Specifications

1204F-E44TA and 1204F-E44TTA

Industrial Engines

MT (Engine)

MU(Engine)

This document is printed from SPI2. NOT FOR RESALE

Important Safety Information

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

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

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

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

Improper operation, lubrication, maintenance or repair  of this product can be dangerous and

could result in injury  or death.

Do not operate or perform any lubrication, maintenance or repair on this  product, until you have

read and understood the operation, lubrication, maintenance and repair information.

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

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

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

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

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

Attention! Become Alert! Your Safety is  Involved.

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

pictorially   presente  d.

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

this  pub lication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The

warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,

work method or operating technique that is not specifically recommended by Perkins is used,

you must satisfy yourself that it is safe  for you and for others. You should also ensure that the

product will not be damaged or be  made unsafe by the operation, lubrication, maintenance or

repair procedures that you choose.

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

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

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

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

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

When  replacement  parts  are  required  for  this

product Perkins recommends using Perkins

 replacement  parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

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UENR4489

3

Table of Contents

Table of Contents

Accessory Drive (SAE  “B” ).............. ............. 38

Accessory Drive....................... ....................... 39

Front Housing and Covers............... ............... 39

Gear Group (Front)..................... .................... 40

Flywheel .......................................................... 41

Flywheel Housing...................... ..................... 41

Crankshaft Pulley ...................... ..................... 42

Belt Tensioner......................... ........................ 42

Refrigerant Compressor................. ................ 42

Fan Drive............................ ............................ 43

Engine Lifting Bracket................... .................. 43

Alternator............................ ............................ 43

Starter Motor.......................... ......................... 44

Nitrogen Oxide Sensor .................. ................. 45

Coolant Temperature Sensor............. ............. 45

Engine Oil Pressure Sensor.............. ............. 46

Boost Pressure Sensor.................. ................. 46

Ammonia Sensor (If equipped)............ ........... 46

Atmospheric Pressure Sensor............ ............ 47

Inlet Manifold Temperature Sensor......... ........ 47

Temperature Sensor (DPF Inlet)........... .......... 48

Temperature Sensor (DOC Inlet).......... .......... 48

Temperature Sensor (Exhaust) (Selective

SpecificationsSection

Engine Design ......................... ......................... 4

Fuel Injection Lines...................... ..................... 4

Fuel Injection Pump..................... ..................... 5

Fuel Injectors.......................... .......................... 6

Fuel Transfer Pump..................... ..................... 6

Fuel Filter Base (Single Secondary Fuel Filter

Base) ............................... ............................... 7

Fuel Filter Base (Twin Secondary Fuel Filter

Base) ............................... ............................... 7

Fuel Filter Base (Primary Fuel Filter Base)... ... 8

Fuel Manifold (Rail)...................... ..................... 8

Lifter Group............................ ........................... 9

Rocker Shaft........................... .......................... 9

Valve Mechanism Cover................. .................11

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

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

Turbocharger (Single Turbocharger)....... ....... 14

Turbocharger (Series Turbochargers)...... ...... 16

Exhaust Gas Valve (NRS) ............... ............... 18

Injector (Diesel Exhaust Fluid)............ ............ 19

Manifold (Diesel Exhaust Fluid)........... ........... 19

Diesel Exhaust Fluid Tank ............... ............... 20

Diesel Exhaust Fluid Pump .............. .............. 20

Solenoid Valve (DEF Heater Coolant)...... ...... 21

Exhaust Cooler (NRS).................. .................. 21

Exhaust Manifold...................... ...................... 24

Flexible Exhaust Pipe................... .................. 25

Camshaft............................ ............................ 25

Camshaft Bearings..................... .................... 26

Engine Oil Filter Base................... .................. 27

Engine Oil Cooler...................... ...................... 27

Engine Oil Pump....................... ...................... 28

Engine Oil Pressure.................... .................... 28

Engine Oil Pan........................ ........................ 29

Crankcase Breather.................... .................... 30

Water Temperature Regulator and Housing.. . 30

Water Pump.......................... .......................... 31

Cylinder Block......................... ........................ 31

Crankshaft........................... ........................... 32

Crankshaft Seals ...................... ...................... 33

Connecting Rod Bearing Journal.......... .......... 34

Main Bearing Journal................... ................... 34

Connecting Rod....................... ....................... 35

Piston and Rings ...................... ...................... 36

Piston Cooling Jet...................... ..................... 37

Balancer .......................................................... 38

Catalytic Reduction (SCR) Temperature

Sensor)............................. ............................ 48

Pressure Sensor (NOx Reduction System)

(Differential Pressure Sensor) ........... ........... 49

Pressure Sensor (NOx Reduction System).. .. 49

Temperature Sensor (NOx Reduction System)49

Soot Antenna......................... ......................... 50

Speed/Timing Sensor................... .................. 50

Electronic Control Module ............... ............... 51

Glow Plugs .......................... ........................... 51

Air Compressor (Twin Cylinder Compressor)  52

Air Compressor (Single Cylinder)......... ......... 53

Index Section

Index................................ ............................... 55

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UENR4489

Specifications Section

SpecificationsSection

When the camshaft is viewed from the front of the

engine, the camshaft rotates in the following direction:

.....................................................................Clockwise

i05937832

The front of the engine is opposite the flywheel end.

The left side and the right side of the engine are

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

the front cylinder.

Engine Design  

i05847993

Fuel Injection Lines  

Contact with  high pressure fuel may  cause fluid

penetration and burn hazards. High pressure fuel

spray may  cause a  fire hazard. Failure  to follow

these  inspection,  maintenance  and  service  in-

structions may cause personal injury or death.

Refer to Operation and Maintenance Manual,

“General Hazard Information and High Pressure Fuel

Lines” before adjustments and repairs are performed.

NOTICE

Refer to Systems Operation, Testing, and Adjust-

ing,  “Cleanliness of  Fuel  System  Components”

for detailed information on the standards of clean-

liness that must be observed during ALL work on

the fuel system.

Illustration 1

g01335181

Cylinder and valve location

(A)  Exhaust valve

(B) Inlet valve

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

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

Displacement........................................4.4 L (269 in3)

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

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

Compression ratio

Ensure that all adjustments and repairs are

performed by authorized personnel that have had the

correct training.

Turbocharged engines and turbocharged charge

cooled engines ...........................................16.5:1

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

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

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

When the crankshaft is viewed from the front of the

engine, the crankshaft rotates in the following

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

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UENR4489

5

Specifications Section

Illustration 2

g02334261

Typical example

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

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

i04138513

Fuel Injection Pump

Note: The timing of the fuel injection pump will need

to be checked by trained personnel. In order to check

the timing of the fuel injection pump, refer to Systems

Operation, Testing, and Adjusting, “Fuel Injection

Pump Timing - Check”.

NOTICE

Refer to Systems Operation, Testing, and Adjust-

ing,  “Cleanliness of  Fuel  System Components”

for detailed information on the standards of clean-

liness that must be observed during ALL work on

the fuel system.

Illustration 3

g02335956

Typical example

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

(97 lb in)

(2) Tighten the mounting nut to the following torque.

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

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6

UENR4489

Specifications Section

(3) Tighten the setscrews to the following torque.

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

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

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

(4) Tighten the screws for the suction control valve to

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

i05847994

Fuel Transfer Pump

(5) Tighten the fuel temperature sensor to the

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

(6) Tighten the screw to the following torque.

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

i03631793

Fuel Injectors  

NOTICE

Refer to Systems  Operation, Testing and Adjust-

ing,  “Cleanliness of  Fuel  System Components”

for detailed information on the standards of clean-

liness that must be observed during ALL work on

the fuel system.

Illustration 5

g02337197

Typical example

(1) Tighten the allen head screws to the following

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

(2) Tighten the connection to the following torque.

.........................................................21.5 N·m (16 lb ft)

Illustration 4

g01862457

Typical example

(3) Clamp

(4) Washer

(5) O ring seal

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

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UENR4489

7

Specifications Section

Illustration 6

g02337198

Illustration 7

g02484376

Typical example

Typical example

(3) (4) Tighten the bolts to the following torque.

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

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

(33 lb ft)

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

(13 lb ft)

i04325509

Fuel Filter Base

(Single Secondary Fuel Filter

Base)

i04330369

Fuel Filter Base

(Twin Secondary Fuel Filter

Base)

NOTICE

Refer to Systems  Operation, Testing and Adjust-

ing,  “Cleanliness of  Fuel  System Components”

for detailed information on the standards of clean-

liness that must be observed during ALL work on

the fuel system.

NOTICE

Refer to Systems  Operation, Testing and  Adjust-

ing,  “Cleanliness of  Fuel  System  Components”

for detailed information on the standards of clean-

liness that must be observed during ALL work on

the fuel system.

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

Refer to Operation and Maintenance Manual, “Fuel

System Secondary Filter - Replace” for the correct

procedure.

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

Refer to Operation and Maintenance Manual, “Fuel

System Secondary Filter - Replace” for the correct

procedure.

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UENR4489

Specifications Section

Illustration 9

g03084516

Typical example

Tighten water in fuel switch (1) hand tight.

(3) Tighten the connection to the following torque.

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

Illustration 8

g02485877

Typical example

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

(32 lb ft)

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

(33 lb ft)

(5) Tighten the connection to the following torque.

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

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

(15 lb ft)

i04139570

Fuel Manifold (Rail)  

i04916708

Fuel Filter Base

(Primary Fuel Filter Base)  

Refer to Operation and Maintenance Manual,

“General Hazard Information and High Pressure Fuel

Lines” before adjustments and repairs are performed.

NOTICE

NOTICE

Refer to Systems  Operation, Testing and Adjust-

ing,  “Cleanliness of  Fuel  System Components”

for detailed information on the standards of clean-

liness that must be observed during ALL work on

the fuel system.

Refer to Systems  Operation, Testing and  Adjust-

ing,  “Cleanliness of  Fuel  System  Components”

for detailed information on the standards of clean-

liness that must be observed during ALL work on

the fuel system.

If necessary, install a new fuel filter element to

canister (2). Refer to Operation and Maintenance

Manual, “Fuel System Primary Filter (Water

Separator) Element - Replace” for the correct

procedure.

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UENR4489

9

Specifications Section

Illustration 10

g02337196

Illustration 11

g01344742

Typical example

Typical example

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

(16 lb ft)

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

(0.86370 to 0.86468 inch)

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

(89 lb in)

Bore diameter in the cylinder block

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

(3) Tighten the fuel pressure relief valve to the

Clearance

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

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

(0.0015 to 0.0037 inch)

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

tightened an additional 24 degrees.

i03916469

i04381710

Rocker Shaft

Lifter Group  

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UENR4489

Specifications Section

(9) Spring

Illustration 13

g02150797

Tightening sequence

Tighten the fasteners in the sequence that is in

illustration 13 . Tighten the fasteners to the following

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

Illustration 12

g02150799

Typical example

(1) Tighten the threaded inserts to the following

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

(2) Retaining clip

(3) Spring

(4) Inlet rocker arm

Diameter of the rocker arm bore

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

(5) Exhaust rocker arm

Diameter of the rocker arm bore

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

Clearance

Maximum clearance of both the rocker arm

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

The service limit for both rocker arm bores

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

(6) Guide

(7) Rocker shaft

Diameter of the rocker shaft

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

(0.98275 to 0.98374 inch)

(8) Retaining clip

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Specifications Section

i04351269

Valve Mechanism Cover  

Illustration 14

g02161123

Typical example

Tighten the fasteners for the valve mechanism cover

in the sequence that is shown in illustration 14  to the

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

i05800591

Cylinder Head Valves  

Illustration 15

g01335203

Typical example

When the valve springs (1) are replaced the valve

springs must be replaced in pairs.

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UENR4489

Specifications Section

Table 1

Inlet valve.............................109.82 to 110.27 mm

(4.32361 to 4.34133 inch)

Exhaust valve.................. 109.853 to 110.303 mm

(4.32491 to 4.34263 inch)

The load for the inlet valve

spring

The length of the inlet valve

spring

209 to 231 N (47 to 52 lb)

31.5 mm (1.2402 inch)

(5) Valve head

389.5 to 430.5 N (87.5 to 97 lb)  22.2 mm  (0.87401 inch)

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

(1.3780 inch)

Table 2

The load for the exhaust valve

spring

The length of the exhaust valve

spring

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

(1.2992 inch)

285 to 315 N

31.5 mm (1.2402 inch)

(64.07085 to 70.81515 lb)

i05800598

408.5 to 451.5 N

(91.83488 to 101.50172 lb)

22.3 mm (0.87795 inch)

Cylinder Head  

Illustration 16

g01335204

(2) Valve face angle

Illustration 17

g01250785

Typical example

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

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

Lubricate the threads and the underside of the head

bolts with clean engine oil.

(3) Valve stem diameter

Inlet....6.970 to 6.985 mm (0.2744 to 0.2750 inch)

Exhaust...................................6.945  to 6.960 mm

(0.2734 to 0.2740 inch)

Tighten the bolts in the sequence that is shown in

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

(37 lb ft)

Tighten the bolts again to the following torque.

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

Tighten the head bolts to the additional amount.

..........................................................225 degrees

Clearance

Maximum clearance of the inlet valve stem

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

The service limit for the inlet valve stem

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

(5.93700 inch)

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

Clearance

Maximum clearance of the exhaust valve stem

......................................0.075 mm (0.00295 inch)

The service limit for the exhaust valve stem

........................................0.10 mm (0.00394 inch)

(4) Length of valve

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UENR4489

13

Specifications Section

Illustration 18

g01455374

Note: The maximum distortion of the bottom face of

the cylinder head is given in table 3 .

Table 3

Maximum Permissible

Dimension

Distortion

Illustration 19

g02328933

Typical example

Width (A)

Length (B)

0.08 mm (0.0032 inch)

0.08 mm (0.0032 inch)

0.08 mm (0.0032 inch)

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

to the valve spring seat...................10.85 to 11.15 mm

(0.42716 to 0.43898 inch)

Diagonal Line (C)

(E) Outside diameter of the valve guides

......... 11.029 to 11.040 mm (0.43421 to 0.43464 inch)

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

(1.72244 to 1.74212 inch)

(G) Internal diameter of the valve guides

.............7.007 to 7.020 mm (0.27587 to 0.27638 inch)

(H) Valve depths

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

The service limit for the depth of the inlet valve

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

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

(0.0345 to 0.0445 inch)

The service limit for the exhaust valve depth

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

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UENR4489

Specifications Section

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

(M) Concentricity of valve seat to valve guide parent

bore Maximum Total Indicated Reading (TIR)

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

i05847995

Turbocharger

(Single Turbocharger)  

Illustration 20

g02474819

Typical example

(J) Diameter of the parent bore in the cylinder head

......... 11.000 to 11.022 mm (0.43307 to 0.43394 inch)

(K) Seat angle

Inlet .............................................. 119.25 degrees

Exhaust .........................................89.25  degrees

Illustration 22

g03696193

Typical example

(1) Actuator

The test pressure for the wastegate actuator

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

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

(0.0394 inch)

(2) Tighten the studs to the following torque.

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

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

(32 lb ft)

(4) Tighten the studs to the following torque.

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

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

(32 lb ft)

Illustration 21

g02475018

Typical example

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UENR4489

15

Specifications Section

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

(13 lb ft)

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

(30 lb ft)

(11) Tighten the bolts to the following torque.

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

Illustration 23

g02469717

Typical example

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

(16 lb ft)

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

(80 lb in)

Illustration 25

g02469836

Typical example

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

(16 lb ft)

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

(11 lb ft)

Illustration 24

g02469740

Typical example

Illustration 26

g03696194

Typical example

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

(16 lb ft)

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UENR4489

Specifications Section

(14) Tighten the clamps to the following torque.

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

i05848007

Turbocharger

(Series Turbochargers)  

Note: For the correct procedure to install the

turbochargers, refer to Disassembly and Assembly,

“Turbocharger - Install”.

Illustration 28

g02467764

Typical example

(4) Tighten the studs to the following torque.

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

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

(32 lb ft)

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

(32 lb ft)

Illustration 27

g03696205

Typical example

(1) Actuator

The test pressure for the wastegate actuator

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

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

(0.0394 inch)

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

(97 lb in)

Illustration 29

g02467778

Typical example

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

(18 lb ft)

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

(16 lb ft)

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

(80 lb in)

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17

Specifications Section

(17) Tighten the clamps to the following torque.

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

Illustration 30

g02467817

Typical example

Illustration 32

g03696203

(9) Tighten the nut to the following torque........30 N·m

(22 lb ft)

Typical example

(18) Tighten the bolts to the following torque.

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

(10) (14) (15) Tighten the bolts to the following torque.

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

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

(11 lb ft)

(11) (12) Tighten the bolt to the following torque.

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

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

(29 lb ft)

Illustration 33

g02469676

Typical example

(20) Tighten the bolts to the following torque.

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

Illustration 31

g02469656

Typical example

(21) Tighten the clamps to the following torque.

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

(16) Tighten the clamps to the following torque.

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

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UENR4489

Specifications Section

i04138516

Exhaust Gas Valve (NRS)  

Illustration 35

g02337116

Typical example

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

(97 lb in)

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

(26 lb ft)

Illustration 34

g02337096

Typical example

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

(16 lb ft)

Illustration 36

g02337117

Typical example

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

(80 lb in)

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

(84 lb in)

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UENR4489

19

Specifications Section

i05882350

Injector (Diesel Exhaust Fluid)  

Illustration 37

g02337118

Typical example

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

(13 lb ft)

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

(13 lb ft)

Illustration 39

g03729126

Typical example

(1) Tighten the bolt for the clamp to the following

torque...................................................4 N·m (35 lb in)

i05882355

Manifold (Diesel Exhaust Fluid)

Illustration 38

g02337119

Typical example

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

(80 lb in)

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20

UENR4489

Specifications Section

Illustration 41

g03719679

Typical example

(1) Tighten the plug to the following torque. .......6 N·m

(53 lb in)

Note: The Original Equipment Manufacturer (OEM)

may supply the Diesel Exhaust Fluid (DEF) tank.

Refer to the OEM for more information if the DEF tank

has been supplied by the OEM.

Illustration 40

g03722372

Typical example

(1) Tighten the screws to the following torque.

.............................................................3 N·m (27 lb in)

i05882416

Diesel Exhaust Fluid Pump  

i05882407

Diesel Exhaust Fluid Tank  

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UENR4489

21

Specifications Section

Illustration 42

g03722354

Illustration 43

g03722361

Typical example

(2) M8 mounting holes

Typical example

(2) M8 mounting holes

Note: The diesel exhaust fluid pump (1) is mounted to

the application.

Note: The coolant diverter valve (1) is mounted to the

application. The coolant diverter valve must be

mounted with three M8 bolts.

Tighten the recommended M8 fasteners to the

following torque................................16 N·m (142 lb in)

Tighten the recommended M8 fasteners to the

following torque................................22 N·m (195 lb in)

i05914961

Solenoid Valve (DEF Heater

Coolant)

i04138514

Exhaust Cooler (NRS)

Note: When the pipes for the exhaust cooler are

removed or installed, care must be taken so that the

pipes are not bent or the pipes are not damaged.

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UENR4489

Specifications Section

Illustration 44

g02337136

Typical example

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

(80 lb in)

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

(16 lb ft)

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

(16 lb ft)

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

(16 lb ft)

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

(16 lb ft)

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

(16 lb ft)

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UENR4489

23

Specifications Section

Illustration 45

g02337137

Typical example

(7) (8) Tighten the bolts to the following torque.

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

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

(16 lb ft)

(10) Tighten the bolts to the following torque.

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

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24

UENR4489

Specifications Section

i03914512

Exhaust Manifold  

Illustration 46

g02150456

Typical example

Tighten the exhaust manifold bolts in the sequence

that is shown in illustration 46 to the following torque.

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

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UENR4489

25

Specifications Section

i03936932

Flexible Exhaust Pipe  

Illustration 47

g02155429

Typical example

(1) Tighten the clamp to the following torque.

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

(2) Tighten the clamp to the following torque.

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

Refer to Disassembly and Assembly for the correct

procedure to install the flexible exhaust pipe.

i04156670

Camshaft

Illustration 48

g01927854

Checking the end play of the camshaft

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26

UENR4489

Specifications Section

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

(0.00417 to 0.02197 inch)

Maximum permissible end play of a worn camshaft

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

Illustration 50

g02474757

Typical example

(4) Camshaft thrust washer

Illustration 49

g02150828

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

(2.872 to 2.874 inch)

Typical example

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

(0.21598 to 0.21799 inch)

(2) Bolt

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

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

(89 lb ft)

i03916857

Camshaft Bearings  

(3) The diameters of the camshaft journals are given

in the following tables.

Table 4

Camshaft Journals from

the Front End of the

Engine

Standard Diameter

1

Front

50.711 to 50.737 mm

(1.9965 to 1.9975 inch)

50.457 to 50.483 mm

(1.9865 to 1.9875 inch)

2

3

Rear

49.949 to 49.975 mm

(1.9665 to 1.9675 inch)

Maximum wear on the camshaft journals...... 0.05 mm

(0.0021 inch)

Check the camshaft lobes for visible damage. If a

new camshaft is installed, you must install new lifters.

Illustration 51

g02150875

Typical example

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UENR4489

27

Specifications Section

(1) The diameter of the installed camshaft bearing

.............50.787 to 50.848 mm (1.9995 to 2.0019 inch)

i03914549

Engine Oil Filter Base  

Illustration 53

g02600976

Typical example

Tighten the setscrews in the sequence that is in

illustration 53 to the following torque. ..............10 N·m

(89 lb in)

Illustration 52

g02150462

Typical example

(1) Setscrew

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

(2) Dust cap

(3) Oil sampling valve

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

(106 lb in)

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

(4) Engine oil filter

Illustration 54

g02600977

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

Typical example

i04406752

Tighten the setscrews in the sequence that is in

illustration 54 to the following torque. ..............26 N·m

(19 lb ft)

Engine Oil Cooler  

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UENR4489

Specifications Section

i04346632

Engine Oil Pump  

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

Number of lobes

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

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

Illustration 57

g00938799

Checking the end play

(3) End play of rotor assembly

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

(0.0020 to 0.0071 inch)

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

(0.0020 to 0.0071 inch)

Illustration 55

g00938064

Typical example

(1) Clearance of the outer rotor to the body

.................0.050 to 0.330 mm (0.0020 to 0.0130 inch)

Illustration 58

g02501636

Typical example

Illustration 56

g00938061

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

(32 lb ft)

Checking the clearance

(2) Service limit of inner rotor to outer rotor

.................0.080 to 0.250 mm (0.0031 to 0.0098 inch)

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

(16 lb ft)

i03994212

Engine Oil Pressure  

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UENR4489

29

Specifications Section

The minimum oil pressure at a maximum engine

speed of 2200 rpm and at normal operating

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

i04315734

Engine Oil Pan

Table 5

Required Tools

Tool

Part Number

Part Description

Loctite 5900

Qty

A

-

1

Front sealant

Illustration 60

g01254887

Applying sealant

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

protrude more than 5 mm (0.1969 inch) above the

bridge.

Illustration 59

g01254690

Applying sealant

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

timing case.

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

that is shown in illustration 59 .

Rear sealant

Note: Install the rear oil seal before sealant is applied

to the bridge.

Illustration 61

g01255016

Typical example

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

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

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UENR4489

Specifications Section

Tighten the remaining bolts to the following torque.

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

(2) Drain plug

Tighten the drain plug for the engine oil pan to the

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

i03969629

Crankcase Breather  

Illustration 63

g02150761

Typical example

(3) Water temperatureregulator housing

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

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

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

Illustration 62

g02162137

Typical example

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

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

i03916250

Water Temperature Regulator

and Housing

Illustration 64

g02150762

Typical example

(4) Water temperature regulator

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

(151° to 176°F)

Maximum open length of 11 mm (0.43307 inch)

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

(201° F)

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UENR4489

31

Specifications Section

i03916132

Water Pump  

Illustration 66

g02150944

Typical example

(1) Cylinder block

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

(4.1338 to 4.1348 inch)

Illustration 65

g02150757

The maximum permissible wear for the cylinder bore

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

Tightening sequence

Tighten the setscrews in the numerical sequence that

is shown in illustration 65 to the following torque.

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

(3) Camshaft bearings

Diameter of the bushing in the cylinder block for

the number 1 camshaft bearing

......55.563 to 55.593 mm (2.1875 to 2.1887 inch)

i05800601

Cylinder Block  

Diameter of the bore in the cylinder block for the

number 2 camshaft journal

......50.546 to 50.597 mm (1.9900 to 1.9920 inch)

Diameter of the bore in the cylinder block for the

number 3 camshaft journal

......50.038 to 50.089 mm (1.9700 to 1.9720 inch)

(4) Main bearings

Bore in the cylinder block for the main bearings

......88.246 to 88.272 mm (3.4742 to 3.4753 inch)

(5) Main bearing cap bolts

Use the following procedure in order to install the

main bearing cap bolts:

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

bearing cap bolts.

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UENR4489

Specifications Section

2. Put the main bearing caps in the correct position

that is indicated by a number on the top of the main

bearing cap. Install the main bearing caps with the

locating tabs in correct alignment with the recess in

the cylinder block.

Standard thickness of thrust washer

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

Oversize thickness of thrust washer

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

3. Evenly tighten the main bearing cap bolts.

Torque for the main bearing cap bolts. ...........245 N·m

(181 lb ft)

Note: Ensure that the crankshaft can rotate freely.

i04129189

Crankshaft  

Illustration 67

g02155393

Typical example

(1) Crankshaft gear

(2) Crankshaft

(3) Crankshaft thrust washers

Maximum permissible temperature of the gear for

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

Maximum permissible temperature of the drive gear

for the balancer (if equipped) for installation on the

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

Note: Refer to Disassembly and Assembly for the

correct procedure to remove and install the drive gear

for the balancer.

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

(0.00394 to 0.01614 inch)

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UENR4489

33

Specifications Section

Illustration 68

g02155394

i02934550

Typical example

(4) Journal 1

(5) Journal 2

(6) Journal 3

(7) Journal 4

(8) Journal 5

Refer to table 6 for the run out of the crankshaft

journals.

Crankshaft Seals

Table 6

Journal

Run out of the Journals

(1)

Mounting

(2)

(3)

(4)

(5)

0.08 mm (0.0031 inch)

0.15 mm (0.0059 inch)

0.08 mm (0.0031 inch)

Mounting

Inspect the crankshaft for wear or for damage. For

more information regarding the servicing of the

crankshaft, contact the Global Technical Support

Center.

Refer to Specifications, “Connecting Rod Bearing

Journal” for more information on the connecting rod

bearing journals and connecting rod bearings.

Refer to Specifications, “Main Bearing Journal” for

information on the main bearing journals and for

information on the main bearings.

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UENR4489

Specifications Section

i03996317

Connecting Rod Bearing

Journal

The original size of the connecting rod bearing journal

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

(2.67677 to 2.67755 inch)

Maximum permissible wear of a bearing journal on

the crankshaft when a new connecting rod is installed

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

Width of the connecting rod bearing journals on the

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

(1.58681 to 1.59271 inch)

Surface finish of connecting rod bearing journals

Illustration 69

g01455434

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

Typical example

(1) Crankshaft

i05800602

(2) Crankshaft seal

(3) Plastic sleeve

(4) Alignment tool

Main Bearing Journal

The original size of the main bearing journal

.........83.980 to 84.000 mm (3.30629 to 3.30708 inch)

Maximum permissible wear of the main bearing

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

Surface finish of bearing journals and crank pins

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

Width of new main bearing journal where the thrust

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

(1.56555 to 1.56830 inch)

Width of new main bearing journal where the thrust

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

(1.54291 to 1.55078 inch)

The shell for the main bearings

The shells for the main bearings are available for

remachined journals which have the following

oversize dimensions.

Illustration 70

g00915076

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

sequence that is shown in Illustration 70  to the

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

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

Oversize bearing shell ........0.51 mm (0.020 inch)

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

Remove the alignment tool.

Thickness at center of the shells of oversize bearing

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

(0.08764 to 0.08787 inch)

Tighten bolts 8 and 9 in the sequence that is shown in

Illustration 70 to the following torque...............22 N·m

(16 lb ft)

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UENR4489

35

Specifications Section

Thickness at center of the shells of oversize bearing

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

(0.09264 to 0.09287 inch)

Thickness at center of the shells of oversize bearing

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

(0.09764 to 0.09787 inch)

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

(1.03622 to 1.04645 inch)

Clearance between the bearing shell and the main

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

(0.00142 to 0.00370 inch)

i05380410

Connecting Rod

Illustration 72

g01950657

Typical example

(U) Day code

(V) Code for the connecting rod

(X) Code for the Connecting rod cap

(Y) Year code

(Z) Code for the grade of connecting rod

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

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

appropriate year.

The mating surfaces of the connecting rod are

produced by hydraulically fracturing the forged

connecting rod. Ensure that the correct cap for the

connecting rod is installed with the correct connecting

rod. Ensure that the serial numbers for both

components match.

Illustration 71

g01254512

Typical example

(2) Torque of the setscrews for the connecting rod

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

(1) The bearing shell for the connecting rod

Tighten the setscrews for the connecting rod for an

additional 120 degrees. The setscrews for the

connecting rod (2) must be replaced after this

procedure.

For the correct procedure to install the bearing shell

for the connecting rod, refer to Disassembly and

Assembly, “Pistons and Connecting Rods -

Assemble”.

Table 7

Note: Always tighten the connecting rod cap to the

connecting rod, when the assembly is out of the

engine. Tighten the assembly to the following torque

20 N·m (14 lb ft).

Thickness of ConnectingRod

Bearing at the Center

1.995 to 2.002 mm

(0.07854 to 0.07882 inch)

0.031 to 0.078 mm

(0.00122 to 0.00307 inch)

Bearing Clearance

Table 8

Oversize Connecting Rod Bearing

0.25 mm (0.010 inch)

0.51 mm (0.020 inch)

0.76 mm (0.030 inch)

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UENR4489

Specifications Section

Illustration 74

g03120776

Typical example

(1) Top compression ring

The shape of the top compression ring

...............................................................Keystone

Illustration 73

g01254518

Typical example

Ring gap......................................0.25 to 0.35 mm

(0.00984 to 0.01378 inch)

(3) Diameter of the finished bore for the piston pin

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

Note: When you install a new top compression ring,

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

the piston. New top piston rings have a black

identification mark. The identification mark must be

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

is installed on an upright piston.

(4) Distance between the parent bores

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

(5) Diameter for the finished bore for the connecting

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

(2.83641 to 2.83692 inch)

(2) Intermediate compression ring

The connecting rod is color coded. The color code is

a reference for the length of the connecting rod. Refer

to table 9 for the length of connecting rod.

The shape of the intermediate compression ring

...............Internal bevel in the bottom edge with a

tapered face

Table 9

Width of intermediate compression ring

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

Specificationsfor the Connecting Rod

Length Of The Connect-

Grade Letter    Color Code

ing Rod

The clearance between a new intermediate

compression ring and the piston groove in a new

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

(0.00256 to 0.00433 inch)

163.081 to 163.114 mm

B

Blue

(6.42050 to 6.42180 inch)

i04939374

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

(0.0256 to 0.0335 inch)

Piston and Rings

Note: When you install a new intermediate

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

facing the top of the piston. New intermediate rings

have a blue identification mark. The identification

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

top piston ring is installed on an upright piston.

This document is printed from SPI2. NOT FOR RESALE

UENR4489

37

Specifications Section

(3) The oil control ring

Width of oil control ring................2.79 to 3.00 mm

(0.10984 to 0.11811 inch)

The clearance between a new oil control ring and

the groove in a new piston..........0.05 to 0.10 mm

(0.00197 to 0.00394 inch)

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

(0.0118 to 0.0216 inch)

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

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

piston. New oil control rings have a red identification

mark. The identification mark must be on the left of

the ring end gap when the top piston ring is installed

on an upright piston. The oil control ring is a two-

piece ring that is spring loaded. A pin is used in order

to hold both ends of the spring of the oil control ring in

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

must be installed opposite the end gap of the oil

control ring.

Illustration 75

g01352576

(1) Installed piston cooling jets

The valve must move freely. Tighten the bolt to the

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

Piston Cooling Jet Alignment

Note: Ensure that the ring end gaps of the piston

rings are spaced 120 degrees from each other.

Piston

Note: An arrow which is marked on the piston crown

must be toward the front of the engine.

Piston height above cylinder block.... 0.55 to 0.20 mm

(0.02165 to 0.00787 inch)

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

Width of second groove in new piston

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

Width of third groove in new piston.... 3.05 to 3.07 mm

(0.12008 to 0.12087 inch)

Piston pin

Diameter of a new piston pin

......39.694 to 39.700 mm (1.5628 to 1.5630 inch)

Illustration 76

g01352578

(2) Piston cooling jet

(3) Rod

(4) Cylinder block

i02696381

Piston Cooling Jet

Use the following procedure in order to check the

alignment of the piston cooling jet.

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

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

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

of the cylinder block.

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

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

Dimension (A) and dimension (B) are tangential to

the cylinder bore (4).

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UENR4489

Specifications Section

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

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

(0.5512 inch).

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

piston cooling jet when the alignment is checked. The

piston cooling jets can not be adjusted. If a piston

cooling jet is not in alignment the piston cooling jet

must be replaced.

i04555039

Balancer

Illustration 78

g02148374

Typical example

(1) Tighten allen head screws to the following torque.

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

(2) Tighten the allen head screw to the following

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

Illustration 77

g02150753

Typical example

Tighten the bolts in the sequence that is shown in

illustration 77 to the following torque. ..............54 N·m

(40 lb ft)

Backlash values

Backlash between crankshaft ring gear and the

balancer intermediate gear..... 0.020 to 0.240 mm

(0.0008 to 0.009 inch)

Backlash between the balancer shaft gears

..........0.020 to 0.160 mm (0.0008 to 0.0063 inch)

Illustration 79

g02148375

i03907005

Typical example

Accessory Drive

(SAE  “B”  )

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

(33 lb ft)

This document is printed from SPI2. NOT FOR RESALE

UENR4489

39

Specifications Section

i03907004

Accessory Drive  

Illustration 81

g01860874

Typical example

Tighten the setscrew to the sequence that is shown in

illustration 81 to the following torque. ..............28 N·m

(20 lb ft)

Illustration 80

g02148372

Typical example

(1) Tighten the allen head screws to the following

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

(2) Tighten the allen head screws to the following

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

i03917090

Front Housing and Covers  

Illustration 82

g02150954

Typical example

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

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

(16 lb ft)

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

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

(16 lb ft)

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

correct bolt tightening sequence for the water pump.

This document is printed from SPI2. NOT FOR RESALE

40

UENR4489

Specifications Section

i05805182

The end play of the medium duty and heavy duty

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

(0.00197 to 0.00591 inch)

Gear Group (Front)  

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

(3) Fuel injection pump drive gear

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

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

(4) Oil pump gear

The number of teeth on the oil pump gear ....... 18

Backlash values

Backlash between the oil pump idler gear (5) and

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

(0.0020 to 0.0059 inch)

Backlash between the oil pump idler gear (5) and

the crankshaft gear (6) ...........0.025 to 0.210 mm

(0.00098 to 0.00827 inch)

Backlash between the idler gear (2) and the

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

(0.0020 to 0.0059 inch)

Illustration 83

g01857156

Backlash between the camshaft gear (1) and the

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

(0.0020 to 0.0059 inch)

Gear train

(1) Camshaft gear

Backlash between the fuel injection pump gear

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

(0.0020 to 0.0059 inch)

Torque for the 8.8 graded bolt for the camshaft

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

Torque for the 10.9 graded bolt for the camshaft

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

Backlash between the water pump gear (not

shown) and the fuel injection pump gear (3)

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

Backlash between the power take-off drive (if

equipped) and the idler gear (2)

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

(2) Idler gear and hub

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

(33 lb ft)

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

(5) Oil pump idler gear

Width of medium duty and heavy duty idler gear

bearing....................................25.45  to 25.55 mm

(1.00197 to 1.00590 inch)

Inside diameter of oil pump idler gear bearing

......16.012 to 16.038 mm (0.6304 to 0.6314 inch)

Inside diameter of medium duty and heavy duty

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

(2.20472 to 2.20590 inch)

Outside diameter of oil pump idler gear shaft

......15.966 to 15.984 mm (0.6286 to 0.6293 inch)

Clearance of oil pump idler gear bearing on shaft

..........0.028 to 0.072 mm (0.0011 to 0.0028 inch)

Outside diameter of medium duty and heavy duty

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

(2.20275 to 2.20354 inch)

End play of the oil pump idler gear

..........0.050 to 0.275 mm (0.0019 to 0.0108 inch)

Clearance of medium duty and heavy duty idler

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

(0.00118 to 0.00315 inch)

End play of the oil pump drive gear

......0.005 to 0.090 mm (0.00020 to 0.00354 inch)

(6) Crankshaft gear

This document is printed from SPI2. NOT FOR RESALE

UENR4489

41

Specifications Section

Bore diameter of crankshaft gear

i04315754

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

Flywheel Housing  

Outside diameter of crankshaft hub

......51.021 to 51.002 mm (2.0087 to 2.0079 inch)

Clearance of gear on crankshaft

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

(−0.00083 to 0.00110 inch)

Table 10

Required Tools

Part Description

Loctite 575

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

Tool

Part Number

Qty

A

-

1

i03520340

Flywheel  

Illustration 84

g00584712

Typical example

Illustration 85

g01254486

Typical example

(1) Flywheel ring gear

Setscrew

Heat the flywheel ring gear to the following

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

(1)Tighten the setscrew to the following torque.

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

Note: Do not use an oxyacetylene torch to heat the

flywheel ring gear.

Setscrew

(2) Flywheel

(3) Bolt

(2)Tighten the setscrew to the following torque.

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

Note: If 12.9 setscrews are installed, apply Tooling

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

torque of 70 N·m (52 lb ft).

Tighten the flywheel bolts to the following torque.

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

This document is printed from SPI2. NOT FOR RESALE

42

UENR4489

Specifications Section

i05800618

Crankshaft Pulley  

Illustration 87

g02291813

Typical example

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

(33 lb ft)

Note: To install the belt tensioner, refer to

Disassembly and Assembly, “Belt Tensioner -

Remove and Install” for the correct procedure.

Illustration 86

g02155003

Typical example

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

(58 lb ft)

i03629003

Refrigerant Compressor

(3) Bolts

Tighten the bolts to the following torque.

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

Tighten the bolts to the additional amount. .... 120

degrees

(2) Auxiliary pulley

(4) Crankshaft pulley

i04083729

Belt Tensioner

Illustration 88

g01946810

Typical example

This document is printed from SPI2. NOT FOR RESALE