Specifications

1204E-E44TA and  1204E-E44TTA

Industrial Engines

MK (Engine)

ML (Engine)

This document is printed from SPI². Not for RESALE

 

Important Safety Information

Most  accidents    tha t involve  produc  t  op eration,  ma intena nc e and   repair   are  caus  ed  by  failure  to

ob serve  basic   safety   rules  or  precautions  .  An accident    can   often  be  avoided   by  recog nizing  pote ntially

ha za rdous  situations   before   an  accident    oc curs . A person    mus t be  alert   to pote ntial  ha za rds.  This

person   should   also  ha ve  the  ne cessary   training,  skills  and   tools  to perform   the se  func tions 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.

Sa fety precautions     and  warning s  are   provided   in this  ma nua l and   on  the  produc t.  If the se  ha za rd

warning s  are  not  he eded,   bod ily injury  or death   could   oc cur to  you  or to  othe r persons  .

The  ha za rds are   identified   by  the  “Safety  Alert  Symb ol”  and  followed  by  a  “Signa l  Word” suc h  as

“DANGER”, “WARNING”  or “CAUTION”.  The Sa fety  Alert  “WARNING” label  is  shown   below.

The  me aning  of  this safety   alert   symb ol is  as  follows:

Attention! Become Alert! Your Safety is  Involved.

The  me ssage   tha t appears     und er the   warning  explains    the  ha za rd and   can  be   either  written  or

pictorially   presente  d.

Op erations  tha t  ma y caus e  produc  t dama  ge  are  identified   by  “NOTICE” labels   on  the  produc  t and   in

this  pub lication.

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  informa tion, specifications   ,  and  illustrations   in  this  pub lication  are   on the  basis    of informa tion tha t

was  available    at  the  time  tha t the  pub lication   was  written.   The  specifications   , torque  s,  pressure  s,

me asure me nts , adjustme  nts , illustrations ,  and  othe r  items  can  cha  ng e at  any  time.  These  cha ng es  can

affect   the  service   tha t is given   to the  produc  t.  Ob tain the  comp  lete  and  mos t current   informa tion before

you  start any   job. Pe  rkins  dealers   or   Pe rkins  distributors     ha ve  the  mos t current   informa tion  available.

When  replacement  parts  are  required  for  this

product Perkins recommends using Perkins

 replacement  parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

This document is printed from SPI². Not for RESALE

 

KENR9123-01

3

Table of  Contents

Table of Contents

Engine Oil Pressure Sensor .................................  44

Boost Pressure Sensor ......................................... 45

Atmospheric Pressure Sensor .............................. 45

Inlet Manifold Temperature Sensor ....................... 46

Temperature Sensor (DPF Inlet) ........................... 46

Pressure Sensor (NOx Reduction System) ..........  46

Temperature Sensor (NOx Reduction System) ....  47

Speed/Timing Sensor  ..........................................  47

Electronic Control Module ..................................... 48

Glow Plugs  ........................................................... 48

Air Compressor (Twin Cylinder Compressor) ....... 49

Air Compressor (Single Cylinder) .........................  50

Specifications Section

Engine Design  .....................................................

Fuel Injection Lines  ..............................................

Fuel Injection Pump  .............................................

Fuel Injectors  .......................................................

Fuel Transfer Pump  .............................................

Fuel Filter Base  (Single Secondary Fuel Filter

Base) ...................................................................

Fuel Filter Base  (Twin Secondary Fuel Filter

Base) ...................................................................

Fuel Filter Base (Primary Fuel Filter Base) ...........

Fuel Manifold (Rail) ...............................................

Lifter Group ...........................................................

Rocker Shaft  ........................................................

4

4

5

6

6

7

Index Section

7

8

8

9

9

Index .....................................................................  51

Valve Mechanism Cover  ...................................... 10

Cylinder Head Valves ...........................................  11

Cylinder Head  ...................................................... 12

Turbocharger (Series Turbochargers) ..................  13

Turbocharger (Single Turbocharger) ....................  15

Exhaust Gas Valve (NRS) ....................................  17

Exhaust Sensor and Lines (NRS) ......................... 18

Exhaust Cooler (NRS) ..........................................  19

Exhaust Manifold  .................................................  21

Flexible Exhaust Pipe ...........................................  22

Diesel Particulate Filter ......................................... 22

Camshaft  .............................................................  23

Camshaft Bearings  ..............................................  24

Engine Oil Filter Base  .......................................... 24

Engine Oil Cooler  ................................................. 25

Engine Oil Pump  .................................................. 25

Engine Oil Pressure  ............................................. 26

Engine Oil Pan  ..................................................... 26

Crankcase Breather  ............................................. 27

Water Temperature Regulator and Housing .........  28

Water Pump  ......................................................... 28

Cylinder Block  ...................................................... 29

Crankshaft  ...........................................................  29

Crankshaft Seals  .................................................  31

Connecting Rod Bearing Journal  ......................... 31

Main Bearing Journal ............................................ 32

Connecting Rod  ................................................... 32

Piston and Rings  .................................................. 34

Piston Cooling Jet ................................................. 35

Balancer Group  .................................................... 35

Accessory Drive (SAE “B”) ...................................  36

Accessory Drive  ................................................... 36

Front Housing and Covers  ................................... 37

Gear Group (Front) ............................................... 37

Flywheel  ............................................................... 39

Flywheel Housing  ................................................  39

Crankshaft Pulley  ................................................. 40

Belt Tensioner ....................................................... 40

Refrigerant Compressor .......................................  41

Fan Drive  .............................................................  41

Engine Lifting Bracket ........................................... 41

Alternator  .............................................................  42

Starter Motor  ........................................................ 43

Coolant Temperature Sensor  ............................... 44

This document is printed from SPI². Not for RESALE

 

4

KENR9123-01

Specifications  Section

Specifications Section

When the camshaft is  viewed from the front of

the engine, the camshaft rotates in  the following

direction: ................................................... Clockwise

i03907589

The front of the engine is opposite the flywheel end.

The left side and the right  side of the engine are

viewed from the flywheel end. The No. 1 cylinder is

the front cylinder.

Engine Design

i04136796

Fuel Injection Lines

Contact with  high pressure fuel  may cause fluid

penetration and  burn hazards. High pressure  fu-

el spray  may cause  a fire  hazard. Failure to  fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

Refer to Operation  and Maintenance Manual,

“General Hazard Information and High Pressure Fuel

Lines” before adjustments and repairs are performed.

g01335181

NOTICE

Illustration 1

Refer to Systems Operation, Testing, and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work on

the fuel system.

Cylinder and valve location

(A) Exhaust valve

(B) Inlet valve

Bore .........................................  105 mm (4.133 inch)

Stroke ......................................  127 mm (5.000 inch)

Ensure that all adjustments and repairs are performed

by authorized personnel that have had the correct

training.

Displacement ...................................... 4.4 L (269 in )

3

Cylinder arrangement .....................................  In-line

Type of combustion ............................ Direct injection

Compression ratio

Turbocharged engines and turbocharged charge

cooled engines  ........................................  16.2:1

Number of cylinders ................................................ 4

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

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

When the crankshaft is viewed  from the front of

the engine, the crankshaft rotates in the following

direction: ...................................................  Clockwise

This document is printed from SPI². Not for RESALE

 

KENR9123-01

5

Specifications Section

g02334261

Illustration 2

Typical example

(1), (2)  Torque for the nuts on the high-pressure fuel

lines ..........................................  40 N·m (30 lb ft)

i04138513

Fuel Injection Pump

Note: The timing of the fuel injection pump will need

to be checked by trained personnel. In order to check

the timing of the fuel injection pump, refer to Systems

Operation, Testing, and Adjusting, “Fuel Injection

Pump Timing - Check”.

NOTICE

Refer to Systems Operation, Testing, and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work  on

the fuel system.

g02335956

Illustration 3

Typical example

(1)  Tighten the studs to the following torque. .. 11 N·m

(97 lb in)

(2)  Tighten the mounting nut  to the following

torque. ......................................  22 N·m (16 lb ft)

(3)  Tighten the setscrews  to the following

torque. ......................................  22 N·m (16 lb ft)

This document is printed from SPI². Not for RESALE

 

6

KENR9123-01

Specifications  Section

(4)  Tighten the screws for the suction control valve

to the following torque. ............... 9 N·m (80 lb in)

i04139569

Fuel Transfer Pump

(5)  Tighten the fuel temperature sensor  to the

following torque. .......................  22 N·m (16 lb ft)

(6)  Tighten the  screw to  the following

torque. ......................................  14 N·m (10 lb ft)

i03631793

Fuel Injectors

NOTICE

Refer to Systems  Operation, Testing and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work  on

the fuel system.

g02337197

Illustration 5

Typical example

(1)  Tighten the allen head screws to the following

torque. ........................................ 9 N·m (80 lb in)

(2)  Tighten the connection  to the following

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

g01862457

Illustration 4

Typical example

(3) Clamp

(4) Washer

(5) O ring seal

g02337198

Illustration 6

(1)  Torque for the nuts ...................... 2 N·m (18 lb in)

Typical example

(2)  Torque for the bolt in  the clamp for the fuel

injection nozzle ......................  21 N·m (15.5 lb ft)

(3), (4)  Tighten the  bolts to  the following

torque. ......................................  22 N·m (16 lb ft)

This document is printed from SPI². Not for RESALE

 

KENR9123-01

7

Specifications Section

i04325509

i04330369

Fuel Filter Base

(Single Secondary Fuel Filter

Base)

Fuel Filter Base

(Twin Secondary Fuel Filter

Base)

NOTICE

NOTICE

Refer to Systems  Operation, Testing and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work  on

the fuel system.

Refer to Systems  Operation, Testing and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work on

the fuel system.

If necessary, install a new fuel filter (2) to canister (1).

Refer to Operation and Maintenance Manual, “Fuel

System Secondary Filter - Replace” for the correct

procedure.

If necessary, install a new fuel filter (2) to canister (1).

Refer to Operation and Maintenance Manual, “Fuel

System Secondary Filter - Replace” for the correct

procedure.

g02484376

Illustration 7

Typical example

(3)  Tighten the bolts to the following torque. .. 44 N·m

(33 lb ft)

(4)  Tighten the bolt to the following torque. ... 17 N·m

(13 lb ft)

g02485877

Illustration 8

Typical example

(3)  Tighten the bolts to the following torque. .. 44 N·m

(33 lb ft)

(4)  Tighten the bolt to the following torque. ... 20 N·m

(15 lb ft)

This document is printed from SPI². Not for RESALE

 

8

KENR9123-01

Specifications  Section

i04363635

i04139570

Fuel Filter Base

Fuel Manifold (Rail)

(Primary Fuel Filter Base)

Refer to Operation  and Maintenance Manual,

“General Hazard Information and High Pressure Fuel

Lines” before adjustments and repairs are performed.

NOTICE

Refer to Systems  Operation, Testing and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work  on

the fuel system.

NOTICE

Refer to Systems  Operation, Testing and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work on

the fuel system.

If necessary, install a  new fuel filter element to

canister (2). Refer to Operation and Maintenance

Manual, “Fuel System  Primary Filter (Water

Separator) Element -  Replace” for the correct

procedure.

g02337196

Illustration 10

Typical example

g02289936

(1)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

Illustration 9

Typical example

(2)  Tighten the bolts to the following torque. .. 10 N·m

(89 lb in)

Tighten water in fuel switch (1) hand tight.

(3)  Tighten the connection  to the following

torque. ......................................  17 N·m (13 lb ft)

(3)  Tighten the fuel pressure relief valve  to the

following torque. .......................  30 N·m (22 lb ft)

(4)  Tighten the bolts to the following torque. .. 44 N·m

(32 lb ft)

Note: The fuel pressure relief valve (3) should  be

tightened an additional 24 degrees.

(5)  Tighten the connection  to the following

torque. ......................................  17 N·m (13 lb ft)

(6)  Tighten the connection  to the following

torque. ......................................  17 N·m (13 lb ft)

This document is printed from SPI². Not for RESALE

 

KENR9123-01

9

Specifications Section

i04381710

i03916469

Lifter Group

Rocker Shaft

g01344742

Illustration 11

Typical example

(A)  Diameter of the lifter body .. 21.938 to 21.963 mm

(0.86370 to 0.86468 inch)

Bore diameter  in  the cylinder  block

...... 22.000 to 22.032 mm (0.86614 to 0.86740 inch)

g02150799

Illustration 12

Typical example

Clearance

(1)  Tighten the threaded inserts to the following

torque. ......................................  30 N·m (22 lb ft)

Clearance of the lifter  ..........  0.038 to 0.095 mm

(0.0015 to 0.0037 inch)

(2)  Retaining clip

(3)  Spring

(4)  Inlet rocker arm

Diameter of  the  rocker arm  bore

.... 25.013 to 25.051 mm (0.9848 to 0.9863 inch)

(5)  Exhaust rocker arm

Diameter of  the  rocker arm  bore

.... 25.013 to 25.051 mm (0.9848 to 0.9863 inch)

Clearance

Maximum clearance of both  the rocker arm

bores. ............................ 0.089 mm (0.0035 inch)

The service  limit for  both rocker arm

bores ............................... 0.17 mm (0.0067 inch)

(6)  Guide

This document is printed from SPI². Not for RESALE

 

10

KENR9123-01

Specifications  Section

(7)  Rocker shaft

Diameter  of  the  rocker

shaft .................................. 24.962 to 24.987 mm

(0.98275 to 0.98374 inch)

(8)  Retaining clip

(9)  Spring

g02150797

Illustration 13

Tightening sequence

Tighten the fasteners in the  sequence that is in

illustration 13. Tighten the fasteners to the following

torque. ............................................. 35 N·m (26 lb ft)

i04351269

Valve Mechanism Cover

g02161123

Illustration 14

Typical example

This document is printed from SPI². Not for RESALE

 

KENR9123-01

11

Specifications Section

Tighten the fasteners for the valve mechanism cover

in the sequence that is shown in illustration 14 to the

following torque. .............................. 22 N·m (16 lb ft)

i04458277

Cylinder Head Valves

g01335204

Illustration 16

(2)  Valve face angle

Inlet ................................................... 30 degrees

Exhaust ............................................. 45 degrees

(3)  Valve stem diameter

Inlet .. 5.942 to 5.957 mm (0.2339 to 0.2345 inch)

Exhaust ................................. 5.927 to 5.942 mm

(0.2333 to 0.2339 inch)

Clearance

Maximum clearance  of the inlet  valve

stem ................................ 0.05 mm (0.0020 inch)

The service  limit for  the inlet  valve

stem ................................ 0.08 mm (0.0031 inch)

g01335203

Illustration 15

Typical example

Clearance

When the valve springs (1) are replaced the valve

springs must be replaced in pairs.

Maximum clearance of  the exhaust valve

stem .............................. 0.065 mm (0.0026 inch)

The service  limit for the  exhaust valve

Table 1

stem ................................ 0.09 mm (0.0035 inch)

The load for the inlet valve    The length of the inlet valve

(4)  Length of valve

spring

spring

209 to 231 N (47 to 52 lb)

31.5 mm (1.2402 inch)

22.2 mm (0.87401 inch)

Inlet valve .....................  107.925 to 108.375 mm

(4.2490 to 4.2667 inch)

Exhaust valve ...............  107.703 to 108.153 mm

389.5  to 430.5  N

(87.5 to 97 lb)

(4.2403 to 4.2580 inch)

Table 2

(5)  Valve head

The load for the exhaust

valve spring

The length of the exhaust

valve spring

Diameter of inlet valve head .................... 35 mm

(1.3780 inch)

Diameter of exhaust valve head .............. 33 mm

(1.2992 inch)

161.5  to 178.5  N

(36.3 to 40.1 lb)

31.5 mm (1.2402 inch)

337.9  to 373.5  N

(76 to 84 lb)

21.5 mm (0.8465 inch)

This document is printed from SPI². Not for RESALE

 

12

KENR9123-01

Specifications  Section

i04136793

Table 3

Cylinder Head

Maximum Permissible

Distortion

Dimension

Width (A)

0.03 mm (0.0018 inch)

0.05 mm (0.0019 inch)

0.05 mm (0.0019 inch)

Length (B)

Diagonal Line (C)

g01250785

Illustration 17

Typical example

Lubricate the threads and the underside of the head

bolts with clean engine oil.

Tighten the bolts in the sequence that is shown in

illustration 17 to the following torque. ...... 50 N·m

(37 lb ft)

Tighten the  bolts again to the  following

torque. ....................................  100 N·m (74 lb ft)

Tighten the  head bolts to the  additional

amount. ........................................... 225 degrees

Minimum thickness of cylinder head ......... 150.8 mm

(5.93700 inch)

g02328933

Illustration 19

Typical example

(D)  Valve guide height from the top of the valve guide

to the valve spring seat .......... 10.75 to 11.25 mm

(0.42323 to 0.44291 inch)

(E)  Outside diameter  of  the valve

guides ................................ 11.029 to 11.040 mm

(0.43421 to 0.43464 inch)

(F)  Length of the valve guides ... 43.75 to 44.25 mm

(1.72244 to 1.74212 inch)

(G)  Internal diameter  of  the valve

guides ...................................  7.007 to 7.020 mm

(0.27587 to 0.27638 inch)

(H)  Valve depths

Inlet .. 0.905 to 1.163 mm (0.0356 to 0.0458 inch)

The service limit for the depth of the inlet valve

........................................ 1.41 mm (0.0555 inch)

Exhaust ................................. 0.876 to 1.131 mm

(0.0345 to 0.0445 inch)

The service  limit for the  exhaust valve

depth ............................... 1.38 mm (0.0543 inch)

g01455374

Illustration 18

Note: The maximum distortion of the bottom face of

the cylinder head is given in table 3.

This document is printed from SPI². Not for RESALE

 

KENR9123-01

13

Specifications Section

(L)  Seat surface finish ...................... Ra 0.8 microns

(M)  Concentricity of valve seat to  valve guide

parent bore Maximum Total Indicated Reading

(TIR) .............................  0.08 mm (0.00315 inch)

i04303429

Turbocharger

(Series Turbochargers)

Note: For the  correct procedure to install the

turbochargers, refer to Disassembly and Assembly,

“Turbocharger - Install”.

g02474819

Illustration 20

Typical example

(J)  Diameter of the parent bore  in the cylinder

head ................................... 11.000 to 11.022 mm

(0.43307 to 0.43394 inch)

(K)  Seat angle

Inlet ............................................. 119.15 degrees

Exhaust ........................................ 89.15 degrees

g02467657

Illustration 22

Typical example

(1)  Actuator

The test  pressure for  the wastegate

actuator .................................. 100 kPa (14.5 psi)

The movement for the rod actuator ........... 1 mm

(0.0394 inch)

(2)  Tighten the studs to the following torque. .. 11 N·m

(97 lb in)

(3)  Tighten the nuts to the following torque. .. 24 N·m

(18 lb ft)

g02475018

Illustration 21

Typical example

This document is printed from SPI². Not for RESALE

 

14

KENR9123-01

Specifications  Section

g02467764

g02467817

Illustration 23

Illustration 25

Typical example

Typical example

(4)  Tighten the  studs to  the following

(9)  Tighten the nut to the following torque. .. (22 lb ft)

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

(10), (14), (15)  Tighten the bolts to the  following

torque. ......................................  22 N·m (16 lb ft)

(5)  Tighten the bolts to the following torque. .. 44 N·m

(32 lb ft)

(11), (12)  Tighten the  bolt to the  following

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

(6)  Tighten the nuts to the following torque. .. 44 N·m

(32 lb ft)

(13)  Tighten the bolt to the following torque. .. 40 N·m

(29 lb ft)

g02467778

Illustration 24

Typical example

g02469656

Illustration 26

(7)  Tighten the bolt to the following torque. ... 22 N·m

(16 lb ft)

Typical example

(16)  Tighten the clamps  to the  following

(8)  Tighten the bolts to the following torque. ... 9 N·m

(80 lb in)

torque. .................................... 12 N·m (106 lb in)

This document is printed from SPI². Not for RESALE

 

KENR9123-01

15

Specifications Section

(17)  Tighten the clamps  to the  following

i04303430

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

Turbocharger

(Single Turbocharger)

g02469659

Illustration 27

Typical example

(18)  Tighten the  bolts to  the following

torque. ......................................  22 N·m (16 lb ft)

(19)  Tighten the bolt to the following torque. .. 15 N·m

(11 lb ft)

g02469696

Illustration 29

Typical example

(1)  Actuator

The test  pressure for  the wastegate

actuator .................................. 100 kPa (14.5 psi)

The movement for the rod actuator ........... 1 mm

(0.0394 inch)

(2)  Tighten the  studs to  the following

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

(3)  Tighten the nuts to the following torque. .. 44 N·m

(32 lb ft)

(4)  Tighten the  studs to  the following

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

(5)  Tighten the nuts to the following torque. .. 44 N·m

(32 lb ft)

g02469676

Illustration 28

Typical example

(20)  Tighten the  bolts to  the following

torque. ......................................  22 N·m (16 lb ft)

(21)  Tighten the clamps  to the  following

torque. .................................... 12 N·m (106 lb in)

This document is printed from SPI². Not for RESALE

 

16

KENR9123-01

Specifications  Section

(9)  Tighten the bolts to the following torque. .. 18 N·m

(13 lb ft)

(10)  Tighten the bolt to the following torque. .. 40 N·m

(30 lb ft)

(11)  Tighten the  bolts to  the following

torque. ......................................  22 N·m (16 lb ft)

g02469717

Illustration 30

Typical example

(6)  Tighten the bolt to the following torque. ... 22 N·m

(16 lb ft)

(7)  Tighten the bolt to the following torque. ..... 9 N·m

(80 lb in)

g02469836

Illustration 32

Typical example

(12)  Tighten the bolt to the following torque. .. 22 N·m

(16 lb ft)

(13)  Tighten the bolt to the following torque. .. 15 N·m

(11 lb ft)

g02469740

Illustration 31

Typical example

g02469857

Illustration 33

Typical example

(8)  Tighten the bolt to the following torque. ... 22 N·m

(16 lb ft)

This document is printed from SPI². Not for RESALE

 

KENR9123-01

17

Specifications Section

(14)  Tighten the clamps  to the  following

torque. .................................... 12 N·m (106 lb in)

i04138516

Exhaust Gas Valve (NRS)

g02337116

Illustration 35

Typical example

(2)  Tighten the stud to the following torque. .. 11 N·m

(97 lb in)

(3)  Tighten the plug to the following torque. .. 35 N·m

(26 lb ft)

g02337096

Illustration 34

Typical example

(1)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

g02337117

Illustration 36

Typical example

(4)  Tighten the bolts to the following torque. ... 9 N·m

(80 lb in)

(5)  Tighten the plug to the following torque. .. 9.5 N·m

(84 lb in)

This document is printed from SPI². Not for RESALE

 

18

KENR9123-01

Specifications  Section

i04448752

Exhaust Sensor and  Lines

(NRS)

Table 4

Required Tools

Part Number          Part  Description

Tool

QTY

Bostik Pure Nickel

Anti-Seize Compound

A

-

1

g02337118

Illustration 37

Typical example

(6)  Tighten the nut to the following torque. .... 18 N·m

(13 lb ft)

(7)  Tighten the bolts to the following torque. .. 18 N·m

(13 lb ft)

g02148954

Illustration 39

Typical example

Note: Apply Tooling (A) to the sensors before the

sensors are installed.

(1)  Tighten the sensors  to the  following

torque. ......................................  45 N·m (33 lb ft)

Tighten the harness for the sensors (not shown) to

the following torque. .................... 1.2 N·m (10.6 lb in)

g02337119

Illustration 38

Typical example

(8)  Tighten the bolts to the following torque. ... 9 N·m

(80 lb in)

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KENR9123-01

19

Specifications Section

i04138514

Exhaust Cooler (NRS)

Note: When the pipes for the  exhaust cooler are

removed or installed, care must be taken so that the

pipes are not bent or the pipes are not damaged.

g02337136

Illustration 40

Typical example

(1)  Tighten the bolts to the following torque. ... 9 N·m

(80 lb in)

(2)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

(3)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

(4)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

(5)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

(6)  Tighten the bolt to the following torque. ... 22 N·m

(16 lb ft)

This document is printed from SPI². Not for RESALE

 

20

KENR9123-01

Specifications  Section

g02337137

Illustration 41

Typical example

(7), (8)  Tighten the  bolts to  the following

torque. ......................................  22 N·m (16 lb ft)

(9)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

(10)  Tighten the  bolts to  the following

torque. ......................................  22 N·m (16 lb ft)

This document is printed from SPI². Not for RESALE

 

KENR9123-01

21

Specifications Section

i03914512

Exhaust Manifold

g02150456

Illustration 42

Typical example

Tighten the exhaust manifold bolts in the sequence

that is shown in  illustration 42 to the following

torque. ............................................. 44 N·m (32 lb ft)

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22

KENR9123-01

Specifications  Section

i03936932

Flexible Exhaust Pipe

g02155429

Illustration 43

Typical example

(1)  Tighten the  clamp to  the following

torque. ......................................  35 N·m (26 lb ft)

(2)  Tighten the  clamp to  the following

torque. ......................................  55 N·m (41 lb ft)

Refer to Disassembly and Assembly for the correct

procedure to install the flexible exhaust pipe.

i04229372

Diesel Particulate Filter

Note: To remove and install the Diesel Particulate

Filter (DPF), refer to Disassembly and Assembly for

the correct procedures.

This document is printed from SPI². Not for RESALE

 

KENR9123-01

23

Specifications Section

Maximum permissible  end play of  a worn

camshaft ...............................  0.62 mm (0.0244 inch)

g02405938

Illustration 44

Typical example

g02150828

Illustration 46

(1)  Tighten the nuts on clamps to  the following

torque. ......................................  17 N·m (13 lb ft)

Typical example

(2)  Bolt

i04156670

, Torque for the 8.8 graded bolt ..  95 N·m (70 lb ft)

Torque for the 10.9 graded bolt ............. 120 N·m

(89 lb ft)

Camshaft

(3)  The diameters of the camshaft journals are given

in the following tables.

Table 5

Camshaft Journals

from the Front End

of the Engine

Standard Diameter

1

Front

50.711 to  50.737  mm

(1.9965 to 1.9975 inch)

50.457 to  50.483  mm

(1.9865 to 1.9875 inch)

2

3

Rear

49.949 to  49.975  mm

(1.9665 to 1.9675 inch)

Maximum wear on the camshaft journals ...  0.05 mm

(0.0021 inch)

Check the camshaft lobes for visible damage. If  a

new camshaft is installed, you must install new lifters.

g01927854

Illustration 45

Checking the end play of the camshaft

(1)  End play of a camshaft ......... 0.106 to 0.558 mm

(0.00417 to 0.02197 inch)

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24

KENR9123-01

Specifications  Section

(1)  The diameter of  the installed camshaft

bearing .............................. 50.787 to 50.848 mm

(1.9995 to 2.0019 inch)

i03914549

Engine Oil Filter Base

g02474757

Illustration 47

Typical example

(4)  Camshaft thrust washer

Outer diameter (X) ............ 72.949 to 73.000 mm

(2.872 to 2.874 inch)

Thickness (Y) ........................ 5.486 to 5.537 mm

(0.21598 to 0.21799 inch)

i03916857

g02150462

Illustration 49

Camshaft Bearings

Typical example

(1)  Setscrew

Torque for the setscrews ..........  22 N·m (16 lb ft)

(2)  Dust cap

(3)  Oil sampling valve

Torque for the Oil sampling valve ............ 12 N·m

(106 lb in)

Torque for the plug (if equipped)  .. 12 N·m (106 lb in)

(4)  Engine oil filter

Torque for the engine oil filter .. 12 N·m (106 lb in)

g02150875

Illustration 48

Typical example

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KENR9123-01

25

Specifications Section

i04406752

i04346632

Engine Oil Cooler

Engine Oil Pump

  

  

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

Number of lobes

Inner rotor ......................................................... 6

Outer rotor ........................................................  7

g02600976

g00938064

Illustration 50

Illustration 52

Typical example

Typical example

Tighten the setscrews in the  sequence that is in

illustration 50 to the following torque. ............ 10 N·m

(89 lb in)

(1)  Clearance of  the outer  rotor to the

body ...................................... 0.050 to 0.330 mm

(0.0020 to 0.0130 inch)

g00938061

Illustration 53

Checking the clearance

(2)  Service limit  of inner  rotor to outer

rotor ......................................  0.080 to 0.250 mm

(0.0031 to 0.0098 inch)

g02600977

Illustration 51

Typical example

Tighten the setscrews in the  sequence that is in

illustration 51 to the following torque. ............ 26 N·m

(19 lb ft)

This document is printed from SPI². Not for RESALE

 

26

KENR9123-01

Specifications  Section

i03994212

Engine Oil Pressure

The minimum oil pressure at a  maximum engine

speed of 2200  rpm and at normal  operating

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

i04315734

Engine Oil Pan

g00938799

Illustration 54

Checking the end play

(3)  End play of rotor assembly

Inner rotor ............................. 0.050 to 0.180 mm

(0.0020 to 0.0071 inch)

Table 6

Required Tools

Outer rotor ............................  0.050 to 0.180 mm

(0.0020 to 0.0071 inch)

Tool

Part Number

Part Description

Qty

A

-

Loctite 5900

1

Front sealant

g02501636

Illustration 55

Typical example

(4)  Tighten the bolts to the following torque. .. 44 N·m

(32 lb ft)

g01254690

Illustration 56

Applying sealant

(5)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

Apply Tooling (A) to the cylinder block  and to the

timing case.

Note: Apply a sealant bead of 3.5 mm (0.1378 inch)

that is shown in illustration 56.

Rear sealant

Note: Install the rear oil seal before sealant is applied

to the bridge.

This document is printed from SPI². Not for RESALE

 

KENR9123-01

27

Specifications Section

Tighten the  remaining bolts to the  following

torque. ............................................. 22 N·m (16 lb ft)

(2)  Drain plug

Tighten the drain plug for the engine oil pan to

the following torque. .................  34 N·m (25 lb ft)

i03969629

Crankcase Breather

g01254887

Illustration 57

Applying sealant

ApplyTooling (A) to the bridge. The sealant must not

protrude more than 5 mm (0.1969 inch) above the

bridge.

g02162137

Illustration 59

Typical example

(1), (2), (3)  Tighten the setscrews to the following

torque. ......................................  22 N·m (16 lb ft)

g01255016

Illustration 58

Typical example

(1)  Tighten the four front bolts in position (X) to the

following torque. .......................  22 N·m (16 lb ft)

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28

KENR9123-01

Specifications  Section

i03916250

Opening temperature ........................ 80° to 84°C

(151° to 176°F)

Water Temperature Regulator

and Housing

Maximum open length of 11 mm (0.43307 inch) is

achieved at the following temperature. ...... 94° C

(201° F)

i03916132

Water Pump

g02150761

Illustration 60

Typical example

(3) Water temperature regulator housing

(1)  Torque for the vent plug ....... 22 N·m (16.22 lb ft)

g02150757

Illustration 62

(2)  Torque for the bolts that fasten the housing to the

cylinder head ............................  22 N·m (16 lb ft)

Tightening sequence

Tighten the setscrews in the numerical sequence

that is shown  in illustration 62 to the following

torque. ............................................. 22 N·m (16 lb ft)

g02150762

Illustration 61

Typical example

(4)  Water temperature regulator

This document is printed from SPI². Not for RESALE

 

KENR9123-01

29

Specifications Section

i03917011

Bore in  the cylinder block  for the main

bearings ............................ 88.246 to 88.272 mm

(3.4742 to 3.4753 inch)

Cylinder Block

(5)  Main bearing cap bolts

Use the following procedure in order to install  the

main bearing cap bolts:

1.  Apply clean engine oil to the threads of the main

bearing cap bolts.

2.  Put the main bearing caps in the correct position

that is indicated by a number on  the top of the

main bearing cap. Install the main bearing caps

with the locating tabs in correct alignment with the

recess in the cylinder block.

3.  Evenly tighten the main bearing cap bolts.

Torque for the main bearing cap bolts. ...... 80 N·m

(59 lb ft)

4.   After torquing the bolts for the main bearing caps,

the bolts must be rotated  for an additional 90

degrees.

Note: Ensure that the crankshaft can rotate freely.

g02150944

Illustration 63

Typical example

i04129189

(1)  Cylinder block

Crankshaft

(2)  Cylinder bore ................ 105.000 to 105.025 mm

(4.1338 to 4.1348 inch)

The maximum permissible wear for  the cylinder

bore ....................................... 0.15 mm (0.0059 inch)

(3)  Camshaft bearings

Diameter of  the bushing in  the cylinder

block for  the number  1  camshaft

bearing .............................. 55.563 to 55.593 mm

(2.1875 to 2.1887 inch)

Diameter of  the bore  in the cylinder

block for  the number  2  camshaft

journal ............................... 50.546 to 50.597 mm

(1.9900 to 1.9920 inch)

Diameter of  the bore  in the cylinder

block for  the number  3  camshaft

journal ............................... 50.292 to 50.343 mm

(1.9800 to 1.9820 inch)

Diameter of  the bore  in the cylinder

block for  the number  4  camshaft

journal ............................... 50.038 to 50.089 mm

(1.9700 to 1.9720 inch)

g02155393

Illustration 64

Typical example

(4)  Main bearings

(1) Crankshaft gear

(2) Crankshaft

(3) Crankshaft thrust washers

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30

KENR9123-01

Specifications  Section

Maximum permissible temperature of the gear for

installation on the crankshaft ........... 180 °C (356 °F)

Maximum permissible temperature of the drive gear

for the balancer (if equipped) for installation on the

crankshaft ........................................  180 °C (356 °F)

Note: Refer to Disassembly and Assembly for the

correct procedure to remove and install the  drive

gear for the balancer.

The end play of a new crankshaft ..... 0.1 to 0.41 mm

(0.00394 to 0.01614 inch)

Standard  thickness of  thrust

washer ..  2.69 to 2.75 mm (0.10591 to 0.10827 inch)

Oversize  thickness of  thrust

washer ... 2.89 to 2.95 mm (0.11378 to 0.11614 inch)

g02155394

Illustration 65

Typical example

(4) Journal 1

(5) Journal 2

(6) Journal 3

(7) Journal 4

(8) Journal 5

Refer to table 7 for the  run out of the crankshaft

journals.

Table 7

Journal

(1)

Run out of the Journals

Mounting

(2)

0.08 mm (0.0031 inch)

0.15 mm (0.0059 inch)

0.08 mm (0.0031 inch)

Mounting

(3)

(4)

(5)

This document is printed from SPI². Not for RESALE

 

KENR9123-01

31

Specifications Section

Inspect the crankshaft for wear or for damage. For

more information regarding the servicing  of the

crankshaft, contact the Global Technical Support

Center.

Refer to Specifications, “Connecting Rod Bearing

Journal” for more information on the connecting rod

bearing journals and connecting rod bearings.

Refer to Specifications, “Main Bearing Journal” for

information on the main bearing  journals and for

information on the main bearings.

i02934550

Crankshaft Seals

g00915076

Illustration 67

(5)  Tighten bolts 1, 2, 3, 4, 5, 6, 7,  and 10 in the

sequence that is shown in Illustration 67 to the

following torque. .......................  22 N·m (16 lb ft)

Remove the alignment tool.

Tighten bolts 8 and 9 in the sequence that is shown

in Illustration 67 to the following torque. ........ 22 N·m

(16 lb ft)

i03996317

Connecting Rod  Bearing

Journal

g01455434

Illustration 66

Typical example

The original size of the connecting rod bearing journal

on the crankshaft ........................  67.99 to 68.01 mm

(2.67677 to 2.67755 inch)

(1)  Crankshaft

(2)  Crankshaft seal

(3)  Plastic sleeve

(4)  Alignment tool

Maximum permissible wear of a  bearing journal

on the crankshaft when a  new connecting rod is

installed ................................. 0.04 mm (0.0016 inch)

Width of the connecting rod bearing journals on the

crankshaft ...............................  40.305 to 40.455 mm

(1.58681 to 1.59271 inch)

Surface finish  of connecting rod  bearing

journals ........................................... Ra 0.25 microns

This document is printed from SPI². Not for RESALE

 

32

KENR9123-01

Specifications  Section

i03996318

i04285130

Main Bearing Journal

Connecting Rod

The original  size of  the main  bearing

journal ..................................... 83.980 to 84.000 mm

(3.30629 to 3.30708 inch)

Maximum permissible wear of the  main bearing

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

Surface finish of bearing journals and  crank pins

........................................................ Ra 0.25 microns

Width of new main bearing journal where the thrust

washer is installed ..................  39.765 to 39.835 mm

(1.56555 to 1.56830 inch)

g01254512

Width of new main bearing journal where the thrust

washer is not installed ................  39.19 to 39.39 mm

(1.54291 to 1.55078 inch)

Illustration 68

Typical example

(1)  The bearing shell for the connecting rod

The shell for the main bearings

For the correct procedure  to install the bearing

shell for the connecting rod, refer to Disassembly

and Assembly, “Pistons and Connecting  Rods -

Assemble”.

The shells for  the main bearings are available

for remachined journals which have the following

oversize dimensions.

Table 8

Oversize bearing shell ...... 0.25 mm (0.010 inch)

Oversize bearing shell ...... 0.50 mm (0.020 inch)

Oversize bearing shell ...... 0.76 mm (0.030 inch)

Thickness of Connecting

1.995 to  2.002 mm

Rod Bearing  at the

(0.07854 to 0.07882 inch)

Center

Thickness at center of the shells of oversize bearing

shell 0.25 mm (0.010 inch) .........  2.226 to 2.232 mm

(0.08764 to 0.08787 inch)

0.031 to  0.038 mm

Bearing Clearance

(0.00122 to 0.00150 inch)

Table 9

Thickness at center of the shells of oversize bearing

shell 0.50 mm (0.020 inch) .........  2.353 to 2.359 mm

(0.09264 to 0.09287 inch)

Oversize Connecting Rod  Bearing

0.25 mm  (0.010 inch)

0.51 mm  (0.020 inch)

0.76 mm  (0.030 inch)

Thickness at center of the shells of oversize bearing

shell 0.76 mm (0.030 inch) .........  2.480 to 2.486 mm

(0.09764 to 0.09787 inch)

Width of the main bearing shells .. 26.32 to 26.58 mm

(1.03622 to 1.04645 inch)

Clearance between the bearing shell and the main

bearing journals ..........................  0.036 to 0.094 mm

(0.00142 to 0.00370 inch)

This document is printed from SPI². Not for RESALE

 

KENR9123-01

33

Specifications Section

g01950657

Illustration 69

Typical example

(U) Day code

(V) Code for the connecting rod

(X) Code for the Connecting rod  cap

(Y) Year code

(Z) Code for the grade of connecting rod

g01254518

Illustration 70

Note: The day code  is from the first day in  the

year. For example, “001” will be the first day of the

appropriate year.

Typical example

(3)  Diameter of the finished bore for  the piston

pin ..................................... 39.738 to 39.723 mm

(1.5645 to 1.5639 inch)

The mating surfaces of  the connecting rod are

produced by hydraulically fracturing  the forged

connecting rod. Ensure that  the correct cap for

the connecting rod is  installed with the correct

connecting rod. Ensure that the serial numbers for

both components match.

(4)  Distance between  the parent bores

...... 219.05 to 219.1 mm (8.6240 to 8.6260 inch)

(5)  Diameter for the finished bore for the connecting

rod bearing .......................  72.045 to 72.058 mm

(2.83641 to 2.83692 inch)

(2)  Torque of the setscrews for the connecting rod

..................................................  40 N·m (30 lb ft)

The connecting rod is color coded. The color code

is a reference for the length of the connecting rod.

Refer to table 10 for the length of connecting rod.

Tighten the setscrews for the  connecting rod for

an additional 120 degrees. The setscrews for the

connecting rod (2) must  be replaced after this

procedure.

Table 10

Specifications for the Connecting  Rod

Note: Always tighten the connecting rod cap to the

connecting rod, when the assembly is  out of the

engine. Tighten the assembly to the following torque

20 N·m (14 lb ft).

Grade

Letter

Length  Of The

Connecting Rod

Color Code

163.081 to 163.114 mm

(6.42050 to 6.42180

inch)

B

Blue

This document is printed from SPI². Not for RESALE

 

34

KENR9123-01

Specifications  Section

i04041471

Width of oil control ring ............. 2.97 to 2.99 mm

(0.1169 to 0.1177 inch)

Piston and Rings

The clearance between a new oil control ring and

the groove in a new piston ........ 0.03 to 0.07 mm

(0.0011 to 0.0027 inch)

Ring gap ...................................  0.30 to 0.55 mm

(0.0118 to 0.0216 inch)

Note: When you install a new oil control ring, make

sure that the word “TOP” is  facing the top of the

piston. New oil control rings have a red identification

mark. The identification mark must be  on the left

of the ring end  gap when the top piston ring  is

installed on an upright piston. The oil control ring is

a two-piece ring that is spring loaded. A pin is used

in order to hold both ends  of the spring of the oil

control ring in position. The ends of the spring of the

oil control ring must be installed opposite the end gap

of the oil control ring.

Note: Ensure that the ring end gaps of the  piston

rings are spaced 120 degrees from each other.

g01155119

Illustration 71

Typical example

Piston

(1)  Top compression ring

The shape  of the  top compression

ring ....................................................... Keystone

Note: An arrow which is marked on the piston crown

must be toward the front of the engine.

Ring gap ...................................  0.30 to 0.40 mm

(0.01181 to 0.01575 inch)

Piston height above cylinder block .. 0.55 to 0.20 mm

(0.02165 to 0.00787 inch)

Note: When you install a new top compression ring,

make sure that the word  “TOP” is facing the top

of the piston. New top piston  rings have a black

identification mark. The identification mark must be

on the left of the ring end gap when the  top piston

ring is installed on an upright piston.

Width of top groove in the piston .................  Tapered

Width  of second  groove  in new

piston ........  2.56 to 2.58 mm (0.1008 to 0.1016 inch)

Width of third groove in new piston .. 3.02 to 3.04 mm

(0.1189 to 0.1197 inch)

(2)  Intermediate compression ring

Piston pin

The shape of the intermediate  compression

ring ....................................... Internal bevel in the

bottom edge with a tapered face

Diameter  of  a new  piston

pin ..................................... 39.694 to 39.700 mm

(1.5628 to 1.5630 inch)

Width of  intermediate compression

ring .... 2.47 to 2.495 mm (0.0972 to 0.0982 inch)

The clearance between a  new intermediate

compression ring and the piston groove in a new

piston ..................................... 0.065 to 0.110 mm

(0.00256 to 0.00433 inch)

Ring gap ...................................  0.65 to 0.85 mm

(0.0256 to 0.0335 inch)

Note: When you  install a new  intermediate

compression ring, make sure that the word “TOP” is

facing the top of the piston. New intermediate rings

have a blue identification mark. The identification

mark must be on the left of the ring end gap when the

top piston ring is installed on an upright piston.

(3)  The oil control ring

This document is printed from SPI². Not for RESALE

 

KENR9123-01

35

Specifications Section

i02696381

2.  Dimension (A) is 50.75  mm (1.9980 inch)

and dimension (B) is 9.35  mm (0.3681 inch).

Dimension (A) and dimension (B) are tangential

to the cylinder bore (4).

Piston Cooling Jet

3.  The position of the  rod (3) must be  within

dimension (C).  Dimension (C) is 14  mm

(0.5512 inch).

Note: Ensure that the rod (3) can not damage the

piston cooling jet when the alignment is checked. The

piston cooling jets can not be adjusted. If a piston

cooling jet is not in alignment the piston cooling jet

must be replaced.

i04313812

Balancer Group

g01352576

Illustration 72

(1) Installed piston cooling jets

The valve must move freely. Tighten the bolt to the

following torque. .................................. 9 N·m (7 lb ft)

Piston Cooling Jet Alignment

g02150753

Illustration 74

Typical example

Tighten the bolts in the sequence that is shown  in

illustration 74 to the following torque. ............ 54 N·m

(40 lb ft)

g01352578

Illustration 73

Backlash values

(2) Piston cooling jet

(3) Rod

(4) Cylinder block

Backlash between crankshaft ring gear and the

balancer intermediate gear ... 0.020 to 0.240 mm

(0.0008 to 0.009 inch)

Use the following procedure in order to check  the

alignment of the piston cooling jet.

Backlash between  the balancer shaft

gears ..................................... 0.020 to 0.160 mm

(0.0008 to 0.0063 inch)

1.  Insert rod (3) into the end of the piston cooling

jet (2). Rod  (3) has a diameter of  1.70 mm

(0.067 inch). Rod (3) must protrude out of the top

of the cylinder block.

This document is printed from SPI². Not for RESALE

 

36

KENR9123-01

Specifications  Section

i03907005

(3)  Tighten bolts to the following torque. ....... 44 N·m

(33 lb ft)

Accessory Drive

(SAE “B”)

i03907004

Accessory Drive

g02148374

Illustration 75

Typical example

g02148372

Illustration 77

(1)  Tighten allen head screws to  the following

torque. ......................................  22 N·m (16 lb ft)

Typical example

(1)  Tighten the allen head screws to the following

torque. ......................................  22 N·m (16 lb ft)

(2)  Tighten the allen head screw to the following

torque. ......................................  78 N·m (58 lb ft)

(2)  Tighten the allen head screws to the following

torque. ......................................  78 N·m (58 lb ft)

g02148375

Illustration 76

Typical example

This document is printed from SPI². Not for RESALE

 

KENR9123-01

37

Specifications Section

i03917090

(2)  Tighten the bolts that fasten the water pump to the

front housing to the following torque. ....... 22 N·m

(16 lb ft)

Front Housing and Covers

Note: Refer to Specifications, “Water Pump” for the

correct bolt tightening sequence for the water pump.

i04351939

Gear Group (Front)

g01860874

Illustration 78

Typical example

Tighten the setscrew to the sequence that is shown

in illustration 78 to the following torque. ......... 28 N·m

(20 lb ft)

g01857156

Illustration 80

Gear train

(1)  Camshaft gear

Torque for the 8.8 graded bolt for the camshaft

gear ..........................................  95 N·m (70 lb ft)

Torque for the 10.9 graded bolt for the camshaft

gear ........................................  120 N·m (89 lb ft)

Number of teeth .............................................. 72

(2)  Idler gear and hub

Torque for the bolts for the idler gear ....... 44 N·m

(33 lb ft)

Width of light  duty idler gear and  bearing

assembly ..............................  19.95 to 20.05 mm

(0.78543 to 0.78937 inch)

Width of medium duty and heavy duty idler gear

and bearing assembly ..........  25.45 to 25.55 mm

(1.00197 to 1.00590 inch)

g02150954

Illustration 79

Typical example

Inside diameter  of light duty  idler gear

bearings ............................ 60.022 to 60.052 mm

(2.36307 to 2.36425 inch)

(1)  Tighten the bolts that fasten the front cover to the

front housing to the following torque. ....... 22 N·m

(16 lb ft)

This document is printed from SPI². Not for RESALE

 

38

KENR9123-01

Specifications  Section

Inside diameter of medium duty and heavy duty

idler gear bearings ................ 56.00 to 56.03 mm

(2.20472 to 2.20590 inch)

Backlash between  the power take-off

drive (if  equipped) and  the idler gear

(2) .....  0.05 to 0.250 mm (0.0020 to 0.0098 inch)

Outside diameter of  light duty idler  gear

hub ........................................ 59.95 to 59.97 mm

(2.36023 to 2.36102 inch)

(5)  Oil pump idler gear

Inside diameter  of oil pump  idler gear

bearing .............................. 16.012 to 16.038 mm

(0.6304 to 0.6314 inch)

Outside diameter of medium duty and heavy duty

idler gear hub ........................ 55.95 to 55.97 mm

(2.20275 to 2.20354 inch)

Outside diameter  of oil pump idler  gear

shaft .................................. 15.966 to 15.984 mm

(0.6286 to 0.6293 inch)

Clearance of light duty idler  gear bearing on

hub ........................................ 0.052 to 0.102 mm

(0.00205 to 0.00402 inch)

Clearance of oil pump  idler gear bearing on

shaft ...................................... 0.028 to 0.072 mm

(0.0011 to 0.0028 inch)

Clearance of medium duty and heavy duty idler

gear bearing on hub .................  0.03 to 0.08 mm

(0.00118 to 0.00315 inch)

End  play of  the oil  pump  idler

gear ......................................  0.050 to 0.275 mm

(0.0019 to 0.0108 inch)

The end  play of  the light  duty idler

gear ..........................................  0.05 to 0.25 mm

(0.00197 to 0.00984 inch)

End play  of  the oil  pump  drive

gear ......................................  0.005 to 0.090 mm

(0.00020 to 0.00354 inch)

The end play of the medium duty and heavy duty

idler gear ................................... 0.05 to 0.15 mm

(0.00197 to 0.00591 inch)

(6)  Crankshaft gear

Number of teeth .............................................. 97

Bore diameter  of crankshaft  gear

........ 51.00 to 51.03 mm (2.0079 to 2.0091 inch)

(3)  Fuel injection pump drive gear

Outside  diameter of  crankshaft

hub .................................... 51.021 to 51.002 mm

(2.0087 to 2.0079 inch)

Torque for the nut .....................  64 N·m (47 lb ft)

Number of teeth .............................................. 36

Clearance  of  gear  on

crankshaft ......................... −0.021 to +0.028 mm

(4)  Oil pump gear

(−0.00083 to 0.00110 inch)

The number of teeth on the oil pump gear .....  21

Number of teeth .............................................. 36

Backlash values

Backlash between the oil pump idler gear (5) and

the oil pump drive gear (4) ........ 0.05 to 0.15 mm

(0.0020 to 0.0059 inch)

Backlash between the oil pump idler gear (5) and

the crankshaft gear (6) .........  0.025 to 0.160 mm

(0.00098 to 0.00630 inch)

Backlash between the idler gear  (2) and the

crankshaft gear (6) ...................  0.05 to 0.15 mm

(0.0020 to 0.0059 inch)

Backlash between the camshaft gear (1) and the

idler gear (2) .............................  0.05 to 0.15 mm

(0.0020 to 0.0059 inch)

Backlash between the fuel injection pump gear

(3) and the idler gear (2) ........... 0.05 to 0.15 mm

(0.0020 to 0.0059 inch)

Backlash between the water pump  gear (not

shown) and the  fuel injection pump gear

(3) .......  0.05 to 0.15 mm (0.0020 to 0.0059 inch)

This document is printed from SPI². Not for RESALE

 

KENR9123-01

39

Specifications Section

i03520340

Flywheel

g00584712

g01254486

Illustration 81

Illustration 82

Typical example

Typical example

(1)  Flywheel ring gear

Setscrew

Heat the flywheel ring  gear to the following

temperature. ..............................  250 °C (480 °F)

(1)  Tighten the setscrew  to the following

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

Note: Do not use an oxyacetylene torch to heat the

flywheel ring gear.

Setscrew

(2)  Tighten the setscrew  to the following

torque. ................................  63 N·m (46 lb ft)

(2)  Flywheel

(3)  Bolt

Note: If 12.9 setscrews are installed, apply Tooling

(A) to the setscrews. Tighten the 12.9 setscrews to a

torque of 70 N·m (52 lb ft).

Tighten the flywheel  bolts to the following

torque. ..................................  140 N·m (103 lb ft)

i04315754

Flywheel Housing

Table 11

Required Tools

Tool

Part Number

Part Description

Qty

A

-

Loctite 575

1

This document is printed from SPI². Not for RESALE

 

40

KENR9123-01

Specifications  Section

i03934631

i04083729

Crankshaft Pulley

Belt Tensioner

g02155003

g02291813

Illustration 83

Illustration 84

Typical example

Typical example

(1)  Tighten the bolts to the following torque. .. 78 N·m

(58 lb ft)

(1)  Tighten the bolt to the following torque. ... 45 N·m

(33 lb ft)

(3)  Tighten the  bolts to  the following

torque. ...................................  22.5 N·m (17 lb ft)

Note: To  install the belt tensioner,  refer to

Disassembly and Assembly,  “Belt Tensioner -

Remove and Install” for the correct procedure.

Note: Tighten the bolts (3) must be tightened through

an angle of 120 degrees.

(2)  Auxiliary pulley

(4)  Crankshaft pulley

This document is printed from SPI². Not for RESALE

 

KENR9123-01

41

Specifications Section

i03629003

i04089710

Refrigerant Compressor

Fan Drive

g01946810

g02297293

Illustration 85

Illustration 86

Typical example

Typical example

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

(32 lb ft)

(1)  Tighten the locking nuts  to the following

torque. ......................................  22 N·m (16 lb ft)

(2)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

(2)  Tighten the studs (if equipped) to the following

torque. ......................................  11 N·m (97 lb in)

(3)  Tighten the bolts to the following torque. .. 44 N·m

(32 lb ft)

i03520381

Engine Lifting Bracket

All engines are equipped engine lifting  brackets.

Some lifting brackets require two bolts and  some

lifting brackets may require four bolts.

Tighten the bolts on the engine lifting brackets to

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

This document is printed from SPI². Not for RESALE

 

42

KENR9123-01

Specifications  Section

i03917270

Output

Alternator

The outputs of the alternators ........... 55 Amp, 80

Amp, 100 Amp, 120 Amp or 150 Amp

Alternator Bracket

The 12  V and  24 V Type  1

Alternators

g02151927

Illustration 88

Typical example

(1)  Tighten the setscrews that secure the alternator

to the bracket to the following torque. ...... 50 N·m

(37 lb ft)

(2)  Tighten the setscrews  that secure the

bracket to the cylinder block  to the following

torque. ......................................  44 N·m (32 lb ft)

g02149533

Illustration 87

Typical example

(1)  Terminal “B+”

Tighten the  nut on the  terminal to the

following. .................................. 7.5 N·m (66 lb in)

(2)  Terminal “D+”

Tighten the nut on the terminal to the following

torque. ..................................... 2.2 N·m (19 lb in)

(3)  Terminal “B-” (if equipped)

Tighten the nut on the terminal to the following

torque. ........................................ 7 N·m (62 lb in)

(4)  Terminal “W”

Tighten the nut on the terminal to the following

torque. ..................................... 2.2 N·m (19 lb in)

Tighten the nut for  the alternator pulley to the

following torque. .............................. 95 N·m (70 lb ft)

This document is printed from SPI². Not for RESALE

 

KENR9123-01

43

Specifications Section

12 V Starting Motor 3 kW, 4 kW, and

24 V Starting Motor 4.5 kW

i04458352

Starter Motor

24 V Starting Motor 5.5 kW

g01943502

Illustration 90

Typical example

(1)  Tighten the positive terminal nut to the following

torque. ....................................... 15 N·m (11 lb ft)

(2)  Tighten the solenoid terminal to the following

torque. ..................................... 5.8 N·m (51 lb in)

g02643800

Illustration 89

Typical example

(3)  Tighten the negative terminal nut to the following

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

(1)  Tighten the solenoid terminal to the following

torque. ..................................... 2.5 N·m (22 lb in)

Rated voltage ..................................................... 12 V

(2)  Tighten the positive terminal nut to the following

torque. ....................................... 15 N·m (11 lb ft)

(3)  Tighten the negative terminal nut to the following

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

Rated voltage ..................................................... 24 V

This document is printed from SPI². Not for RESALE

 

44

KENR9123-01

Specifications  Section

i04067589

i03916100

Coolant Temperature Sensor

Engine Oil Pressure Sensor

g02285594

g02150747

Illustration 91

Illustration 92

Typical example

Typical example

(1)  Sensor

(1)  Sensor

Torque for the sensor  ............... 20 N·m (15 lb ft)

Tighten the  sensor. Torque  for the

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

This document is printed from SPI². Not for RESALE

 

KENR9123-01

45

Specifications Section

i03916119

i04285191

Boost Pressure Sensor

Atmospheric Pressure Sensor

g02150750

g02452158

Illustration 93

Illustration 95

Typical example

Typical example

(1)  Tighten the atmospheric pressure sensor to the

following torque. ....................... 10 N·m (89 lb in)

g01332534

Illustration 94

Typical example

(1)  Tighten the  sensor to  the following

torque. ......., ............................... 10 N·m (89 lb in)

This document is printed from SPI². Not for RESALE

 

46

KENR9123-01

Specifications  Section

i03916112

Inlet Manifold Temperature

Sensor

g02154926

Illustration 97

Typical example

Note: Use tooling (A) in order to lubricate the thread

of temperature sensor (1).

(1)  Tighten the temperature sensors to the following

torque. ......................................  45 N·m (33 lb ft)

g02150749

Illustration 96

Typical example

i03996416

Pressure Sensor  (NOx

Reduction System)

(1)  Tighten the  sensor to  the following

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

i04229390

Temperature Sensor (DPF

Inlet)

Table 12

Required Tools

Tool

Part Number

Part Description

Qty

Bostik Pure Nickel

Anti-Seize Compound

A

-

1

g02174143

Illustration 98

Typical example

This document is printed from SPI². Not for RESALE

 

KENR9123-01

47

Specifications Section

(1)  Tighten the pressure sensors to the following

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

Operating voltage ........................................... 5 VDC

i04285189

i04285190

Temperature Sensor (NOx

Reduction System)

Speed/Timing Sensor

g01854256

Illustration 101

Typical example

g02452136

Illustration 99

Typical example

g02150748

Illustration 102

Typical example

(1)  Tighten the bolt for the crankshaft position sensor

to the following torque. .............  14 N·m (10 lb ft)

(2)  Tighten the bolt for the camshaft position sensor

to the following torque. .............  14 N·m (10 lb ft)

g02152917

Illustration 100

Typical example

(1)  Tighten the  sensor to  the following

torque. ......................................  30 N·m (22 lb ft)

This document is printed from SPI². Not for RESALE

 

48

KENR9123-01

Specifications  Section

i04285193

i03918469

Electronic Control Module

Glow Plugs

g02465316

Illustration 103

Typical example

(1) Electronic control module (ECM)

(3) Fuel line connectors

g01861335

Illustration 104

(2)  Bolt

Typical example

Tighten the four bolts for the ECM. Torque for the

bolts ..........................................  22 N·m (16 lb ft)

Tighten the glow plugs (2) in the cylinder head to the

following torque. ............................... 15 N·m (11 lb ft)

Tighten the nuts  (1) for the bus bar  (3) that is

installed on top of the glow plugs  to the following

torque. ............................................... 2 N·m (18 lb in)

Tighten the nut (4) for the isolator for the bus bar to

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

Voltage .................................................. 12 V or 24 V

This document is printed from SPI². Not for RESALE

 

KENR9123-01

49

Specifications Section

i03907009

(3)  Tighten the bolts to the following torque. .. 16 N·m

(12 lb ft)

Air Compressor

(Twin Cylinder Compressor)

g02148381

Illustration 107

Typical example

(4)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

g02148379

Illustration 105

(5)  Tighten the bolts to the following torque. .. 44 N·m

(32 lb ft)

Typical example

(1)  Tighten the nut to the following torque. .. 120 N·m

(89 lb ft)

g02148408

Illustration 108

Typical example

g02148380

Illustration 106

(6)  Tighten the banjo  bolt to the  following

Typical example

torque. ........................................ 9 N·m (80 lb in)

(2)  Tighten the nuts to the following torque. .. 78 N·m

(58 lb ft)

For the correct procedure to install the air compressor,

refer to Disassembly and Assembly, “Air Compressor

- Remove and Install - Twin Cylinder Compressor”.

This document is printed from SPI². Not for RESALE

 

50

KENR9123-01

Specifications  Section

i03907068

(3)  Tighten the bolts to the following torque. .. 13 N·m

(115 lb in)

Air Compressor

(Single Cylinder)

g02148447

Illustration 111

Typical example

(4)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

g02148439

Illustration 109

(5)  Tighten the bolts to the following torque. .. 44 N·m

(32 lb ft)

Typical example

(1)  Tighten the nut to the following torque. .. 120 N·m

(89 lb ft)

(6)  Tighten the banjo  bolt to the  following

torque. ........................................ 9 N·m (80 lb in)

For the correct procedure to install the air compressor,

refer to Disassembly and Assembly, “Air Compressor

- Remove and Install - Single Cylinder”.

g02148442

Illustration 110

Typical example

(2)  Tighten the nuts to the following torque. .. 78 N·m

(58 lb ft)

This document is printed from SPI². Not for RESALE

 

KENR9123-01

51

Index  Section

Index

A

F

Accessory Drive..................................................... 36

Accessory Drive (SAE “B”) .................................... 36

Air Compressor (Single Cylinder)..........................  50

Air Compressor (Twin Cylinder Compressor)........  49

Alternator...............................................................  42

Alternator Bracket .............................................. 42

The 12 V and 24 V Type 1 Alternators............... 42

Atmospheric Pressure Sensor...............................  45

Fan Drive...............................................................  41

Flexible Exhaust Pipe............................................  22

Flywheel ................................................................ 39

Flywheel Housing .................................................. 39

Front Housing and Covers..................................... 37

Fuel Filter Base (Primary Fuel Filter Base) ...........

Fuel Filter Base  (Single Secondary Fuel Filter

Base) ...................................................................

Fuel Filter Base  (Twin Secondary Fuel Filter

Base) ...................................................................

Fuel Injection Lines................................................

Fuel Injection Pump...............................................

Fuel Injectors.........................................................

Fuel Manifold (Rail) ...............................................

Fuel Transfer Pump...............................................

8

7

7

4

5

6

8

6

B

Balancer Group ..................................................... 35

Belt Tensioner........................................................ 40

Boost Pressure Sensor.......................................... 45

C

G

Camshaft...............................................................  23

Camshaft Bearings................................................  24

Connecting Rod.....................................................  32

Connecting Rod Bearing Journal........................... 31

Coolant Temperature Sensor................................. 44

Crankcase Breather............................................... 27

Crankshaft ............................................................  29

Crankshaft Pulley .................................................. 40

Crankshaft Seals...................................................  31

Cylinder Block........................................................ 29

Cylinder Head........................................................  12

Cylinder Head Valves ............................................ 11

Gear Group (Front)................................................ 37

Glow Plugs ............................................................ 48

I

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

2

Inlet Manifold Temperature Sensor........................ 46

L

Lifter Group............................................................

9

D

M

Diesel Particulate Filter.......................................... 22

Main Bearing Journal............................................. 32

The shell for the main bearings.......................... 32

E

Electronic Control Module ..................................... 48

P

Engine Design.......................................................

4

Engine Lifting Bracket............................................ 41

Engine Oil Cooler .................................................. 25

Engine Oil Filter Base............................................ 24

Engine Oil Pan....................................................... 26

Front sealant......................................................  26

Rear sealant....................................................... 26

Engine Oil Pressure............................................... 26

Engine Oil Pressure Sensor..................................  44

Engine Oil Pump.................................................... 25

Exhaust Cooler (NRS)...........................................  19

Exhaust Gas Valve (NRS) ..................................... 17

Exhaust Manifold...................................................  21

Exhaust Sensor and Lines (NRS).......................... 18

Piston and Rings ................................................... 34

Piston.................................................................  34

Piston Cooling Jet.................................................. 35

Piston Cooling Jet Alignment.............................  35

Pressure Sensor (NOx Reduction System)...........  46

R

Refrigerant Compressor........................................  41

Rocker Shaft..........................................................

9

S

Specifications Section ...........................................

4

This document is printed from SPI². Not for RESALE

 

Speed/Timing Sensor............................................  47

Starter Motor.......................................................... 43

12 V Starting Motor 3 kW, 4 kW, and 24 V Starting

Motor 4.5 kW....................................................  43

24 V Starting Motor 5.5 kW................................ 43

T

Table of Contents...................................................

3

Temperature Sensor (DPF Inlet)............................ 46

Temperature Sensor (NOx Reduction System) ..... 47

Turbocharger (Series Turbochargers) ................... 13

Turbocharger (Single Turbocharger) ..................... 15

V

Valve Mechanism Cover........................................  10

W

Water Pump........................................................... 28

Water Temperature Regulator and Housing..........  28