SENR9742

February 2003

Specifications
1106E Engine
VK11-Up (Machine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read 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 warnings
are 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 as
“DANGER”, “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 pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins 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 Perkins
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Perkins dealers have the most current information available.

When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts or parts with equivalent
specifications 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 or
death.
 3
Table of Contents

Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Injection Lines .............................................. 4
Fuel Injection Pump ............................................. 4
Fuel Injection Nozzles .......................................... 5
Fuel Lines ............................................................. 6
Fuel Filter Base .................................................... 7
Fuel Priming Pump .............................................. 8
Lifter Group ........................................................... 8
Rocker Shaft ........................................................ 8
Valve Mechanism Cover ...................................... 10
Cylinder Head Valves ........................................... 10
Cylinder Head ...................................................... 13
Turbocharger ....................................................... 14
Inlet Manifold ....................................................... 14
Exhaust Manifold ................................................. 15
Camshaft ............................................................. 15
Camshaft Bearings .............................................. 16
Engine Oil Filter Base .......................................... 17
Engine Oil Filter Bypass Valve .............................. 17
Engine Oil Cooler ................................................. 17
Engine Oil Pump .................................................. 18
Engine Oil Pressure ............................................. 19
Engine Oil Bypass Valve ...................................... 19
Engine Oil Pan ..................................................... 19
Crankcase Breather ............................................. 20
Water Temperature Regulator Housing ................ 21
Water Temperature Regulator .............................. 21
Water Pump ......................................................... 21
Cylinder Block ...................................................... 21
Cylinder Liner ....................................................... 23
Crankshaft ........................................................... 23
Crankshaft Seals ................................................. 25
Vibration Damper and Pulley ............................... 26
Connecting Rod Bearing Journal ......................... 27
Main Bearing Journal ............................................ 27
Connecting Rod ................................................... 27
Piston and Rings .................................................. 28
Piston Cooling Jet ................................................. 29
Front Housing and Covers ................................... 29
Gear Group (Front) ............................................... 30
Flywheel ............................................................... 31
Flywheel Housing ................................................ 31
Engine Lifting Bracket ........................................... 31
Alternator (12 volt and 24 volt alternator) ............. 32
Starter Motor ........................................................ 33
Coolant Temperature Sensor ............................... 34
Boost Pressure Sensor ......................................... 35
Inlet Manifold Temperature Sensor ....................... 35
Speed/Timing Sensor .......................................... 36
Electronic Control Module ..................................... 36
Air Inlet Heater ...................................................... 36

Index Section
Index ..................................................................... 38
4
Specifications Section

Specifications Section The front of the engine is opposite the flywheel end
of the engine. The left side of the engine and the right
side of the engine are determined from the flywheel
i01843807 end. No. 1 cylinder is the front cylinder of the engine.
Engine Design
i01714138

Fuel Injection Lines

g00939480
Illustration 1
Cylinder and valve location
(A) Inlet valve g00885325
Illustration 2
(B) Exhaust valve
Typical example

Bore ......................................... 100 mm (3.937 inch)

(1) Tighten the union nut to the following
Stroke ........................................ 127 mm (5.00 inch) torque. ................................... 27.5 N·m (20 lb ft)

Displacement ......................................... 6 L (366 in3) (2) Tighten the union nut to the following
torque. ................................... 27.5 N·m (20 lb ft)
Cylinder arrangement ..................................... In-line
i01714139
Type of combustion ............................ Direct injection
Fuel Injection Pump
Compression ratio ......................................... 17.25:1

Number of cylinders ................................................ 6

Valves per cylinder .................................................. 2

Valve lash
Inlet valve ......................... 0.20 mm (0.008 inch)
Exhaust valve ................... 0.45 mm (0.018 inch)

Firing order ........................................ 1, 5, 3, 6, 2, 4

When the crankshaft is viewed from the front of

the engine, the crankshaft rotates in the following
direction. ................................................... Clockwise

When the camshaft is viewed from the front of g00889064

Illustration 3
the engine, the camshaft rotates in the following
direction. ................................................... Clockwise (1) Tighten the compression nut to the following
torque. ........................................ 9 N·m (80 lb in)
 5
Specifications Section

(2) Tighten the compression to the following Bench test the fuel injection nozzles at the following
torque. ........................................ 9 N·m (80 lb in) temperature. ..................... 18° to 20°C (64° to 70°F)

(3) Tighten the Cap nut to the following Refer to Testing and Adjusting, “Fuel System” for
torque. ...................................... 22 N·m (16 lb ft) additional information.

(4) Tighten the banjo bolt to the following Leakage in 10 seconds ................................. 0 drops
torque. ...................................... 25 N·m (19 lb ft)
NOTICE
Tighten the nuts (not shown) for the fuel injection Ensure that the new fuel injection nozzles have the
pump flange to the timing case to the following same identification code as the previous fuel injection
torque. ............................................. 22 N·m (16 lb ft) nozzles in the cylinder head. If the fuel injection noz-
zles have an incorrect identification code, damage to
Tighten the bolt (not shown) for the support bracket the engine may occur.
for the fuel injection pump to the cylinder block to the
following torque. .............................. 44 N·m (32 lb ft)
NOTICE
Tighten the bolt (not shown) for the mounting Do not use dirty test fluids when you test fuel injection
plate to the fuel injection pump to the following nozzles. Also, do not test fuel injection nozzles unless
torque. ............................................. 22 N·m (16 lb ft) you have the correct service tools.The use of dirty test
fluids and the use of incorrect service tools will result
i01843826
in damage to fuel injection nozzles.

Fuel Injection Nozzles

g00894396
Illustration 4

Remove the original seat washer from the threaded

hole for the fuel injection nozzle which is located in
the cylinder head. If the original seat washer is not
removed, the projection of the nozzle will be incorrect
when a new seat washer is installed. Do not reuse
seat washer (3).

Note: When the fuel injection nozzle is installed, put

a 2 mm (0.08 inch) bead of 1861117 POWERPART
Universal jointing compound on the first two threads
of the gland nut. Do not rotate the fuel injection
nozzle after installation.

(1) Gland nut .................................. 40 N·m (30 lb ft)

(2) Wire clip

(3) Seat washer

6
Specifications Section

i01855626

Fuel Lines

g00959607
Illustration 5
The low mounted system for the fuel line

(1) Tighten the compression nut to the following (6) Tighten the fuel line fitting to the following
torque. ........................................ 6 N·m (53 lb in) torque. ...................................... 23 N·m (17 lb ft)

(2) Fuel block

Tighten the bolt that fastens the fuel block to the

cylinder head to the following torque. ............ 44 N·m
(32 lb ft)

(3) Tighten the top banjo bolt to the fuel block to the
following torque. ..................... 12 N·m (106 lb in)

Tighten the bottom banjo bolt (not shown) to the fuel

block to the following torque. ............ 6 N·m (53 lb in)

(4) Tighten the compression nut to the following

torque. ........................................ 9 N·m (79 lb in)

Tighten all the other fittings on the fuel block “2” to

the following torque. ....................... 23 N·m ( 17 lb ft)

(5) Tighten the banjo bolt to the following

torque. ........................................ 12 N·m (9 lb ft)
 7
Specifications Section

g00977252
Illustration 6
The high mounted fuel system

(7) Tighten the fuel line fitting to the following (2) Sealing washers
torque. ...................................... 23 N·m (17 lb ft)
(3) Tighten the banjo bolt to the following
Note: The torque values for the high mounted fuel torque. .................................... 12 N·m (106 lb in)
system are equal to the torque values of the low
mounted system. Apply 1861108 Powerpart silicone rubber to the M16
setscrews.
i01885021
Tighten the bolts for the filter bracket (not shown) to
Fuel Filter Base the following torque:
Filter bracket to the cylinder head
M10 ........................................... 44 N·m (32 lb ft)
Filter bracket to the engine block
M16 ........................................... 44 N·m (32 lb ft)

Install new sealing washers when the banjo bolt is

removed. Do not reuse the original sealing washers.

g00888095
Illustration 7
The fuel filter

(1) Tighten the two bolts to the following

torque. ...................................... 44 N·m (32 lb ft)
8
Specifications Section

i01843933 i01714153

Fuel Priming Pump Lifter Group

g00629433
Illustration 9

(1) Diameter of the lifter body .... 18.99 to 19.01 mm

(0.7475 to 0.7485 inch)

Clearance of the lifter in the cylinder block

g00628370 bore ........... 0.04 to 0.09 mm (0.0015 to 0.0037 inch)
Illustration 8

(1) Bolt i01843982

Apply 1861108 POWERPART Silicon rubber Rocker Shaft

sealant to the first three threads of the bolts.
Tighten the 4 bolts that fasten the fuel transfer
pump to the cylinder block to the following
torque. ...................................... 22 N·m (16 lb ft)

Static pressure .......... 73 to 80 kPa (10.6 to 11.6 psi)

Test pressure ................................... 55 kPa (7.9 psi)

Refer to the Testing and Adjusting Module, “Fuel

System pressure - Test” for information on testing the
operation of the fuel priming pump.

Note: When the fuel transfer pump is installed on the

engine, ensure that the camshaft is on minimum lobe
lift and that the bolts are evenly tightened. Failure to
follow this procedure can cause the loss of maximum g00876530
Illustration 10
engine power and damage to the fuel transfer pump.
(1) Rocker arm
Diameter of the rocker arm bore for the
bushing ................................. 22.23 to 22.26 mm
(0.8750 to 0.8762 inch)

(2) Rocker arm bushing

Outside diameter of the rocker arm
bushing ................................. 22.28 to 22.31 mm
(0.8770 to 0.8785 inch)
 9
Specifications Section

Inside diameter of the rocker arm

bushing ................................. 19.06 to 19.10 mm
(0.7505 to 0.7520 inch)
Clearance between the rocker arm bushing and
the rocker shaft ......................... 0.03 to 0.09 mm
(0.001 to 0.0035 inch)
Maximum permissible clearance between
the rocker arm bushing and the rocker
shaft .................................. 0.13 mm (0.005 inch)

Note: Refer to illustration 11, in order to tighten the

nuts and the bolts in the correct sequence.

(3) Tighten the nuts and the bolts to the following

torque. ...................................... 75 N·m (55 lb ft)

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

(0.7485 to 0.7495 inch)

(5) Tighten the bolt to the following torque. ..... 4 N·m

(35 lb in)

g00954315
Illustration 11
The tightening sequence for the rocker shaft
10
Specifications Section

i01714274 i01855498

Valve Mechanism Cover Cylinder Head Valves

g00882246
Illustration 12

g00294082
Illustration 14

(1) Valve springs

Length of the valve springs under test
force .................................... 39.0 mm (1.54 inch)
Test force of the valve springs. .... 246 to 277.5 N
(55 to 62 lb)
g00882273
Illustration 13 (2) Valve spring recess
Numerical sequence for the bolts
(3) Valve guides
(1) The bolts are tightened in the numerical sequence
that is shown in illustration 13. Tighten the bolts Partially finished valve
to the following torque. ............... 9 N·m (80 lb in) guide .............................. 8.600 mm to 8.700 mm
(0.3386 inch to 0.3425 inch)
(2) O-ring for oil filler cap Inside diameter of finished valve
guide ..................................... 9.000 to 9.022 mm
(3) Valve mechanism cover (0.3543 to 0.3552 inch)

(4) Gasket Outside diameter of the inlet valve

guide ................................. 13.034 to 13.047 mm
(5) Breather assembly (0.5131 to 0.5137 inch)
Outside diameter of exhaust valve
guide ................................. 14.034 to 14.047 mm
(0.5525 to 0.5530 inch)
Bore diameter in the cylinder head for the inlet
valve guide ........................... 13.00 to 13.03 mm
(0.512 to 0.513 inch)
Bore diameter in the cylinder head for the exhaust
valve guide ....................... 14.000 to 14.027 mm
(0.5512 to 0.5522 inch)
 11
Specifications Section

Overall length of inlet and exhaust valve Minimum ........................... 1.40 mm (0.055 inch)
guides ............................. 51.25 mm (2.012 inch) Maximum ........................ 1.70 mm (0.0669 inch)
Service limit .................... 1.95 mm (0.0768 inch)
Projection of the valve guide above the valve
spring recess (2) ................... 14.85 to 15.15 mm (9) Angle of the face of the inlet valve
(0.585 to 0.596 inch)
Valve face angle ............................... 45 degrees
Note: When new valve guides are installed, new Valve seat angle ............................... 46 degrees
valves and new valve seat inserts must be installed.
The valve guides and the valve seat inserts are The valve lash is the following value when the engine
supplied as partially finished parts. The unfinished is hot or cold:
valve guides and unfinished valve seat inserts are
installed in the cylinder head. Then, the guides Inlet valves ........................ 0.20 mm (0.008 inch)
and inserts are cut and reamed in one operation Exhaust valves ................. 0.45 mm (0.018 inch)
with special tooling. This procedure ensures the
concentricity of the valve seat to the valve guide
in order to create a seal that is tight. Refer to the
Disassembly and Assembly Manual for removal and
installation procedures.

(4) Exhaust valve stem

Diameter of the exhaust valve
stem ...................................... 8.938 to 8.960 mm
(0.3525 to 0.3533 inch)

Clearance of exhaust valve in valve

guide ..... 0.040 to 0.084 mm (0.0016 to 0.0033 inch)
g00840529
Overall length of the exhaust Illustration 15
valve ..... 122.65 to 123.30 mm (4.829 to 4.854 inch)
(10) Machine the recess in the head for valve seat
(5) Inlet valve stem inserts to the following dimensions.
Diameter of the inlet valve Inlet valve
stem ...................................... 8.953 to 8.975 mm (A) ..................................... 10.585 to 10.715 mm
(0.3525 to 0.3533 inch) (0.4167 to 0.4219 inch)
Clearance of inlet valve in valve (B) ..................................... 45.535 to 45.560 mm
guide ..................................... 0.025 to 0.069 mm (1.7927 to 1.7937 inch)
(0.0010 to 0.0027 inch) (C) Maximum radius ......... 0.38 mm (0.015 inch)
Overall length of the inlet Exhaust valve
valve ..... 122.65 to 123.30 mm (4.829 to 4.854 inch) (A) ..................................... 10.585 to 10.715 mm
(0.4167 to 0.4219 inch)
(6) Exhaust valve face angle (B) ..................................... 43.535 to 43.560 mm
Valve face angle ............................... 30 degrees (1.7140 to 1.7150 inch)
Valve seat angle ............................... 31 degrees (C) Maximum radius ......... 0.38 mm (0.015 inch)

(7) Exhaust valve head

diameter ......................... 42.88 mm to 43.12 mm
(1.6882 inch to 1.697 inch)

Exhaust valve depth below the cylinder head face

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

(8) Diameter of the head of the inlet

valve ... 42.88 to 43.12 mm (1.688 to 1.698 inch)

Depth between the inlet valve and the cylinder head

face
12
Specifications Section

g00840530
Illustration 16

(11) Valve seat insert

Inlet valve
(D) Included angle of the faces of the valve seat
insert ................................................ 118 degrees
(E) Horizontal dimension of the
chamfer ............................. 0.38 mm (0.015 inch)
(F) Vertical dimension of the chamfer ... 0.38 mm
(0.015 inch)
Exhaust valve
(D) Included angle of the faces of the valve seat
insert ................................................. 88 degrees
(E) Horizontal dimension of the chamfer
.......................................... 0.38 mm (0.015 inch)
(F) Vertical dimension of the chamfer ... 0.38 mm
(0.015 inch)
 13
Specifications Section

i01855449

Cylinder Head

g00876966
Illustration 17
Cylinder head tightening sequence

Use the following procedure in order to tighten the Maximum permissible projection of the fuel injection
bolts for the cylinder head: nozzle below the face of the cylinder head after
resurfacing ............................ 3.06 mm (0.1205 inch)
1. Put clean engine oil on the threads of the bolts.
The bolts are tightened in the numerical sequence
that is shown in Illustration 17.

Tighten the bolts to the following torque. .. 110 N·m

(80 lb ft)

2. Repeat the procedure in Step 1 to ensure that all

of the bolts are tightened to the correct torque.

3. Use the numerical sequence that is shown in

Illustration 17 to tighten the bolts for the additional
torque-turn specification.

a. Tighten the short bolts (S) for an additional 150

g00295372
degrees (2.5 flats). Illustration 18
Checking the distortion of the cylinder head
b. Tighten the medium sized bolts (M) for an
additional 180 degrees (3.0 flats). Maximum distortion of the cylinder head is given in
the following table.
c. Tighten the long bolts (L) for an additional 210
degrees (3.5 flats). Table 1
Dimension Maximum Permissible Distortion
Cylinder head thickness .......... 102.79 to 103.59 mm
(4.047 to 4.078 inch) Width “A” 0.13 mm (0.005 inch)
Length “B” 0.25 mm (0.009 inch)
Minimum permissible thickness after the cylinder
head face has been resurfaced. ............. 102.48 mm Diagonal “C” 0.25 mm (0.009 inch)
(4.035 inch)
14
Specifications Section

i01844373 i01846903

Turbocharger Inlet Manifold

g00883118 g00876646
Illustration 19 Illustration 20
Typical example Typical example

Note: New nuts are treated in order to prevent

seizure. In order to reuse the old nuts, clean the nuts
and apply 21820122 POWERPART Pipe sealant.

(1) Tighten the nut to the following torque. .... 44 N·m

(32 lb ft)

(2) Tighten the stud into the exhaust manifold to the

following torque. ....................... 18 N·m (13 lb ft)

(3) Tighten the bolt for the oil supply line to the
following torque. ....................... 22 N·m (16 lb ft)

(4) Tighten the bolt for the oil return line to the
g00876652
following torque. ....................... 22 N·m (16 lb ft) Illustration 21
Typical example
(5) Tighten the nut for the compression fitting to the
following torque. ........................ 15 N·m (11 lb ft) Note: New bolts have sealant to the first 13 mm
(0.512 inch) of the threads. In order to reuse the old
(6) Tighten the union to the following bolts, clean the old sealant from the bolts and apply
torque. ...................................... 23 N·m (17 lb ft) 21820117 POWERPART Threadlock and nutlock
to the bolts.
(7) Tighten the bolt for the oil return line to the
following torque. ....................... 25 N·m (18 lb ft) (1) Tighten the bolts in a numerical sequence to the
following torque. ....................... 22 N·m (16 lb ft)
Tighten the nut for the exhaust elbow (not shown) to
the following torque. ........................ 22 N·m (16 lb ft) (2) Tighten the bolts to the following torque. .. 22 N·m
(16 lb ft)

(3) Connector

(4) Inlet manifold

 15
Specifications Section

i01844590 i01853426

Exhaust Manifold Camshaft

g00943878 g00976240
Illustration 22 Illustration 24
Two-piece exhaust manifold Checking the end play of the camshaft

(1) End play of a new camshaft ..... 0.10 to 0.41 mm

(0.004 to 0.016 inch)

Maximum permissible end play of a worn

camshaft ................................. 0.53 mm (0.021 inch)

g00944336
Illustration 23
Three-piece exhaust manifold

Note: New bolts have sealant to the first 13 mm

(0.512 inch) of the threads. In order to reuse the old
bolts, clean the old sealant from the bolts and apply
g00976195
21820638 POWERPART Retainer high strength to Illustration 25
the bolts. The camshaft and the thrust washer

Tighten the bolts for the exhaust manifold in the (2) Bolt
numerical sequence to the following starting torque.
......................................................... 13 N·m (10 lb ft) Tighten the bolt to the following torque. .. 95 N·m
(70 lb ft)
Tighten the bolts in a numerical sequence to the
following final torque. ...................... 33 N·m (24 lb ft) (3) Camshaft thrust washer
Thickness of the thrust washer .. 5.49 to 5.54 mm
(0.216 to 0.218 inch)
Depth of the recess in the cylinder block for the
thrust washer ............................ 5.46 to 5.54 mm
(0.215 to 0.218 inch)
Tolerance of the thrust washer in cylinder block
front face ............................... −0.05 to +0.08 mm
(−0.002 to +0.003 inch)
16
Specifications Section

(4) The diameters of the camshaft journals are given (7) Base circle
in the following table.
To determine the lobe lift, use the procedure that
Table 2 follows:
Diameters of Camshaft Journals
1. Measure the camshaft lobe height (6).
Camshaft Service Limit
Standard Diameter
Journals Diameter(1) 2. Measure the base circle (7).
50.710 to 50.740 mm 50.660 mm
1 (1.9965 to 1.9975 (1.9945 inch) 3. Subtract the base circle that is found in Step 2
inch) from the camshaft lobe height that is found in Step
1. The difference is the actual camshaft lobe lift.
50.460 to 50.480 mm 50.410 mm
2 (1.9865 to 1.9875 (1.9845 inch)
inch) Maximum permissible clearance between the
actual lobe lift and the specified lobe lift of a new
50.200 to 50.230 mm 50.150 mm camshaft ................................. 0.05 mm (0.002 inch)
3 (1.9764 to 1.9775 (1.9745 inch)
inch)
i01602266
49.950 to 49.980 mm 49.900 mm
4 (1.9665 to 1.9675
inch)
(1.9645 inch) Camshaft Bearings
(1) The service limit is the maximum or the minimum dimension
which is specified for a part. A part which has reached the
service limit must be replaced.

Internal clearance of the journals .... 0.06 to 0.14 mm

(0.002 to 0.006 inch)

g00584302
Illustration 27

(1) Camshaft bearing

g00629702
Bore of bearing for the number 1 camshaft
Illustration 26 journal ....... 50.79 to 50.85 mm (2.000 to 2.002 inch)
Cross section of the camshaft
(2) Cylinder block
(5) Camshaft lobe lift

Specified camshaft lobe lift (5)

Inlet lobe .. 7.62 to 7.69 mm (0.300 to 0.303 inch)
Exhaust lobe ............................. 7.71 to 7.79 mm
(0.304 to 0.307 inch)

(6) Camshaft lobe height

 17
Specifications Section

i01853455 Pressure to open bypass valve ............ 55 to 83 kPa

(10 to 12 psi)
Engine Oil Filter Base
i01853445

Engine Oil Cooler

g00887068
Illustration 28
Typical example

(1) Engine oil filter base

The engine oil filter bypass valve will open with
the following pressure difference. ... 55 to 83 kPa
(8 to 12 psi)

(2) Tighten the bolts to the following torque.

g00879440
Illustration 30
Filter base to the cylinder block .. 44 N·m (33 lb ft)

i01853469

Engine Oil Filter Bypass Valve

Note: There is two types of oil filter base. The high

mounted Oil filter base has an oil filter bypass valve
that is installed in the filter base. The other bypass
valve is installed in the oil filter.

g00887098
Illustration 31

Note: The baffle on the engine oil cooler core must

face the front of the engine.

(1) Engine oil cooler core

(2) Seal

(3) Housing

g00907545
(4) The bolts are tightened in the numerical sequence
Illustration 29 that is shown in illustration 31. Tighten the bolts
Oil filter bypass valve to the following torque. ............. 22 N·m (16 lb ft)

(1) Torque the bolt for the oil filter bypass valve to (5) Tighten the nuts to the following torque. .. 22 N·m
the following torque. ................. 60 N·m (44 lb ft) (16 lb ft)
18
Specifications Section

(6) Tighten the bolts to the following torque. .. 22 N·m (2) Tighten the bolts for the cover on the engine oil
(16 lb ft) pump to the following torque. ............... 28.5 N·m
(21.02 lb ft)
i01854853
Tighten the bolts that fasten the engine oil pump
Engine Oil Pump to the front main bearing cap to the following
torque. ............................................. 22 N·m (16 lb ft)

Tighten the bolts for the engine oil suction tube to the
following torque. .............................. 22 N·m (16 lb ft)

Type ............................. Gear-driven differential rotor

Number of lobes
Inner rotor ......................................................... 4
Outer rotor ........................................................ 5

g00887110
Illustration 32

(1) Backlash (minimum) between the oil pump idler

gear and the oil pump gear ................. 0.062 mm
(0.0024 inch)

Backlash (minimum) between the oil pump idler gear

and the crankshaft gear ...... 0.095 mm (0.0037 inch)
g00888637
Illustration 34
End play (minimum) for oil pump idler
gear ..................................... 0.015 mm (0.0006 inch) (3) Clearance of the outer rotor to the
body ........ 0.15 to 0.34 mm (0.006 to 0.013 inch)
Inside diameter of bearing for oil pump idler
gear ........... 22.22 to 22.26 mm (0.875 to 0.876 inch)

Outside diameter of idler shaft .... 22.19 to 22.21 mm

(0.8736 to 0.8744 inch)

Clearance of the oil pump idler gear bearing on the

shaft ...... 0.024 to 0.030 mm (0.0009 to 0.0012 inch)

g00876990
Illustration 35

(4) Clearance of inner rotor to outer

rotor ...................................... 0.040 to 0.130 mm
(0.0015 to 0.0050 inch)

g00876984
Illustration 33
 19
Specifications Section

(2) End plate

(3) Spring
Assembled length ............... 55.6 mm (2.19 inch)
Load at assembled length ........ 12.9 to 18.6 N·m
(9.52 to 13.72 lb ft)

(4) The plunger

The diameter of the plunger .. 18.16 to 18.18 mm
(0.715 to 0.716 inch)

(5) Valve body

g00888620
Illustration 36 Diameter of the bore for the
plunger .................................. 18.24 to 18.27 mm
(5) End play of rotor assembly (0.718 to 0.719 inch)
Inner rotor .............................. 0.043 to 0.118 mm Clearance of the plunger in the
(0.0017 to 0.0046 inch) bore ......... 0.06 to 0.11 mm (0.002 to 0.004 inch)
Outer rotor ............................ 0.031 to 0.106 mm
(0.0012 to 0.0042 inch)
i01891277

i01855409 Engine Oil Pan

Engine Oil Pressure

The minimum oil pressure at low idle with an ambient

temperature of 18 to 20°C (64 to 68°F) is the following
value. .............................................. 150 kPa (28 psi)

The minimum oil pressure at high idle and at

normal operating temperature is the following
value. .............................................. 280 kPa (40 psi)

i01727002

Engine Oil Bypass Valve

g00767653
Illustration 38
Typical example of the engine oil pan

g00888110
Illustration 37
g00984376
Illustration 39
Bypass pressure ......... 345 to 414 kPa (50 to 60 psi) The tightening sequence for the engine oil pan

(1) Retaining ring

20
Specifications Section

Note: Apply 1861108 Powerpart silicone rubber to i01885714

the cylinder block. Apply the sealant to the cylinder
block face between number 5 and number 6. Also Crankcase Breather
apply sealant between number 25 and number 26.
Refer to illustration 39.

(1) Tighten the bolts in the numerical sequence that

is shown in illustration 39. Tighten the bolts to the
following torque. ....................... 22 N·m (16 lb ft)

Note: The engine may be equipped with an oil drain

plug or the engine may be equipped with a drain
valve.

(2) Drain plug

Tighten the drain plug for the engine oil pan to
the following torque. ................. 34 N·m (25 lb ft)

g00888603 g00945263
Illustration 40 Illustration 41
The drain valve The crankcase breather

(3) Drain valve (1) Tighten the bolts to the following torque. ... 9 N·m
(80 lb in)
Tighten the drain valve into the adapter to the
following torque. ....................... 34 N·m (25 lb ft) (2) Apply 21820117 Powerpart Threadlock and
nutlock to the adapter. Tighten the adapter to the
(4) Adapter following torque. ....................... 30 N·m (22 lb ft)
Tighten the adapter into the engine oil pan to the
Note: There is no specific torque for the compression
following torque. ....................... 34 N·m (25 lb ft)
nuts.

(3) Finger tighten both the compression nuts on the

elbow. Rotate the compression nuts again by
1.25 turns.

Tighten the bolts (not shown) that fasten the bracket

to the cylinder head to the following torque. .. 44 N·m
(32 lb ft)
 21
Specifications Section

i01600716 Minimum stroke of the water temperature regulator at

the fully open temperature ............. 9 mm (0.35 inch)
Water Temperature Regulator
Housing i01860821

Water Pump

g00629806
Illustration 42
Typical example
g00885051
Illustration 44
(1) Tighten the bolts to the following torque. .. 22 N·m
(16 lb ft) Note: New bolts have sealant to the first 13 mm
(0.512 inch) of the threads. In order to reuse the old
(2) Cover for the water temperature regulator bolts, clean the old sealant from the bolts and apply
housing 21820117 POWERPART thread and nutlock to the
bolts.
(3) The base of the water temperature regulator
housing is a component of the cylinder head. (1) Tighten the bolts to the following torque. .. 22 N·m
(16 lb ft)
i01703394 (2) Tighten the bolts to the following torque. .. 22 N·m
Water Temperature Regulator (16 lb ft)

Note: Refer to the Disassembly and Assembly

Manual for information in order to repair the coolant
pump.

i01888916

Cylinder Block

g00877006
Illustration 43

Temperature that is stamped on the water

temperature regulator ........................... 82° (180° F)

Opening temperature of the water temperature

regulator ................... 80° to 84° C (176° F to 183° F)
g00888427
Fully open temperature of the water temperature Illustration 45
regulator ............................................. 96 °C (204° F) The cylinder block
22
Specifications Section

(1) Cylinder liner

(2) Cylinder block

Diameter of the bore for the cylinder
liner .. 104.20 to 104.23 mm (4.102 to 4.104 inch)
Depth of the recess for the cylinder liner
flange ...... 3.81 to 3.91 mm (0.150 to 0.154 inch)
Diameter of the recess for the cylinder liner
flange ................................ 107.82 to 107.95 mm
(4.245 to 4.250 inch)

(3) Camshaft bearings

g00887142
Diameter of the bore in the cylinder block for the Illustration 46
number 1 camshaft bearing .. 55.56 to 55.59 mm The application of sealant to the bridge
(2.187 to 2.189 inch)
Note: After the sealant is applied, both the oil pan and
Diameter of the bore in the cylinder block for the the rear seal must be installed within twenty minutes.
number 2 camshaft bearing .. 50.55 to 50.60 mm
(1.990 to 1.992 inch) Total height of the cylinder block between the top and
the bottom faces. .................... 441.12 to 441.33 mm
Diameter of the bore in the cylinder block for the
(17.367 to 17.375 inch)
number 3 camshaft bearing .. 50.29 to 50.34 mm
(1.980 to 1.982 inch)
(6) Main bearing cap bolts
Diameter of the bore in the cylinder block for the
number 4 camshaft bearing .. 50.04 to 50.09 mm Use the following procedure in order to install the
(1.970 to 1.972 inch) main bearing cap bolts:

Clearance between the cylinder block and the 1. Apply clean engine oil to the threads of the main
cylinder liner .................................. 3 mm (0.118 inch) bearing cap bolts.

(4) Main bearings 2. Put the main bearing caps in the correct position
that is indicated by a number on the top of the
Bore in the cylinder block for the main main bearing cap. Install the main bearing caps
bearings ............................ 80.416 to 80.442 mm with the locating tabs in correct alignment with the
(3.1660 to 3.1670 inch) recess in the cylinder block.

(5) Bolt 3. Evenly tighten the main bearing cap bolts.

Use the following procedure in order to install the Torque for the main bearing cap bolts. .... 265 N·m
bolts for the bridge. (195 lb ft)

1. Use a straight edge in order to ensure that the

bridge is aligned with the rear face of the cylinder
block.

2. Tighten the bolts for the bridge.

Torque for the bridge bolts. ........ 16 N·m (12 lb ft)

3. When the bridge is installed on the cylinder block,

apply a thin bead of 1861108 POWERPART
Silicone Rubber Sealant into the groove at each
end of the bridge. Ensure that the groove is
completely full of sealant and that the sealant is
protruding from the bridge.
g00887815
Illustration 47
“D” plug
 23
Specifications Section

The “D” plugs are only on the pushrod side of the i01885751
engine.
Crankshaft
Apply 21820122 POWERPART Pipe Sealant to the
outer edge of the “D” plug.

The baffle plate of the “D” plug must be aligned with

the horizontal and vertical lines ±5°.

i01884381

Cylinder Liner

g00979485
Illustration 49
The crankshaft

(1) Crankshaft

The end play of the crankshaft ....... 0.05 to 0.38 mm

(0.002 to 0.015 inch)

Maximum crankshaft end play .................... 0.51 mm

g00790690 (0.020 inch)
Illustration 48

(1) Outside diameter of cylinder (2) Thrust washers

liner .. 104.25 to 104.28 mm (4.105 to 4.106 inch) Standard thickness ................... 2.26 to 2.31 mm
(0.089 to 0.091 inch)
Interference fit of cylinder liner in cylinder
block ............. 0.03 to 0.08 mm (0.001 to 0.003 inch) Oversize thickness ................... 2.45 to 2.50 mm
(0.096 to 0.098 inch)
(2) Inside diameter of cylinder
liner .. 100.00 to 100.03 mm (3.937 to 3.938 inch) (3) Crankshaft gear

Maximum permissible wear of cylinder liner Number of teeth on the crankshaft gear ......... 28
bore ......................................... 0.25 mm (0.010 inch)
Bore diameter of the crankshaft
gear .................................. 47.625 to 47.650 mm
The projection of the liner flange can be 0.10 mm
(1.8750 to 1.8760 inch)
(0.004 inch) above to 0.10 mm (0.004 inch) below
the top face of the cylinder block. Maximum permissible temperature of the gear for
installation on the crankshaft ..... 180 °C (356 °F)
(3) Flange thickness of cylinder
liner ......... 3.81 to 3.86 mm (0.150 to 0.152 inch) Note: Ensure that the timing mark on the crankshaft
gear is visible when the gear is installed.
24
Specifications Section

g00886525
Illustration 50
Timing ring

(4) Locating dowel

(5) Timing ring

The temperature of the timing ring for

installation ........................................ 270 °C (518 °F)

The temperature of the timing ring for

removal ...................... 207 to 250 °C (404 to 482 °F)

Note: All new crankshafts are nitrocarburised. The

crankshaft can also be nitrided for 20 hours, if the
nitrocarburised process is not available. After a
crankshaft has been machined, the crankshaft must
be rehardened. Inspect the crankshaft for cracks
before machining and after machining.

Table 3

Diameter of the Crankshaft Journals

NUMBER 0.25 mm (0.010 inch) 0.51 mm (0.020 inch) 0.76 mm (0.030 inch)
75.905 mm (2.9884 inch) to 75.651 mm (2.9784 inch) to 75.397 mm (2.9684 inch) to
1
75.926 mm (2.9892 inch) 75.672 mm (2.9792 inch) 75.418 mm (2.9692 inch)
63.216 mm (2.4888 inch) to 62.962 mm (2.4788 inch) to 62.708 mm (2.4688 inch) to
2
63.236 mm (2.4896 inch) 62.982 mm (2.4796 inch) 62.728 mm (2.4696 inch)
39.47 mm
3 N/A N/A
(1.5539 inch)maximum
37.82 mm
4 N/A N/A
(1.4890 inch)maximum
44.68 mm
5 N/A N/A
(1.7591 inch)maximum
40.55 mm
6 N/A N/A
(1.5965 inch)maximum
133.17 mm
7 N/A N/A
(5.2429 inch)maximum
8 Do not machine this diameter. N/A N/A
3.68 mm (0.1449 inch) to
9 N/A N/A
3.96 mm (0.1559 inch)
 25
Specifications Section

Note: Refer to illustration 51 in order to use table 3.

g00979724
Illustration 51
The crankshaft

i01882388

Crankshaft Seals

Crankshaft Front Seal

Depth of the crankshaft front seal from the front face
of the oil seal housing ................. 10.20 to 10.70 mm
(0.402 to 0.421 inch)

Crankshaft Rear Seal

A new crankshaft rear seal has a plastic sleeve inside
the seal. The plastic sleeve is used to protect the
seal. The plastic sleeve is also used to assemble the
seal to the engine. The seal must be aligned to the
engine. The alignment tool must be used to install the
rear oil seal. Refer to illustration 53.
g00955880
Illustration 52
The tightening sequence for the rear oil seal
26
Specifications Section

g00975010
Illustration 53
The alignment tool

(1) Tighten the bolts in the numerical sequence that (5) Wear sleeve installation tool
is shown in illustration 52. Tighten the bolts to the
following torque. ....................... 22 N·m (16 lb ft)
i01884984

Wear Sleeve Vibration Damper and Pulley

g00886912
Illustration 54
The wear sleeve for the crankshaft flange

Note: If the crankshaft flange has a wear groove, use

a wear sleeve to renew the sealing surface before
the housing assembly is installed.

(2) The gap between the wear sleeve and the cylinder
block is the following distance. ..... 0.4 to 0.6 mm g00953667
Illustration 55
(0.016 to 0.024 inch)
Rear mounted vibration damper
(3) Apply a continuous bead of 21820518 Powerpart
liquid gasket around the inner surface of the wear Note: Apply 21820603 powerpart to the bolts that
sleeve. .................................... 5 mm (0.20 inch) fasten the rear mounted vibration damper.

(4) Crankshaft (1) Crankshaft

 27
Specifications Section

(2) Vibration damper Clearance between the connecting rod and

the crankshaft journal for turbocharged
(3) Crankshaft pulley engines .. 0.030 to 0.081 mm (0.0012 to 0.0032 inch)

(4) Tighten the bolts evenly to the following

i01721833
torque. ......................................... 115 N·m (85 ft)

Note: Recheck the torque of the bolts (4) twice.

Main Bearing Journal
(5) bolts
Table 5
Tighten the rear mounted “M8” bolts that fasten
the crankshaft pulley to the vibration damper to Main Bearing Journal
the following torque. ................. 35 N·m (26 lb ft) 76.16 to 76.18 mm
Tighten the rear mounted “M10” bolts that fasten Original Size Journal
(2.998 to 2.999 inch)
the crankshaft pulley to the vibration damper to
the following torque. ................. 65 N·m (48 lb ft) Undersize Journal 75.91 to 75.93 mm
0.25 mm (0.010 inch) (2.988 to 2.989 inch)
Undersize Journal 75.65 to 75.67 mm
0.51 mm (0.020 inch) (2.978 to 2.979 inch)
Undersize Journal 75.40 to 75.42 mm
0.76 mm (0.030 inch) (2.968 to 2.969 inch)

Maximum permissible wear of the main bearing

journals ............................... 0.040 mm (0.0016 inch)

Clearance between the main bearing and the

crankshaft journals ....................... 0.047 to 0.117 mm
(0.0019 to 0.0046 inch)

Diameter of the main bearing bore in the cylinder

g00951990
Illustration 56 block .. 80.416 to 80.442 mm (3.1660 to 3.1670 inch)
Front mounted vibration damper

i01708286
(6) Tighten the front mounted “M12” bolts to the
following torque. ....................... 78 N·m (57 lb ft) Connecting Rod
i01878761

Connecting Rod Bearing

Journal

Table 4

Connecting Rod Bearing Journal

63.47 to 63.49 mm
Original Size Journal
(2.499 to 2.500 inch)
Undersize Journal 63.22 to 63.24 mm
0.25 mm (0.010 inch) (2.489 to 2.490 inch)
Undersize Journal 62.96 to 62.98 mm
0.51 mm (0.020 inch) (2.479 to 2.480 inch)
Undersize Journal 62.71 to 62.73 mm
0.76 mm (0.030 inch) (2.469 to 2.470 inch)

Maximum permissible wear of the main bearing

journals ............................... 0.040 mm (0.0016 inch) Illustration 57
g00889532
28
Specifications Section

(1) Inside diameter of connecting rod for i01859737

bearing .............................. 43.010 to 43.040 mm
(1.6933 to 1.6945 inch) Piston and Rings
(2) Outside diameter of bearing for piston
pin ...................................... 43.110 to 43.150 mm
(1.6972 to 1.6988 inch)

Inside diameter of bearing for piston pin after

reaming ................................... 39.723 to 39.738 mm
(1.5639 to 1.5645 inch)

Clearance between small end bearing and piston

pin ....................................... 0.023 mm (0.0009 inch)

(3) Distance between center of piston pin and center

of crankshaft bearing ........ 219.05 to 219.10 mm
(8.624 to 8.626 inch)

(4) Bearings are available for remachined journals of g00888215

Illustration 58
the crankshaft which have the following undersize
dimensions: The cross section view of the piston and rings

• 0.25 mm (0.010 inch) Note: The word “Front” or an arrow which is marked
on the piston crown must be toward the front of the
• 0.51 mm (0.020 inch) engine. If the piston crown is not marked, put the
narrowest side of the piston crater toward the side of
• 0.76 mm (0.030 inch) the engine with the fuel injection pump. The shortest
distance between the edge of the piston crater and
Shell thickness at center of the edge of the piston is the narrowest side of the
bearing .. 1.835 to 1.842 mm (0.0723 to 0.0726 inch) piston crater.

Width of connecting rod bearing for naturally (1) Top piston ring
aspirated engines ....................... 31.88 to 31.55 mm
Clearance between the ends of the top
(1.255 to 1.242 inch)
piston ring in a cylinder liner without any
wear ....... 0.28 to 0.43 mm (0.011 to 0.1009 inch)
Bearing clearance ....................... 0.030 to 0.081 mm
(0.0012 to 0.0032 inch)
Note: Install the word “TOP” toward the top of the
piston. New top rings have a red identification mark
(5) Inside diameter of connecting rod for
which must be on the left of the ring gap when the top
bearing .............................. 67.210 to 67.220 mm
ring is installed on an upright piston.
(2.6460 to 2.6465 inch)
(2) Intermediate ring
(6) Tighten the nuts for the connecting rod to the
following torque. ..................... 125 N·m (92 lb ft) Width of groove in piston for intermediate
ring ...... 2.562 to 2.580 mm (0.101 to 0.102 inch)
Thickness of intermediate
ring .. 2.471 to 2.490 mm (0.0972 to 0.0980 inch)
Clearance between groove and intermediate
ring ......... 0.07 to 0.11 mm (0.003 to 0.0043 inch)
Clearance between the ends of an
intermediate ring in a cylinder liner without any
wear ...................................... 0.300 to 0.550 mm
(0.0118 to 0.0217 inch)
 29
Specifications Section

Note: Install the word “TOP” toward the top of Tighten the banjo bolts for the piston cooling jets
the piston. New intermediate rings have a green to the following torque. ............. 27 N·m (20 lb ft)
identification mark which must be on the left of the
ring gap when the intermediate ring is installed on an Note: Ensure that the piston cooling jet is positioned
upright piston. correctly on the dowel in the cylinder block (not
shown).
(3) Oil control ring
(2) Rod
Width of groove in piston for oil control
ring .......... 3.54 to 3.56 mm (0.139 to 0.140 inch) Use the following procedure in order to check the
Thickness of oil control ring ...... 3.47 to 3.49 mm alignment of the piston cooling jet:
(0.136 to 0.137 inch)
1. Insert rod (2) into the end of the piston cooling jet.
Clearance between groove and oil control Rod (2) has a diameter of 1.70 mm (0.067 inch).
ring .......... 0.05 to 0.09 mm (0.002 to 0.004 inch) Rod (2) should protrude out of the top of the
cylinder block.
Clearance between the ends of an oil
control ring in a cylinder liner without any 2. Dimension (A) is 33 mm (1.3 inch) and dimension
wear ...................................... 0.300 to 0.550 mm (B) is 21 mm (0.8 inch). Dimension (A) and
(0.0118 to 0.0217 inch) dimension (B) are tangent to the cylinder bore.

Note: The rings should be positioned with the gaps of 3. Position rod (2) within dimension (C). Dimension
the rings approximately 120 degrees from each other. (C) is 14 mm (0.6 inch).

Note: A latch pin is used in order to hold both ends (3) Cylinder block
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. i01600755

Diameter of new piston pin ..... 39.694 to 39.700 mm

Front Housing and Covers
(1.5628 to 1.5630 inch)

Bore in piston for piston pin .... 39.703 to 39.709 mm

(1.5631 to 1.5633 inch)

Piston height above cylinder block (not

shown) .......... 0.38 to 0.50 mm (0.015 to 0.020 inch)

i01708413

Piston Cooling Jet

g00888229
Illustration 59
g00635918
Illustration 60
(1) Piston cooling jet
(1) Front cover
30
Specifications Section

Tighten the nuts and the bolts that fasten the Clearance between the camshaft gear and the
front cover to the front housing to the following camshaft hub ........................ 0.008 to 0.048 mm
torque. ...................................... 22 N·m (16 lb ft) (0.0003 to 0.0019 inch)

(2) Front housing (3) Tighten the bolt for the camshaft gear to the
following torque. ....................... 95 N·m (70 lb ft)
(3) Bolt
(4) Idler gear and hub
Tighten the bolts that fasten the front housing
and the front cover to the cylinder block to the Bore diameter of the idler gear
following torque: ............ 57.14 to 57.18 mm (2.250 to 2.251 inch)
M8 ............................................. 22 N·m (16 lb ft) Width of the idler gear and split bearing
M10 ........................................... 44 N·m (33 lb ft) assembly .............................. 30.14 to 30.16 mm
(1.186 to 1.187 inch)
(4) Crankshaft
Inside diameter of the idler gear
bearing .................................. 50.78 to 50.80 mm
i01735288
(1.999 to 2.000 inch)
Gear Group (Front) Outside diameter of the idler gear
hub ...... 50.70 to 50.74 mm (1.996 to 1.998 inch)
Clearance of the bearing on the idler gear
hub .......... 0.04 to 0.10 mm (0.002 to 0.004 inch)
Idler gear end play .................... 0.10 to 0.20 mm
(0.004 to 0.008 inch)
Maximum permissible end play ............ 0.38 mm
(0.015 inch)
Backlash (minimum) ......... 0.08 mm (0.003 inch)

(5) Tighten the bolts for the idler gear to the following
torque. ...................................... 44 N·m (33 lb ft)

(6) Crankshaft gear

g00889556
Illustration 61 Bore diameter of the crankshaft
gear .................................. 47.625 to 47.650 mm
(1) Fuel injection pump gear (1.8750 to 1.8760 inch)
Bore .... 36.00 to 36.06 mm (1.417 to 1.420 inch) Outside diameter of the crankshaft for the
Tighten the four bolts to the following crankshaft gear ................. 47.625 to 47.645 mm
torque. ...................................... 28 N·m (21 lb ft) (1.8750 to 1.8758 inch)
Clearance of the crankshaft gear on the
Note: The crankshaft must not be turned unless the crankshaft for a press fit ........ 0.015 ± 0.035 mm
fuel injection pump gear is installed. (0.0006 ± 0.0014 inch)
Note: Do not remove the nut that retains the hub
of the fuel injection pump to the shaft of the fuel
injection pump. If the hub is removed, the hub must
be positioned by correctly trained personnel and
special test equipment.

(2) Camshaft gear

Bore diameter of the camshaft gear
.... 34.930 to 34.950 mm (1.3752 to 1.3760 inch)
Outside diameter of camshaft
hub .................................... 34.900 to 34.920 mm
(1.3741 to 1.3747 inch)
 31
Specifications Section

i01854866 i01600766

Flywheel Flywheel Housing

g00631781
Illustration 63

(1) Bolt
Tighten the bolts for the aluminum flywheel
housing to the following torque. ............... 70 N·m
(52 lb ft)
g00584712
Illustration 62
Tighten the bolts for the cast iron flywheel
(1) Flywheel ring gear housing to the following torque:
M10 “8.8” .................................. 44 N·m (33 lb ft)
Heat the flywheel ring gear to the following
M10 “10.9” ................................ 63 N·m (47 lb ft)
temperature. .............................. 250 °C (480 °F)
M12 “8.8” .................................. 75 N·m (55 lb ft)
M12 “10.9” ............................... 115 N·m (85 lb ft)
Note: Do not use a torch to heat the flywheel ring
gear.
i01721280
(2) Flywheel
Engine Lifting Bracket
(3) Bolt
Tighten the flywheel bolts to the following
torque. .................................... 120 N·m (88 lb ft) All engines are equipped with two engine lifting
brackets.
Tighten the two bolts on each engine lifting
bracket to the following torque. .. 44 N·m (32 lb ft)
32
Specifications Section

i01866226

Alternator
(12 volt and 24 volt alternator)

g00959541
Illustration 64
The end view of the alternator which shows electrical connections

(1) Tighten terminal nut “W” to the following

torque. ........................................ 2 N·m (17 lb in)

(2) Tighten terminal nut “D+” to the following

torque. ..................................... 4.3 N·m (38 lb in)

(3) Tighten terminal nut “B+” to the following

torque. ..................................... 4.3 N·m (38 lb in)

Tighten the pulley nut (not shown) to the following

torque. ............................................. 80 N·m (59 lb ft)

Alignment of the alternator pulley to the crankshaft

pulley .............................. ± 2.4 mm ( ± 0.0945 inch)

Rotation .................................................... clockwise

Polarity ............................................... Negative earth

 33
Specifications Section

i01866400

Starter Motor

g00974968
Illustration 65
The 24 volt starter motor which shows the electrical connections

24 Volt Starter Motor

(1) Tighten the negative positive terminal nut to the
following torque. ........................ 15 N·m (11 lb ft)

(2) Tighten the positive terminal nut to the following

torque. ...................................... 21 N·m (15 lb ft)

(3) Tighten the solenoid terminal to the following

torque. ..................................... 3.5 N·m (31 lb in)

Rated voltage ................................................ 24 volts

Pull in voltage ............................................... 16 volts

34
Specifications Section

12 volt starter motor

g00977365
Illustration 66
The 12 volt starter motor which shows the electrical connections

(1) Tighten the solenoid terminal to the following

torque. ....................................... 8 N·m ( 70 lb in)

(2) Tighten the positive terminal nut to the following

torque. ....................................... 6 N·m ( 53 lb in)

(3) Tighten the negative terminal nut to the following

torque. ....................................... 8 N·m (70 lb in)

Rated voltage ................................................ 12 volts

Pull in voltage ................................................. 8 volts

i01746134
g00884683
Illustration 68
Coolant Temperature Sensor Coolant temperature sensor

(1) Tighten the sensor to the following

torque. ...................................... 20 N·m (15 lb ft)

g00884680
Illustration 67
Location of the coolant temperature sensor
 35
Specifications Section

i01746847 i01746858

Boost Pressure Sensor Inlet Manifold Temperature

Sensor

g00884732
Illustration 69
Location of the boost pressure sensor on a side mounted g00887774
Illustration 72
turbocharger
Location of the inlet manifold pressure sensor on a side mounted
turbocharger

g00884734
Illustration 70
Location of the boost pressure sensor on a top mounted g00887773
Illustration 73
turbocharger
Location of the inlet manifold temperature sensor on a side
mounted turbocharger

g00884730
Illustration 71
Boost pressure sensor g00884683
Illustration 74
Inlet manifold temperature sensor
(1) Tighten the sensor to the following
torque. ...................................... 10 N·m (89 lb in)
(1) Tighten the sensor to the following
torque. ...................................... 20 N·m (15 lb ft)
36
Specifications Section

i01860273 i01854832

Speed/Timing Sensor Electronic Control Module

g00884737 g00884768
Illustration 75 Illustration 77
Location of the speed/timing sensor
(1) Tighten the bolt to the following torque. ... 22 N·m
(16 lb ft)

(2) Tighten the allen head screw to the following

torque. ........................................ 6 N·m (53 lb in)

Tighten the 3 bolts that hold the machine interface

connector (not shown) to the bracket, to the following
torque. ............................................... 2 N·m (18 lb in)

Tighten the retaining screw that holds the machine

interface connector to the electronic control connector
(not shown) to the following torque. .. 5 N·m (44 lb in)

g00884736 i01853830
Illustration 76
Speed/timing sensor Air Inlet Heater
(1) Tighten the bolt to the following torque. ... 22 N·m
(16 lb ft)

g00884774
Illustration 78
Air inlet heater for top mounted turbocharger
 37
Specifications Section

g00884777
Illustration 79
Air inlet heater for side mounted turbocharger

(1) A suitable locking compound must be applied to

the threads of the air inlet heater. The compound
that is used on the threads of the air inlet heater
must be able to fill the space between the threads
and the compound must also be resistant to oil.

Note: There is no specific torque for the air inlet

heater.

Tighten the air inlet heater into the inlet manifold.

ensure that the air inlet heater has one thread or less
remaining.

(2) Check that the electrical terminal is in the correct

position.

Allow the compound to harden.

38
Index Section

Index
A G

Air Inlet Heater....................................................... 36 Gear Group (Front)................................................ 30

Alternator (12 volt and 24 volt alternator) .............. 32

I
B
Important Safety Information ................................. 2
Boost Pressure Sensor.......................................... 35 Inlet Manifold ......................................................... 14
Inlet Manifold Temperature Sensor........................ 35

C
L
Camshaft ............................................................... 15
Camshaft Bearings ................................................ 16 Lifter Group............................................................ 8
Connecting Rod..................................................... 27
Connecting Rod Bearing Journal........................... 27
Coolant Temperature Sensor................................. 34 M
Crankcase Breather............................................... 20
Crankshaft ............................................................ 23 Main Bearing Journal............................................. 27
Crankshaft Seals ................................................... 25
Crankshaft Front Seal ........................................ 25
Crankshaft Rear Seal......................................... 25 P
Cylinder Block........................................................ 21
Cylinder Head........................................................ 13 Piston and Rings ................................................... 28
Cylinder Head Valves ............................................ 10 Piston Cooling Jet.................................................. 29
Cylinder Liner ........................................................ 23

R
E
Rocker Shaft.......................................................... 8
Electronic Control Module ..................................... 36
Engine Design ....................................................... 4
Engine Lifting Bracket............................................ 31 S
Engine Oil Bypass Valve ....................................... 19
Engine Oil Cooler .................................................. 17 Specifications Section ........................................... 4
Engine Oil Filter Base............................................ 17 Speed/Timing Sensor ............................................ 36
Engine Oil Filter Bypass Valve .............................. 17 Starter Motor.......................................................... 33
Engine Oil Pan....................................................... 19 12 volt starter motor ........................................... 34
Engine Oil Pressure............................................... 19 24 Volt Starter Motor .......................................... 33
Engine Oil Pump.................................................... 18
Exhaust Manifold ................................................... 15
T

F Table of Contents................................................... 3
Turbocharger ......................................................... 14
Flywheel ................................................................ 31
Flywheel Housing .................................................. 31
Front Housing and Covers..................................... 29 V
Fuel Filter Base ..................................................... 7
Fuel Injection Lines................................................ 4 Valve Mechanism Cover........................................ 10
Fuel Injection Nozzles ........................................... 5 Vibration Damper and Pulley................................. 26
Fuel Injection Pump............................................... 4
Fuel Lines .............................................................. 6
Fuel Priming Pump ................................................ 8 W

Water Pump........................................................... 21
Water Temperature Regulator ............................... 21
 39
Index Section

Water Temperature Regulator Housing ................. 21

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