Cat C11 & C13 On-highway Engines Specifications Manual - PDF DOWNLOAD

SENR9702-05 July 2005

Specifications C11 and C13 On-highway Engines KCA1-Up (Engine) KCB1-Up (Engine) JAM1-Up (Engine)

i01658146

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

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

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

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

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

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

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

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 that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material.

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

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Table of Contents Specifications Section Engine Design ....................................................... 4 Engine Design ....................................................... 4 Fuel Transfer Pump ............................................... 5 Electronic Unit Injector ............................................ 5 Electronic Unit Injector Mechanism ....................... 6 Electronic Unit Injector Rocker Arm ........................ 6 Electronic Unit Injector Wiring ................................. 7 Lifter Group ............................................................. 8 Rocker Shaft .......................................................... 8 Valve Mechanism ................................................... 9 Cylinder Head Valves ........................................... 10 Cylinder Head ....................................................... 11 CAT Compression Brake ...................................... 13 Turbocharger ....................................................... 14 Turbocharger ....................................................... 15 Turbocharger ....................................................... 15 Air Lines ................................................................ 16 Air Lines ................................................................ 16 Air Lines ................................................................ 17 Air Lines ................................................................ 17 Air Lines ................................................................ 18 Air Lines ................................................................ 19 Air Lines ................................................................ 19 Air Lines ................................................................ 20 Air Lines ................................................................ 20 Exhaust Manifold ................................................. 21 Camshaft ............................................................. 22 Engine Oil Filter Base .......................................... 22 Engine Oil Cooler ................................................. 24 Engine Oil Pump .................................................. 24 Engine Oil Pan ..................................................... 25 Engine Oil Pan ..................................................... 25 Engine Oil Pan ..................................................... 25 Precooler .............................................................. 26 Water Temperature Regulator Housing ................ 27 Water Temperature Regulator .............................. 27 Water Pump ......................................................... 28 Cylinder Block ...................................................... 28 Cylinder Liner ....................................................... 30 Cylinder Liner Projection ...................................... 30 Crankshaft ........................................................... 31 Crankshaft Seals ................................................. 31 Connecting Rod Bearing Journal ......................... 32 Main Bearing Journal ............................................ 32 Connecting Rod ................................................... 33 Connecting Rod ................................................... 34 Piston and Rings .................................................. 35 Piston Cooling Jet ................................................. 36 Housing (Front) ..................................................... 36 Gear Group (Front) ............................................... 37 Gear Group (Rear) ................................................ 38 Flywheel Housing ................................................ 38 Flywheel Housing ................................................ 39 Engine to Transmission Adapter .......................... 39 Belt Tensioner ....................................................... 40 Electric Starting Motor ......................................... 40 Electric Starting Motor ......................................... 41

3 Table of Contents

Electric Starting Motor .........................................

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

Fuel Temperature Sensor .....................................

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

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

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

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

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

42 43 43 43 43 44 44 44

Index Section Index ..................................................................... 46

4 Specifications Section

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Specifications Section

The crankshaft rotation is viewed from the flywheel end of the engine. Crankshaft rotation .......................................... Counterclockwise i02165970

Engine Design SMCS Code: 1201 S/N: KCA1-Up

C11

Note: The front of the engine is opposite of the flywheel end of the engine. The left side of the engine and the right side of the engine are viewed from the flywheel end of the engine. The No. 1 cylinder is the front cylinder. i02379619

Engine Design SMCS Code: 1201 S/N: KCB1-Up S/N: JAM1-Up

C13

Illustration 1

g01098200

(A) Exhaust valves (B) Inlet valves

Bore ............................................................. 130 mm (5.12 inch) Stroke .......................................................... 140 mm (5.51 inch) Displacement ................................................... 11.1 L (680 cu in) Cylinder arrangement ..................................... In-line Valves per cylinder .................................................. 4 In order to check the engine valve lash setting, the engine must be cold and the engine must be stopped.

Engine valve lash Inlet ............................................ 0.38 ± 0.08 mm (0.015 ± 0.003 inch) Exhaust ...................................... 0.64 ± 0.08 mm (0.025 ± 0.003 inch) Variable valve actuator .......... 0.610 ± 0.075 mm (0.0240 ± 0.0030 inch) Compression brake ............... 0.864 ± 0.050 mm (0.0340 ± 0.0020 inch) Type of combustion ............................ Direct injection Firing order ............................................. 1-5-3-6-2-4

Illustration 2

g01098200

(A) Exhaust valves (B) Inlet valves

Bore ............................................................. 130 mm (5.12 inch) Stroke .......................................................... 157 mm (6.18 inch) Displacement .................................................. 12.5 L (763 cu in) Cylinder arrangement ..................................... In-line Valves per cylinder .................................................. 4 In order to check the engine valve lash setting, the engine must be cold and the engine must be stopped.

Engine valve lash Inlet ............................................ 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

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5 Specifications Section

Exhaust ...................................... 0.64 ± 0.08 mm (0.025 ± 0.003 inch) Variable valve actuator .......... 0.610 ± 0.075 mm (0.0240 ± 0.0030 inch) Compression brake ............... 0.864 ± 0.050 mm (0.0340 ± 0.0020 inch) Type of combustion ............................ Direct injection Firing order ............................................. 1-5-3-6-2-4 The crankshaft rotation is viewed from the flywheel end of the engine. Crankshaft rotation .......................................... Counterclockwise Note: The front end of the engine is opposite of the flywheel end of the engine. The left side of the engine and the right side of the engine are viewed from the flywheel end of the engine. The No. 1 cylinder is the front cylinder. i02035050

Run the pump at 2940 rpm. The full bypass pressure should be the following value. ........... 716 to 786 kPa (104 to 114 psi) Run the pump at 840 rpm. The flow at 550 kPa (80 psi) must be 3.0 L/min (0.8 US gpm).

Run the pump at 100 rpm with a blocked inlet for 30 seconds. The pump inlet must have a suction lift of 60.9 kPa (18 In Hg) minimum.

Run the pump at 2940 rpm. The flow at 650 kPa (94 psi) must be 4.5 L/min (1.19 US gpm).

When the pump is viewed from the drive end the rotation of the pump is counterclockwise. i01831899

Electronic Unit Injector SMCS Code: 1290

Fuel Transfer Pump

Part No.: 251-7164 S/N: KCA1-Up

SMCS Code: 1256

Part No.: 251-4513 S/N: KCB1-Up

Part No.: 227-5723

Part No.: 251-4513 S/N: JAM1-Up

Illustration 3

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(1) Outlet port (2) Drain hole

Illustration 4

g00935781

(3) Inlet port

(1) Lubricate the seals and the bore with a 50 percent mix of 8T-2998 Lubricant and engine oil.

(4) Pressure regulating valve

(2) Bolt torque ................... 55 ± 10 N·m (40 ± 7 lb ft)

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

6 Specifications Section

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i02158853

i02347715

Electronic Unit Injector Mechanism

Electronic Unit Injector Rocker Arm

SMCS Code: 1290

SMCS Code: 1123

Part No.: 240-7272

Part No.: 241-0845

Illustration 6

g00950406

(A) Oil passage angle ............................ 13 degrees (B) Bearing bore diameter ......... 34.050 ± 0.015 mm (1.3405 ± 0.0006 inch) Illustration 5

g01095007

(1) Unit injector The adjusting instructions for the unit injector are listed below.

1. Loosen the locknut (2).

2. Turn the adjustment screw clockwise. Stop turning the adjustment screw when contact is made with the unit injector.

3. Turn the adjustment screw.

Turn ............................ 180 degrees (1/2 of a turn) 4. Hold the adjustment screw. Tighten the locknut (2).

Tighten the locknut to the following torque. ........................... 55 ± 10 N·m (40 ± 7 lb ft) (3) Rocker arm (4) Rocker arm shaft (5) Lifter group shaft (6) Unit injector lifter assembly

Bore in the rocker arm for the bearing .. 37.000 ± 0.020 mm (1.4567 ± 0.0008 inch) (C) Oil passage angle ........................... 20 degrees Note: The rocker arm bearing must not extend beyond either face of the rocker arm.

(D) Preset location from factory .... 13.40 ± 0.50 mm (0.528 ± 0.020 inch) (E) Preset location from factory ................. 6.50 mm (0.256 inch)

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7 Specifications Section

i02166534

Electronic Unit Injector Wiring SMCS Code: 1290 Part No.: 229-2919

Illustration 7

(1) Wiring harness connectors (2) Cat brake connectors (3) Torque for the cap nuts ................ 2.5 ± 0.25 N·m (22 ± 2 lb in) The rear harness has connectors for two brake solenoids. The connection at the Cat brake solenoid is not serviceable.

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8 Specifications Section

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i01832505

Lifter Group

Rocker Shaft

SMCS Code: 1209

SMCS Code: 1102

Part No.: 237-4376

Part No.: 224-4418

Illustration 9

g00936120

(A) Install plugs to the following depth. .. 1 ± 0.25 mm (0.040 ± 0.010 inch)

Illustration 8

g00936107

(1) Tighten the seven bolts to the following torque. ............................................. 60 ± 12 N·m (45 ± 9 lb ft) (2) The alignment dowel for the oil hole extends past the shaft by the following distance. ....... 19.7 mm (0.78 inch) (3) Valve lifters (4) Electronic unit injector lifter (5) The depth is measured from the end of the shaft to the top edge of the cup plug. Depth of installation ..................................... 18 ± 0.25 mm (0.708 ± 0.010 inch) Diameter of the lifter shaft .................. 20 ± 0.01 mm (0.787 ± 0.0004 inch)

(B) Diameter of the rocker shaft .. 34.00 ± 0.010 mm (1.339 ± 0.0005 inch)

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9 Specifications Section

i02379906

Valve Mechanism SMCS Code: 1102

Tighten the jam nut after setting the valve lash to the following torque. .......................... 30 ± 7 N·m (20 ± 5 lb ft) (3) Unit injector

Part No.: 240-7272

Adjust the unit injector as the unit injector is described below.

1. Loosen locknut (2).

2. Turn the adjustment screw clockwise. Stop turning the adjustment screw when contact is made with the unit injector.

3. Place an identifying mark on the adjustment screw.

Tighten the adjustment screw additionally. ................ 180 degrees (1/2 of a turn) 4. Hold the adjustment screw. Tighten locknut (2).

Tighten the locknut to the following torque. ........................... 55 ± 10 N·m (40 ± 7 lb ft) (4) Inlet rocker arm Valve lash setting ....................... 0.38 ± 0.08 mm (0.015 ± 0.003 inch) Tighten jam nut (3) after setting the valve lash to the following torque. .......................... 30 ± 7 N·m (20 ± 5 lb ft) (5) Rocker arm shaft

Illustration 10

g01188376

Procedure for setting the valve lash and the unit injector assembly 1. Set number 1 piston at TDC of the compression stroke a. Set inlet valves on cylinder 1, 2, and 4 b. Set exhaust valves on cylinders 1, 3, and 5 c. Set unit injectors on cylinders 3, 5, and 6 2. Turn the crankshaft 360 degrees in direction of engine rotation (number 6 piston at TDC of the compression stroke). a. Set inlet valves on cylinder 3, 5, and 6 b. Set exhaust valves on cylinders 2, 4, and 6 c. Set unit injectors on cylinders 1, 2, and 4 (1) Exhaust rocker arm Valve lash setting ...................... 0.64 ± 0.08 mm (0.025 ± 0.003 inch)

(6) Exhaust valve pushrod (7) Pushrod for the unit injector (8) Pushrod for the inlet valve (9) Lifter group shaft

10 Specifications Section

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Cylinder Head Valves SMCS Code: 1105 Part No.: 257-4095

Illustration 13

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(2) Exhaust valve

Illustration 11

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(E) Diameter of valve head ........ 41.5 ± 0.13 mm (1.634 ± 0.005 inch) (F) Valve face angle ..................... 45.75° ± 0.25° (G) Valve stem diameter ........ 9.441 ± 0.008 mm (0.3717 ± 0.0003 inch) Minimum valve stem diameter ............ 9.309 mm (0.3665 inch) (3) Height of installation for the valve guide Height to the step in the valve guide .. 22 ± 0.5 mm (0.87 ± 0.012 inch) (4) 224-4441 Spring Inner valve spring

Illustration 12

g00936340

Note: Apply engine oil to the valve stems prior to installation in the cylinder head.

(1) Inlet valve (A) Diameter of valve head ........ 44.5 ± 0.13 mm (1.752 ± 0.005 inch) (B) Valve face angle .................... 60.75° ± 0.25° (C) Valve stem diameter ........ 9.441 ± 0.008 mm (0.3717 ± 0.0003 inch) Minimum valve stem diameter ............ 9.309 mm (0.3665 inch)

Assembled length ............................... 50.47 mm (1.987 inch) Load at assembled length ................. 160 ± 13 N (36 ± 3 lb) Minimum operating length .................. 34.92 mm (1.375 inch) Load at minimum operating length .... 385 ± 18 N (87 ± 4 lb) Outside diameter ................................ 23.24 mm (0.915 inch) Free length after test ............................ 64.1 mm (2.52 inch) (5) 214-0586 Spring Outer valve spring Assembled length ............................... 52.95 mm (2.085 inch) Load at assembled length ................. 320 ± 31 N (72 ± 7 lb) Minimum operating length .................. 37.40 mm (1.472 inch) Load at minimum operating length .... 860 ± 34 N (193 ± 8 lb) Outside diameter ..................................... 34 mm (1.34 inch)

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11 Specifications Section

Free length after test ............................ 62.7 mm (2.47 inch) (6) Valve guides Bore of installed valve guide .. 9.490 ± 0.026 mm (0.3740 ± 0.0010 inch) Maximum recommended diameter of the valve guide bore ........................................... 9.544 mm (0.3760 inch) Note: Do not use a combination of a valve and a valve guide that has a difference of 0.13 mm (0.005 inch) or more.

(7) Inlet valve seat Angle of valve seat ...................... 60.25° ± 0.25° Diameter of valve seat ......... 45.525 ± 0.013 mm (1.7923 ± 0.0005 inch) Bore in cylinder head for valve seat ...................................... 45.461 ± 0.015 mm (1.7898 ± 0.0006 inch) (8) Exhaust valve seat Angle of valve seat ...................... 44.75° ± 0.25° Diameter of valve seat ......... 42.390 ± 0.015 mm (1.6690 ± 0.0006 inch) Bore in cylinder head for valve seat ........................................ 42.32 ± 0.015 mm (1.6661 ± 0.0006 inch) i02378890

Cylinder Head SMCS Code: 1100 Part No.: 257-2170

Illustration 14

g00950659

12 Specifications Section

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Note: Lubricate the bolt threads, the underside of the bolt heads, and the washers with 6V-4876 Lubricant prior to assembly.

Use the following procedure in order to tighten the cylinder head bolts: 1. Tighten bolt (1) through bolt (26) in a numerical sequence.

Tighten the bolts to the following torque. ....................... 170 ± 10 N·m (125 ± 7 lb ft) 2. Tighten bolt (1) through bolt (26) again in a numerical sequence.

Tighten the bolts again to the following torque. ............................................. 170 ± 10 N·m (125 ± 7 lb ft) 3. Place a mark on bolt (1) through bolt (26). Rotate bolt (1) through bolt (26) in a numerical sequence.

Rotate the bolts in the clockwise direction. ..................... 120 ± 5 degrees (1/3 turn) 4. Loosen bolt (1) through bolt (26) until the washers are loose under the bolt heads.

5. Tighten bolt (1) through bolt (26) in a numerical sequence.

Tighten the bolts to the following torque. ............................................. 170 ± 10 N·m (125 ± 7 lb ft) 6. Tighten bolt (1) through bolt (26) again in a numerical sequence.

Tighten the bolts again to the following torque. ............................................. 170 ± 10 N·m (125 ± 7 lb ft) 7. Place a mark on bolt (1) through bolt (26). Rotate bolt (1) through bolt (26) in a numerical sequence.

Rotate the bolts in the clockwise direction. ..................... 120 ± 5 degrees (1/3 turn) 8. Tighten bolt (27) through bolt (33) in a numerical sequence.

Tighten the bolts to the following torque. ............................................... 55 ± 10 N·m (41 ± 7 lb ft)

Illustration 15

g00284618

View A-A

Note: Lubricate the bores for the cup plugs with 6V-6640 Sealant prior to installing the cup plugs.

(34) The cup plugs are measured from the head face to the top edge of the plug. Depth of installation .................................. 1.25 ± 0.25 mm (0.049 ± 0.010 inch) Minimum permissible thickness of cylinder head ........................................................ 164.85 mm (6.4901 inch) Maximum permissible thickness of cylinder head ........................................................ 165.15 mm (6.502 inch) Note: The flatness of the cylinder head should be within 0.15 mm (0.006 inch). The flatness should also be a maximum of 0.05 mm (0.002 inch) for any 150.00 mm (5.906 inch) span.

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13 Specifications Section

i02385807

CAT Compression Brake SMCS Code: 1119; 1129 Part No.: 229-2618

Illustration 17

g01078418

Lash for variable valve actuator

(4) Adjustment screw and jam nut for the variable valve actuator Lash setting for the variable valve actuator .................................. 0.610 ± 0.075 mm (0.0240 ± 0.0030 inch) Tighten the jam nut to the following torque. ......................... 50 ± 10 N·m (37 ± 7 lb ft)

Illustration 16

(1) Locknut (2) Exhaust brake solenoid (3) Master piston

g01180174

14 Specifications Section

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i02217255

Turbocharger SMCS Code: 1052 Part No.: 229-3547 S/N: KCA1-Up Part No.: 229-3547 S/N: KCB1-Up

Illustration 19

Illustration 18

g01078423

Lash for exhaust brake

(5) Adjustment screw and jam nut for the Cat compression brake Cat compression brake lash setting .................................... 0.864 ± 0.050 mm (0.0340 ± 0.0020 inch) Tighten the jam nut to the following torque. ..................... 15 ± 3 N·m (11.0 ± 2.2 lb ft) (6) Stud (7) Exhaust rocker arm

g01119092

(1) Tube As Tighten the nuts on the Tube As to the following torque. ................... 12 ± 1.5 N·m (106 ± 13 lb in) (2) Nuts for mounting the turbocharger Apply 5P-3931 Anti-Seize Compound on the washer face and the threads of the mounting studs for the turbocharger before assembly.

Tighten the nuts that hold the turbocharger to the exhaust manifold to the following torque. ....................... 70 ± 15 N·m (52 ± 11 lb ft) (3) Stud Tighten the stud to the following torque. ........................... 35 ± 5 N·m (26 ± 4 lb ft) Note: Install the stud with the stamped letter X showing.

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15 Specifications Section

i02217215

i02380404

Turbocharger

Turbocharger

SMCS Code: 1052

SMCS Code: 1052

Part No.: 259-9038 S/N: KCA1-Up

Part No.: 229-3553 S/N: KCB1-Up

Part No.: 259-9038 S/N: KCB1-Up

Part No.: 229-3553 S/N: JAM1-Up

Illustration 20

g01119067

(1) Tube As Tighten the nuts on the Tube As to the following torque. ................... 12 ± 1.5 N·m (106 ± 13 lb in) (2) Nuts for mounting the turbocharger Apply 5P-3931 Anti-Seize Compound on the washer face and the threads of the mounting studs for the turbocharger before assembly.

Tighten the nuts that hold the turbocharger to the exhaust manifold to the following torque. ....................... 70 ± 15 N·m (52 ± 11 lb ft) (3) Stud Tighten the stud to the following torque. ........................... 35 ± 5 N·m (26 ± 4 lb ft) Note: Install the stud with the stamped letter X showing.

Illustration 21

g01188495

(1) Tube As Tighten the nuts on the Tube As to the following torque. ................... 12 ± 1.5 N·m (106 ± 13 lb in) (2) Nuts for mounting the turbocharger Apply5P-3931 Anti-Seize Compound (HIGH TEMPERATURE) on the washer face and the threads of the mounting studs for the turbocharger before assembly. Tighten the nuts that hold the turbocharger to the exhaust manifold to the following torque. .................... 70 ± 15 N·m (52 ± 11 lb ft) (3) Stud Tighten the stud to the following torque. ........................... 35 ± 5 N·m (26 ± 4 lb ft) Note: Install the stud with the stamped letter X showing.

16 Specifications Section

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i02219319

Air Lines

Note: Refer to illustration 22 for the correct orientation of the clamp for the air inlet elbow.

SMCS Code: 1058; 1071

i02219491

Air Lines

Part No.: 242-6219 S/N: KCA1-Up

SMCS Code: 1058; 1071

Part No.: 242-6219 S/N: KCB1-Up

Part No.: 233-2515 S/N: KCA1-Up

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

NOTICE The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression.

Inspect the bellows for damage prior to installation.

If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows.

Illustration 22

Part No.: 233-2515 S/N: KCB1-Up

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

NOTICE The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression.

Inspect the bellows for damage prior to installation.

If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows.

g01120233

Right side of engine, typical view

(1) Torque for band clamp .. 8 ± 4 N·m (71 ± 35 lb in) (2) Air inlet elbow

Illustration 23 Left side of engine, typical view

(1) High pressure turbocharger

g01120309

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17 Specifications Section

(2) Torque for band clamps ....................... 8 ± 3 N·m (71 ± 27 lb in)

(1) Torque for band clamps ....................... 8 ± 3 N·m (71 ± 27 lb in)

Note: Refer to illustration 23 for the correct orientation of the clamp for the air intake elbow.

(2) Outlet elbow for the precooler

i02219432

Note: Refer to illustration 24 for the correct orientation of the clamp for the outlet elbow for the precooler.

Air Lines

i02220217

SMCS Code: 1058; 1071

Air Lines

Part No.: 233-2517 S/N: KCA1-Up

SMCS Code: 1058; 1071 Part No.: 224-5396, 224-5397, 224-5443 S/N: KCA1-Up

Part No.: 233-2517 S/N: KCB1-Up

Part No.: 224-5396, 224-5397, 224-5443 S/N: KCB1-Up

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

NOTICE The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression.

Inspect the bellows for damage prior to installation.

If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows.

Illustration 24 Right side of engine, typical view

g01120271

Part No.: 224-5397 S/N: JAM1-Up

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

NOTICE The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression.

Inspect the bellows for damage prior to installation.

If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows.

18 Specifications Section

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i02219543

Air Lines SMCS Code: 1058; 1071 Part No.: 233-2514 S/N: KCA1-Up Part No.: 233-2514 S/N: KCB1-Up

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

Illustration 25

g01078415

Right side of engine, typical view

Note: Refer to illustration 25 for the correct orientation of the turbocharger clamps.

(1) Low pressure turbocharger (2) Low pressure turbocharger clamps ... 12 ± 1 N·m (106 ± 9 lb in)

NOTICE The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression.

Inspect the bellows for damage prior to installation.

If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows.

(3) Compressor interstage clamps ......... 12 ± 1 N·m (106 ± 9 lb in) (4) Precooler (5) Inlet for the precooler ......................... 12 ± 4 N·m (106 ± 35 lb in) (6) Clamps for interstage turbine ........... 12 ± 1 N·m (106 ± 9 lb in) (7) High pressure turbocharger (8) Torque for band clamps ..................... 12 ± 1 N·m (106 ± 9 lb in) (9) Fitting

Illustration 26

g01120325

Left side of engine, typical view

(1) Air intake elbow (2) Torque for band clamps ....................... 8 ± 3 N·m (71 ± 27 lb in)

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19 Specifications Section

Note: Refer to illustration 26 for the correct orientation of the clamps for the air intake elbow. i02219368

Air Lines

i02380437

Air Lines SMCS Code: 1058; 1071 Part No.: 237-4984

SMCS Code: 1058; 1071 Part No.: 224-5394

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

NOTICE The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression.

Inspect the bellows for damage prior to installation.

If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows.

NOTICE The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression.

Inspect the bellows for damage prior to installation.

If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows.

Illustration 28

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Right side of engine Illustration 27

g01120245

Right side of engine, typical view

(1) Torque for band clamps ....................... 8 ± 2 N·m (71 ± 18 lb in) (2) Air inlet elbow Note: Refer to illustration 27 for the correct orientation of the clamp for the air inlet elbow. The clamp must be ±10 degrees of horizontal.

(1) Torque for band clamps ....................... 8 ± 3 N·m (70 ± 27 lb in) (2) Air inlet elbow Note: Refer to illustration 28 for the correct orientation of the clamp for the air inlet elbow.

20 Specifications Section

SENR9702-05

i02219472

Air Lines

Note: Refer to illustration 29 for the correct orientation of the clamp for the air inlet elbow.

SMCS Code: 1058; 1071

i02219301

Air Lines

Part No.: 224-5395 S/N: KCA1-Up

SMCS Code: 1058; 1071

Part No.: 224-5395 S/N: KCB1-Up

Part No.: 250-0784 S/N: KCA1-Up

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

NOTICE The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression.

Inspect the bellows for damage prior to installation.

If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows.

Illustration 29

Part No.: 250-0784 S/N: KCB1-Up

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

NOTICE The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression.

Inspect the bellows for damage prior to installation.

If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows.

g01120288

Right side of engine, typical view

(8) Torque for band clamps ..................... 12 ± 4 N·m (106 ± 35 lb in) (7) Air inlet elbow

Illustration 30

g01120210

Right side of engine, typical view

(1) Torque for band clamp .. 8 ± 4 N·m (71 ± 35 lb in)

SENR9702-05

21 Specifications Section

(2) Air inlet elbow Note: Refer to illustration 30 for the correct orientation of the clamp for the air inlet elbow. i02351281

Exhaust Manifold

2. Apply engine oil to the female ends of the exhaust manifold before assembly. Apply 2P-2333 High Temperature Sealer to the outside diameter of the male ends of the exhaust manifold. Do not apply the sealer at the tip of the male ends. Remove any excess sealer from the assembled joint.

(2) Position the packing material so that the split line of the packing material is at the 12:00 o’clock position.

SMCS Code: 1059

(3) Position the shields so that the gaps of the shields are positioned at 3:00 o’clock and at 9:00 o’clock. Do not pinch the packing material when you install the shields. Position the exhaust clamps as the clamps are shown in illustration 31.

Part No.: 224-5446

Use the following procedure to assemble the shield and clamp over the joint in the exhaust.

1. Torque for the clamps to 5 ± 1 N·m (44 ± 9 lb in) 2. Again tighten both of the clamps to 16 ± 1 N·m (142 ± 9 lb in).

3. Again tighten both clamps after the hot test to 16 ± 1 N·m (142 ± 9 lb in).

(4) Apply 5P-3931 Anti-Seize Compound to the stud threads. Assemble the studs with the letter “X” outward. Tighten the studs to the following torque. ........................... 35 ± 5 N·m (26 ± 4 lb ft) Illustration 31

g01174664

Three-piece exhaust manifold (typical example) (1) (2) (3) (4) (5) (6) (7) (8)

Exhaust manifold gasket Packing material Shields Studs Spacer Washer Spiralock nut Stud

(5) Spacer (6) Washer (7) Spiralock nut

(1) Exhaust manifold gasket Note: The exhaust manifold gaskets have tabs. The tabs should point downward to the oil pan.

Use the following procedure during assembly of the three-piece exhaust manifold to the cylinder block.

NOTICE Excessive use of sealant can cause damage to components.

To avoid component damage use only the amount of sealant necessary for the application.

1. Mounting surfaces should be clean, and dry. In addition, mounting surfaces should be free of any other foreign matter.

Illustration 32

g00566145

Tightening sequence for the Spiralock nuts on the exhaust manifold studs

(8) Apply 5P-3931 Anti-seize Compound to the threads of the studs. Tighten the locknuts in the numerical sequence that is shown above in illustration 32 to the following torque. ......................... 55 ± 10 N·m (41 ± 7 lb ft)

22 Specifications Section

SENR9702-05

Note: Prior to starting or running the engine, allow the sealant in the exhaust manifold joints to air dry for 24 hours.

i02383634

Engine Oil Filter Base SMCS Code: 1306

i02380681

Camshaft

Part No.: 251-6669

SMCS Code: 1210 Part No.: 223-7462

Illustration 34

g01188954

Right side view

Illustration 33

g01188644

(1) Diameter of camshaft bearing journal ........................................ 77.850 ± 0.025 mm (3.0650 ± 0.0010 inch) The lobe on the camshaft for the injector has the most lift when the cam is at zero degrees of rotation. ................................................... 12.703 mm (0.5001 inch) The lobe on the camshaft for the injector has zero lift through the given rotation. .......................... 74 degrees to 254 degrees When the injector lobe has a lift height of 5.238 mm (0.2062 inch), the camshaft should have an angle of rotation. ........................................ 35 ± 0.25 degrees (2) Bolts Torque for the bolts ........ 35 ± 8 N·m (26 ± 6 lb ft)

Illustration 35

g00950317

Section D-D

Oil filter bypass 4N-8150 Spring Full open pressure ...... 255 ± 20 kPa (37 ± 3 psi) Assembled length ............................... 55.25 mm (2.175 inch) Load at assembled length ..................... 76 ± 6 N (17 ± 1.3 lb) Free length after test ............................ 93.7 mm (3.69 inch) Outside diameter .................................. 20.6 mm (0.81 inch)

SENR9702-05

23 Specifications Section

Assembled length ............................... 96.52 mm (3.800 inch) Load at assembled length ...................... 92.52 N (20.800 lb) Free length after test ........................ 124.71 mm (4.910 inch) Outside diameter ................................ 21.84 mm (0.860 inch)

Illustration 36

g00950317

Section A-A

Oil cooler bypass 4N-8150 Spring Full open pressure ...... 255 ± 20 kPa (37 ± 3 psi) Assembled length ............................... 55.25 mm (2.175 inch) Load at assembled length ..................... 76 ± 6 N (17 ± 1.3 lb) Free length after test ............................ 93.7 mm (3.69 inch) Outside diameter .................................. 20.6 mm (0.81 inch)

Illustration 37

g01188945

Section B-B

(1) Plug Torque for plug ......... 100 ± 15 N·m (75 ± 10 lb ft) Pump bypass valve 7C-3954 Spring Full open pressure ........ 374.70 kPa (54.346 psi)

Illustration 38

g00950314

Section C-C

High pressure relief valve 1A-2170 Retainer Spring Relief pressure ............. 679.77 kPa (98.594 psi) Assembled length ............................... 21.41 mm (0.843 inch) Load at assembled length ................. 200 ± 15 N (45 ± 3.5 lb) Free length after test ............................ 31.0 mm (1.22 inch) Outside diameter ................................ 16.97 mm (0.668 inch)

24 Specifications Section

SENR9702-05

i02383708

i02383769

Engine Oil Cooler

Engine Oil Pump

SMCS Code: 1378

SMCS Code: 1304

Part No.: 230-4516

Part No.: 223-1608

Illustration 39

g01188995

Note: Two valves are available. The valves are designed to operate on either 12 or 24 volts. The valves are not interchangeable.

(1) Engine oil cooler (2) Coolant diverter valve (3) Hose (3) Cut off length for hose ................. 90 ± 2 mm (3.5433 ± 0.0787 inch)

Illustration 40

g01189123

NOTICE Before operating the engine, the oil pump must be lubricated with clean engine oil. The oil pump must turn freely by hand. Damage to the drive gear and internal pump damage can occur if the oil pump is not lubricated with clean engine oil.

Engine oil pump Oil type ................................................... SAE 30 Oil temperature ............................ 50 °C (122 °F) Pump speed ........................................ 3045 rpm Oil pressure .............................. 359 kPa (52 psi) Minimum oil flow ............ 155 L/min (41 US gpm) (1) Diameter of two shafts ......... 18.000 ± 0.005 mm (.7087 ± .0002 inch) Bores in pump body for two shafts ........ 18.050 ± 0.010 mm (.7106 ± .0004 inch) (2) Seal groove

SENR9702-05

25 Specifications Section

Prior to installation, lubricate the bore in the engine front cover. This will allow the seal groove and the seal to slide.

Engine Oil Pan

(3) Drive gear

SMCS Code: 1302

In order to install the drive gear, heat the drive gear to the following temperature. ........... 316 °C (600 °F)

i02196624

Part No.: 215-9005

Diameter of the drive gear ............. 92.28 ± 0.10 mm (3.6331 ± 0.0039 inch) (4) Seal (5) Distance between front face of gear and housing ..... 29.40 ± 0.50 mm (1.158 ± .020 inch) i02204941

Engine Oil Pan Illustration 42

SMCS Code: 1302

g01098480

Front sump

Part No.: 229-6171, 264-5081 S/N: KCA1-Up

(1) Oil pan

Part No.: 229-6171 S/N: KCB1-Up

(2) Torque for plugs ............................... 70 ± 15 N·m (52 ± 11 lb ft)

Part No.: 229-6171 S/N: JAM1-Up

(3) Rubber grommet (4) Oil pan bolt i02205054

Engine Oil Pan SMCS Code: 1302 Part No.: 215-9007

Illustration 41

g01098467

Center sump

(1) Oil pan (2) Torque for plugs ............................... 70 ± 15 N·m (52 ± 11 lb ft) (3) Rubber grommet Illustration 43

(4) Oil pan bolt

g01098531

Rear sump

(1) Oil pan (2) Torque for plugs ............................... 70 ± 15 N·m (52 ± 11 lb ft)

26 Specifications Section

SENR9702-05

(3) Rubber grommet (4) Oil pan bolts i02384834

Precooler SMCS Code: 1063; 1378 Part No.: 227-6756

Illustration 45

g01189454

Engine coolant diverter valve

(3) Torque for locking nut ..................... 20 ± 2.5 N·m (14.8 ± 1.8 lb ft) (4) Torque for cartridge (solenoid) ........... 37 ± 2 N·m (27.2 ± 1.5 lb ft) (5) Engine coolant diverter valve Engine coolant diverter valve (5) will use either a 12 V switch or a 24 V switch. The voltage that is used depends on the electrical system of the engine. The valve is normally open.

(6) Torque for nut ......... 11 ± 1 N·m (97.3 ± 8.9 lb in) Illustration 44

g01189380

Right side view of engine

(1) Precooler for intake air (2) Torque for clamps ........ 5.6 ± 1 N·m (50 ± 9 lb in)

Illustration 46

g01189462

SENR9702-05

27 Specifications Section

(7) Torque for plug .......... 8 ± 1 N·m (70.8 ± 8.9 lb in)

i02349951

Water Temperature Regulator i02110191

Water Temperature Regulator Housing

SMCS Code: 1355 Part No.: 247-7133

SMCS Code: 1393 Part No.: 238-6730

Illustration 49

g01099611

(1) Water temperature regulator (2) Seal

(A) Minimum stroke at full open temperature ........................ 10.4 mm (0.41 inch) Opening temperature ......................... 87 °C to 90 °C (189 °F to 194 °F) Illustration 47

g01074249

Fully open temperature ...................... 98 °C (208 °F) Force that is required to separate valve from seat Test temperature .......................... 80 °C (176 °F) Force ......................... 165 ± 9 N·m (122 ± 7 lb ft) Maximum rate for valve leakage Test temperature .......................... 80 °C (176 °F) Test pressure ............................ 210 kPa (30 psi) Maximum leakage ........................ 10 cc (0.6 in3) Maximum opening time for valve Temperature at fully closed position .......... 85 °C (185 °F) Temperature at fully open position ........... 100 °C (212 °F) Maximum opening time ....................... 3 minutes Maximum closing time for valve

Illustration 48

g01074251

The lip seal (2) is installed in the water temperature regulator housing (1). This is shown in illustration 48.

Note: Lightly lubricate the sealing lip with a small amount of glycerin.

Temperature at fully open position ........... 100 °C (212 °F) Temperature at fully closed position .......... 85 °C (185 °F) Maximum opening time ....................... 6 minutes

28 Specifications Section

SENR9702-05

i02385085

i02385285

Water Pump

Cylinder Block

SMCS Code: 1361

SMCS Code: 1201

Part No.: 228-5811

Part No.: 239-7358 The flatness of the top contact surface of the cylinder block must be within 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) section of the surface.

Illustration 51 Illustration 50

g01189596

Water pump

(1) Washer (2) Bolt (3) Bearing (4) Gear (5) Retaining ring (6) Seal (7) Impeller (8) Shaft (9) Housing (B) The distance between the pump flange and the impeller hub ................................ 8.4 ± 0.25 mm (0.331 ± 0.010 inch)

g00488509

Bore diameters in the cylinder block for the cylinder block liners: Position (A) ............................ 151.50 ± 0.03 mm (5.965 ± 0.001 inch) Position (B) ................................ 149.8 ± 0.3 mm (5.898 ± 0.012 inch) Position (C) ............................ 148.00 ± 0.03 mm (5.827 ± 0.001 inch) Position (D) ............................ 141.90 ± 0.05 mm (5.587 ± 0.002 inch)

SENR9702-05

29 Specifications Section

1. Orient the main bearing cap correctly. The part number on the main bearing cap must face to the right and to the front face of the block. Also, the tab slots that are in the block and the main bearing caps must be adjacent.

Note: The main bearing caps are marked with identification numbers 1 through 7. Install the main bearing caps into the correct positions.

2. Lubricate the main bearing cap bolts. Use “SAE 30W” oil or molybdenum grease to lubricate the threads and the washer face.

3. Tighten the main bearing cap bolts.

Tighten bolts to the following torque. .. 150 ± 5 N·m (111 ± 4 lb ft) 4. Put an alignment mark on each cap and bolt.

Rotate the bolts in the clockwise direction. ............................................ 60 degrees

Illustration 52

g01189825

(E) Distance from the centerline of the crankshaft bore to the top surface of the cylinder block ................................................. 387.00 mm (15.236 inch) (F) Diameter of the camshaft bores ...................................... 85.00 ± 0.015 mm (3.3465 ± 0.0006 inch) (G) Distance from the centerline of the crankshaft to the bottom surface of the cylinder block ................................................... 120.0 mm (4.72 inch) Width in cylinder block for the main bearing cap .................................................. 178 ± 0.018 mm (7.0079 ± 0.0007 inch) (H) Width of the main bearing cap ... 178 ± 0.02 mm (7.008 ± 0.001 inch) (I) Bore in the cylinder block for the seven main bearings .............................. 116.000 ± 0.013 mm (4.5669 ± 0.0005 inch) (1) Bolts for the piston cooling jets

Illustration 53

g01189811

The camshaft bearings are installed into the cylinder block at the values that follow.

Position (J) .......................................... 36.50 mm (1.437 inch) Position (K) ....................................... 192.50 mm (7.578 inch) Position (L) ....................................... 348.50 mm (13.720 inch) Position (M) ...................................... 504.50 mm (19.862 inch) Position (N) ....................................... 660.50 mm (26.004 inch) Position (P) ....................................... 816.50 mm (32.145 inch) Position (R) ....................................... 972.50 mm (38.287 inch)

(2) Main bearing cap bolts Use the following procedure in order to install the main bearing cap bolts:

NOTICE Camshaft bearings must be installed into their correct position. Failure to do so will result in engine damage.

30 Specifications Section

SENR9702-05

Table 1

Position A

151.42 ± 0.05 mm (5.961 ± 0.002 inch)

Position B

147.90 ± 0.03 mm (5.823± 0.001 inch)

Position C

141.38 ± 0.08 mm (5.566 ± 0.003 inch)

Inner Bore Diameter

130.025 ± 0.025 mm (5.1191 ± 0.0010 inch)

Note: Apply 5P-3975 Rubber Lubricant to the cylinder liner seals prior to assembly. i02212928

Illustration 54

g01189826

Cylinder Liner Projection

(3) Bearing joint

SMCS Code: 1216

(4) Oil hole

Part No.: 252-2180

(S) Bearing oil hole is located at a 45 degree angle from vertical. All seven bearings have the same angle.

Table 2

i02385372

Cylinder Liner SMCS Code: 1216 Part No.: 197-9330

Specifications Liner Projection

0.060 to 0.180 mm (0.0024 to 0.0071 inch)

Maximum Variation in Each Liner

0.050 mm (0.0020 inch)

Maximum Average Variation Between Adjacent Liners

0.080 mm (0.0031 inch)

Maximum Variation Between All Liners

0.100 mm (0.0040 inch)

For more information on measuring the cylinder liner projection, refer to the Testing and Adjusting manual.

Illustration 55

Outside diameters of the cylinder liner

g00517737

SENR9702-05

31 Specifications Section

i02100826

i02204815

Crankshaft

Crankshaft Seals

SMCS Code: 1202

SMCS Code: 1160; 1161

Part No.: 224-3882 S/N: KCA1-Up

Part No.: 116-1091

Part No.: 224-3881 S/N: KCB1-Up Part No.: 238-8373 S/N: JAM1-Up

Illustration 56

g01070489

Illustration 57

g00984057

(1) Main bearing journals

Note: Install the front crankshaft seals and the rear crankshaft seals dry.

The thrust plate is used on the center main bearing only.

(1) Seal group

(2) Crankshaft gear

(2) O-ring seal

(A) Average diameter of gear after assembly .......................... 136.20 ± 0.11 mm (5.362 ± 0.004 inch) Maximum diameter of gear after assembly ...................... 136.36 mm (5.368 inch) (B) Maximum distance between the crankshaft gear and the crankshaft flange ....... 0.10 mm (0.004 inch) (C) Install the alignment dowel to the following depth. ......... 8.0 ± 0.5 mm (0.32 ± 0.02 inch) (3) Connecting rod bearing journals Note: After the crankshaft is assembled into the block, the crankshaft end play should be a maximum of 0.50 mm (0.020 inch) and a minimum of 0.10 mm (0.004 inch).

Lightly lubricate the O-ring seal. Use the lubricant that is being sealed.

(3) Crankshaft Apply 7M-7456 Bearing Mount Compound to the bolt threads.

32 Specifications Section

SENR9702-05

i02199495

Main Bearing Journal SMCS Code: 1202; 1203 Part No.: 224-3882 S/N: KCA1-Up Part No.: 224-3881 S/N: KCB1-Up Part No.: 238-8272 S/N: JAM1-Up Table 4

Main Bearing Journal

g00951705

Illustration 58 Tightening sequence for the rear seal

Note: Use an alternating sequence when tightening the front and rear seal bolts. i02199486

Connecting Rod Bearing Journal SMCS Code: 1202; 1219; 1225 Part No.: 224-3882 S/N: KCA1-Up Part No.: 224-3881 S/N: KCB1-Up Part No.: 238-8372 S/N: JAM1-Up Table 3

Connecting Rod Bearing Journal Original size journal

89.000 ± 0.020 mm (3.5039 ± .0008 inch)

Undersize journal 0.508 mm (.0200 inch)

88.492 ± 0.020 mm (3.4839 ± .0008 inch)

Undersize journal 0.762 mm (.0300 inch)

87.238 ± 0.020 mm (3.4346 ± .0008 inch)

The clearance between a new bearing and a new journal is the following value. .. 0.33 mm to 0.131 mm (0.0130 inch to 0.0052 inch)

Original size journal

108.000 ± 0.020 mm (4.2520 ± .0008 inch)

Undersize journal 0.508 mm (.0200 inch)

107.492 ± 0.020 mm (4.2320 ± .0008 inch)

Undersize journal 0.762 mm (.0300 inch)

107.238 ± 0.020 mm (4.2220 ± .0008 inch)

The clearance between a new bearing and a new journal is the following value. ...... 0.059 to 0.157 mm (.0023 to .0062 inch) Table 5

Main Bearing Bore Main bearing bore (original size)

116.000 ± 0.013 mm (4.5669 ± .0005 inch)

Oversize bore in block 0.508 mm (.0200 inch)

116.508 ± 0.013 mm (4.5869 ± .0005 inch)

SENR9702-05

33 Specifications Section

i02385617

Connecting Rod

Diameter of the piston pin .......... 53.155 ± 0.005 mm (2.0927 ± 0.0002 inch) Thoroughly lubricate the piston pin with clean engine oil prior to assembly of the piston and connecting rod.

SMCS Code: 1218 Part No.: 197-9307 S/N: KCA1-Up

(4) The bearing joint must be within ± 12.5 degrees of either location.

(5) Distance between the center of the bearings .............................................. 247.5 mm (9.7441 inch) (6) Etch the cylinder number on the connecting rod and the cap in this location. Mark the connecting rod and the cap with a number 1 through 6. Mark the numbers on the same side of the connecting rod as the bearing retainer notch.

Note: Install the connecting rod in the engine with the part number to the rear of the engine.

(7) Tighten the connecting rod bolts. Use the instructions that follow.

1. Before installing the connecting rod bolts, lubricate the bolt threads and the seating faces of the caps with 2P-2506 Thread Lubricant.

2. Tighten the connecting rod bolts.

Tighten the connecting rod bolts to the following torque. ............................................... 130 ± 7 N·m (95 ± 5 lb ft) 3. Tighten each connecting rod bolt for an additional amount.

Rotate each connecting rod bolt in the clockwise direction. ................ 60 ± 5 degrees (1/6 of a turn)

Illustration 59

g01096964

(1) Bore in the connecting rod for the piston pin bearing ................................. 57.810 ± 0.013 mm (2.2760 ± 0.0005 inch) Note: The connecting rod must be heated for the installation of the piston pin bearing. Do not use a torch.

(2) The connecting rod may be heated from 175 °C to 260 °C (347 °F to 500 °F) for the installation of the piston pin bearing.

Maximum distance for heating the connecting rod ...................................................... 88.00 mm (3.4646 inch) (3) Bore in the bearing for the piston pin ........................................ 53.205 ± 0.008 mm (2.0947 ± 0.0003 inch)

(8) Bore in the connecting rod for the crankshaft bearing ................................. 93.800 ± 0.013 mm (3.6929 ± 0.0005 inch)

34 Specifications Section

SENR9702-05

i02385589

Connecting Rod SMCS Code: 1218

(3) Bore in the bearing for the piston pin ........................................ 53.205 ± 0.008 mm (2.095 ± 0.0003 inch) Diameter of the piston pin .......... 53.155 ± 0.005 mm (2.0927 ± 0.0002 inch)

Part No.: 197-9309 S/N: KCB1-Up

Thoroughly lubricate the piston pin with clean engine oil prior to assembly of the piston and connecting rod.

Part No.: 197-9309 S/N: JAM1-Up

(4) The bearing joint must be within ± 12.5 degrees of either location.

(5) Distance between the center of the bearings ............................................ 239.00 mm (9.4094 inch) (6) Etch the cylinder number on the connecting rod and the cap in this location. Mark the connecting rod and the cap with a number 1 through 6. Mark the numbers on the same side of the connecting rod as the bearing retainer notch.

Note: Install the connecting rod in the engine with the part number to the rear of the engine.

(7) Tighten the connecting rod bolts. Use the instructions that follow.

1. Before installing the connecting rod bolts, lubricate the bolt threads and the seating faces of the caps with 2P-2506 Thread Lubricant.

2. Tighten the connecting rod bolts.

Tighten the connecting rod bolts to the following torque. ............................................... 130 ± 7 N·m (95 ± 5 lb ft) 3. Tighten each connecting rod bolt for an additional amount.

Rotate each connecting rod bolt in the clockwise direction. ................ 60 ± 5 degrees (1/6 of a turn)

Illustration 60

g01096964

(1) Bore in the connecting rod for the piston pin bearing ................................. 57.810 ± 0.013 mm (2.2760 ± 0.0005 inch) Note: The connecting rod must be heated for the installation of the piston pin bearing. Do not use a torch.

(2) The connecting rod may be heated from 175 °C to 260 °C (347 °F to 500 °F) for the installation of the piston pin bearing.

Maximum distance for heating the connecting rod ...................................................... 88.00 mm (3.465 inch)

(8) Bore in the connecting rod for the crankshaft bearing ................................... 93.80 ± 0.013 mm (3.6929 ± 0.0005 inch)

SENR9702-05

35 Specifications Section

i02387032

Piston and Rings SMCS Code: 1214; 1215 Part No.: 197-9381 S/N: KCA1-Up Part No.: 197-9383 S/N: KCB1-Up Part No.: 197-9383 S/N: JAM1-Up

Thickness of new intermediate piston ring ........... 2.98 ± 0.01 mm (0.117 ± 0.0004 inch) The ends of the piston ring have a clearance when the piston ring is installed in a cylinder liner with a bore of 130.000 mm (5.1181 inch).

Clearance ..................................... 1 ± 0.125 mm (0.0394 ± 0.0049 inch) The intermediate piston ring has an increase in clearance for each 0.03 mm (0.001 inch) increase in the cylinder liner bore. Increase ........ 0.09 mm (0.004 inch) (4) Oil control ring groove The ends of the oil control piston ring should be a distance of 180 degrees from the ring end gap when the oil control piston ring is assembled. The white colored portion of the piston ring must be visible at the ring end gap.

Width of groove in new piston for oil control piston ring ......................................... 4.052 ± 0.012 mm (0.1595 ± 0.0005 inch) Thickness of new oil control piston ring ......................................... 3.987 ± 0.013 mm (0.1570 ± 0.0005 inch) The ends of the piston ring have a clearance when the piston ring is installed in a cylinder liner with a bore of 130.000 mm (5.1181 inch).

Clearance .................................. 0.44 ± 0.15 mm (0.017 ± 0.006 inch) The oil control piston ring has an increase in clearance for each 0.03 mm (0.001 inch) increase in the cylinder liner bore. Increase ........ 0.09 mm (0.004 inch)

Illustration 61

g01191302

(1) The piston is symmetrical with a center crater.

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

Lubricate the entire piston to 360 ° in zone (A) prior to assembly into the cylinder block. Use clean engine oil.

(A) Piston pin bore diameter ......... 53.22 ± 0.01 mm (2.0953 ± 0.0004 inch)

(2) Top piston ring groove

Thoroughly lubricate the piston pin with clean engine oil prior to assembly.

Install the piston ring with the side marked “UP-1” toward the top of the piston.

The ends of the piston ring have a clearance when the piston ring is installed in a cylinder liner with a bore of 130.000 mm (5.1181 inch).

Clearance ..... 0.5 ± 0.1 mm (0.020 ± 0.004 inch) The top piston ring has an increase in clearance for each 0.03 mm (0.001 inch) increase in the cylinder liner bore. Increase ................. 0.09 mm (0.004 inch) (3) Intermediate piston ring groove Install the piston ring with the side marked “UP-2” toward the top of the piston.

Width of groove in new piston for intermediate piston ring .............................. 3.053 ± 0.013 mm (0.1202 ± 0.0005 inch)

36 Specifications Section

SENR9702-05

i02199538

Piston Cooling Jet SMCS Code: 1331 Part No.: 226-6478

Illustration 64

g00952129

Tightening sequence for the front crankshaft seal

(1) Self locking bolt M8 - 1.25 (2) Seventeen bolts fasten the cover to the housing.

Illustration 62

g01098595

Note: Bolt (1) is different from the other cover bolts.

Tighten the bolt (1) for the piston cooling jet to the following torque. ....................................... 35 ± 3 N·m (26 ± 2 lb ft) Note: Visually check that the piston cooling jet is properly seated in the cylinder block before applying torque. i02386035

Housing (Front)

(4) O-ring seal and crankshaft front seal The O-ring seal and the crankshaft front seal are part of the front housing. Lubricate the O-ring seal lightly.

Use the lubricant that is being sealed.

(5) Accessory drive assembly Note: Apply 8T-9022 Silicone Gasket in order to fill the space at the connecting joint of the front housing, engine oil pan, and cylinder block.

SMCS Code: 1151 Part No.: 218-7272

Illustration 63

(3) Nine bolts fasten the housing to the block.

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37 Specifications Section

i02386244

Gear Group (Front) SMCS Code: 1206 Part No.: 222-3088

g01098608

Illustration 65

(1) Camshaft gear Number of teeth .............................................. 96 Bore diameter .......................... 58.9 ± 0.013 mm (2.3189 ± 0.0005 inch) (2) Align the timing marks on the idler gear to the timing marks on the camshaft gear and the marks on the crankshaft gear.

(3) Idler gear for the water pump Number of teeth .............................................. 64 Bore diameter for bearing .. 60.0163 ± 0.015 mm (2.3628 ± 0.0006 inch) Bore diameter of the bearing ................................. 60.281 ± 0.013 mm (2.3733 ± 0.0005 inch) (4) Crankshaft gear

Number of teeth .............................................. 48 Bore diameter ............................ 96.9 ± 0.02 mm (3.815 ± 0.001 inch) (5) Idler gear Number of teeth .............................................. 71 Bore diameter for bearing .... 74.452 ± 0.015 mm (2.9312 ± 0.0006 inch) Bore diameter of the bearing ................................. 69.205 ± 0.013 mm (2.7246 ± 0.0005 inch) (6) Mounting bolts for accessory drive.

38 Specifications Section

SENR9702-05

i02169326

Gear Group (Rear) SMCS Code: 1204; 1206 Part No.: 117-2769 S/N: KCA1-Up Part No.: 117-2769 S/N: KCB1-Up

Note: During assembly, inspect the following components for any foreign materials: the front face of the flywheel housing, the two sides of the flywheel housing gasket and the rear face of the cylinder block. These components must be free of the following substances: oil, fuel, water, gasket adhesive, assembly compounds, and any other foreign material. Apply a small amount of 8T-9022 Silicone Gasket in order to fill the space between the cylinder block, the flywheel housing, and the oil pan before installing the oil pan gasket and the oil pan.

The components must be assembled within twenty minutes of applying the sealant.

(1) Lubricate the bore with oil.

(2) Tighten the bolt to the following torque. ..................... 105 ± 20 N·m (77 ± 15 lb ft) i02386341

Flywheel Housing SMCS Code: 1157 Part No.: 222-3094 S/N: KCA1-Up Part No.: 222-3090 S/N: KCB1-Up Part No.: 222-3090 S/N: JAM1-Up

Illustration 67

(1) Flywheel housing Illustration 66

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39 Specifications Section

Apply 1U-8846 Gasket Sealant on the gasket surface of the flywheel housing. Assemble the flywheel housing to the cylinder block and tighten within ten minutes of applying the sealant. i02169784

Flywheel Housing

i02169177

Engine to Transmission Adapter SMCS Code: 1001 Part No.: 124-2665

SMCS Code: 1157 S/N: KCA1-Up S/N: KCB1-Up

Illustration 68

g01099632

Illustration 69

(1) Flywheel housing

Typical Example

(2) Torque the bolts to the following torque. ..................... 125 ± 20 N·m (92 ± 15 lb ft)

(1) Plate

Apply 1U-8846 Gasket Sealant on the gasket surface of the flywheel housing. Assemble the flywheel housing to the cylinder block and tighten within ten minutes of applying the sealant.

g01099066

(2) Adapter (3) Apply 9S-3263 Thread Lock Compound to the bolts. Tighten the bolts to the following torque. ................... 300 ± 40 N·m (220 ± 30 lb ft) (4) Tighten the bolts to the following torque. ....................... 70 ± 15 N·m (51 ± 11 lb ft)

40 Specifications Section

SENR9702-05

i02359520

i02169999

Belt Tensioner

Electric Starting Motor

SMCS Code: 1358

SMCS Code: 1453

Part No.: 222-2901

Part No.: 207-1537

Illustration 70

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(1) Mounting bracket (2) The tensioner is in the free position when the belt is not on the tensioner. Required torque for rotating the tensioner to a 30 degree angle from the free position .......................... 58.8 ± 5.9 N·m (43 ± 4 lb ft)

Illustration 71

g01099859

When the electric starting motor is viewed from the drive end, the motor rotates in the following direction. ................................................... Clockwise No load conditions at 25 °C (77 °F) Minimum speed with no load ... 6900 ± 1800 rpm Maximum current with no load .. 127.5 ± 27.5 amp Voltage ......................................................... 11 V (1) Battery terminal A maximum of three cable or wire terminals should be between the nuts.

Tighten the nut on the battery terminal to the following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft) (2) Motor terminal Tighten the nut on the motor terminal to the following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft) (3) Ground terminal Tighten the nut on the ground terminal to the following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft) (4) Ground terminal Tighten the nut on the ground terminal to the following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)

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41 Specifications Section

(5) Switch terminal The wire terminal that is on the switch terminal must be insulated with heat shrink tubing. Do not use molded terminals.

Tighten the nut on the switch terminal to the following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in) (6) Motor frame terminal Tighten the nut on the motor frame terminal to the following torque. ........... 8 ± 3 N·m (71 ± 27 lb in)

Solenoid

A maximum of three cable or wire terminals should be between the nuts.

Tighten the nut on the battery terminal to the following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft) (2) Ground terminal Tighten the nut on the ground terminal to the following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft) (3) Ground terminal Tighten the nut on the ground terminal to the following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in) (4) Switch terminal

Current draw at 10 V and 25 °C (77 °F) Pull-in windings ........................... 92.5 ± 7.5 Amp Hold-in windings .................... 23 Amp maximum i02225007

Electric Starting Motor

The wire terminal that is on the switch terminal must be insulated with heat shrink tubing. Do not use molded terminals.

Tighten the nut on the switch terminal to the following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in) (5) Motor terminal Tighten the nut on the motor terminal to the following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)

SMCS Code: 1453 Part No.: 207-1557

(6) Motor frame terminal Tighten the nut on the motor frame terminal to the following torque. ........... 8 ± 3 N·m (70 ± 27 lb in)

Solenoid Current draw at 20 V and 25 °C (77 °F) Pull-in windings ....................................... 57 Amp Hold-in windings .................... 16 Amp maximum

Illustration 72

g01099879

When the electric starting motor is viewed from the drive end, the motor rotates in the following direction. ................................................... Clockwise No load conditions at 25 °C (77 °F) Minimum speed with no load ... 7643 ± 1683 rpm Maximum current with no load .. 76.5 ± 14.5 amp Voltage ......................................................... 23 V (1) Battery terminal

42 Specifications Section

SENR9702-05

i02169978

Electric Starting Motor SMCS Code: 1453 Part No.: 207-1511 S/N: KCB1-Up

A maximum of three cable or wire terminals should be between the nuts.

Tighten the nut on the battery terminal to the following torque. .......................... 30.5 ± 3.5 N·m (22 ± 3 lb ft) (2) Switch terminal The wire terminal that is on the switch terminal must be insulated with heat shrink tubing. Do not use molded terminals.

Tighten the nut on the switch terminal to the following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in) (3) Motor terminal Tighten the nut on the motor terminal to the following torque. .......................... 14.7 ± 3.4 N·m (11 ± 3 lb ft) Note: The internal Torx screw must be held during tightening or loosening of the nut.

Illustration 73

g01099827

(4) Motor frame terminal Tighten the nut on the motor frame terminal to the following torque. ........... 8 ± 3 N·m (71 ± 27 lb in) (5) Ground terminal Tighten the nut on the ground terminal to the following torque. .......................... 30.5 ± 3.5 N·m (22 ± 3 lb ft)

Solenoid Current draw at 20 V and 25 °C (77 °F) Pull-in windings ....................................... 36 Amp Hold-in windings ...................... 6 Amp maximum

Illustration 74

g01099828

When the electric starting motor is viewed from the drive end, the motor rotates in the following direction. ................................................... Clockwise No load conditions at 25 °C (77 °F) Minimum speed with no load ..... 3638 ± 413 rpm Maximum current with no load ........ 90 ± 16 amp Voltage ......................................................... 23 V (1) Battery terminal

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43 Specifications Section

i02358664

i02358641

Coolant Temperature Sensor

Engine Oil Pressure Sensor

SMCS Code: 1906

SMCS Code: 1924

Part No.: 234-5012

Part No.: 276-9067

Illustration 75

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(1) Sensor assembly

Illustration 77

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(1) Sensor assembly

Tighten the sensor assembly to the following torque. ............................................... 20 ± 3 N·m (15 ± 2 lb ft)

Tighten the sensor assembly to the following torque. ............................... 10 ± 2 N·m (90 ± 20 lb in) i02363398

i02363248

Fuel Temperature Sensor

SMCS Code: 1917

SMCS Code: 1922

Part No.: 249-0096

Part No.: 234-5013

Illustration 76

Boost Pressure Sensor

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(1) Sensor assembly Tighten the sensor assembly to the following torque. ........................... 20 ± 3 N·m (15 ± 2 lb ft)

Illustration 78

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(1) Sensor assembly Tighten the sensor assembly to the following torque. ........................ 10 ± 2 N·m (90 ± 20 lb in)

44 Specifications Section

SENR9702-05

i02358620

i02266728

Atmospheric Pressure Sensor

Speed/Timing Sensor

SMCS Code: 1923

SMCS Code: 1907; 1912

Part No.: 276-8548

Part No.: 230-7149, 239-2397 S/N: KCA1-Up S/N: KCB1-Up Part No.: 230-7149, 239-2397 S/N: JAM1-Up

Secondary Speed/Timing Sensor

Illustration 79

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(1) Sensor assembly Tighten the sensor assembly to the following torque. ........................ 10 ± 2 N·m (90 ± 20 lb in) i02386689

Inlet Manifold Temperature Sensor SMCS Code: 1921 Part No.: 234-5013

Illustration 81

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Secondary speed/timing sensor

(1) Sensor (2) Bracket

Illustration 80

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(1) Sensor assembly Tighten the sensor assembly to the following torque. ........................... 20 ± 3 N·m (15 ± 2 lb ft)

Ensure that the bracket is installed in the orientation that is shown.

(3) Tighten the bolt to the following torque. ........................... 28 ± 7 N·m (21 ± 5 lb ft) Ensure that the sensor is seated before the bolt is tightened.

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45 Specifications Section

Primary Speed/Timing Sensor

Illustration 82

g01025562

Primary speed/timing sensor

(1) Sensor (2) Bracket Ensure that the bracket is installed in the orientation that is shown.

(3) Tighten the bolt to the following torque. ........................... 28 ± 7 N·m (21 ± 5 lb ft) Ensure that the sensor is seated before the bolt is tightened.

46 Index Section

SENR9702-05

Index A

Gear Group (Rear) ................................................ 38

Air Lines........................................................... 16–20 Atmospheric Pressure Sensor............................... 44

H

B Belt Tensioner........................................................ 40 Boost Pressure Sensor.......................................... 43 C Camshaft ............................................................... 22 CAT Compression Brake ....................................... 13 Connecting Rod............................................... 33–34 Connecting Rod Bearing Journal........................... 32 Coolant Temperature Sensor................................. 43 Crankshaft ............................................................ 31 Crankshaft Seals ................................................... 31 Cylinder Block........................................................ 28 Cylinder Head......................................................... 11 Cylinder Head Valves ............................................ 10 Cylinder Liner ........................................................ 30 Cylinder Liner Projection ....................................... 30 E Electric Starting Motor ..................................... 40–42 Solenoid ....................................................... 41–42 Electronic Unit Injector............................................. 5 Electronic Unit Injector Mechanism ......................... 6 Electronic Unit Injector Rocker Arm......................... 6 Electronic Unit Injector Wiring ................................. 7 Engine Design ......................................................... 4 C11....................................................................... 4 C13 ...................................................................... 4 Engine Oil Cooler .................................................. 24 Engine Oil Filter Base............................................ 22 Engine Oil Pan....................................................... 25 Engine Oil Pressure Sensor .................................. 43 Engine Oil Pump.................................................... 24 Engine to Transmission Adapter ........................... 39 Exhaust Manifold ................................................... 21 F

Housing (Front)...................................................... 36 I Important Safety Information ................................... 2 Inlet Manifold Temperature Sensor........................ 44 L Lifter Group.............................................................. 8 M Main Bearing Journal............................................. 32 P Piston and Rings ................................................... 35 Piston Cooling Jet.................................................. 36 Precooler ............................................................... 26 R Rocker Shaft............................................................ 8 S Specifications Section ............................................. 4 Speed/Timing Sensor ............................................ 44 Primary Speed/Timing Sensor ........................... 45 Secondary Speed/Timing Sensor ...................... 44 T Table of Contents..................................................... 3 Turbocharger ................................................... 14–15

Flywheel Housing ............................................ 38–39 Fuel Temperature Sensor ...................................... 43 Fuel Transfer Pump ................................................. 5

V

G

W

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

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

Valve Mechanism .................................................... 9

SENR9702-05

Water Temperature Regulator ............................... 27 Water Temperature Regulator Housing ................. 27

47 Index Section

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