SENR9702-05

July 2005

Specifications
C11 and C13 On-highway Engines
KCA1-Up (Engine)
KCB1-Up (Engine)
JAM1-Up (Engine)
 i01658146

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product Caterpillar recommends using 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.
SENR9702-05 3
Table of Contents

Table of Contents Electric Starting Motor .........................................

Coolant Temperature Sensor ...............................
42
43
Fuel Temperature Sensor ..................................... 43
Engine Oil Pressure Sensor ................................. 43
Specifications Section Boost Pressure Sensor ......................................... 43
Atmospheric Pressure Sensor .............................. 44
Engine Design ....................................................... 4
Inlet Manifold Temperature Sensor ....................... 44
Engine Design ....................................................... 4
Speed/Timing Sensor .......................................... 44
Fuel Transfer Pump ............................................... 5
Electronic Unit Injector ............................................ 5
Electronic Unit Injector Mechanism ....................... 6 Index Section
Electronic Unit Injector Rocker Arm ........................ 6
Electronic Unit Injector Wiring ................................. 7 Index ..................................................................... 46
Lifter Group ............................................................. 8
Rocker Shaft .......................................................... 8
Valve Mechanism ................................................... 9
Cylinder Head Valves ........................................... 10
Cylinder Head ....................................................... 11
CAT Compression Brake ...................................... 13
Turbocharger ....................................................... 14
Turbocharger ....................................................... 15
Turbocharger ....................................................... 15
Air Lines ................................................................ 16
Air Lines ................................................................ 16
Air Lines ................................................................ 17
Air Lines ................................................................ 17
Air Lines ................................................................ 18
Air Lines ................................................................ 19
Air Lines ................................................................ 19
Air Lines ................................................................ 20
Air Lines ................................................................ 20
Exhaust Manifold ................................................. 21
Camshaft ............................................................. 22
Engine Oil Filter Base .......................................... 22
Engine Oil Cooler ................................................. 24
Engine Oil Pump .................................................. 24
Engine Oil Pan ..................................................... 25
Engine Oil Pan ..................................................... 25
Engine Oil Pan ..................................................... 25
Precooler .............................................................. 26
Water Temperature Regulator Housing ................ 27
Water Temperature Regulator .............................. 27
Water Pump ......................................................... 28
Cylinder Block ...................................................... 28
Cylinder Liner ....................................................... 30
Cylinder Liner Projection ...................................... 30
Crankshaft ........................................................... 31
Crankshaft Seals ................................................. 31
Connecting Rod Bearing Journal ......................... 32
Main Bearing Journal ............................................ 32
Connecting Rod ................................................... 33
Connecting Rod ................................................... 34
Piston and Rings .................................................. 35
Piston Cooling Jet ................................................. 36
Housing (Front) ..................................................... 36
Gear Group (Front) ............................................... 37
Gear Group (Rear) ................................................ 38
Flywheel Housing ................................................ 38
Flywheel Housing ................................................ 39
Engine to Transmission Adapter .......................... 39
Belt Tensioner ....................................................... 40
Electric Starting Motor ......................................... 40
Electric Starting Motor ......................................... 41
4 SENR9702-05
Specifications Section

Specifications Section The crankshaft rotation is viewed from the

flywheel end of the engine. Crankshaft
rotation .......................................... Counterclockwise
i02165970
Note: The front of the engine is opposite of the
Engine Design flywheel end of the engine. The left side of the engine
and the right side of the engine are viewed from the
SMCS Code: 1201 flywheel end of the engine. The No. 1 cylinder is the
front cylinder.
S/N: KCA1-Up

C11 i02379619

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

C13

g01098200
Illustration 1
(A) Exhaust valves
(B) Inlet valves

Bore ............................................................. 130 mm

(5.12 inch)

Stroke .......................................................... 140 mm

(5.51 inch)
g01098200
Illustration 2
Displacement ................................................... 11.1 L
(A) Exhaust valves
(680 cu in) (B) Inlet valves

Cylinder arrangement ..................................... In-line Bore ............................................................. 130 mm

Valves per cylinder .................................................. 4
In order to check the engine valve lash setting, the
engine must be cold and the engine must be stopped.
Engine valve lash
Inlet ............................................ 0.38 ± 0.08 mm
(0.015 ± 0.003 inch)
Exhaust ...................................... 0.64 ± 0.08 mm
(0.025 ± 0.003 inch)
Variable valve actuator .......... 0.610 ± 0.075 mm
(0.0240 ± 0.0030 inch)
Compression brake ............... 0.864 ± 0.050 mm
(0.0340 ± 0.0020 inch)
Type of combustion ............................ Direct injection
Firing order ............................................. 1-5-3-6-2-4
(5.12 inch)
Stroke .......................................................... 157 mm
(6.18 inch)
Displacement .................................................. 12.5 L
(763 cu in)
Cylinder arrangement ..................................... In-line
Valves per cylinder .................................................. 4
In order to check the engine valve lash setting, the
engine must be cold and the engine must be stopped.
Engine valve lash
Inlet ............................................ 0.38 ± 0.08 mm
(0.015 ± 0.003 inch)
SENR9702-05 5
Specifications Section

Exhaust ...................................... 0.64 ± 0.08 mm
(0.025 ± 0.003 inch)
Variable valve actuator .......... 0.610 ± 0.075 mm
(0.0240 ± 0.0030 inch)
Compression brake ............... 0.864 ± 0.050 mm
(0.0340 ± 0.0020 inch)
Run the pump at 2940 rpm. The full bypass pressure
should be the following value. ........... 716 to 786 kPa
(104 to 114 psi)
Run the pump at 840 rpm. The flow at 550 kPa
(80 psi) must be 3.0 L/min (0.8 US gpm).

Type of combustion ............................ Direct injection Run the pump at 100 rpm with a blocked inlet for 30
seconds. The pump inlet must have a suction lift of
Firing order ............................................. 1-5-3-6-2-4 60.9 kPa (18 In Hg) minimum.

The crankshaft rotation is viewed from the
flywheel end of the engine. Crankshaft
rotation .......................................... Counterclockwise
Note: The front end of the engine is opposite of the
flywheel end of the engine. The left side of the engine
and the right side of the engine are viewed from the
flywheel end of the engine. The No. 1 cylinder is the
front cylinder.
i02035050
Run the pump at 2940 rpm. The flow at 650 kPa
(94 psi) must be 4.5 L/min (1.19 US gpm).
When the pump is viewed from the drive end the
rotation of the pump is counterclockwise.
i01831899
Electronic Unit Injector
SMCS Code: 1290

Fuel Transfer Pump Part No.: 251-7164

S/N: KCA1-Up
SMCS Code: 1256 Part No.: 251-4513
Part No.: 227-5723 S/N: KCB1-Up
Part No.: 251-4513
S/N: JAM1-Up

g00793873
Illustration 3

(1) Outlet port g00935781

Illustration 4
(2) Drain hole
(1) Lubricate the seals and the bore with a 50
(3) Inlet port percent mix of 8T-2998 Lubricant and engine oil.

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

When the fuel transfer pump is using diesel fuel, the

fuel transfer pump has the following specifications.
6 SENR9702-05
Specifications Section

i02158853 i02347715

Electronic Unit Injector Electronic Unit Injector Rocker

Mechanism Arm
SMCS Code: 1290 SMCS Code: 1123
Part No.: 240-7272 Part No.: 241-0845

g00950406
Illustration 6

(A) Oil passage angle ............................ 13 degrees

(B) Bearing bore diameter ......... 34.050 ± 0.015 mm

(1.3405 ± 0.0006 inch)
g01095007
Illustration 5
Bore in the rocker arm for the
bearing .. 37.000 ± 0.020 mm (1.4567 ± 0.0008 inch)
(1) Unit injector
(C) Oil passage angle ........................... 20 degrees
The adjusting instructions for the unit injector are
listed below. Note: The rocker arm bearing must not extend
beyond either face of the rocker arm.
1. Loosen the locknut (2).
(D) Preset location from factory .... 13.40 ± 0.50 mm
2. Turn the adjustment screw clockwise. Stop turning (0.528 ± 0.020 inch)
the adjustment screw when contact is made with
the unit injector. (E) Preset location from factory ................. 6.50 mm
(0.256 inch)
3. Turn the adjustment screw.

Turn ............................ 180 degrees (1/2 of a turn)

4. Hold the adjustment screw. Tighten the locknut (2).

Tighten the locknut to the following

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

(3) Rocker arm

(4) Rocker arm shaft

(5) Lifter group shaft

(6) Unit injector lifter assembly

SENR9702-05 7
Specifications Section

i02166534

Electronic Unit Injector Wiring

SMCS Code: 1290
Part No.: 229-2919

g01098400
Illustration 7

(1) Wiring harness connectors

(2) Cat brake connectors

(3) Torque for the cap nuts ................ 2.5 ± 0.25 N·m
(22 ± 2 lb in)

The rear harness has connectors for two brake

solenoids. The connection at the Cat brake solenoid
is not serviceable.
8 SENR9702-05
Specifications Section

i01832493 i01832505

Lifter Group Rocker Shaft

SMCS Code: 1209 SMCS Code: 1102
Part No.: 237-4376 Part No.: 224-4418

g00936120
Illustration 9

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

(0.040 ± 0.010 inch)

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

g00936107 (1.339 ± 0.0005 inch)
Illustration 8

(1) Tighten the seven bolts to the following

torque. ............................................. 60 ± 12 N·m
(45 ± 9 lb ft)

(2) The alignment dowel for the oil hole extends past
the shaft by the following distance. ....... 19.7 mm
(0.78 inch)

(3) Valve lifters

(4) Electronic unit injector lifter

(5) The depth is measured from the end of the

shaft to the top edge of the cup plug. Depth of
installation ..................................... 18 ± 0.25 mm
(0.708 ± 0.010 inch)

Diameter of the lifter shaft .................. 20 ± 0.01 mm

(0.787 ± 0.0004 inch)
SENR9702-05 9
Specifications Section

i02379906 Tighten the jam nut after setting the valve lash to
the following torque. .......................... 30 ± 7 N·m
Valve Mechanism (20 ± 5 lb ft)
SMCS Code: 1102 (3) Unit injector
Part No.: 240-7272
Adjust the unit injector as the unit injector is described
below.

1. Loosen locknut (2).

2. Turn the adjustment screw clockwise. Stop turning

the adjustment screw when contact is made with
the unit injector.

3. Place an identifying mark on the adjustment screw.

Tighten the adjustment screw

additionally. ................ 180 degrees (1/2 of a turn)

4. Hold the adjustment screw. Tighten locknut (2).

Tighten the locknut to the following

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

(4) Inlet rocker arm

Valve lash setting ....................... 0.38 ± 0.08 mm
(0.015 ± 0.003 inch)
Tighten jam nut (3) after setting the valve lash to
the following torque. .......................... 30 ± 7 N·m
(20 ± 5 lb ft)

(5) Rocker arm shaft

g01188376
Illustration 10
(6) Exhaust valve pushrod
Procedure for setting the valve lash and the unit (7) Pushrod for the unit injector
injector assembly
(8) Pushrod for the inlet valve
1. Set number 1 piston at TDC of the compression
stroke (9) Lifter group shaft
a. Set inlet valves on cylinder 1, 2, and 4

b. Set exhaust valves on cylinders 1, 3, and 5

c. Set unit injectors on cylinders 3, 5, and 6

2. Turn the crankshaft 360 degrees in direction of

engine rotation (number 6 piston at TDC of the
compression stroke).

a. Set inlet valves on cylinder 3, 5, and 6

b. Set exhaust valves on cylinders 2, 4, and 6

c. Set unit injectors on cylinders 1, 2, and 4

(1) Exhaust rocker arm

Valve lash setting ...................... 0.64 ± 0.08 mm
(0.025 ± 0.003 inch)
10 SENR9702-05
Specifications Section

i02386997

Cylinder Head Valves

SMCS Code: 1105
Part No.: 257-4095

g00936327
Illustration 13

(2) Exhaust valve

(E) Diameter of valve head ........ 41.5 ± 0.13 mm
(1.634 ± 0.005 inch)
g01191261
(F) Valve face angle ..................... 45.75° ± 0.25°
Illustration 11 (G) Valve stem diameter ........ 9.441 ± 0.008 mm
(0.3717 ± 0.0003 inch)
Minimum valve stem diameter ............ 9.309 mm
(0.3665 inch)

(3) Height of installation for the valve guide

Height to the step in the valve guide .. 22 ± 0.5 mm
(0.87 ± 0.012 inch)

(4) 224-4441 Spring

Inner valve spring
Assembled length ............................... 50.47 mm
(1.987 inch)
g00936340
Load at assembled length ................. 160 ± 13 N
Illustration 12 (36 ± 3 lb)
Minimum operating length .................. 34.92 mm
Note: Apply engine oil to the valve stems prior to (1.375 inch)
installation in the cylinder head. Load at minimum operating length .... 385 ± 18 N
(87 ± 4 lb)
(1) Inlet valve Outside diameter ................................ 23.24 mm
(A) Diameter of valve head ........ 44.5 ± 0.13 mm (0.915 inch)
(1.752 ± 0.005 inch) Free length after test ............................ 64.1 mm
(B) Valve face angle .................... 60.75° ± 0.25° (2.52 inch)
(C) Valve stem diameter ........ 9.441 ± 0.008 mm
(0.3717 ± 0.0003 inch) (5) 214-0586 Spring
Minimum valve stem diameter ............ 9.309 mm Outer valve spring
(0.3665 inch)
Assembled length ............................... 52.95 mm
(2.085 inch)
Load at assembled length ................. 320 ± 31 N
(72 ± 7 lb)
Minimum operating length .................. 37.40 mm
(1.472 inch)
Load at minimum operating length .... 860 ± 34 N
(193 ± 8 lb)
Outside diameter ..................................... 34 mm
(1.34 inch)
SENR9702-05 11
Specifications Section

Free length after test ............................ 62.7 mm

(2.47 inch)

(6) Valve guides

Bore of installed valve guide .. 9.490 ± 0.026 mm
(0.3740 ± 0.0010 inch)
Maximum recommended diameter of the valve
guide bore ........................................... 9.544 mm
(0.3760 inch)

Note: Do not use a combination of a valve and

a valve guide that has a difference of 0.13 mm
(0.005 inch) or more.

(7) Inlet valve seat

Angle of valve seat ...................... 60.25° ± 0.25°
Diameter of valve seat ......... 45.525 ± 0.013 mm
(1.7923 ± 0.0005 inch)
Bore in cylinder head for valve
seat ...................................... 45.461 ± 0.015 mm
(1.7898 ± 0.0006 inch)

(8) Exhaust valve seat

Angle of valve seat ...................... 44.75° ± 0.25°
Diameter of valve seat ......... 42.390 ± 0.015 mm
(1.6690 ± 0.0006 inch)
Bore in cylinder head for valve
seat ........................................ 42.32 ± 0.015 mm
(1.6661 ± 0.0006 inch)

i02378890

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

g00950659
Illustration 14
12 SENR9702-05
Specifications Section

Note: Lubricate the bolt threads, the underside of the

bolt heads, and the washers with 6V-4876 Lubricant
prior to assembly.

Use the following procedure in order to tighten the

cylinder head bolts:

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

sequence.

Tighten the bolts to the following

torque. ....................... 170 ± 10 N·m (125 ± 7 lb ft)

2. Tighten bolt (1) through bolt (26) again in a

numerical sequence.
Tighten the bolts again to the following
torque. ............................................. 170 ± 10 N·m
(125 ± 7 lb ft)
3. Place a mark on bolt (1) through bolt (26). Rotate
bolt (1) through bolt (26) in a numerical sequence.
Rotate the bolts in the clockwise
direction. ..................... 120 ± 5 degrees (1/3 turn)
g00284618
Illustration 15
View A-A
Note: Lubricate the bores for the cup plugs with
6V-6640 Sealant prior to installing the cup plugs.
(34) The cup plugs are measured from the head
face to the top edge of the plug. Depth of
installation .................................. 1.25 ± 0.25 mm
(0.049 ± 0.010 inch)

4. Loosen bolt (1) through bolt (26) until the
washers are loose under the bolt heads.
5. Tighten bolt (1) through bolt (26) in a numerical
sequence.
Tighten the bolts to the following
torque. ............................................. 170 ± 10 N·m
(125 ± 7 lb ft)
6. Tighten bolt (1) through bolt (26) again in a
numerical sequence.
Tighten the bolts again to the following
torque. ............................................. 170 ± 10 N·m
(125 ± 7 lb ft)
Minimum permissible thickness of cylinder
head ........................................................ 164.85 mm
(6.4901 inch)
Maximum permissible thickness of cylinder
head ........................................................ 165.15 mm
(6.502 inch)
Note: The flatness of the cylinder
head should be within 0.15 mm
(0.006 inch). The flatness should also be a
maximum of 0.05 mm (0.002 inch) for any 150.00 mm
(5.906 inch) span.

7. Place a mark on bolt (1) through bolt (26). Rotate

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

Rotate the bolts in the clockwise

direction. ..................... 120 ± 5 degrees (1/3 turn)

8. Tighten bolt (27) through bolt (33) in a numerical

sequence.

Tighten the bolts to the following

torque. ............................................... 55 ± 10 N·m
(41 ± 7 lb ft)
SENR9702-05 13
Specifications Section

i02385807

CAT Compression Brake

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

g01078418
Illustration 17
Lash for variable valve actuator

(4) Adjustment screw and jam nut for the variable

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

g01180174
Illustration 16

(1) Locknut

(2) Exhaust brake solenoid

(3) Master piston

14 SENR9702-05
Specifications Section

i02217255

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

g01119092
Illustration 19

g01078423
(1) Tube As
Illustration 18
Lash for exhaust brake Tighten the nuts on the Tube As to the following
torque. ................... 12 ± 1.5 N·m (106 ± 13 lb in)
(5) Adjustment screw and jam nut for the Cat
compression brake (2) Nuts for mounting the turbocharger

Cat compression brake lash Apply 5P-3931 Anti-Seize Compound on the

setting .................................... 0.864 ± 0.050 mm washer face and the threads of the mounting
(0.0340 ± 0.0020 inch) studs for the turbocharger before assembly.
Tighten the jam nut to the following Tighten the nuts that hold the turbocharger
torque. ..................... 15 ± 3 N·m (11.0 ± 2.2 lb ft) to the exhaust manifold to the following
torque. ....................... 70 ± 15 N·m (52 ± 11 lb ft)
(6) Stud
(3) Stud
(7) Exhaust rocker arm
Tighten the stud to the following
torque. ........................... 35 ± 5 N·m (26 ± 4 lb ft)

Note: Install the stud with the stamped letter X

showing.
SENR9702-05 15
Specifications Section

i02217215 i02380404

Turbocharger Turbocharger
SMCS Code: 1052 SMCS Code: 1052
Part No.: 259-9038 Part No.: 229-3553
S/N: KCA1-Up S/N: KCB1-Up
Part No.: 259-9038 Part No.: 229-3553
S/N: KCB1-Up S/N: JAM1-Up

g01119067 g01188495
Illustration 20 Illustration 21

(1) Tube As (1) Tube As

Tighten the nuts on the Tube As to the following Tighten the nuts on the Tube As to the following
torque. ................... 12 ± 1.5 N·m (106 ± 13 lb in) torque. ................... 12 ± 1.5 N·m (106 ± 13 lb in)

(2) Nuts for mounting the turbocharger
Apply 5P-3931 Anti-Seize Compound on the
washer face and the threads of the mounting
studs for the turbocharger before assembly.
Tighten the nuts that hold the turbocharger
to the exhaust manifold to the following
torque. ....................... 70 ± 15 N·m (52 ± 11 lb ft)
(3) Stud
Tighten the stud to the following
torque. ........................... 35 ± 5 N·m (26 ± 4 lb ft)
Note: Install the stud with the stamped letter X
showing.
(2) Nuts for mounting the turbocharger
Apply5P-3931 Anti-Seize Compound (HIGH
TEMPERATURE) on the washer face and
the threads of the mounting studs for the
turbocharger before assembly. Tighten the nuts
that hold the turbocharger to the exhaust manifold
to the following torque. .................... 70 ± 15 N·m
(52 ± 11 lb ft)
(3) Stud
Tighten the stud to the following
torque. ........................... 35 ± 5 N·m (26 ± 4 lb ft)
Note: Install the stud with the stamped letter X
showing.
16 SENR9702-05
Specifications Section

i02219319 Note: Refer to illustration 22 for the correct orientation

of the clamp for the air inlet elbow.
Air Lines
SMCS Code: 1058; 1071 i02219491

Part No.: 242-6219 Air Lines

S/N: KCA1-Up
Part No.: 242-6219
S/N: KCB1-Up
The ends of the bellows are very sharp. Injury
could occur if the bellows are not handled prop-
erly. Handle the bellows by the convolutions.
NOTICE
The alignment of the bellows is important. Improper
alignment may lead to premature failure of the bel-
lows. Misalignment can be identified by visually in-
specting the convolutions for uniformity of compres-
sion.
Inspect the bellows for damage prior to installation.
If there is any damage to the convolutions, discard
the bellows. Minor damage to the ends of the bellows
may be repaired. However, if there is any difficulty in
installation after the repair, discard the bellows.
SMCS Code: 1058; 1071
Part No.: 233-2515
S/N: KCA1-Up
Part No.: 233-2515
S/N: KCB1-Up
The ends of the bellows are very sharp. Injury
could occur if the bellows are not handled prop-
erly. Handle the bellows by the convolutions.
NOTICE
The alignment of the bellows is important. Improper
alignment may lead to premature failure of the bel-
lows. Misalignment can be identified by visually in-
specting the convolutions for uniformity of compres-
sion.
Inspect the bellows for damage prior to installation.
If there is any damage to the convolutions, discard
the bellows. Minor damage to the ends of the bellows
may be repaired. However, if there is any difficulty in
installation after the repair, discard the bellows.

g01120233
Illustration 22
Right side of engine, typical view

(1) Torque for band clamp .. 8 ± 4 N·m (71 ± 35 lb in) g01120309

Illustration 23
Left side of engine, typical view
(2) Air inlet elbow
(1) High pressure turbocharger
SENR9702-05
(2) Torque for band clamps ....................... 8 ± 3 N·m
(71 ± 27 lb in)
Note: Refer to illustration 23 for the correct orientation
of the clamp for the air intake elbow.
i02219432
Air Lines
SMCS Code: 1058; 1071
Part No.: 233-2517
S/N: KCA1-Up
Part No.: 233-2517
S/N: KCB1-Up
The ends of the bellows are very sharp. Injury
could occur if the bellows are not handled prop-
erly. Handle the bellows by the convolutions.
NOTICE
The alignment of the bellows is important. Improper
alignment may lead to premature failure of the bel-
lows. Misalignment can be identified by visually in-
specting the convolutions for uniformity of compres-
sion.
Inspect the bellows for damage prior to installation.
If there is any damage to the convolutions, discard
the bellows. Minor damage to the ends of the bellows
may be repaired. However, if there is any difficulty in
installation after the repair, discard the bellows.
g01120271
Illustration 24
Right side of engine, typical view
17
Specifications Section
(1) Torque for band clamps ....................... 8 ± 3 N·m
(71 ± 27 lb in)
(2) Outlet elbow for the precooler
Note: Refer to illustration 24 for the correct orientation
of the clamp for the outlet elbow for the precooler.
i02220217
Air Lines
SMCS Code: 1058; 1071
Part No.: 224-5396, 224-5397, 224-5443
S/N: KCA1-Up
Part No.: 224-5396, 224-5397, 224-5443
S/N: KCB1-Up
Part No.: 224-5397
S/N: JAM1-Up
The ends of the bellows are very sharp. Injury
could occur if the bellows are not handled prop-
erly. Handle the bellows by the convolutions.
NOTICE
The alignment of the bellows is important. Improper
alignment may lead to premature failure of the bel-
lows. Misalignment can be identified by visually in-
specting the convolutions for uniformity of compres-
sion.
Inspect the bellows for damage prior to installation.
If there is any damage to the convolutions, discard
the bellows. Minor damage to the ends of the bellows
may be repaired. However, if there is any difficulty in
installation after the repair, discard the bellows.
18 SENR9702-05
Specifications Section

i02219543

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

The ends of the bellows are very sharp. Injury

could occur if the bellows are not handled prop-
erly. Handle the bellows by the convolutions.

NOTICE
The alignment of the bellows is important. Improper
alignment may lead to premature failure of the bel-
g01078415
Illustration 25 lows. Misalignment can be identified by visually in-
Right side of engine, typical view specting the convolutions for uniformity of compres-
sion.
Note: Refer to illustration 25 for the correct orientation
of the turbocharger clamps. Inspect the bellows for damage prior to installation.
If there is any damage to the convolutions, discard
(1) Low pressure turbocharger the bellows. Minor damage to the ends of the bellows
may be repaired. However, if there is any difficulty in
(2) Low pressure turbocharger clamps ... 12 ± 1 N·m installation after the repair, discard the bellows.
(106 ± 9 lb in)

(3) Compressor interstage clamps ......... 12 ± 1 N·m

(106 ± 9 lb in)

(4) Precooler

(5) Inlet for the precooler ......................... 12 ± 4 N·m

(106 ± 35 lb in)

(6) Clamps for interstage turbine ........... 12 ± 1 N·m

(106 ± 9 lb in)

(7) High pressure turbocharger

(8) Torque for band clamps ..................... 12 ± 1 N·m

(106 ± 9 lb in)

(9) Fitting

g01120325
Illustration 26
Left side of engine, typical view

(1) Air intake elbow

(2) Torque for band clamps ....................... 8 ± 3 N·m

(71 ± 27 lb in)
SENR9702-05
Note: Refer to illustration 26 for the correct orientation
of the clamps for the air intake elbow.
i02219368
Air Lines
SMCS Code: 1058; 1071
Part No.: 224-5394
The ends of the bellows are very sharp. Injury
could occur if the bellows are not handled prop-
erly. Handle the bellows by the convolutions.
NOTICE
The alignment of the bellows is important. Improper
alignment may lead to premature failure of the bel-
lows. Misalignment can be identified by visually in-
specting the convolutions for uniformity of compres-
sion.
Inspect the bellows for damage prior to installation.
If there is any damage to the convolutions, discard
the bellows. Minor damage to the ends of the bellows
may be repaired. However, if there is any difficulty in
installation after the repair, discard the bellows.
g01120245
Illustration 27
Right side of engine, typical view
(1) Torque for band clamps ....................... 8 ± 2 N·m
(71 ± 18 lb in)
(2) Air inlet elbow
Note: Refer to illustration 27 for the correct orientation
of the clamp for the air inlet elbow. The clamp must
be ±10 degrees of horizontal.
19
Specifications Section
i02380437
Air Lines
SMCS Code: 1058; 1071
Part No.: 237-4984
The ends of the bellows are very sharp. Injury
could occur if the bellows are not handled prop-
erly. Handle the bellows by the convolutions.
NOTICE
The alignment of the bellows is important. Improper
alignment may lead to premature failure of the bel-
lows. Misalignment can be identified by visually in-
specting the convolutions for uniformity of compres-
sion.
Inspect the bellows for damage prior to installation.
If there is any damage to the convolutions, discard
the bellows. Minor damage to the ends of the bellows
may be repaired. However, if there is any difficulty in
installation after the repair, discard the bellows.
g01188536
Illustration 28
Right side of engine
(1) Torque for band clamps ....................... 8 ± 3 N·m
(70 ± 27 lb in)
(2) Air inlet elbow
Note: Refer to illustration 28 for the correct orientation
of the clamp for the air inlet elbow.
20 SENR9702-05
Specifications Section

i02219472 Note: Refer to illustration 29 for the correct orientation

of the clamp for the air inlet elbow.
Air Lines
SMCS Code: 1058; 1071 i02219301

Part No.: 224-5395 Air Lines

S/N: KCA1-Up
Part No.: 224-5395
S/N: KCB1-Up
The ends of the bellows are very sharp. Injury
could occur if the bellows are not handled prop-
erly. Handle the bellows by the convolutions.
NOTICE
The alignment of the bellows is important. Improper
alignment may lead to premature failure of the bel-
lows. Misalignment can be identified by visually in-
specting the convolutions for uniformity of compres-
sion.
Inspect the bellows for damage prior to installation.
If there is any damage to the convolutions, discard
the bellows. Minor damage to the ends of the bellows
may be repaired. However, if there is any difficulty in
installation after the repair, discard the bellows.
SMCS Code: 1058; 1071
Part No.: 250-0784
S/N: KCA1-Up
Part No.: 250-0784
S/N: KCB1-Up
The ends of the bellows are very sharp. Injury
could occur if the bellows are not handled prop-
erly. Handle the bellows by the convolutions.
NOTICE
The alignment of the bellows is important. Improper
alignment may lead to premature failure of the bel-
lows. Misalignment can be identified by visually in-
specting the convolutions for uniformity of compres-
sion.
Inspect the bellows for damage prior to installation.
If there is any damage to the convolutions, discard
the bellows. Minor damage to the ends of the bellows
may be repaired. However, if there is any difficulty in
installation after the repair, discard the bellows.

g01120288
Illustration 29
Right side of engine, typical view

(8) Torque for band clamps ..................... 12 ± 4 N·m g01120210

Illustration 30
(106 ± 35 lb in)
Right side of engine, typical view
(7) Air inlet elbow
(1) Torque for band clamp .. 8 ± 4 N·m (71 ± 35 lb in)
SENR9702-05 21
Specifications Section

(2) Air inlet elbow 2. Apply engine oil to the female ends of the exhaust
manifold before assembly. Apply 2P-2333 High
Note: Refer to illustration 30 for the correct orientation Temperature Sealer to the outside diameter of the
of the clamp for the air inlet elbow. male ends of the exhaust manifold. Do not apply
the sealer at the tip of the male ends. Remove any
excess sealer from the assembled joint.
i02351281

Exhaust Manifold (2) Position the packing material so that the split line
of the packing material is at the 12:00 o’clock
SMCS Code: 1059 position.

Part No.: 224-5446 (3) Position the shields so that the gaps of the
shields are positioned at 3:00 o’clock and at
9:00 o’clock. Do not pinch the packing material
when you install the shields. Position the exhaust
clamps as the clamps are shown in illustration 31.

Use the following procedure to assemble the shield

and clamp over the joint in the exhaust.

1. Torque for the clamps to 5 ± 1 N·m (44 ± 9 lb in)

2. Again tighten both of the clamps to 16 ± 1 N·m

(142 ± 9 lb in).

3. Again tighten both clamps after the hot test to

16 ± 1 N·m (142 ± 9 lb in).

(4) Apply 5P-3931 Anti-Seize Compound to the

stud threads. Assemble the studs with the letter
“X” outward. Tighten the studs to the following
torque. ........................... 35 ± 5 N·m (26 ± 4 lb ft)

Illustration 31
g01174664 (5) Spacer
Three-piece exhaust manifold (typical example)
(6) Washer
(1) Exhaust manifold gasket
(2) Packing material
(3) Shields
(7) Spiralock nut
(4) Studs
(5) Spacer
(6) Washer
(7) Spiralock nut
(8) Stud

(1) Exhaust manifold gasket

Note: The exhaust manifold gaskets have tabs. The

tabs should point downward to the oil pan.

Use the following procedure during assembly of the

three-piece exhaust manifold to the cylinder block.

NOTICE
Excessive use of sealant can cause damage to com-
ponents.
To avoid component damage use only the amount of
sealant necessary for the application.
1. Mounting surfaces should be clean, and dry. In
addition, mounting surfaces should be free of any
other foreign matter.
g00566145
Illustration 32
Tightening sequence for the Spiralock nuts on the exhaust
manifold studs
(8) Apply 5P-3931 Anti-seize Compound to the
threads of the studs. Tighten the locknuts
in the numerical sequence that is shown
above in illustration 32 to the following
torque. ......................... 55 ± 10 N·m (41 ± 7 lb ft)
22 SENR9702-05
Specifications Section

Note: Prior to starting or running the engine, allow i02383634

the sealant in the exhaust manifold joints to air dry
for 24 hours. Engine Oil Filter Base
SMCS Code: 1306
i02380681
Part No.: 251-6669
Camshaft
SMCS Code: 1210
Part No.: 223-7462

g01188954
Illustration 34
Right side view

g01188644
Illustration 33

(1) Diameter of camshaft bearing

journal ........................................ 77.850 ± 0.025 mm
(3.0650 ± 0.0010 inch)
g00950317
The lobe on the camshaft for the injector has Illustration 35
the most lift when the cam is at zero degrees of Section D-D
rotation. ................................................... 12.703 mm
(0.5001 inch) Oil filter bypass

The lobe on the camshaft for the 4N-8150 Spring

injector has zero lift through the given
rotation. .......................... 74 degrees to 254 degrees
When the injector lobe has a lift height of 5.238 mm
(0.2062 inch), the camshaft should have an angle of
rotation. ........................................ 35 ± 0.25 degrees
(2) Bolts
Torque for the bolts ........ 35 ± 8 N·m (26 ± 6 lb ft)
Full open pressure ...... 255 ± 20 kPa (37 ± 3 psi)
Assembled length ............................... 55.25 mm
(2.175 inch)
Load at assembled length ..................... 76 ± 6 N
(17 ± 1.3 lb)
Free length after test ............................ 93.7 mm
(3.69 inch)
Outside diameter .................................. 20.6 mm
(0.81 inch)
SENR9702-05 23
Specifications Section

Assembled length ............................... 96.52 mm

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

g00950317
Illustration 36
Section A-A

Oil cooler bypass

4N-8150 Spring
Full open pressure ...... 255 ± 20 kPa (37 ± 3 psi)
Assembled length ............................... 55.25 mm
g00950314
(2.175 inch) Illustration 38
Load at assembled length ..................... 76 ± 6 N Section C-C
(17 ± 1.3 lb)
Free length after test ............................ 93.7 mm High pressure relief valve
(3.69 inch)
Outside diameter .................................. 20.6 mm 1A-2170 Retainer Spring
(0.81 inch) Relief pressure ............. 679.77 kPa (98.594 psi)
Assembled length ............................... 21.41 mm
(0.843 inch)
Load at assembled length ................. 200 ± 15 N
(45 ± 3.5 lb)
Free length after test ............................ 31.0 mm
(1.22 inch)
Outside diameter ................................ 16.97 mm
(0.668 inch)

g01188945
Illustration 37
Section B-B

(1) Plug
Torque for plug ......... 100 ± 15 N·m (75 ± 10 lb ft)

Pump bypass valve

7C-3954 Spring
Full open pressure ........ 374.70 kPa (54.346 psi)
24 SENR9702-05
Specifications Section

i02383708 i02383769

Engine Oil Cooler Engine Oil Pump

SMCS Code: 1378 SMCS Code: 1304
Part No.: 230-4516 Part No.: 223-1608

g01188995
Illustration 39

Note: Two valves are available. The valves are

designed to operate on either 12 or 24 volts. The
valves are not interchangeable.

(1) Engine oil cooler g01189123

Illustration 40

(2) Coolant diverter valve

NOTICE
(3) Hose Before operating the engine, the oil pump must be
lubricated with clean engine oil. The oil pump must
(3) Cut off length for hose ................. 90 ± 2 mm turn freely by hand. Damage to the drive gear and
(3.5433 ± 0.0787 inch) internal pump damage can occur if the oil pump is not
lubricated with clean engine oil.

Engine oil pump

Oil type ................................................... SAE 30
Oil temperature ............................ 50 °C (122 °F)
Pump speed ........................................ 3045 rpm
Oil pressure .............................. 359 kPa (52 psi)
Minimum oil flow ............ 155 L/min (41 US gpm)

(1) Diameter of two shafts ......... 18.000 ± 0.005 mm

(.7087 ± .0002 inch)

Bores in pump body for two

shafts ........ 18.050 ± 0.010 mm (.7106 ± .0004 inch)

(2) Seal groove

SENR9702-05 25
Specifications Section

Prior to installation, lubricate the bore in the engine i02196624

front cover. This will allow the seal groove and the
seal to slide. Engine Oil Pan
(3) Drive gear SMCS Code: 1302

In order to install the drive gear, heat the drive Part No.: 215-9005
gear to the following temperature. ........... 316 °C
(600 °F)

Diameter of the drive gear ............. 92.28 ± 0.10 mm

(3.6331 ± 0.0039 inch)

(4) Seal

(5) Distance between front face of gear and

housing ..... 29.40 ± 0.50 mm (1.158 ± .020 inch)

i02204941

Engine Oil Pan

g01098480
Illustration 42
SMCS Code: 1302 Front sump

Part No.: 229-6171, 264-5081

S/N: KCA1-Up (1) Oil pan

Part No.: 229-6171 (2) Torque for plugs ............................... 70 ± 15 N·m

S/N: KCB1-Up (52 ± 11 lb ft)

Part No.: 229-6171 (3) Rubber grommet

S/N: JAM1-Up
(4) Oil pan bolt

i02205054

Engine Oil Pan

SMCS Code: 1302
Part No.: 215-9007

g01098467
Illustration 41
Center sump

(1) Oil pan

(2) Torque for plugs ............................... 70 ± 15 N·m

(52 ± 11 lb ft)

(3) Rubber grommet

g01098531
Illustration 43
(4) Oil pan bolt Rear sump

(1) Oil pan

(2) Torque for plugs ............................... 70 ± 15 N·m

(52 ± 11 lb ft)
26 SENR9702-05
Specifications Section

(3) Rubber grommet

(4) Oil pan bolts

i02384834

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

g01189454
Illustration 45
Engine coolant diverter valve

(3) Torque for locking nut ..................... 20 ± 2.5 N·m

(14.8 ± 1.8 lb ft)

(4) Torque for cartridge (solenoid) ........... 37 ± 2 N·m

(27.2 ± 1.5 lb ft)

(5) Engine coolant diverter valve

Engine coolant diverter valve (5) will use either a 12

V switch or a 24 V switch. The voltage that is used
depends on the electrical system of the engine. The
valve is normally open.

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

g01189380
Illustration 44
Right side view of engine

(1) Precooler for intake air

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

g01189462
Illustration 46
SENR9702-05 27
Specifications Section

(7) Torque for plug .......... 8 ± 1 N·m (70.8 ± 8.9 lb in) i02349951

Water Temperature Regulator

i02110191
SMCS Code: 1355
Water Temperature Regulator
Part No.: 247-7133
Housing
SMCS Code: 1393
Part No.: 238-6730

g01099611
Illustration 49
(1) Water temperature regulator
(2) Seal

(A) Minimum stroke at full open

temperature ........................ 10.4 mm (0.41 inch)

Opening temperature ......................... 87 °C to 90 °C

(189 °F to 194 °F)

g01074249
Fully open temperature ...................... 98 °C (208 °F)
Illustration 47
Force that is required to separate valve from seat
Test temperature .......................... 80 °C (176 °F)
Force ......................... 165 ± 9 N·m (122 ± 7 lb ft)

Maximum rate for valve leakage

Test temperature .......................... 80 °C (176 °F)
Test pressure ............................ 210 kPa (30 psi)
Maximum leakage ........................ 10 cc (0.6 in3)

Maximum opening time for valve

Temperature at fully closed position .......... 85 °C
(185 °F)
Temperature at fully open position ........... 100 °C
(212 °F)
Maximum opening time ....................... 3 minutes

Maximum closing time for valve

Illustration 48
g01074251
The lip seal (2) is installed in the water temperature
regulator housing (1). This is shown in illustration 48.
Note: Lightly lubricate the sealing lip with a small
amount of glycerin.
Temperature at fully open position ........... 100 °C
(212 °F)
Temperature at fully closed position .......... 85 °C
(185 °F)
Maximum opening time ....................... 6 minutes
28 SENR9702-05
Specifications Section

i02385085 i02385285

Water Pump Cylinder Block

SMCS Code: 1361 SMCS Code: 1201
Part No.: 228-5811 Part No.: 239-7358

The flatness of the top contact surface of the cylinder

block must be within 0.05 mm (0.002 inch) for any
150 mm (5.9 inch) section of the surface.

g00488509
Illustration 51

Illustration 50
g01189596 Bore diameters in the cylinder block for the cylinder
block liners:
Water pump
Position (A) ............................ 151.50 ± 0.03 mm
(1) Washer (5.965 ± 0.001 inch)
Position (B) ................................ 149.8 ± 0.3 mm
(2) Bolt (5.898 ± 0.012 inch)
Position (C) ............................ 148.00 ± 0.03 mm
(3) Bearing (5.827 ± 0.001 inch)
Position (D) ............................ 141.90 ± 0.05 mm
(4) Gear (5.587 ± 0.002 inch)

(5) Retaining ring

(6) Seal

(7) Impeller

(8) Shaft

(9) Housing

(B) The distance between the pump flange and the

impeller hub ................................ 8.4 ± 0.25 mm
(0.331 ± 0.010 inch)
SENR9702-05 29
Specifications Section

1. Orient the main bearing cap correctly. The part

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

Note: The main bearing caps are marked with

identification numbers 1 through 7. Install the main
bearing caps into the correct positions.

2. Lubricate the main bearing cap bolts. Use “SAE

30W” oil or molybdenum grease to lubricate the
threads and the washer face.

3. Tighten the main bearing cap bolts.

Tighten bolts to the following torque. .. 150 ± 5 N·m

(111 ± 4 lb ft)

4. Put an alignment mark on each cap and bolt.

Rotate the bolts in the clockwise

direction. ............................................ 60 degrees

g01189825
Illustration 52

(E) Distance from the centerline of the crankshaft

bore to the top surface of the cylinder
block ................................................. 387.00 mm
(15.236 inch)

(F) Diameter of the camshaft

bores ...................................... 85.00 ± 0.015 mm
(3.3465 ± 0.0006 inch)
g01189811
Illustration 53
(G) Distance from the centerline of the crankshaft
to the bottom surface of the cylinder The camshaft bearings are installed into the cylinder
block ................................................... 120.0 mm block at the values that follow.
(4.72 inch)
Position (J) .......................................... 36.50 mm
Width in cylinder block for the main bearing (1.437 inch)
cap .................................................. 178 ± 0.018 mm Position (K) ....................................... 192.50 mm
(7.0079 ± 0.0007 inch) (7.578 inch)
Position (L) ....................................... 348.50 mm
(H) Width of the main bearing cap ... 178 ± 0.02 mm (13.720 inch)
(7.008 ± 0.001 inch) Position (M) ...................................... 504.50 mm
(19.862 inch)
(I) Bore in the cylinder block for the seven main Position (N) ....................................... 660.50 mm
bearings .............................. 116.000 ± 0.013 mm (26.004 inch)
(4.5669 ± 0.0005 inch) Position (P) ....................................... 816.50 mm
(32.145 inch)
(1) Bolts for the piston cooling jets Position (R) ....................................... 972.50 mm
(38.287 inch)
(2) Main bearing cap bolts
NOTICE
Use the following procedure in order to install the Camshaft bearings must be installed into their correct
main bearing cap bolts: position. Failure to do so will result in engine damage.
30 SENR9702-05
Specifications Section

Table 1
Position A 151.42 ± 0.05 mm (5.961 ± 0.002 inch)
Position B 147.90 ± 0.03 mm (5.823± 0.001 inch)
Position C 141.38 ± 0.08 mm (5.566 ± 0.003 inch)
Inner Bore
130.025 ± 0.025 mm (5.1191 ± 0.0010 inch)
Diameter

Note: Apply 5P-3975 Rubber Lubricant to the

cylinder liner seals prior to assembly.

i02212928

Illustration 54
g01189826
Cylinder Liner Projection
(3) Bearing joint SMCS Code: 1216

(4) Oil hole Part No.: 252-2180

Table 2
(S) Bearing oil hole is located at a 45 degree angle
from vertical. All seven bearings have the same Specifications
angle.
Liner Projection 0.060 to 0.180 mm
(0.0024 to 0.0071 inch)
i02385372 Maximum Variation in Each
0.050 mm (0.0020 inch)
Liner
Cylinder Liner
Maximum Average
SMCS Code: 1216 Variation Between 0.080 mm (0.0031 inch)
Adjacent Liners
Part No.: 197-9330
Maximum Variation
0.100 mm (0.0040 inch)
Between All Liners

For more information on measuring the cylinder liner

projection, refer to the Testing and Adjusting manual.

g00517737
Illustration 55

Outside diameters of the cylinder liner

SENR9702-05 31
Specifications Section

i02100826 i02204815

Crankshaft Crankshaft Seals

SMCS Code: 1202 SMCS Code: 1160; 1161
Part No.: 224-3882 Part No.: 116-1091
S/N: KCA1-Up
Part No.: 224-3881
S/N: KCB1-Up
Part No.: 238-8373
S/N: JAM1-Up

g01070489 g00984057
Illustration 56 Illustration 57

(1) Main bearing journals Note: Install the front crankshaft seals and the rear
crankshaft seals dry.
The thrust plate is used on the center main bearing
only. (1) Seal group

(2) Crankshaft gear (2) O-ring seal

(A) Average diameter of gear after Lightly lubricate the O-ring seal. Use the lubricant
assembly .......................... 136.20 ± 0.11 mm that is being sealed.
(5.362 ± 0.004 inch)
Maximum diameter of gear after (3) Crankshaft
assembly ...................... 136.36 mm (5.368 inch)
(B) Maximum distance between the crankshaft Apply 7M-7456 Bearing Mount Compound to the
gear and the crankshaft flange ....... 0.10 mm bolt threads.
(0.004 inch)
(C) Install the alignment dowel to the following
depth. ......... 8.0 ± 0.5 mm (0.32 ± 0.02 inch)

(3) Connecting rod bearing journals

Note: After the crankshaft is assembled into the

block, the crankshaft end play should be a maximum
of 0.50 mm (0.020 inch) and a minimum of 0.10 mm
(0.004 inch).
32 SENR9702-05
Specifications Section

i02199495

Main Bearing Journal

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

Table 4
Main Bearing Journal
Original size journal 108.000 ± 0.020 mm
(4.2520 ± .0008 inch)
Undersize journal 107.492 ± 0.020 mm
0.508 mm (.0200 inch) (4.2320 ± .0008 inch)
g00951705
Illustration 58 Undersize journal 107.238 ± 0.020 mm
Tightening sequence for the rear seal 0.762 mm (.0300 inch) (4.2220 ± .0008 inch)

Note: Use an alternating sequence when tightening The clearance between a new bearing and a new
the front and rear seal bolts. journal is the following value. ...... 0.059 to 0.157 mm
(.0023 to .0062 inch)
i02199486
Table 5
Connecting Rod Bearing Main Bearing Bore
Journal Main bearing bore (original 116.000 ± 0.013 mm
size) (4.5669 ± .0005 inch)
SMCS Code: 1202; 1219; 1225
Oversize bore in block 116.508 ± 0.013 mm
Part No.: 224-3882 0.508 mm (.0200 inch) (4.5869 ± .0005 inch)
S/N: KCA1-Up
Part No.: 224-3881
S/N: KCB1-Up
Part No.: 238-8372
S/N: JAM1-Up

Table 3

Connecting Rod Bearing Journal

Original size journal
Undersize journal
0.508 mm (.0200 inch)
Undersize journal
0.762 mm (.0300 inch)
89.000 ± 0.020 mm
(3.5039 ± .0008 inch)
88.492 ± 0.020 mm
(3.4839 ± .0008 inch)
87.238 ± 0.020 mm
(3.4346 ± .0008 inch)

The clearance between a new bearing and a new

journal is the following value. .. 0.33 mm to 0.131 mm
(0.0130 inch to 0.0052 inch)
SENR9702-05 33
Specifications Section

i02385617 Diameter of the piston pin .......... 53.155 ± 0.005 mm

(2.0927 ± 0.0002 inch)
Connecting Rod
Thoroughly lubricate the piston pin with clean engine
SMCS Code: 1218 oil prior to assembly of the piston and connecting rod.
Part No.: 197-9307
(4) The bearing joint must be within ± 12.5 degrees
S/N: KCA1-Up
of either location.

(5) Distance between the center of the

bearings .............................................. 247.5 mm
(9.7441 inch)

(6) Etch the cylinder number on the connecting rod

and the cap in this location. Mark the connecting
rod and the cap with a number 1 through 6. Mark
the numbers on the same side of the connecting
rod as the bearing retainer notch.

Note: Install the connecting rod in the engine with the

part number to the rear of the engine.

(7) Tighten the connecting rod bolts. Use the

instructions that follow.

1. Before installing the connecting rod bolts, lubricate

the bolt threads and the seating faces of the caps
with 2P-2506 Thread Lubricant.

2. Tighten the connecting rod bolts.

Tighten the connecting rod bolts to the following

torque. ............................................... 130 ± 7 N·m
(95 ± 5 lb ft)

3. Tighten each connecting rod bolt for an additional

amount.

Rotate each connecting rod bolt in the clockwise

direction. ................ 60 ± 5 degrees (1/6 of a turn)

(8) Bore in the connecting rod for the crankshaft

g01096964 bearing ................................. 93.800 ± 0.013 mm
Illustration 59
(3.6929 ± 0.0005 inch)
(1) Bore in the connecting rod for the piston pin
bearing ................................. 57.810 ± 0.013 mm
(2.2760 ± 0.0005 inch)

Note: The connecting rod must be heated for the

installation of the piston pin bearing. Do not use a
torch.

(2) The connecting rod may be heated from

175 °C to 260 °C (347 °F to 500 °F) for
the installation of the piston pin bearing.
Maximum distance for heating the connecting
rod ...................................................... 88.00 mm
(3.4646 inch)

(3) Bore in the bearing for the piston

pin ........................................ 53.205 ± 0.008 mm
(2.0947 ± 0.0003 inch)
34 SENR9702-05
Specifications Section

i02385589 (3) Bore in the bearing for the piston

pin ........................................ 53.205 ± 0.008 mm
Connecting Rod (2.095 ± 0.0003 inch)
SMCS Code: 1218 Diameter of the piston pin .......... 53.155 ± 0.005 mm
(2.0927 ± 0.0002 inch)
Part No.: 197-9309
S/N: KCB1-Up
Thoroughly lubricate the piston pin with clean engine
Part No.: 197-9309 oil prior to assembly of the piston and connecting rod.
S/N: JAM1-Up
(4) The bearing joint must be within ± 12.5 degrees
of either location.

(5) Distance between the center of the

bearings ............................................ 239.00 mm
(9.4094 inch)

(6) Etch the cylinder number on the connecting rod

and the cap in this location. Mark the connecting
rod and the cap with a number 1 through 6. Mark
the numbers on the same side of the connecting
rod as the bearing retainer notch.

Note: Install the connecting rod in the engine with the

part number to the rear of the engine.

(7) Tighten the connecting rod bolts. Use the

instructions that follow.

1. Before installing the connecting rod bolts, lubricate

the bolt threads and the seating faces of the caps
with 2P-2506 Thread Lubricant.

2. Tighten the connecting rod bolts.

Tighten the connecting rod bolts to the following

torque. ............................................... 130 ± 7 N·m
(95 ± 5 lb ft)

3. Tighten each connecting rod bolt for an additional

amount.

Rotate each connecting rod bolt in the clockwise

direction. ................ 60 ± 5 degrees (1/6 of a turn)
g01096964
Illustration 60 (8) Bore in the connecting rod for the crankshaft
bearing ................................... 93.80 ± 0.013 mm
(1) Bore in the connecting rod for the piston pin (3.6929 ± 0.0005 inch)
bearing ................................. 57.810 ± 0.013 mm
(2.2760 ± 0.0005 inch)

Note: The connecting rod must be heated for the

installation of the piston pin bearing. Do not use a
torch.

(2) The connecting rod may be heated from

175 °C to 260 °C (347 °F to 500 °F) for
the installation of the piston pin bearing.
Maximum distance for heating the connecting
rod ...................................................... 88.00 mm
(3.465 inch)
SENR9702-05 35
Specifications Section

i02387032 Thickness of new intermediate piston

ring ........... 2.98 ± 0.01 mm (0.117 ± 0.0004 inch)
Piston and Rings The ends of the piston ring have a clearance
when the piston ring is installed in a cylinder
SMCS Code: 1214; 1215 liner with a bore of 130.000 mm (5.1181 inch).
Clearance ..................................... 1 ± 0.125 mm
Part No.: 197-9381
(0.0394 ± 0.0049 inch)
S/N: KCA1-Up
The intermediate piston ring has an increase in
Part No.: 197-9383 clearance for each 0.03 mm (0.001 inch) increase
S/N: KCB1-Up in the cylinder liner bore. Increase ........ 0.09 mm
(0.004 inch)
Part No.: 197-9383
S/N: JAM1-Up (4) Oil control ring groove
The ends of the oil control piston ring should be
a distance of 180 degrees from the ring end gap
when the oil control piston ring is assembled. The
white colored portion of the piston ring must be
visible at the ring end gap.
Width of groove in new piston for oil control piston
ring ......................................... 4.052 ± 0.012 mm
(0.1595 ± 0.0005 inch)
Thickness of new oil control piston
ring ......................................... 3.987 ± 0.013 mm
(0.1570 ± 0.0005 inch)
The ends of the piston ring have a clearance
when the piston ring is installed in a cylinder
liner with a bore of 130.000 mm (5.1181 inch).
Clearance .................................. 0.44 ± 0.15 mm
(0.017 ± 0.006 inch)
The oil control piston ring has an increase in
clearance for each 0.03 mm (0.001 inch) increase
in the cylinder liner bore. Increase ........ 0.09 mm
(0.004 inch)
g01191302
Illustration 61
After the piston rings have been installed, rotate the
(1) The piston is symmetrical with a center crater. piston rings so that the end gaps are 120 degrees
from each other.
Lubricate the entire piston to 360 ° in zone (A) prior
to assembly into the cylinder block. Use clean engine (A) Piston pin bore diameter ......... 53.22 ± 0.01 mm
oil. (2.0953 ± 0.0004 inch)

(2) Top piston ring groove Thoroughly lubricate the piston pin with clean engine
oil prior to assembly.
Install the piston ring with the side marked “UP-1”
toward the top of the piston.
The ends of the piston ring have a clearance
when the piston ring is installed in a cylinder
liner with a bore of 130.000 mm (5.1181 inch).
Clearance ..... 0.5 ± 0.1 mm (0.020 ± 0.004 inch)
The top piston ring has an increase in clearance
for each 0.03 mm (0.001 inch) increase in the
cylinder liner bore. Increase ................. 0.09 mm
(0.004 inch)

(3) Intermediate piston ring groove

Install the piston ring with the side marked “UP-2”
toward the top of the piston.
Width of groove in new piston for intermediate
piston ring .............................. 3.053 ± 0.013 mm
(0.1202 ± 0.0005 inch)
36 SENR9702-05
Specifications Section

i02199538

Piston Cooling Jet

SMCS Code: 1331
Part No.: 226-6478

g00952129
Illustration 64
Tightening sequence for the front crankshaft seal

(1) Self locking bolt M8 - 1.25

(2) Seventeen bolts fasten the cover to the housing.

g01098595
Illustration 62
Note: Bolt (1) is different from the other cover bolts.
Tighten the bolt (1) for the piston cooling jet to the
following torque. ....................................... 35 ± 3 N·m (3) Nine bolts fasten the housing to the block.
(26 ± 2 lb ft)
(4) O-ring seal and crankshaft front seal
Note: Visually check that the piston cooling jet is
properly seated in the cylinder block before applying The O-ring seal and the crankshaft front seal are part
torque. of the front housing. Lubricate the O-ring seal lightly.
Use the lubricant that is being sealed.

i02386035 (5) Accessory drive assembly

Housing (Front) Note: Apply 8T-9022 Silicone Gasket in order to fill
the space at the connecting joint of the front housing,
SMCS Code: 1151 engine oil pan, and cylinder block.
Part No.: 218-7272

g01190314
Illustration 63
SENR9702-05 37
Specifications Section

i02386244

Gear Group (Front)

SMCS Code: 1206
Part No.: 222-3088

g01098608
Illustration 65

(1) Camshaft gear Number of teeth .............................................. 48

Bore diameter ............................ 96.9 ± 0.02 mm
Number of teeth .............................................. 96 (3.815 ± 0.001 inch)
Bore diameter .......................... 58.9 ± 0.013 mm
(2.3189 ± 0.0005 inch) (5) Idler gear
(2) Align the timing marks on the idler gear to the Number of teeth .............................................. 71
timing marks on the camshaft gear and the marks Bore diameter for bearing .... 74.452 ± 0.015 mm
on the crankshaft gear. (2.9312 ± 0.0006 inch)
Bore diameter of the
(3) Idler gear for the water pump bearing ................................. 69.205 ± 0.013 mm
(2.7246 ± 0.0005 inch)
Number of teeth .............................................. 64
Bore diameter for bearing .. 60.0163 ± 0.015 mm (6) Mounting bolts for accessory drive.
(2.3628 ± 0.0006 inch)
Bore diameter of the
bearing ................................. 60.281 ± 0.013 mm
(2.3733 ± 0.0005 inch)

(4) Crankshaft gear

38 SENR9702-05
Specifications Section

i02169326 Note: During assembly, inspect the following

components for any foreign materials: the front
Gear Group (Rear) face of the flywheel housing, the two sides of the
flywheel housing gasket and the rear face of the
SMCS Code: 1204; 1206 cylinder block. These components must be free of
the following substances: oil, fuel, water, gasket
Part No.: 117-2769
adhesive, assembly compounds, and any other
S/N: KCA1-Up
foreign material. Apply a small amount of 8T-9022
Part No.: 117-2769 Silicone Gasket in order to fill the space between the
S/N: KCB1-Up cylinder block, the flywheel housing, and the oil pan
before installing the oil pan gasket and the oil pan.
The components must be assembled within twenty
minutes of applying the sealant.

(1) Lubricate the bore with oil.

(2) Tighten the bolt to the following

torque. ..................... 105 ± 20 N·m (77 ± 15 lb ft)

i02386341

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

g01190562
Illustration 67

(1) Flywheel housing

g01099294
Illustration 66
SENR9702-05 39
Specifications Section

Apply 1U-8846 Gasket Sealant on the gasket i02169177

surface of the flywheel housing. Assemble the
flywheel housing to the cylinder block and tighten Engine to Transmission
within ten minutes of applying the sealant. Adapter
i02169784
SMCS Code: 1001

Flywheel Housing Part No.: 124-2665

SMCS Code: 1157

S/N: KCA1-Up
S/N: KCB1-Up

g01099632
Illustration 68 g01099066
Illustration 69
(1) Flywheel housing Typical Example

(2) Torque the bolts to the following (1) Plate

torque. ..................... 125 ± 20 N·m (92 ± 15 lb ft)
Apply 1U-8846 Gasket Sealant on the gasket
surface of the flywheel housing. Assemble the
flywheel housing to the cylinder block and tighten
within ten minutes of applying the sealant.
(2) Adapter
(3) Apply 9S-3263 Thread Lock Compound to
the bolts. Tighten the bolts to the following
torque. ................... 300 ± 40 N·m (220 ± 30 lb ft)

(4) Tighten the bolts to the following

torque. ....................... 70 ± 15 N·m (51 ± 11 lb ft)
40 SENR9702-05
Specifications Section

i02359520 i02169999

Belt Tensioner Electric Starting Motor

SMCS Code: 1358 SMCS Code: 1453
Part No.: 222-2901 Part No.: 207-1537

g01181614 g01099859
Illustration 70 Illustration 71

(1) Mounting bracket
(2) The tensioner is in the free position when the
belt is not on the tensioner. Required torque for
rotating the tensioner to a 30 degree angle from
the free position .......................... 58.8 ± 5.9 N·m
(43 ± 4 lb ft)
When the electric starting motor is viewed from
the drive end, the motor rotates in the following
direction. ................................................... Clockwise
No load conditions at 25 °C (77 °F)
Minimum speed with no load ... 6900 ± 1800 rpm
Maximum current with no load .. 127.5 ± 27.5 amp
Voltage ......................................................... 11 V

(1) Battery terminal

A maximum of three cable or wire terminals
should be between the nuts.
Tighten the nut on the battery terminal to the
following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)

(2) Motor terminal

Tighten the nut on the motor terminal to the
following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)

(3) Ground terminal

Tighten the nut on the ground terminal to the
following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)

(4) Ground terminal

Tighten the nut on the ground terminal to the
following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
SENR9702-05
(5) Switch terminal
The wire terminal that is on the switch terminal
must be insulated with heat shrink tubing. Do not
use molded terminals.
Tighten the nut on the switch terminal to the
following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(6) Motor frame terminal
Tighten the nut on the motor frame terminal to the
following torque. ........... 8 ± 3 N·m (71 ± 27 lb in)
Solenoid
Current draw at 10 V and 25 °C (77 °F)
Pull-in windings ........................... 92.5 ± 7.5 Amp
Hold-in windings .................... 23 Amp maximum
i02225007
Electric Starting Motor
SMCS Code: 1453
Part No.: 207-1557
g01099879
Illustration 72
When the electric starting motor is viewed from
the drive end, the motor rotates in the following
direction. ................................................... Clockwise
No load conditions at 25 °C (77 °F)
Minimum speed with no load ... 7643 ± 1683 rpm
Maximum current with no load .. 76.5 ± 14.5 amp
Voltage ......................................................... 23 V
(1) Battery terminal
41
Specifications Section
A maximum of three cable or wire terminals
should be between the nuts.
Tighten the nut on the battery terminal to the
following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
(2) Ground terminal
Tighten the nut on the ground terminal to the
following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
(3) Ground terminal
Tighten the nut on the ground terminal to the
following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(4) Switch terminal
The wire terminal that is on the switch terminal
must be insulated with heat shrink tubing. Do not
use molded terminals.
Tighten the nut on the switch terminal to the
following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(5) Motor terminal
Tighten the nut on the motor terminal to the
following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
(6) Motor frame terminal
Tighten the nut on the motor frame terminal to the
following torque. ........... 8 ± 3 N·m (70 ± 27 lb in)
Solenoid
Current draw at 20 V and 25 °C (77 °F)
Pull-in windings ....................................... 57 Amp
Hold-in windings .................... 16 Amp maximum
42 SENR9702-05
Specifications Section

i02169978 A maximum of three cable or wire terminals

should be between the nuts.
Electric Starting Motor Tighten the nut on the battery terminal to the
SMCS Code: 1453 following torque. .......................... 30.5 ± 3.5 N·m
(22 ± 3 lb ft)
Part No.: 207-1511
S/N: KCB1-Up (2) Switch terminal
The wire terminal that is on the switch terminal
must be insulated with heat shrink tubing. Do not
use molded terminals.
Tighten the nut on the switch terminal to the
following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)

(3) Motor terminal

Tighten the nut on the motor terminal to the
following torque. .......................... 14.7 ± 3.4 N·m
(11 ± 3 lb ft)

Note: The internal Torx screw must be held during

tightening or loosening of the nut.
g01099827
Illustration 73
(4) Motor frame terminal
Tighten the nut on the motor frame terminal to the
following torque. ........... 8 ± 3 N·m (71 ± 27 lb in)

(5) Ground terminal

Tighten the nut on the ground terminal to the
following torque. .......................... 30.5 ± 3.5 N·m
(22 ± 3 lb ft)

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

g01099828
Illustration 74

When the electric starting motor is viewed from

the drive end, the motor rotates in the following
direction. ................................................... Clockwise

No load conditions at 25 °C (77 °F)

Minimum speed with no load ..... 3638 ± 413 rpm
Maximum current with no load ........ 90 ± 16 amp
Voltage ......................................................... 23 V

(1) Battery terminal

SENR9702-05 43
Specifications Section

i02358664 i02358641

Coolant Temperature Sensor Engine Oil Pressure Sensor

SMCS Code: 1906 SMCS Code: 1924
Part No.: 234-5012 Part No.: 276-9067

g01178443 g01178427
Illustration 75 Illustration 77

(1) Sensor assembly (1) Sensor assembly

Tighten the sensor assembly to the following Tighten the sensor assembly to the following
torque. ............................................... 20 ± 3 N·m torque. ............................... 10 ± 2 N·m (90 ± 20 lb in)
(15 ± 2 lb ft)

i02363398
i02363248
Boost Pressure Sensor
Fuel Temperature Sensor
SMCS Code: 1917
SMCS Code: 1922
Part No.: 249-0096
Part No.: 234-5013

g01180421
Illustration 78
g01178443
Illustration 76
(1) Sensor assembly
(1) Sensor assembly
Tighten the sensor assembly to the following
Tighten the sensor assembly to the following torque. ........................ 10 ± 2 N·m (90 ± 20 lb in)
torque. ........................... 20 ± 3 N·m (15 ± 2 lb ft)
44 SENR9702-05
Specifications Section

i02358620 i02266728

Atmospheric Pressure Sensor Speed/Timing Sensor

SMCS Code: 1923 SMCS Code: 1907; 1912
Part No.: 276-8548 Part No.: 230-7149, 239-2397
S/N: KCA1-Up
S/N: KCB1-Up
Part No.: 230-7149, 239-2397
S/N: JAM1-Up

Secondary Speed/Timing Sensor

g01178383
Illustration 79

(1) Sensor assembly

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

i02386689

Inlet Manifold Temperature

Sensor
SMCS Code: 1921
Part No.: 234-5013

g01136912
Illustration 81
Secondary speed/timing sensor

(1) Sensor

(2) Bracket

Ensure that the bracket is installed in the orientation

g01178443 that is shown.
Illustration 80
(3) Tighten the bolt to the following
(1) Sensor assembly torque. ........................... 28 ± 7 N·m (21 ± 5 lb ft)
Tighten the sensor assembly to the following
torque. ........................... 20 ± 3 N·m (15 ± 2 lb ft) Ensure that the sensor is seated before the bolt is
tightened.
SENR9702-05 45
Specifications Section

Primary Speed/Timing Sensor

g01025562
Illustration 82
Primary speed/timing sensor

(1) Sensor

(2) Bracket

Ensure that the bracket is installed in the orientation

that is shown.

(3) Tighten the bolt to the following

torque. ........................... 28 ± 7 N·m (21 ± 5 lb ft)

Ensure that the sensor is seated before the bolt is

tightened.
46 SENR9702-05
Index Section

Index
A Gear Group (Rear) ................................................ 38

Air Lines........................................................... 16–20

Atmospheric Pressure Sensor............................... 44 H

Housing (Front)...................................................... 36
B

Belt Tensioner........................................................ 40
Boost Pressure Sensor.......................................... 43
C
I
Important Safety Information ................................... 2
Inlet Manifold Temperature Sensor........................ 44

Camshaft ............................................................... 22 L
CAT Compression Brake ....................................... 13
Connecting Rod............................................... 33–34 Lifter Group.............................................................. 8
Connecting Rod Bearing Journal........................... 32
Coolant Temperature Sensor................................. 43
Crankshaft ............................................................ 31 M
Crankshaft Seals ................................................... 31
Cylinder Block........................................................ 28 Main Bearing Journal............................................. 32
Cylinder Head......................................................... 11
Cylinder Head Valves ............................................ 10
Cylinder Liner ........................................................ 30 P
Cylinder Liner Projection ....................................... 30
Piston and Rings ................................................... 35
Piston Cooling Jet.................................................. 36
E Precooler ............................................................... 26

Electric Starting Motor ..................................... 40–42

Solenoid ....................................................... 41–42 R
Electronic Unit Injector............................................. 5
Electronic Unit Injector Mechanism ......................... 6 Rocker Shaft............................................................ 8
Electronic Unit Injector Rocker Arm......................... 6
Electronic Unit Injector Wiring ................................. 7
Engine Design ......................................................... 4 S
C11....................................................................... 4
C13 ...................................................................... 4 Specifications Section ............................................. 4
Engine Oil Cooler .................................................. 24 Speed/Timing Sensor ............................................ 44
Engine Oil Filter Base............................................ 22 Primary Speed/Timing Sensor ........................... 45
Engine Oil Pan....................................................... 25 Secondary Speed/Timing Sensor ...................... 44
Engine Oil Pressure Sensor .................................. 43
Engine Oil Pump.................................................... 24
Engine to Transmission Adapter ........................... 39 T
Exhaust Manifold ................................................... 21
Table of Contents..................................................... 3
Turbocharger ................................................... 14–15
F

Flywheel Housing ............................................ 38–39 V

Fuel Temperature Sensor ...................................... 43
Fuel Transfer Pump ................................................. 5 Valve Mechanism .................................................... 9

G W

Gear Group (Front)................................................ 37 Water Pump........................................................... 28

SENR9702-05 47
Index Section

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

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