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SENR9936-06

January 2008

Specifications
C27 and C32 Engines for Caterpillar
Built Machines
5301-Up (Machine)
2211-Up (Machine)
LWA1-Up (Machine)
GEB1-Up (Machine)
TPB1-Up (Machine)
H4C1-Up (Machine)
EED1-Up (Machine)
RJG1-Up (Machine)
Z9K1-Up (Machine)
JRP1-Up (Machine)
DLS1-Up (Machine)
BTW1-Up (Machine)
JNW1-Up (Machine)
BWX1-Up (Machine)
i01658146

Important Safety Information


Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:


Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this


product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-


ture failures, product damage, personal injury or
death.
SENR9936-06 3
Table of Contents

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


Flywheel ...............................................................
68
69
Flywheel ............................................................... 70
Flywheel Housing ................................................ 70
Specifications Section Flywheel Housing ................................................ 72
Flywheel Housing ................................................ 73
Engine Design ....................................................... 4
Flywheel Housing ................................................ 75
Engine Design ....................................................... 4
Flywheel Housing ................................................ 77
Fuel Transfer Pump ............................................... 5
Coolant Temperature Sensor ............................... 78
Fuel Filter Base ...................................................... 5
Coolant Temperature Sensor ............................... 79
Fuel Filter Base ...................................................... 6
Coolant Flow Switch ............................................ 79
Electronic Unit Injector Mechanism ....................... 6
Fuel Temperature Sensor ..................................... 80
Electronic Unit Injector Rocker Arm ........................ 7
Fuel Temperature Sensor ..................................... 81
Electronic Unit Injector Wiring ................................. 7
Fuel Filter Pressure Differential Switch ................. 81
Valve Mechanism ................................................... 8
Mass Air Flow Sensor ........................................... 82
Valve Mechanism ................................................... 9
Mass Air Flow Sensor ........................................... 83
Cylinder Head Valves ........................................... 10
Engine Oil Pressure Sensor ................................. 83
Cylinder Head ....................................................... 11
Engine Oil Pressure Sensor ................................. 84
Compression Brake .............................................. 13
Atmospheric Pressure Sensor .............................. 84
Turbocharger ....................................................... 16
Atmospheric Pressure Sensor .............................. 85
Turbocharger ....................................................... 18
Atmospheric Pressure Sensor .............................. 85
Turbocharger ....................................................... 20
Inlet Manifold Temperature Sensor ....................... 86
Turbocharger ....................................................... 21
Turbocharger Inlet Pressure Sensor ..................... 86
Turbocharger ....................................................... 22
Turbocharger Inlet Pressure Sensor ..................... 87
Exhaust Manifold ................................................. 24
Speed/Timing Sensor .......................................... 87
Exhaust Manifold ................................................. 26
Exhaust Manifold ................................................. 28
Exhaust Manifold ................................................. 29 Index Section
Exhaust Manifold ................................................. 30
Camshaft ............................................................. 31 Index ..................................................................... 89
Engine Oil Filter Base .......................................... 32
Engine Oil Filter Base .......................................... 33
Engine Oil Pump .................................................. 34
Engine Oil Pump .................................................. 36
Engine Oil Bypass Valve ...................................... 38
Engine Oil Bypass Valve ...................................... 39
Engine Oil Pan ..................................................... 40
Engine Oil Pan ..................................................... 41
Engine Oil Pan ..................................................... 42
Water Temperature Regulator .............................. 42
Water Pump ......................................................... 43
Cylinder Block ...................................................... 43
Cylinder Liner ....................................................... 45
Cylinder Liner ....................................................... 46
Crankshaft ........................................................... 47
Crankshaft Seals ................................................. 49
Vibration Damper ................................................. 49
Vibration Damper ................................................. 50
Vibration Damper ................................................. 50
Vibration Damper ................................................. 51
Vibration Damper ................................................. 51
Connecting Rod Bearing Journal ......................... 52
Main Bearing Journal ............................................ 52
Connecting Rod ................................................... 53
Piston and Rings .................................................. 55
Piston and Rings .................................................. 57
Housing (Front) ..................................................... 58
Housing (Rear) ..................................................... 59
Gear Group (Front) ............................................... 61
Gear Group (Rear) ................................................ 62
Gear Group (Rear) ................................................ 63
Gear Group (Rear) ................................................ 65
Gear Group (Rear) ................................................ 67
4 SENR9936-06
Specifications Section

Specifications Section Note: The front of the engine is opposite of the


flywheel end of the engine. The left side and the right
side of the engine are viewed from the flywheel end
i02810716 of the engine. The No. 1 cylinder is the front cylinder
on the left side. The No. 2 cylinder is the front cylinder
Engine Design on the right side.
SMCS Code: 1201 The crankshaft rotation is viewed from the flywheel
end of the engine.
S/N: EED1-Up
Crankshaft rotation ................. Counterclockwise
S/N: RJG1-Up
S/N: DLS1-Up Note: Number one cylinder is the front cylinder
on the left side of the cylinder block. Number two
S/N: BTW1-Up cylinder is the front cylinder on the right side of the
cylinder block.
S/N: JNW1-Up
S/N: BWX1-Up Firing order ............ 1, 10, 9, 6, 5, 12, 11, 4, 3, 8, 7, 2

i02856750

Engine Design
SMCS Code: 1201
S/N: 5301-Up
S/N: 2211-Up
S/N: LWA1-Up
S/N: GEB1-Up
S/N: TPB1-Up
g01113721
Illustration 1
S/N: H4C1-Up
(A) Inlet valves
(B) Exhaust valves S/N: Z9K1-Up

Bore ........................................ 137.2 mm (5.40 inch) S/N: JRP1-Up

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

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

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

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

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

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

Valve lash with engine stopped (cold)


g01113721
Inlet ........... 0.38 ± 0.08 mm (0.015 ± 0.003 inch) Illustration 2
Exhaust ..... 0.76 ± 0.08 mm (0.030 ± 0.003 inch) (A) Inlet valves
(B) Exhaust valves

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

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


SENR9936-06 5
Specifications Section

Displacement ................................. 32 L (1953 cu in) When the fuel transfer pump is using diesel fuel, the
fuel transfer pump has the following specifications:
Compression ratio .............................................. 15:1
Run the pump at 2940 rpm. The full bypass pressure
Cylinder arrangement ...................... 65 degrees V12 should be the following value. ........... 716 to 786 kPa
(104 to 114 psi)
Valves per cylinder .................................................. 4
Run the pump at 840 rpm. The flow at 550 kPa
Type of combustion ............................ Direct injection (80 psi) must be 6.0 L/min (1.6 US gpm).

Valve lash measurement Run the pump at 2940 rpm. The flow at 650 kPa
(94 psi) must be 9.0 L/min (2.38 US gpm).
Inlet ................. 0.38 ± 0.08 mm (0.015 ± 0.003 inch)
Run the pump at 120 rpm with the inlet open to the
Exhaust ........... 0.76 ± 0.08 mm (0.030 ± 0.003 inch) atmosphere for 10 seconds. Block the inlet. The
pump must maintain vacuum of 30 kPa (4.5 psi)
Crankshaft rotation direction (view from the flywheel minimum in 30 seconds.
end) ............................................... Counterclockwise
Run the pump at 840 rpm with the inlet open to the
Firing order (injection atmosphere for 10 seconds. Block the inlet. The
sequence) .............. 1, 10, 9, 6, 5, 12, 11, 4, 3, 8, 7, 2 pump must maintain vacuum of 45 kPa (6.5 psi)
minimum in 30 seconds.
The no. 1 cylinder is the front cylinder on the left side
of the cylinder block. The no. 2 cylinder is the front Run the pump at 120 rpm with a blocked inlet that is
cylinder on the right side of the cylinder block. full of fuel for 30 seconds. The pump inlet must have
a suction lift of 60.9 kPa (18 In Hg) minimum.
Note: The front of the engine is opposite of the
flywheel end of the engine. The left side of the engine When the pump is viewed from the drive gear
and the right side of the engine is viewed from the end or the drive shaft, the rotation of the pump is
flywheel end of the engine. counterclockwise.

i02774897 i02774886

Fuel Transfer Pump Fuel Filter Base


SMCS Code: 1256 SMCS Code: 1261; 1262
Part No.: 286-2531 Part No.: 237-9307

g01391562
Illustration 3
(1) Pressure regulating valve
(2) Weep hole
(3) Inlet port
(4) Outlet port

Note: Maximum inlet pressure to the pump shall not


g01386907
exceed 69 kPa (10 psi). Illustration 4
(1) Base
6 SENR9936-06
Specifications Section

(A) Apply 154-9731 Thread Lock Compound to the Part No.: 260-9631
threads on the taperlock end of the stud to the S/N: GEB1-Up
following distance. ....................... 39.5 ± 0.5 mm
(1.56 ± 0.02 inch) Part No.: 260-9631
S/N: TPB1-Up
(2) Torque for the stud ..... 70 ± 15 N·m (50 ± 11 lb ft)
Part No.: 255-8001, 260-9631
S/N: H4C1-Up
i02864490
Part No.: 255-8001, 260-9631
Fuel Filter Base S/N: EED1-Up
Part No.: 260-9631
SMCS Code: 1261; 1262
S/N: RJG1-Up
Part No.: 266-9459
Part No.: 255-8001, 260-9631
S/N: LWA1-Up
S/N: Z9K1-Up
Part No.: 266-9459
Part No.: 255-8001, 260-9631
S/N: GEB1-Up
S/N: JRP1-Up
Part No.: 266-9459
Part No.: 255-8001, 260-9631
S/N: TPB1-Up
S/N: DLS1-Up
Part No.: 266-9459
Part No.: 260-9631
S/N: Z9K1-Up
S/N: BTW1-Up
Part No.: 260-9631
S/N: JNW1-Up
Part No.: 260-9631
S/N: BWX1-Up

g01426884
Illustration 5

(A) Length for applying 154-9731 Thread Lock


Compound to the threads on the taperlock end of
the stud ........... 39.5 ± 0.5 mm (1.56 ± 0.02 inch)

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

i02792816

Electronic Unit Injector


Mechanism Illustration 6
g01395719

SMCS Code: 1290 (4) Spacer

Part No.: 255-8001, 260-9631 Note: Refer to Testing and Adjusting, “Electronic Unit
S/N: 5301-Up Injector - Adjust” for the correct procedure for setting
the lash on the electronic unit injector.
Part No.: 255-8001, 260-9631
S/N: 2211-Up Note: Before installation of the unit injector, lubricate
Part No.: 255-8001, 260-9631 the top two O-ring seals (6) with a 50/50 mixture of
S/N: LWA1-Up clean engine oil and 8T-2998 Lubricant.
SENR9936-06 7
Specifications Section

(1) Torque for cap nut .. 2.50 ± 0.25 N·m (22 ± 2 lb in) Part No.: 223-6408, 249-8717
S/N: 2211-Up
(2) Torque for nut ............ 100 ± 10 N·m (75 ± 7 lb ft)
Part No.: 223-6408, 249-8717
(A) Adjust the unit injector height from the timing seat S/N: LWA1-Up
to the following distance. ............. 78.0 ± 0.2 mm
Part No.: 223-6408
(3.07 ± 0.01 inch)
S/N: GEB1-Up
Use the following procedure to tighten the bolt (3) Part No.: 223-6408
for clamp (5): S/N: TPB1-Up

1. Tighten the bolt for the clamp to 55 ± 10 N·m Part No.: 223-6408, 249-8717
(41 ± 7 lb ft). S/N: H4C1-Up

2. Loosen the bolt for the clamp until the bolt is finger Part No.: 223-6408, 249-8717
tight. S/N: EED1-Up
Part No.: 223-6408
3. Tighten the bolt for the clamp again to 55 ± 10 N·m S/N: RJG1-Up
(41 ± 7 lb ft).
Part No.: 223-6408, 249-8717
S/N: Z9K1-Up
i02796857
Part No.: 223-6408, 249-8717
Electronic Unit Injector Rocker S/N: JRP1-Up
Arm Part No.: 223-6408, 249-8717
SMCS Code: 1123 S/N: DLS1-Up

Part No.: 278-1363 Part No.: 223-6408


S/N: BTW1-Up
Part No.: 223-6408
S/N: JNW1-Up
Part No.: 223-6408
S/N: BWX1-Up

g01397096
Illustration 7
Typical example
(1) Location of bearing joint

Note: The sleeve bearing and pin must not extend


beyond either face of the rocker arm.

(A) Dimension for bore of new sleeve bearing after


installation ............................ 40.065 ± 0.015 mm
(1.5774 ± 0.0006 inch)

i02864507
g01075720
Illustration 8
Electronic Unit Injector Wiring Typical example
(1) Engine harness assembly and connector seal
SMCS Code: 1290
Part No.: 223-6408, 249-8717
S/N: 5301-Up
8 SENR9936-06
Specifications Section

Note: Install the flat part of the connector seal against Note: Refer to Testing and Adjusting, “Engine Valve
the connector surface. The curved part of the seal Lash - Inspect/Adjust” for the correct procedure on
must be installed so that the seal is against the valve setting the engine valve lash.
mechanism cover base.
(5) Location for checking the valve lash
(2) Torque for the 24 retainer nuts that are on the 12
cap assemblies ..... 2.50 ± 0.25 N·m (22 ± 2 lb in) Inlet valves ................................. 0.38 ± 0.08 mm
(0.015 ± 0.003 inch)
Note: Orient connectors so wires are not contacting Exhaust valves .......................... 0.76 ± 0.08 mm
metal surfaces. (0.030 ± 0.003 inch)

i02897419

Valve Mechanism
SMCS Code: 1102
Part No.: 260-9631

g01404154
Illustration 10
Left side of engine

g01442728
Illustration 9
(1) Rocker arm
(4) Camshaft Illustration 11
g01404155
(6) Valve bridge
Right side of engine
(2) Torque for the adjustment screw
locknut ........................... 30 ± 7 N·m (22 ± 5 lb ft)

(3) Rocker shaft assembly


Diameter of a new rocker arm
shaft ..................................... 40.000 ± 0.010 mm
(1.5748 ± 0.0004 inch)
Bore in a new bearing for rocker arm
shaft ..................................... 40.065 ± 0.015 mm
(1.5774 ± 0.0006 inch)
Maximum dimension for the bore in a worn
bearing for rocker arm shaft ............. 40.193 mm
(1.5824 inch)
g01400354
Illustration 12
Tightening sequence
SENR9936-06 9
Specifications Section

Note: Tighten the bolts for the rocker arm group in the Diameter of a new rocker arm shaft
sequence 9, 10, 8, 11, 9, 10. Refer to Illustration 12. ........ 40.000 ± 0.010 mm (1.5748 ± 0.0004 inch)
Bore in a new bearing for rocker arm
(7) Torque for bolts ........ 109 ± 15 N·m (80 ± 11 lb ft) shaft ..................................... 40.065 ± 0.015 mm
(1.5774 ± 0.0006 inch)
Maximum dimension for the bore in a worn
i02794903
bearing for rocker arm shaft ............. 40.193 mm
Valve Mechanism (1.5824 inch)

SMCS Code: 1102 Note: Refer to Testing and Adjusting, “Engine Valve
Lash - Inspect/Adjust” for the correct procedure on
Part No.: 255-8001 setting the engine valve lash.
S/N: 5301-Up
(5) Location for checking the valve lash
Part No.: 255-8001
S/N: 2211-Up Inlet valves ................................. 0.38 ± 0.08 mm
(0.015 ± 0.003 inch)
Part No.: 255-8001 Exhaust valves .......................... 0.76 ± 0.08 mm
S/N: LWA1-Up (0.030 ± 0.003 inch)
Part No.: 255-8001
S/N: H4C1-Up
Part No.: 255-8001
S/N: EED1-Up
Part No.: 255-8001
S/N: Z9K1-Up
Part No.: 255-8001
S/N: JRP1-Up
Part No.: 255-8001
S/N: DLS1-Up

g01400357
Illustration 14
Left side of engine

g01400358
Illustration 15
Right side of engine

g01246863
Illustration 13 (7) Torque for bolts ........ 109 ± 15 N·m (80 ± 11 lb ft)
(1) Rocker arm
(4) Camshaft
(6) Valve bridge

(2) Torque for the adjustment screw


locknut ........................... 30 ± 7 N·m (22 ± 5 lb ft)

(3) Rocker shaft assembly


10 SENR9936-06
Specifications Section

i02838507 Inlet valve ................................ 47.00 ± 0.13 mm


(1.850 ± 0.005 inch)
Cylinder Head Valves Exhaust valve .......................... 41.81 ± 0.13 mm
(1.646 ± 0.005 inch)
SMCS Code: 1105
Part No.: 284-8892

g01415562
Illustration 17
View of area D
Inlet valve seat insert

g01415536
Illustration 16
(1) Exhaust valve
(2) Inlet valve

Note: Lubricate inner diameter of valve guides with


clean engine oil immediately prior to valve installation
in the cylinder.

(3) 247-9908 Springs


g01415565
Illustration 18
Quantity .......................................................... 24
Length under test force ... 67.12 mm (2.643 inch) View of area E
Test force .................... 320 ± 25 N (71.9 ± 5.6 lb) Exhaust valve seat insert
Approximate free length after test ...... 76.70 mm
(3.020 inch) (F) Angle of face of valve seat insert
Outside diameter ................ 36.3 mm (1.43 inch)
Inlet valve ......................... 30.25 ± 0.25 degrees
(4) 211-3122 Springs Exhaust valve ................... 45.25 ± 0.25 degrees

Quantity .......................................................... 24
Length under test force ... 60.14 mm (2.368 inch)
Test force .................... 150 ± 12 N (33.7 ± 2.7 lb)
Approximate free length after test ...... 71.70 mm
(2.823 inch)
Outside diameter ............ 25.17 mm (0.991 inch)

(A) Height to the step that is in the valve


guide ............... 35.0 ± 0.5 mm (1.38 ± 0.02 inch)

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


(0.3711 ± 0.0004 inch)

(C) Diameter of valve head g01415570


Illustration 19
SENR9936-06 11
Specifications Section

(G) Depth of the bore in the cylinder head for the


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

(H) Angle of valve face


Angle of the face of the inlet
valve ................................. 29.25 ± 0.25 degrees
Angle of the face of the exhaust
valve ................................. 44.25 ± 0.25 degrees

Note: Shrink the valve seat inserts by reducing the


temperature. Shrinking the valve seat inserts allows
placement into the counterbore.

(J) Valve seat insert


Diameter of valve seat insert (inlet
valve) ................................... 48.025 ± 0.013 mm
(1.8907 ± 0.0005 inch)
Bore in cylinder head for valve seat insert (inlet
valve) ................................... 47.950 ± 0.025 mm
(1.8878 ± 0.0010 inch)
Diameter of valve seat insert (exhaust
valve) ................................... 42.840 ± 0.013 mm
(1.6866 ± 0.0005 inch)
Bore in cylinder head for valve seat insert
(exhaust valve) .................... 42.774 ± 0.025 mm
(1.6840 ± 0.0010 inch)

i02846910

Cylinder Head
SMCS Code: 1100
Part No.: 284-8895

g01423291
Illustration 20
Bolt tightening sequence
12 SENR9936-06
Specifications Section

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

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

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


long.

Use the following procedure in order to tighten the


cylinder head bolts:

Note: Apply 4C-5592 Anti-Seize Compound to the


bolt threads and to both sides of the washers for bolt
1 through bolt 26 prior to assembly.
g01419267
1. Torque for bolt 1 through bolt 26 in a numerical Illustration 22
sequence to 270 ± 15 N·m (200 ± 11 lb ft) Cylinder head face

2. Torque for bolt 1 through bolt 26 in a numerical Note: Lubricate the bores for the cup plugs with
sequence to 450 ± 15 N·m (330 ± 11 lb ft) 6V-6640 Sealant prior to installing the cup plugs.

3. Again torque the bolt 1 through bolt 26 in (B) The cup plugs are measured from the face of the
a numerical sequence to 450 ± 15 N·m cylinder head to the top edge of the plug. Depth
(330 ± 11 lb ft). of installation .............................. 1.25 ± 0.25 mm
(0.049 ± 0.010 inch)
4. Torque for bolt 27 through bolt 39 in a numerical
sequence to 45 ± 7 N·m (33 ± 5 lb ft) NOTICE
Camshaft bearings must be installed into their correct
Note: Install the taperlock studs so that the letter “Y” position. Failure to do so will result in engine damage.
is showing.

(40) Torque for 24 taperlock studs .......... 35 ± 5 N·m


(26 ± 4 lb ft)

g01419268
Illustration 23

(C) Orientation of bearing


joint .................. 20 ± 3 degrees below horizontal

g01419264
Illustration 21
(41) Oil gallery
(42) Camshaft bearing
(43) Oil holes
(44) Typical location for cup plug
SENR9936-06 13
Specifications Section

g01423293 g01427660
Illustration 24 Illustration 25
Top view of engine
The installation depth of the camshaft bearings (42)
is very important. Install the camshaft bearings to the
following depths:
(D) ..................... 8.0 ± 0.5 mm (0.31 ± 0.02 inch)
(E) ................. 227.5 ± 0.5 mm (8.96 ± 0.02 inch)
(F) ................ 411.7 ± 0.5 mm (16.21 ± 0.02 inch)
(G) .............. 595.8 ± 0.5 mm (23.46 ± 0.02 inch)
(H) ............... 780.0 ± 0.5 mm (30.71 ± 0.02 inch)
(J) ............... 964.1 ± 0.5 mm (37.96 ± 0.02 inch)
(K) .............. 1140.3 ± 0.5 mm (44.89 ± 0.02 inch)

i02857841

Compression Brake g01431042


Illustration 26
SMCS Code: 1119; 1129 Tightening sequence for the rocker arm shaft
Right side view
Part No.: 255-7955
S/N: 5301-Up
Use the following procedure to tighten the nine studs
Part No.: 255-7955 (1):
S/N: 2211-Up
1. Tighten the studs in the numerical sequence that is
Part No.: 255-7955 shown in Illustration 26 to 50 ± 5 N·m (37 ± 4 lb ft).
S/N: LWA1-Up
2. Turn the studs to an additional 45 ± 5 degrees.
Part No.: 255-7955
S/N: H4C1-Up
Part No.: 255-7955
S/N: EED1-Up
Part No.: 255-7955
S/N: Z9K1-Up
Part No.: 255-7955
S/N: JRP1-Up
Part No.: 255-7955
S/N: DLS1-Up

NOTICE
g01431037
Do not disassemble the Variable Valve Actuator. Illustration 27
There are no components of the Variable Valve Tightening sequence for the rocker arm shaft
Actuator that are serviceable. If the Variable Valve Left side view
Actuator is disassembled, the warranty will be void.
14 SENR9936-06
Specifications Section

Use the following procedure to tighten the nine studs


(2):

1. Tighten the studs in the numerical sequence that is


shown in Illustration 27 to 50 ± 5 N·m (37 ± 4 lb ft).

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

g01428104
Illustration 29
Left side view of engine

(6) Torque for six taperlock studs .......... 65 ± 10 N·m


(48 ± 7 lb ft)

g01427680
Illustration 28
Right side view of engine

g01428087
Illustration 30
Right side view of engine
Tightening sequence for the valve actuator group
SENR9936-06 15
Specifications Section

g01436074 g01427354
Illustration 31 Illustration 32
Left side view of engine Typical example
Tightening sequence for the valve actuator group
Note: The lash setting for the exhaust valve to rocker
Use the following procedure to tighten the valve arm must be completed before the lash setting of the
actuator group: compression brake. Refer to Testing and Adjusting,
“Engine Valve Lash - Inspect/Adjust” for procedural
1. In order to install the valve actuator group for the information.
compression brake to the cylinder head, place the
housing over the mounting studs. Finger tighten (14) Lash setting for compression
the mounting stud nuts and the mounting bolt. brake ......... 0.76 ± 0.08 mm (0.030 ± 0.003 inch)

2. Tighten the nuts, the bolt and flange nuts of each (15) Torque for locknut ........ 15 ± 3 N·m (11 ± 2 lb ft)
valve actuator group in the sequence 9, 12, 8, 10,
7, 13, 11, 9 to standard torque. Refer to Illustration Reference: Refer to Testing and Adjusting,
30 and Illustration 31. “Compression Brake Lash - Adjust” for procedural
information that is related to the adjustment of the
3. Again tighten the nuts, the bolt and flange nuts of compression brake.
each valve actuator group in the sequence 9, 12,
8, 10, 7, 13, 11, 9 to standard torque.
16 SENR9936-06
Specifications Section

i02884389

Turbocharger
SMCS Code: 1052
Part No.: 290-4621
S/N: 5301-Up
Part No.: 290-4621
S/N: 2211-Up
Part No.: 290-4621
S/N: H4C1-Up
Part No.: 277-8418
S/N: EED1-Up
Part No.: 217-6570
S/N: RJG1-Up
Part No.: 277-8419
S/N: JRP1-Up
Part No.: 277-8418
S/N: DLS1-Up

g01436068
Illustration 33
Typical example
Front view
(3) Spacer

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


threads of the six bolts before assembly.

(2) Torque for the eight locknuts ............. 55 ± 9 N·m


(41 ± 7 lb ft)
SENR9936-06 17
Specifications Section

g01436065
Illustration 34
Typical example

(4) Torque for the compressor clamp


assembly .............. 13.5 ± 1.0 N·m (120 ± 9 lb in)

Use the following procedure to tighten the turbine


clamp assembly (5):

1. Tighten the turbine clamp assembly to 18.1 N·m


(160 lb in).

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


(50 lb in).

3. Again tighten the turbine clamp assembly to


13.5 ± 1.0 N·m (120 ± 9 lb in).
18 SENR9936-06
Specifications Section

i02844244

Turbocharger
SMCS Code: 1052
Part No.: 217-5689
S/N: RJG1-Up
Part No.: 217-5689
S/N: BTW1-Up
Part No.: 217-5689
S/N: BWX1-Up

g01434386
Illustration 35
Front view of engine
SENR9936-06 19
Specifications Section

g01434384
Illustration 36
Top view of engine

Note: The oil supply and the oil drain holes should
be in the vertical position with respect to the engine
when the turbocharger group (1) is attached to the
exhaust manifold.

Use the following procedure to tighten the compressor


clamp assembly and the turbine clamp assembly for
the turbocharger group:

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


(125 ± 9 lb in).

2. Lightly tap around the clamp assemblies with a


soft faced hammer.

3. Again tighten the clamp assemblies to 14 ± 1 N·m


(125 ± 9 lb in).

Note: Apply 4C-5599 Anti-Seize Compound on the


threads of the six bolts (3).

(2) Torque for eight locknuts ................... 55 ± 9 N·m


(41 ± 7 lb ft)
20 SENR9936-06
Specifications Section

i02884391

Turbocharger
SMCS Code: 1052
Part No.: 245-9774
S/N: LWA1-Up
Part No.: 245-9774
S/N: Z9K1-Up

g01436070
Illustration 37
Front view
(3) Spacer

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


threads of the six bolts before assembly.

(2) Torque for the eight locknuts ............. 55 ± 9 N·m


(41 ± 7 lb ft)
SENR9936-06 21
Specifications Section

i02884396

Turbocharger
SMCS Code: 1052
Part No.: 294-9711
S/N: JNW1-Up

g01436069
Illustration 38
g01436082
Illustration 39
(4) Torque for the compressor clamp Rear view
assembly .............. 13.5 ± 1.0 N·m (120 ± 9 lb in)
(1) Apply 4C-5599 Anti-Seize Compound to the
Use the following procedure to tighten the turbine threads of the eight bolts before assembly.
clamp assembly (5):
(2) Torque for the eight locknuts ............. 55 ± 9 N·m
1. Tighten the turbine clamp assembly to 18.1 N·m (41 ± 7 lb ft)
(160 lb in).

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


(50 lb in).

3. Again tighten the turbine clamp assembly to


13.5 ± 1.0 N·m (120 ± 9 lb in).

g01436083
Illustration 40

(3) Torque for the compressor clamp


assembly .............. 13.5 ± 1.0 N·m (120 ± 9 lb in)
22 SENR9936-06
Specifications Section

Use the following procedure to tighten the turbine


clamp assembly (4):

1. Tighten the turbine clamp assembly to 18.1 N·m


(160 lb in).

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


(50 lb in).

3. Again tighten the turbine clamp assembly to


13.5 ± 1.0 N·m (120 ± 9 lb in).

i02844349

Turbocharger
SMCS Code: 1052
Part No.: 292-8580
S/N: GEB1-Up
Part No.: 292-8580
S/N: TPB1-Up

g01436071
Illustration 41
Front view

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


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

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


threads of the four bolts before assembly. These
bolts are 3/8-16 X 1 3/4 inches.

(3) Torque for the eight locknuts ............. 55 ± 9 N·m


(41 ± 7 lb ft)
SENR9936-06 23
Specifications Section

g01435716
Illustration 42
Turbocharger group

Note: The oil supply and the oil drain holes should
be in the vertical position with respect to the engine
when the turbocharger group is attached to the
exhaust manifold.

Use the following procedure to tighten the compressor


clamp assembly and the turbine clamp assembly for
the turbocharger group:

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


(125 ± 9 lb in).

2. Lightly tap around the clamp assemblies with a


soft faced hammer.

3. Again tighten the clamp assemblies to 14 ± 1 N·m


(125 ± 9 lb in).
24 SENR9936-06
Specifications Section

i02841625

Exhaust Manifold
SMCS Code: 1059
Part No.: 295-0647
S/N: 5301-Up
Part No.: 295-0647
S/N: 2211-Up
Part No.: 259-6926
S/N: EED1-Up
Part No.: 253-2633, 259-6926
S/N: JRP1-Up
Part No.: 259-6926
S/N: DLS1-Up
Part No.: 253-2633, 259-6926, 291-3026
S/N: BTW1-Up
Part No.: 253-2633, 259-6926, 291-3026
S/N: BWX1-Up

g01417453
Illustration 43
Typical example
SENR9936-06 25
Specifications Section

(1) Install the gaskets so that the “MANIFOLD SIDE”


marking faces away from the cylinder head.

(2) Apply 4C-5599 Anti-Seize Compound on the


threads of the 24 locknuts before assembly.

g01417476
Illustration 44
Exhaust manifold
Tightening sequence for the exhaust manifold

Note: Use a centering tool in at least one oversize


hole per exhaust manifold section in order to align
the exhaust manifolds. Do not remove the centering
tool until removal is required to tighten the locknuts.

Use the following procedure to tighten the exhaust


manifold on the cylinder head:

1. Tighten locknuts 4 through 15 in a numerical


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

2. Again tighten locknuts 4 through 15 in a numerical


sequence to 38 ± 5 N·m (28 ± 4 lb ft).

Note: Apply 4C-5599 Anti-Seize Compound on the


two taperlock studs before assembly.

(3) Torque for two taperlock studs ........... 35 ± 5 N·m


(26 ± 4 lb ft)

(16) Torque for eight clamps ............... 8.5 ± 1.0 N·m


(75 ± 9 lb in)
26 SENR9936-06
Specifications Section

i02843153

Exhaust Manifold
SMCS Code: 1059
Part No.: 217-6686
S/N: EED1-Up
Part No.: 217-6686
S/N: RJG1-Up
Part No.: 217-6686
S/N: BTW1-Up
Part No.: 217-6686
S/N: BWX1-Up

g01417760
Illustration 45
Front view

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


threads of the 24 locknuts before assembly.
SENR9936-06 27
Specifications Section

g01417778
Illustration 46
Exhaust manifold
Tightening sequence for the exhaust manifold

Note: Use a centering tool in at least one oversize


hole per exhaust manifold section in order to align
the exhaust manifolds. Do not remove the centering
tool until removal is required to tighten the locknuts.

Use the following procedure to tighten the exhaust


manifold on the cylinder head:

1. Tighten locknuts 6 through 17 in a numerical


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

2. Again tighten locknuts 6 through 17 in a numerical


sequence to 38 ± 5 N·m (28 ± 4 lb ft).

(2) Coat the female ends of the two exhaust


manifolds with clean engine oil.

Note: Apply 4C-5599 Anti-Seize Compound on the


taperlock studs (3) before assembly.

(3) Torque for two taperlock studs ........... 35 ± 5 N·m


(26 ± 4 lb ft)

(4) Apply a thin coat of 2P-2333 High Temperature


Sealer to the outside diameter of the male ends
of the four exhaust manifolds prior to assembly.
Remove excess sealer from the assembled joint.

(5) Torque for 12 taperlock studs ............ 35 ± 5 N·m


(26 ± 4 lb ft)
28 SENR9936-06
Specifications Section

i02866063

Exhaust Manifold
SMCS Code: 1059
Part No.: 251-1088
S/N: LWA1-Up
Part No.: 251-1088
S/N: H4C1-Up
Part No.: 251-1088
S/N: Z9K1-Up

g01427800
Illustration 47
Front view

(1) Install the 12 gaskets so that the “MANIFOLD Note: Use a centering tool in at least one oversize
SIDE” marking faces away from the cylinder hole per exhaust manifold section in order to align
head. the exhaust manifolds. Do not remove the centering
tool until removal is required to tighten the locknuts.
(2) Torque for the two taperlock studs ..... 35 ± 5 N·m
(26 ± 4 lb ft) Use the following procedure to tighten locknut 4
through locknut 15:
(3) Torque for the eight clamps ........... 8.5 ± 1.0 N·m
(75 ± 9 lb in) Note: Apply 4C-5599 Anti-Seize Compound to the
threads of the 24 locknuts.
SENR9936-06 29
Specifications Section

1. Tighten the locknuts in a numerical sequence to


20 ± 3 N·m (15 ± 2 lb ft).

2. Again tighten the locknuts in a numerical sequence


to 38 ± 5 N·m (28 ± 4 lb ft).

i02843234

Exhaust Manifold
SMCS Code: 1059
Part No.: 283-1004
S/N: JNW1-Up

g01417806
Illustration 48
Orientation of clamps from front view of engine
Tightening sequence for the exhaust manifold

(C) Orientation for the four clamps ... 78 ± 2 degrees Note: Use a centering tool in at least one oversize
hole per exhaust manifold section in order to align
(D) Orientation for the four clamps ... 90 ± 2 degrees the exhaust manifolds. Do not remove the centering
tools until removal is required to tighten the locknuts.
(13) Torque for the eight clamps ......... 8.5 ± 1.0 N·m
(75 ± 9 lb in) Use the following procedure to tighten the locknuts:
30 SENR9936-06
Specifications Section

Note: Apply 4C-5599 Anti-Seize Compound to the


threads of locknuts and to the bearing surface of the
locknuts and the spacers and the washers before
assembly.

1. Tighten locknuts 1 through 12 in a numerical


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

2. Again tighten locknuts 1 through 12 in a numerical


sequence to 38 ± 5 N·m (28 ± 4 lb ft).

i02843368

Exhaust Manifold
SMCS Code: 1059
Part No.: 272-2953
S/N: GEB1-Up
Part No.: 272-2953
S/N: TPB1-Up Illustration 50
g01417902

Tightening sequence for the exhaust manifold

Note: Use a centering tool in at least one oversize


hole per exhaust manifold section in order to align
the exhaust manifolds. Do not remove the centering
tool until removal is required to tighten the locknuts.

Note: Apply 4C-5599 Anti-Seize Compound on the


threads of the 24 locknuts before assembly.

Use the following procedure to tighten the exhaust


manifold on the cylinder head:

1. Tighten locknuts 3 through 14 in a numerical


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

2. Again tighten locknuts 3 through 14 in a numerical


sequence to 38 ± 5 N·m (28 ± 4 lb ft).

(1) Torque for 12 taperlock studs ............ 35 ± 5 N·m


(26 ± 4 lb ft)

(2) Torque for eight clamps ................. 8.5 ± 1.0 N·m


(75 ± 9 lb in)

i02840165

Illustration 49
g01432982 Camshaft
Front view
SMCS Code: 1210
Part No.: 260-9307
S/N: 5301-Up
Part No.: 260-9307
S/N: 2211-Up
Part No.: 260-9307
S/N: LWA1-Up
SENR9936-06 31
Specifications Section

Part No.: 260-9307 (1) The end of the camshaft that is marked “F” must
S/N: GEB1-Up be placed at the front of the engine. Lubricate the
camshaft bearings, the journals, and the lobes
Part No.: 260-9307 with a 50/50 mixture of 8T-2998 Lubricant and
S/N: TPB1-Up clean engine oil.
Part No.: 260-9307
S/N: H4C1-Up
Part No.: 260-9306
S/N: EED1-Up
Part No.: 260-9306
S/N: RJG1-Up
Part No.: 260-9307
S/N: Z9K1-Up
Part No.: 260-9307
S/N: JRP1-Up
Part No.: 260-9306
g01416694
S/N: DLS1-Up Illustration 52
(2) Exhaust lobe
Part No.: 260-9306 (3) Injector lobe
S/N: BTW1-Up (4) Inlet lobe

Part No.: 260-9306 (A) Diameter of camshaft journal .. 84.85 ± 0.02 mm


S/N: JNW1-Up (3.341 ± 0.001 inch)
Part No.: 260-9306
S/N: BWX1-Up

g01416960
Illustration 53

(B) Camshaft lobe lift

Use the following procedure in order to determine


the camshaft lobe lift:

1. Measure the camshaft lobe height (C).

2. Measure the base circle (D).

3. Subtract the base circle measurement in Step


2 from the camshaft lobe height in Step 1. The
difference is the actual camshaft lobe lift (B).

g01427361 Specified camshaft lobe lift


Illustration 51
Inlet lobe ....................... 9.619 mm (0.3787 inch)
Exhaust lobe ................. 8.515 mm (0.3352 inch)
Injector lobe (right bank) ................... 10.337 mm
(0.4070 inch)
32 SENR9936-06
Specifications Section

Injector lobe (left bank) ..................... 10.338 mm i02847540


(0.4070 inch)
Engine Oil Filter Base
The maximum permissible difference between the
actual camshaft lobe lift in Step 3 and the specified SMCS Code: 1306
camshaft lobe lift is 0.13 mm (0.005 inch).
Part No.: 4N-2357
S/N: 5301-Up
Part No.: 4N-2357
S/N: 2211-Up
Part No.: 4N-2357
S/N: LWA1-Up
Part No.: 4N-2357
S/N: H4C1-Up
Part No.: 231-0211, 4N-2357
S/N: EED1-Up
Part No.: 4N-2357
S/N: Z9K1-Up
Part No.: 231-0211, 4N-2357
S/N: JRP1-Up
Part No.: 231-0211, 4N-2357
S/N: DLS1-Up
Part No.: 4N-2357
S/N: BTW1-Up
Part No.: 231-0211, 4N-2357
S/N: JNW1-Up
Part No.: 4N-2357
S/N: BWX1-Up

g01419688
Illustration 54
(1) Oil filter base assembly
(2) Fluid sampling valve
(3) Oil supply line (unfiltered oil)
(5) Oil cooler bypass valves
(6) Oil return line (filtered oil)

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

(7) Lubricate the seal of the engine oil filter element


assembly with clean engine oil.
SENR9936-06 33
Specifications Section

i02848619

Engine Oil Filter Base


SMCS Code: 1306
Part No.: 216-0819
S/N: GEB1-Up
Part No.: 216-0819
S/N: TPB1-Up
Part No.: 216-0819
S/N: RJG1-Up

g01419678
Illustration 55

(A) Length for applying 154-9731 Thread Lock


Compound to the threads of the hollow
stud ................. 10.2 ± 1.5 mm (0.40 ± 0.06 inch)

(8) Torque for the hollow stud ............... 80 ± 14 N·m


(60 ± 10 lb ft)

g01432945
Illustration 56
Left side view of engine
34 SENR9936-06
Specifications Section

(D) Length for applying 154-9731 Thread Lock


Compound on the two taperlock studs ...... 8 mm
(0.3 inch)

(5) Torque for two taperlock studs ......... 80 ± 15 N·m


(60 ± 11 lb ft)

i02847457

Engine Oil Pump


SMCS Code: 1304
Part No.: 116-1980
S/N: 5301-Up
Part No.: 116-1980
S/N: 2211-Up
Part No.: 116-1980
S/N: LWA1-Up
Part No.: 116-1980
S/N: H4C1-Up
Part No.: 116-1980
S/N: EED1-Up
Part No.: 116-1980
g01432946 S/N: RJG1-Up
Illustration 57
Front view of engine
Part No.: 116-1980
S/N: Z9K1-Up
(1) Lubricate the bore of the O-ring seal lightly with
lubricant that is being sealed. Part No.: 116-1980
S/N: JRP1-Up
Use the following procedure to tighten the bolts:
Part No.: 116-1980
1. Torque bolts (4) to 47 ± 9 N·m (35 ± 7 lb ft). S/N: DLS1-Up

2. Torque bolts (2) to 5 ± 3 N·m (45 ± 27 lb in). Part No.: 116-1980


S/N: BTW1-Up
3. Torque bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft). Part No.: 116-1980
S/N: JNW1-Up
4. Again torque bolts (2) to 47 ± 9 N·m (35 ± 7 lb ft).
Part No.: 116-1980
S/N: BWX1-Up

g01420429
Illustration 58
Section C-C
SENR9936-06 35
Specifications Section

g01419620
Illustration 60
Oil pump body

(E) Extension of dowel from the oil pump


body .................. 6.4 ± 0.5 mm (0.25 ± 0.02 inch)

Illustration 59
g01419619 (F) Installation depth for sleeve bearing
.................. 0.30 ± 0.25 mm (0.012 ± 0.010 inch)
(A) Diameters of the shafts
Oil pump drive shaft for the pump drive shaft
assembly ............................. 22.217 ± 0.005 mm
(0.8747 ± 0.0002 inch)
Oil pump drive shaft for the idler shaft
assembly ............................. 22.217 ± 0.005 mm
(0.8747 ± 0.0002 inch)

(B) Dimensions for the gears


Length of new gears .......... 140.000 ± 0.025 mm
(5.5118 ± 0.0010 inch)
Depth of bores in oil pump body for new
gears .................................. 140.127 ± 0.020 mm
(5.5168 ± 0.0008 inch) g01419634
Illustration 61
Oil pump cover
(1) 2S-2760 Spring
(D) Position of bearing joint from the centerline
Length under test force .. 117.14 mm (4.612 inch)
through bearing bores .............. 30 ± 15 degrees
Test force .................. 499 ± 24 N (112.2 ± 5.4 lb)
Approximate free length after test .... 152.91 mm
Note: The sleeve bearings should be installed so
(6.020 inch)
that the edge of the bearing is flush with the outside
Outside diameter ............ 27.00 mm (1.063 inch)
of the oil pump body. The sleeve bearings should
also be installed so that the edge of the bearing is
Note: The 2S-2760 Spring is for the relief of oil
flush with face (2).
pressure.
36 SENR9936-06
Specifications Section

i02857697

Engine Oil Pump


SMCS Code: 1304
Part No.: 7C-1772
S/N: GEB1-Up
Part No.: 7C-1772
S/N: TPB1-Up
Part No.: 7C-1772
S/N: RJG1-Up

g01422622
Illustration 62

Depth of bores for pump


NOTICE gears .................................... 65.197 ± 0.020 mm
Before operation, the pump must be lubricated with (2.5667 ± 0.0008 inch)
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result. (E) Diameter of a new shaft for the drive shaft
assembly ............................. 22.217 ± 0.005 mm
(0.8747 ± 0.0002 inch)
(B) Diameter of a new shaft for the drive shaft
assembly ............................. 20.320 ± 0.005 mm (F) Diameter of a new shaft for the idler shaft
(0.8000 ± 0.0002 inch) assembly ............................. 22.217 ± 0.005 mm
(0.8747 ± 0.0002 inch)
(C) Diameter of a new shaft for the idler shaft
assembly ............................. 20.320 ± 0.005 mm (G) Dimensions for new gears
(0.8000 ± 0.0002 inch)
Length of new gears ............ 79.375 ± 0.025 mm
(D) Dimensions for new pump gears (3.1250 ± 0.0010 inch)
Length of pump gears .............. 65.07 ± 0.05 mm
(2.562 ± 0.002 inch)
SENR9936-06 37
Specifications Section

Depth of bores for new Oil Pump Spacer Assembly (3)


gears .................................... 79.502 ± 0.020 mm
(3.1300 ± 0.0008 inch)

(1) 236-6733 Spring


Length under test force ... 82.87 mm (3.263 inch)
Test force .................. 709 ± 35 N (159.4 ± 7.9 lb)
Approximate free length after test ......... 130 mm
(5.1 inch)
Outside diameter ............ 27.00 mm (1.063 inch)

Pump Body (2)

g01423433
Illustration 64

(K) Installation depth for the two sleeve


bearings ............................ 0.76 mm (0.030 inch)

(5) The two sleeve bearings should be located with


the oil holes on the horizontal centerline slots.

Oil Pump Body (4)

g01423414
Illustration 63

(H) Installation depth for the two sleeve


bearings ............................ 1.52 mm (0.060 inch)

(J) Position of bearing joint from the centerline


through bearing bores .............. 30 ± 15 degrees

g01423468
Illustration 65
38 SENR9936-06
Specifications Section

(L) Position of bearing joint from the centerline


through bearing bores .............. 30 ± 15 degrees

(N) Projection of dowel from the surface of the oil


pump body ........ 6.4 ± 0.5 mm (0.25 ± 0.02 inch)

(P) Installation depth for the two sleeve


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

i02865988

Engine Oil Bypass Valve


SMCS Code: 1306-BV
Part No.: 316-5686
S/N: 5301-Up
Part No.: 316-5686
S/N: 2211-Up
Part No.: 225-9619
S/N: LWA1-Up
Part No.: 225-9619
S/N: H4C1-Up
Part No.: 231-0211
S/N: EED1-Up
Part No.: 225-9619
S/N: Z9K1-Up
Part No.: 231-0211
S/N: JRP1-Up
Part No.: 231-0211 Illustration 66
g01427693
S/N: DLS1-Up Typical example
Part No.: 225-9619 Right side view of engine
S/N: BTW1-Up
Note: Check the valve and the valve seat for
Part No.: 231-0211 abnormal contact patterns.
S/N: JNW1-Up
(1) The 9M-0853 Valve Plunger is for the oil filter
Part No.: 225-9619 bypass valve.
S/N: BWX1-Up
(2) The 9F-6304 Spring is for the oil filter bypass
valve.
Length under test force ... 53.98 mm (2.125 inch)
Test force ............. 145 to 160 N (32.3 to 35.7 lb)
Free length after test .... 105.56 mm (4.156 inch)
Outside diameter ............ 20.65 mm (0.813 inch)
SENR9936-06 39
Specifications Section

i02865980

Engine Oil Bypass Valve


SMCS Code: 1306-BV
Part No.: 266-9446
S/N: GEB1-Up
Part No.: 266-9446
S/N: TPB1-Up
Part No.: 216-0810
S/N: RJG1-Up

g01427688
Illustration 67
Typical example
Right side view

Note: Check the valve and the valve seat for


abnormal contact patterns.

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


bypass valve.

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


valve.
Length under test force ... 53.98 mm (2.125 inch)
Test force ............. 145 to 160 N (32.3 to 35.7 lb)
Free length after test .... 105.56 mm (4.156 inch)
Outside diameter ............ 20.65 mm (0.813 inch)
40 SENR9936-06
Specifications Section

i02855050

Engine Oil Pan


SMCS Code: 1302
Part No.: 291-1432
S/N: 5301-Up
Part No.: 291-1432
S/N: 2211-Up
Part No.: 291-1432
S/N: H4C1-Up

g01422063
Illustration 68
Typical example
Right side view

Use the following procedure to tighten the bolts for 1. Tighten the bolts in the numerical sequence to
the oil pan: 47 ± 9 N·m (35 ± 7 lb ft).
SENR9936-06 41
Specifications Section

2. Again tighten the bolts in the numerical sequence (3) After assembly, trim off excess gasket material
to 47 ± 9 N·m (35 ± 7 lb ft). from outside of assembled joint.

Note: Lubricate the threads of the drain plug lightly


with clean engine oil before assembly.

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


(50 ± 7 lb ft)

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

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

Bolts (5) are 3/8-16 X 4 1/4 inches.

Bolts (6) are 3/8-16 X 1 3/8 inches.


g01427674
Illustration 69 The remaining oil pan bolts are 3/8-16 X 1 1/4 inches.
Detail of the oil pan gasket joint

(41) Apply sealant below the four ball and socket


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

i02857775

Engine Oil Pan


SMCS Code: 1302
Part No.: 119-8582
S/N: RJG1-Up

g01433353
Illustration 70
42 SENR9936-06
Specifications Section

i02879916 (3) After assembly, trim off excess gasket material


from outside of assembled joint.
Engine Oil Pan
Bolts (1) are 3/8-16 X 2 3/4 inches.
SMCS Code: 1302
Bolts (4) are 3/8-16 X 4 1/4 inches.
Part No.: 266-9450
S/N: GEB1-Up
Bolts (5) are 3/8-16 X 1 3/8 inches.
Part No.: 266-9450
S/N: TPB1-Up The remaining oil pan bolts are 3/8-16 X 1 1/4 inches.

i02799191

Water Temperature Regulator


SMCS Code: 1355
Part No.: 248-5513

g01056598
Illustration 72
Typical example
(1) Seal

(2) Water temperature regulator


Opening temperature ........................ 81 to 84 °C
(178 to 183 °F)
Fully open temperature ................ 92 °C (198 °F)
Minimum stroke at fully open
temperature ........................ 10.4 mm (0.41 inch)

i02798334

Water Pump
SMCS Code: 1361

Illustration 71
g01433751 Part No.: 230-4172
S/N: 5301-Up
Note: Lubricate the threads of the drain plug lightly Part No.: 230-4172
with clean engine oil before assembly. S/N: 2211-Up
(2) Torque for the drain plug .................. 70 ± 10 N·m Part No.: 230-4172
(50 ± 7 lb ft) S/N: LWA1-Up
Part No.: 230-4172
S/N: GEB1-Up
SENR9936-06 43
Specifications Section

Part No.: 230-4172 (A) Diameter of the water pump


S/N: TPB1-Up shaft ..................................... 19.100 ± 0.010 mm
(0.7520 ± 0.0004 inch)
Part No.: 230-4172
S/N: H4C1-Up Maximum air leakage per minute with an air pressure
test of 140 kPa (20 psi)
Part No.: 4N-5837
S/N: EED1-Up Water side .................................. 10 cc (0.6 cu in)
Side with oil ............................... 24 cc (1.5 cu in)
Part No.: 230-4172
S/N: RJG1-Up
i02899215
Part No.: 230-4172
S/N: Z9K1-Up Cylinder Block
Part No.: 230-4172
SMCS Code: 1201
S/N: JRP1-Up
Part No.: 253-9882
Part No.: 4N-5837
S/N: 5301-Up
S/N: DLS1-Up
Part No.: 253-9882
Part No.: 4N-5837
S/N: 2211-Up
S/N: BTW1-Up
Part No.: 253-9882
Part No.: 4N-5837
S/N: LWA1-Up
S/N: JNW1-Up
Part No.: 253-9882
Part No.: 4N-5837
S/N: GEB1-Up
S/N: BWX1-Up
Part No.: 253-9882
S/N: TPB1-Up
Part No.: 253-9882
S/N: H4C1-Up
Part No.: 237-0842
S/N: EED1-Up
Part No.: 237-0842
S/N: RJG1-Up
Part No.: 253-9882
S/N: Z9K1-Up
Part No.: 253-9882
S/N: JRP1-Up
Part No.: 237-0842
S/N: DLS1-Up
Part No.: 237-0842
S/N: BTW1-Up
g01398145
Illustration 73
Part No.: 237-0842
S/N: JNW1-Up
Note: Do not install the lip type seal (1) by hand. Use
the installation tool and a press to install the lip type Part No.: 237-0842
seal. Make sure that the primary lip is toward the S/N: BWX1-Up
water pump drive gear. Press the lip type seal until
the lip type seal is flush into the counterbore.

Note: Use the installation tool to install the seal


group (2). Press the seal group onto the shaft until
the stationary cup of the seal group is fully seated in
the pump housing.

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


44 SENR9936-06
Specifications Section

(D) Bore in cylinder block for main


bearing ............................... 129.891 ± 0.013 mm
(5.1138 ± 0.0005 inch)

(E) Dimensions for main bearing cap


The width of the slot for the main bearing
caps ...... 236.00 ± 0.05 mm (9.291 ± 0.002 inch)
Width of main bearing cap .. 235.500 ± 0.025 mm
(9.2716 ± 0.0010 inch)

g01403680
Illustration 75
Right side of the engine
g01443593
Illustration 74
Front of the engine
(F) Extension of dowels from the rear face of the
cylinder block and from the front face of the
Note: Apply 6V-6640 Sealant to the pipe threads cylinder block .. 19.0 ± 0.5 mm (0.75 ± 0.02 inch)
of stud (1). Tighten the stud with the coated pipe
Note: The main bearing caps (7) must be installed
threads into the cylinder block.
with the identifying marks toward the front of the
(4) Torque for three taperlock studs ........ 35 ± 5 N·m engine. The number of the main bearing cap (7) must
also match the cast number on the left side of each
(26 ± 4 lb ft)
main bearing saddle.
Note: The top face of the cylinder block, both sides
Use the following procedure to install the main
of plate gasket (3) and bottom surface of spacer plate
(2) must be free of fuel, oil, water, gasket adhesives, bearing caps:
assembly compounds and any other contaminants
during assembly.

(A) Thickness of the spacer


plates ..................................... 8.585 ± 0.025 mm
(0.3380 ± 0.0010 inch)

(B) Thickness of plate gasket that is between cylinder


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

(C) Extension of the dowels on the left bank and right


bank from the cylinder block ....... 18.5 ± 0.5 mm
(0.73 ± 0.02 inch)
g01398970
Illustration 76
Note: Apply 5P-3413 Pipe Sealant on the threads of
the taperlock plugs (5) before assembly. Marks for tightening main bearings

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


(60 ± 11 lb ft)
SENR9936-06 45
Specifications Section

1. Apply clean engine oil on the threads of the main (J) The distance from the centerline of the crankshaft
bearing cap bolts (8). Loosely install the main bearing bore to the bottom of the cylinder block
bearing cap bolts (8). .............. 165.10 ± 0.10 mm (6.500 ± 0.004 inch)

2. Apply clean engine oil on the threads of the side


i02788282
bolts (6) and the washers. Loosely install the side
bolts and the washers. Cylinder Liner
3. Tighten the main bearing cap bolts (8) first on the SMCS Code: 1216
main bearing tab side of the main bearing cap (7)
to 258 ± 14 N·m (190 ± 10 lb ft). Part No.: 197-9322
S/N: EED1-Up
4. Tighten the main bearing cap bolts (8) that are
opposite the main bearing tab side of the main Part No.: 197-9322
bearing cap (7) to 258 ± 14 N·m (190 ± 10 lb ft). S/N: RJG1-Up

5. Put a mark on each main bearing cap bolt (8) and Part No.: 197-9322
each main bearing cap (7). See Illustration 76. S/N: DLS1-Up
Part No.: 197-9322
6. Tighten the main bearing cap bolts (8) that are S/N: BTW1-Up
placed opposite the main bearing tab side of the
main bearing cap (7) from the mark by angle (G) Part No.: 197-9322
of 120 ± 5 degrees. S/N: JNW1-Up

7. Tighten the main bearing cap bolts (8) that are Part No.: 197-9322
placed on the main bearing tab side of the main S/N: BWX1-Up
bearing cap (7) from the mark by angle (G) of 120
± 5 degrees.

8. Tighten the side bolts (6) that are opposite the


main bearing tab side of the main bearing cap (7)
to 80 ± 10 N·m (60 ± 7 lb ft).

9. Tighten the side bolts (6) that are placed on the


main bearing tab side of the main bearing cap (7)
to 80 ± 10 N·m (60 ± 7 lb ft).

g01392812
Illustration 78
(1) Filler band

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


(5.4010 ± 0.0010 inch)

(B) Flange
Thickness .............................. 8.890 ± 0.020 mm
(0.3500 ± 0.0008 inch)
Minimum thickness ....... 8.870 mm (0.3492 inch)

Use the following procedure to install the cylinder


liner:

1. Put liquid soap on the cylinder block liner bore


surfaces and the rubber seals that are on the
g01398978
Illustration 77 lower end of the cylinder liner.

(H) The distance from the centerline of the 2. Dip the filler band completely in clean engine oil.
crankshaft bearing bore to the top of the cylinder
block ... 419.10 ± 0.15 mm (16.500 ± 0.006 inch)
46 SENR9936-06
Specifications Section

3. Immediately install the filler band in the groove Thickness of flange on cylinder
that is under the cylinder liner flange. liner ........... 8.89 ± 0.02 mm (0.350 ± 0.001 inch)
Minimum thickness ....... 8.870 mm (0.3492 inch)
4. Install the cylinder liner into the cylinder block
before the expansion of the filler band. Use the following procedure to install the cylinder
liner:
Note: Refer to Guideline For Reusable Parts and
Salvage Operations, SEBF8068, “Cylinder Liners” for 1. Apply liquid soap on the cylinder block liner bore
more information. Also, refer to Reuse And Salvage surfaces and the rubber seals that are on the
Guidelines, SEBF8049, “Visual Inspection of the lower end of the cylinder liner.
Piston” for more information.
2. Dip the filler band (2) completely in clean engine
oil.
i02801040

Cylinder Liner 3. Immediately install the filler band in the groove


that is under the flange.
SMCS Code: 1216
4. Install the cylinder liner into the cylinder block
Part No.: 253-8766 before the expansion of the filler band.
S/N: 5301-Up
Note: Refer to Reuse And Salvage Guidelines,
Part No.: 253-8766 SEBF8049, “Visual Inspection of the Piston” for more
S/N: 2211-Up information. Also, refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8068, “Cylinder
Part No.: 253-8766
Liners” for more information.
S/N: LWA1-Up
Part No.: 253-8766
S/N: GEB1-Up
Part No.: 253-8766
S/N: TPB1-Up
Part No.: 253-8766
S/N: H4C1-Up
Part No.: 253-8766
S/N: Z9K1-Up
Part No.: 253-8766
S/N: JRP1-Up

g01399536
Illustration 79

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


(5.7086 ± 0.0010 inch)

(B) Dimensions for flange (1)


SENR9936-06 47
Specifications Section

i02801044

Crankshaft
SMCS Code: 1202
Part No.: 224-3250
S/N: 5301-Up
Part No.: 224-3250
S/N: 2211-Up
Part No.: 224-3250
S/N: LWA1-Up
Part No.: 224-3250
S/N: GEB1-Up
Part No.: 224-3250
S/N: TPB1-Up
Part No.: 224-3250
S/N: H4C1-Up
Part No.: 225-6052
S/N: EED1-Up
Part No.: 225-6052
S/N: RJG1-Up
Part No.: 224-3250
S/N: Z9K1-Up
Part No.: 224-3250
S/N: JRP1-Up
Part No.: 225-6052
S/N: DLS1-Up
Part No.: 225-6052
S/N: BTW1-Up
Part No.: 225-6052
S/N: JNW1-Up
Part No.: 225-6052
S/N: BWX1-Up

Note: To measure a crankshaft that may be bent, a


procedure must be followed. Refer to the Guideline
For Reusable Parts And Salvage Operations,
SEBF8054, “Procedure to Measure and Straighten
Bent Crankshafts” for the correct procedure.
48 SENR9936-06
Specifications Section

g01399550
Illustration 80
Typical example
(3) Main journal (4) Rod journal

Note: Thrust plates (1) are used on the center main Note: The seal and the sleeve can not be used if the
bearing only. seal and the sleeve have been separated.

(A) Thickness of new thrust plate .... 5.74 ± 0.04 mm Note: The sleeve must be flush with the front face of
(0.226 ± 0.002 inch) the crankshaft within 0.13 mm (0.005 inch).

Note: Check assembled installation depth with the


crankshaft in any axial position.

(B) Assembled installation depth ... 4.68 to 5.28 mm


(0.184 ± 0.208 inch)

(C) Maximum extension of dowel from the crankshaft


face ....................................... 8.4 mm (0.33 inch)

(E) End play


New crankshaft ......................... 0.10 to 0.60 mm
(0.004 to 0.024 inch)
Maximum end play with used bearings .. 0.89 mm
(0.035 inch)

(2) The crankshaft gear must be installed on the


crankshaft with the timing mark “V” on the outside
of the crankshaft.

(3), (4) Refer to the Specifications, “Connecting Rod g01399556


and Main Bearing Journals” for more information. Illustration 81
View D-D
Note: The seal and the sleeve should not be used if
the seal and the sleeve have been separated. (F) Extension of the dowel from the surface of the
crankshaft ......... 4.1 ± 0.5 mm (0.16 ± 0.02 inch)
(5) The front crankshaft seal is installed on the
front of the crankshaft. The seal driver can not
contact the seal inside a 177.80 ± 0.25 mm
(7.000 ± 0.010 inch) diameter.
SENR9936-06 49
Specifications Section

i02287333 i02866012

Crankshaft Seals Vibration Damper


SMCS Code: 1160; 1161 SMCS Code: 1205
Part No.: 142-5867 Part No.: 6N-2229
S/N: EED1-Up
Part No.: 6N-2229
S/N: RJG1-Up
Part No.: 6N-2229
S/N: Z9K1-Up
Part No.: 6N-2229
S/N: JRP1-Up
Part No.: 6N-2229
S/N: DLS1-Up
Part No.: 6N-2229
S/N: BTW1-Up
Part No.: 6N-2229
S/N: BWX1-Up

g01144821
Illustration 82

(1) Front crankshaft seal

The front seal should be installed even with


the front of the crankshaft with the following
tolerance. ...................................... −0.13 to 0.13 mm
(−0.005 to 0.005 inch)

The seal driver should not contact the seal within the
following diameter. ....................... 177.80 ± 0.25 mm
g01427717
(7.000 ± 0.010 inch) Illustration 83
(1) Damper adapter
(2) Rear crankshaft seal (2) Damper

Install the rear seal to the following distance from the (3) Torque for 12 bolts .. 135 ± 20 N·m (100 ± 15 lb ft)
end of the crankshaft. .......................... 1.5 ± 0.5 mm
(0.06 ± 0.02 inch)

The seal driver should not contact the seal within the
following diameter. ....................... 177.80 ± 0.25 mm
(7.000 ± 0.010 inch)

Note: Do not separate the seal from the sleeve.


Replace the seal if the seal is separated from the
sleeve.

Note: The assembled installation depth may be


checked with the crankshaft in any axial position.
50 SENR9936-06
Specifications Section

i02866018 i02856619

Vibration Damper Vibration Damper


SMCS Code: 1205 SMCS Code: 1205
Part No.: 259-3105 Part No.: 263-5259
S/N: JRP1-Up S/N: BTW1-Up
Part No.: 263-5259
S/N: JNW1-Up
Part No.: 263-5259
S/N: BWX1-Up

g01427740
Illustration 84
(1) Damper
(2) Damper adapter

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


g01248941
Illustration 85
(1) Damper
(2) Crankshaft pulley

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


SENR9936-06 51
Specifications Section

i02866033 i02866067

Vibration Damper Vibration Damper


SMCS Code: 1205 SMCS Code: 1205
Part No.: 257-8730 Part No.: 298-3542
S/N: 5301-Up S/N: GEB1-Up
Part No.: 257-8730 Part No.: 298-3542
S/N: 2211-Up S/N: TPB1-Up
Part No.: 257-8730
S/N: LWA1-Up
Part No.: 257-8730
S/N: H4C1-Up
Part No.: 257-8730
S/N: Z9K1-Up

g01427778
Illustration 87
(1) Dampers
(3) Damper adapter

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

g01427752
Illustration 86
(1) Damper adapter
(2) Dampers

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


52 SENR9936-06
Specifications Section

i02776231 i02776201

Connecting Rod Bearing Main Bearing Journal


Journal SMCS Code: 1202; 1203
SMCS Code: 1202; 1219; 1225 Part No.: 219-4454
S/N: 5301-Up
Part No.: 219-4454
S/N: 5301-Up Part No.: 219-4454
S/N: 2211-Up
Part No.: 219-4454
S/N: 2211-Up Part No.: 219-4454
S/N: LWA1-Up
Part No.: 219-4454
S/N: LWA1-Up Part No.: 219-4454
S/N: GEB1-Up
Part No.: 219-4454
S/N: GEB1-Up Part No.: 219-4454
S/N: TPB1-Up
Part No.: 219-4454
S/N: TPB1-Up Part No.: 219-4454
S/N: H4C1-Up
Part No.: 219-4454
S/N: H4C1-Up Part No.: 219-4453
S/N: EED1-Up
Part No.: 219-4453
S/N: EED1-Up Part No.: 219-4453
S/N: RJG1-Up
Part No.: 219-4453
S/N: RJG1-Up Part No.: 219-4454
S/N: Z9K1-Up
Part No.: 219-4454
S/N: Z9K1-Up Part No.: 219-4454
S/N: JRP1-Up
Part No.: 219-4454
S/N: JRP1-Up Part No.: 219-4453
S/N: DLS1-Up
Part No.: 219-4453
S/N: DLS1-Up Part No.: 219-4453
S/N: BTW1-Up
Part No.: 219-4453
S/N: BTW1-Up Part No.: 219-4453
S/N: JNW1-Up
Part No.: 219-4453
S/N: JNW1-Up Part No.: 219-4453
S/N: BWX1-Up
Part No.: 219-4453
S/N: BWX1-Up
Refer to Guideline For Reusable Parts And Salvage
Table 1
Operations, SEBF8009, “Main and Connecting Rod
Bearings” and Guideline For Reusable Parts and
Diameter of Crankshaft Journal (Bearing Salvage Operations, SEBF8041, “Specifications for
Surface) For Connecting Rod Crankshaft in Caterpillar Engines”.
Original Size Journal 97.028 ± 0.020 mm
(3.8200 ± 0.0008 inch) Table 2
Main Bearing Journals
Clearance between new bearing and new 120.650 ± 0.020 mm
journal ... 0.070 to 0.178 mm (0.0028 to 0.0070 inch) Original Size Journal
(4.7500 ± 0.0008 inch)
Undersize Journal 120.015 ± 0.020 mm
0.63 mm (0.025 inch) (4.7250 ± 0.0008 inch)
Undersize Journal 119.380 ± 0.020 mm
1.27 mm (0.050 inch) (4.7000 ± 0.0008 inch)
SENR9936-06 53
Specifications Section

Main bearing cap with two bolts i02801090

Clearance between new bearing and new Connecting Rod


journal ................................... 0.076 to 0.186 mm
(0.0030 to 0.0073 inch) SMCS Code: 1218

Main bearing cap with four bolts Part No.: 319-6714


S/N: 5301-Up
Clearance between new bearing and new
journal ................................... 0.071 to 0.178 mm Part No.: 319-6714
(0.0028 to 0.0070 inch) S/N: 2211-Up

Table 3
Part No.: 319-6714
S/N: LWA1-Up
Main Bearing Bore
Part No.: 319-6714
Original Size of the Bore 129.891 ± 0.013 mm
(5.1138 ± 0.0005 inch)
S/N: GEB1-Up
In the Block
Oversize Bore 0.63 mm 130.526 ± 0.013 mm Part No.: 319-6714
(0.025 inch) (5.1388 ± 0.0005 inch) S/N: TPB1-Up
Part No.: 319-6714
S/N: H4C1-Up
Part No.: 213-4836
S/N: EED1-Up
Part No.: 213-4836
S/N: RJG1-Up
Part No.: 319-6714
S/N: Z9K1-Up
Part No.: 239-6144
S/N: JRP1-Up
Part No.: 213-4836
S/N: DLS1-Up
Part No.: 213-4836
S/N: BTW1-Up
Part No.: 213-4836
S/N: JNW1-Up
Part No.: 213-4836
S/N: BWX1-Up

g01318414
Illustration 88
Tightening sequence, and index mark for torque-turn process
(1),(2),(3),(4) Bolts for rod cap
54 SENR9936-06
Specifications Section

Note: The connecting rods should be installed in the


engine so that the part number of the forging for the
rod assembly is facing the connecting rod that is on
the same crankshaft pin. The opposite side of the
connecting rods will face the thrust surface of the
crankshaft journal.

Use the following procedure for tightening the bolts


for the rod cap:

1. Prior to assembly, lubricate the threads of the


bolts and the seating face of the bolt heads with
clean engine oil.

2. Finger tighten all of the bolts.

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

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

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


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

5. Tighten bolts (2) and (4) by an additional angle


(A) of 60 ± 5 degrees.

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


g01399607
(50 ± 3 lb ft). Illustration 89
(6) Bearing for piston pin
7. Tighten bolts (1) and (3) by an additional angle
(A) of 60 ± 5 degrees. (5) Connecting rod
(B) Inside diameter of connecting rod of bearing
for the piston pin ............ 64.592 ± 0.013 mm
(2.5430 ± 0.0005 inch)
(C) Distance between the center of the bore for
the bearing for piston pin and the center of the
bore for the crankshaft journal .... 274.91 mm
(10.823 inch)
(D) Inside diameter of connecting rod
for the crankshaft journal after the
bearing for connecting rod has been
installed and the bolts have been
torqued. ....................... 103.500 ± 0.013 mm
(4.0748 ± 0.0005 inch)
SENR9936-06 55
Specifications Section

g01399634 g01401199
Illustration 90 Illustration 91
(7) Oil jet tube assembly
Note: The bearing joint must be located within area
(E) along the horizontal centerline of the piston pin (8) Torque for the special bolt of oil jet tube
bore. assembly ....................... 25 ± 6 N·m (18 ± 4 lb ft)

(F) Maximum angle from the horizontal


centerline ......................................... ± 5 degrees i02856149

Note: The bore of bearing for piston pin must be Piston and Rings
machined after installation into the connecting rod.
SMCS Code: 1214; 1215
(G) Outside diameter of bearing for piston Part No.: 213-4836
pin before installation into the connecting S/N: EED1-Up
rod .. 64.717 ± 0.013 mm (2.5479 ± 0.0005 inch)
Part No.: 213-4836
(H) Dimensions for piston pin S/N: RJG1-Up
Bore diameter of bearing for the piston pin after Part No.: 213-4836
machining ............................ 60.035 ± 0.008 mm S/N: DLS1-Up
(2.3636 ± 0.0003 inch)
Part No.: 213-4836
Diameter of piston pin .......... 59.975 ± 0.005 mm S/N: BTW1-Up
(2.3612 ± 0.0002 inch)
Part No.: 213-4836
Note: Apply heat to the connecting rod prior to S/N: JNW1-Up
installation of bearing for piston pin. Do not use a
Part No.: 213-4836
torch to heat the connecting rod.
S/N: BWX1-Up
(J) Maximum length for heating the connecting
rod during the installation of bearing for piston
pin ............................................ 95 mm (3.7 inch)

Temperature for heating for connecting


rod .............................. 175 to 260 °C (347 to 500 °F)

g01391600
Illustration 92

Note: Refer to Guideline for Reusable Parts for


information on the pistons, the piston pins, and the
retaining rings.
56 SENR9936-06
Specifications Section

The 1U-6431 Piston Ring Groove Gauge Gp is Clearance between groove and oil control piston
used for measuring the ring grooves in keystone ring .......................................... 0.05 mm (0.002 inch)
style pistons. Refer to the Special Instruction that is
supplied with the piston ring groove gauge group. When a new piston ring is installed in a cylinder liner
with a bore of 137.16 mm (5.400 inch), the clearance
The 5P-3519 Piston Ring Groove Gauge Gp is between the ends of the piston ring is the following
available for checking the ring grooves with straight value: .............. 0.55 ± 0.15 mm (0.022 ± 0.006 inch)
sides. Refer to the Guideline for Reusable Parts for
instructions on the piston ring groove gauge group. Increase in the clearance between the ends of the
piston ring for each 0.03 mm (0.001 inch) increase in
Note: Lubricate the entire piston in zone (A) with the cylinder liner bore ............. 0.08 mm (0.003 inch)
clean engine oil prior to assembly into the cylinder
block. Note: After the piston rings have been installed,
rotate the piston rings so that the end gaps are 120
degrees from each other.
Top Piston Ring (1)
Install the piston ring with the side marked “UP-1” Piston Pin Bore (4)
toward the top of the piston. The red stripe faces to
the right of the piston ring end gap. Note: Thoroughly lubricate the piston pin with clean
engine oil before the piston is inserted into the piston
When a new piston ring is installed in a cylinder liner and the rod assembly.
with a bore of 137.16 mm (5.400 inch), the clearance
between the ends of the piston ring is the following Diameter of the bore in the finished bearing that
value: .............. 0.40 ± 0.10 mm (0.016 ± 0.004 inch) is installed into the piston skirt for the piston
pin .. 60.0925 ± 0.0075 mm (2.36584 ± 0.00030 inch)
Increase in the clearance between the ends of the
piston ring for each 0.03 mm (0.001 inch) increase in Diameter of the new piston pin .. 59.975 ± 0.005 mm
the cylinder liner bore ............. 0.08 mm (0.003 inch) (2.3612 ± 0.0002 inch)

Intermediate Piston Ring (2)


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

When a new piston ring is installed in a cylinder liner


with a bore of 137.16 mm (5.400 inch), the clearance
between the ends of the piston ring is the following
value: ...... 0.770 ± 0.125 mm (0.0303 ± 0.0049 inch)

Increase in the clearance between the ends of the


piston ring for each 0.03 mm (0.001 inch) increase in
the cylinder liner bore ............. 0.08 mm (0.003 inch)

Oil Control Piston Ring (3)


The ends of the oil control piston ring should be a
distance of 180 degrees from the ring end gap when
the oil control piston ring is assembled. The white
colored portion of the piston ring must be visible at
the ring end gap.

Width of groove in new piston for oil control piston


ring .......... 4.030 ± 0.010 mm (0.1587 ± 0.0004 inch)

Thickness of new oil control piston


ring .......... 3.980 ± 0.010 mm (0.1567 ± 0.0004 inch)
SENR9936-06 57
Specifications Section

i02856206 Top Piston Ring (1)


Piston and Rings Install the piston ring with the side marked “UP-1”
toward the top of the piston. The purple colored stripe
SMCS Code: 1214; 1215 faces to the right of the piston ring end gap.
Part No.: 319-6714
S/N: 5301-Up When a new piston ring is installed in a cylinder
liner with a bore of 145 mm (5.7 inch), the clearance
Part No.: 319-6714 between the ends of the piston ring is the following
S/N: 2211-Up value: .............. 0.40 ± 0.10 mm (0.016 ± 0.004 inch)

Part No.: 319-6714 Increase in clearance between the ends of the piston
S/N: LWA1-Up rings for each 0.030 mm (0.0012 inch) increase in the
cylinder liner bore ................... 0.08 mm (0.003 inch)
Part No.: 319-6714
S/N: GEB1-Up
Intermediate Piston Ring (2)
Part No.: 319-6714
S/N: TPB1-Up Install the piston ring with the side marked “UP-2”
toward the top of the piston. The white colored stripes
Part No.: 319-6714 face to the right of the piston ring end gap.
S/N: H4C1-Up
Part No.: 319-6714 When a new piston ring is installed in a cylinder
S/N: Z9K1-Up liner with a bore of 145 mm (5.7 inch), the clearance
between the ends of the piston ring is the following
Part No.: 239-6144 value: ...... 0.600 ± 0.125 mm (0.0236 ± 0.0049 inch)
S/N: JRP1-Up
Increase in clearance between the ends of the piston
ring for each 0.030 mm (0.0012 inch) increase in the
cylinder liner bore ................... 0.08 mm (0.003 inch)

Oil Control Piston Ring (3)


The spring ends of the new piston ring should be a
distance of 180 degrees from the ring end gap when
the piston ring is assembled. The green colored
stripe must be visible at the ring end gap.

Width of groove in new piston for piston


ring ............ 3.020± 0.010 mm (0.1189 ± 0.0004 inch)

g01391600 Thickness of new piston ring ....... 2.980 ± 0.010 mm


Illustration 93
(0.1173 ± 0.0004 inch)
Note: Refer to Guideline for Reusable Parts for
Clearance between groove and piston ring .. 0.05 mm
information on the pistons, the piston pins, and the
(0.002 inch)
retaining rings.
When a new piston ring is installed in a cylinder
The 1U-6431 Piston Ring Groove Gauge Gp is
liner with a bore of 145 mm (5.7 inch), the clearance
used for measuring the ring grooves in keystone
between the ends of the piston ring is the following
style pistons. Refer to the Special Instruction that is
value. .............. 0.55 ± 0.15 mm (0.022 ± 0.006 inch)
supplied with the piston ring groove gauge group.
Increase in clearance between the ends of the piston
The 5P-3519 Piston Ring Groove Gauge Gp is
ring for each 0.030 mm (0.0012 inch) increase in the
available for checking the ring grooves with straight
cylinder liner bore ................... 0.08 mm (0.003 inch)
sides. Refer to the Guideline for Reusable Parts for
instructions on the piston ring groove gauge group.
Note: After all piston rings have been installed, rotate
the piston rings so that the end gaps are 120 degrees
Note: Lubricate the entire piston in zone (A) with
from each other.
clean engine oil prior to assembly into the cylinder
block.
58 SENR9936-06
Specifications Section

Piston Pin Bore (4)


Note: Thoroughly lubricate the piston pin with clean
engine oil before the piston is inserted into the piston
and the rod assembly.

Diameter of the bore in the bearing that is


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

Diameter of the new piston pin .. 59.975 ± 0.005 mm


(2.3612 ± 0.0002 inch)

i02801103

Housing (Front)
SMCS Code: 1151
Part No.: 238-9862

g01399843
Illustration 95

Note: The rear face of the front housing assembly (3)


and the front face of the cylinder block must be free of
oil, fuel, water, dirt and any other contaminants during
assembly. The gasket for the front housing assembly
must also be free of contaminants during assembly.

Note: The gasket (2) for the front housing assembly


must be trimmed after assembly with the face (4) so
that the gasket is flush.

g01399842
Illustration 94

(1) Studs are supplied with a previously applied


thread lock compound. Install the shortest
threaded end of stud into the front housing
assembly.
SENR9936-06 59
Specifications Section

Part No.: 233-2462


S/N: LWA1-Up
Part No.: 219-6921
S/N: GEB1-Up
Part No.: 219-6921
S/N: TPB1-Up
Part No.: 233-2462
S/N: H4C1-Up
Part No.: 233-2462
S/N: EED1-Up
Part No.: 233-2462
S/N: RJG1-Up
Part No.: 233-2462
S/N: Z9K1-Up
Part No.: 233-2462
S/N: JRP1-Up
Part No.: 233-2462
S/N: DLS1-Up
Part No.: 233-2462
S/N: BTW1-Up
Part No.: 233-2462
S/N: JNW1-Up
Part No.: 233-2462
S/N: BWX1-Up

g01399846
Illustration 96
View A-A
(6) Cylinder block

(5) Apply a continuous bead of 4C-9612 Silicone


Sealant immediately prior to assembling the front
housing assembly. After assembly of the front
housing assembly, remove excess sealant from
the flange with a straight edge.

(7) Apply 4C-9612 Silicone Sealant to the T-shaped


joints immediately prior to the installation of the
gasket for the pan. The application of the sealant
should cover the entire width of the T-shaped
joints, as shown.

i02801118

Housing (Rear)
SMCS Code: 1157
Part No.: 233-2462
S/N: 5301-Up
Part No.: 233-2462 g01399863
Illustration 97
S/N: 2211-Up
Left side view of engine
60 SENR9936-06
Specifications Section

Note: The rear face of the cylinder block and the


front face of the rear housing (1) must be free of
oil, fuel, water, dirt, assembly compounds and any
other contaminants during assembly. The gasket for
the rear housing must also be free of contaminants
during assembly.

(B) Dowel extension from the rear housing at two


places ............. 19.0 ± 0.5 mm (0.75 ± 0.02 inch)

g01399869
Illustration 99
Rear view

Use the following procedure to tighten the bolts for


the rear housing:

1. Start with bolt (5) and continue to tighten all of the


remaining bolts in the numerical sequence that is
shown to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

• Bolt (5) and bolt (6) are 3/8-16 X 1 3/4 inches.


• Bolts (7) through bolts (14) are 3/8-16 X 2 1/4
inches.

g01399864
Illustration 98 i02801133
View A-A
(3) Cylinder block
Gear Group (Front)
SMCS Code: 1206
(2) Apply a continuous bead of 230-6262 Sealant
immediately prior to assembling the rear housing. Part No.: 235-0993
After assembly of the rear housing, remove any S/N: 5301-Up
excess sealant from the flange with a straight
edge. Part No.: 235-0993
S/N: 2211-Up
(4) Apply 230-6262 Sealant to the T-shaped joints
immediately prior to the installation of the gasket Part No.: 235-0993
for the pan. The application of the sealant should S/N: LWA1-Up
cover the entire width of the T-shaped joints, as Part No.: 235-7134
shown. S/N: GEB1-Up
SENR9936-06 61
Specifications Section

Part No.: 235-7134


S/N: TPB1-Up
Part No.: 235-0993
S/N: H4C1-Up
Part No.: 235-0993
S/N: EED1-Up
Part No.: 235-7134
S/N: RJG1-Up
Part No.: 235-0993
S/N: Z9K1-Up
Part No.: 235-0993
g01399901
S/N: JRP1-Up Illustration 101
Tightening sequence
Part No.: 235-0993
S/N: DLS1-Up
Note: Tighten the bolts for the camshaft gear in the
Part No.: 235-0993 sequence 1, 4, 2, 5, 3, 6, 1, 4. Refer to Illustration
S/N: BTW1-Up 101.

Part No.: 235-0993 (2) Torque for the 12 bolts of the camshaft
S/N: JNW1-Up gear ....................... 240 ± 40 N·m (175 ± 30 lb ft)
Part No.: 235-0993 (4) Lubricate the shaft, the bearing bore, and the
S/N: BWX1-Up thrust faces of the idler gear assembly with clean
engine oil.

(7) Torque for the bolt ........ 55 ± 10 N·m (41 ± 7 lb ft)

g01399922
Illustration 102
Section A-A

g01399881 (8) Lubricate the drive idler shaft with clean engine
Illustration 100
(1) Damper group oil.
(3) Gear assembly
(5) Crankshaft gear Note: Install the thrust plate with the oil groove side
(6) Gear toward the idler gear assembly.

(9) Lubricate the thrust faces of the thrust plate with


clean engine oil.

(10) Torque for the five locking bolts ..... 55 ± 10 N·m


(41 ± 7 lb ft)
62 SENR9936-06
Specifications Section

i02866666

Gear Group (Rear)


SMCS Code: 1204; 1206
S/N: LWA1-Up
S/N: H4C1-Up
Part No.: 231-6378
S/N: EED1-Up
Part No.: 216-0812
S/N: RJG1-Up
S/N: Z9K1-Up
Part No.: 231-6378
S/N: DLS1-Up
Part No.: 295-7963
S/N: JNW1-Up
g01428030
Illustration 104
Typical example
Tightening sequence

(1) Lubricate the shaft, the bearing bore, and the


thrust faces of the idler gear assembly with clean
engine oil.

(2) Lubricate the shaft, the bearing bore, and the


thrust faces of the camshaft gear assembly with
clean engine oil.

(3) With the no. 1 piston in the top dead center (TDC)
position, align the timing marks. The mark on the
camshaft gear assembly must be in alignment
with the drilled timing marks in the rear housing.

Tighten the bolts for the camshaft gear assembly (2)


in the sequence 7, 10, 8, 11, 9, 12, 7, 10. Refer to
Illustration 104. ............ 240 ± 40 N·m (175 ± 30 lb ft)

(5) With the no. 1 piston in the top dead center (TDC)
position, align the timing marks. The mark on the
idler gear assembly (4) must be in alignment with
the mark on the crankshaft gear assembly.

(6) Lubricate the shaft, the bearing bore, and the


Illustration 103
g01428033 thrust faces of the crankshaft gear assembly with
Typical example
clean engine oil.
Rear view of engine
SENR9936-06 63
Specifications Section

(17) Torque for two bearing locknuts ... 406 ± 68 N·m


(300 ± 50 lb ft)

(18) Bend the tab on the two lockwashers that aligns


with the slot in the bearing locknuts.

i02867504

Gear Group (Rear)


SMCS Code: 1204; 1206
Part No.: 253-2634
S/N: JRP1-Up

g01428031
Illustration 105
Typical example
Section A-A

(13) Install the plate with the side marked “OUT”


away from the gear face.

(14) Lubricate the shaft, the bearing bore, and the


thrust faces of the idler gear assembly with clean
engine oil.

(15) Install the thrust plate with the side marked


“OUT” away from the gear face.
g01428404
Illustration 107
Rear view of engine

g01428029
Illustration 106
Typical example
Section B-B

(16) Lubricate the bore and the O-ring seals lightly


with the lubricant that is being sealed.
64 SENR9936-06
Specifications Section

g01428402
Illustration 108
Tightening sequence

(1) Lubricate the shaft, the bearing bore, and the


thrust faces of the idler gear assembly with clean
engine oil.
g01428403
Illustration 109
(2) Lubricate the shaft, the bearing bore, and the
Section A-A
thrust faces of the camshaft gear assembly with
clean engine oil.
(14) Install the plate with the side marked “OUT”
(3) With the no. 1 piston in the top dead center (TDC) away from the gear face.
position, align the timing marks. The mark on the
camshaft gear assembly must be in alignment (15) Lubricate the shaft, the bearing bore, and the
with the drilled timing marks in the rear housing. thrust faces of the idler gear assembly with clean
engine oil.
Tighten the bolts for the camshaft gear assembly (2)
in the sequence 8, 11, 9, 12, 10, 13, 8, 11. Refer to (16) Install the thrust plate with the side marked
Illustration 108. ............ 240 ± 40 N·m (175 ± 30 lb ft) “OUT” away from the gear face.

(4) Lubricate the shaft, the bearing bore, and the


thrust faces of the idler gear assembly with clean
engine oil.

(5) Lubricate the shaft, the bearing bore, and the


thrust faces of the idler gear assembly with clean
engine oil.

(6) With the no. 1 piston in the top dead center (TDC)
position, align the timing marks. The mark on the
idler gear assembly (5) must be in alignment with
the mark on the crankshaft gear assembly (7).

(7) Lubricate the shaft, the bearing bore, and the


thrust faces of the crankshaft gear assembly with
clean engine oil.
SENR9936-06 65
Specifications Section

i02866758

Gear Group (Rear)


SMCS Code: 1204; 1206
Part No.: 263-2941
S/N: BTW1-Up
Part No.: 263-2941
S/N: BWX1-Up

g01428401
Illustration 110
Section B-B

(17) Torque for two bearing locknuts ... 406 ± 68 N·m


(300 ± 50 lb ft)

(18) Bend the tab on the two lockwashers that aligns


with the slot in the bearing locknuts.

(19) Lubricate the bore and the O-ring seals lightly


with the lubricant that is being sealed.

g01428074
Illustration 111
Rear view of engine
66 SENR9936-06
Specifications Section

g01428072
Illustration 112
Tightening sequence

(1) Lubricate the shaft, the bearing bore, and the


thrust faces of the idler gear assembly with clean
engine oil.
g01428073
Illustration 113
(2) Lubricate the shaft, the bearing bore, and the
Section A-A
thrust faces of the camshaft gear assembly with
clean engine oil.
(14) Install the plate with the side marked “OUT”
(3) With the no. 1 piston in the top dead center (TDC) away from the gear face.
position, align the timing marks. The mark on the
camshaft gear assembly must be in alignment (15) Lubricate the shaft, the bearing bore, and the
with the drilled timing marks in the rear housing. thrust faces of the idler gear assembly with clean
engine oil.
Tighten the bolts for the camshaft gear assembly (2)
in the sequence 8, 11, 9, 12, 10, 13, 8, 11. Refer to (16) Install the thrust plate with the side marked
Illustration 112. ............. 240 ± 40 N·m (175 ± 30 lb ft) “OUT” away from the gear face.

(4) Lubricate the shaft, the bearing bore, and the


thrust faces of the idler gear assembly with clean
engine oil.

(5) Lubricate the shaft, the bearing bore, and the


thrust faces of the idler gear assembly with clean
engine oil.

(6) With the no. 1 piston in the top dead center (TDC)
position, align the timing marks. The mark on the
idler gear assembly (5) must be in alignment with
the mark on the crankshaft gear assembly.

(7) Lubricate the shaft, the bearing bore, and the


thrust faces of the crankshaft gear assembly with
clean engine oil.
SENR9936-06 67
Specifications Section

i02899682

Gear Group (Rear)


SMCS Code: 1204; 1206
Part No.: 245-9776
S/N: 5301-Up
Part No.: 245-9776
S/N: 2211-Up
Part No.: 245-9776
S/N: LWA1-Up
Part No.: 245-9776
S/N: GEB1-Up
Part No.: 245-9776
S/N: TPB1-Up
Part No.: 245-9776
S/N: H4C1-Up
g01428071
Illustration 114
Part No.: 245-9776
Section B-B
S/N: Z9K1-Up
(17) Torque for two bearing locknuts ... 406 ± 68 N·m
(300 ± 50 lb ft)

(18) Bend the tab on the two lockwashers that aligns


with the slot in the bearing locknuts.

(19) Lubricate the bore and the O-ring seals lightly


with the lubricant that is being sealed.

g01443779
Illustration 115

Note: Lubricate the shaft, the bearing bore, and the


thrust faces of the idler gear assembly with clean
engine oil.

(1) Torque for the bolts of the idler gear


assembly ..................... 55 ± 10 N·m (41 ± 7 lb ft)
68 SENR9936-06
Specifications Section

(2) Lubricate the shaft, the bearing bore, and the (11) Lubricate the shaft, the bearing bore, and the
thrust faces of the camshaft gear assembly with thrust faces of the cranshaft gear assembly with
clean engine oil. clean engine oil.

(3) With the number one piston in the top dead


center position, align the timing marks. The mark
on the camshaft gear must be in alignment with
the mark in the rear housing.

g01400787
Illustration 117
Section A-A

(12) Lubricate the O-ring seals lightly with clean


engine oil.
g01400123
Illustration 116
Tightening sequence
i02857719

Note: Tighten the bolts for the camshaft gear in the


sequence 1, 4, 2, 5, 3, 6, 1, 4. Refer to Illustration 116.
Flywheel
SMCS Code: 1156
(4) Torque for the 12 bolts of the camshaft gear
assembly ............... 240 ± 40 N·m (175 ± 30 lb ft) Part No.: 245-9777
S/N: 5301-Up
(5) Install the plate with the side marked “OUT” away
from the gear face. Part No.: 245-9777
S/N: 2211-Up
Note: Lubricate the shaft, the bearing bore, and the
thrust faces of the idler gear assembly with clean Part No.: 245-9777
engine oil. S/N: LWA1-Up
Part No.: 245-9777
(6) Torque for the bolts of the idler gear S/N: H4C1-Up
assembly ..................... 55 ± 10 N·m (41 ± 7 lb ft)
Part No.: 231-6377
Note: Lubricate the shaft, the bearing bore, and the S/N: EED1-Up
thrust faces of the idler gear assembly with clean
engine oil. Part No.: 245-9777
S/N: Z9K1-Up
(7) Torque for the locking bolt of idler gear
Part No.: 245-9777
assembly ..................... 55 ± 10 N·m (41 ± 7 lb ft)
S/N: JRP1-Up
(8) Torque for the bolts for the stub shaft of idler gear Part No.: 231-6377
assembly ............... 135 ± 20 N·m (100 ± 15 lb ft) S/N: DLS1-Up
(9) Install the thrust plate with the side marked “OUT” Part No.: 224-3167
away from the gear face. S/N: BTW1-Up

(10) With the number one piston in the top dead Part No.: 231-6377
center position, align the timing marks. The mark S/N: JNW1-Up
on the idler gear must be in alignment with the Part No.: 224-3167
mark on the crankshaft gear. S/N: BWX1-Up
SENR9936-06 69
Specifications Section

i02900830

Flywheel
SMCS Code: 1156
Part No.: 273-2713, 273-2715, 273-2716,
273-7293
S/N: JRP1-Up

g01450105
Illustration 119
Typical example

(1) Torque for the eight bolts ............... 120 ± 20 N·m


Illustration 118
g01427833 (90 ± 15 lb ft)

(1) Flywheel assembly


Maximum runout of the face ................. 0.43 mm
(0.017 inch)
Maximum eccentricity of the pilot bore in the drive
hub .................................... 0.23 mm (0.009 inch)
Eccentricity of the coupling pilot bore ........... N/A

Note: Lubricate the threads of the bolts with clean


engine oil, molybdenum disulfide or a graphite base
lubricant before assembly.

(2) Torque for 12 bolts .. 270 ± 40 N·m (200 ± 30 lb ft)


70 SENR9936-06
Specifications Section

i02857727 i02857899

Flywheel Flywheel Housing


SMCS Code: 1156 SMCS Code: 1157
Part No.: 248-3309 Part No.: 226-0297, 302-4288
S/N: GEB1-Up S/N: EED1-Up
Part No.: 248-3309 Part No.: 226-0297
S/N: TPB1-Up S/N: RJG1-Up
Part No.: 216-0811 Part No.: 226-0297, 302-4288
S/N: RJG1-Up S/N: DLS1-Up

g01249502 g01423950
Illustration 120 Illustration 121
(1) Gear Rear view of engine

(2) Flywheel assembly


Maximum runout of the face ................. 0.43 mm
(0.017 inch)
Maximum eccentricity of the pilot bore in the drive
hub .................................... 0.23 mm (0.009 inch)
Eccentricity of the coupling pilot bore ........... N/A

Note: Lubricate the threads with clean engine oil,


molybdenum disulfide or a graphite base lubricant
before assembly.

(3) Torque for 12 bolts .. 270 ± 40 N·m (200 ± 30 lb ft)


SENR9936-06 71
Specifications Section

g01427297
Illustration 123
Section A-A

Note: The seal and the sleeve of the crankshaft seal


group must not be used if the seal and the sleeve
have been separated.

(37) The seal driver must not contact the seal within
the following diameter. ........... 177.80 ± 0.25 mm
(7.000 ± 0.010 inch)

Note: Check assembled installation depth of the


crankshaft seal group with the crankshaft in any axial
g01423951
Illustration 122 position.
Right side view of engine
(C) Assembled installation depth ........ 6.4 ± 0.6 mm
Note: The front face of the flywheel housing group (0.25 ± 0.02 inch)
and the rear face of the rear housing must be free of
oil, fuel, water, assembly compounds and any other
contaminants during assembly. The gasket for the
flywheel housing group must be free of contaminants
during assembly.

Use the following procedure to tighten the bolts for


the flywheel housing group:

1. For bolt (1) and bolt (2), use 3/8-16 X 6 1/4


inch bolts. Torque the bolt (1) and bolt (2) in the
numerical sequence that is shown in Illustration
121 to 55 ± 10 N·m (41 ± 7 lb ft).

2. For bolt (3) through bolt (10), use 1/2-13 X 6


1/2 inch bolts. Torque the bolt (3) through bolt
(10) in the numerical sequence that is shown in
Illustration 121 to 135 ± 20 N·m (100 ± 15 lb ft).

3. For bolt (11) through bolt (16), use 3/8-16 X 4 inch


bolts. For bolt (17) through bolt (30), use 3/8-16 X
5 1/4 inch bolts. For bolt (31) through bolt (36), use
3/8-16 X 3 inch bolts. Torque the bolt (11) through
bolt (36) in the numerical sequence that is shown
in Illustration 121 to 47 ± 9 N·m (35 ± 7 lb ft).
72 SENR9936-06
Specifications Section

i02884495

Flywheel Housing
SMCS Code: 1157
Part No.: 245-9775
S/N: 5301-Up
Part No.: 245-9775
S/N: 2211-Up
Part No.: 245-9775
S/N: LWA1-Up
Part No.: 245-9775
S/N: H4C1-Up
Part No.: 245-9775
S/N: Z9K1-Up
Part No.: 259-3123
S/N: JRP1-Up
Part No.: 217-5685
S/N: BTW1-Up
Part No.: 217-5685
S/N: BWX1-Up

g01424823
Illustration 125
Typical example
Right side view of the engine

Note: The front face of the flywheel housing group


and the rear face of the rear housing must be free of
oil, fuel, water, assembly compounds and any other
contaminants during assembly. The gasket for the
flywheel housing group must be free of contaminants
during assembly.

Use the following procedure to tighten the bolts for


the flywheel housing group:
g01424781
Illustration 124
Typical example
1. For bolt (1) and bolt (2), use 3/8-16 X 6 1/4 inch
bolts. Torque the bolt (1) and bolt (2 ) in the
Rear view of engine
numerical sequence that is shown in Illustration
124 to 55 ± 10 N·m (41 ± 7 lb ft).
SENR9936-06 73
Specifications Section

1. For bolt (3) through bolt (10), use 1/2-13 X 6 i02883213


1/2 inch bolts. Torque the bolt (3) through bolt
(10) in the numerical sequence that is shown in Flywheel Housing
Illustration 124 to 135 ± 20 N·m (100 ± 15 lb ft).
SMCS Code: 1157
2. For bolt (11) through bolt (16), use 3/8-16 X 4 inch
Part No.: 273-1642
bolts. For bolt (17) through bolt (34), use 3/8-16 X
S/N: BTW1-Up
4 3/4 inch bolts. For bolt (35) and bolt (36), use
3/8-16 X 3 inch bolts. Torque the bolt (11) through Part No.: 273-1642
bolt (36) in the numerical sequence that is shown S/N: BWX1-Up
in Illustration 124 to 47 ± 9 N·m (35 ± 7 lb ft).

3. Again torque the bolt (1) and bolt (2) in the


numerical sequence that is shown in Illustration
124 to 55 ± 10 N·m (41 ± 7 lb ft).

g01436141
Illustration 126
Section A-A

Note: The seal and the sleeve of the crankshaft seal


group must not be used if the seal and the sleeve
have been separated.

(37) The seal driver must not contact the seal within
the following diameter. ........... 177.80 ± 0.25 mm Illustration 127
g01435183
(7.000 ± 0.010 inch) Rear view of engine

Note: Check assembled installation depth of the


crankshaft seal group with the crankshaft in any axial
position.

(C) Assembled installation depth ........ 6.4 ± 0.6 mm


(0.25 ± 0.02 inch)
74 SENR9936-06
Specifications Section

1. For bolt (3) through bolt (10), use 1/2-13 X 6


1/2 inch bolts. Torque the bolt (3) through bolt
(10) in the numerical sequence that is shown in
Illustration 127 to 135 ± 20 N·m (100 ± 15 lb ft).

2. For bolt (11) through bolt (16), use 3/8-16 X 4 inch


bolts. For bolt (17) and bolt (18), use 3/8-16 X
5 1/2 inch bolts. For bolt (19) and bolt (20), use
3/8-16 X 4 3/4 inch bolts. For bolt (21) and bolt
(22), use 3/8-16 X 5 1/2 inch bolts. For bolt (23)
through bolt (28), use 3/8-16 X 4 3/4 inch bolts.
For bolt (29) through bolt (34), use 3/8-16 X 5 1/2
inch bolts. For bolt (35) and bolt (36), use 3/8-16
X 3 inch bolts. Torque the bolt (11) through bolt
(36) in the numerical sequence that is shown in
Illustration 127 to 47 ± 9 N·m (35 ± 7 lb ft).

3. Again torque the bolt (1) and bolt (2) in the


numerical sequence that is shown in Illustration
127 to 55 ± 10 N·m (41 ± 7 lb ft).

g01435182
Illustration 129
Section A-A

Note: The seal and the sleeve of the crankshaft seal


group must not be used if the seal and the sleeve
have been separated.
g01435181
Illustration 128
Right side view of the engine (37) The seal driver must not contact the seal within
the following diameter. ........... 177.80 ± 0.25 mm
Note: The front face of the flywheel housing group (7.000 ± 0.010 inch)
and the rear face of the rear housing must be free of
oil, fuel, water, assembly compounds and any other Note: Check assembled installation depth of the
contaminants during assembly. The gasket for the crankshaft seal group with the crankshaft in any axial
flywheel housing group must be free of contaminants position.
during assembly.
(C) Assembled installation depth ........ 6.4 ± 0.6 mm
Use the following procedure to tighten the bolts for (0.25 ± 0.02 inch)
the flywheel housing group:

1. For bolt (1) and bolt (2), use 3/8-16 X 6 1/4 inch
bolts. Torque the bolt (1) and bolt (2 ) in the
numerical sequence that is shown in Illustration
127 to 55 ± 10 N·m (41 ± 7 lb ft).
SENR9936-06 75
Specifications Section

i02883207

Flywheel Housing
SMCS Code: 1157
Part No.: 294-9164
S/N: JNW1-Up

g01435175
Illustration 131
Right side view of engine

Note: The front face of the flywheel housing group


and the rear face of the rear housing must be free of
oil, fuel, water, assembly compounds and any other
contaminants during assembly. The gasket for the
g01435177 flywheel housing group must be free of contaminants
Illustration 130
during assembly.
Rear view of engine
Use the following procedure to tighten the bolts for
the flywheel housing group:

1. For bolt (1) and bolt (2), use 3/8-16 X 6 1/4


inch bolts. Torque the bolt (1) and bolt (2) in the
numerical sequence that is shown in Illustration
130 to 55 ± 10 N·m (41 ± 7 lb ft).

2. For bolt (3) through bolt (10), use 1/2-13 X 6


1/2 inch bolts. Torque the bolt (3) through bolt
(10) in the numerical sequence that is shown in
Illustration 130 to 135 ± 20 N·m (100 ± 15 lb ft).

3. For bolt (11) through bolt (16), use 3/8-16 X 4 inch


bolts. For bolt (17), use bolt size of 3/8-16 X 5 1/2
inches. For bolt (18) through bolt (24), use 3/8-16
X 5 1/4 inch bolts. For bolt (33) and bolt (34), use
3/8-16 X 3 1/2 inch bolts. For bolt (35) and bolt
(36), use 3/8-16 X 3 inch bolts. Torque the bolt
(11) through bolt (36) in the numerical sequence
that is shown in Illustration 130 to 47 ± 9 N·m
(35 ± 7 lb ft).
76 SENR9936-06
Specifications Section

g01435176
Illustration 132
Section A-A

Note: The seal and the sleeve of the crankshaft seal


group must not be used if the seal and the sleeve
have been separated.

(37) The seal driver must not contact the seal within
the following diameter. ........... 177.80 ± 0.25 mm
(7.000 ± 0.010 inch)

Note: Check assembled installation depth of the


crankshaft seal group with the crankshaft in any axial
position.

(C) Assembled installation depth ....... 5.8 to 6.4 mm


(0.23 to 0.25 inch)
SENR9936-06 77
Specifications Section

i02858265

Flywheel Housing
SMCS Code: 1157
Part No.: 216-0822
S/N: GEB1-Up
Part No.: 216-0822
S/N: TPB1-Up

g01424195
Illustration 133
Rear view of engine

Note: The front face of the flywheel housing group 3. For bolt (10) through bolt (15), use 3/8-16 X 4
and the rear face of the rear housing must be free of inch bolts. For bolt (16) through bolt (26), use
oil, fuel, water, assembly compounds and any other 3/8-16 X 3 inch bolts. For bolt (27) through bolt
contaminants during assembly. The gasket for the (42), use 3/8-16 X 5 1/4 inch bolts. Torque the bolt
flywheel housing group must be free of contaminants (10) through bolt (42) in the numerical sequence
during assembly. that is shown in Illustration 133 to 47 ± 9 N·m
(35 ± 7 lb ft).
Use the following procedure to tighten the bolts for
the flywheel housing group:

1. For bolt (1) through bolt (8), use 1/2-13 X 6


1/2 inch bolts. Torque the bolt (1) through bolt
(8) in the numerical sequence that is shown in
Illustration 133 to 135 ± 20 N·m (100 ± 15 lb ft).

2. For bolt (9), use bolt size of 3/8-16 X 6 1/4 inches.


Torque the bolt (9) in the numerical sequence
that is shown in Illustration 133 to 55 ± 10 N·m
(41 ± 7 lb ft).
78 SENR9936-06
Specifications Section

i02845077

Coolant Temperature Sensor


SMCS Code: 1906
Part No.: 256-6453
S/N: 5301-Up
Part No.: 256-6453
S/N: 2211-Up
S/N: LWA1-Up
Part No.: 197-8392, 264-4297
S/N: GEB1-Up
g01427322
Illustration 134
Part No.: 197-8392, 264-4297
Section A-A
S/N: TPB1-Up
Note: The seal and the sleeve of the crankshaft seal Part No.: 256-6453
group must not be used if the seal and the sleeve S/N: H4C1-Up
have been separated.
Part No.: 197-8392, 256-6453, 264-4297
(43) The seal driver must not contact the seal within S/N: EED1-Up
the following diameter. ........... 177.80 ± 0.25 mm
(7.000 ± 0.010 inch) Part No.: 197-8392, 264-4297
S/N: RJG1-Up
Note: Check assembled installation depth of the Part No.: 256-6453
crankshaft seal group with the crankshaft in any axial S/N: Z9K1-Up
position.
Part No.: 197-8392, 256-6453, 264-4297
(B) Assembled installation depth ........ 6.4 ± 0.6 mm S/N: JRP1-Up
(0.25 ± 0.02 mm)
Part No.: 197-8392, 256-6453, 264-4297
S/N: DLS1-Up
Part No.: 197-8392, 256-6453, 264-4297
S/N: BTW1-Up
Part No.: 256-6453, 264-4297
S/N: JNW1-Up
Part No.: 197-8392, 256-6453, 264-4297
S/N: BWX1-Up

g01089060
Illustration 135

(1) Final installation torque for the temperature


sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft)
SENR9936-06 79
Specifications Section

Output type ................................................... Passive i01432272

Operating temperature ........................ −40 to 150 °C Coolant Flow Switch


(−40 to 302 °F)
SMCS Code: 7422

i02847523 Part No.: 171-8708


S/N: LWA1-Up
Coolant Temperature Sensor
Part No.: 171-8708
SMCS Code: 1906 S/N: GEB1-Up

Part No.: 130-9811 Part No.: 171-8708


S/N: EED1-Up S/N: TPB1-Up

Part No.: 130-9811 Part No.: 171-8708


S/N: RJG1-Up S/N: H4C1-Up

Part No.: 130-9811 Part No.: 171-8708


S/N: JRP1-Up S/N: RJG1-Up

Part No.: 130-9811 Part No.: 171-8708


S/N: DLS1-Up S/N: Z9K1-Up

Part No.: 130-9811 Part No.: 171-8708


S/N: BTW1-Up S/N: JRP1-Up

Part No.: 130-9811 Part No.: 171-8708


S/N: JNW1-Up S/N: BTW1-Up

Part No.: 130-9811 Part No.: 134-6054


S/N: BWX1-Up S/N: JNW1-Up
Part No.: 171-8708
S/N: BWX1-Up

g01391967
Illustration 136

(1) Final installation torque for the temperature


sensor group .................. 20 ± 5 N·m (15 ± 4 lb ft)

Output type ................................................... Passive

Operating temperature ........................ −40 to 150 °C


(−40 to 302 °F)
g00117939
Illustration 137
Typical example

(1) Connector

(2) Rivet head for test procedure

Test with the paddle in a vertical position and the


force (F) on rivet head (2):
80 SENR9936-06
Specifications Section

With an increase in flow (force), the switch opens at (1) Final installation torque for the temperature
the following value: .......................... 0.362 ± 0.029 N sensor ............................ 20 ± 5 N·m (15 ± 4 lb ft)
(0.0814 ± 0.0065 lb)
Output type ................................................... Passive
With a decrease in flow (force), the switch closes at
the following minimum value: ..... 0.303 N (0.0681 lb) Operating temperature ........................ −40 to 150 °C
(−40 to 302 °F)
Note: When the switch is installed in the engine
cooling system, there is not enough force from the
flow of coolant at engine cranking speed in order to
activate the switch. When the engine is running at
low idle, the flow of coolant has enough force in order
to activate the switch.

i02839267

Fuel Temperature Sensor


SMCS Code: 1922
Part No.: 130-9811
S/N: GEB1-Up
Part No.: 130-9811
S/N: TPB1-Up
Part No.: 130-9811
S/N: EED1-Up
Part No.: 130-9811
S/N: RJG1-Up
Part No.: 130-9811
S/N: JRP1-Up
Part No.: 130-9811
S/N: DLS1-Up
Part No.: 130-9811
S/N: BTW1-Up
Part No.: 130-9811
S/N: JNW1-Up
Part No.: 130-9811
S/N: BWX1-Up

g01089060
Illustration 138
SENR9936-06 81
Specifications Section

i02845081 Output type ................................................... Passive


Fuel Temperature Sensor Operating temperature ........................ −40 to 150 °C
(−40 to 302 °F)
SMCS Code: 1922
Part No.: 256-6453 i02787430
S/N: 5301-Up
Fuel Filter Pressure Differential
Part No.: 256-6453
S/N: 2211-Up Switch
Part No.: 256-6453, 264-4297 SMCS Code: 1256; 1261
S/N: LWA1-Up
Part No.: 275-1253
Part No.: 197-8392, 264-4297 S/N: 5301-Up
S/N: GEB1-Up
Part No.: 275-1253
Part No.: 197-8392, 264-4297 S/N: 2211-Up
S/N: TPB1-Up
Part No.: 258-0883
Part No.: 256-6453, 264-4297 S/N: LWA1-Up
S/N: H4C1-Up
Part No.: 258-0883
Part No.: 197-8392, 256-6453, 264-4297 S/N: GEB1-Up
S/N: EED1-Up
Part No.: 258-0883
Part No.: 197-8392, 264-4297 S/N: TPB1-Up
S/N: RJG1-Up
Part No.: 275-1253
Part No.: 256-6453, 264-4297 S/N: H4C1-Up
S/N: Z9K1-Up
Part No.: 258-0883, 275-1253
Part No.: 197-8392, 256-6453, 264-4297 S/N: EED1-Up
S/N: JRP1-Up
Part No.: 258-0883
Part No.: 197-8392, 256-6453, 264-4297 S/N: RJG1-Up
S/N: DLS1-Up
Part No.: 258-0883
Part No.: 197-8392, 256-6453, 264-4297 S/N: Z9K1-Up
S/N: BTW1-Up
Part No.: 258-0883, 275-1253
Part No.: 256-6453, 264-4297 S/N: JRP1-Up
S/N: JNW1-Up
Part No.: 258-0883, 275-1253
Part No.: 197-8392, 256-6453, 264-4297 S/N: DLS1-Up
S/N: BWX1-Up
Part No.: 258-0883, 275-1253
S/N: BTW1-Up
Part No.: 258-0883, 275-1253
S/N: JNW1-Up
Part No.: 258-0883, 275-1253
S/N: BWX1-Up

g01089060
Illustration 139

(1) Final installation torque for the temperature


sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft)
82 SENR9936-06
Specifications Section

i02853439

Mass Air Flow Sensor


SMCS Code: 1439-AI
Part No.: 194-6725
S/N: 5301-Up
Part No.: 194-6725
S/N: 2211-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: GEB1-Up
Part No.: 194-6722, 194-6724, 194-6725
g01392341
Illustration 140 S/N: TPB1-Up
(1) O-ring seals
(2) Sleeve Part No.: 194-6722, 194-6724, 194-6725
S/N: EED1-Up
(3) Final installation torque for the pressure switch Part No.: 194-6722, 194-6724, 194-6725
group .................. 6.78 ± 1.41 N·m (60 ± 12 lb in) S/N: RJG1-Up
Actuation pressure at 21 ± 3 °C Part No.: 194-6722, 194-6724, 194-6725
(70 ± 37 °F) ........... 110.3 ± 13.8 kPa (16.0 ± 2.0 psi) S/N: JRP1-Up

Actuation pressure at 40 ± 3 °C Part No.: 194-6722, 194-6724, 194-6725


(104 ± 37 °F) ..... 89.6 to 124.1 kPa (13.0 to 18.0 psi) S/N: DLS1-Up

Actuation pressure at 90 ± 3 °C Part No.: 194-6722, 194-6724, 194-6725


(194 ± 37 °F) ......... 103.4 ± 20.7 kPa (15.0 ± 3.0 psi) S/N: BTW1-Up
Part No.: 194-6724, 194-6725
Minimum deactuation pressure at −40 to 121 °C S/N: JNW1-Up
(−40 to 250 °F) ............................... 69 kPa (10.0 psi)
Part No.: 194-6722, 194-6724, 194-6725
Contact position .......................................... Normally S/N: BWX1-Up
closed below deactuation pressure

g01421159
Illustration 141

(1) Final installation torque for the pressure sensor


group .......................... 10 ± 2 N·m (90 ± 18 lb in)

Operating voltage ........................... 5.00 ± 0.25 VDC

Operating temperature ........................ −40 to 125 °C


(−40 to 257 °F)
SENR9936-06 83
Specifications Section

i02853437 i02665532

Mass Air Flow Sensor Engine Oil Pressure Sensor


SMCS Code: 1439-AI SMCS Code: 1924
Part No.: 274-6717, 274-6719, 276-6793 Part No.: 274-6717, 274-6719, 276-6793
S/N: 5301-Up S/N: 5301-Up
Part No.: 274-6717, 274-6719, 276-6793 Part No.: 274-6717, 274-6719, 276-6793
S/N: 2211-Up S/N: 2211-Up
Part No.: 274-6717, 274-6719, 276-6793 Part No.: 274-6717, 274-6719, 276-6793
S/N: LWA1-Up S/N: LWA1-Up
S/N: H4C1-Up Part No.: 274-6717, 274-6719, 276-6793
S/N: H4C1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: EED1-Up Part No.: 274-6717, 274-6719, 276-6793
S/N: EED1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: Z9K1-Up Part No.: 274-6717, 274-6719, 276-6793
S/N: Z9K1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: JRP1-Up Part No.: 274-6717, 274-6719, 276-6793
S/N: JRP1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: DLS1-Up Part No.: 274-6717, 274-6719, 276-6793
S/N: DLS1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: JNW1-Up Part No.: 274-6717, 274-6719, 276-6793
S/N: JNW1-Up

g01275664
Illustration 142
g01155331
Illustration 143
(1) Final installation torque for the pressure sensor
group .......................... 10 ± 2 N·m (90 ± 18 lb in) Note: Prior to installing the pressure sensor group
onto the engine, apply 5P-3413 Pipe Sealant to the
Operating voltage ............................... 5.0 ± 0.5 VDC first three threads of the pressure sensor group.

Operating temperature ........................ −40 to 125 °C (1) Final installation torque for the pressure sensor
(−40 to 257 °F) group .......................... 10 ± 2 N·m (90 ± 18 lb in)

Operating voltage ............................... 5.0 ± 0.5 VDC

Operating temperature ........................ −40 to 125 °C


(−40 to 257 °F)

Maximum operating pressure (absolute


pressure) ..................................... 1135 kPa (165 psi)
84 SENR9936-06
Specifications Section

i02845092 i02666631

Engine Oil Pressure Sensor Atmospheric Pressure Sensor


SMCS Code: 1924 SMCS Code: 1923
Part No.: 194-6725 Part No.: 194-6724
S/N: 5301-Up S/N: GEB1-Up
Part No.: 194-6725 Part No.: 194-6724
S/N: 2211-Up S/N: TPB1-Up
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724
S/N: GEB1-Up S/N: EED1-Up
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724
S/N: TPB1-Up S/N: RJG1-Up
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724
S/N: EED1-Up S/N: JRP1-Up
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724
S/N: RJG1-Up S/N: DLS1-Up
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724
S/N: JRP1-Up S/N: BTW1-Up
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724
S/N: DLS1-Up S/N: JNW1-Up
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724
S/N: BTW1-Up S/N: BWX1-Up
Part No.: 194-6724, 194-6725
S/N: JNW1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: BWX1-Up

g01190345
Illustration 145

(1) Final installation torque for the pressure sensor


group .......................... 10 ± 2 N·m (90 ± 18 lb in)

Illustration 144
g01068621 Operating voltage ........................... 5.00 ± 0.25 VDC

Operating temperature ........................ −40 to 125 °C


(1) Final installation torque for the pressure sensor
group .......................... 10 ± 2 N·m (90 ± 18 lb in) (−40 to 257 °F)

Maximum operating pressure (absolute


Operating temperature ........................ −40 to 125 °C
(−40 to 257 °F) pressure) ......................................... 472 kPa (68 psi)

Operating voltage ........................... 5.00 ± 0.25 VDC


SENR9936-06 85
Specifications Section

i02879859 i02845102

Atmospheric Pressure Sensor Atmospheric Pressure Sensor


SMCS Code: 1923 SMCS Code: 1923
Part No.: 274-6717, 274-6719, 276-6793 Part No.: 194-6725
S/N: 5301-Up S/N: 5301-Up
Part No.: 274-6717, 274-6719, 276-6793 Part No.: 194-6725
S/N: 2211-Up S/N: 2211-Up
Part No.: 274-6717, 274-6719, 276-6793 Part No.: 194-6722, 194-6725
S/N: LWA1-Up S/N: GEB1-Up
Part No.: 248-2162, 274-6717, 274-6719, Part No.: 194-6722, 194-6725
276-6793 S/N: TPB1-Up
S/N: H4C1-Up
Part No.: 194-6722, 194-6725
Part No.: 274-6717, 274-6719, 276-6793 S/N: EED1-Up
S/N: EED1-Up
Part No.: 194-6722, 194-6725
Part No.: 248-2162, 274-6717, 274-6719, S/N: RJG1-Up
276-6793
S/N: Z9K1-Up Part No.: 194-6722, 194-6725
S/N: JRP1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: JRP1-Up Part No.: 194-6722, 194-6725
S/N: DLS1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: DLS1-Up Part No.: 194-6722, 194-6725
S/N: BTW1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: JNW1-Up Part No.: 194-6725
S/N: JNW1-Up
Part No.: 194-6722, 194-6725
S/N: BWX1-Up

g01154731
Illustration 146

(1) Final installation torque for the pressure sensor


group .......................... 10 ± 2 N·m (90 ± 18 lb in) Illustration 147
g01392045

Operating voltage ............................... 5.0 ± 0.5 VDC


(1) Final installation torque for the pressure sensor
group .......................... 10 ± 2 N·m (90 ± 18 lb in)
Operating temperature ........................ −40 to 125 °C
(−40 to 257 °F)
Operating voltage ........................... 5.00 ± 0.25 VDC

Operating temperature ........................ −40 to 125 °C


(−40 to 257 °F)
86 SENR9936-06
Specifications Section

i02854065 i02854115

Inlet Manifold Temperature Turbocharger Inlet Pressure


Sensor Sensor
SMCS Code: 1921 SMCS Code: 1052; 1917
Part No.: 130-9811 Part No.: 194-6725
S/N: GEB1-Up S/N: 5301-Up
Part No.: 130-9811 Part No.: 194-6725
S/N: TPB1-Up S/N: 2211-Up
Part No.: 130-9811 Part No.: 194-6722, 194-6724, 194-6725
S/N: EED1-Up S/N: GEB1-Up
Part No.: 130-9811 Part No.: 194-6722, 194-6724, 194-6725
S/N: RJG1-Up S/N: TPB1-Up
Part No.: 130-9811 Part No.: 194-6722, 194-6724, 194-6725
S/N: JRP1-Up S/N: EED1-Up
Part No.: 130-9811 Part No.: 194-6722, 194-6724, 194-6725
S/N: DLS1-Up S/N: RJG1-Up
Part No.: 130-9811 Part No.: 194-6722, 194-6724, 194-6725
S/N: BTW1-Up S/N: JRP1-Up
Part No.: 130-9811 Part No.: 194-6722, 194-6724, 194-6725
S/N: JNW1-Up S/N: DLS1-Up
Part No.: 130-9811 Part No.: 194-6722, 194-6724, 194-6725
S/N: BWX1-Up S/N: BTW1-Up
Part No.: 194-6724, 194-6725
S/N: JNW1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: BWX1-Up

g01391967
Illustration 148

(1) Final installation torque for the temperature


sensor group .................. 20 ± 5 N·m (15 ± 4 lb ft)

Output type ................................................... Passive g01190345


Illustration 149

Operating temperature ........................ −40 to 150 °C (1) Final installation torque for the pressure sensor
(−40 to 302 °F)
group .......................... 10 ± 2 N·m (90 ± 18 lb in)

Operating voltage ........................... 5.00 ± 0.25 VDC

Operating temperature ........................ −40 to 125 °C


(−40 to 257 °F)
SENR9936-06 87
Specifications Section

i02854172 Part No.: 279-9828, 279-9829


S/N: 5301-Up
Turbocharger Inlet Pressure
Part No.: 279-9828, 279-9829
Sensor S/N: 2211-Up
SMCS Code: 1052; 1917 Part No.: 279-9828, 279-9829
S/N: LWA1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: 5301-Up Part No.: 230-7149, 235-8210, 239-2397
S/N: GEB1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: 2211-Up Part No.: 230-7149, 235-8210, 239-2397
S/N: TPB1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: LWA1-Up Part No.: 279-9828, 279-9829
S/N: H4C1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: H4C1-Up Part No.: 279-9828, 279-9829, 283-3443
S/N: EED1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: EED1-Up Part No.: 230-7149, 235-8210, 239-2397
S/N: RJG1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: Z9K1-Up Part No.: 279-9828, 279-9829
S/N: Z9K1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: JRP1-Up Part No.: 279-9828, 279-9829
S/N: JRP1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: DLS1-Up Part No.: 279-9828, 279-9829, 283-3443
S/N: DLS1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: JNW1-Up Part No.: 230-7149, 239-2397, 280-4101
S/N: BTW1-Up
Part No.: 230-7149, 239-2397, 279-9828
S/N: JNW1-Up
Part No.: 230-7149, 239-2397, 280-4101
S/N: BWX1-Up

g01154731
Illustration 150

(1) Final installation torque for the pressure sensor


group .......................... 10 ± 2 N·m (90 ± 18 lb in)

Operating voltage ............................... 5.0 ± 0.5 VDC

Operating temperature ........................ −40 to 125 °C


(−40 to 257 °F)

i02857202

Speed/Timing Sensor
SMCS Code: 1907; 1912
88 SENR9936-06
Specifications Section

Camshaft Position Sensor Crankshaft Position Sensor

g01423342
Illustration 152
(2) Speed sensor
(3) Bracket

Ensure that the bracket is installed in the orientation


that is shown.
g01423337
Illustration 151
Lubricate the seal for the speed sensor with clean
(2) Bracket engine oil before installation.
(3) Speed sensor

(1) Torque for bolt ................ 28 ± 7 N·m (21 ± 5 lb ft)


Ensure that the bracket is installed in the orientation
that is shown. Ensure that the speed sensor is seated before the
bolt is tightened.
Lubricate the seal for the speed sensor with clean
engine oil before installation.

(1) Torque for the bolt .......... 28 ± 7 N·m (21 ± 5 lb ft)

Ensure that the speed sensor is seated before the


bolt is tightened.
SENR9936-06 89
Index Section

Index
A I

Atmospheric Pressure Sensor......................... 84–85 Important Safety Information ................................... 2


Inlet Manifold Temperature Sensor........................ 86

C
M
Camshaft ............................................................... 31
Compression Brake ............................................... 13 Main Bearing Journal............................................. 52
Connecting Rod..................................................... 53 Mass Air Flow Sensor...................................... 82–83
Connecting Rod Bearing Journal........................... 52
Coolant Flow Switch .............................................. 79
Coolant Temperature Sensor........................... 78–79 P
Crankshaft ............................................................ 47
Crankshaft Seals ................................................... 49 Piston and Rings ............................................. 55, 57
Cylinder Block........................................................ 43 Intermediate Piston Ring (2) ........................ 56–57
Cylinder Head......................................................... 11 Oil Control Piston Ring (3) ........................... 56–57
Cylinder Head Valves ............................................ 10 Piston Pin Bore (4)....................................... 56, 58
Cylinder Liner .................................................. 45–46 Top Piston Ring (1) ...................................... 56–57

E S

Electronic Unit Injector Mechanism ......................... 6 Specifications Section ............................................. 4


Electronic Unit Injector Rocker Arm......................... 7 Speed/Timing Sensor ............................................ 87
Electronic Unit Injector Wiring ................................. 7 Camshaft Position Sensor ................................. 88
Engine Design ......................................................... 4 Crankshaft Position Sensor ............................... 88
Engine Oil Bypass Valve ................................. 38–39
Engine Oil Filter Base...................................... 32–33
Engine Oil Pan................................................. 40–42 T
Engine Oil Pressure Sensor ............................ 83–84
Engine Oil Pump.............................................. 34, 36 Table of Contents..................................................... 3
Oil Pump Body (4).............................................. 37 Turbocharger ....................................... 16, 18, 20–22
Oil Pump Spacer Assembly (3).......................... 37 Turbocharger Inlet Pressure Sensor ............... 86–87
Pump Body (2) ................................................... 37
Exhaust Manifold ................................. 24, 26, 28–30
V

F Valve Mechanism ................................................ 8–9


Vibration Damper............................................. 49–51
Flywheel .......................................................... 68–70
Flywheel Housing .......................... 70, 72–73, 75, 77
Fuel Filter Base ................................................... 5–6 W
Fuel Filter Pressure Differential Switch ................. 81
Fuel Temperature Sensor ................................ 80–81 Water Pump........................................................... 43
Fuel Transfer Pump ................................................. 5 Water Temperature Regulator ............................... 42

Gear Group (Front)................................................ 61


Gear Group (Rear) .............................. 62–63, 65, 67

Housing (Front)...................................................... 58
Housing (Rear) ...................................................... 59
90 SENR9936-06
Index Section
SENR9936-06 91
Index Section
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