for the high pressure fuel line connection to the following torque. ...22 Nm (16 lb ft)

(7) Tighten the flange nuts to the following torque. ... 22 Nm (16 lb ft)

(8) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to81.4 Nm (52 to 60 lb ft)

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(9) Locking spacer (If equipped)

Note: The drive shaft of the fuel injection pump must not be turned without the spacerin position under the locking screw (10) .

(10) Tighten the locking screw to the following torque. ... 27 Nm (20 lb ft)

(11) Tighten the nut for the drive gear to the following torque. ... 80 Nm (59 lb ft)

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Note: Before the crankshaft is turned or the fuel injection pump is installed, move thelocking spacer (9) under the locking screw (10). Refer to position (A) that is inIllustration 3. This position ensures that the pump drive shaft is released.

Timing Information for the Bosch Fuel Injection Pump

Table 1

Early Bosch Fuel Injection Pump Without Locking Screw

Code Letterson FuelInjection

Pump

Engine CheckAngle(degrees) (1)

Fuel InjectionPump Mark Angle(degrees) (1)

Static TimingPosition BeforeTC Position

(degrees)

PistonDisplacement (1)

"BK" 308 314 12 1.78 mm (0.070

inch)

"CK" 308 314 12 1.78 mm (0.070

inch)


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"DK" 306 313 14 2.42 mm (0.095

inch)

"EK" 308.5 315.5 14 2.42 mm (0.095

inch)

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

inch)

"EM" 288.5 295.5 14 2.42 mm (0.095inch)

"FM" 289 295 12.5 1.93 mm (0.076inch)

"JM" - - 6 -

"JM" (3) - - 2 -

"JM" (4) - - TDC -

"KC" (5) - - TDC -

"KL" (5) - - TDC -

"ML" (5) - - TDC -

"PM" - - 12 -

"SK" - - 9 -

"TL" (5) - - TDC -

VM - - 2 ATDC -


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( 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.

Stanadyne Fuel Injection Pump (DB2 or DB4)

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Note: Parts that are inside of the fuel injection pump are only serviceable by anauthorized Stanadyne dealer. Please consult your parts book for availability of parts onthe outside of the pump that are not related to the settings of the fuel pump and for the

possibility of remanufacturing options.

Hub nut (not shown)


(1) Electrical connection for the stop solenoid


(3) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5 Nm (35 to 40 lb in)

(4) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to4.5 Nm (35 to 40 lb in)


(6) Adjustment screw for advance timing

(7) Tighten the fittings for the fuel discharge to the following torque. ... 70.5 to 81.4 Nm (52 to 60 lb ft)

(8) Tighten the nuts for the high pressure fuel injection line to the following torque. ...22 Nm (16 lb ft)

(9) Tighten the nut for the end cap to the following torque. ... 22 Nm (16 lb ft)

NOTICE

The No. 1 cylinder must be at the top center position on thecompression stroke before the fuel injection pump is installed. If thecrankshaft needs to be rotated, the fuel injection pump must bemounted temporarily or the loose gear could cause damage to the fronthousing.


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Timing Information for the Stanadyne Fuel Injection Pump

Table 2

Stanadyne Fuel Injection Pump

Code Letters on FuelInjection Pump

Engine Check Angle(degrees)

Fuel Injection Pump Mark Angle(degrees)

"AC" 282 291

"AL" 326 336

"BL" 326 336

"CL" 327 333

"CL" (1) - 247.5

"DL" 332 338

"FL" 326 333

"GL" 326 332

"HC" 282 290.5

"JL" 325 334.5

"KM" 282 290

"LM" 282 287

"LM" (2) 288.5 295

"MM" 282 287

"MM" (3) 288.5 295


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"NC" 282 294

"SL" 331.5 338

"SM" 282 291

"TC" 282 290

"TM" 282 290.5

"UC" 228.5 296

"VL" 326 389

"XK" 325 331.5

"YK" 325 334.5

"YL" 330 338

"ZK" 326 334

"ZM" (4) 282 287

"ZM" (5) 282 289

( 1 ) The fuel injection pump is timed with a pin.

( 2 ) The fuel injection pump is coded "2643U211" or "2643U213".

( 3 ) The fuel injection pump is coded "2643U214".

( 4 ) The values are for the fuel injection pumps with a serial number up to "7665964".

( 5 ) The values are for the fuel injection pump with a serial number that includes "7665965". The values

are also for the fuel injection pumps with serial numbers that are higher than "7665965".

Delphi Fuel Injection Pump (DPA or DPS)


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Note: Parts that are inside of the fuel injection pump are only serviceable by anauthorized Delphi dealer. Please consult your parts book for availability of parts on theoutside of the pump that are not related to the settings of the fuel pump and for the

possibility of remanufacturing options.

(1) Hub nut


(2) O-ring

(3) Locking spacer


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The drive shaft of the fuel injection pump must not be turned without the spacer in position under the locking screw (4) .

(4) Tighten the locking screw to the following torque. ... 10 Nm (7 lb ft)

The locking screw prevents the rotation of the drive shaft.

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Before the crankshaft is turned or the fuel injection pump is installed, move the lockingspacer (3) under the locking screw (4). Refer to position (A) that is in Illustration 6.This position ensures that the pump drive shaft is released.


(6) Tighten the adjustment screw for low idle to the following torque. ... 4 to 4.5 Nm(35 to 40 lb in)

(7) Tighten the adjustment screw for high idle to the following torque. ... 4 to 4.5 Nm(35 to 40 lb in)

(8) Electrical connection for the stop solenoid

(9) Tighten the fitting for the fuel supply connection to the following torque. ... 22 Nm(16 lb ft)


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(10) Tighten the nuts for the fuel line to the following torque. ... 22 Nm (16 lb ft)


(12) Electrical connection for cold starting aid

(13) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to81.4 Nm (52 to 60 lb ft)

Timing Information for the Delphi Fuel Injection Pump

Table 3

Delphi Fuel Injection Pump

Code that is on the FuelInjection Pump

Engine Check Angle(degrees)

Fuel Injection Pump Mark Angle(degrees)

"AK" 325.5 336

"AM" 282 290.5

"BF" 326 334

"BM" 281 291

"CM" 282.5 291.5

"DM" 282.25 290.5

"FK" 325.5 336

"GK" 325 336

"GM" 282 290.5

"HK" 326 336

"HM" 282 291

"JK" 325 334


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"KK" 325 334

"LK" 327 337.5

"LK" (1) 328 337.5

"MK" 326 336

"MK" (2) 325 336

"PK" 326 334

"RK" 328 336

"RM" 282.5 290.5

"TK" 327 334

"UK" 326 334

"XM" 282 291

( 1 ) "YA31257" only

( 2 ) "YA50532" only

Table 4

Dephi Fuel Injection Pump With Locking Screw

Code Letters on Fuel Injection Pump Locking Angle (degrees)

"BC" 336.5

"CC" 338.5

"DC" 337.5


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"EC" 337.5

"FC" 335.5

"GC" 337

"PC" 339

"RC" 339

"SC" 341

"XL" 22

Note: Later Delphi Fuel Injection Pumps are timed with a pin.1

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Fuel Injection Nozzles

SMCS - 1254



Note: For a complete description of Type 1 and Type 2 engines, refer to theSpecifications Module, "Engine Design" for more information.

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Fuel injection nozzle

(1) Connection for the union nut of the fuel supply line

(2) Threaded hole for the banjo bolt of the leak off line

(3) Clamp

(4) Seal

(5) Spacer

(6) Fuel injector assembly

(7) Seat washer

(1) Tighten the union nut of the high pressure fuel line (not shown) to the followingtorque: ... 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 injectionnozzle 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. Donot reuse the seal (4) and the seat washer (7) .

Bench test the fuel injection nozzles at a temperature of 18 to 20 C (64 to 70 F).


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Note: Use clean SAE J-967 oil (ISO 4113) when you are conducting the test. The oil isavailable 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 fuelinjection nozzle will be damaged.

Refer to Testing And Adjusting, "Pressure Adjustment, Back Leakage Test, Nozzle andSeat Test".

Table 1

Pressure Settings for the Fuel Injection Nozzles for the Type 1 Engines and 9RMEngines

Code (1) Pressure Setting

"HU"

22291 kPa (3233 psi)"HV"

25331 kPa (3674 psi)

"HZ"22291 kPa (3233 psi)

"JA"25331 kPa (3674 psi)

"JB"25331 kPa (3674 psi)

"JE"22291 kPa (3233 psi)

"JF"25331 kPa (3674 psi)

"JG"23304 kPa (3380 psi)

"JH"25331 kPa (3674 psi)

"JJ"25331 kPa (3674 psi)

"JK"22291 kPa (3233 psi)

"JL"25331 kPa (3674 psi)

"JR" 25331 kPa (3674 psi)


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"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)


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"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)

The code letters are stamped on the side of the fuel injector body. The code letters are located belowthe connection for the nut of the high pressure fuel line.

Note: Ensure that the new fuel injection nozzles have the same identification code asthe nozzles which were originally installed in the cylinder head.

Leakage in 10 seconds ... 0 drops



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Fuel injection nozzle

(1) Connection for the union nut of the fuel supply line

(2) Threaded hole for the banjo bolt of the leak off line

(3) Nut of the fuel injection nozzle

(4) Wire clip

(5) Seat washer

(1) Tighten the union nut of the high pressure fuel line (not shown) to the following

torque: ... 22 Nm (16 lb ft)


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(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 lbft)

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 thefuel injection nozzle after installation. The seal which is made by the anti-seizecompound may break. A broken seal may allow leakage past the seat of the fuelinjection nozzle.

(4) Wire clip

(5) Seat washer

Note: Remove the original seat washer from the threaded hole for the fuel injectionnozzle 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. Donot reuse the seat washer (5) .

Bench test the fuel injection nozzles at a temperature of 18 to 20 C (64 to 70 F).

Note: Use clean SAE J-967 oil (ISO 4113) when you are conducting the test. The oil isavailable 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 fuelinjection nozzle will be damaged.

Refer to Testing And Adjusting, "Pressure Adjustment, Back Leakage Test, Nozzle andSeat Test".

Table 2

Pressure Settings for the Fuel Injection Nozzles for the Type 2 Engines and 7BJEngines

Code (1) Pressure Setting

"KB"30406 kPa (4410 psi)

"KC"28979 kPa (4203 psi)

"KD"29385 kPa (4262 psi)

"KE"29385 kPa (4262 psi)

"KF"


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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"


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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 belowthe connection for the nut of the high pressure fuel line.

Note: Ensure that the new fuel injection nozzles have the same identification code asthe nozzles which were originally installed in the cylinder head.

Leakage in 10 seconds ... 0 drops1 1 0

Fuel Transfer Pump

SMCS - 1256


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Typical example of the fuel transfer pump

Method of drive ... Camshaft

Output pressure during the first ten seconds of cranking:

Normal pressure ... 42 to 70 kPa (6 to 10 psi)Minimum pressure ... 30 kPa (4.4 psi)

The engine may be equipped with four mounting bolts or four mounting studs with nuts.Tighten to the following torque: ... 22 Nm (16 lb ft)

Apply 4C-4030 Thread Lock Compound to the first three threads of the mounting boltsor 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 ison minimum lobe lift and that the bolts are evenly tightened. Failure to follow this

procedure can cause the following conditions: loss of maximum engine power and

damage to the fuel transfer pump.1 1 0


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Rocker Shaft

SMCS - 1102


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(1) Rocker arm

Diameter of the rocker arm bore for the bushing ... 22.23 to 22.26 mm (0.8750 to0.8762 inch)

(2) Rocker arm bushing

Outside diameter of the rocker arm bushing ... 22.28 to 22.31 mm (0.8770 to0.8785 inch)Inside diameter of the rocker arm bushing ... 19.06 to 19.10 mm (0.7505 to0.7520 inch)Clearance between the rocker arm bushing and the rocker shaft ... 0.03 to 0.09mm (0.001 to 0.0035 inch)Maximum permissible clearance between the rocker arm bushing and the rockershaft ... 0.13 mm (0.005 inch)

(3) Tighten the bolts evenly. Begin in the center and work toward the outside. Tightenthe bolts to the following torque.

Cast iron or steel rocker shaft brackets ... 88 Nm (65 lb ft)Aluminum rocker shaft brackets ... 40 Nm (30 lb ft)


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(4) Diameter of the rocker shaft ... 19.01 to 19.04 mm (0.7485 to 0.7495 inch)

(5) Tighten the bolt to the following torque. ... 4 Nm (35 lb in)1

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Valve Mechanism Cover

SMCS - 1107


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(1) Tighten the nut to the following torque.

Composite cover ... 20 Nm (15 lb ft)Aluminum cover ... 30 Nm (22 lb ft)

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Cylinder Head Valves

SMCS - 1105



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Inlet valves and exhaust valves

Double valve springs:

(1) Outer spring

Length under test force ... 35.8 mm (1.41 inch)Test force ... 176 to 195 N (40 to 44 lb)

(2) Inner spring

Length under test force ... 34.0 mm (1.34 inch)

Test force ... 89 to 104 N (20 to 23 lb)


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Single valve springs (not shown)

Length under test force ... 40.0 mm (1.57 inch)Test force ... 310 to 344 N (70 to 77 lb)Free length after test ... 53.4 mm (2.10 inch)

(3) Valve spring recess for the valve spring

(4) Valve guides for the inlet and exhaust valves

Inside diameter ... 9.51 to 9.56 mm (0.374 to 0.376 inch)Outside diameter ... 15.900 to 15.910 mm (0.6260 to 0.6265 inch)Bore diameter in cylinder head for valve guide ... 15.87 to 15.89 mm (0.625 to0.626 inch)Interference fit of valve guide in cylinder head ... 0.03 to 0.07 mm (0.001 to0.003 inch)

Overall length of valve guideInlet ... 57.94 mm (2.281 inch)Exhaust ... 61.1 mm (2.406 inch)Projection of valve guide above valve spring recess (3) ... 15.1 mm (0.595 inch)

Note: When new valve guides are installed, new valves and new valve seat inserts must be installed. The valve guides and the valve seat inserts are supplied as partially finished parts. The unfinished valve guides and unfinished valve seat inserts are installed in thecylinder head. Then, the guides and inserts are cut and reamed in one operation withspecial tooling. This procedure ensures the concentricity of the valve seat to the valveguide in order to create a seal that is tight. Refer to the Disassembly and AssemblyManual for removal and installation procedures.

(5) Diameter of the exhaust valve stem ... 9.43 to 9.46 mm (0.371 to 0.372 inch)

Clearance of valve in valve guide ... 0.05 to 0.13 mm (0.002 to 0.005 inch)

Maximum permissible clearance of valve in valve guide ... 0.15 mm (0.006 inch)

Overall length of the exhaust valve ... 123.07 to 123.57 mm (4.845 to 4.865 inch)

(6) Diameter of the inlet valve stem ... 9.460 to 9.490 mm (0.3724 to 0.3735 inch)

Clearance of valve in the valve guide ... 0.02 to 0.10 mm (0.001 to 0.004 inch)


Overall length of the inlet valve ... 122.66 to 123.07 mm (4.829 to 4.845 inch)

(7) Exhaust valve face angle ... 45 degrees

Valve seat angle ... 46 degrees

(8) Diameter of the exhaust valve ... 37.26 to 37.52 mm (1.467 to 1.477 inch)


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Valve depth below the cylinder head face

Minimum ... 1.28 mm (0.050 inch)

Maximum ... 1.83 mm (0.072 inch)

Service wear limit ... 2.08 mm (0.082 inch)

(9) Diameter of the inlet valve ... 44.86 to 45.11 mm (1.766 to 1.776 inch)


Minimum ... 1.27 mm (0.050 inch)

Maximum ... 1.60 mm (0.063 inch)

Service wear limit ... 1.85 mm (0.073 inch)

(10) Inlet valve face angle ... 45 degrees


Note: Some engines may have valve face angles of 30 degrees and valve seat angles of31 degrees.

The valve lash is the following value when the engine is hot or cold:

Inlet valves ... 0.20 mm (0.008 inch)Exhaust valves ... 0.45 mm (0.018 inch)

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Recess for a valve insert

(11) Machine the recess in the head for valve seat inserts to the following dimensions:

Inlet(A) ... 7.19 to 7.32 mm (0.283 to 0.288 inch)(B) ... 51.220 to 51.240 mm (2.0167 to 2.0175 inch)(C) Maximum radius ... 0.38 mm (0.015 inch)

Exhaust(A) ... 9.52 to 9.65 mm (0.375 to 0.380 inch)(B) ... 42.620 to 42.650 mm (1.6779 to 1.6790 inch)(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 beinstalled. Refer to the Disassembly and Assembly for removal and installation

procedures.

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Angles and dimensions of the valve seat insert


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(12) Valve seat insert

(D) Included angle of the faces

(E) Dimension of chamfer

(F) Vertical angle of chamfer


(D) Included angle of the faces of the valve seat insertEngines with 46 degree valve seats ... 88 degreesEngines with 31 degree valve seats ... 118 degrees

(E) Dimension of chamfer for all engines ... 1.10 0.20 mm (0.043 0.008 inch)

(F) Angle of chamfer from the vertical for all engines ... 30 degrees



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Inlet valves and exhaust valves

(1) Single valve springs

Length under test force ... 39.0 mm (1.54 inch)Test force ... 246 to 277 N (55 to 62 lb)

(2) Valve spring insert for the valve spring

(3) Valve guides

Inside diameter of finished valve guide ... 9.00 to 9.02 mm (0.354 to 0.355 inch)Outside diameter of inlet valve ... 13.03 to 13.05 mm (0.513 to 0.514 inch)

Outside diameter of exhaust valve ... 14.03 to 14.05 mm (0.552 to 0.553 inch)Bore diameter in the cylinder head for the inlet valve guide ... 13.00 to 13.03mm (0.512 to 0.513 inch)Bore diameter in the cylinder head for the exhaust valve guide ... 14.000 to14.027 mm (0.5512 to 0.5522 inch)Interference fit of valve guide in the cylinder head ... 0.007 to 0.047 mm (0.0003to 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 thecylinder head. Then, the guides and inserts are cut and reamed in one operation withspecial tooling. This procedure ensures the concentricity of the valve seat to the valveguide in order to create a seal that is tight. Refer to the Disassembly and AssemblyManual for removal and installation procedures.

(4) Diameter of the exhaust valve stem ... 8.94 to 8.96 mm (0.352 to 0.353 inch)

Clearance of valve in valve guide ... 0.040 to 0.084 mm (0.0026 to 0.0033 inch)


Overall length of the exhaust valve ... 122.65 to 123.30 mm (4.829 to 4.854 inch)

(5) Diameter of the inlet valve stem ... 8.953 to 8.975 mm (0.3525 to 0.3533 inch)

Clearance of valve in the valve guide ... 0.025 to 0.069 mm (0.001 to 0.003 inch)


Overall length of the inlet valve ... 122.65 to 123.30 mm (4.829 to 4.854 inch)


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(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)


Minimum ... 1.50 mm (0.059 inch)Maximum ... 1.80 mm (0.071 inch)Service wear limit ... 2.05 mm (0.081 inch)

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


Minimum ... 1.40 mm (0.055 inch)Maximum ... 1.70 mm (0.067 inch)Service wear limit ... 1.95 mm (0.077 inch)

(9) Inlet valve face angle ... 45 degrees


Note: Some engines may have valve face angles of 30 degrees and valve seat angles of31 degrees.

The valve lash is the following value when the engine is hot or cold:

Inlet valves ... 0.20 mm (0.008 inch)Exhaust valves ... 0.45 mm (0.018 inch)

Ver imagen


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Recess for a valve insert

(11) Machine the recess in the head for valve seat inserts to the following dimensions.

Inlet(A) ... 10.585 to 10.715 mm (0.4167 to 0.4219 inch)(B) ... 45.535 to 45.560 mm (1.7927 to 1.7937 inch)

(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 beinstalled. Refer to Disassembly and Assembly for removal and installation procedures.

Ver imagen


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Angles and dimensions of the valve seat insert


(D) Included angle of the faces

(E) Dimension of chamfer

(F) Vertical angle of chamfer


(D) Included angle of the faces of the valve seat insertEngines with 46 degree valve seats ... 88 degreesEngines with 31 degree valve seats ... 118 degrees

(E) Dimension of chamfer for all engines ... 1.10 0.20 mm (0.043 0.008 inch)

(F) Angle of chamfer from the vertical for all engines ... 30 degrees1

1 0

Cylinder Head


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SMCS - 1100


Type 1 Engines and 9RM EnginesNote: For a complete description of Type 1 and Type 2 engines, refer to theSpecifications Module, "Engine Design" for more information.

Ver imagen


Bolt tightening sequence for the cylinder head

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.

Torque for the bolts ... 110 Nm (81 lb ft)

2. Tighten bolts (1) through bolts (22) again in a numerical sequence.

Torque for bolts ... 110 Nm (81 lb ft)

3. Rotate bolts (1) through bolts (22) in a numerical sequence to the followingvalues:

a. Tighten the bolts of short length "S" to the following value.

Rotate the bolts in a clockwise direction: ... 150 degrees


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


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


Ver imagen


Bolts, nuts, and components of the cylinder head

(1) Tighten the nuts that hold fuel injectors to the following torque: ... 12 Nm (10 lb ft)

Note: When the fuel injection nozzle is removed, the following items must be replaced:dust seal and seat washer.

(2) Tighten the nuts for fuel line to the following torque: ... 18 Nm (13 lb ft)

(3) Tighten the bolts that hold the rocker shaft to the cylinder head to the followingtorque:

Begin tightening the inner bolts. Then tighten the bolts by working toward the end ofthe shaft.

Cast iron or steel bracket ... 75 Nm (55 lb ft)Aluminum bracket ... 40 Nm (30 lb ft)

(4) Valve lash


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Inlet ... 0.20 mm (.008 inch)Exhaust ... 0.45 mm (.018 inch)

(5) Maximum permissible nozzle projection below cylinder head face after resurfacing... 4.45 mm (.175 inch)

Maximum allowance for resurfacing ... 0.30 mm (.012 inch)

(6) Depth of new cylinder head ... 102.79 to 103.59 mm (4.047 to 4.078 inch)

Minimum depth of cylinder head after resurfacing ... 102.48 mm (4.035 inch)

Ver imagen


Positions for measuring the bow of the cylinder head (typical example)

Maximum permissible amount of bow (curve of cylinder head)

Naturally aspirated enginesA ... 0.08 mm (.003 inch)B ... 0.15 mm (.006 inch)C ... 0.15 mm (.006 inch)

Turbocharged enginesA ... 0.13 mm (.005 inch)B ... 0.25 mm (.010 inch)C ... 0.25 mm (.010 inch)

Tighten the bolts of the inlet manifold (not shown) to the following torque: ... 44 Nm

(32 lb ft)


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Tighten exhaust manifold nuts (not shown) to the following torque:

Plated ... 44 Nm (32 lb ft)Plain ... 50 Nm (37 lb ft)

Type 2 Engines and 7BJ EnginesNote: For a complete description of Type 1 and Type 2 engines, refer to theSpecifications Module, "Engine Design" for more information.

Ver imagen


Bolt tightening sequence for the cylinder head

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 anumerical sequence in Illustration 4.


2. Tighten bolts (1) through bolts (22) again in a numerical sequence.


3. Rotate bolts (1) through bolts (26) in a numerical sequence to the followingvalues:

a. Tighten the bolts of short length "S" to the following value.



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


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


Ver imagen


Bolts, nuts, and components of the cylinder head

Note: When the fuel injection nozzle is removed, the following items must be replaced:dust seal and seat washer.

(1) Tighten the bolts that hold the rocker shaft to the cylinder head to the followingtorques:

Begin tightening the inner bolts. Then tighten the bolts by working toward the end ofthe shaft.

Cast iron or steel bracket ... 75 Nm (55 lb ft)Aluminum bracket ... 40 Nm (30 lb ft)


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(2) Valve lash

Inlet ... 0.20 mm (.008 inch)Exhaust ... 0.45 mm (.018 inch)

(3) Maximum permissible nozzle projection below cylinder head face after resurfacing... 4.45 mm (.175 inch)

Maximum allowance for resurfacing ... 0.30 mm (.012 inch)

(4) Depth of new cylinder head ... 102.79 to 103.59 mm (4.047 to 4.078 inch)

Minimum depth of cylinder head after resurfacing ... 102.48 mm (4.035 inch)

Ver imagen


Positions for measuring the bow of the cylinder head (typical example)

Maximum permissible amount of bow (curve of the cylinder head)

A ... 0.08 mm (.003 inch)B ... 0.15 mm (.006 inch)C ... 0.15 mm (.006 inch)

Tighten the bolts for the inlet manifold (not shown) to the following torque: ... 44 Nm(32 lb ft)

Tighten the nuts for the exhaust manifold (not shown) to the following torque:

Plated ... 44 Nm (32 lb ft)


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Plain ... 50 Nm (37 lb ft)1 1 0

Turbocharger

SMCS - 1052


Turbocharger

Ver imagen


(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.


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(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 thecompressor 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 theturbine housing to the center section, to the following torque: ... 18.6 to 20.4 Nm (14 to15 lb ft)

(5) Turbine wheel assembly

Minimum journal outside diameter ... 10.152 mm (.3997 inch)Ring groove diameter (minimum) ... 14.401 mm (.5670 inch)Ring groove width (maximum) ... 1.740 mm (.0685 inch)Hub outside diameter (minimum) ... 17.323 mm (.6820 inch)

(6) End play for shaft

Minimum permissible end play ... .03 mm (.001 inch)Maximum permissible end play ... .10 mm (.004 inch)

(7) Compressor wheel

Bore inside diameter (maximum) ... 6.353 mm (.2501 inch)

(8) Backplate assembly

Seal inside diameter (maximum) ... 12.713 mm (.5005 inch)Flatness from the backplate to the mating surface of the center housing is withinthe following value: ... .013 mm (.0005 inch)

(9) Thrust collar

Thickness (maximum) ... 18.339 mm (0.7220 inch)Bore inside diameter (maximum) ... 6.363 mm (.2505 inch)

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

(10) Thrust bearing

Thickness (minimum) ... 4.359 mm (0.1716 inch)Bore inside diameter (maximum) ... 10.922 mm (.4300 inch)

(11) Radial play (side to side movement) for shaft

Minimum permissible radial play (side to side movement) ... .08 mm (.003 inch)


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Current draw ... 13.5 amperes

Tighten the air inlet heater to the inlet manifold to the following torque: ... 31 8 Nm

(23 6 lb ft)1 1 0

Exhaust Manifold

SMCS - 1059



Ver imagen


The cylinder head is shown.

Refer to Illustration 1 for the tightening sequence. Tighten the plated nuts for theexhaust manifold to the following torque. ... 44 Nm (33 lb ft)

Refer to Illustration 1 for the tightening sequence. Tighten the nuts that are not platedfor the exhaust manifold to the following torque. ... 50 Nm (37 lb ft)


Ver imagen
http://viewimage%28%27g00559857%27%2C%27d%27%29/http://viewimage%28%27g00559857%27%2C%27d%27%29/http://viewimage%28%27g00501179%27%2C%27d%27%29/http://viewimage%28%27g00501179%27%2C%27d%27%29/http://viewimage%28%27g00501179%27%2C%27d%27%29/http://viewimage%28%27g00559857%27%2C%27d%27%29/


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Apply 4C-9507 Retaining Compound to the stud threads.

Refer to Illustration 2 for the tightening sequence. Tighten the exhaust manifold nuts or

bolts gradually to the following torque. ... 44 Nm (33 lb ft)1

1 0

Muffler

SMCS - 1062


Ver imagen


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(1) Tighten the nuts to the following torque. ... 30 7 Nm (22 5 lb ft)

(2) Tighten the bolts and the nuts to the following torque. ... 55 10 Nm (41 7 lb ft

Camshaft

SMCS - 1210


Ver imagen


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Camshaft lobe lift

To determine lobe lift, use the procedure that follows:

1. Measure the height (B) of the camshaft lobe.

2. Measure the base circle (C) .

3. Subtract the base circle (C) from the height (B) of the lobe. The difference is theactual lobe lift (A) .

4. Specified camshaft lobe lift (A)

Inlet ... 7.62 to 7.69 mm (0.300 to 0.303 inch)

Exhaust ... 7.71 to 7.79 mm (0.304 to 0.307 inch)

Minimum permissible height of lobes ... 7.37 mm (0.290 inch)

1 1 0


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Engine Oil Filter Base

SMCS - 1306


Ver imagen


(1) Engine oil filter base

The bypass valve in the engine oil filter opens at the following pressure difference: ...55 to 83 kPa (8 to 12 psi)

(2) Engine oil cooler

The bypass valve in the engine oil cooler opens at the following pressure: ... 172 kPa(25 psi)

Tighten the threaded adapter that fastens the engine oil cooler to the engine oil filter

base to the following torque: ... 37 Nm (27 lb ft)1 1

0

Engine Oil Relief Valve

SMCS - 1315



53/100

Ver imagen


The relief valve for the engine oil pressure should open at the following pressuresetting:

Engines that are not equipped with piston cooling jets ... 340 to 395 kPa (49 to57 psi)Engines that are equipped with piston cooling jets ... 415 to 470 kPa (60 to 68

psi)

Engines that are equipped with counter balancer ... 523 kPa (76 psi)

(1) Spring

Length under test force ... 59.8 mm (2.35 inch)Length under test force for engines that are equipped with counter balancer ...42.7 mm (1.681 inch)Test force ... 15.9 to 23.1 N (3.6 to 5.2 lb)Test force with engines that are equipped with counter balancer ... 34 to 38 N(7.6 to 8.5 lb)

(2) Outside diameter of plunger ... 18.16 to 18.18 mm (.715 to .716 inch)


54/100


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When the oil pump is mounted to a balancer unit, tighten the single bolt on the oil pumpcover (not shown) to the following torque: ... 22 Nm (16 lb ft)

Type ... Gerotor pump

Number of lobes

Inner rotor ... 6Outer rotor ... 7

Ver imagen


Clearance for the outer rotor body

Clearance of the outer rotor to the body

The balancer unit is not installed. ... 0.15 to 0.34 mm (0.006 to 0.013 inch)The balancer unit is installed. ... 0.31 to 0.45 mm (0.012 to 0.018 inch)

Ver imagen
http://viewimage%28%27g00295515%27%2C%27d%27%29/http://viewimage%28%27g00295515%27%2C%27d%27%29/http://viewimage%28%27g00295516%27%2C%27d%27%29/http://viewimage%28%27g00295516%27%2C%27d%27%29/http://viewimage%28%27g00295516%27%2C%27d%27%29/http://viewimage%28%27g00295515%27%2C%27d%27%29/


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Tighten the oil pressure switch, which is located on the left side of the engine block, to

the following torque: ... 7 to 12 Nm (62 to 107 lb in)1 1

0

Water Temperature RegulatorSMCS - 1355


Ver imagen


Opening temperature ... 77 to 85 C (171 to 185 F)

Full open temperature ... 92 to 98 C (198 to 208 F)

Minimum stroke at full open temperature ... 9 mm (0.35 inch)1

1 0

Water Pump

SMCS - 1361




58/100


Ver imagen


(1) Outside diameter of shaft for drive gear ... 15.91 to 15.92 mm (.626 to .627 inch)

(2) Diameter of bore of drive gear ... 15.86 to 15.88 mm (.624 to .625 inch)

Interference fit of drive gear on shaft ... 0.03 to 0.06 mm (.001 to .002 inch)

(3) Diameter of bore of impeller ... 15.87 to 15.89 mm (.625 to .626 inch)


59/100


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Typical example

(1) Cylinder liner

Outside diameter of cylinder liner ... 104.25 to 104.28 mm (4.105 to 4.106 inch)Inside diameter of cylinder liner ... 100.00 to 100.03 mm (3.937 to 3.938 inch)Maximum permissible wear of cylinder liner bore ... 0.25 mm (0.010 inch)Interference fit of cylinder liner in cylinder block ... 0.03 to 0.08 mm (0.001 to0.003 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 (0.004inch) below the top face of the cylinder block.

(2) Plug with baffle plates (if equipped)

Orientation of baffle plates to the vertical plane ... +/- 5 degreesDepth of plug from face of cylinder block ... 3 mm (0.12 inch)

(3) Cylinder block

Diameter of the bore for the cylinder liner ... 104.20 to 104.23 mm (4.103 to4.104 inch)


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Depth of the recess for the cylinder liner flange ... 3.81 to 3.91 mm (0.150 to0.154 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 tothe following torque.

M6 ... 13 Nm (10 lb ft)M8 ... 22 Nm (16 lb ft)

(6) Bridge bolt

Use the following procedure in order to install the bridge bolts.

1. Use a straight edge in order to ensure that the bridge is aligned with the frontface of the cylinder block.

2. Evenly tighten the bridge bolts to a torque of 16 Nm (12 lb ft).

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.

(7) Main bearing cap bolts

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 onthe top of the main bearing cap. Install the main bearing caps with the locatingtabs 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 to3.1670 inch)

(9) Camshaft bearing

Inside diameter of the camshaft bearing for the number 1 camshaft journal ...50.79 to 50.85 mm (2.000 to 2.002 inch)Bore diameter in the cylinder block for the number 1 camshaft bearing ... 55.56to 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)


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Bore diameter in the cylinder block for the number 3 camshaft journal ... 50.04to 50.09 mm (1.970 to 1.972 inch)

Total height of cylinder block between the top and the bottom faces. ... 441.12 to 441.33mm (17.367 to 17.375 inch)

Piston Cooling Jets (If Equipped)

Ver imagen


(1) Tighten the piston cooling jets to the following torque. ... 27 Nm (20 lb ft)

(2) Diameter of rod ... 1.70 mm (0.067 inch)

(3) Cylinder block

Note: Ensure that the piston cooling jet is positioned correctly on the dowel in thecylinder block (not shown).

Use the following procedure in order to ensure the correct alignment of the pistoncooling jet.


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1. Insert rod (2) into the end of the piston cooling jet. Rod (2) should protrude outof the top of the cylinder block.

2. Use the following dimensions to locate the center point of diameter (C) .

Dimension (A) ... 33 mm (1.3 inch)

Dimension (B) ... 21 mm (0.8 inch)

Diameter (C) ... 14 mm (0.6 inch)

Note: Dimension (A) and dimension (B) are tangent to the cylinder bore.

3. Position rod (2) within diameter (C) .

1 1 0

Crankshaft

SMCS - 1201


Ver imagen


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Crankshaft and main bearing journals

Note: If a crankshaft that was not originally induction hardened has been remachined,then the crankshaft must be rehardened. Use one of the process that follow for 20 hoursin order to reharden the crankshaft: nitrocarburizing process and nitriding process

(1) Connecting rod bearing

(2) Top and bottom thrust washer thickness

Standard ... 2.26 to 2.31 mm (0.089 to 0.091 inch)Oversize ... 2.45 to 2.50 mm (0.096 to 0.098 inch)

(3) Main bearing

Clearance for main bearings ... 0.057 to 0.117 mm (0.0022 to 0.0046 inch)Bearing width

Center bearing ... 36.32 to 36.70 mm (1.430 to 1.445 inch)All other bearings ... 31.62 to 31.88 mm (1.245 to 1.255 inch)

Thickness of the bearing at the centerAll bearings ... 2.083 to 2.086 mm (0.0820 to 0.0821 inch)

(4) Crankshaft gear

(5) End play of the crankshaft ... 0.05 to 0.38 mm (0.002 to 0.015 inch)

Maximum permissible end play ... 0.51 mm (0.020 inch)

(6) Width of the connecting rod journal ... 40.35 to 40.42 mm (1.589 to 1.591 inch)

Connecting rod journal diameter of flange ... 133.27 to 133.37 mm (5.247 to 5.251 inch)

Depth of recess for connecting rod bearing ... 20.22 to 20.98 mm (0.796 to 0.826 inch)

Bore of recess for connecting rod bearing ... 46.96 to 46.99 mm (1.849 to 1.850 inch)

Measure the connecting rod journals on the crankshaft. See the following chart for thedimensions.

Table 1

Connecting Rod Bearing Journal

If the bearing journal has been ground beyond this size, thenregrind the bearing journals to the next undersize journal. 63.43 mm (2.497

inch)


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Original Size Journal63.47 to 63.49 mm(2.499 to 2.500 inch)

Undersize Journal0.25 mm (0.010 inch) 63.22 to 63.24 mm

(2.489 to 2.490 inch)


(2.479 to 2.480 inch)


(2.469 to 2.470 inch)

Connecting rod bearings are available for remachined journals with the followingundersize dimensions:

Undersize ... 0.25 (0.010)Undersize ... 0.51 (0.020)Undersize ... 0.76 (0.030)

(7) Dimensions of main journals which are the standard, original size

Width of front journal ... 36.93 to 37.69 mm (1.454 to 1.484 inch)

Width of center journal ... 44.15 to 44.22 mm (1.738 to 1.741 inch)Width of all other journals ... 39.24 to 39.35 mm (1.545 to 1.549 inch)

Measure the main bearing journals on the crankshaft. See the following chart fordimensions.

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 (2.996inch)

Original Size Journal76.16 to 76.18 mm(2.998 to 2.999 inch)


(2.988 to 2.989 inch)



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(2.978 to 2.979 inch)


(2.968 to 2.969 inch)

Tighten the bolts for the main bearing journal to the following torque: ... 265 Nm (195lb ft)

Main bearings are available for remachined journals with the following undersizedimensions:

Undersize ... 0.25 (0.010)Undersize ... 0.51 (0.020)Undersize ... 0.76 (0.030)

Tighten the retaining bolts of the crankshaft pulley (not shown) to the following torque:... 115 Nm (85 lb ft)

Apply 9S-3263 Thread Lock Compound to the bolts of the crankshaft damper. Tightenthe bolts (not shown) to the following torque:

M8 bolts ... 35 Nm (26 lb ft)M12 bolts ... 75 Nm (55 lb ft)

Tighten the bolts that fasten the rear oil seal housing to the cylinder block (not shown)to the following torque: ... 22 Nm (16 lb ft)

Tighten the bolts that fasten the rear oil seal housing to the bridge (not shown) to thefollowing torque:

M6 ... 13 Nm (10 lb ft)M8 ... 18 Nm (13 lb ft)

1 1 0

Crankshaft Seals

SMCS - 1160; 1161


Crankshaft Front Seal

Ver imagen


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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 causewear on the hub of crankshaft pulley (3). This wear may allow oil leakage past the oilseal. If this situation occurs, the front oil seal can be installed to a depth of 9.3 mm (0.37inch) 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 isinstalled, the flange of the wear sleeve does not require removal. If a wear sleeve isinstalled, a new front oil seal must be installed.

(5) Tighten three bolts for the crankshaft pulley to the following torque. ... 115 Nm (85lb ft)

Crankshaft Rear Seal

Engines with 14 Bolt Housing Assembly


68/100

Ver imagen


Positions of the crankshaft seal

Position (1) is 0 mm (0.0 inch) from the face of the rear housing.

Position (2) is 4.6 mm (0.18 inch) from the face of the rear housing. Use position (2) if

the crankshaft surface is worn in position (1) .

Position (3) is 6.9 mm (0.27 inch) from the face of the rear housing. Use position (3) ifthe crankshaft surface is worn in both of the other positions.

Engines with 10 Bolt Housing Assembly

The 10 bolt housing assembly is manufactured as a one-piece assembly. There is noadjustment of the position from the face of the rear housing.

Note: If a wear groove on the crankshaft flange has occurred, use a 209-8228 Sleeve torenew the sealing surface when you replace the housing assembly.


69/100

Tighten the bolts that fasten the rear housing for the crankshaft rear seal to the cylinder

block to the following torque. ... 22 Nm (16 lb ft)1 1

0

Connecting RodSMCS - 1218




Ver imagen



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Connecting Rod And Bearings

Naturally Aspirated Engines

(1) Inside diameter of rod for bearing ... 38.89 to 38.92 mm (1.531 to 1.532 inch)

(2) Outside diameter of bearing for piston pin ... 38.94 to 39.03 mm (1.535 to 1.536inch)

Inside diameter of bearing for piston pin after reaming ... 34.940 to 34.960 mm (1.3758to 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 to219.10 mm (8.624 to 8.626 inch)

(4) Bearings are available for remachined journals of the crankshaft which have thefollowing undersize dimensions:

0.25 mm (.010 inch)

0.51 mm (.020 inch)

0.76 mm (.030 inch)

Shell thickness ... 1.835 to 1.842 mm (.0723 to .0726 inch)

Width of connecting rod bearing ... 31.62 to 31.88 mm (1.245 to 1.255 inch)

Bearing clearance ... 0.035 to 0.081 mm (.0014 to .0032 inch)


(6) Connecting rod cap with nuts and bolts

Tighten the nuts for the connecting rod to the following torque: ... 125 Nm (92 lb ft)

Connecting rod cap with bolts only

Tighten the bolts for the connecting rod to the following torque: ... 155 Nm (114 lb ft)

Turbocharged Engines



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(2) Outside diameter of bearing for piston pin ... 42.160 to 42.190 mm (1.6600 to1.6613 inch)




(4) Bearings are available for remachined journals of the crankshaft which have thefollowing undersize dimensions:

0.25 mm (.010 inch)

0.51 mm (.020 inch)

0.76 mm (.030 inch)









Note: If piston cooling jets are installed, the piston and the connecting rod assemblymust be turned when the piston and rod assembly are installed. Turning the piston andconnecting 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 theconnecting rod until the arrow or "Front" mark on the top of the piston is toward thefront of the engine.


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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The piston height is controlled by the length of the connecting rod. Connecting rods aresupplied in six grades of length. The different grades of length are manufactured bymachining the hole in the piston pin bearing in an off-center position. The differentgrades of length are created by the following method:

Machining the center of the hole in the piston pin Machining the center of the hole in the bearing

If the connecting rod is replaced, ensure that the same grade of length as the originalconnecting rod is used.

However, if the crankshaft or the cylinder block is replaced, the required grade of lengthof the connecting rods may change.

A correct grade of length of a connecting rod can be ordered for replacement. Theconnecting rod includes the piston pin bearing. The piston pin bearing is machined inorder to create the correct grade of length. The piston pin is installed in the connectingrod 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 theconnecting rod. Refer to Table 2 for the different lengths of connecting rods.

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Table 1

Grade of Length Color Length of the Connecting Rod

"F" Red165.728 to 165.761 mm (6.5247 to 6.5265 inch)

"G" Orange165.682 to 165.715 mm (6.5229 to 6.5247 inch)

"H" White165.637 to 165.670 mm (6.5211 to 6.5229 inch)

"J" Green165.591 to 165.624 mm (6.5193 to 6.5211 inch)

"K" Purple165.545 to 165.578 mm (6.5175 to 6.5193 inch)

"L" Blue165.499 to 165.532 mm (6.5157 to 6.5175 inch)

If a piston pin bearing requires replacement but the connecting rod does not requirereplacement, 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 tocreate a connecting rod assembly that is the correct grade of length.

Refer to the Testing and Adjusting manual for the following procedures:

Determine the length of the connecting rod. Determine the distortion of a connecting rod. Replace the piston pin bearing.


Serrated Connecting Rods and Flat Connecting Rods

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Connecting Rod And Bearings


(2) Outside diameter of bearing for piston pin ... 43.11 to 43.15 mm (1.697 to 1.699inch)




(4) Bearing for connecting rod journal



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Note: If piston cooling jets are installed, the piston and the connecting rod assemblymust be turned when the piston and rod assembly are installed. Turning the piston andconnecting 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 theconnecting rod until the arrow or "Front" mark on top of the piston is toward the frontof the engine.

Hydraulically Fractured Connecting Rods

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Note: The caps and rods must stay together as a pair.

Note: When the connecting rods are replaced, do not reuse the connecting rod bolts. New connecting rod bolts must be used.

The mating surfaces of the connecting rod are produced by hydraulically fracturing the

forged connecting rod.

(7) Tighten the connecting rod bolts to the following torque. ... 18 Nm (13 lb ft)

Tighten the connecting rod bolts again to the following torque. ... 70 Nm (52 lb ft)

Tighten the connecting rod bolt for an additional 120 degrees.

(8) Connecting rod bearing


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(9) Diameter of the bore for the piston pin ... 43.01 to 43.04 mm (1.693 to 1.694 inch)

(10) Distance between bearing centers ... 219.05 to 219.10 mm (8.624 to 8.626 inch)

(11) D Piston and Rings

SMCS - 1214; 1215


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Piston and rings

Note: The word "Front" or an arrow which is marked on the piston crown must betoward the front of the engine. If the piston crown is not marked, put the narrowest sideof the piston crater toward the side of the engine with the fuel injection pump. Theshortest distance between the edge of the piston crater and the edge of the piston is thenarrowest side of the piston crater.


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Note: Be sure that the ring end gaps of all the piston rings have 120 degrees spacingfrom each other.

Note: Refer to Systems Operation, "General Information" for the location of the serialnumber.

Naturally Aspirated Engines

(1) Width of groove in piston for top ring ... 2.57 to 2.59 mm (.101 to .102 inch)

Thickness of top ring ... 2.48 to 2.49 mm (.097 to .098 inch)

Clearance between groove and piston ring ... 0.08 to 0.11 mm (.003 to .004 inch)

Clearance between the ends of the top ring with a cylinder liner without any wear ...0.40 to 0.85 mm (.016 to .033 inch)

(2) Width of groove in piston for intermediate ring ... 2.55 to 2.57 mm (.100 to .101inch)

Thickness of intermediate ring ... 2.48 to 2.49 mm (.097 to .098 inch)

Clearance between groove and intermediate ring ... 0.06 to 0.09 mm (.002 to .003 inch)

Clearance between the ends of the intermediate ring with a cylinder liner without anywear ... 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 .1598inch)

Thickness of oil control ring ... 3.980 to 3.990 mm (.1566 to .1571 inch)

Clearance between groove and oil control ring ... 0.04 to 0.08 mm (.002 to .003 inch)

Clearance between the ends of oil control ring with a cylinder liner without any wear ...0.38 to 0.84 mm (.015 to .033 inch)

(4) Diameter of new piston pin ... 34.920 to 34.925 mm (1.3748 to 1.3750 inch)

Bore for piston pin ... 34.928 to 34.934 mm (1.3751 to 1.3754 inch)


(1) Shape of groove in piston for top ring ... Taper

Shape of top ring ... Taper

Clearance between the ends of top ring in a cylinder liner without any wear ... 0.35 to0.75 mm (.014 to .030 inch)


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(2) Width of groove in piston for intermediate ring ... 2.56 to 2.58 mm (.101 to .102inch)

Thickness of intermediate ring ... 2.48 to 2.49 mm (.097 to .098 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 .1598inch)



Clearance between the ends of an oil control ring in a cylinder liner without any wear ...0.38 to 0.84 mm (.015 to .033 inch)



Piston Height

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Quadram piston

There are two different designs for the crown of the piston. One design is the Quadram piston. There is only one grade of piston for the replacement of a Quadram piston.

Grade of piston for service ... L

Height of a Quadram piston above the top face of the cylinder block ... 0.14 to 0.36 mm(0.005 to 0.014 inch)

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Fastram piston

The other style of piston is the Fastram piston. The piston height above the top face ofthe cylinder block is controlled by different grades of height of the piston. Identificationof the height grade is by the letter that is stamped on the top of each piston. The heightgrade can be checked by measuring from the center of the piston pin to the top of the

piston. The difference between each grade of height is 0.045 mm (0.0018 inch). Table 1 provides the specifications for the grade of height for a Fastram piston.

Table 1

Height Grades for the Piston


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Letter on top of Piston Height Dimension Latest Equivalent Grade

A (1) 70.334 mm (2.7690 inch)

G

B (1) 70.289 mm (2.7673 inch)

H

C (1) 70.244 mm (2.7655 inch)

J

D (1) 70.199 mm (2.7637 inch)

K

E (1) 70.154 mm (2.7620 inch)

L

F70.391 mm (2.7713 inch)

-

G70.345 mm (2.7695 inch)

-

H70.299 mm (2.7677 inch)

-

J70.253 mm (2.7659 inch)

-

K 70.207 mm (2.7640 inch) -

L70.161 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)


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Note: The word "Front" or an arrow which is marked on the piston crown must betoward the front of the engine. If the piston crown is not marked, put the narrowest sideof the piston crater toward the side of the engine with the fuel injection pump. Theshortest distance between the edge of the piston crater and the edge of the piston is thenarrowest side of the piston crater.

Note: Be sure that the ring end gaps of all the piston rings have 120 degrees spacingfrom each other.


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Note: Refer to Systems Operation, "General Information" for the location of the serialnumber.


(1) Top piston ring

Shape of groove in piston for top ring ... Taper

Shape of top ring ... Taper

Clearance between the ends of the top ring in a cylinder liner without any wear ... 0.28

to 0.63 mm (.011 to .025 inch)

Note: Install the word "TOP" toward the top of the piston. New top rings have a redidentification mark which must be on the left of the ring gap when the intermediate ringis installed on an upright piston.

(2) Intermediate ring

Width of groove in piston for intermediate ring ... 2.56 to 2.58 mm (0.101 to 0.102

inch)

Thickness of intermediate ring ... 2.48 to 2.49 mm (0.097 to 0.098 inch)

Clearance between 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 havea green identification mark which must be on the left of the ring gap when theintermediate ring is installed on an upright piston.

(3) Oil control ring

Width of groove in piston for oil control ring ... 3.54 to 3.56 mm (.139 to .140 inch)



Clearance between the ends of an oil control ring in a cylinder liner without any wear

... 0.38 to 0.83 mm (.015 to .033 inch)

Note: A pin is used in order to hold both ends of the spring of the oil control ring in position. The ends of the spring of the oil control ring must be 180 degrees opposite the

end gap of the oil control ring.


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Piston height above cylinder block (not shown) ... 0.36 to 0.50 mm ( .014 to .020 inch)1 1 0

iameter for the bore for the connecting rod bearing ... 67.21 to 67.22 mm (2.6460 to2.6465 inch)

Housing (Front)

SMCS - 1151


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Front housing and front cover

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9U-6200 Front Cover Installer

(1) Front cover

The front cover must be centered on the front of the engine before the bolts aretightened. Use a 9U-6200 Front Cover Installer to center the front cover before the boltsare tightened.

(2) Front housing

Tighten the M8 bolts (not shown) that fasten the front housing to the cylinder block to the following torque: ... 22 Nm (16 lb ft)Tighten the M10 bolts (not shown) that fasten the front housing to the cylinder

block to the following torque: ... 44 Nm (33 lb ft)

(3) Bolts

After the front cover is centered on the front of the engine, tighten the bolts and

the two nuts that fasten the front cover to the front housing. Tighten the boltsand the nuts to the following torque: ... 22 Nm (16 lb ft)

(4) 9U-6200 Front Cover Installer

The front cover installer is used to center the front cover on the front of the engine.Refer to the Disassembly and Assembly Module, "Front Cover - Install" topic for

additional information.1 1 0

Gear Group (Front)


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SMCS - 1206


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(1) Fuel injection pump gear

Bore ... 36.00 to 36.06 mm

(1.417 to 1.420 inch)Tighten the four bolts to the following torque. ... 28 Nm (21 lb ft)Tighten the two torx screws to the following torque. ... 9 Nm (7 lb ft)

Note: The torx screws retain the timing plate on the front of the gear. This plate isinstalled in the factory after the fuel injection pump timing has been accurately set to thetop center position on the compression stroke of the No. 1 cylinder. If the timing plate ismoved, 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.


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Note: Do not remove the nut that retains the hub of the fuel injection pump to the shaftof the fuel injection pump. If the hub is removed, the hub must be positioned bycorrectly trained personnel and special test equipment.

(2) Camshaft gear

Diameter of the camshaft gear bore ... 34.930 to 34.950 mm (1.3752 to 1.3760inch)Outside diameter of camshaft hub ... 34.900 to 34.920 mm (1.3741 to 1.3747inch)Clearance between the camshaft gear and the camshaft hub ... 0.008 to 0.048mm (0.0003 to 0.0019 inch)

(3) Tighten the bolt for the camshaft gear to the following torque. ... 95 Nm(70.0682 lb ft)

(4) Idler gear and hub

Diameter of the idler gear bore ... 57.14 to 57.18 mm(2.250 to 2.251 inch)Width of the idler gear and split bearing ass

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Motor Caterpillar 3054