Beruflich Dokumente
Kultur Dokumente
October 2004
Number of Cylinders 8
Connecting Rods Piston & Rod 9 Oil liners, rings and bearings.
Assembly
Rings 10 Install pistons and rod caps.
Pistons Q – 11 Torque rod bolts and rotate crankshaft to T.D.C. 5
#1 Cylinder.
Pins
Install piston cooling jets.
Rod Bearings 12
Install lower side covers.
13 Flywheel Housing Bolt Bolt Length Flywheel Housing Bolt Bolt Length
Installation (version 1) Installation (version 2) (excluding
(excluding head)
Camshafts Camshaft 14 Install camshafts and oil journals. head)
Spacers Assembly 15 Install camshaft timing pins.
Dia (in.) Bolt Part No. mm inch Dia Bolt Part No. mm inch
Bolts Location (in.) Location
Thrust Plates
Timing Pins 1/2 A 0S-1595 31.8 1.25 1/2 A 9X-8873 57.2 2.25
Shaft-Fuel Control Fuel Injector 16 Install fuel control shafts. 6 1/2 B 9X-8875 88.9 3.50 1/2 B 9X-8875 88.9 3.5
Cross Shaft
Control Group Q – 17 Install cross shaft, lever as., gov. lever, and
Supports As. adjust. 1/2 C 6M-9613 228.6 9.00 1/2 C 6M-9613 228.6 9
Bracket As.
Lever As. 1/2 D 9S-1374 203.2 8.00 1/2 D 9S-1374 203.2 8
Lever-Governor
6 Fuel Injection Control Linkage 1/2 E 8S-9089 114.3 4.50 1/2 E 8S-9089 114.3 4.5
Gaskets Cylinder Head 18 Install space plate gasket, spacer plate, water
(1) Tighten locknuts at each end of bellcrank to a torque of 8 ± 2 N·m (6 ± 1 lb ft). 5/8 F 1D-4590 120.7 4.75 5/8 F 1D-4590 120.7 4.75
Seals Group seals, O-ring seals, and cylinder head gaskets.
O-rings (2) Clearance between lever assemblies on front cross shaft side shafts 0.20 ± 0.10 mm (0.008 ± 0.004 in.).
Install cylinder heads.
Cylinder Heads 19
Q – 20 Torque cylinder head bolts.
Cam Followers 7
Flywheel Group 35 Install flywheel. 12 1/2 H 1D-4574 152.4 6.00 1/2 H 1D-4574 152.4 6.00
(Cont. on back) Q – 36 Torque bolts & check flywheel runout. Note: The plug at location (A) must be
installed on these engines. 1/2 I 9X-8878 133.4 5.25 1/2 I 9X-8878 133.4 5.25
a. Tighten bolts 1 thru 8 in numerical 5/8 K 1D-4602 241.3 9.50 5/8 K 1D-4602 241.3 9.50
Cylinder Liner Installation: sequence to 30 ± 5 N·m (22 ± 4 lb ft).
b. Tighten bolts 1 thru 8 in numerical 5/8 L 1D-4593 139.7 5.50 5/8 L 1D-4593 139.7 5.50
a. Put liquid soap on cylinder block liner bore surfaces
and rubber seals on the lower part of the liner. sequence to 200 ± 15 N·m (147 ± 11 lb ft).
c. Re-tighten bolts 1 thru 8 in numerical 1/2 M 2B-0947 57.15 2.25 1/2 N 1D-4574 152.4 6.00
b. Put the filler band completely in clean engine oil for sequence to 200 ± 15 N·m (147 ± 11 lb ft).
a moment.
d. Turn bolts 1 thru 8 in numerical Tools needed to install
c. Install filler band in the groove under the liner flange, sequence an additional 180o ±5 o.
without delay. Flywheel Housing Crankshaft Wear Sleeves & Quantity
(2) Install 2 cap plugs in top of cylinder head to Seals (Front & Rear)
d. Install the liner in the block immediately, before a depth of 9.0 ± 0.5 mm (0.35 ± 0.02 inch). Installation Steps:
expansion of the filler band. Apply 6V-6640 Sealant to cup bores prior 6V-4002 Forcing Bracket 2
Make reference to Flywheel Housing Runout
to assembly. & Flywheel Housing Bore Runout for correct
Cylinder Liner Projection methods of flywheel housing inspection.
6V-4001 Forcing Ring 1
(3) Height of cylinder head (new) is 142.00 ±
Make reference to Cylinder Liner Projection in Testing 0.15 mm (5.591 ± 0.006 inch). (1) Plug’s torque 70 ± 15 N·m (50 ± 11 lb ft). 1D-4716 Nut (5/16"-18 NC) 4
and Adjusting for the complete procedure. 3. Measure cylinder liner projection with dial
indicator (2) in 1P-2402 Gauge Body (3) as (4) Depth below bottom of chamfer, which (2) Install three dowels to a height of 6.0 ±
1. Install the gasket and spacer plate (5). Install copper 6V-4003 Locator 1
shown. Measure at four places around each remainder of cup plugs are installed in 0.5 mm (0.24 ± 0.02 inch).
washers and bolts (4) to hold the spacer plate. cylinder liner near the clamped area. head is 1.0 ± 0.5 mm (0.04 ± 0.02 in.).
(3) Install two dowels to a height of 3.5 ± 0.5 2N-5006 Bolt 1"-14NF X 63.5mm 2
Tighten bolts (4) evenly in four steps: Apply 6V-6640 Sealant to cup bores prior (2.5 inch) long
Average of our projection measurements mm (0.14 ± 0.02 inch).
1st step 14 N·m (10 lb ft) to assembly.
from any cylinder must be 0.059 to 0.199
2nd step 35 N·m (25 lb ft) (4) Put 6V-6640 Gasket Sealant on Guide Bolts 5/16"-18NC X 101.6 mm 4
mm (0.0023 to 0.0078 inch).
3rd step 70 N·m (50 lb ft) complete surface of flywheel housing that (4 inch) long
4th step 95 N·m (70 lb ft) Maximum permissible difference between all makes contact with the cylinder block.
6V-4977 Installer 1
2. Install tooling as shown. Tighten bolts for crossbar
four measurements around each cylinder
liner is 0.05 mm (0.002 inch). 8 Fuel Injection (5) Tighten bolts holding flywheel housing to
the rear face of the cylinder block.
evenly in four steps: 9S-8858 Nut 1
1st step 7 N·m (5 lb ft) (1) 3H-0465 Plate
Torque for 1/2 inch - 13 NC bolts is 135 ± 20
2nd step 20 N·m (15 lb ft) (6) 8B-7548 Push-Puller Crossbar (1) Torque for injector rocker arm adjustment screw N·m (100 ± 15 lb ft). 8T-3099 Installer 1
3rd step 35 N·m (20 lb ft) locknut is:
4th step 70 N·m (50 lb ft) 5/8 inch locknut: 120 ± 15 N·m (89 ± 11 lb ft) Torque for 5/8 inch - 11 NC bolts is 270 ± 40 Removal:
1/2 inch locknut: 70 ± 15 N·m (52 ± 11 lb ft). N·m (199 ± 30 lb ft).
a. Remove seal from each end of engine.
(2) Injector installation:
2 Cooling Jet Sequence a. Put 1P-0808 multipurpose grease in bore of
Note: Seals & wear sleeves cannot be
used again, after seals & wear sleeves
Valve 3 Cylinder Block cylinder head for lubrication of O-ring seals.
b. Put injector in bore. Use clamp to push
are separated.
injector into correct position. b. Remove wear sleeves with 5P-7409
(3) Fuel timing dimension set by gauge Distorter and 6V-3143 Distorter Adapter.
Note: Do not tap (hit) surface "Y" to install injector.
(Fuel setting information located on Drawing Installation:
c. Tighten bolt that holds fuel injector clamp to #16 of this chart.
65 ± 7 N·m (48 ± 5 lb ft). a. Do not separate wear sleeves (6) from
d. After clamp is tightened, injector rack "X" crankshaft seals (3) & (4). Once they are
must move freely. separated they cannot be used again.
b. Install sleeve and seal assembly with the
correct tools.
9 Exhaust Manifolds c. Clean outer surface of crankshaft and the
inner surface of wear sleeve (6) with
169-5464 Quick Cure Primer (Aerosol
spray).
Main Bearing Cap Bolt Torque Crankshaft Wear Sleeves & Seals d. Carefully put a thin coat of 4C-9507
6B-9202 Spring for cooling jet sequence valve Note: Assemble main bearing caps with (Front & Rear) Retaining Compound on the inner
(one at each end of block): “FRONT” & cast part no. toward front of block. (1) Flywheel housing. surface of wear sleeve (6) and on
Length under test force is 68.3 mm (2.69 inch). 1. Completely lubricate bolt threads with SAE crankshaft surface.
(2) Front housing.
Test force is 85 to 102 N (19 to 23 lb). 30 engine oil before assembly. e. Install seals (3) and (4) with wear sleeve
(3) 113-8433 Seal Group (rear). (6) as a unit on the end of the crankshaft
Free length after test is 112.7 mm (4.44 inch). 2. Start bolts in tapped holes “by hand”.
(4) 113-8432 Seal Group (front). with the correct tools.
Outside diameter is 24.60 mm (0.969 inch). 3a. If the main bearing cap bolts are 19.05 mm
(0.75 inch), then tighten in letter sequence to (5) Crankshaft seal installed from both ends
Both cooling jet sequence valves must start to 136 ± 14 N·m (101 ± 10 lb ft). Next, tighten of crankshaft 8.0 ± 0.5 mm (0.315 ± 0.020
open at a pressure difference of 130 ± 30 kPa bolts in letter sequence an additional 180 o ± 5°. in.).
(19 ± 4.5 psi) and must be fully open at Typical Example Crankshaft seals must be installed with lip of
200 ± 30 kPa (29 ± 4.5 psi). 3b. If the main bearing cap bolts are 22.23 mm the seal toward inside of engine as shown.
(0.875 inch), then torque in letter sequence to (1) Left exhaust manifold. Make sure correct seal is installed on each
190 ± 14 N·m (140 ± 10 lb ft). Next, tighten end of the crankshaft. Use 113-8432 Seal
bolts in letter sequence an additional 180 o ± 5°. (2) Put 5P-3931 Anti-Seize Compound on washer face & threads of all exhaust manifold bolts, then tighten
Gp on front & 113-8433 Seal Gp on rear.
to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Diagonally opposed bolts are to be tightened simultaneously.
(6) Wear sleeve.
(3) Right exhaust manifold.
(7) Dimension installed from both ends of
4 Crankshaft Specifications 10 Aftercooler
crankshaft 0.5 ± 0.5 mm (0.020 ± 0.020 in.).
Out of
Main
Round
Main
Out of
Rod
Round
Rod
Taper
Main
Taper
Rod
Thrust
Face
Thrust
Face
Radius2
Main
Radius2
& Rod
Journal
Hardness 12 Flywheel Installation, Bolt Torque & Runout
Min. Max. Min. Max. Max. Max. Min. Max.1 Min. Max.
Each counterweight has a number and must be installed in the same position as the correct number on the (4) Torque for bolts that hold the aftercooler housings to the cylinder block is 55 ± 7 N·m (41 ± 5 lb ft).
crankshaft mounting pad to prevent damage to the crankshaft when the engine is run.
3508 & 3508B Engine Assembly Procedure
Sub
Assembly Sub Assembly
Installation
Parts Assembly Procedure
13 (Continued) Flywheel Housing Runout 17 Trunnion
Parts Sequence
Flywheel Group Q – 37 Check flywheel housing bore (1) Tighten the bolts that hold the mount
(continued from and face runout. 13 assembly to the support to a torque
front) of 190 ± 30 N·m (140 ± 22 lb ft).
Q – 38 Install timing pin.
(2) Tighten the bolts that hold trunnion to
front drive housing to a torque of 135
Camshaft Drive 39 Install camshaft gears.
± 20 N·m (100 ± 15 lb ft).
Gears (Timing pins in place)
14 (3) Tighten the bolts that hold trunnion to
& Q – 40 Torque bolts. front engine support to a torque of
Front Balance Q – 41 Remove timing pins. 475 ± 60 N·m (350 ± 45 lb ft).
Gears
(Flywheel & Cams)