Engine Design

/sisw
/sisw eb/si
eb/sisw
sw eb/
eb/ /sisw
/sisw eb/m
eb/media
ediase
se

Type 1 Engines and 9RM Engines

Ver imagen

g00296342
Illustration 1

Cylinder and valve location for Type 1 engines and 9RM engines

(A) Exhaust valves

(B) Inlet valves

Note: Type 1 engines can be identified in two ways. The first met hod refers to
Illustration 1. When the valve cover is removed, look at the cylinder head valves. Type
1 engines have two exhaust valves in a row and two inlet valves that are in a row.

The second method does not require the removal of the valve cover. Refer to the inlet
manifold and the exhaust manifold. Type 1 engines have two exhaust ports in a row and
two inlet ports that are in a row.

Type ... Four cylinder and four stroke

str oke

Combustion system ... Direct injection

Nominal Bore ... 100 mm (3.937 inch)

Stroke ... 127 mm (5.00 inch)

Capacity ... 4 liters (243 in 3)

Compression Ratio ... 16:1

Number of cylinders ... 4

Arrangement of cylinders ... in-line

Firing Order ... 1, 3, 4, 2

Valve Lash

Inlet valve ... 0.20 mm (.008

(. 008 inch)
Exhaust valve ... 0.45 mm (.018 inch)

When the crankshaft is viewed from the front of the engine the crankshaft rotates in the
following direction: ... Clockwise

When the camshaft is viewed from the front of the engine the camshaft rotates in the
following direction: ... Clockwise

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

Type 2 Engines and 7BJ Engines

Ver imagen

g00296424
Illustration 2
Cylinder and valve location for Type 2 engines and 7BJ engines

(A) Exhaust valves

(B) Inlet valves

Note: Type 2 engines can be identified in two ways. The first met hod refers to
Illustration 2. When the valve cover is removed, look at the cylinder head valves. Type
2 engines alternate the exhaust valves and the inlet valves.

Note: Some of the Type 2 7BJ engines may look like the Type 1 engines. When the
valve cover is removed, these engines may have two exhaust valves in a row and two
inlet valves in a row. This is only a small percentage of the Type 2 7BJ engines.

The second method does not require the removal of the valve cover. Refer to the inlet
manifold and the exhaust manifold. Type 2 engines alternate the exhaust ports and the
inlet ports.

Type ... Four cylinder and four stroke

str oke

Combustion system ... Direct injection

Nominal Bore ... 100 mm (3.937 inch)

Stroke ... 127 mm (5.00 inch)

Capacity ... 4 liters (243 in 3)

Compression Ratio ... 17.25:1

Number of cylinders ... 4

Arrangement of cylinders ... in-line

Firing Order ... 1, 3, 4, 2

Valve Lash

Inlet valve ... 0.20 mm (.008

(. 008 inch)
Exhaust valve ... 0.45 mm (.018 inch)

When the crankshaft is viewed from the front of the engine the crankshaft rotates in the
following direction: ... Clockwise

When the camshaft is viewed from the front of the engine the camshaft rotates in the
following direction: ... Clockwise

Note: The front end of the engine is opposite the flywheel end. The left side and the
right side of the engine are viewed from the fl ywheel end. The No. 1 cylinder is the
1 1 0
front cylinder.
Fuel Injection Pump
SMCS - 1251; 1290

/sisw eb/sisw eb/ /sisw eb/mediase

Various Fuel Injection Pumps may be equipped to the engine. Bosch, Delphi, or
Stanadyne fuel injection pumps may be equipped to the engine.

Bosch Fuel Injection Pump (EPVE)

Ver imagen

g00896561
Illustration 1

Note: Parts that are inside of the fuel injection pump are only serviceable by an
authorized Bosch dealer. Please consult your parts book for availabilit y of parts on the
outside of the pump that are not related to the s ettings of the fuel pump and for the
possibility of remanufacturing options.

Hub nut (not shown)

Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is
positioned to the pump shaft in order to ensure that the fuel pump is in the correct
position for timing. If the hub is removed, the hub will need to be accurately positioned
to the pump shaft. Accurate positioning requires the use of speci al equipment by a
Caterpillar Dealer.

(1) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to
4.5 N·m (35 to 40 lb in)

(2) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to
6 N·m (44 to 53 lb in)

(3) Tighten the fitting for the fuel supply connection to the following torque. ... 22 N·m
(16 lb ft)

(4) Boost control (if equipped)

(5) Tighten the high idle speed adjustment screw to t he following torque. ... 4 to 4.5
N·m (35 to 40 lb in)

(6) Tighten the nuts for the high pressure fuel line connection to the following torque. ...
22 N·m (16 lb ft)

(7) Tighten the flange nuts to the following torque. ... 22 N·m (16 lb ft)

(8) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to
81.4 N·m (52 to 60 lb ft)

Ver imagen
 g00766439
Illustration 2

(9) Locking spacer (If equipped)

Note: The drive shaft of the fuel injection pump must not be turned without the spacer
in position under the locking screw (10) .

(10) Tighten the locking screw to the following torque. ... 27 N·m (20 lb ft)

(11) Tighten the nut for the drive gear to the following torque. ... 80 N·m (59 lb ft)

Ver imagen
 g00639086
Illustration 3

Note: Before the crankshaft is turned or the fuel injection pump is installed, move the
locking spacer (9) under the locking screw (10). Refer to position (A) that is in
Illustration 3. This position ensures that the pump drive shaft is released.

Timing Information for the Bosch Fuel Injection Pump

Table 1

Early Bosch Fuel Injection Pump Without Locking Screw

Code Letters Static Timing

Engine Check Fuel Injection Piston
on Fuel Position Before (1)
Angle Pump Mark Angle Displacement
Injection (1) (1) TC Position
(degrees) (degrees)
Pump (degrees)

"BK" 308 314 12 1.78 mm (0.070

inch)

"CK" 308 314 12 1.78 mm (0.070

inch)
Ver imagen

g00788005
Illustration 5

Note: Parts that are inside of the fuel injection pump are only serviceable by an
authorized Delphi dealer. Please consult your parts book for availabilit y of parts on the
outside of the pump that are not related to the s ettings of the fuel pump and for the
possibility of remanufacturing options.

(1) Hub nut

Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is
positioned to the pump shaft in order
order to ensure that the fuel pump is in the correct
position for timing. If the hub is removed, the
the hub will need to be accurately positioned
to the pump shaft. Accurate positioning requires the use of special equipment by a
Caterpillar Dealer.

(2) O-ring

(3) Locking spacer

The drive shaft of the fuel injection pump must not be turned without the spacer in
position under the locking screw (4) .

(4) Tighten the locking screw to the following torque. ... 10 N·m (7 lb ft)

The locking screw prevents the rotation of the drive shaft.

Ver imagen

g00292837
Illustration 6

Before the crankshaft is turned or the fuel injection pump is installed, move the locking
spacer (3) under the locking screw (4). Refer to position (A) that is in Illustration
Illustrati on 6.
This position ensures that the pump drive shaft is released.

(5) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to
6 N·m (44 to 53 lb in)

(6) Tighten the adjustment screw for low idle to the following torque. ... 4 to 4.5 N·m
(35 to 40 lb in)

(7) Tighten the adjustment screw for high idle to the following torque. ... 4 to 4.5 N·m
(35 to 40 lb in)

(8) Electrical connection for the stop solenoid

(9) Tighten the fitting for the fuel supply connection to the following torque. ... 22 N·m
(16 lb ft)
(10) Tighten the nuts for the fuel line to the following torque. ... 22 N·m (16 lb ft)

(11) Tighten the flange nuts to the following torque. ... 22 N·m (16 lb ft)

(12) Electrical connection for cold starting aid

(13) Tighten the fittings for the fuel discharge

dischar ge lines to the following torque. ... 70.5 to
81.4 N·m (52 to 60 lb ft)

Timing Information for the Delphi Fuel Injection Pump

Table 3

Delphi Fuel Injection Pump

Code that is on the Fuel Engine Check Angle Fuel Injection Pump Mark Angle
Injection Pump (degrees) (degrees)

"AK" 325.5 336

"AM" 282 290.5

"BF" 326 334

"BM" 281 291

"CM" 282.5 291.5

"DM" 282.25 290.5

"FK" 325.5 336

"GK" 325 336

"GM" 282 290.5

"HK" 326 336

"HM" 282 291

"JK" 325 334

"KK" 325 334

"LK" 327 337.5

(1)
"LK" 328 337.5

"MK" 326 336

(2)
"MK" 325 336

"PK" 326 334

"RK" 328 336

"RM" 282.5 290.5

"TK" 327 334

"UK" 326 334

"XM" 282 291

(1)
"YA31257" only

(2)
"YA50532" only

Table 4

Dephi Fuel Injection Pump With Locking Screw

Code Letters on Fuel Injection Pump Locking Angle (degrees)

"BC" 336.5

"CC" 338.5

"DC" 337.5
"EC" 337.5

"FC" 335.5

"GC" 337

"PC" 339

"RC" 339

"SC" 341

"XL" 22

1
Note: Later Delphi Fuel Injection Pumps are timed with a pin.
1 0

Fuel Injection Nozzles

SMCS - 1254

/sisw eb/sisw eb/ /sisw eb/mediase

Type 1 Engines and 9RM Engines

Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.

Ver imagen
 g00308903
Illustration 1

Fuel injection nozzle

(1) Connection for the union nut of the fuel supply line

(2) Threaded hole for the banjo bolt of the leak off li ne

(3) Clamp

(4) Seal

(5) Spacer

(6) Fuel injector assembly

(7) Seat washer

(1) Tighten the union nut of the high pressure fuel line (not shown) to the following
torque: ... 18 N·m (13.3 lb ft)

(2) Tighten the banjo bolts of the leak off tubing (not shown) to the following torque: ...
9.5 N·m (84 lb in)

(3) Tighten the flange bolts (not shown) for the clamp to the following torque: ... 12
N·m (9 lb ft)

Note: Remove the original seat washer from the threaded hole for the fuel injection
nozzle which is located in the c ylinder head. If the original seat washer is not removed,
the projection of the nozzle will be incorrect when a new seat washer is installed. Do
not reuse the seal (4) and the seat washer (7) .

Bench test the fuel injection nozzles at a temperature of 18 to 20 °C (64 to 70 °F).

Note: Use clean SAE J-967 oil (ISO 4113) when you are conducting the test. The oil i s
available in 5 gallon containers ( 6V-6068 Calibration Fluid ) and 55 gallon containers (
6V-6067 Calibration Fluid ). If dirty oil is used for the test, the components of the fuel
injection nozzle will be damaged.

Refer to Testing And Adjusting, "Pressure Adjustment, Back Leakage Test, Nozzle and
Seat Test".

Table 1

Pressure Settings for the Fuel Injection Nozzles for the Type 1 Engines and 9RM
Engines

Code (1) Pressure Setting

"HU"
22291 kPa (3233 psi)

"HV"
25331 kPa (3674 psi)

"HZ"
22291 kPa (3233 psi)

"JA"
25331 kPa (3674 psi)

"JB"
25331 kPa (3674 psi)

"JE"
22291 kPa (3233 psi)

"JF"
25331 kPa (3674 psi)

"JG"
23304 kPa (3380 psi)

"JH"
25331 kPa (3674 psi)

"JJ"
25331 kPa (3674 psi)

"JK"
22291 kPa (3233 psi)

"JL"
25331 kPa (3674 psi)

"JR"
25331 kPa (3674 psi)
"JS"
25331 kPa (3674 psi)

"JT"
25331 kPa (3674 psi)

"JU"
22291 kPa (3233 psi)

"JY"
25331 kPa (3674 psi)

"NJ"
22291 kPa (3233 psi)

"NK"
22801 kPa (3307 psi)

"NL"
22801 kPa (3307 psi)

"NM"
23304 kPa (3380 psi)

"NN"
23304 kPa (3380 psi)

"NP"
22291 kPa (3233 psi)

"NR"
23304 kPa (3380 psi)

"NS"
25331 kPa (3674 psi)

"NT"
23304 kPa (3380 psi)

"NU"
22291 kPa (3233 psi)

"NV"
22291 kPa (3233 psi)

"NW"
22291 kPa (3233 psi)

"RD"
25028 kPa (3630 psi)

"RE"
25028 kPa (3630 psi)
Type 1 Engines and 9RM Engines
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.

Ver imagen

g00295326
Illustration 1

Inlet valves and exhaust valves

Double valve springs:

(1) Outer spring

Length under test force ... 35.8 mm (1.41 inch)

Test force ... 176 to 195 N (40 to 44 lb)

(2) Inner spring

Length under test force ... 34.0 mm (1.34 inch)

Test force ... 89 to 104 N (20 to 23 lb)
Single valve springs (not shown)

Length under test force ... 40.0 mm (1.57 inch)

Test force ... 310 to 344 N (70 to 77 lb)
Free length after test ... 53.4 mm (2.10 inch)

(3) Valve spring recess for the valve spring

(4) Valve guides for the inlet and exhaust valves

Inside diameter ... 9.51 to 9.56 mm (0.374 to 0.376 inch)

Outside diameter ... 15.900 to 15.910 mm (0.6260
( 0.6260 to 0.6265 inch)
Bore diameter in cylinder head for valve guide ... 15.87 to 15.89 mm (0.625 to
0.626 inch)
Interference fit of valve guide in cylinder head ... 0.03 to 0.07 mm (0.001 to
0.003 inch)
Overall length of valve guide
Inlet ... 57.94 mm (2.281 inch)
Exhaust ... 61.1 mm (2.406 inch)
Projection of valve guide above valve spring recess (3) ... 15.1 mm (0.595 inch)

Note: When new valve guides are installed, new valves and new valve s eat inserts must
be installed. The valve guides and the valve seat inserts are supplied as partially finished
parts. The unfinished valve guides and unfinished
unfinished valve seat inserts are installed in the
cylinder head. Then, the guides and inserts are cut and reamed in one operation with
special tooling. This procedure ensures the concentricity of the valve seat to the valve
guide in order to create a seal that is tight. Refer to the Disassembly and Assembly
Manual for removal and installation procedures.

(5) Diameter of the exhaust valve stem ... 9.43 to 9.46 mm (0.371 to 0.372 inch)

Clearance of valve in valve guide ... 0.05 to 0.13 mm (0.002 to 0.005 inch)

Maximum permissible clearance of valve in valve guide ... 0.15 mm (0.006 inch)

Overall length of the exhaust valve ... 123.07 to 123.57 mm (4.845 to 4.865 inch)

(6) Diameter of the inlet valve stem ... 9.460 to 9.490 mm (0.3724 to 0.3735 inch)

Clearance of valve in the valve guide ... 0.02 to 0.10 mm (0.001 to 0.004
0.004 inch)

Maximum permissible clearance of valve in valve guide ... 0.13 mm (0.005 inch)

Overall length of the inlet valve ... 122.66 to 123.07 mm (4.829 to 4.845 inch)

(7) Exhaust valve face angle ... 45 degrees

Valve seat angle ... 46 degrees

(8) Diameter of the

t he exhaust valve ... 37.26 to 37.52 mm (1.467 to 1.477 inch)
Valve depth below the cylinder head face

Minimum ... 1.28 mm (0.050 inch)

Maximum ... 1.83 mm (0.072 inch)

Service wear limit ... 2.08 mm (0.082 inch)

(9) Diameter of the inlet valve ... 44.86 to 45.11 mm (1.766 to 1.776 inch)

Valve depth below the cylinder head face

Minimum ... 1.27 mm (0.050 inch)

Maximum ... 1.60 mm (0.063 inch)

Service wear limit ... 1.85 mm (0.073 inch)

(10) Inlet valve face angle ... 45 degrees

Valve seat angle ... 46 degrees

Note: Some engines may have valve face angles of 30 degrees and valve seat angles of
31 degrees.

The valve lash is the following value when the engine is hot or cold:

Inlet valves ... 0.20 mm (0.008 inch)

Exhaust valves ... 0.45 mm (0.018 inch)

Ver imagen

Illustration 2 g00295327
Recess for a valve insert

(11) Machine the recess in the head for valve seat inserts to the following dimensions:

Inlet
(A) ... 7.19 to 7.32 mm (0.283 to 0.288 inch)
(B) ... 51.220 to 51.240 mm (2.0167 to 2.0175 inch)
(C) Maximum radius ... 0.38 mm (0.015 inch)
Exhaust
(A) ... 9.52 to 9.65 mm (0.375 to 0.380 inch)
(B) ... 42.620 to 42.650 mm (1.6779 to 1.6790 inch)
(C) Maximum radius ... 0.38 mm (0.015 inch)

Note: When a new valve seat insert is installed, a new valve and valve guide must be
installed. Refer to the Disassembly and Assembly for removal and installation
procedures.

Ver imagen

g00517019
Illustration 3

Angles and dimensions of the valve seat insert

(12) Valve seat insert

(D) Included angle of the faces

(E) Dimension of chamfer

(F) Vertical angle of chamfer

(12) Valve seat insert

(D) Included angle of the faces of the valve seat insert

Engines with 46 degree valve seats ... 88 degrees
Engines with 31 degree valve seats ... 118 degrees

(E) Dimension of chamfer for all engines ... 1.10 ± 0.20 mm (0.043 ± 0.008 inch)

(F) Angle of chamfer from the vertical for all engines ... 30 degrees

Type 2 Engines and 7BJ Engines

Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.

Ver imagen
 g00294082
Illustration 4

Inlet valves and exhaust valves

(1) Single valve springs

Length under test force ... 39.0 mm (1.54 inch)

Test force ... 246 to 277 N (55 to 62 lb)

(2) Valve spring insert for the valve spring

(3) Valve guides

Inside diameter of finished valve guide ... 9.00 to 9.02 mm (0.354 to 0.355 inch)
Outside diameter of inlet valve ... 13.03 to 13.05 mm (0.513 to 0.514 inch)
Outside diameter of exhaust valve ... 14.03 to 14.05 mm (0.552 to 0.553 inch)
Bore diameter in the cylinder head for the inlet valve guide ... 13.00 to 13.03
mm (0.512 to 0.513 inch)
Bore diameter in the cylinder head for the exhaust val ve guide ... 14.000 to
14.027 mm (0.5512 to 0.5522 inch)
Interference fit of valve guide in the cylinder head ... 0.007 to 0.047 mm (0.0003
to 0.0019 inch)
Overall length of inlet and exhaust valve guides ... 51.25 mm (2.012 inch)
Projection of valve guide above the valve spring recess (2) ... 14.85 to 15.15 mm
(0.585 to 0.596 inch)

Note: When new valve guides are installed, new valves and new valve s eat inserts must
be installed. The valve guides and the valve seat inserts are supplied as partially finished
parts. The unfinished valve guides and unfinished valve seat inserts are installed in the
cylinder head. Then, the guides and inserts are cut and reamed in one operation with
special tooling. This procedure ensures the concentricity of the valve seat to the valve
guide in order to create a seal that is tight. Refer to the Disassembly and Assembly
Manual for removal and installation procedures.

(4) Diameter of the exhaust valve stem ... 8.94 to 8.96 mm (0.352 to 0.353 inch)

Clearance of valve in valve guide ... 0.040 to 0.084 mm (0.0026 to 0.0033 inch)

Maximum permissible clearance of valve in valve guide ... 0.104 mm (0.0041 inch)

Overall length of the exhaust valve ... 122.65 to 123.30 mm (4.829 to 4.854 inch)

(5) Diameter of the inlet valve stem ... 8.953 to 8.975 mm (0.3525 to 0.3533 inch)

Clearance of valve in the valve guide ... 0.025 to 0.069 mm (0.001 to 0.003 inch)

Maximum permissible clearance of valve in valve guide ... 0.089 mm (0.0035 inch)

Overall length of the inlet valve ... 122.65 to 123.30 mm (4.829 to 4.854 inch)
(6) Exhaust valve face angle ... 45 degrees

Valve seat angle ... 46 degrees

Note: Some engines may have valve face angles of 30 degrees and valve seat angles of
31 degrees.

(7) Exhaust valve head diameter ... 40.88 to 41.12 mm (1.609 to 1.619 inch)

Valve depth below the cylinder head face

Minimum ... 1.50 mm (0.059 inch)

Maximum ... 1.80 mm (0.071 inch)
Service wear limit ... 2.05 mm (0.081 inch)

(8) Diameter of the inlet valve ... 42.88 to 43.12 mm (1.688 to 1.698 inch)

Valve depth below the cylinder head face

Minimum ... 1.40 mm (0.055 inch)

Maximum ... 1.70 mm (0.067 inch)
Service wear limit ... 1.95 mm (0.077 inch)

(9) Inlet valve face angle ... 45 degrees

Valve seat angle ... 46 degrees

Note: Some engines may have valve face angles of 30 degrees and valve seat angles of
31 degrees.

The valve lash is the following value when the engine is hot or cold:

Inlet valves ... 0.20 mm (0.008 inch)

Exhaust valves ... 0.45 mm (0.018 inch)

Ver imagen
 Inlet ... 0.20 mm (.008 inch)
Exhaust ... 0.45 mm (.018 inch)

(5) Maximum permissible nozzle projection below cylinder head face after resurfacing
... 4.45 mm (.175 inch)

Maximum allowance for resurfacing ... 0.30 mm (.012 inch)

(6) Depth of new cylinder head ... 102.79 to 103.59 mm (4.047 to 4.078 inch)

Minimum depth of cylinder head after resurfacing ... 102.48 mm (4.035 inch)

Ver imagen

g00295372
Illustration 3

Positions for measuring the bow of the c ylinder head (typical example)

Maximum permissible amount of bow (curve of cylinder head)

Naturally aspirated engines

A ... 0.08 mm (.003 inch)
B ... 0.15 mm (.006 inch)
C ... 0.15 mm (.006 inch)
Turbocharged engines
A ... 0.13 mm (.005 inch)
B ... 0.25 mm (.010 inch)
C ... 0.25 mm (.010 inch)

Tighten the bolts of the inlet manifold (not shown) to the following torque: ... 44 N·m
(32 lb ft)
Tighten exhaust manifold nuts (not shown) to the following torque:

Plated ... 44 N·m (32 lb ft)

Plain ... 50 N·m (37 lb ft)

Type 2 Engines and 7BJ Engines

Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.

Ver imagen

g00295370
Illustration 4

Bolt tightening sequence for the cylinder head

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

1. Put engine oil on the threads of bolts. Tighten bolts (1) through bolts (22) in a
numerical sequence in Illustration 4.

Torque for bolts ... 110 N·m (81 lb ft)

2. Tighten bolts (1) through bolts (22) again in a numerical sequence.

Torque for bolts ... 110 N·m (81 lb ft)

3. Rotate bolts (1) through bolts (26) in a numerical sequence to the following
values:
a. Tighten the bolts of short length "S" to the following value.

Rotate the bolts in a clockwise direction: ... 150 degrees

 b. Tighten the bolts of medium length "M" to the following value.

Rotate the bolts in a clockwise direction: ... 180 degrees

c. Tighten the bolts of long length "L" to the following value.

Rotate the bolts in a clockwise direction: ... 210 degrees

Ver imagen

g00295373
Illustration 5

Bolts, nuts, and components of the cylinder head

Note: When the fuel injection nozzle is removed, the following items must be replaced:
dust seal and seat washer.

(1) Tighten the bolts that hold the rocker shaft to the cylinder head to the following
torques:

Begin tightening the inner bolts. Then tighten the bolts by working toward the end of
the shaft.
Cast iron or steel bracket ... 75 N·m (55 lb ft)
Aluminum bracket ... 40 N·m (30 lb ft)
(2) Valve lash

Inlet ... 0.20 mm (.008 inch)

Exhaust ... 0.45 mm (.018 inch)

(3) Maximum permissible nozzle projection below cylinder head face after resurfacing
... 4.45 mm (.175 inch)

Maximum allowance for resurfacing ... 0.30 mm (.012 inch)

(4) Depth of new cylinder head ... 102.79 to 103.59 mm (4.047 to 4.078 inch)

Minimum depth of cylinder head after resurfacing ... 102.48 mm (4.035 inch)

Ver imagen

g00295372
Illustration 6

Positions for measuring the bow of the cylinder head (t ypical example)

Maximum permissible amount of bow (curve of the cylinder head)

A ... 0.08 mm (.003 inch)

B ... 0.15 mm (.006 inch)
C ... 0.15 mm (.006 inch)

Tighten the bolts for the inlet manifold (not shown) to the following torque: ... 44 N·m
(32 lb ft)

Tighten the nuts for the exhaust manifold (not shown) to the following torque:

Plated ... 44 N·m (32 lb ft)

(2) Tighten the bolts, which hold the back plate, to the following torque: ... 8.5 to 10.2
N·m (75 to 90 lb in)

(3) Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the
compressor housing to the center section, to the following torque: ... 15.3 to 18.7 N·m
(12 to 14 lb ft)

(4) Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the
turbine housing to the center section, to the following torque: ... 18.6 to 20.4 N·m (14 to
15 lb ft)

(5) Turbine wheel assembly

Minimum journal outside diameter ... 10.152 mm (.3997 inch)

Ring groove diameter (minimum) ... 14.401 mm (.5670 inch)
Ring groove width (maximum) ... 1.740 mm (.0685 inch)
Hub outside diameter (minimum) ... 17.323 mm (.6820 inch)

(6) End play for shaft

Minimum permissible end play ... .03 mm (.001 inch)

Maximum permissible end play ... .10 mm (.004 inch)

(7) Compressor wheel

Bore inside diameter (maximum) ... 6.353 mm (.2501 inch)

(8) Backplate assembly

Seal inside diameter (maximum) ... 12.713 mm (.5005 inch)

Flatness from the backplate to the mating surface of the center housing is within
the following value: ... .013 mm (.0005 inch)

(9) Thrust collar

Thickness (maximum) ... 18.339 mm (0.7220 inch)

Bore inside diameter (maximum) ... 6.363 mm (.2505 inch)
Thrust bearing groove width (maximum) ... 4.440 mm (.1748 inch)
Thrust bearing groove diameter (minimum) ... 9.398 mm (.3700 inch)
Piston ring groove width (maximum) ... 1.659 mm (.0653 inch)

(10) Thrust bearing

Thickness (minimum) ... 4.359 mm (0.1716 inch)

Bore inside diameter (maximum) ... 10.922 mm (.4300 inch)

(11) Radial play (side to side movement) for shaft

Minimum permissible radial play (side to side movement) ... .08 mm (.003 inch)
 Maximum permissible radial play (side to side movement) ... .15 mm (.0059
inch)

(12) Center housing

Bearing inside diameter (maximum) ... 15.806 mm (.6223 inch)

Seal inside diameter (maximum) ... 17.805 mm (.7010 inch)

Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the
turbocharger to the manifold (not shown), to the following torque: ... 55 ± 5 N·m (40 ±
4 lb ft)

Air Inlet Heater

Ver imagen

g00298861
Illustration 2

(1) Electrical connection

(2) Fuel inlet

(3) Ball valve

(4) Valve holder

(5) Wire coil

(6) Ignition coil

Voltage ... 12 volts

Current draw ... 13.5 amperes

Tighten the air inlet heater to the inlet manifold to the following torque: ... 31 ± 8 N·m
1 1 0
(23 ± 6 lb ft)

Exhaust Manifold
SMCS - 1059

/sisw eb/sisw eb/ /sisw eb/mediase

Type 1 Engines and 9RM Engines

Ver imagen

g00559857
Illustration 1

The cylinder head is shown.

Refer to Illustration 1 for the tightening sequence. Tighten the plated nuts for the
exhaust manifold to the following torque. ... 44 N·m (33 lb ft)

Refer to Illustration 1 for the tightening sequence. Tighten the nuts that are not plated
for the exhaust manifold to the following torque. ... 50 N·m (37 lb ft)

Type 2 Engines and 7BJ Engines

Ver imagen
 g00501179
Illustration 2

Apply 4C-9507 Retaining Compound to the stud threads.

Refer to Illustration 2 for the tightening sequence. Tighten the exhaust manifold nuts or
1
bolts gradually to the following torque. ... 44 N·m (33 lb ft)
1 0

Muffler
SMCS - 1062

/sisw eb/sisw eb/ /sisw eb/mediase

Ver imagen
 Depth of the recess for the c ylinder liner flange ... 3.81 to 3.91 mm (0.150 to
0.154 inch)
Diameter of the recess for the cylinder liner flange ... 107.82 to 107.95 mm
(4.245 to 4.250 inch)

(4) Tighten the bolts that fasten the housing for the crankshaft rear seal to the cylinder
block to the following torque. ... 22 N·m (16 lb ft)

(5) Tighten the bolts that fasten the housing for the crankshaft rear seal to the bridge to
the following torque.

M6 ... 13 N·m (10 lb ft)

M8 ... 22 N·m (16 lb ft)

(6) Bridge bolt

Use the following procedure in order to install the bridge bolts.

1. Use a straight edge in order to ensure that the bridge is aligned with the front
face of the cylinder block.

2. Evenly tighten the bridge bolts to a torque of 16 N·m (12 lb ft).

3. When the bridge is installed on the cylinder block, apply a thin bead of 8T-9013
Silicone Sealant into the groove at each end of the bridge.

(7) Main bearing cap bolts

Use the following procedure in order to install the main bearing cap bolts.

1. Apply clean engine oil to the threads of the main bearing cap bolts.

2. Put the main bearing caps in the correct position that is indicated by a number on
the top of the main bearing cap. Install the main bear ing caps with the locating
tabs in correct alignment with the recess in the cylinder block.

3. Evenly tighten the main bearing cap bolts to a torque of 265 N·m (195 lb ft).

(8) Bore in the cylinder block for the main bearings ... 80.416 to 80.442 mm (3.1660 to
3.1670 inch)

(9) Camshaft bearing

Inside diameter of the camshaft bearing for the number 1 camshaft journal ...
50.79 to 50.85 mm (2.000 to 2.002 inch)
Bore diameter in the cylinder block for the number 1 camshaft bear ing ... 55.56
to 55.59 mm (2.187 to 2.189 inch)
Bore diameter in the cylinder block for the number 2 camshaft journal ... 50.55
to 50.60 mm (1.990 to 1.992 inch)
 Bore diameter in the cylinder block for the number 3 camshaft j ournal ... 50.04
to 50.09 mm (1.970 to 1.972 inch)

Total height of cylinder block between the top and the bottom faces. ... 441.12 to 441.33
mm (17.367 to 17.375 inch)

Piston Cooling Jets (If Equipped)

Ver imagen

g00631670
Illustration 2

(1) Tighten the piston cooling jets to the following torque. ... 27 N·m (20 lb ft)

(2) Diameter of rod ... 1.70 mm (0.067 inch)

(3) Cylinder block

Note: Ensure that the piston cooling jet is positioned correctly on the dowel in the
cylinder block (not shown).

Use the following procedure in order to ensure the correct a lignment of the piston
cooling jet.
 1. Insert rod (2) into the end of the piston cooling jet. Rod (2) should protrude out
of the top of the cylinder block.

2. Use the following dimensions to locate the center point of diameter (C) .

Dimension (A) ... 33 mm (1.3 inch)

Dimension (B) ... 21 mm (0.8 inch)

Diameter (C) ... 14 mm (0.6 inch)

Note: Dimension (A) and dimension (B) are tangent to the cylinder bore.

3. Position rod (2) within diameter (C) .

1 1 0

Crankshaft
SMCS - 1201

/sisw eb/sisw eb/ /sisw eb/mediase

Ver imagen
 g00295557
Illustration 1

Crankshaft and main bearing journals

Note: If a crankshaft that was not originally induction hardened has been remachined,
then the crankshaft must be rehardened. Use one of the process that follow for 20 hours
in order to reharden the crankshaft: nitrocarburizing process and nitriding process

(1) Connecting rod bearing

(2) Top and bottom thrust washer thickness

Standard ... 2.26 to 2.31 mm (0.089 to 0.091 inch)

Oversize ... 2.45 to 2.50 mm (0.096 to 0.098 inch)

(3) Main bearing

Clearance for main bearings ... 0.057 to 0.117 mm (0.0022 to 0.0046 inch)
Bearing width
Center bearing ... 36.32 to 36.70 mm (1.430 to 1.445 inch)
All other bearings ... 31.62 to 31.88 mm (1.245 to 1.255 inch)
Thickness of the bearing at the center
All bearings ... 2.083 to 2.086 mm (0.0820 to 0.0821 inch)

(4) Crankshaft gear

(5) End play of the crankshaft ... 0.05 to 0.38 mm (0.002 to 0.015 inch)

Maximum permissible end play ... 0.51 mm (0.020 inch)

(6) Width of the connecting rod journal ... 40.35 to 40.42 mm (1.589 to 1.591 inch)

Connecting rod journal diameter of flange ... 133.27 to 133.37 mm (5.247 to 5.251 inch)

Depth of recess for connecting rod bearing ... 20.22 to 20.98 mm (0.796 to 0.826 inch)

Bore of recess for connecting rod bearing ... 46.96 to 46.99 mm (1.849 to 1.850 inch)

Measure the connecting rod journals on the crankshaft. See the following chart for t he
dimensions.

Table 1

Connecting Rod Bearing Journal

If the bearing journal has been ground beyond this size, then
regrind the bearing journals to the next undersize journal. 63.43 mm (2.497 inch)
 g01064497
Illustration 4

Note: The caps and rods must stay together as a pair.

Note: When the connecting rods are replaced, do not reuse the connecting r od bolts.
New connecting rod bolts must be used.

The mating surfaces of the connecting rod are produced by hydraulically fracturing the
forged connecting rod.

(7) Tighten the connecting rod bolts to the following torque. ... 18 N·m (13 lb ft)

Tighten the connecting rod bolts again to the following torque. ... 70 N·m (52 lb ft)

Tighten the connecting rod bolt for an additional 120 degrees.

(8) Connecting rod bearing

Ver imagen

g01064498
Illustration 5

(9) Diameter of the bore for the piston pin ... 43.01 to 43.04 mm (1.693 to 1.694 inch)

(10) Distance between bearing centers ... 219.05 to 219.10 mm (8.624 to 8.626 inch)

(11) DPiston and Rings

SMCS - 1214; 1215
 /sisw eb/sisw eb/ /sisw eb/mediase

Type 1 Engines and 9RM Engines

Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.

Ver imagen

g00295711
Illustration 1

Piston and rings

Note: The word "Front" or an arrow which is marked on the piston crown must be
toward the front of the engine. If the piston crown is not marked, put the nar rowest side
of the piston crater toward the side of the engine with the fuel injection pump. The
shortest distance between the edge of the piston crater and the edge of the piston is the
narrowest side of the piston crater.
Note: Be sure that the ring end gaps of all the piston rings have 120 degrees spacing
from each other.

Note: Refer to Systems Operation, "General Information" for the location of the serial
number.

Naturally Aspirated Engines

(1) Width of groove in piston for top ring ... 2.57 to 2.59 mm (.101 to .102 inch)

Thickness of top ring ... 2.48 to 2.49 mm (.097 to .098 inch)

Clearance between groove and piston ring ... 0.08 to 0.11 mm (.003 to .004 inch)

Clearance between the ends of the top ring with a cylinder liner without any wear ...
0.40 to 0.85 mm (.016 to .033 inch)

(2) Width of groove in piston for intermediate ring ... 2.55 to 2.57 mm (.100 to .101
inch)

Thickness of intermediate ring ... 2.48 to 2.49 mm (.097 to .098 inch)

Clearance between groove and intermediate ring ... 0.06 to 0.09 mm (.002 to .003 inch)

Clearance between the ends of the intermediate ring with a cylinder liner without any
wear ... 0.30 to 0.76 mm (.012 to .030 inch)

(3) Width of groove in piston for oil control ring ... 4.030 to 4.060 mm (.1587 to .1598
inch)

Thickness of oil control ring ... 3.980 to 3.990 mm (.1566 to .1571 inch)

Clearance between groove and oil control ring ... 0.04 to 0.08 mm (.002 to .003 inch)

Clearance between the ends of oil control ring with a cylinder liner without any wear ...
0.38 to 0.84 mm (.015 to .033 inch)

(4) Diameter of new piston pin ... 34.920 to 34.925 mm (1.3748 to 1.3750 inch)

Bore for piston pin ... 34.928 to 34.934 mm (1.3751 to 1.3754 inch)

Turbocharged Engines

(1) Shape of groove in piston for top ring ... Taper

Shape of top ring ... Taper

Clearance between the ends of top ring in a cylinder liner without any wear ... 0.35 to
0.75 mm (.014 to .030 inch)
Ver imagen

g00295928
Illustration 1

Starting Motor (Side View)

Ver imagen
 g00295930
Illustration 2

End view of the starting motor which shows the electrical connections

No load conditions at 25 °C (77 °F)

Rpm of shaft ... 7000 minimum

Current draw ... 130 amperes maximum

Voltage ... 11.5 volts

Rated voltage ... 12 volts

(1) Tighten the battery terminal nut to the following torque: ... 24 to 32 N·m (18 to 24 lb
ft)

(2) Tighten the nut for the switch terminal to the following torque: ... 1.0 to 1.3 N·m (9
to 12 lb in)

Tension of the spring for the motor brush ... 8.34 to 11.00 N (1.9 to 2.5 lb)
Minimum resistance of the starter cable at 200 °C (392 °F) and at 12 volts ... 0.0017
ohms

Start Relays
9G-4368 Relay

Ver imagen

g00731492
Illustration 3

Voltage ... 12 VDC

Resistance between "W1" terminal and "W2" terminal ... 15 ± 1.5 ohms

069-5466 Relay

Ver imagen
 g00295932
Illustration 4

Voltage ... 6 VDC

Resistance between terminal "A" and terminal "B" ... 30 to 34 ohms

24 Volt Starting Motor

No load conditions at 25 °C (77 °F)

Rpm of shaft ... 7000 minimum

Current draw ... 85 amperes maximum

Voltage ... 23 volts

Rated voltage ... 24 volts

Minimum pull-in voltage ... 18 volts

Brush length:
 Minimum brush length ... 15.5 mm (0.61 inch)

Armature end play ... 0.1 to 0.3 mm (0.004 to 0.012 inch)

Install shims or remove shims in order to adjust the armature end play to the correct
specification.

Commutator

New diameter ... 45 mm (1.77 inch)

Minimum diameter ... 42.5 mm (1.67 inch)

1 1 5