renr9337-00 specification manual

7/29/2019 RENR9337-00 Specification Manual

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RENR9337

July 2006

SpecificationsPreliminary Information

C175-16 Generator Set Engine

WYB1-Up (Generator Set)


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i01658146

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not 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 asDANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

Operations that may cause product damage are identified by NOTICE labels on the product and inthis publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The 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 Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.


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RENR9337 3Table of Contents

Table of Contents

Specifications Section

Engine Design ....................................................... 4Fuel Filter (Primary) ................................................ 4Fuel Filter (Secondary) ........................................... 5Fuel Transfer Pump ............................................... 5Fuel Injector ............................................................ 6Fuel Lines ............................................................... 7Fuel Lines ............................................................... 8Camshaft .............................................................. 11Lifter Group ........................................................... 12Valve Mechanism ................................................. 13Cylinder Head ...................................................... 13Cylinder Head Valves ........................................... 15Turbocharger ....................................................... 16

Air Lines ................................................................ 17Exhaust Manifold ................................................. 17

Exhaust Manifold ................................................. 18Exhaust Fitting ...................................................... 18Exhaust Fitting ...................................................... 19

Air Cleaner ........................................................... 19Engine Oil Pump .................................................. 19Pressure Control Valve (Oil Regulator Valve and Oil

Bypass Valve) ..................................................... 20Engine Oil Pan ..................................................... 21Water Pump ......................................................... 21

Auxiliary Water Pump .......................................... 23Cylinder Block ...................................................... 24Cylinder Liner ....................................................... 27Piston and Rings .................................................. 28Connecting Rod ................................................... 30

Connecting Rod and Main Bearing Journals ........ 31Crankshaft ........................................................... 32Crankshaft Wear Sleeves and Seals ................... 33Gear Group (Front) ............................................... 35Gear Group (Front) ............................................... 37Gear Group (Rear) ................................................ 38Fan Drive ............................................................. 39Flywheel ............................................................... 40Flywheel Housing ................................................ 40Vibration Damper ................................................. 41Fastener Group (Vibration Damper) ..................... 42Fastener Group (Vibration Damper) ..................... 42Belt Tension Chart ............................................... 42Belt Tensioner ....................................................... 44

Alternator and Regulator ...................................... 44Electric Starting Motor ......................................... 45Engine Harness .................................................... 46Engine Speed Sensor ........................................... 47Engine Speed Sensor ........................................... 47Pressure Sensor ................................................... 47Pressure Sensor ................................................... 48Temperature Sensor ............................................. 48Temperature Sensor ............................................. 48

Index Section

Index ..................................................................... 50


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4 RENR9337Specifications Section

Specifications Section

i02524923

Engine Design

SMCS Code: 1000

g01262912Illustration 1

Cylinder and valve location

(A) Inlet valves(B) Exhaust valves

Number and arrangement ofcylinders ............................................ 60 degree V-16

Valves per cylinder .................................................. 4

Displacement ................................. 85 L (5187 cu in)

Bore ............................................. 175 mm (6.7 inch)

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

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

Combustion ........................................ Direct injection

When the crankshaft is viewed from the flywheelend the crankshaft rotates in the followingdirection. ....................................... Counterclockwise

Firing order (injection sequence)

Standard rotationCCW .. 1, 2, 5, 6, 3, 4, 9, 10, 15,16, 11, 12, 13, 14,7, 8

Note: The front end of the engine is opposite theflywheel end of the engine. The left and the right sideof the engine are determined from the flywheel end.The number 1 cylinder is the front cylinder on theright side. The number 2 cylinder is the front cylinderon the left side.

i02525081

Fuel Filter (Primary)

SMCS Code: 1260

Part No.: 247-2696


(1) O-ring

Lubricate the O-ring with clean diesel fuel prior toinstallation.

(2) Element

(3) Filter housing

Do not use an air wrench.

Torque ............................ 55 5 Nm (41 4 lb ft)


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RENR9337 5Specifications Section

i02525340

Fuel Filter (Secondary)

SMCS Code: 1261

Part No.: 249-2345


(1) O-ring

Lubricate the O-ring with clean diesel fuel prior toinstallation.

(2) Element

(3) Filter housing

Do not use an air wrench.

Torque ............................ 55 5 Nm (41 4 lb ft)

i02525379

Fuel Transfer Pump

SMCS Code: 1256

Part No.: 286-4580


(1) Inlet port

(2) Outlet port

(3) Priming port

Minimum requirements

Volume per minute at 650 kPa (94 psi) and 2860RPM .......................................... 36 L (10 US gal)Volume per minute at 650 kPa (94 psi) and 2412RPM ............................................ 34 L (9 US gal)Volume per minute at 650 kPa (94 psi) and 1740RPM ............................................ 21 L (6 US gal)Volume per minute at 450 kPa (65 psi) and 108RPM .................................... 0.6 L (0.159 US gal)The setting for the cracking pressure for thebypass valve is the following value: ....... 793 kPa

(115 psi)

The setting for the full open pressure for thebypass valve is the following value: ....... 862 kPa(125 psi)


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i02525593

Fuel Injector

SMCS Code: 1290

Part No.: 239-6105


(1) Stud

Torque .......................... 60 12 Nm (44 9 lb ft)

(2) Nut

(3) Fuel injector

(4) Fuel injector tip ........................ Protect the spraytip from debris and from damage.

(A) Bolts

(B) Bolts

Fuel injector removal

1. Loosen bolts (A) from the fuel line to the cylinderhead.

2. Loosen bolts (B) from the fuel line to the fuelsupply rail.

3. Ensure that bolts (A) and bolts (B) are completelyloose.

4. Retract the fuel line from cylinder headapproximately 8 mm (0.315 inch).

5. Remove the hold-down nut (2) for the fuel injector.

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

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

Fuel injector installation

1. For lubrication of the O-ring seals, lightly coat1P-0808 Multipurpose Grease in the bore of thecylinder head.

2. Seat the fuel injector and tighten the hold downclamp nut (2).

3. Tighten bolts (A) and bolts (B) hand tight.

4. Tighten hold down clamp nut (2).

Torque .......................................... 5 Nm (44 lb in)

5. Evenly tighten bolts (A) from the fuel line to the

cylinder head.

Torque ........................................ 20 Nm (15 lb ft)

6. Evenly tighten bolts (B) from fuel line to the fuelsupply rail.

Torque ........................................ 20 Nm (15 lb ft)

7. Tighten clamp nut (4) for the fuel injector.

Torque ........................... 100 2 Nm (74 1 lb ft)

8. Again, evenly tighten bolts (A) and bolts (B) in

pairs.

Torque ........................................ 40 Nm (30 lb ft)


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i02564673

Fuel Lines

SMCS Code: 1274

Part No.: 284-8351


(1) O-ring seal

Lubricate the bore for the O-ring seal lightly with5P-3975 Rubber Lubricant.

(2) Connector

Torque ............................ 40 4 Nm (30 3 lb ft)

(3) Tube


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i02564838

Fuel Lines

SMCS Code: 1274

Part No.: 286-4595



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Figure A


Figure B


Figure C

Note: Ensure that all parts are extremely clean. Allof the parts must not be contaminated with any dirtor debris.

Reference: Reuse and Salvage Guidelines,SEBF9109, Cleaning and Handling Procedures forthe Common Rail Fuel System Components

Procedure for the installation of the rails and the quilltubes

1. Tighten the bolts that hold rail (1) and rail (7) tothe 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 boltsthat attach quill tubes (5) to the rails. If the boltsare already installed, remove the bolts that attachthe quill tubes to the cylinder head.

3. Apply clean engine oil to joint (13) at the collar toquill tube. Refer to Illustration 8. Slide the collaraway from the cylinder head and the rail prior todisassembly.

4. Apply clean engine oil to O-rings (14). Refer toIllustration 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 tubesinto the cylinder head and the rail.

6. Evenly hand tighten the bolts into the cylinder

head.


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7. Evenly hand tighten the bolts into the rail.

8. Evenly tighten the bolts into the cylinder head.

Torque ........................................ 20 Nm (15 lb ft)

9. Evenly tighten the bolts into the rail.

Torque ........................................ 20 Nm (15 lb ft)

10. Evenly tighten the bolts into the cylinder head.

Torque ........................................ 40 Nm (30 lb ft)

11. Evenly tighten the bolts into the rail.

Torque ........................................ 40 Nm (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 Illustration9. 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 thewashers and the bolts.

Torque ........................................ 10 Nm (89 lb in)

4. Lubricate the O-ring that seals the collar of theline (10) with clean engine oil. Lubricate the end of

line (10) with 10 cu in in cm (0.61 cu in) 6V-4876Lubricant prior to assembly. Refer to Illustration 9.

5. On the engine, insert line (10) into rail (1).

6. Evenly hand tighten line (10) to rail (1) with thewashers and the bolts.

7. Evenly hand tighten block (6) to the pump adapter.

8. Evenly tighten line (10) to rail (1).

Torque ........................................ 20 Nm (15 lb ft)

9. Evenly tighten block (6) to the pump adapter.

Torque ........................................ 20 Nm (15 lb ft)


Torque ........................................ 40 Nm (30 lb ft)

11. Evenly tighten block (6) to the pump adapter.

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

12. Install adjustable bracket (11) and tightenadjustable bracket (11) by using the adjustablebrackets mounting hardware.

13. Lubricate the O-ring that seals the collar of theline (9) with clean engine oil. Refer to Illustration9. 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 thewashers and the bolts.

15. Evenly hand tighten line (9) to block (6) with thewashers and the bolts.

16. Evenly tighten line (9) to the pump.

Torque ........................................ 20 Nm (15 lb ft)

17. Evenly tighten line (9) to block (6).

Torque ........................................ 20 Nm (15 lb ft)

18. Evenly tighten line (9) to the pump.

Torque ........................................ 40 Nm (30 lb ft)

19. Evenly tighten line (9) to block (6) to the pumpadapter.


20. Lubricate the O-ring that seals the collar of theline (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.

21. Insert line (4) into rail (1) and into rail (7).

22. Evenly hand tighten line (4) to rail (1).

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

24. Install the low pressure fuel line and the mountinghardware for the low pressure fuel line thatconnects to rail (1) and to rail (7).

25. Evenly hand tighten clamps (3) and hardware toline (4).

26. Evenly hand tighten clamps (2) and hardware toline (4).


Torque ........................................ 20 Nm (15 lb ft)



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Torque ........................................ 20 Nm (15 lb ft)

29. Evenly tighten clamps (3) and hardware to line(4).

Torque ........................................ 20 Nm (15 lb ft)


Torque ........................................ 20 Nm (15 lb ft)


Torque ........................................ 40 Nm (30 lb ft)


Torque ........................................ 40 Nm (30 lb ft)

33. Evenly tighten clamps (3) and hardware to line

(4).




i02527814

Camshaft

SMCS Code: 1210Part No.: 274-7725



(1) Front camshaft

(2) Inlet lobe (odd numbers cylinders)

(3) Exhaust lobe (odd numbers cylinders)

(4) Exhaust lobe (even numbers cylinders)

(5) Inlet lobe (even numbers cylinders)

(6) Journal surface

Diameter of surface (journals) for new camshaftbearings .. 91.88 0.02 mm (3.617 0.001 inch)Bore in bearings for camshafts afterassembly ............................. 92.152 0.015 mm

(3.628 0.0006 inch)

(7) Rear camshaft

(8) Thrust washer

Thickness of a new thrustwasher ...... 8.50 0.05 mm (0.335 0.002 inch)Thickness of the groove in a newcamshaft ... 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 ofthe front camshaft by the followingdistance: .... 11.5 0.5 mm (0.453 0.0197 inch)

(10) Studs

Torque ............................ 35 5 Nm (26 4 lb ft)


(12) Camshaft lobe height


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In order to determine the height, use the followingprocedure:

1. Measure camshaft lobe height (12).

2. Measure base circle (13).

3. Subtract the base circle (Step 2) from the lobeheight (Step 1). The difference is the actual lobelift.

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.: 283-9354


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

(1) Bolt

Torque .......................... 55 10 Nm (41 7 lb ft)


(4) Bolts

(4) Bolt

Torque .......................... 55 10 Nm (41 7 lb ft)


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

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


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i02530414

Valve Mechanism

SMCS Code: 1102

Part No.: 273-1225


(1) Bolt

Torque .................... 240 40 Nm (177 30 lb ft)

(2) Locknut

Torque ...................... 120 15 Nm (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 therocker arm the bearing must be machined tosize. .. 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)

i02531323

Cylinder Head

SMCS Code: 1100

Part No.: 273-1221


Use the following procedure to tighten cylinder headbolts (1).

1. Coat the threads of the cylinder head bolts withclean engine oil.

2. Tighten bolts A through F in the lettered sequencethat is pictured in Illustration 18.

Torque ............................. 30 5 Nm (22 4 lb ft)

3. Tighten bolts A through F again in the lettered

sequence.

Torque ..................... 190 15 Nm (140 11 lb ft)

4. Tighten bolts A through F again in the letteredsequence.

Torque ..................... 190 15 Nm (140 11 lb ft)

5. Tighten bolts A through F again to the followingrotation.

Rotation for bolts ........................ 180 5 degrees


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(2) Injector sleeve

Apply 6V-6640 Sealant to the outside of injectorsleeve (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 toassembly.

Two plugs are installed in the top of the cylinderhead 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 toassembly.

Two plugs are installed in the top of the cylinderhead to the following depth: ................ 0.750 mm

(0.0295 inch)

(6) Height ofnew cylinder head ............. 208.00 mm(8.1890 inch)


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i02532590

Cylinder Head Valves

SMCS Code: 1105

Part No.: 273-1221, 274-7704, 283-1684,283-1686


(1) Valve stem diameter and valve guide bore

Diameter of the new valve stems in the area ofthe valve guide ...................... 12.573 0.01 mm

(0.4950 0.0004 inch)

When the valve guides are installed in thecylinder head the bore in the valve guides is thefollowing value: .................... 12.626 0.020 mm

(0.4971 0.0008 inch)When the valve guides are installed in thecylinder head the maximum bore that can beused again in the valve guides is the followingvalue: ............................ 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 valveguides ... 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 degreesExhaust ............................. 45.60 0.25 degrees


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(7) Depth of bore in head for valve seatinserts ..... 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 degreesExhaust .................................. 45 0.25 degrees

(10) Outside diameter of the face of the valve seatinserts ... 55.0 0.25 mm (2.1654 0.0098 inch)

i02535620

Turbocharger

SMCS Code: 1052

Part No.: 254-6777, 263-1454


(1) V-band clamp

1. Tighten the V-band clamp.

Torque ........................................ 20 Nm (15 lb ft)

2. Loosen the V-band clamp by 2 to 3 turns.

3. Tighten the V-band clamp again.

Torque ............................. 19 1 Nm (14 1 lb ft)

(2) Bolts

Torque ............................ 40 3 Nm (29 2 lb ft)


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i02564541

Air Lines

SMCS Code: 1058; 1071

Part No.: 283-9364


(1) Clamps

Lubricate the nut face and threads 5P-3931Anti-Seize Compound before assembly.

Torque .............................. 12 2 Nm (9 1 lb ft)

(2) O-ring

Lubricate the bore lightly with 5P-3975 RubberLubricant.


(3) Bolts

Torque ...................... 100 20 Nm (74 15 lb ft)

i02536571

Exhaust Manifold

SMCS Code: 1059

Part No.: 243-2972, 253-7723, 282-8533


(1) V-band clamps

Torque .............................. 12 2 Nm (9 1 lb ft)

(2) Washers

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

(3) Bolts

Lubricate the bolts with 5P-3931 Anti-SeizeCompound before assembly.

Torque ............................ 65 5 Nm (49 4 lb ft)


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i02536701

Exhaust Manifold

SMCS Code: 1059

Part No.: 254-2062, 254-2063, 282-8534


(1) V-band clamps

Torque .............................. 12 2 Nm (9 1 lb ft)

(2) Washers

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

(3) Bolts

Lubricate the bolts with 5P-3931 Anti-SeizeCompound before assembly.

Torque ............................ 65 5 Nm (49 4 lb ft)

i02536935

Exhaust Fitting

SMCS Code: 1061-X6

Part No.: 269-2551


(1) V-band clamp

1. Tighten all the V-band clamps.

Torque ................................. 8.5 1 Nm (6 1 ft)

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

3. Tighten all the V-band clamps again.

Torque ................................. 8.5 1 Nm (6 1 ft)


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i02536750

Exhaust Fitting

SMCS Code: 1061-X6

Part No.: 245-4875


(1) V-band clamp

1. Tighten all the V-band clamps.

Torque ............................... 12 2 Nm (9 1 lb ft)

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

3. Tighten all the V-band clamps again.

Torque ............................... 12 2 Nm (9 1 lb ft)

i02537004

Air Cleaner

SMCS Code: 1051

Part No.: 276-5929


(1) Clamp

Torque .......................... 4 0.6 Nm (35 5 lb in)

i02537201

Engine Oil Pump

SMCS Code: 1304

Part No.: 255-4846



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(1) Distance from the end of the drive shaft to gearface ......... 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 bythe following distance. ................... 8.0 0.5 mm

(0.3150 0.0197 inch)

(4) The bearings are installed in the cover at thefollowing 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 afterassembly ............................ 55.655 mm (2.1911 inch)

(6) The bearings are installed in the housing at thefollowing depth. .. 1.5 0.5 mm (0.06 0.02 inch)

(7) Distance from the end of the idler shafts to gearfaces ....... 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 centerlinethrough the bearing bores to the followingangle. ................................................ 30 degrees

Bench test specifications

Unrestricted flow rate per minute at 2394rpm ..................................... 1296 L (342 US gal)

Note: Before you install the pump, lubricate themoving parts with engine oil. Rotate the pump byhand in order to ensure that the pump rotates freely.

i02538181

Pressure Control Valve(Oil Regulator Valve and OilBypass Valve)

SMCS Code: 1315; 1319-VL

Part No.: 274-2148


(1) Shim

Thickness ......................... 1.0 mm (0.0394 inch)

Used with the 288-4597 Spring

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


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Used with the 285-6589 Spring

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

(2) 288-4597 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)

(3) 285-6589 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


(1) O-ring

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

i02544912

Water Pump

SMCS Code: 1361

Part No.: 248-4129




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View A-A

(1) O-ring seal

Lubricate the bore for the O-ring seal with cleanengine oil prior to assembly.

(2) Stud

Torque ............................ 35 5 Nm (26 4 lb ft)

(3) Shaft

Shafts outer diameter forimpeller ... 25.4 0.01 mm (1.000 0.0004 inch)

(4) Retainer

(5) Bearing assembly

(6) Oil seal

(7) Locknut

Torque .................... 300 30 Nm (221 22 lb ft)

(8) O-ring seal

Lubricate the O-ring with 1U-6396 O-Ring AssemblyCompound prior to assembly.

(9) Seal assembly

(10) Impeller

Diameter of impellers bore .... 25.35 0.012 mm(0.9980 0.0005 inch)

(11) Setscrew

Torque .... 4 1.25 Nm (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 thereplacement seal assembly. Install the oil seal withintwo minutes of the removal from the tube for shipping.

3. Install oil seal (7) into the pump housing. Install theoil seal dry. Do not lubricate the sealing lip. Usethe correct installation tool and use a slow, evenmotion to press the seal into the pump housing.

4. Install shaft (3) through the oil seal.

5. Install retainer plate (4).

6. Tighten setscrews (11) according to the specifiedtorque.

7. Install seal assembly (9). Use the seal installationtool and hand pressure to install the seal assemblyonto the shaft.

8. Lubricate the shaft with clean engine oil. Place theshaft onto a fixture that will absorb the load andpress impeller (10) onto the shaft until the face ofthe 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 at138 kPa (20 psi) of air pressure ..... 24 cc (1.46 cu in)


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i02547236

Auxiliary Water Pump

SMCS Code: 1371

Part No.: 250-6720



Area B

(1) Stud

Torque ............................ 35 5 Nm (26 4 lb ft)

(2) O-ring seal

(3) Impeller

Diameter of impellers bore .. 25.342 0.013 mm(0.9977 0.0005 inch)

(4) Shaft

Shafts outer diameter forimpeller ................................ 25.400 0.013 mm

(1.0000 0.0005 inch)Width of shafts groove for thrustwasher ...... 8.75 0.05 mm (0.345 0.002 inch)

(5) Stud

Torque ............................ 35 5 Nm (26 4 lb ft)

(6) Nut

Torque ............................ 27 4 Nm (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


24/52


(10) Ring assembly

(11) Ceramic ring and rubber seal

(12) Seal assembly

(13) Spring

Follow this procedure for assembly:

Note: The seal installation tool is part of thereplacement seal assembly.

1. Install ring assembly (10) and oil seal (9) intothe pump housing. Install the oil seal dry. Donot lubricate the sealing lip. Use the correctinstallation tool and use a slow, even motion topress the seal into the pump housing.

2. Install shaft (4) through the oil seal and throughthe ring assembly.

3. Install thrust washer (7).

4. Lubricate the outside diameter of the ceramicring and rubber seal (11) with clean water or with207-1600 Rubber Lubricant.

5. Orient the polished face of the ceramic ring towardseal assembly (12). Use the installation tool andhand pressure to seat the ceramic ring and therubber 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 RubberLubricant.

7. Use the seal installation tool and hand pressureto install the seal assembly onto the shaft until theface of the seal assembly makes light contact withthe face of the ceramic ring and rubber seal.

8. Install the spring onto the seal assembly.

9. Lubricate the shaft with clean engine oil. Place theshaft onto a fixture that will absorb the load andpress impeller (3) onto the shaft until the face ofthe impeller is flush with the face of the shaft.

10. Lubricate the bore for O-ring seal (2) with cleanengine oil.

11. Lubricate the bore for O-ring seal (8) with cleanengine coolant.

12. Tighten studs (5) according to the specifiedtorque.

13. Tighten nuts (6) according to the specified torque.

Maximum leakage per minute for the water seal at138 kPa (20 psi) of air pressure ..... 20 cc (1.22 cu in)

Maximum leakage per minute for the oil seal at138 kPa (20 psi) of air pressure ..... 24 cc (1.46 cu in)

i02550794

Cylinder Block

SMCS Code: 1201

Part No.: 283-9344


Pictorial view


25/52



Front view


Right side view


Rear view


Front view


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Right side view

(1) 248-7585 Orifice

Orifice (1) must be fully seated in the bore andflush with the head face of the cylinder block. Afteryou start the orifice into the bores, apply 4C-9507Retaining Compound to the outside diameter of theorifice. Install the outside diameter of the orificeschamfer toward the cylinder block. Orifice (1) is onlyfor the number eight cylinder (2) through the numberthree cylinder (6).

(2) Cylinder 8

(3) Cylinder 7

(4) Cylinder 4

(5) Cylinder 6

(6) Cylinder 3

(7) Cylinder 4

(8) 248-7584 Orifice

Orifice (8) must be fully seated in the bore andflush with the head face of the cylinder block. Afteryou start the orifice into the bores, apply 4C-9507Retaining Compound to the outside diameter of theorifice. Install the outside diameter of the orificeschamfer toward the cylinder block. Orifice (8) is onlyfor the number one cylinder (9) and for the numbertwo cylinder (10).

(9) Cylinder 1

(10) Cylinder 2

(11) O-ring seal

Lubricate the O-ring seal with clean engine oil priorto assembly.

(12) Dowel

The dowels extend from the face by the followingdistance: ....... 16 1 mm (0.6299 0.0394 inch)

(13) Centerline through the oil holes in the camshaftbearings

Install the camshaft bearings so the oil holes arehorizontal.

(14) O-ring seal

Lubricate the O-ring seal with clean engine oil prior

to assembly.

(15) Dowel

The dowels extend from the face by the followingdistance: ....... 19 1 mm (0.7480 0.0394 inch)

(16) Cup Plug

Apply 6v-6640 Sealant to the outside diameter ofthe cup plug prior to assembly.

(17) New dimension from centerline of crankshaftbearing bore to the top of the block ....... 650 mm

(25.5905 inch)

(18) Depth of all cup plugs from the face of the holesfor the cup plugs. ........................... 3.4 1.8 mm

(0.1339 0.0709 inch)

(19) Main bearing cap

(20) Washer

(21) Bolt

(22) Nut

(23) Stud

(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 mainbearing cap bolts:

1. Tighten studs (23) again.

Torque ....................... 100 20 Nm (74 15 lb ft)


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2. Assemble main bearing caps (19) with the partnumber toward the front of the cylinder block.

3. Lubricate the treads of studs (23) and the face ofnuts (22). Assemble and hand tighten the nuts.

4. Lubricate the threads of bolts (21) and both sides

of washers (20). Assemble and hand tighten thebolts and the washers in the side of the cylinderblock.

5. Start at the front of the engine (number one mainbearing cap). Tighten all the side bolts on the righthand side (same side as the bearing tab slots) ofthe cylinder block.

Torque ....................... 100 20 Nm (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 thegear drives on the tensioner.

8. Release the hydraulic pressure on the tensioner.

9. Repeat Step 6 through Step 8 for main bearingcaps 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 mainbearing). Tighten all the side bolts on the left handside (opposite side as the bearing tab slots) of thecylinder block.

Torque ....................... 100 20 Nm (74 15 lb ft)

12. Start at the front of the engine (number one mainbearing cap). Tighten all the side bolts on the righthand side (same side as the bearing tab slots) ofthe cylinder block.

Torque ... 530 70 Nm (390.9068 51.6292 lb ft)

13. Start at the front of the engine (number one mainbearing). Tighten all the side bolts on the left handside (opposite side as the bearing tab slots) of thecylinder block.

Torque ... 530 70 Nm (390.9068 51.6292 lb ft)

i02550061

Cylinder Liner

SMCS Code: 1216

Part No.: 286-4564



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(1) Cylinder liner

(2) 246-7264 O-Ring Seal

(3) 253-9950 O-Ring Seal

(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 thesleeve .................................. 185.45 0.025 mm

(7.3012 0.0010 inch)

(9) Inside diameter of thesleeve .................................. 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)

Cylinder Liner Installation

1. Put liquid soap on the cylinder block liner boresurface. Also, put liquid soap on the O-ring seals.

2. Install the liner in the cylinder block immediately,before the O-ring seals expand.

i02558469

Piston and Rings

SMCS Code: 1214

Part No.: 270-6823




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(1) Top ring

Install the top ring with the Up-1 side toward thetop of the piston.

When the piston ring is installed in a cylinder liner witha bore size of 175 mm (6.8898 inch), the clearancebetween the ends of the piston ring is the followingvalue. ...... 0.625 0.125 mm (0.0246 0.0049 inch)

(2) Intermediate ring

Install the intermediate ring with the Up-2 sidetoward the top of the piston.

When the piston is installed in a cylinder liner witha bore size of 175 mm (6.8898 inch), the clearancebetween the ends of the piston ring is the followingvalue. .......... 1.0 0.125 mm (0.0394 0.0049 inch)

(3) Oil control ring

Width of groove in piston for the new oil controlring ................ 4.06 0.1 mm (0.1598 0.0039 inch)

Maximum thickness of new oil controlring ...................................... 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 cylinderliner with a bore size of 175 mm (6.8898 inch), theclearance between the ends of the piston ring is thefollowing value. ................................... 0.5 to 0.8 mm

(0.0197 to 0.0315 inch)

Install the oil control ring so that the gap in the springis 180 degrees away from the gap in the ring. Thewhite portion of the spring must be visible at the ringgap.

After all of the piston rings have been installed, rotatethe rings so that the end gaps are separated by 120degrees. The ring gap for the oil ring must be alignedin 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

(7) Area A

Assemble the retainer with the opening within area A.

Refer to Table 1 for the part numbers of the tools thatare used in servicing the piston.

Table 1

Service Tools

Pt. No. Description

271-0504 Piston Ring Expander Gp

255-8897 Piston Ring Compressor Gp1P-1861 Retaining Ring Pliers


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i02557016

Connecting Rod

SMCS Code: 1218

Part No.: 293-2260



(1) Bore in bearing for new pistonpin ..... 75.04 0.008 mm (2.9543 0.0003 inch)

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

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

The rod eye bushing must be cooled for the

installation of the rod eye bushing.

Cool the rod eye bushing with the use of liquidnitrogen to the following temperature. ......... 195 C

(319 F)

After assembly, the rod eye bushing can not coverthe oil hole in the connecting rod. The oil hole mustbe completely open.

The ends of the rod eye bushing must not extendmore than the connecting rod by the followingvalue: .................................... 0.25 mm (0.0098 inch)

(2) Distance between center of bearings .... 420 mm(16.5354 inch)

(3) Bore in bearing forcrankshaft .......................... 150.197 0.016 mm

(5.9133 0.0006 inch)

(4) After the bolts are tightened, the bore in theconnecting rod for the bearing is the followingdimension. ................................ 157 0.013 mm

(6.1811 0.0005 inch)

(5) Spacer

(6) Bolt

Clearance between bearing and newcrankshaft ................................... 0.181 to 0.213 mm

(0.0071 to 0.0084 inch)

The side clearance between two connecting rodson the same new crankshaft pin is the followingvalue. ...... 0.850 0.332 mm (0.0335 0.0131 inch)

The word FRONT on the shank of the connectingrod must face the front of the engine in the cylinderbank with an odd number in a standard rotationengine.

The word FRONT on the shank of the connectingrod must face the rear of the engine in the cylinderbank with an odd number in a reverse rotation engine.


31/52


Careful handling of the connecting rod is requiredat all times. The fracture face of the connecting rodand the fracture face of the connecting rod cap mustnot make contact with any surface. The connectingrod and the connecting rod cap must be laid flat onthe sides. When possible, the rod assembly shouldbe kept together in order to protect the fracture face

when the connecting rod is out of the engine.

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

Procedure for TighteningConnecting Rod Bolts

1. Before assembly, put 6V-4876 Lubricant on thethreads 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 thebolts.

3. Tighten bolts A and B.

Torque ............................. 80 5 Nm (59 4 lb ft)

4. Tighten bolts C and D.

Torque ............................. 80 5 Nm (59 4 lb ft)

5. Tighten bolts E and F.

Torque ............................. 80 5 Nm (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

i02560298

Connecting Rod and MainBearing Journals

SMCS Code: 1230

Part No.: 286-5799, 286-5801

Refer to Guidelines For Reusable Parts, SEBF8009,Main Bearings And Connecting Rod Bearings formore information.

Connecting Rod Bearing Journals

Table 2

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)

Undersize Journal1.27 mm (0.050 inch)

148.73 mm (5.8555 inch)

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

Main Bearing Journals

Table 3

Diameter Of Crankshaft Journal (BearingSurface) 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 newjournal ... 0.145 to 0.262 mm (0.0057 to 0.0103 inch)


32/52


i02559833

Crankshaft

SMCS Code: 1202

Part No.: 285-3719



(1) Connecting rod journal

Refer to Specifications, Connecting Rod And MainBearing Journals.

(2) Main bearing journal

Refer to Specifications, Connecting Rod And MainBearing 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 Nm (37 5 lb ft)

Use the following procedure to tighten thecounterweight bolts:


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1. Prior to assembly, put 6V-4876 Lubricant on thebolt threads, on the shank, and on the undersideof the bolt head.

2. Tighten the bolts evenly.

Torque ..................... 220 20 Nm (162 15 lb ft)

3. Tighten each bolt again to the following rotation.

Rotation ........................................ 90 5 degrees

i02560387

Crankshaft Wear Sleeves andSeals

SMCS Code: 1160

Part No.: 248-4115



(1) 245-3574 Crankshaft Seal Gp

Install the245-3574 Crankshaft Seal Gp in the fronthousing on a standard rotation engine.

Install the 245-3574 Crankshaft Seal Gp in theflywheel housing on a reverse rotation engine.

(2) 245-3575 Crankshaft Seal Gp

Install the 245-3575 Crankshaft Seal Gp in theflywheel housing on a standard rotation engine.

Install the 245-3575 Crankshaft Seal Gp in the fronthousing on a reverse rotation engine.

(3) Flywheel housing

(4) Front housing

Make sure that the correct seal is installed on eachend 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 thefollowing 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.


34/52


2. Remove the wear sleeves with the 5P-7409Sleeve Distorter and the 6V-3143 Distorter

Adapter.

Installation

1. DO NOT separate the wear sleeves from the

crankshaft seals. Once the wear sleeves andcrankshaft seals are separated, the crankshaftseals 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 thecorrect tools.

3. Clean the outer surface of the crankshaft and theinner surface of the wear sleeve with 169-5464Quick Cure Primer (Aerosol Spray).

4. Carefully, put a thin coat of4C-9507 RetainingCompound on the inner surface of the wear sleeveand on the crankshaft surface.

5. Install the crankshaft seals and the wear sleevesas a unit. Install the unit on the end of thecrankshaft 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

258-0933 Bolt 2

9S-8858 Nut 2


35/52


i02563409

Gear Group (Front)

SMCS Code: 1206

Part No.: 250-9959


(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 thebearing 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


Bore in bearings afterassembly ............................. 75.000 0.055 mm

(2.9528 0.0022 inch)

(5) O-ring

Lubricate the bore for all O-rings with clean engineoil prior to assembly.

(6) Drive gear

(7) Bolt

Torque ...................... 120 20 Nm (89 15 lb ft)

(8) Bolt

Torque .................... 190 30 Nm (140 22 lb ft)


36/52


(9) Shaft


Note:

(10) AdapterAfter the bearing is installed in the gear thebearing must be machined to size.


(2.9528 0.0022 inch)

Maximum roughness average (Ra) for all bearingsthat are machined to size .................. 0.8 micrometer

(32 microinch)


37/52


i02564515

Gear Group (Front)

SMCS Code: 1206

Part No.: 277-6909, 282-8771


(1) Shaft


(2) Idler gear


Bore in bearings after assembly .. 90.0 0.01 mm(3.5433 0.0004 inch)

(3) Crankshaft gear

(4) Adapter



(2.9528 0.0022 inch)

(5) O-ring

Lubricate the bore for all O-rings with clean engineoil prior to assembly.

(6) Drive gear

(7) Bolt

Torque ...................... 100 20 Nm (74 15 lb ft)

(8) Bolt

Torque .................... 190 30 Nm (140 22 lb ft)


38/52


(9) Shaft


Note:

(10) AdapterAfter the bearing is installed in the gear thebearing must be machined to size.


(2.9528 0.0022 inch)

Maximum roughness average (Ra) for all bearingsthat are machined to size .................. 0.8 micrometer

(32 microinch)

i02562764

Gear Group (Rear)SMCS Code: 1206

Part No.: 254-2074


(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


The bore in the bearings after machining is thefollowing 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 inalignment with the mark on the crankshaft gear.

(5) Crankshaft gear


39/52


i02563615

Fan Drive

SMCS Code: 1359

Part No.: 259-9221


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

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

(7) Yoke adapter

1. Install yoke adapter (7) prior to installing jointgroup (5).

2. Bearing caps (4) need to be removed from yokeend (2) in order to allow the joint group to beinstalled.

3. Install the yoke end onto the pulley shaft.

4. Turn the fan in order to provide proper alignmentbetween the bearing cross and the yoke.

5. Install the bearing caps.

Tighten the bolts that support the cover for thebearing cap.

Torque ............................. 28 7 Nm (21 5 lb ft)

6. Apply 4C-9506 Retaining Compound to the setscrew (3).

7. Install the set screw.


40/52


i02550818

Flywheel

SMCS Code: 1156

Part No.: 282-8773


Refer to Testing And Adjusting, Flywheel - Inspectfor the correct method of flywheel inspection.

(1) Flywheel

(2) Gear

(3) Bolts

Use clean unused engine oil on the bolt threadsand the bolt seats before assembly.

Torque .................. 1100 60 Nm (811 44 lb ft)

i02564826

Flywheel Housing

SMCS Code: 1157

Part No.: 287-7079


(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 andthe rear face of the cylinder block. The componentsmust be free of the following substances: oil, fuel,water, gasket adhesive, assembly compounds, andany other foreign material.

To seal the joint between the flywheel housing andthe cylinder block, apply a 6 mm (0.250 inch) of4C-5300 Gasket Sealant or185-3984 GasketSealant to the mating surface of the flywheel housing.


41/52



(X) 6V-3532 Bolts

(Y) 259-9148 Bolts

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


View A-A

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

i02550922

Vibration Damper

SMCS Code: 1205

Part No.: 283-1678


Note: Apply 9S-3263 Thread Lock Compound tothe bolt threads.

(1) Tighten the bolts to the followingtorque. ........................... 55 7 Nm (40 5 lb ft)

(2) Damper


42/52


i02550925

Fastener Group (VibrationDamper)

SMCS Code: 1205-FG

Part No.: 249-6399


(1) Damper

(2) Spacer

(3) Bolts

Torque .................... 625 50 Nm (461 37 lb ft)

i02550951

Fastener Group (VibrationDamper)

SMCS Code: 1205-FG

Part No.: 266-2193, 270-6862, 283-1676,288-9940


(1) Damper

(2) Spacer

(3) Bolts

lubricate the bolt threads, bolt head and thespacer plate with clean engine oil.

Torque .................... 700 50 Nm (516 37 lb ft)

i01617888

Belt Tension Chart

SMCS Code: 1357

Note: Do not use the belt tension charts for belts withtensioners that are spring loaded.


43/52


Table 5

Belt Tension Chart

Gauge ReadingKent-Moore Gauge

NumbersSize of

BeltWidth of Belt

Belt Tension

Initial(1)

Belt Tension

Used(2)(3)

Numberof the Old

Gauge

Number of the

New Gauge

3/8 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-33-

72CBT 3372C

11/16 17.48 mm (0.688 Inch)712 111 N(160 25 lb)

445 44 N (100 10 lb)BT-33-

72CBT 3372C

3/4 19.05 mm (0.750 Inch)712 111 N(160 25 lb)

445 44 N (100 10 lb)BT-33-

72CBT 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-33-

109BT 33109

6PK 20.94 mm (0.824 Inch)801 111 N(180 25 lb)

667 44 N (150 10 lb)BT-33-

109BT 33109

Measure the tension of the belt that is farthest from the engine.

(1) Belt tension Initial is for a new belt.(2) Belt tension Used is for a belt that has operated for 30 minutes or more of operation at the rated speed.(3) 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

Size of BeltBelt 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)

(1) Belt tension Initial is for a new belt.(2) Belt tension Used is for a belt that has operated for 30 minutes or more of operation at the rated speed.(4) If a belt falls below the Used belt tension, the belt should be tightened again to the Initial belt tension.


44/52


i02561293

Belt Tensioner

SMCS Code: 1358

Part No.: 190-0642


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

(2) Spring force at assembly 25.4 2.6 Nm(19 2 lb ft) at 30 degrees from the free arm stop

i02561119

Alternator and Regulator

SMCS Code: 1405

Part No.: 276-8899



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

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

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

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

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

The minimum full load current at 5000 rpm is thefollowing value: .......................................... 67.5 Amp

The minimum full load current at 2000 rpm is thefollowing value: ............................................. 26 Amp

Output voltage .......................................... 28 1.0 V

(1) Bolt

Torque ....................... 6.2 0.6 Nm (55 5 lb in)

(2) Shaft nut

Torque .......................... 102 7 Nm (75 5 lb ft)

(3) Positive terminal nut

Torque ....................... 6.2 0.6 Nm (55 5 lb in)

(4) R terminal ............................................ Optionalalternating current from the stator

(5) I terminal

Torque ............. 2.25 0.25 Nm (20.0 2.2 lb in)


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i02100780

Electric Starting Motor

SMCS Code: 1453

Part No.: 276-8900, 276-8901


Typical example

Rotation of the starting motor when viewed from thepinion end ................................................. Clockwise

The following performance specifications are rated atno load at 25 C (77 F):

Speed ............................................ 6950 1650 rpm

Current draw ....................................... 115 25 Amp

Voltage ............................................................... 23 V

(1) Large terminal nuts

Torque ...................... 30.5 3.5 Nm (22 3 lb ft)

(2) Solenoid

Current consumption (draw) at 20 V

Pull-in windings ........................... 49.3 3.3 AmpHold-in windings ............................ 6.8 Amp max

(B) Allowable range from the horizontal plane for theposition of the solenoid

(3) Small terminal nut (ground)

Torque ................... 2.25 0.25 Nm (20 2 lb in)

(4) Small terminal nut (switch)

Heat shrink tubes must be used to insulateterminals for the switch terminal. Do not usemolded terminals.

Torque ................... 2.25 0.25 Nm (20 2 lb in)

(5) Large terminal nut


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There can be no more than three cable or wireterminals between nuts. Only two of the cable orwire terminals can be larger than 0 AWG.

Torque ...................... 30.5 3.5 Nm (22 3 lb ft)

(6) Clearance between the pinion and the housingwith the pinion in the extended position .. 9.1 mm

(0.36 inch)

Note: Twelve point bolts are required for themounting of the starting motor.

i02580020

Engine Harness

SMCS Code: 1408

Part No.: 285-3991, 285-3993


(4) Nuts

M40

Torque ......................... 15 1 Nm (132 9 lb in)

(1) Nuts

M20

Torque ............................. 5 1 Nm (45 9 lb in)

(3) Nuts

M12

Torque ............................ 1 0.5 Nm (9 5 lb in)

(2) Nuts

M16

Torque .......................... 3 0.5 Nm (27 5 lb in)

(5) Connector

Torque ............................. 6 1 Nm (53 9 lb in)


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i02425985

Engine Speed Sensor

SMCS Code: 1907

Part No.: 191-8304, 191-8305


(1) Sensor assembly

Torque ............................ 25 5 Nm (18 4 lb ft)Clearance between the sensor and the geartooth ................ 1.0 0.4 mm (0.04 0.016 inch)

i02562514

Engine Speed Sensor

SMCS Code: 1907

Part No.: 244-5544


Note: Lubricate the O-ring with clean unused engineoil.

(1) Bolt

Torque ............................ 28 7 Nm (21 5 lb ft)(2) Clearance between the sensor and the gear

tooth ........................... 0.5 mm (0.0197 inch)

Note: The wiring harness must be tied down and

supported less than 102 mm (4 inches) from thesensor. Twisting of the wires minimizes the effect ofthe electrical noise.

i02577495

Pressure Sensor

SMCS Code: 7400-NS; 7450-NS

Part No.: 287-1866


(1) Sensor assembly

Torque .......... 45 6 Nm (33.1902 4.4254 lb ft)

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

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

Operating temperature ...................... 40 150 C( 40 270 F)

Sensed media ......................... Engine oil, and diesel


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i02562825

Pressure Sensor

SMCS Code: 7400-NS; 7450-NS

Part No.: 241-1798, 274-6721


(1) Sensor assembly

Torque ........................ 10 2 Nm (90 18 lb in)


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

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 tothe vertical position as possible. This reduces thepossibility of ice that forms on the diaphragm in thesensor.

i02562983

Temperature Sensor

SMCS Code: 7400

Part No.: 238-0112


Note: Do not connect the sensor directly to batteryvoltage.

(1) Sensor assembly

Torque ............................ 20 3 Nm (15 2 lb ft)


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

i02576336

Temperature Sensor

SMCS Code: 7400

Part No.: 247-7635


(1) Fitting


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Torque ............................ 45 5 Nm (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


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50 RENR9337Index Section

Index

A

Air Cleaner............................................................. 19Air Lines....................... .......................................... 17

Alternator and Regulator ....................................... 44Auxiliary Water Pump ............................................ 23

B

Belt Tension Chart ................................................. 42Belt Tensioner........................................................ 44

C

Camshaft ................................................................ 11Connecting Rod..................................................... 30

Procedure for Tightening Connecting RodBolts ................................................................. 31

Connecting Rod and Main Bearing Journals......... 31Crankshaft ............................................................ 32Crankshaft Wear Sleeves and Seals ..................... 33Cylinder Block........................................................ 24Cylinder Head........................................................ 13Cylinder Head Valves ............................................ 15Cylinder Liner ........................................................ 27

E

Electric Starting Motor ........................................... 45Engine Design ......................................................... 4Engine Harness ..................................................... 46Engine Oil Pan....................................................... 21Engine Oil Pump.................................................... 19Engine Speed Sensor............................................ 47Exhaust Fitting................................................. 1819Exhaust Manifold ............................................. 1718

F

Fan Drive............................................................... 39Fastener Group (Vibration Damper) ...................... 42

Flywheel ................................................................ 40Flywheel Housing .................................................. 40Fuel Filter (Primary)................................................. 4Fuel Filter (Secondary)............................................ 5Fuel Injector............................................................. 6Fuel Lines............................................................ 78Fuel Transfer Pump ................................................. 5

G

Gear Group (Front).......................................... 35, 37Gear Group (Rear) ................................................ 38

I

Important Safety Information ................................... 2

L

Lifter Group............................................................ 12

P

Piston and Rings ................................................... 28Pressure Control Valve (Oil Regulator Valve and Oil

Bypass Valve)...................................................... 20Pressure Sensor.............................................. 4748

S

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

T

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

V

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

W

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


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RENR9337 51Index Section


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renr9337-00 specification manual

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