001a HM02316_00 Engine Specifications

8/18/2019 001a HM02316_00 Engine Specifications

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SENR9936-06

January 2008

SpecificationsC27 and C32 Engines for Caterpillar Built Machines

5301-Up (Machine)2211-Up (Machine)LWA1-Up (Machine)GEB1-Up (Machine)TPB1-Up (Machine)H4C1-Up (Machine)EED1-Up (Machine)RJG1-Up (Machine)Z9K1-Up (Machine)JRP1-Up (Machine)DLS1-Up (Machine)BTW1-Up (Machine)JNW1-Up (Machine)BWX1-Up (Machine)


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i01658146

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

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

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

Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such 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 pictoriallypresented.

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

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,

measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

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

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


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SENR9936-06 3Table of Contents

Table of Contents

Specifications Section

Engine Design ....................................................... 4Engine Design ....................................................... 4Fuel Transfer Pump ............................................... 5Fuel Filter Base ...................................................... 5Fuel Filter Base ...................................................... 6Electronic Unit Injector Mechanism ....................... 6Electronic Unit Injector Rocker Arm ........................ 7Electronic Unit Injector Wiring ................................. 7Valve Mechanism ................................................... 8Valve Mechanism ................................................... 9Cylinder Head Valves ........................................... 10Cylinder Head ....................................................... 11Compression Brake .............................................. 13Turbocharger ....................................................... 16Turbocharger ....................................................... 18

Turbocharger ....................................................... 20Turbocharger ....................................................... 21Turbocharger ....................................................... 22Exhaust Manifold ................................................. 24Exhaust Manifold ................................................. 26Exhaust Manifold ................................................. 28Exhaust Manifold ................................................. 29Exhaust Manifold ................................................. 30Camshaft ............................................................. 31Engine Oil Filter Base .......................................... 32Engine Oil Filter Base .......................................... 33Engine Oil Pump .................................................. 34Engine Oil Pump .................................................. 36Engine Oil Bypass Valve ...................................... 38

Engine Oil Bypass Valve ...................................... 39Engine Oil Pan ..................................................... 40Engine Oil Pan ..................................................... 41Engine Oil Pan ..................................................... 42Water Temperature Regulator .............................. 42Water Pump ......................................................... 43Cylinder Block ...................................................... 43Cylinder Liner ....................................................... 45Cylinder Liner ....................................................... 46Crankshaft ........................................................... 47Crankshaft Seals ................................................. 49Vibration Damper ................................................. 49Vibration Damper ................................................. 50Vibration Damper ................................................. 50

Vibration Damper ................................................. 51Vibration Damper ................................................. 51Connecting Rod Bearing Journal ......................... 52Main Bearing Journal ............................................ 52Connecting Rod ................................................... 53Piston and Rings .................................................. 55Piston and Rings .................................................. 57Housing (Front) ..................................................... 58Housing (Rear) ..................................................... 59Gear Group (Front) ............................................... 61Gear Group (Rear) ................................................ 62Gear Group (Rear) ................................................ 63Gear Group (Rear) ................................................ 65Gear Group (Rear) ................................................ 67

Flywheel ............................................................... 68Flywheel ............................................................... 69Flywheel ............................................................... 70Flywheel Housing ................................................ 70Flywheel Housing ................................................ 72Flywheel Housing ................................................ 73Flywheel Housing ................................................ 75

Flywheel Housing ................................................ 77Coolant Temperature Sensor ............................... 78Coolant Temperature Sensor ............................... 79Coolant Flow Switch ............................................ 79Fuel Temperature Sensor ..................................... 80Fuel Temperature Sensor ..................................... 81Fuel Filter Pressure Differential Switch ................. 81Mass Air Flow Sensor ........................................... 82Mass Air Flow Sensor ........................................... 83Engine Oil Pressur e Sensor ................................. 83Engine Oil Pressure Sensor ................................. 84

Atmospheric Pressure Sensor .............................. 84 Atmospheric Pressure Sensor .............................. 85 Atmospheric Pressure Sensor .............................. 85

Inlet Manifold Temperature Sensor ....................... 86Turbocharger Inlet Pressure Sensor ..................... 86Turbocharger Inlet Pressure Sensor ..................... 87Speed/Timing Sensor .......................................... 87

Index Section

Index ..................................................................... 89


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4 SENR9936-06Specifications Section

Specifications Section

i02810716

Engine Design

SMCS Code: 1201

S/N: EED1-Up

S/N: RJG1-Up

S/N: DLS1-Up

S/N: BTW1-Up

S/N: JNW1-Up

S/N: BWX1-Up

g01113721Illustration 1

(A) Inlet valves(B) Exhaust valves

Bore ........................................ 137.2 mm (5.40 inch)

Stroke ..................................... 152.4 mm (6.00 inch)

Displacement ................................. 27 L (1648 cu in)

Compression ratio .............................................. 15:1

Cylinder arrangement ..................... 65 degrees V 12

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

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

Valve lash with engine stopped (cold)

Inlet ........... 0.38 ± 0.08 mm (0.015 ± 0.003 inch)Exhaust ..... 0.76 ± 0.08 mm (0.030 ± 0.003 inch)

Note: The front of the engine is opposite of theflywheel end of the engine. The left side and the rightside of the engine are viewed from the flywheel endof the engine. The No. 1 cylinder is the front cylinder on the left side. The No. 2 cylinder is the front cylinder on the right side.

The crankshaft rotation is viewed from the flywheelend of the engine.

Crankshaft r otation ................. Counterclockwise

Note: Number one cylinder is the front cylinder on the left side of the cylinder block. Number twocylinder is the front cylinder on the right side of thecylinder block.

Firing order ............ 1, 10, 9, 6, 5, 12, 11, 4, 3, 8, 7, 2

i02856750

Engine DesignSMCS Code: 1201

S/N: 5301-Up

S/N: 2211-Up

S/N: LWA1-Up

S/N: GEB1-Up

S/N: TPB1-Up

S/N: H4C1-Up

S/N: Z9K1-Up

S/N: JRP1-Up


(A) Inlet valves(B) Exhaust valves

Bore ............................................. 145 mm (5.7 inch)

Stroke .......................................... 162 mm (6.4 inch)


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SENR9936-06 5Specifications Section

Displacement ................................. 32 L (1953 cu in)

Compression ratio .............................................. 15:1

Cylinder arrangement ...................... 65 degrees V12

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

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

Valve lash measurement

Inlet ................. 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

Exhaust ........... 0.76 ± 0.08 mm (0.030 ± 0.003 inch)

Crankshaft rotation direction (view from the flywheelend) ............................................... Counterclockwise

Firing order (injectionsequence) .............. 1, 10, 9, 6, 5, 12, 11, 4, 3, 8, 7, 2

The no. 1 cylinder is the front cylinder on the left sideof the cylinder block. The no. 2 cylinder is the frontcylinder on the right side of the cylinder block.

Note: The front of the engine is opposite of theflywheel end of the engine. The left side of the engineand the right side of the engine is viewed from theflywheel end of the engine.

i02774897

Fuel Transfer Pump

SMCS Code: 1256

Part No.: 286-2531


(1) Pressure regulating valve(2) Weep hole(3) Inlet port(4) Outlet port

Note: Maximum inlet pressure to the pump shall notexceed 69 kPa (10 psi).

When the fuel transfer pump is using diesel fuel, thefuel transfer pump has the following specifications:

Run the pump at 2940 rpm. The full bypass pressureshould be the f ollowing value. ........... 716 to 786 kPa

(104 to 114 psi)

Run the pump at 840 rpm. The flow at 550 kPa(80 psi) must be 6.0 L/min (1.6 US gpm).

Run the pump at 2940 rpm. The flow at 650 kPa(94 psi) must be 9.0 L/min (2.38 US gpm).

Run the pump at 120 rpm with the inlet open to theatmosphere for 10 seconds. Block the inlet. Thepump must maintain vacuum of 30 kPa (4.5 psi)minimum in 30 seconds.

Run the pump at 840 rpm with the inlet open to theatmosphere f or 10 seconds. Block the inlet. Thepump must maintain vacuum of 45 kPa (6.5 psi)

minimum in 30 seconds.

Run the pump at 120 rpm with a blocked inlet that isfull of fuel for 30 seconds. The pump inlet must havea suction lift of 60.9 kPa (18 In Hg) minimum.

When the pump is viewed from the drive gear end or the dr ive shaft, the rotation of the pump iscounterclockwise.

i02774886

Fuel Filter Base

SMCS Code: 1261; 1262

Part No.: 237-9307


(1) Base


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(A) Apply 154-9731 Thread Lock Compound to thethreads on the taperlock end of the stud to thefollowing distance. ....................... 39.5 ± 0.5 mm

(1.56 ± 0.02 inch)

(2) Torque for the stud ..... 70 ± 15 N·m (50 ± 11 lb ft)

i02864490

Fuel Filter Base

SMCS Code: 1261; 1262

Part No.: 266-9459S/N: LWA1-Up

Part No.: 266-9459S/N: GEB1-Up

Part No.: 266-9459S/N: TPB1-Up

Part No.: 266-9459S/N: Z9K1-Up


(A) Length for applying 154-9731 Thread LockCompound to the threads on the taperlock end of the stud ........... 39.5 ± 0.5 mm (1.56 ± 0.02 inch)

(1) Torque for the stud ..... 70 ± 15 N·m (50 ± 11 lb ft)

i02792816

Electronic Unit Injector Mechanism

SMCS Code: 1290

Part No.: 255-8001, 260-9631S/N: 5301-Up

Part No.: 255-8001, 260-9631S/N: 2211-Up

Part No.: 255-8001, 260-9631S/N: LWA1-Up



Part No.: 255-8001, 260-9631S/N: H4C1-Up

Part No.: 255-8001, 260-9631S/N: EED1-Up

Part No.: 260-9631S/N: RJG1-Up

Part No.: 255-8001, 260-9631S/N: Z9K1-Up

Part No.: 255-8001, 260-9631S/N: JRP1-Up

Part No.: 255-8001, 260-9631S/N: DLS1-Up

Part No.: 260-9631S/N: BTW1-Up

Part No.: 260-9631S/N: JNW1-Up

Part No.: 260-9631S/N: BWX1-Up


(4) Spacer

Note: Refer to Testing and Adjusting, “Electronic UnitInjector - Adjust” for the correct procedure for settingthe lash on the electronic unit injector.

Note: Before installation of the unit injector, lubricatethe top two O-ring seals (6) with a 50/50 mixture of clean engine oil and 8T-2998 Lubricant.


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(1) Torque for cap nut .. 2.50 ± 0.25 N·m (22 ± 2 lb in)

(2) Torque for nut ............ 100 ± 10 N·m (75 ± 7 lb ft)

(A) Adjust the unit injector height from the timing seatto the following distance. ............. 78.0 ± 0.2 mm

(3.07 ± 0.01 inch)

Use the following procedure to tighten the bolt (3)for clamp (5):

1. Tighten the bolt for the clamp to 55 ± 10 N·m(41 ± 7 lb ft).

2. Loosen the bolt for the clamp until the bolt is finger tight.

3. Tighten the bolt for the clamp again to 55 ± 10 N·m(41 ± 7 lb ft).

i02796857

Electronic Unit Injector Rocker Arm

SMCS Code: 1123

Part No.: 278-1363


Typical example

(1) Location of bearing joint

Note: The sleeve bearing and pin must not extend

beyond either face of the rocker arm.

(A) Dimension for bore of new sleeve bearing after installation ............................ 40.065 ± 0.015 mm

(1.5774 ± 0.0006 inch)

i02864507

Electronic Unit Injector Wiring

SMCS Code: 1290

Part No.: 223-6408, 249-8717S/N: 5301-Up

Part No.: 223-6408, 249-8717S/N: 2211-Up

Part No.: 223-6408, 249-8717S/N: LWA1-Up



Part No.: 223-6408, 249-8717S/N: H4C1-Up

Part No.: 223-6408, 249-8717S/N: EED1-Up


Part No.: 223-6408, 249-8717S/N: Z9K1-Up

Part No.: 223-6408, 249-8717S/N: JRP1-Up

Part No.: 223-6408, 249-8717S/N: DLS1-Up





Typical example

(1) Engine harness assembly and connector seal


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Note: Install the flat part of the connector seal againstthe connector surface. The curved part of the sealmust be installed so that the seal is against the valvemechanism cover base.

(2) Torque for the 24 retainer nuts that are on the 12cap assemblies ..... 2.50 ± 0.25 N·m (22 ± 2 lb in)

Note: Orient connectors so wires are not contactingmetal surfaces.

i02897419

Valve Mechanism

SMCS Code: 1102

Part No.: 260-9631


(1) Rocker arm(4) Camshaft(6) Valve bridge

(2) Torque for the adjustment screwlocknut ........................... 30 ± 7 N·m (22 ± 5 lb ft)

(3) Rocker shaft assembly

Diameter of a new rocker armshaft ..................................... 40.000 ± 0.010 mm

(1.5748 ± 0.0004 inch)Bore in a new bearing for rocker armshaft ..................................... 40.065 ± 0.015 mm

(1.5774 ± 0.0006 inch)Maximum dimension for the bore in a wornbearing for rocker arm shaft ............. 40.193 mm

(1.5824 inch)

Note: Refer to Testing and Adjusting, “Engine ValveLash - Inspect/ Adjust” for the correct procedure onsetting the engine valve lash.

(5) Location f or checking the valve lash

Inlet valves ................................. 0.38 ± 0.08 mm

(0.015 ± 0.003 inch)Exhaust valves .......................... 0.76 ± 0.08 mm(0.030 ± 0.003 inch)


Left side of engine


Right side of engine


Tightening sequence


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Note: Tighten the bolts for the rocker arm group in thesequence 9, 10, 8, 11, 9, 10. Refer to Illustration 12.

(7) Torque for bolts ........ 109 ± 15 N·m (80 ± 11 lb ft)

i02794903

Valve MechanismSMCS Code: 1102

Part No.: 255-8001S/N: 5301-Up

Part No.: 255-8001S/N: 2211-Up


Part No.: 255-8001S/N: H4C1-Up

Part No.: 255-8001S/N: EED1-Up


Part No.: 255-8001S/N: JRP1-Up

Part No.: 255-8001S/N: DLS1-Up


(1) Rocker arm(4) Camshaft(6) Valve bridge

(2) Torque for the adjustment screwlocknut ........................... 30 ± 7 N·m (22 ± 5 lb ft)

(3) Rocker shaft assembly

Diameter of a new rocker arm shaft........ 40.000 ± 0.010 mm (1.5748 ± 0.0004 inch)

Bore in a new bearing for rocker armshaft ..................................... 40.065 ± 0.015 mm

(1.5774 ± 0.0006 inch)Maximum dimension for the bore in a wornbearing for rocker arm shaft ............. 40.193 mm

(1.5824 inch)

Note: Refer to Testing and Adjusting, “Engine ValveLash - Inspect/Adjust” for the correct procedure onsetting the engine valve lash.

(5) Location for checking the valve lash

Inlet valves ................................. 0.38 ± 0.08 mm(0.015 ± 0.003 inch)

Exhaust valves .......................... 0.76 ± 0.08 mm(0.030 ± 0.003 inch)


Left side of engine


Right side of engine

(7) Torque for bolts ........ 109 ± 15 N·m (80 ± 11 lb ft)


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i02838507

Cylinder Head Valves

SMCS Code: 1105

Part No.: 284-8892


(1) Exhaust valve(2) Inlet valve

Note: Lubricate inner diameter of valve guides withclean engine oil immediately prior to valve installationin the cylinder.

(3) 247-9908 Springs

Quantity .......................................................... 24Length under test force ... 67.12 mm (2.643 inch)Test force .................... 320 ± 25 N (71.9 ± 5.6 lb)

Approximate free length after test ...... 76.70 mm(3.020 inch)

Outside diameter ................ 36.3 mm (1.43 inch)

(4) 211-3122 Springs

Quantity .......................................................... 24Length under test force ... 60.14 mm (2.368 inch)

Test force .................... 150 ± 12 N (33.7 ± 2.7 lb) Approximate free length after test ...... 71.70 mm(2.823 inch)

Outside diameter ............ 25.17 mm (0.991 inch)

(A) Height to the step that is in the valveguide ............... 35.0 ± 0.5 mm (1.38 ± 0.02 inch)

(B) New valve stem diameter ...... 9.427 ± 0.010 mm(0.3711 ± 0.0004 inch)

(C) Diameter of valve head

Inlet valve ................................ 47.00 ± 0.13 mm(1.850 ± 0.005 inch)

Exhaust valve .......................... 41.81 ± 0.13 mm(1.646 ± 0.005 inch)


View of area D

Inlet valve seat insert


View of area E

Exhaust valve seat insert

(F) Angle of face of valve seat insert

Inlet valve ......................... 30.25 ± 0.25 degreesExhaust valve ................... 45.25 ± 0.25 degrees



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(G) Depth of the bore in the cylinder head for thevalve seat insert

Inlet ......... 14.00 ± 0.05 mm (0.551 ± 0.002 inch)Exhaust ... 13.90 ± 0.05 mm (0.547 ± 0.002 inch)

(H) Angle of valve face

Angle of the face of the inletvalve ................................. 29.25 ± 0.25 degrees

Angle of the face of the exhaustvalve ................................. 44.25 ± 0.25 degrees

Note: Shrink the valve seat inserts by reducing thetemperature. Shrinking the valve seat inserts allowsplacement into the counterbore.

(J) Valve seat insert

Diameter of valve seat insert (inletvalve) ................................... 48.025 ± 0.013 mm

(1.8907 ± 0.0005 inch)

Bore in cylinder head for valve seat insert (inletvalve) ................................... 47.950 ± 0.025 mm

(1.8878 ± 0.0010 inch)Diameter of valve seat insert (exhaustvalve) ................................... 42.840 ± 0.013 mm

(1.6866 ± 0.0005 inch)Bore in cylinder head for valve seat insert(exhaust valve) .................... 42.774 ± 0.025 mm

(1.6840 ± 0.0010 inch)

i02846910

Cylinder Head

SMCS Code: 1100

Part No.: 284-8895


Bolt tightening sequence


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The bolts that are marked “X” are 216 mm (8.5 inch)long.

Bolts 27 through 39 are 150 mm (5.9 inch) long.

The remainder of the bolts are 194 mm (7.6 inch)long.

Use the following procedure in order to tighten thecylinder head bolts:

Note: Apply 4C-5592 Anti-Seize Compound to thebolt threads and to both sides of the washers for bolt1 through bolt 26 prior to assembly.

1. Torque for bolt 1 through bolt 26 in a numericalsequence to 270 ± 15 N·m (200 ± 11 lb ft)


3. Again torque the bolt 1 through bolt 26 ina numerical sequence to 450 ± 15 N·m(330 ± 11 lb ft).


Note: Install the taperlock studs so that the letter “Y”is showing.

(40) Torque for 24 taperlock studs .......... 35 ± 5 N·m(26 ± 4 lb ft)


(41) Oil gallery(42) Camshaft bearing(43) Oil holes(44) Typical location for cup plug


Cylinder head face

Note: Lubricate the bores for the cup plugs with6V-6640 Sealant prior to installing the cup plugs.

(B) The cup plugs are measured from the face of thecylinder head to the top edge of the plug. Depthof installation .............................. 1.25 ± 0.25 mm

(0.049 ± 0.010 inch)

NOTICECamshaft bearings must be installed into their correctposition. Failure to do so will result in engine damage.


(C) Orientation of bearing joint .................. 20 ± 3 degrees below horizontal


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The installation depth of the camshaft bearings (42)is very important. Install the camshaft bearings to thefollowing depths:

(D) ..................... 8.0 ± 0.5 mm (0.31 ± 0.02 inch)(E) ................. 227.5 ± 0.5 mm (8.96 ± 0.02 inch)(F) ................ 411.7 ± 0.5 mm (16.21 ± 0.02 inch)(G) .............. 595.8 ± 0.5 mm (23.46 ± 0.02 inch)(H) ............... 780.0 ± 0.5 mm (30.71 ± 0.02 inch)(J) ............... 964.1 ± 0.5 mm (37.96 ± 0.02 inch)(K) .............. 1140.3 ± 0.5 mm (44.89 ± 0.02 inch)

i02857841

Compression Brake

SMCS Code: 1119; 1129

Part No.: 255-7955S/N: 5301-Up

Part No.: 255-7955S/N: 2211-Up







NOTICEDo not disassemble the Variable Valve Actuator.There are no components of the Variable Valve

Actuator that are serviceable. If the Variable Valve Actuator is disassembled, the warranty will be void.


Top view of engine


Tightening sequence for the rocker arm shaft

Right side view

Use the following procedure to tighten the nine studs(1):

1. Tighten the studs in the numerical sequence that isshown in Illustration 26 to 50 ± 5 N·m (37 ± 4 lb ft).

2. Turn the studs to an additional 45 ± 5 degrees.


Tightening sequence for the rocker arm shaft

Left side view


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Use the following procedure to tighten the nine studs(2):

1. Tighten the studs in the numerical sequence that isshown in Illustration 27 to 50 ± 5 N·m (37 ± 4 lb ft).

2. Turn the studs to an additional 45 ± 5 degrees.


Right side view of engine


Left side view of engine

(6) Torque for six taperlock studs .......... 65 ± 10 N·m(48 ± 7 lb ft)



Tightening sequence for the valve actuator group


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Tightening sequence for the valve actuator group

Use the following procedure to tighten the valveactuator group:

1. In order to install the valve actuator group for thecompression brake to the cylinder head, place thehousing over the mounting studs. Finger tightenthe mounting stud nuts and the mounting bolt.

2. Tighten the nuts, the bolt and flange nuts of each

valve actuator group in the sequence 9, 12, 8, 10,7, 13, 11, 9 to standard torque. Refer to Illustration30 and Illustration 31.

3. Again tighten the nuts, the bolt and flange nuts of each valve actuator group in the sequence 9, 12,8, 10, 7, 13, 11, 9 to standard torque.


Typical example

Note: The lash setting for the exhaust valve to rocker arm must be completed before the lash setting of thecompression brake. Refer to Testing and Adjusting,“Engine Valve Lash - Inspect/Adjust” for proceduralinformation.

(14) Lash setting for compressionbrake ......... 0.76 ± 0.08 mm (0.030 ± 0.003 inch)

(15) Torque for locknut ........ 15 ± 3 N·m (11 ± 2 lb ft)

Reference: Refer to Testing and Adjusting,“Compression Brake Lash - Adjust” for proceduralinformation that is related to the adjustment of thecompression brake.


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i02884389

Turbocharger

SMCS Code: 1052

Part No.: 290-4621S/N: 5301-Up

Part No.: 290-4621S/N: 2211-Up







Typical example

Front view

(3) Spacer

(1) Apply 4C-5599 Anti-Seize Compound to thethreads of the six bolts before assembly.

(2) Torque for the eight locknuts ............. 55 ± 9 N·m(41 ± 7 lb ft)


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Typical example

(4) Torque for the compressor clampassembly .............. 13.5 ± 1.0 N·m (120 ± 9 lb in)

Use the following procedure to tighten the turbine

clamp assembly (5):

1. Tighten the turbine clamp assembly to 18.1 N·m(160 lb in).

2. Loosen the turbine clamp assembly to 5.6 N·m(50 lb in).

3. Again tighten the turbine clamp assembly to13.5 ± 1.0 N·m (120 ± 9 lb in).


18/92


i02844244

Turbocharger

SMCS Code: 1052





Front view of engine


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Top view of engine

Note: The oil supply and the oil drain holes shouldbe in the vertical position with respect to the enginewhen the turbocharger group (1) is attached to theexhaust manifold.

Use the following procedure to tighten the compressor clamp assembly and the turbine clamp assembly for the turbocharger group:

1. Tighten the clamp assemblies to 14 ± 1 N·m(125 ± 9 lb in).

2. Lightly tap around the clamp assemblies with asoft faced hammer.

3. Again tighten the clamp assemblies to 14 ± 1 N·m(125 ± 9 lb in).

Note: Apply 4C-5599 Anti-Seize Compound on thethreads of the six bolts (3).

(2) Torque for eight locknuts ................... 55 ± 9 N·m(41 ± 7 lb ft)


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i02884391

Turbocharger

SMCS Code: 1052




Front view

(3) Spacer

(1) Apply 4C-5599 Anti-Seize Compound to thethreads of the six bolts before assembly.



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Use the following procedure to tighten the turbineclamp assembly (5):


2. Loosen the turbine clamp assembly to 5.6 N·m(50 lb in).


i02884396

Turbocharger

SMCS Code: 1052



Rear view

(1) Apply 4C-5599 Anti-Seize Compound to thethreads of the eight bolts before assembly.


g01436083Illustr ation 40



22/92


Use the following procedure to tighten the turbineclamp assembly (4):


2. Loosen the turbine clamp assembly to 5.6 N·m

(50 lb in).


i02844349

Turbocharger

SMCS Code: 1052




Front view

(1) Apply 4C-5599 Anti-Seize Compound to the

threads of the four bolts before assembly. Thesebolts are 3/8-16 X 2 inches.

(2) Apply 4C-5599 Anti-Seize Compound to thethreads of the four bolts before assembly. Thesebolts are 3/8-16 X 1 3/4 inches.



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Turbocharger group

Note: The oil supply and the oil drain holes shouldbe in the vertical position with respect to the enginewhen the turbocharger group is attached to theexhaust manifold.

Use the following procedure to tighten the compressor clamp assembly and the turbine clamp assembly for the turbocharger group:

1. Tighten the clamp assemblies to 14 ± 1 N·m

(125 ± 9 lb in).

2. Lightly tap around the clamp assemblies with asoft faced hammer.

3. Again tighten the clamp assemblies to 14 ± 1 N·m(125 ± 9 lb in).


24/92


i02841625

Exhaust Manifold

SMCS Code: 1059

Part No.: 295-0647S/N: 5301-Up

Part No.: 295-0647S/N: 2211-Up


Part No.: 253-2633, 259-6926S/N: JRP1-Up


Part No.: 253-2633, 259-6926, 291-3026S/N: BTW1-Up

Part No.: 253-2633, 259-6926, 291-3026S/N: BWX1-Up


Typical example


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(1) Install the gaskets so that the “MANIFOLD SIDE”marking faces away from the cylinder head.

(2) Apply 4C-5599 Anti-Seize Compound on thethreads of the 24 locknuts before assembly.


Exhaust manifold

Tightening sequence for the exhaust manifold

Note: Use a centering tool in at least one oversizehole per exhaust manifold section in order to alignthe exhaust manifolds. Do not remove the centeringtool until removal is required to tighten the locknuts.

Use the following procedure to tighten the exhaustmanifold on the cylinder head:

1. Tighten locknuts 4 through 15 in a numericalsequence to 20 ± 3 N·m (15 ± 2 lb ft).

2. Again tighten locknuts 4 through 15 in a numericalsequence to 38 ± 5 N·m (28 ± 4 lb ft).

Note: Apply 4C-5599 Anti-Seize Compound on thetwo taperlock studs before assembly.

(3) Torque for two taperlock studs ........... 35 ± 5 N·m(26 ± 4 lb ft)

(16) Torque for eight clamps ............... 8.5 ± 1.0 N·m(75 ± 9 lb in)


26/92


i02843153

Exhaust Manifold

SMCS Code: 1059






Front view

(1) Apply 4C-5599 Anti-Seize Compound on thethreads of the 24 locknuts before assembly.


27/92



Exhaust manifold




1. Tighten locknuts 6 through 17 in a numerical

sequence to 20 ± 3 N·m (15 ± 2 lb ft).


(2) Coat the female ends of the two exhaustmanifolds with clean engine oil.

Note: Apply 4C-5599 Anti-Seize Compound on thetaperlock studs (3) before assembly.

(3) Torque for two taperlock studs ........... 35 ± 5 N·m(26 ± 4 lb ft)

(4) Apply a thin coat of 2P-2333 High TemperatureSealer to the outside diameter of the male endsof the four exhaust manifolds prior to assembly.Remove excess sealer from the assembled joint.

(5) Torque for 12 taperlock studs ............ 35 ± 5 N·m(26 ± 4 lb ft)


28/92


i02866063

Exhaust Manifold

SMCS Code: 1059





Front view

(1) Install the 12 gaskets so that the “MANIFOLDSIDE” marking faces away from the cylinder head.

(2) Torque for the two taperlock studs ..... 35 ± 5 N·m(26 ± 4 lb ft)

(3) Torque for the eight clamps ........... 8.5 ± 1.0 N·m(75 ± 9 lb in)


Use the following procedure to tighten locknut 4through locknut 15:

Note: Apply 4C-5599 Anti-Seize Compound to thethreads of the 24 locknuts.


29/92


1. Tighten the locknuts in a numerical sequence to20 ± 3 N·m (15 ± 2 lb ft).

2. Again tighten the locknuts in a numerical sequenceto 38 ± 5 N·m (28 ± 4 lb ft).

i02843234

Exhaust Manifold

SMCS Code: 1059


g01417806

Illustration 48Orientation of clamps from front view of engine


(C) Orientation for the four clamps ... 78 ± 2 degrees

(D) Orientation for the four clamps ... 90 ± 2 degrees

(13) Torque for the eight clamps ......... 8.5 ± 1.0 N·m(75 ± 9 lb in)

Note: Use a centering tool in at least one oversizehole per exhaust manifold section in order to alignthe exhaust manifolds. Do not remove the centeringtools until removal is required to tighten the locknuts.

Use the following procedure to tighten the locknuts:


30/92


Note: Apply 4C-5599 Anti-Seize Compound to thethreads of locknuts and to the bearing surface of thelocknuts and the spacers and the washers beforeassembly.



i02843368

Exhaust Manifold

SMCS Code: 1059


Part No.: 272-2953

S/N: TPB1-Up


Front view




Note: Apply 4C-5599 Anti-Seize Compound on thethreads of the 24 locknuts before assembly.




(1) Torque for 12 taperlock studs ............ 35 ± 5 N·m(26 ± 4 lb ft)

(2) Torque for eight clamps ................. 8.5 ± 1.0 N·m(75 ± 9 lb in)

i02840165

Camshaft

SMCS Code: 1210

Part No.: 260-9307S/N: 5301-Up

Part No.: 260-9307S/N: 2211-Up



31/92














(1) The end of the camshaft that is marked “F” mustbe placed at the front of the engine. Lubricate thecamshaft bearings, the journals, and the lobeswith a 50/50 mixture of 8T-2998 Lubricant andclean engine oil.


(2) Exhaust lobe(3) Injector lobe(4) Inlet lobe

(A) Diameter of camshaft journal .. 84.85 ± 0.02 mm(3.341 ± 0.001 inch)


(B) Camshaft lobe lift

Use the following procedure in order to determinethe camshaft lobe lift:

1. Measure the camshaft lobe height (C).

2. Measure the base circle (D).

3. Subtract the base circle measurement in Step2 from the camshaft lobe height in Step 1. Thedifference is the actual camshaft lobe lift (B).

Specified camshaft lobe lift

Inlet lobe ....................... 9.619 mm (0.3787 inch)Exhaust lobe ................. 8.515 mm (0.3352 inch)Injector lobe (right bank) ................... 10.337 mm

(0.4070 inch)


32/92


Injector lobe (left bank) ..................... 10.338 mm(0.4070 inch)

The maximum permissible difference between theactual camshaft lobe lift in Step 3 and the specifiedcamshaft lobe lift is 0.13 mm (0.005 inch).

i02847540

Engine Oil Filter Base

SMCS Code: 1306

Part No.: 4N-2357S/N: 5301-Up

Part No.: 4N-2357S/N: 2211-Up

Part No.: 4N-2357S/N: LWA1-Up

Part No.: 4N-2357S/N: H4C1-Up

Part No.: 231-0211, 4N-2357S/N: EED1-Up

Part No.: 4N-2357S/N: Z9K1-Up

Part No.: 231-0211, 4N-2357S/N: JRP1-Up

Part No.: 231-0211, 4N-2357S/N: DLS1-Up

Part No.: 4N-2357S/N: BTW1-Up

Part No.: 231-0211, 4N-2357S/N: JNW1-Up

Part No.: 4N-2357S/N: BWX1-Up


(1) Oil filter base assembly(2) Fluid sampling valve(3) Oil supply line (unfiltered oil)(5) Oil cooler bypass valves(6) Oil return line (filtered oil)

(4) Lightly lubricate the bore and the O-ring seals for the cooler bypass tube with clean engine oil.

(7) Lubricate the seal of the engine oil fi lter elementassembly with clean engine oil.


33/92



(A) Length for applying 154-9731 Thread LockCompound to the threads of the hollowstud ................. 10.2 ± 1.5 mm (0.40 ± 0.06 inch)

(8) Torque for the hollow stud ............... 80 ± 14 N·m(60 ± 10 lb ft)

i02848619

Engine Oil Filter Base

SMCS Code: 1306







34/92



Front view of engine

(1) Lubricate the bore of the O-ring seal lightly withlubricant that is being sealed.

Use the following procedure to tighten the bolts:

1. Torque bolts (4) to 47 ± 9 N·m (35 ± 7 lb ft).

2. Torque bolts (2) to 5 ± 3 N·m (45 ± 27 lb in).

3. Torque bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft).

4. Again tor que bolts (2) to 47 ± 9 N·m (35 ± 7 lb ft).


Section C-C

(D) Length for applying 154-9731 Thread LockCompound on the two taperlock studs ...... 8 mm

(0.3 inch)

(5) Torque for two taperlock studs ......... 80 ± 15 N·m(60 ± 11 lb ft)

i02847457

Engine Oil Pump

SMCS Code: 1304

Part No.: 116-1980S/N: 5301-Up

Part No.: 116-1980S/N: 2211-Up












35/92



(A) Diameters of the shafts

Oil pump drive shaft for the pump drive shaftassembly ............................. 22.217 ± 0.005 mm

(0.8747 ± 0.0002 inch)Oil pump drive shaft for the idler shaftassembly ............................. 22.217 ± 0.005 mm

(0.8747 ± 0.0002 inch)

(B) Dimensions for the gears

Length of new gears .......... 140.000 ± 0.025 mm

(5.5118 ± 0.0010 inch)Depth of bores in oil pump body for newgears .................................. 140.127 ± 0.020 mm

(5.5168 ± 0.0008 inch)

(1) 2S-2760 Spring

Length under test force .. 117.14 mm (4.612 inch)Test force .................. 499 ± 24 N (112.2 ± 5.4 lb)

Approximate free length after test .... 152.91 mm(6.020 inch)


Note: The 2S-2760 Spring is for the relief of oil

pressure.


Oil pump body

(E) Extension of dowel from the oil pumpbody .................. 6.4 ± 0.5 mm (0.25 ± 0.02 inch)

(F) Installation depth for sleeve bearing.................. 0.30 ± 0.25 mm (0.012 ± 0.010 inch)


Oil pump cover

(D) Position of bearing joint from the centerlinethrough bearing bores .............. 30 ± 15 degrees

Note: The sleeve bearings should be installed sothat the edge of the bearing is flush with the outsideof the oil pump body. The sleeve bearings shouldalso be installed so that the edge of the bearing isflush with face (2).


36/92


i02857697

Engine Oil Pump

SMCS Code: 1304

Part No.: 7C-1772S/N: GEB1-Up

Part No.: 7C-1772S/N: TPB1-Up

Part No.: 7C-1772S/N: RJG1-Up


NOTICEBefore operation, the pump must be lubricated withclean engine oil and the pump must turn freely by handor damage to parts can be the result.

(B) Diameter of a new shaft for the drive shaftassembly ............................. 20.320 ± 0.005 mm

(0.8000 ± 0.0002 inch)

(C) Diameter of a new shaft for the idler shaftassembly ............................. 20.320 ± 0.005 mm

(0.8000 ± 0.0002 inch)

(D) Dimensions for new pump gears

Length of pump gears .............. 65.07 ± 0.05 mm(2.562 ± 0.002 inch)

Depth of bores for pumpgears .................................... 65.197 ± 0.020 mm

(2.5667 ± 0.0008 inch)

(E) Diameter of a new shaft for the drive shaftassembly ............................. 22.217 ± 0.005 mm

(0.8747 ± 0.0002 inch)

(F) Diameter of a new shaft for the idler shaftassembly ............................. 22.217 ± 0.005 mm

(0.8747 ± 0.0002 inch)

(G) Dimensions for new gears

Length of new gears ............ 79.375 ± 0.025 mm(3.1250 ± 0.0010 inch)


37/92


Depth of bores for newgears .................................... 79.502 ± 0.020 mm

(3.1300 ± 0.0008 inch)

(1) 236-6733 Spring

Length under test force ... 82.87 mm (3.263 inch)

Test force .................. 709 ± 35 N (159.4 ± 7.9 lb) Approximate free length after test ......... 130 mm(5.1 inch)


Pump Body (2)


(H) Installation depth for the two sleevebearings ............................ 1.52 mm (0.060 inch)

(J) Position of bearing joint from the centerlinethrough bearing bores .............. 30 ± 15 degrees

Oil Pump Spacer Assembly (3)


(K) Installation depth for the two sleevebearings ............................ 0.76 mm (0.030 inch)

(5) The two sleeve bearings should be located withthe oil holes on the horizontal centerline slots.

Oil Pump Body (4)



38/92


(L) Position of bearing joint from the centerlinethrough bearing bores .............. 30 ± 15 degrees

(N) Projection of dowel from the surface of the oilpump body ........ 6.4 ± 0.5 mm (0.25 ± 0.02 inch)

(P) Installation depth for the two sleeve

bearings .... 0.30 ± 0.25 mm (0.012 ± 0.010 inch)

i02865988

Engine Oil Bypass Valve

SMCS Code: 1306-BV

Part No.: 316-5686S/N: 5301-Up

Part No.: 316-5686S/N: 2211-Up

Part No.: 225-9619

S/N: LWA1-Up









g01427693

Illustration 66Typical example


Note: Check the valve and the valve seat for abnormal contact patterns.

(1) The 9M-0853 Valve Plunger is for the oil filter bypass valve.

(2) The 9F-6304 Spring is for the oil filter bypassvalve.

Length under test force ... 53.98 mm (2.125 inch)

Test force ............. 145 to 160 N (32.3 to 35.7 lb)Free length after test .... 105.56 mm (4.156 inch)Outside diameter ............ 20.65 mm (0.813 inch)


39/92


i02865980

Engine Oil Bypass Valve

SMCS Code: 1306-BV





Typical example

Right side view

Note: Check the valve and the valve seat for abnormal contact patterns.

(1) The 9M-0853

Valve Plunger is for the oil fi

lter bypass valve.

(2) The 9F-6304 Spring is for the oil filter bypassvalve.

Length under test force ... 53.98 mm (2.125 inch)Test force ............. 145 to 160 N (32.3 to 35.7 lb)Free length after test .... 105.56 mm (4.156 inch)Outside diameter ............ 20.65 mm (0.813 inch)


40/92


i02855050

Engine Oil Pan

SMCS Code: 1302

Part No.: 291-1432S/N: 5301-Up

Part No.: 291-1432S/N: 2211-Up



Typical example

Right side view

Use the f ollowing procedure to tighten the bolts for the oil pan:

1. Tighten the bolts in the numerical sequence to47 ± 9 N·m (35 ± 7 lb ft).


41/92


2. Again tighten the bolts in the numerical sequenceto 47 ± 9 N·m (35 ± 7 lb ft).


Detail of the oil pan gasket joint

(41) Apply sealant below the four ball and socket

joints of the oil pan gasket and over the four balland socket joints of the oil pan gasket.

i02857775

Engine Oil Pan

SMCS Code: 1302



(3) After assembly, trim off excess gasket materialfrom outside of assembled joint.

Note: Lubricate the threads of the drain plug lightlywith clean engine oil before assembly.

(4) Torque for the drain plug .................. 70 ± 10 N·m

(50 ± 7 lb ft)

Bolts (1) are 3/8-16 X 2 3/4 inches.




The remaining oil pan bolts are 3/8-16 X 1 1/4 inches.


42/92


i02879916

Engine Oil Pan

SMCS Code: 1302




Note: Lubricate the threads of the drain plug lightlywith clean engine oil before assembly.

(2) Tor que for the drain plug .................. 70 ± 10 N·m(50 ± 7 lb ft)

(3) After assembly, trim off excess gasket materialfrom outside of assembled joint.




The remaining oil pan bolts are 3/8-16 X 1 1/4 inches.

i02799191

Water Temperature Regulator

SMCS Code: 1355

Part No.: 248-5513


Typical example

(1) Seal

(2) Water temperature regulator

Opening temperature ........................ 81 to 84 °C(178 to 183 °F)

Fully open temperature ................ 92 °C (198 °F)Minimum stroke at fully opentemperature ........................ 10.4 mm (0.41 inch)

i02798334

Water Pump

SMCS Code: 1361

Part No.: 230-4172S/N: 5301-Up

Part No.: 230-4172S/N: 2211-Up




43/92




Part No.: 4N-5837S/N: EED1-Up




Part No.: 4N-5837S/N: DLS1-Up


Part No.: 4N-5837S/N: JNW1-Up



Note: Do not install the lip type seal (1) by hand. Usethe installation tool and a press to install the lip typeseal. Make sure that the primary lip is toward thewater pump drive gear. Press the lip type seal untilthe lip type seal is flush into the counterbore.

Note: Use the installation tool to install the sealgroup (2). Press the seal group onto the shaft untilthe stationary cup of the seal group is fully seated inthe pump housing.

(3) Torque for the bolt .......... 39 ± 3 N·m (29 ± 2 lb ft)

(A) Diameter of the water pumpshaft ..................................... 19.100 ± 0.010 mm

(0.7520 ± 0.0004 inch)

Maximum air leakage per minute with an air pressuretest of 140 kPa (20 psi)

Water side .................................. 10 cc (0.6 cu in)Side with oil ............................... 24 cc (1.5 cu in)

i02899215

Cylinder Block

SMCS Code: 1201

Part No.: 253-9882S/N: 5301-Up

Part No.: 253-9882S/N: 2211-Up














44/92



Front of the engine

Note: Apply 6V-6640 Sealant to the pipe threadsof stud (1). Tighten the stud with the coated pipethreads into the cylinder block.

(4) Torque for three taperlock studs ........ 35 ± 5 N·m(26 ± 4 lb f t)

Note: The top face of the cylinder block, both sidesof plate gasket (3) and bottom surface of spacer plate(2) must be free of fuel, oil, water, gasket adhesives,assembly compounds and any other contaminantsduring assembly.

(A) Thickness of the spacer plates ..................................... 8.585 ± 0.025 mm

(0.3380 ± 0.0010 inch)

(B) Thickness of plate gasket that is between cylinder

block and spacer plate ........... 0.208 ± 0.025 mm(0.0082 ± 0.0010 inch)

(C) Extension of the dowels on the left bank and rightbank from the cylinder block ....... 18.5 ± 0.5 mm

(0.73 ± 0.02 inch)

Note: Apply 5P-3413 Pipe Sealant on the threads of the taperlock plugs (5) before assembly.

(5) Torque for the four taperlock plugs .. 80 ± 15 N·m(60 ± 11 lb ft)

(D) Bore in cylinder block for mainbearing ............................... 129.891 ± 0.013 mm

(5.1138 ± 0.0005 inch)

(E) Dimensions for main bearing cap

The width of the slot for the main bearing

caps ...... 236.00 ± 0.05 mm (9.291 ± 0.002 inch)Width of main bearing cap .. 235.500 ± 0.025 mm

(9.2716 ± 0.0010 inch)


Right side of the engine

(F) Extension of dowels from the rear face of thecylinder block and from the front face of thecylinder block .. 19.0 ± 0.5 mm (0.75 ± 0.02 inch)

Note: The main bearing caps (7) must be installedwith the identifying marks toward the front of the

engine. The number of the main bearing cap (7) mustalso match the cast number on the left side of eachmain bearing saddle.

Use the following procedure to install the mainbearing caps:


Marks for tightening main bearings


45/92


1. Apply clean engine oil on the threads of the mainbearing cap bolts (8). Loosely install the mainbearing cap bolts (8).

2. Apply clean engine oil on the threads of the sidebolts (6) and the washers. Loosely install the sidebolts and the washers.

3. Tighten the main bearing cap bolts (8) first on themain bearing tab side of the main bearing cap (7)to 258 ± 14 N·m (190 ± 10 lb ft).

4. Tighten the main bearing cap bolts (8) that areopposite the main bearing tab side of the mainbearing cap (7) to 258 ± 14 N·m (190 ± 10 lb ft).

5. Put a mark on each main bearing cap bolt (8) andeach main bearing cap (7). See Illustration 76.

6. Tighten the main bearing cap bolts (8) that areplaced opposite the main bearing tab side of the

main bearing cap (7) from the mark by angle (G)of 120 ± 5 degrees.

7. Tighten the main bearing cap bolts (8) that areplaced on the main bearing tab side of the mainbearing cap (7) from the mark by angle (G) of 120± 5 degrees.

8. Tighten the side bolts (6) that are opposite themain bearing tab side of the main bearing cap (7)to 80 ± 10 N·m (60 ± 7 lb ft).

9. Tighten the side bolts (6) that are placed on themain bearing tab side of the main bearing cap (7)

to 80 ± 10 N·m (60 ± 7 lb ft).


(H) The distance from the centerline of thecrankshaft bearing bore to the top of the cylinder block ... 419.10 ± 0.15 mm (16.500 ± 0.006 inch)

(J) The distance from the centerline of the crankshaftbearing bore to the bottom of the cylinder block.............. 165.10 ± 0.10 mm (6.500 ± 0.004 inch)

i02788282

Cylinder Liner

SMCS Code: 1216








(1) Filler band

(A) Bore in new cylinder liner .. 137.185 ± 0.025 mm(5.4010 ± 0.0010 inch)

(B) Flange

Thickness .............................. 8.890 ± 0.020 mm(0.3500 ± 0.0008 inch)

Minimum thickness ....... 8.870 mm (0.3492 inch)

Use the following procedure to install the cylinder liner:

1. Put liquid soap on the cylinder block liner boresurfaces and the rubber seals that are on thelower end of the cylinder liner.

2. Dip the filler band completely in clean engine oil.


46/92


3. Immediately install the filler band in the groovethat is under the cylinder liner flange.

4. Install the cylinder liner into the cylinder blockbefore the expansion of the fi ller band.

Note: Refer to Guideline For Reusable Parts and

Salvage Operations, SEBF8068, “Cylinder Liners” for more information. Also, refer to Reuse And SalvageGuidelines, SEBF8049, “Visual Inspection of thePiston” for more information.

i02801040

Cylinder Liner

SMCS Code: 1216

Part No.: 253-8766S/N: 5301-Up

Part No.: 253-8766S/N: 2211-Up





Part No.: 253-8766

S/N: Z9K1-Up



(A) Bore in new cylinder liner .. 145.000 ± 0.025 mm(5.7086 ± 0.0010 inch)

(B) Dimensions for flange (1)

Thickness of flange on cylinder liner ........... 8.89 ± 0.02 mm (0.350 ± 0.001 inch)Minimum thickness ....... 8.870 mm (0.3492 inch)

Use the following procedure to install the cylinder liner:

1. Apply liquid soap on the cylinder block liner boresurfaces and the rubber seals that are on thelower end of the cylinder liner.

2. Dip the filler band (2) completely in clean engineoil.

3. Immediately install the filler band in the groovethat is under the flange.

4. Install the cylinder liner into the cylinder blockbefore the expansion of the filler band.

Note: Refer to Reuse And Salvage Guidelines,

SEBF8049, “Visual Inspection of the Piston” for moreinformation. Also, refer to Guideline For ReusableParts And Salvage Operations, SEBF8068, “Cylinder Liners” for more information.


47/92


i02801044

Crankshaft

SMCS Code: 1202

Part No.: 224-3250S/N: 5301-Up

Part No.: 224-3250S/N: 2211-Up













Note: To measure a crankshaft that may be bent, aprocedure must be followed. Refer to the GuidelineFor Reusable Parts And Salvage Operations,SEBF8054, “Procedure to Measure and StraightenBent Crankshafts” for the correct procedure.


48/92



Typical example

(3) Main journal (4) Rod journal

Note: Thrust plates (1) are used on the center mainbearing only.

(A) Thickness of new thrust plate .... 5.74 ± 0.04 mm(0.226 ± 0.002 inch)

Note: Check assembled installation depth with thecrankshaft in any axial position.

(B) Assembled installation depth ... 4.68 to 5.28 mm(0.184 ± 0.208 inch)

(C) Maximum extension of dowel from the crankshaftface ....................................... 8.4 mm (0.33 inch)

(E) End play

New crankshaft ......................... 0.10 to 0.60 mm(0.004 to 0.024 inch)

Maximum end play with used bearings .. 0.89 mm(0.035 inch)

(2) The crankshaft gear must be installed on the

crankshaft with the timing mark “V” on the outsideof the crankshaft.

(3), (4) Refer to the Specifications, “Connecting Rodand Main Bearing Journals” for more information.

Note: The seal and the sleeve should not be used if the seal and the sleeve have been separated.

(5) The front crankshaft seal is installed on thefront of the crankshaft. The seal driver can notcontact the seal inside a 177.80 ± 0.25 mm(7.000 ± 0.010 inch) diameter.

Note: The seal and the sleeve can not be used if theseal and the sleeve have been separated.

Note: The sleeve must be flush with the front face of the crankshaft within 0.13 mm (0.005 inch).


View D-D

(F) Extension of the dowel from the surface of thecrankshaft ......... 4.1 ± 0.5 mm (0.16 ± 0.02 inch)


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i02287333

Crankshaft Seals

SMCS Code: 1160; 1161

Part No.: 142-5867


(1) Front crankshaft seal

The front seal should be installed even withthe front of the crankshaft with the followingtolerance. ...................................... −0.13 to 0.13 mm

(−0.005 to 0.005 inch)

The seal driver should not contact the seal within thefollowing diameter. ....................... 177.80 ± 0.25 mm

(7.000 ± 0.010 inch)

(2) Rear crankshaft seal

Install the rear seal to the following distance from theend of the crankshaft. .......................... 1.5 ± 0.5 mm

(0.06 ± 0.02 inch)

The seal driver should not contact the seal within thefollowing diameter. ....................... 177.80 ± 0.25 mm

(7.000 ± 0.010 inch)

Note: Do not separate the seal from the sleeve.Replace the seal if the seal is separated from thesleeve.

Note: The assembled installation depth may be

checked with the crankshaft in any axial position.

i02866012

Vibration Damper

SMCS Code: 1205

Part No.: 6N-2229S/N: EED1-Up

Part No.: 6N-2229S/N: RJG1-Up

Part No.: 6N-2229S/N: Z9K1-Up

Part No.: 6N-2229S/N: JRP1-Up

Part No.: 6N-2229S/N: DLS1-Up




(1) Damper adapter (2) Damper

(3) Torque for 12 bolts .. 135 ± 20 N·m (100 ± 15 lb ft)


50/92


i02866018

Vibration Damper

SMCS Code: 1205



(1) Damper (2) Damper adapter


i02856619

Vibration Damper

SMCS Code: 1205




g01248941

Illustration 85(1) Damper (2) Crankshaft pulley



51/92


i02866033

Vibration Damper

SMCS Code: 1205

Part No.: 257-8730S/N: 5301-Up

Part No.: 257-8730S/N: 2211-Up





(1) Damper adapter (2) Dampers


i02866067

Vibration Damper

SMCS Code: 1205




(1) Dampers(3) Damper adapter



52/92


i02776231

Connecting Rod BearingJournal

SMCS Code: 1202; 1219; 1225

Part No.: 219-4454S/N: 5301-Up

Part No.: 219-4454S/N: 2211-Up













Table 1

Diameter of Crankshaft Journal (BearingSurface) For Connecting Rod

Original Size Journal 97.028 ± 0.020 mm(3.8200 ± 0.0008 inch)

Clearance between new bearing and new journal ... 0.070 to 0.178 mm (0.0028 to 0.0070 inch)

i02776201

Main Bearing Journal

SMCS Code: 1202; 1203

Part No.: 219-4454S/N: 5301-Up

Part No.: 219-4454S/N: 2211-Up













Refer to Guideline For Reusable Parts And SalvageOperations, SEBF8009, “Main and Connecting RodBearings” and Guideline For Reusable Parts andSalvage Operations, SEBF8041, “Specifications for Crankshaft in Caterpillar Engines”.

Table 2

Main Bearing Journals

Original Size Journal 120.650 ± 0.020 mm

(4.7500 ± 0.0008 inch)

Undersize Journal0.63 mm (0.025 inch)

120.015 ± 0.020 mm(4.7250 ± 0.0008 inch)

Undersize Journal1.27 mm (0.050 inch)

119.380 ± 0.020 mm(4.7000 ± 0.0008 inch)


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Main bearing cap with two bolts

Clearance between new bearing and new journal ................................... 0.076 to 0.186 mm

(0.0030 to 0.0073 inch)

Main bearing cap with four bolts

Clearance between new bearing and new journal ................................... 0.071 to 0.178 mm

(0.0028 to 0.0070 inch)

Table 3

Main Bearing Bore

Original Size of the BoreIn the Block

129.891 ± 0.013 mm(5.1138 ± 0.0005 inch)

Oversize Bore 0.63 mm(0.025 inch)

130.526 ± 0.013 mm(5.1388 ± 0.0005 inch)

i02801090

Connecting Rod

SMCS Code: 1218

Part No.: 319-6714S/N: 5301-Up

Part No.: 319-6714S/N: 2211-Up














Tightening sequence, and index mark for torque-turn process

(1),(2),(3),(4) Bolts for rod cap


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Note: The connecting rods should be installed in theengine so that the part number of the forging for therod assembly is facing the connecting rod that is onthe same crankshaft pin. The opposite side of theconnecting rods will face the thrust surface of thecrankshaft journal.

Use the following procedure for tightening the boltsfor the rod cap:

1. Prior to assembly, lubricate the threads of thebolts and the seating face of the bolt heads withclean engine oil.

2. Finger tighten all of the bolts.

3. Tighten bolts (1) and (3) to 70 ± 4 N·m (50 ± 3 lb ft).

4. Tighten bolts (2) and (4) to 70 ± 4 N·m (50 ± 3 lb ft).

Note: Use a paint stick to place an index mark on

each of the bolts. Use the index mark as a referencein order to torque the bolts for an additional angle.

5. Tighten bolts (2) and (4) by an additional angle(A) of 60 ± 5 degrees.

6. Tighten bolts (1) and (3) again to 70 ± 4 N·m(50 ± 3 lb ft).

7. Tighten bolts (1) and (3) by an additional angle(A) of 60 ± 5 degrees.


(6) Bearing for piston pin

(5) Connecting rod

(B) Inside diameter of connecting rod of bearingfor the piston pin ............ 64.592 ± 0.013 mm

(2.5430 ± 0.0005 inch)(C) Distance between the center of the bore for

the bearing for piston pin and the center of thebore for the crankshaft journal .... 274.91 mm

(10.823 inch)(D) Inside diameter of connecting rod

for the crankshaft journal after thebearing f or connecting rod has beeninstalled and the bolts have beentorqued. ....................... 103.500 ± 0.013 mm

(4.0748 ± 0.0005 inch)


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Note: The bearing joint must be located within area(E) along the horizontal centerline of the piston pinbore.

(F) Maximum angle from the horizontalcenterline ......................................... ± 5 degrees

Note: The bore of bearing for piston pin must bemachined after installation into the connecting rod.

(G) Outside diameter of bearing for pistonpin before installation into the connectingrod .. 64.717 ± 0.013 mm (2.5479 ± 0.0005 inch)

(H) Dimensions for piston pin

Bore diameter of bearing for the piston pin after machining ............................ 60.035 ± 0.008 mm

(2.3636 ± 0.0003 inch)Diameter of piston pin .......... 59.975 ± 0.005 mm

(2.3612 ± 0.0002 inch)

Note: Apply heat to the connecting rod prior toinstallation of bearing for piston pin. Do not use atorch to heat the connecting rod.

(J) Maximum length for heating the connectingrod during the installation of bearing for pistonpin ............................................ 95 mm (3.7 inch)

Temperature for heating for connectingrod .............................. 175 to 260 °C (347 to 500 °F)


(7) Oil jet tube assembly

(8) Torque for the special bolt of oil jet tubeassembly ....................... 25 ± 6 N·m (18 ± 4 lb ft)

i02856149

Piston and Rings

SMCS Code: 1214; 1215








Note: Refer to Guideline for Reusable Parts for information on the pistons, the piston pins, and theretaining rings.


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The 1U-6431 Piston Ring Groove Gauge Gp isused for measur ing the ring grooves in keystonestyle pistons. Refer to the Special Instruction that issupplied with the piston ring groove gauge group.

The 5P-3519 Piston Ring Groove Gauge Gp isavailable for checking the ring grooves with straight

sides. Refer to the Guideline for Reusable Parts for instructions on the piston ring groove gauge group.

Note: Lubricate the entire piston in zone (A) withclean engine oil prior to assembly into the cylinder block.

Top Piston Ring (1)

Install the piston ring with the side marked “UP-1”toward the top of the piston. The red stripe faces tothe right of the piston ring end gap.

When a new piston ring is installed in a cylinder liner with a bore of 137.16 mm (5.400 inch), the clearancebetween the ends of the piston ring is the followingvalue: .............. 0.40 ± 0.10 mm (0.016 ± 0.004 inch)

Increase in the clearance between the ends of thepiston ring for each 0.03 mm (0.001 inch) increase inthe cylinder liner bore ............. 0.08 mm (0.003 inch)

Intermediate Piston Ring (2)

Install the piston ring with the side marked “UP-2”toward the top of the piston. The blue stripe faces tothe right of the piston ring end gap.

When a new piston ring is installed in a cylinder liner with a bore of 137.16 mm (5.400 inch), the clearancebetween the ends of the piston ring is the followingvalue: ...... 0.770 ± 0.125 mm (0.0303 ± 0.0049 inch)


Oil Control Piston Ring (3)

The ends of the oil control piston ring should be a

distance of 180 degrees from the ring end gap whenthe oil control piston ring is assembled. The whitecolored portion of the piston ring must be visible atthe ring end gap.

Width of groove in new piston for oil control pistonring .......... 4.030 ± 0.010 mm (0.1587 ± 0.0004 inch)

Thickness of new oil control pistonring .......... 3.980 ± 0.010 mm (0.1567 ± 0.0004 inch)

Clearance between groove and oil control pistonring .......................................... 0.05 mm (0.002 inch)

When a new piston ring is installed in a cylinder liner with a bore of 137.16 mm (5.400 inch), the clearancebetween the ends of the piston ring is the followingvalue: .............. 0.55 ± 0.15 mm (0.022 ± 0.006 inch)


Note: After the piston rings have been installed,rotate the piston rings so that the end gaps are 120degrees from each other.

Piston Pin Bore (4)

Note: Thoroughly lubricate the piston pin with cleanengine oil before the piston is inserted into the piston

and the rod assembly.

Diameter of the bore in the finished bearing thatis installed into the piston skirt for the pistonpin .. 60.0925 ± 0.0075 mm (2.36584 ± 0.00030 inch)

Diameter of the new piston pin .. 59.975 ± 0.005 mm(2.3612 ± 0.0002 inch)


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i02856206

Piston and Rings

SMCS Code: 1214; 1215

Part No.: 319-6714S/N: 5301-Up

Part No.: 319-6714S/N: 2211-Up








Note: Refer to Guideline for Reusable Parts for information on the pistons, the piston pins, and theretaining rings.

The 1U-6431 Piston Ring Groove Gauge Gp is

used for measuring the ring grooves in keystonestyle pistons. Refer to the Special Instruction that issupplied with the piston ring groove gauge group.

The 5P-3519 Piston Ring Groove Gauge Gp isavailable for checking the ring grooves with straightsides. Refer to the Guideline for Reusable Parts for instructions on the piston ring groove gauge group.

Note: Lubricate the entire piston in zone (A) withclean engine oil prior to assembly into the cylinder block.

Top Piston Ring (1)

Install the piston ring with the side marked “UP-1”toward the top of the piston. The purple colored stripefaces to the right of the piston ring end gap.

When a new piston ring is installed in a cylinder

liner with a bore of 145 mm (5.7 inch), the clearancebetween the ends of the piston ring is the followingvalue: .............. 0.40 ± 0.10 mm (0.016 ± 0.004 inch)

Increase in clearance between the ends of the pistonrings for each 0.030 mm (0.0012 inch) increase in thecylinder liner bore ................... 0.08 mm (0.003 inch)

Intermediate Piston Ring (2)

Install the piston ring with the side marked “UP-2”toward the top of the piston. The white colored stripesface to the right of the piston ring end gap.

When a new piston ring is installed in a cylinder liner with a bore of 145 mm (5.7 inch), the clearancebetween the ends of the piston ring is the followingvalue: ...... 0.600 ± 0.125 mm (0.0236 ± 0.0049 inch)

Increase in clearance between the ends of the pistonring for each 0.030 mm (0.0012 inch) increase in thecylinder liner bore ................... 0.08 mm (0.003 inch)

Oil Control Piston Ring (3)

The spring ends of the new piston ring should be adistance of 180 degrees from the ring end gap when

the piston ring is assembled. The green coloredstripe must be visible at the ring end gap.

Width of groove in new piston for pistonring ............ 3.020± 0.010 mm (0.1189 ± 0.0004 inch)

Thickness of new piston ring ....... 2.980 ± 0.010 mm(0.1173 ± 0.0004 inch)

Clearance between groove and piston ring .. 0.05 mm(0.002 inch)

When a new piston ring is installed in a cylinder liner with a bore of 145 mm (5.7 inch), the clearance

between the ends of the piston ring is the followingvalue. .............. 0.55 ± 0.15 mm (0.022 ± 0.006 inch)

Increase in clearance between the ends of the pistonring for each 0.030 mm (0.0012 inch) increase in thecylinder liner bore ................... 0.08 mm (0.003 inch)

Note: After all piston rings have been installed, rotatethe piston rings so that the end gaps are 120 degreesfrom each other.


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Piston Pin Bore (4)

Note: Thoroughly lubricate the piston pin with cleanengine oil before the piston is inserted into the pistonand the rod assembly.

Diameter of the bore in the bearing that is

installed into the piston skirt for the pistonpin .. 60.0925 ± 0.0075 mm (2.36584 ± 0.00030 inch)

Diameter of the new piston pin .. 59.975 ± 0.005 mm(2.3612 ± 0.0002 inch)

i02801103

Housing (Front)

SMCS Code: 1151

Part No.: 238-9862


(1) Studs are supplied with a previously appliedthread lock compound. Install the shortestthreaded end of stud into the front housingassembly.


Note: The rear face of the front housing assembly (3)and the fr ont face of the cylinder block must be free of oil, fuel, water, dirt and any other contaminants duringassembly. The gasket for the front housing assemblymust also be free of contaminants during assembly.

Note: The gasket (2) for the front housing assemblymust be trimmed after assembly with the face (4) sothat the gasket is flush.


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g01399846

Illustration 96View A-A

(6) Cylinder block

(5) Apply a continuous bead of 4C-9612 SiliconeSealant immediately prior to assembling the fronthousing assembly. After assembly of the fronthousing assembly, remove excess sealant fromthe flange with a straight edge.

(7) Apply 4C-9612 Silicone Sealant to the T-shaped joints immediately prior to the installation of thegasket for the pan. The application of the sealantshould cover the entire width of the T-shaped

joints, as shown.

i02801118

Housing (Rear)

SMCS Code: 1157

Part No.: 233-246

001a HM02316_00 Engine Specifications

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Transcript of 001a HM02316_00 Engine Specifications