INTRODUCTION
GENERAL
This section has descriptions and repair instructions for
the engine and the fuel system. Removal, disassembly,
cleaning, assembly, installation, specifications and
troubleshooting procedures are included.
DESCRIPTION
The Perkins 6.3544 and T6.3544 are diesel engines
FIGURE 1. PERKINS 6.3544 ENGINE
with six cylinders and fuel injection. The main differ-
ence between the two engines is that the T6.3544 is
equipped with a turbocharger. The turbine in the turbo-
charger is driven directly by the the exhaust engine.
The turbine in turn, drives the impeller. Rotation of the
impeller pushes air into the inlet manifold. The turbo-
charger increases engine torque and horsepower.
The serial number of the engine is on the auxiliary
drive housing directly below the fuel injection pump.
8100
1
 CYLINDER HEAD AND VALVE MECHANISM

CYLINDER HEAD 5. Disconnect electrical connections to the cylinder

Removal
1. Disconnect the battery connections at the battery.
2. Drain the cooling system. Remove the fan, radiator
and water pump.
3. Disconnect the air cleaner and the exhaust pipe on
the 6.3544 engine.
4. Disconnect and remove all connections to the turbo-
charger. Then remove the turbocharger on the T6.3544
engine.
head and inlet manifold.
6. Remove the water outlet manifold.
7. Remove the inlet and exhaust manifolds.
8. Disconnect and remove the high pressure and the
drain lines at the fuel injectors.
9. Remove the rocker arm cover. Remove the rocker
arm assembly. Remove the push rods.
10. Remove the cylinder head nuts in the opposite or-
der of the tightening sequence shown in FIGURE 5.
Remove the cylinder head.

2
5 6

8101

1. CYLINDER HEAD
2. EXHAUST MANIFOLD
3. VALVES
3 4. ROCKER ARM
COVER
5. ROCKER ARM
6. ROCKER SHAFT

FIGURE 2. CYLINDER HEAD AND VALVE MECHANISM

2
Repairs
The maximum clearance along the length of the surface
of the cylinder head is 0.25 mm (0.010 in). The maxi-
mum clearance across the width of the surface of the
cylinder head is 0.13 mm (0.005 in).
The surface of the cylinder head can be machined a
maximum of 0.30 mm (0.012 in). Replace the cylinder
head that does not equal specifications. It is important
that the nozzles of the fuel injector do not extend be-
yond the specifications given in FIGURE 3. Do not use
additional seat washers to get to the specification.
Valve Guides
1. The maximum clearance between the stem of the in-
let valve and the valve guide is 0.13 mm (0.005 in). The
maximum clearance between the stem of the exhaust
valve and the valve guide is 0.15 mm (0.006 in). If the
clearances are not within specifications, install new
valve guides.
2. When installing new valve guides, lubricate the out-
side surface of the valve guide with oil.
3. When installed, the valve guide must extend 15.09
mm (0.594 in) above the surface of the seat for the
valve spring.
Valve Seats
The valve seats used in the T6.3544 engine can be re-
placed. The valve seat used as replacements in the
T6.3544 engine can be installed in the 6.3544 engine.
See FIGURE 4. for specifications. Do not lubricate
valve seat replacements during installation.
Installation
1. Clean the surface of the cylinder head. Clean the oil
passages.
2. Use Loctite
when installing the studs for the cylin-
der head.

94.87 mm
(3.735 in) MIN

T6.3544: 4.67 mm (0.184 in) MAX 0.30 mm (0.012 in) MAX

6.4544: 3.45 mm (0.136 in) MAX

WIDTH LENGTH

8102

0.13 mm (0.005 in) 0.25 mm (0.010 in)

CLEARANCE STRAIGHT EDGE CLEARANCE

FIGURE 3. CYLINDER HEAD DIMENSIONS

3
 B
C A
8103
INLET
A: 7.19 to 7.31 mm (0.283 to 0.288 in)
B: 51.22 to 51.24 mm in (2.017 to 2.018 in)
C: RADIUS 0.38 mm (0.015 in) MAX.
EXHAUST
A: 9.51 to 9.65 mm (0.375 to 0.380 in)
B: 42.62 to 42.64 mm (1.678 to 1.679 in)
C: RADIUS 0.38 mm (0.015 in) MAX.
FIGURE 4. VALVE SEAT DIMENSIONS
3. Install the gasket for the cylinder head. Make sure
the gasket is aligned with the dowels. Do not use a seal-
ant to seal the gasket.
4. Install the cylinder head. Lubricate the threads of
studs and capscrews with oil. See FIGURE 5. for the
location of the studs and capscrews. Tighten the nuts
and capscrews (1 to 32) to 136 N.m (100 ft lbf) in the
sequence shown in FIGURE 5. Tighten the capscrews
(33 to 38) to 41 N.m (30 ft lbf) in the sequence shown
in FIGURE 5.
8104
FIGURE 5. INSTALLING THE CYLINDER
HEAD
4
1
2
8105
1. ROCKER ARM FITTING
2. SEAL
FIGURE 6. ROCKER ARM FITTING
5. Install the push rods.
6. Lubricate and install the seal for the rocker arm fit-
ting. Install the rocker arm assembly. Make sure the fit-
ting fits into the seal. See FIGURE 6. Tighten the nuts
for the rocker arm assembly from the center to the out-
side to 75 N.m (55 ft lbf).
7. Install the fuel injectors using new copper washers.
Tighten the nuts evenly to 16 N.m (12 ft lbf).
NOTE: Different copper washers are used on the
6.3544 and T6.3544 engines. The washers for the
6.3544 engines are 2.03 mm (0.080 in) thick. The
washers for the T6.3544 engines are 0.71 mm (0.028
in). It is important to use the correct copper washer.
8. Install the high pressure lines, drain lines and fuel fil-
ters. Tighten the high pressure line nuts to 20 N.m (15
ft lbf).
9. Install the inlet manifold. The inlet manifold gaskets
must be installed dry. Tighten the nuts to 33 N.m (24 ft
lbf). After running the engine for 10 minutes, tighten
the nuts again to 33 N.m (24 ft lbf). THIS IS IMPOR-
TANT.
10. Install the exhaust manifold. The 6.3544 engine
uses gaskets on the exhaust manifold that are steel as-
bestos. Use a sealing compound when installing the
gaskets. The T6.3544 engine uses gaskets on the ex-
haust manifold that are stainless steel. Install the gas-
kets with the rough surface facing the manifold.
11. Install water outlet manifold. 175 to 190 N
(39 to 43 lb)
12. Connect the electrical wires to the cylinder head. 47.65 mm 35.81 mm
(1.876 in) (1.410 in)
13. Use new gaskets and install the turbocharger on the
T6.3544 engine. See TURBOCHARGER INSTALLA- OUTER VALVE SPRING
TION in this section.

14. Adjust the valves as described under CHECKS

89 to 102 N
AND ADJUSTMENTS in this section. (20 to 23 lb)
34.04 mm
(1.340 in)
15. Install the rocker arm cover. 40.79 mm
(1.606 in)

VALVE MECHANISM INNER VALVE SPRING 8106

FIGURE 7. VALVE SPRINGS

Repairs Valve Springs

Valves
If the valves are to be used after removal, put an identi-
fication mark on each valve. Use acceptable service
procedures when grinding the valves. Check the valve
head depth. The maximum depth of the valve head be-
low the surface of the cylinder head is 1.27 mm (0.050
in).
When installing the valves, lubricate the valve stems.
Install the washers for the valve spring and the oil seals
for the valve guides. Install the valve springs with the
damper coils toward the cylinder head. See FIGURE 7.
The outer springs have left–hand coils. The inner
springs have right–hand coils.
Check the pressure of the valve springs during engine
overhaul. See FIGURE 7. The inner valve springs need
89 to 102 N (20 to 23 pounds) to compress them to an
installation height of 34.04 mm (1.340 in).
The outer valve springs need 175 to 190 N (39 to 43
pounds) to compress them to an installation height of
35.81 mm (1.410 in).
Rocker Arm Assembly
When disassembling the rocker arm assembly, check
the rocker arms and shaft for wear. The bushings for the
rocker arm can be replaced. Push out the old bushings,
then push in new bushings. Make sure the oil holes
align. See FIGURE 8. Use a reamer to make the inside
diameter of the bushing 19.06 to 19.10 mm (0.751 to
0.752 in).

5
 8108
1

8107
6

1
2 3
1. ROCKER ARM 3
2. BUSHING
3. OIL HOLE 2

FIGURE 8. ROCKER ARM 4

5

1. ROCKER ARM SHAFT 4. SEAL

When assembling the rocker arm assembly, make sure 2. ROCKER ARM 5. WASHER
the oil fitting is correctly installed on the rocker arm 3. OIL FITTING 6. SNAP RING
shaft. Install the parts in the correct sequence. Install
FIGURE 9. ROCKER ARM ASSEMBLY
the washer and snap ring on the shaft. See FIGURE 9.

LUBRICATION SYSTEM

OIL PUMP 3. Install the oil pump on the engine. Use a new gasket.
Install the suction pipe and screen.
Removal And Disassembly
(See FIGURE 10.) 4. Install the oil sump. Tighten the capscrews to 20 N.m
(15 ft lbf).
1. Remove the oil sump.

2. Remove the capscrews that hold the oil pump to the

engine. Remove the oil pump from the engine. 1

3. Remove the suction pipe and the bottom cover of the

oil pump.

Repairs 3
Check the clearances as shown in FIGURE 11. If any
parts of the oil pump are damaged or have too much 4
wear the oil pump must be replaced. Parts are not avail-
able separately.

Assembly And Installation

(See FIGURE 10.)
8109
1. Install the inner and outer rotors in the body of the oil 2
pump. 1. INNER ROTOR 3. BODY
2. OUTER ROTOR 4. END COVER
2. Use a sealant compound and install the end cover on
the oil pump. FIGURE 10. OIL PUMP

6
INNER ROTOR TO OUTER ROTOR
CLEARANCE 0.08 to 0.13 mm (0.003 to 0.005 in)
OUTER ROTOR TO BODY CLEARANCE
0.15 to 0.33 mm (0.006 to 0.013 in)
8115
INNER AND OUTER ROTOR END
CLEARANCE 0.03 to 0.08 mm (0.001 to 0.003 in)
FIGURE 11. CHECKING THE CLEARANCES
ON THE OIL PUMP
2 8111
1
1. COOLING SYSTEM DRAIN PLUG
2. OIL COOLER DRAIN PLUG
FIGURE 12. REMOVING THE OIL COOLER
Relief Valve For The Oil Pressure
(See FIGURE 13.)
The relief valve for the oil pressure on the 6.3544 en-
gines is set to release pressure at 3.5 to 4.2 bar (50 to 60
psi). The relief valve for the oil pressure on the
T6.3544 engines has two settings. The first setting re-
leases pressure to the cooling jets for the pistons at 2.1
to 2.6 bar (30 to 37 psi). The second (main) setting re-
leases the pressure at 3.5 to 4.2 bar (50 to 60 psi).
Oil Cooler (T6.3544 Engine Only)
Removal (See FIGURE 12.)
1. Drain the cooling system for the engine. Remove the
drain plug (1). Drain the coolant from the oil cooler.
2. Remove the drain plug (2) and drain oil from oil
cooler.
3. Disconnect the coolant lines at the oil cooler.
4. Remove the oil filter assembly from the oil cooler.
8117
FIGURE 13. OIL PRESSURE RELIEF VALVE
7

8116
FIGURE 14. INSTALLING THE OIL PUMP
5. Remove the oil cooler from the engine.
Disassembly (See FIGURE 15.)
1. Remove the tube assembly from the housing of the
oil cooler. Remove the O–rings.
2. Remove the relief valve assembly.
Assembly (See FIGURE 15.)
1. Install new O–rings on the tube assembly. During
installation, lubricate the O–rings with oil.
2. Carefully install the tube assembly in the housing of
the oil cooler. Install and tighten the nuts. Install both
drain plugs.
3. Install the relief valve assembly.
8
2
3 8110
1. TUBE ASSEMBLY 3. O–RING
2. RELIEF VALVE ASSEMBLY 4. HOUSING
FIGURE 15. OIL COOLER
Tests
1. To test the coolant chamber of the oil cooler, fill the
coolant chamber with water. Put the oil cooler in water.
Add pressure to the coolant chamber with air at 2.1 bar
(30 psi). Check for leakage.
2. To test the oil chamber of the oil cooler, fill the cool-
ant chamber with water. Put the oil cooler in water. Add
pressure to the oil chamber with air to 6.2 bar (90 psi)
for two minutes. Check for leakage.
3. Replace the tube assembly if leakage occurs at the
inlet or outlet of the coolant chamber.
Installation
1. Install the oil cooler to the adapter. Tighten the caps-
crews.
2. Install the oil filter assembly.
3. Connect the coolant inlet and the coolant outlet lines
to the oil cooler.
4. Check for leakage during operation.
Cooling Jets For The Pistons
NOTE: The cooling jets for the pistons are used only on
the T6.3544 engines.
 4 45.24 mm 16.28 mm
(1.781 in) (0.641 in)

3
2

8112

1. SPECIAL CAPSCREW 3. COOLING JET

2. WASHER 4. DOWEL PIN 8113

FIGURE 16. OIL COOLER FIGURE 17. ALIGNMENT OF THE COOLING

JETS FOR THE PISTONS
Removal (See FIGURE 16.)

1. Remove the oil sump.
2. Remove the special capscrew from the cooling jet.
Remove the cooling jet from the crankcase.
Installation
2. Check alignment of the cooling jet as follows:
a. Install a piece of 2.39 mm (0.094 in) rod into the
nozzle of the jet. The rod must extend above the
top of the face of the crankcase.

1. Install the cooling jets in crankcase. Make sure the b. The correct nozzle position is shown in
dowel is in the correct position. Tighten the special FIGURE 17. Make sure the rod comes to an end
capscrew to 27 N.m (20 ft lbf). at the mark made by the measurements.

TIMING GEARS AND CAMSHAFT

TIMING GEAR CASE (See FIGURE 18.)
Removal
1. Remove the crankshaft pulley. Remove the covers
for the camshaft gear and the auxiliary drive gear.
2. Remove the camshaft gear using a puller. See
FIGURE 19.
3. Remove the retainer for the auxiliary drive gear. Re-
move the auxiliary drive gear.
4. Remove the timing gear case.
Installation (See FIGURE 18., FIGURE 20. and
FIGURE 21.)
1. Install a new crankshaft seal in the timing gear case.
Make sure the seal is installed as shown in FIGURE 20.
The face of the seal must be 6.35 mm (0.25 in) below
the surface of the timing gear case.
2. Remove the rocker arm cover and loosen the adjust-
ment screws for the rocker arms.
3. Rotate the crankshaft until the numbers one and six
pistons are at TDC. The key groove in the crankshaft
gear must also be at TDC.

9
 2

6
4

8114

1. TIMING GEAR CASE

2. CAMSHAFT
1 3. CAMSHAFT GEAR
4. CAMSHAFT GEAR COVER
5. AUXILIARY DRIVE GEAR COVER
6. IDLER GEAR
7. AUXILIARY DRIVE GEAR
5 8. AUXILIARY DRIVE SHAFT
FIGURE 18. TIMING GEARS AND CAMSHAFT

4. The double mark on the lower idler gear must be
aligned with the single mark on the crankshaft gear. If
the marks are not aligned, remove the lower idler gear.
Replace the gear with marks in alignment.
5. Use a new gasket and install timing gear case.
Loosely install the capscrews for the gear case. Install
the crankshaft pulley to hold timing gear case in loca-
tion. Tighten the capscrews for the gear case. Remove
the crankshaft pulley and tighten the other capscrews
and nuts.
6. Install the camshaft gear on the camshaft. The
double marks on the camshaft gear must align with the
single mark on the lower idler gear.
7. Install the lock, washer, shim and capscrew for the
camshaft gear. Tighten the nut to 68 N.m (50 ft lbf).
Install the cover for the camshaft gear.
8. Before installing auxiliary drive gear, remove the
fuel injection pump. Rotate the auxiliary drive shaft.
The slot in the hub for the fuel injection pump must
align with the slot in the pump adapter plate.

10
 shaft are within the three slots of the gear. Install the
gear with the retainer plate and the capscrews.

10. Install the cover for the auxiliary drive gear. Install
the fuel injection pump as described in FUEL INJEC-
TION PUMP in this section.

6.35 mm 1
(0.25 in)

8119
1. TIMING GEAR CASE 2
2. SEAL
FIGURE 20. CRANKSHAFT SEAL
8118

FIGURE 19. REMOVING THE CAMSHAFT 11. Adjust the clearance for the valves as described in
GEAR CHECKS AND ADJUSTMENTS in this section.

9. With engine set as in step 8., install auxiliary drive 12. Install the crankshaft pulley as described in
gear. Make sure the three holes in the auxiliary drive CRANKSHAFT INSTALLATION in this section.

3
1 2
8120

1. CAMSHAFT GEAR 3. IDLER GEAR

2. CRANKSHAFT GEAR 4. AUXILIARY DRIVE GEAR

FIGURE 21. TIMING GEARS

11
 2. Install the idler gear hubs. Make sure the alignment
pins are in their holes. Also make sure that the oil holes
1
2 are open.
3. Install the idler gears. Make sure the double marks
on the lower gear are aligned with the mark on the
crankshaft gear.
4. Install the thrust plates. Install new lock nuts. Tight-
en the nuts to 49 N.m (36 ft lbf). Check the clearance
3 between the idler gear and the thrust plate. The correct
clearance is 0.10 to 0.41 mm (0.004 to 0.016 in).
5. Install the timing gear case as described in TIMING
GEAR CASE in this section.
Camshaft And Cam Followers
2 Removal
4
1. Remove the timing gear case as described in TIM-
ING GEAR CASE in this section.
2. Remove the rocker arm cover, rocker arm assembly
and the push rods.
3. Remove the fuel pump.
4. Remove the oil sump.
8121
1. IDLER GEAR 3. THRUST PLATE 5. Remove the camshaft thrust ring. Make sure the cam
2. HUB 4. ALIGNMENT PIN followers are out of the way, then remove the camshaft.
FIGURE 22. IDLER GEARS AND HUBS See FIGURE 23. Remove the cam followers.

Idler Gears And Hubs Removal Installation

(See FIGURE 22.)
1. Remove the timing gear case as described in TIM-
ING GEAR CASE in this section.
2. Remove the nuts and thrust plate from each idler
gear hub.
3. Remove the thrust plates, idler gears and hubs.
Installation (See FIGURE 22.)
1. Rotate the crankshaft until the numbers one and six
pistons are at TDC. The key groove in the crankshaft
gear must be at TDC.
1. Install the cam followers and the camshaft. Install
the oil sump.
2. Install the camshaft thrust ring. See FIGURE 24.
Measure the distance the thrust ring extends beyond the
face of the crankcase. The correct distance is 0.00 to
0.13 mm (0.000 to 0.005 in).
3. Install the fuel pump.
4. Install the timing gear cases as described in TIMING
GEAR CASE in this section.
5. Install the push rods and the rocker arm assembly.

12
 Auxiliary Drive Shaft And The Drive Shaft For
The Fuel Injection Pump
Removal
1. Remove the timing gear case as described in TIM-
ING GEAR CASE in this section.
2. Remove the air compressor.
3. Using a twisting motion, remove the auxiliary drive
shaft and the two halves of the thrust washer. See
FIGURE 25.
4. Remove the adapter plate for the fuel injection
8122
pump. Remove the upper thrust ring with the piston
CAMSHAFT
ring seal. See FIGURE 26.
5. Remove the drive shaft and gear assembly for the
fuel injection pump. If either the shaft or the gear is
damaged the shaft and gear assembly must be replaced.
FIGURE 23. REMOVING THE CAMSHAFT See FIGURE 26.
6. The lower thrust ring and bearing can be removed af-
ter removing the oil sump and oil pump. Use a puller as
shown in FIGURE 27.

8125

8123

CAMSHAFT THRUST RING

FIGURE 24. CAMSHAFT THRUST RING

FIGURE 25. AUXILIARY DRIVE SHAFT

13
 1 2
3

1
8124 8126

1. UPPER THRUST RING

2. PISTON RING SEAL 1. PULLER
3. DRIVE SHAFT AND GEAR 2. LOWER THRUST RING
FIGURE 26. DRIVE SHAFT FOR THE FUEL FIGURE 27. LOWER THRUST RING
INJECTION PUMP

Installation
1. Install lower thrust ring and bearing. Push the parts
into position.
2. Install the drive shaft and gear assembly for the fuel
injection pump. Install the upper thrust ring with piston
ring seal.
3. Install the oil pump and the oil sump.
4. Install the adapter plate for the fuel injection pump
with the bushing and the seal ring. Make sure the tim-
ing mark on the adapter plate is next to the outer stud.
See FIGURE 28.
5. Install the auxiliary drive shaft with the two halves of
the thrust washer. Make sure the thrust washers are
held in position by the pin. See FIGURE 29. The cor-
rect clearance between the thrust washers and the
groove in the auxiliary drive shaft is 0.06 to 0.23 mm
(0.0025 to 0.009 in)
6. Install the timing gear case as described in TIMING
GEAR CASE in this section.
7. Install the fuel injection pump as described in FUEL
INJECTION PUMP in this section.

14
 2

1
8441 8440

1
2
1. OUTER STUD 1. PIN
2. TIMING MARK 2. THRUST WASHER
FIGURE 28. ADAPTER PLATE FOR THE FUEL FIGURE 29. THRUST WASHER FOR THE
INJECTION PUMP AUXILIARY DRIVE SHAFT

CRANKSHAFT

REMOVAL thrust washers as described in steps 1. and 2. which fol-

low. Install the thrust washers as described in steps 3. to
NOTE: The thrust washers for the crankshaft can be
6.
replaced without removing the crankshaft. Remove the

8127

4
5 3
6

2
7
1. CRANKSHAFT
2. MAIN BEARING CAP
3. THRUST WASHER
4. CRANKSHAFT GEAR
5. OIL SEAL
6. CRANKSHAFT PULLEY
7. THRUST RING

FIGURE 30. CRANKSHAFT

15
1. Remove the oil sump. Remove the oil suction pipe
on the T6.3544 engine.
2. Remove center main bearing cap (number four). Re-
move top and bottom thrust washers from both sides of
the bearing cap. See FIGURE 30.
3. Remove the three capscrews from the crankshaft
pulley. If the pulley cannot be removed, hit the face of
the pulley as shown in FIGURE 31.
CAUTION
Do not use a puller to remove the crankshaft pulley.
The crankshaft and pulley will both be damaged.
4. Remove the timing gear case as described under
TIMING GEAR CASE in this section.
5. Remove the flywheel and the flywheel housing.
6. Remove the housing for the rear oil seal.
7. Remove the front and rear seal blocks from the bot-
tom of the crankcase.
8. Remove the piston and rod caps. Remove the caps
for the main bearings Make sure the caps have identifi-
cation marks. Do not damage the piston cooling jets.
9. Remove the crankshaft.
8428
FIGURE 31. REMOVING THE CRANKSHAFT
PULLEY
16
REPAIR
The crankshaft for the 6.3544 engine can be machined.
The limits are 0.25 mm (0.010 in), 0.51 mm (0.020 in)
or 0.76 mm (0.030 in) under the standard size without
being heat–treated.
CAUTION
The T6.3544 engine has a crankshaft that is heat
treated (Tuftrided). It can be machined only to 0.25
mm (0.010 in) under standard size without being
heat treated again.
INSTALLATION
1. Clean all oil passages in crankcase and crankshaft.
2. Install the top half of main bearings in the crankcase.
Lubricate the bearings with oil. Install the crankshaft.
3. Lubricate the two upper thrust washers. Install the
thrust washers on either side of the center main bear-
ing. Install the two lower thrust washers on the center
main bearing cap. Install the bearing cap.
4. Lubricate the lower halves of main bearings. Install
the bearings and the bearing caps making sure the loca-
tion pins are in position. Make sure the bearing caps are
in the correct position (by number). Also make sure the
serial numbers read in the same direction. See
FIGURE 32.
8129
FIGURE 32. BEARING CAPS

8130
FIGURE 33. INSTALLING THE REAR SEAL
BLOCK
5. Install new washers and tighten the capscrews for the
main bearings to 271 N.m (200 ft lbf).
6. Check the crankshaft end clearance at the center
main bearing. The correct clearance is 0.05 to 0.38 mm
(0.002 to 0.015 in). Use different size thrust washers to
get the correct clearance.
7. Install the bearings and caps for the piston rods as
described in PISTON ROD INSTALLATION in this
section.
8. Use a sealing compound and install the front and rear
seal blocks. Make sure the outside faces of the seal
blocks and the crankcase are even. See FIGURE 33.
9. Install new rubber seals in the grooves of the sealing
block.
10. Install the rear oil seal and the housing as follows:
a. Install the oil seal in the housing at one of the
positions shown in FIGURE 34. On new engines,
the oil seal is even with the face of the seal
housing. If the flange of the crankshaft is worn,
push the seal farther into the housing.
3.2 mm
(0.125 in)
6.4 mm
(0.250 in)
8131
FIGURE 34. REAR OIL SEAL AND HOUSING
b. Lubricate the oil seal and the flange of the
crankshaft. Apply a sealant to the housing for the
oil seal and the crankcase. Install the housing for
the oil seal. Make sure the housing for the oil seal
is installed on the location pins. Tighten the
capscrews for the housing.
11. Install the oil suction pipe on the T6.3544 engine.
Install the oil sump.
12. Install the timing gear case as described in TIMING
GEAR CASE in this section.
13. Install the crankshaft pulley as follows:
a. Clean the grease from the pulley and the parts of
the pulley lock.
b. Install the pulley. Make sure the key and key
groove are aligned.
c. Install the spacer (2), inner lock (3) and outer lock
(4) as shown in FIGURE 35. Make sure inner and
outer lock slots are not aligned.
17
 d. Install the thrust ring (5) with the O–ring (6) as
1 shown in FIGURE 35.
e. Install the capscrews. Tighten the capscrews
5
evenly to 88 N.m (65 ft lbf).
15. Install the flywheel housing and the flywheel as de-
scribed in in this section.

3 2
4

8132

1. PULLEY 4. OUTER LOCK

2. SPACER 5. THRUST RING
3. INNER LOCK 6. O–RING
FIGURE 35. CRANKSHAFT PULLEY

PISTONS AND PISTON RODS

REMOVAL (See FIGURE 36.)

1. Remove the cylinder head as described in in this sec-

tion.

2. Remove the oil sump. Remove the oil suction pipe

on the T6.3544 engine.

3. Remove the nuts for the caps of the piston rods. Re-
move the caps and the bearings.

4. Turn the piston rods to the left and push the rod and
the piston out of the crankcase. Do not damage the
cooling jets on the T6.3544 engine.

DISASSEMBLY (See FIGURE 37.) 8133

1. Remove the piston rings from the piston.

2. Remove the snap rings from piston. Remove the pis-

ton pin. If necessary, heat the piston in oil or water to FIGURE 36. REMOVING THE PISTON ROD
37° to 48°C (100° to 120°F) for removal of the piston
pin. Make sure the pistons and the piston rods have
identification marks. See FIGURE 38.

18
REPAIRS TOWARD FRONT OF THE ENGINE

1. Check the alignment of the piston rod as shown in

FIGURE 36.

2. Install a new bushing for the piston pin as follows:

a. Push the old bushing out of the piston rod.

b. Push the new bushing into the piston rod. Align

the oil hole in the bushing with the hole in the
piston rod.

c.. The correct I.D. for a machined bushing is 38.12

to 38.16 mm (1.501 to 1.502 in) for T6.3544
engine and 34.95 to 34.98 mm (1.376 to 1.377 in)
for a 6.3544 engine. Cut the outside of the 8135
bushing to fit the T6.3544 piston rod. FIGURE 38. IDENTIFICATION OF THE PISTON

3. Measure the clearance of the piston rings in the

grooves of the pistons. See SPECIFICATIONS in this
section for the correct clearance.
1. PISTON
2. PISTON PIN 7
3. SNAP RING ASSEMBLY
4. BUSHING
5. PISTON ROD 1. Check the clearance at the ends of the piston rings as
6. BEARING 1 shown in FIGURE 40. The correct clearance of new
7. PISTON RINGS
rings in a 98.48 mm (3.877 in) bore is as follows:
2
For the top compression ring, the clearance is 0.41 to
0.66 mm (0.016 to 0.026 in).
3
For the second compression ring and the oil ring the
clearance is 0.41 to 0.53 mm (0.016 to 0.021 in).
When measuring the clearance in a larger diameter, add
4 0.08 mm (0.003 in) to clearance specifications for each
0.03 mm (0.001 in) increase in the diameter of the bore.

0.25 mm
0.25 mm
(0.010 in) 127 mm 127 mm (0.010 in)
(5.0 in) (5.0 in)

8134
8136
FIGURE 37. PISTON AND PISTON ROD
FIGURE 39. ALIGNMENT OF THE PISTON ROD

19
 1
2

8137 1. TOP COMPRESSION RING

2. SECOND COMPRESSION RING
8442
3. OIL RING

FIGURE 40. CHECKING THE CLEARANCE AT FIGURE 41. PISTON RINGS

THE ENDS OF THE PISTON RINGS
2. Install the piston pin and new snap rings. If neces-
sary, heat the piston in oil or water to 37° to 48°C (100°
to 120°F) to permit pin installation.
3. Install the piston rings as shown in FIGURE 41.
Install the spring in the groove for the oil ring. Make
sure the pin is engaged at both ends of the spring.
Install the oil ring over the spring with the clearance
opposite the pin. When all the rings are installed, make
sure the clearances are at equal spaces around the pis-
tons. The clearances must not be aligned.
3. Check the height of the pistons. Put the piston at
T.D.C. The piston on the T6.3544 engine can extend
0.18 mm (0.007 in) above the top of the crankcase. The
piston on the 6.3544 engine can extend 0.38 mm (0.015
in) above the top of the crankcase. If necessary, the top
of the piston can be machined to meet specifications.
4. Install the oil suction pipe on the T6.3544 engine.
5. Install the oil sump. Install the cylinder head as de-
scribed in CYLINDER HEAD INSTALLATION in
this section.

INSTALLATION (See FIGURE 42.)

1. Lubricate the piston, piston rings and bearings with

oil. Put the pistons in the correct bores. Install the pis-
tons as shown in FIGURE 42. The identification num-
bers on the piston rods and caps must be towards the
side of the engine with the fuel injectors. (The letter F
on the piston must be toward the front of the engine.)
Do not damage the cooling jets on the T6.3544 engine.

2. Install the piston rod on the crankshaft. Install the

8138
correct bearing caps on the piston rod. Tighten the nuts
for the bearing cap to 102 N.m (75 ft lbf). FIGURE 42. INSTALLING THE PISTONS

20
 CYLINDER LINERS

REMOVAL AND INSTALLATION +0.05 to –0.10 mm 0.66 to 0.94 mm

(See FIGURE 43.) (+0.002 to –0.004 in) (0.026 to 0.037 in)

CAUTION
The face of the top of the crankcase cannot be ma-
chined.

1. Remove all parts from crankcase. Push out the cylin-

der liners from the bottom of the crankcase.

2. Clean the crankcase bore and the outside surface of

the new liners with Loctite
Safety Solvent.

3. Push the liner into the bore until it extends 50 mm (2 8139

in) above the crankcase. FIGURE 43. CYLINDER LINER

6. The height of the cylinder liner above the crankcase

4. Apply Loctite Compound 620 under the flange of the
liner and around the top 25.4 mm (1 in) of the liner.
Also apply Loctite 620 to the groove for the flange in
the crankcase.
5. Push the liner fully into the crankcase. Clean the
Loctite from the top of the crankcase.
is 0.66 to 0.94 mm (0.026 to 0.037 in). The height of
the flange on the liner can be within 0.05 mm (0.002 in)
above to 0.10 mm (0.004 in) below the top of the crank-
case.
7. Let the Loctite set (see instructions from the
manufacturer) before assembling the engine.

FLYWHEEL AND FLYWHEEL HOUSING

REPAIRS INSTALLATION

1. Install a new seal in the flywheel housing on units

1. Replace the ring gear on the flywheel as follows:
a. During removal or installation, do not heat the
gear to more than 230° C (450° F).
b. During installation, push the ring gear fully
against the shoulder of the flywheel.
2. The pilot bearing in the flywheel can be replaced.
Push out the old bearing and push in a new bearing.
with an oil clutch. During installation use a sealant on
the O. D. of the seal. The seal will extend 1.02 to 2.29
mm (0.040 to 0.090 in) beyond the flywheel housing.
2. Install a gasket and the flywheel housing on the
crankcase. Tighten the capscrews to 41 to 68 N.m (30
to 50 ft lbf).
3. Install the flywheel on the flange of the crankshaft.
Use a sealant on the capscrew threads. Tighten the
capscrews to 122 N.m (90 ft lbf).

21
 TURBOCHARGER

REMOVAL (See FIGURE 44.) 6. Remove the thrust collar, bearings and seals from the
center housing.
1. Disconnect the hoses for the air inlet at the turbo-
charger. INSPECTION

2. Disconnect the exhaust pipe at the turbocharger. Dis- Make an inspection of all turbocharger parts for wear
connect the oil lines at the turbocharger. or damage. Do not make repairs to parts with damage.
Replace damaged seals, bearings, capscrews, locknuts,
3. Remove the turbocharger from the exhaust manifold. snap rings and parts during assembly.

DISASSEMBLY (See FIGURE 45.) ASSEMBLY (See FIGURE 45.)

1. Clean the outside of the turbocharger with solvent. 1. Install the bearings and snap rings in the center hous-
Make alignment marks on the housings and covers. ing. Lubricate the bearings with oil.

2. Remove the capscrews holding the turbine housing
and the impeller housing to the center housing. Care-
fully remove the turbine and the impeller housings.
3. Put the center housing in a vise. Hold the turbine to
prevent rotation. Use a wrench with a T handle to re-
move the turbine locknut.
4. Remove the impeller. Remove the turbine assembly
and the cover.
5. Remove the capscrews from the cover plate. Re-
move the cover plate.
2. Install the seal ring on the turbine assembly. Put the
cover in position. Install the turbine assembly in the
center housing.
3. Install the seal ring on the thrust collar. Install the
thrust collar on the shaft so the thrust bearing is against
the center housing. Make sure the thrust collar engages
the pins in the center housing.
4. Install the seal in the groove of the center housing.
Install the thrust spring in the cover plate. Install the
cover plate on the center housing. Do not break the seal
ring during installation of the cover plate. Install the
lock plate and capscrews. Tighten the capscrews to 8.9
N.m (79 in lbf).

4
5. Install the impeller. Lubricate the threads of the shaft
5 and install the locknut. Use a wrench with a T handle to
2
tighten the locknut to 2.3 N.m (20 in lbf). Rotate the
wrench another 90° to tighten the locknut. Check that
the clearance at the end of the shaft is 0.03 to 0.10 mm
(0.001 to 0.004 in). Also, check that there is clearance
between the cover and the turbine.
6. Align the marks and install the impeller housing to
the center housing. Install the capscrews and the lock
8443
plates. Tighten the capscrews to 14.7 N. m (130 in lbf).
7. Align the marks and install the turbine housing to the
1. AIR INLET center housing. Lubricate the threads of the capscrews
3 2. EXHAUST MANIFOLD
1 with a high temperature lubricant. Install the lock
3. EXHAUST PIPE
4. TURBOCHARGER plates, capscrews and clamps. Tighten the capscrews to
5. INTAKE MANIFOLD 14.7 N. m (130 in lbf).
FIGURE 44. TURBOCHARGER 8. Check that the turbine rotates freely in the housing.

22
 17 3 1. IMPELLER HOUSING
10 2. IMPELLER
1 4 11 15 3. SEAL RING
12
4. THRUST COLLAR
5. COVER PLATE
14 6. THRUST SPRING
3 16 7. THRUST BEARING
8. OIL DRAIN LINE
9. CENTER HOUSING
10. SEAL
11. SNAP RING
12. BEARING
13. COVER
2 8140
6 14. TURBINE ASSEMBLY
15. TURBINE HOUSING
7 16. EXHAUST PIPE
5
13 17. OIL SUPPLY LINE
8 9
FIGURE 45. TURBOCHARGER

INSTALLATION (See FIGURE 44.)
1. Use a new gasket and install the turbocharger on the
exhaust manifold. Make sure the gasket does not ex-
tend into the opening of the manifold. Tighten the man-
ifold nuts.
2. Connect the exhaust pipe to the turbocharger. Con-
nect the hoses for air inlet to the turbocharger.
3. Connect the line for the oil supply to the turbochar-
ger. Leave the drain line disconnected.
4. Pull the Engine Stop Control. Rotate the engine until
oil comes out of the oil drain line. Connect the drain
line to turbocharger.
CAUTION
After installing a new or rebuilt turbocharger, do not
operate engine at maximum speed for the first 25
hours.

FUEL SYSTEM

FUEL INJECTORS PRIMARY FUEL

FILTER

CHECK
VALVE
SECONDARY
FUEL FILTER
FUEL INJECTION FUEL PUMP
PUMP
FUEL TANK

8141

FIGURE 46. FUEL SYSTEM

23
FUEL PUMP

Removal (See FIGURE 47.) 4

1. Disconnect the inlet and the outlet lines at the fuel

pump.

2. Remove the capscrews for the fuel pump, then re- 1

move the fuel pump and the gasket.
6
Disassembly (See FIGURE 48.)
5
1. Clean the outside of the fuel pump. Make alignment
marks on the housing of the fuel pump. 2

2. Remove the cover on top of the fuel pump. Remove

the capscrews from the housing and separate the parts.
Remove the parts as necessary. 3
8144
Assembly (See FIGURE 48.)

1. Install the lever and the spring in the bottom half of 1. DIAPHRAGM 4. COVER
the fuel pump body. 2. SPRING 5. SPRING
3. LEVER 6. HOUSING
2. Install the spring and the diaphragm. Push down- FIGURE 48. FUEL PUMP
ward on the diaphragm and rotate it through 90° in ei-
ther direction. This action engages the diaphragm and
the lever. 4. Install the cover on top of the fuel pump.
3. Align the marks and assemble the housings of the Installation (See FIGURE 47.)
fuel pump. Tighten the screws evenly.
1. Use a new gasket and install the fuel pump on the en-
gine. Tighten the capscrews to 27 N.m (20 ft lbf).
Tighten the capscrews again after the engine is hot.

2. Connect the inlet and the outlet fuel lines. Remove

air from the fuel system as described in CHECKS AND
ADJUSTMENTS in this section.

FUEL INJECTION PUMP

Removal (See FIGURE 49.)

1. Disconnect the throttle cable and the engine stop

cable.

2. Remove all the fuel lines from the fuel injection

8142 pump. See FIGURE 46. Do not bend the lines.

3. Remove the nuts for the fuel injection pump. Re-

FIGURE 47. REMOVING THE FUEL PUMP
move the injection pump.

24

8143
FIGURE 49. REMOVING THE FUEL INJECTION
PUMP
Repairs
Unless special equipment is available, do not make any
repairs to the fuel injection pump. Have any necessary
service done by a dealer.
Installation (See FIGURE 50.)
1. Install the fuel injection pump on the adapter plate.
Make sure the splines are aligned.
2. Put the injection pump in position so that the align-
ment marks are aligned. Check the timing of the en-
gine. Tighten the nuts.
3. Connect all the fuel lines to the injection pump.
4. Connect the throttle cable, the engine stop cable and
the springs.
5. Remove air from the fuel system as described in
CHECKS AND ADJUSTMENTS in this section.
6. If necessary, the idle speed can be set by turning the
adjustment screw. See FIGURE 55. When the engine is
warm, turn the screw to the right to increase the speed.
Turn the screw to the left to decrease the speed. The
correct idle speed is 650 RPM. This speed can be ad-
justed to 750 RPM to decrease noise or vibration.
8145
FIGURE 50. INSTALLING THE FUEL
INJECTION PUMP
FUEL INJECTORS
Checks
See CHECKS AND ADJUSTMENTS in this section.
Removal
1. Disconnect and remove the fuel lines at the fuel in-
jector.
2. Remove the nuts and the fuel injector. Do not bend
the fuel lines.
Repairs
Unless special equipment is available, do not make any
repairs to the fuel injectors.
Installation
1. Install the fuel injector and a new copper washer on
the cylinder head. Tighten the nuts evenly to 16 N.m
(12 ft lbf).
NOTE: Different copper washers are used on the
6.3544 and T6.3544 engines. The washers for the
6.3544 engine are 2.03 mm (0.080 in) thick. The wash-
ers for the T6.3544 engine are 0.71 mm (0.028 in). It is
important to use the correct copper washer.
2. Connect the fuel lines to the fuel injector. Tighten the
nuts to 20 N.m (15 ft lbf).
3. Remove air from fuel system as described in
CHECKS AND ADJUSTMENTS in this section.
25
 COLD START AID

Description (See FIGURE 51.)

The cold start aid is used to help start a cold engine. It is
installed in the intake manifold. Pushing the button for
the cold start aid heats the body of the cold start aid.
When heated, hot air and fuel enter the intake manifold.
This mixture then enters the combustion chamber for
starting.
Removal
1. Disconnect the fuel line at the cold start aid. Put a cap
on the fuel line.

SHIELD 6304
2. Disconnect the wire at the cold start aid.
IGNITER 3. Remove the cold start aid.
HEATER BALL VALVE
COIL Installation
1. Install the cold start aid in the intake manifold.
2. Connect the wire to the cold start aid.
3. Remove air from the fuel line to the cold start aid as
follows:
TUBULAR
BODY a. Rotate the engine until fuel flows from the fuel
VALVE
SYSTEM line.
b. Connect the fuel line to the cold start aid.
FIGURE 51. COLD START AID
4. Start the engine and check for leaks and correct op-
eration.

COOLING SYSTEM

THERMOSTATS WATER PUMP

Removal (See FIGURE 52.) Removal (See FIGURE 52.)

1. Drain the cooling system. Disconnect the top radia-
tor hose.
2. Remove water outlet manifold. Remove the thermo-
stats.
Installation (See Figure 53)
1. Install the thermostats in the housing. Use a new gas-
ket and install water outlet manifold.
2. Connect the top radiator hose. Fill the cooling sys-
tem.
1. Drain the cooling system. Disconnect the hoses at
the water pump.
2. Remove the drive belts. Remove the water pump.
Disassembly
1. Remove the fan from the pulley. Remove the lock
nut holding the pulley to the shaft. Use a puller to re-
move the pulley from the shaft.
2. Push the shaft and impeller out of the housing. Re-
move the snap ring, bearings and spacer.

26
 1. THERMOSTAT
2. MANIFOLD
3. HOUSING 2
4. PULLEY
5. SNAP RING
6. BEARING 1
7. SPACER
8. SHAFT
9. SEAL ASSEMBLY 3
10. IMPELLER 10

6 8
4 5 6 7

8416

FIGURE 52. WATER PUMP AND THERMOSTATS

Assembly (See FIGURE 53.)

1. Push the bearings and spacer on the shaft. Make sure

the seals on the bearing are toward the outside.

2. Install the seal assembly with the felt toward the in-
side.

NOTE: On later models, a new water seal has been

fitted to the latest water pumps. The seal has a brass
body and is interchangeable with the earlier seal.

CAUTION
It is important that the seal is not contaminated by
oil or grease and, if it is held in the hand, it should be
held by the edge of the flange. Do not damage the 8147
ring of green sealant applied to the body of the water
FIGURE 53. WATER PUMP
seal just behind the flange.

27
 2.0 mm at 45° 4. Install the curved washer on the end of the shaft with
(0.08 in) at 45° the impeller. Push the shaft and bearings into the hous-
44.0 mm ing from pulley end. Install snap ring.
(1.73 in)
5. Push the rubber washer on the shaft. Push the rear
seal on the end of the shaft with the impeller. Install the
ceramic seal so the face of the seal makes contact with
the carbon face.
40.0 mm
(1.57 in) 6. Install the capscrews in the housing. Install the
pulley and the key on the shaft. Make sure the shaft
does not move to the rear.
16.1 mm
(0.63 in) 7. Use a press to install the impeller on the shaft. There
35.8 mm must be clearance of 0.69 to 0.89 mm (0.027 to 0.035
(1.41 in) 11.2 mm in) between the impeller and the housing.
(0.44in)
1.0 mm at 45°
(0.04 in) at 45° CAUTION
FIGURE 54. SEAL INSTALLATION TOOL Do not use an air wrench to tighten the nut for the
pulley. Use of an air wrench will damage the ceramic
seal.
To press the new seal onto the shaft, a tool can be made
of any suitable material to the dimensions shown in 8. Install the nut for the pulley and the washer. Tighten
FIGURE 54. The tool will not allow axial distortion of
the nut to 81 N.m (60 ft lbf). Turn the pulley to make
the inner part of the seal while the seal is pressed onto
sure the pump is correctly assembled.
the shaft. The tool is for use with the new seal, but it
can also be used for the earlier seal. The tool is a looser Installation (See FIGURE 52.)
fit on the earlier seal, so ensure that the hole in the tool
is aligned with the shaft as the seal is fitted. 1. Use a new gasket and install the water pump. Tighten
the nuts to 27 N.m (20 ft lbf).
Support the pulley end of the shaft. With the ring of
sealant on the body of the seal towards the bearings, 2. Connect the hoses to the housing. Install the drive
use the tool to press the seal onto the shaft. Ensure that belts. Adjust the drive belts so there is 13 to 16 mm
the seal is pressed onto the shaft until the bottom of the (0.50 to 0.63 in) movement on the longest length of the
seal flange is in complete contact with the pump body. belt.

3. Lubricate the bearings and fill half the space be- 3. Fill the cooling system. Start the engine and check
tween the bearings with high temperature grease. for leaks.

CHECKS AND ADJUSTMENTS

REMOVING AIR FROM FUEL SYSTEM

WARNING
(See FIGURE 46.)
Do not start the engine until air is removed from the
Remove air from the fuel system if: (1) the engine has fuel system.
run out of fuel, or (2) when a fuel line(s) is discon-
nected from the system. Remove air from fuel system 1. Loosen vent screw A on top of the housing of the
as follows: governor.

28
2. Loosen vent screw B on the housing of the fuel injec-
tion pump.
3. Loosen vent screw C on top of the fuel filters.
4. Operate the lever on the fuel pump until fuel, free of
air bubbles, comes from each vent.
5. Tighten the vent screws in the following sequence: 1
a. Vent screw C
b. Vent screw B
c. Vent screw A
6. Loosen the nut on line D at the inlet of the fuel injec-
tion pump. Operate the lever on the fuel pump until air,
free of air bubbles, comes out by the threads. Tighten
the nut on the fuel line. 2
7. Loosen the nuts on the lines used for high pressure at 1. IDLE SPEED SCREW
2. ALIGNMENT MARKS 8148
two fuel injectors. Set the accelerator at the fully open
position. Make sure the engine stop control is in the FIGURE 55. ALIGNMENT OF THE FUEL
Start position. Turn the engine until fuel, free of air INJECTION PUMP
bubbles, comes out by the threads. Tighten the nuts on
the fuel lines.
2. Align the slots in the hub of the injection pump with
TIMING the adapter plate for the pump. See FIGURE 28. If the
slots are not aligned, loosen the capscrews on the auxil-
Fuel Injection Pump
iary drive gear. Rotate the auxiliary drive shaft until the
Three methods of timing the fuel injection pump are slots are aligned. Tighten the capscrews.
given. Method A is for checking the timing before the
pump is removed. Method B is for pumps that have 3. Install the fuel injection pump. Make sure the marks
been removed for service or for replacement pumps. on the pump flange and the adapter plate are aligned.
Method C is a procedure that uses a special timing tool. See FIGURE 55.

NOTE: The timing tool (part number 8108) is avail- Method B

able from Nuday Co., 14615 Wyoming Ave., Detroit,
Michigan 48238.
Method A
1. Rotate the crankshaft until the No.1 piston is at TDC
on the compression stroke. Remove the fuel injection
pump. Do not rotate the pump gear.
There is a rotor inside the fuel injection pump that has
marks on it. A snap ring, also inside the pump, must be
set to align with one of these marks.
1. Remove the fuel injection pump from the engine.
Remove the inspection cover from the injection pump.

29

3698
FIGURE 56. DEVICE FOR TESTING THE FUEL
INJECTORS
2. Connect the fitting on the injection pump for the No.
1 cylinder (“X”) to a pump for testing fuel injectors.
See FIGURE 56. Add pressure until it reaches 30.4 bar
(440 psi).
CAUTION
Fuel pressure must be used; Do not use air pressure
and do not go above the specific pressure.
8149
FIGURE 57. FUEL INJECTION PUMP TIMING
30
3. Rotate the pump by hand in the direction of the ar-
row until it stops. Adjust the position of the snap ring.
The straight edge of the snap ring must align with letter
F on the rotor. See FIGURE 57.
4. Align the timing marks and install the fuel injection
pump. See FIGURE 55.
5. Rotate the crankshaft until the No. 1 piston is at TDC
on the compression stroke.
6. Remove the rocker arm cover. Remove the valve
springs from the No. 1 inlet valve. Let the valve stop on
top of the piston. Move the seal for the valve stem to
the groove in the top of the valve stem. This prevents
the valve from falling into the cylinder.
7. Install a dial indicator to measure the movement of
the No. 1 inlet valve. Set the dial indicator to zero at
TDC.
8. Turn the crankshaft in the opposite direction of nor-
mal rotation approximately one eighth of a revolution.
Rotate the crankshaft in the normal direction until the
dial indicator indicates 9.45 mm (0.372 in). This is the
static timing position of 28° BTDC.
9. If the timing is correct, the snap ring and the letter F
on the rotor will be aligned. See FIGURE 57.
10. If the timing is not correct, loosen the nuts for the
fuel injection pump. Rotate the pump until the align-
ment is correct. See FIGURE 55. The adjustment can
be increased by changing the position of the auxiliary
drive gear. See FIGURE 21.
11. Assemble the engine as necessary.
Method C (See FIGURE 58.)
1. Remove the rocker arm cover. Rotate the crankshaft
until the No. 1 piston is at TDC on the compression
stroke.
2. Remove the valve springs from No. 1 inlet valve. Let
the valve stop on top of the piston. Move the seal for
the valve stem to the top groove in the valve stem. This
prevents the valve from falling into the cylinder.
 3 4 5 6 1 2

1. SCREW
2. SHAFT 8439
3. ALIGNMENT BAR
4. SCREW
5. BRACKET
6. SCREW
FIGURE 58. TIMING TOOL
8150

3. Install a dial indicator to measure the movement of

FIGURE 59. INSTALLATION OF THE TIMING
the No. 1 inlet valve. Set dial indicator to zero at TDC. TOOL

4. Remove the fuel injection pump.

5. Loosen the screw (1) on the timing tool. Move the
shaft (2) so that the large end with splines is at the front
of the tool.
6. Install the alignment bar (3) with the slot at the front
of the tool. Make sure the washer behind the screw (4)
holds the bar in position.
11. Rotate the timing tool by hand in the opposite direc-
tion to pump rotation (see pump nameplate). This will
remove clearance between the gears. Check that the
timing mark on the injection pump adapter aligns with
slot in alignment bar. If the timing mark does not align,
adjust the position of the auxiliary drive gear on its
shaft. The drive gear has slots to permit adjustment.
See FIGURE 21.

7. Loosen the screw (6). Set the bracket (5) so the edge
with the chamfer aligns with the 160° mark for timing
the engine.
8. Install the timing tool in the position on the fuel in-
jection pump. Make sure the shaft is aligned with the
drive shaft of the injection pump. Make sure the tool is
in the seat of the injection pump. Tighten the screw (1)
to hold the shaft in the tool.
9. If the pointer is 180° from the timing mark, the en-
gine is on the wrong stroke. Remove the tool and repeat
step 1.
10. Move the alignment bar (3) so that it just touches
the adapter for the injection pump. See FIGURE 59.
12. When timing is set, remove the tool. Install the fuel
injection pump.
Install the No. 1 valve parts and adjust the clearance.
Install the rocker arm cover.
Checking The Timing Angle For The Fuel
Injection Pump (Using The Timing Tool)
1. Loosen the screw (1) and remove the shaft (2).
Install the alignment bar (3) with the slot at the rear of
the tool. Make sure the washer behind the screw (4)
holds the bar in position.
2. Connect the No. 1 outlet, X, of the fuel injection
pump to a pump for testing fuel injectors. Operate the
test pump until the pressure is 30.4 bar (440 psi).

31
 2. Rotate the engine until the No. 6 cylinder is in a posi-
tion between the opening of the inlet valve and the
closing of the exhaust valve. At this time, adjust the
valves on the No. 1 cylinder.

3. Use the same procedure as described in step 2. and

adjust the clearance of the other valves as follows:

a. With the No. 2 cylinder in position, adjust the

clearance of the valves on cylinder No. 5.

b. With the No. 4 cylinder in position, adjust the

clearance of the valves on cylinder No. 3.

c. With the No. 1 cylinder is position, adjust the

clearance of the valves on cylinder No. 6.

d. With the No. 5 cylinder in position, adjust the

8151 clearance of the valves on cylinder No. 2.
FIGURE 60. INSTALLATION OF THE TIMING
e. With the No. 3 cylinder in position, adjust the
TOOL
clearance of the valves on cylinder No. 4.
3. Loosen the screw (4). Set bracket so that chamfer
aligns with the 146° timing mark for the pump. 4. Install the rocker arm cover.

4. Install the timing tool on the drive shaft of the injec-

tion pump. See FIGURE 60.
5. Turn the pump in the direction of normal rotation
(see nameplate) until it stops. Move the alignment bar
to the timing position as shown in FIGURE 60. If the
mark is not aligned, make a new mark at the center of
the alignment bar.

VALVE CLEARANCE ADJUSTMENT

(See FIGURE 61.)

Correct valve clearance is 0.20 mm (0.008 in) for the

inlet valves and 0.45 mm (0.018 in) for the exhaust
valves. Make sure the engine is cold. Adjust the clear-
ance as follows: 8152

1. Remove the rocker arm cover. Pull Engine Stop Con- FIGURE 61. ADJUSTING THE CLEARANCE OF
trol to the Stop position. THE VALVES

32
 THROTTLE
PEDAL

INJECTION
PUMP ROD
END

OIL CLUTCH TRANSMISSION

MONOTROL
PEDAL

PEDAL
STOP

BALL CLAMP
JOINT
BALL
JOINT
THROTTLE
LEVER
POWERSHIFT TRANSMISSION 5892

FIGURE 62. THROTTLE LINKAGE ADJUSTMENTS

ADJUSTING THE THROTTLE LINKAGE
(See FIGURE 62.)
1. Disconnect the throttle cable at the lever on the fuel
injection pump. Set the idle speed to 650 RPM. Use the
adjustment screw on the injection pump.
2. Adjust the length of the cable by loosening the
clamp. The ball joint must align with the throttle lever
on the injection pump. Tighten the clamp.
3. Adjust the ball joint or rod end at the throttle pedal.
The pedal must just touch the floor plate as the throttle
lever on the pump reaches the fully open position.
Install the ball joint or the rod end on the pedal.
4. On lift trucks with a powershift transmission, adjust
the Monotrol pedal stop. The pedal and the throttle le-
ver on the injection pump must reach the full return
positions at the same time.

33
CHECKING THE FUEL INJECTORS
(See FIGURE 63.)

Injector nozzles that are damaged will cause black

smoke in the exhaust, a decrease in engine output, and
an increase in engine noise.
1. Start the engine and run it at half speed.
2. Loosen the fitting for the high pressure fuel line at
the injector. If the engine speed does not change, the in-
2
jector is damaged.
1
3. Use an injector tester check the pressure at which the
nozzle operates. See FIGURE 63.
4. To change the pressure at which the nozzle operates,
add or remove washers at the nozzle holder. The cor-
rect pressure is 17.8 MPa (2575 psi).
5. Check the spray pattern of the nozzle. See 3698
FIGURE 63. If the spray pattern is not correct, the
needle valve is not correctly against the valve seat. Re-
FAULTY
move carbon deposits or replace parts as required. GOOD

3698

1. INJECTOR TESTER
2. FUEL INJECTOR
FIGURE 63. CHECKING THE FUEL INJECTORS

34

PROBLEM
The starter rotates the engine slowly
The engine will not start
The engine is difficult to start
The engine does not have enough
power
The engine has low compression
The engine uses too much fuel
There is black exhaust smoke
There is blue/ white exhaust smoke
The engine has low oil pressure
The engine has high oil pressure
The engine gets too hot
There is too much vibration
The engine makes too much noise
The engine does not run correctly
The engine stops and starts
There is too much pressure inside the
sump
TROUBLESHOOTING
POSSIBLE CAUSE
1, 2, 3, 4
5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32,
33
8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32,
33, 58, 60
11,19, 25, 28, 29, 31, 32, 33, 34, 45, 57
11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 60
11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 42, 58
4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 44, 59
4, 35, 36, 37, 38, 39, 41, 42, 43, 56
4, 37, 40
11, 13, 14, 16, 18, 19, 24, 25, 44, 49, 50, 51, 52, 53, 55
13, 14, 20, 23, 25, 26, 29, 30, 33, 44, 46, 47, 48
9, 14, 20, 23, 25, 26, 29, 30, 33, 44, 46, 47, 48
7, 8, 9, 10, 11, 12, 13, 14, 16, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28,
29, 30, 32, 33, 44, 57
2, 11, 12
25, 31, 33, 34, 44, 54

List of Possible Causes for engine problems: 30. Fuel lines for high pressure are not correct
31. Cylinder bores have wear
1. The battery is weak 32. Valves and seats have corrosion
2. Bad electrical connections 33. Piston rings are worn or have damage
3. Starter is damaged 34. Valve stems and guides have wear
4. Wrong oil 35. Crankshaft bearings have wear or damage
5. Starter rotates engine slowly 36. Not enough oil in the sump
6. Fuel tank is empty 37. Fuel gauge reading is not correct
7. Stop control operation is not correct 38. Oil pump has wear
8. Fuel inlet line has a restriction 39. Relief valve for oil pressure will not close
9. Fuel pump is damaged 40. Relief valve for oil pressure will not open
10. Fuel filter(s) are not clean 41. Spring for the relief valve is damaged
11. Air inlet system has a restriction 42. Oil suction pipe is not clean
12. There is air in fuel system 43. Oil filter has a restriction
13. Fuel injection pump is damaged 44. Piston does not move freely
14. Fuel injectors are damaged or are not correct type 45. Piston height is not correct
15. Cold start aid is not used correctly 46. Fan has damage
16. Cold start aid is damaged 47. Engine mounts are loose or damaged
17. The drive for the fuel injection pump has damage 48. Flywheel or housing is not in alignment
18. The timing for the fuel injection pump is not correct 49. Thermostat(s) are damaged
19. The valve timing is not correct 50. Water passages have a restriction
20. The compression is low 51. Drive belts are loose or damaged
21. Vent for the fuel tank is not clean 52. Radiator passages are not open
22. Fuel type is not correct 53. Water pump is damaged
23. Throttle linkage has a restriction 54. Breather pipe has a restriction
24. Exhaust pipe has a restriction 55. Not enough coolant in the engine
25. Cylinder head gasket has a leak 56. Suction filter for the sump has a restriction
26. Engine runs too hot 57. Valve spring(s) has damage
27. Engine runs too cold 58. Turbocharger impeller has damage
28. Valve clearance is not correct 59. Turbocharger oil seals have leaks
29. Valve movement is not free 60. Air inlet system has leaks

35
 SPECIFICATIONS
ITEM DIMENSIONS
Type 4–stroke, Direct Injection
Firing Order 1–5–3–6–2–4
Capacity 5801 cm3 (354 cu in)
Bore 98.43 mm (3.875 in)
Stroke 127.00 mm (5.000 in)
Compression Ratio 16:1 (6.3544),15.5:1 (T6:3544)
Static Timing 28° BTDC (9.45 mm/0.372 in)

CYLINDER HEAD AND VALVE MECHANISM

Cylinder Head
Height 94.87 to 95.63 mm (3.735 to 3.765 in)
Valve Seat Angle 45°
Valve Guides
I.D. of Valve Guide 9.53 to 9.55 mm (0.375 to 0.376 in)
O.D. of Valve Guide 15.90 to 15.93 mm (0.626 to 0.627 in)
Valve Guide Bore in Cylinder Head 15.88 to 15.90 mm (0.625 to 0.626 in)
Inlet Valve Guide Length 57.94 mm (2.281 in)
Exhaust Valve Guide Length 61.11 mm (2.406 in)
Inlet Valve
Overall Length 122.71 to 123.11 mm (4.832 to 0.847 in)
Valve Stem Diameter 9.47 to 9.50 mm (0.373 to 0.374 in)
Valve Head Diameter 44.09 to 44.35 mm (1.736 to 1.746 in)
Valve Face Angle 45°
Valve Head Depth Below Cylinder
Head Face 1.02 to 1.27 mm (0.040 to 0.050 in)
Exhaust Valve
Overall Length 123.11 to 123.52 mm (4.847 to 4.863 in)
Valve Stem Diameter (6.3544) 9.45 to 9.47 mm (0.372 to 0.373 in)
Valve Stem Diameter (T6.3544) 9.42 to 9.45 mm (0.371 to 0.372 in)
Valve Head Diameter 37.26 to 37.52 mm (1.467 to 1.477 in)
Valve Face Angle 45°
Inner Valve Spring
Installed Length 34.04 mm (1.340 in)
Outer Valve Spring
Installed Length 35.81 mm (1.410 in)
Rocker Arm Shaft
Length 661.19 mm (26.031 in)
Outside Diameter 19.02 to 19.05 mm (0.749 to 0.750 in)
Rocker Arm
I.D. of Rocker Arm for Bushing 22.23 to 22.25 mm (0.875 to 0.876 in)
O.D. of Bushing 22.28 to 22.33 mm (0.877 to 0.879 in)
I.D. of Bushing 19.09 to 19.10 mm (0.751 to 0.752 in)

36
 ITEM DIMENSIONS

LUBRICATION SYSTEM
Capacity with Filter
Oil Pump
Inner Rotor to Outer Rotor Clearance
Outer Rotor to Pump Body Clearance
Inner and Outer Rotor End Clearance
Relief Valve
First Pressure Setting (T6.3544 Only)
Main Pressure Setting
Oil Filter
By–Pass Valve Pressure Setting
15 litre (16 qt)
0.08 to 0.13 mm (0.003 to 0.0095 in)
0.15 to 0.33 mm (0.006 to 0.013 in)
0.03 to 0.08 mm (0.001 to 0.003 in)
2.1 to 2.6 bar (30 to 37 psi)
3.5 to 4.1 bar (50 to 60 psi)
0.6 to 0.8 bar (8 to 12 psi)

TIMING CASE, TIMING DRIVE AND CAMSHAFT

Auxiliary Drive Gear
Bore Diameter 25.40 to 25.43 mm (1.000 to 1.001 in)
Camshaft Gear
Bore Diameter 34.93 to 34.95 mm (1.375 to 1.376 in)
O.D. of Camshaft Hub 34.93 to 34.95 mm (1.375 to 1.376 in)
Crankshaft Gear
Bore Diameter 47.63 to 47.65 mm (1.875 to 1.876 in)
Crankshaft Diameter for Gear 47.63 to 47.65 mm (1.875 to 1.876 in)
Idler Gears and Hubs
Bore Diameter of Gears 52.40 to 52.43 mm (2.063 to 2.064 in)
O.D. of Bushing 52.48 to 52.53 mm (2.066 to 2.068 in)
I.D. of Bushing 47.63 to 47.68 mm (1.875 to 1.877 in)
O.D. of Hub 47.52 to 47.57 mm (1.871 to 1.873 in)
Gear End Clearance 0.05 to 0.30 mm (0.002 to 0.012 in)
Auxiliary Drive Shaft
O.D. of Front Bushing Surface 49.17 to 49.20 mm (1.936 to 1.937 in)
O.D. of Rear Bushing Surface 31.70 to 31.72 mm (1.248 to 1.249 in)
Thrust Washer Thickness 4.78 to 4.85 mm (0.188 to 0.191 in)
Camshaft
Thrust Washer Thickness 5.49 to 5.54 mm (0.216 to 0.218 in)
O.D. of No. 1 Bearing Surface 50.72 to 50.75 mm (1.997 to 1.998 in)
O.D. of No. 2 Bearing Surface 50.47 to 50.50 mm (1.987 to 1.988 in)
O.D. of No. 3 Bearing Surface 50.22 to 50.24 mm (1.977 to 1.978 in)
O.D. of No. 4 Bearing Surface 49.96 to 49.99 mm (1.967 to 1.968 in)
End Clearance 0.10 to 0.41 mm (0.004 to 0.016 in)
Cam Followers
75.41 mm (2.969 in)
Length
19.00 to 19.02 mm (0.748 to 0.749 in)
O.D. of Stem
Push Rods
265.58 to 267.72 mm (10.456 to 10.540 in)
Length

37
 ITEM
CRANKSHAFT
Main Bearing Surface Diameter
Piston Rod Bearing Surface Diameter
End Clearance
PISTONS AND PISTON RODS
Pistons – 6.3544
Height Above Crankcase Top Face
Piston Pin Bore Diameter
No. 1 (Compression Ring) Groove Width
No. 2 (Compression Ring) Groove Width
No. 3 (Oil Ring) Groove Width
Pistons – T6.3544
Height Above Crankcase Top Face
Piston Pin Bore Diameter
No. 1 (Compression Ring) Groove Width
No. 2 (Compression Ring) Groove Width
No. 3 (Oil Ring) Groove Width
Piston Rings – 6.3544
No. 1 Clearance in Groove
No. 2 Clearance in Grove
No. 3 Clearance in Groove
No. 1 End Clearance*
No. 2 and No.3 End Clearance*
Piston Rings – T6.3544
No. 1 Clearance in Groove
No. 2 Clearance in Groove
No. 3 Clearance in Groove
No. 1 End Clearance*
No. 2 and 3 End Clearance*
Piston Pin 6.3544
Outside Diameter
Piston Pin T6.3544
Outside Diameter
*End clearances given are for 98.48 mm (3.877 in) bore. For each 0.03 mm (0.001 in) difference from 98.48 mm
(3.877 in), permit 0.08 mm (0.003 in) in ring end clearance.
Piston Rod
I.D. Piston Pin Bushing
Length – Center to center
CYLINDER LINER
I.D. of Machined Liner
Maximum Bore Wear
Height Above Crankcase Top Face
38
DIMENSIONS
2.998 to 2.999 in (76.15 to 76.17 mm)
2.499 to 2.500 in (63.47 to 63.50 mm)
0.002 to 0.015 in (0.05 to 0.38 mm)
0.18 to 0.38 mm (0.007 to 0.015 in)
34.93 mm (1.375 in)
2.44 to 2.46 mm (0.096 to 0.097 in)
2.44 to 2.46 mm (0.096 to 0.097 in)
4.85 to 4.88 mm (0.191 to 0.192 in)
0.00 to 0.18 mm (0.000 to 0.007 in)
38.13 to 38.20 mm (1.501 to 1.504 in)
Tapered
2.44 to 2.46 mm (0.096 to 0.097 in)
4.83 to 4.85 mm (0.190 to 0.191 in)
0.05 to 0.10 mm (0.002 to 0.004 in)
0.05 to 0.10 mm (0.002 to 0.004 in)
0.08 to 0.13 mm (0.003 to 0.005 in)
0.41 to 0.66 mm (0.016 to 0.026 in)
0.41 to 0.53 mm (0.016 to 0.021 in)
0.08 to 0.10 mm (0.003 to 0.004 in)
0.05 to 0.10 mm (0.002 to 0.004 in)
0.08 to 0.10 mm (0.003 to 0.004 in)
0.41 to 0.66 mm (0.016 to 0.026 in)
0.41 to 0.53 mm (0.016 to 0.021 in)
34.93 mm (1.375 in)
38.10 mm (1.500 in)
38.10 to 38.15 mm (1.500 to 1.502 in)
219.05 to 219.10 mm (8.624 to 8.626 in)
98.48 to 98.50 mm (3.877 to 3.878 in)
0.20 mm (0.008 in)
0.66 to 0.94 mm (0.026 to 0.037 in)
 ITEM DIMENSIONS
CRANKCASE
I.D. for Cylinder Liner 103.20 to 103.23 mm (4.063 to 4.064 in)
No. 1 Camshaft Bore 50.80 to 50.83 mm (2.000 to 2.001 in)
No. 2 Camshaft Bore 50.55 to 50.60 mm (1.990 to 1.992 in)
No. 3 Camshaft Bore 50.30 to 50.34 mm (1.980 to 1.982 in)
No. 4 Camshaft Bore 50.04 to 50.09 mm (1.970 to 1.972 in)
COOLING SYSTEM
Capacity 21 litre (22 qt)
Thermostat 82°C (180°F)
Water Pump
O.D. of Pulley Shaft 22.20 to 22.23 mm (0.874 to 0.875 in)
O.D. of Impeller Shaft 12.73 to 12.75 mm (0.501 to 0.502 in)
I.D. of Pulley 22.23 to 22.25 mm (0.875 to 0.876 in)
I.D. of Impeller 12.70 to 12.73 mm (0.500 to 0.501 in)
Impeller to Housing Clearance 0.28 to 0.89 mm (0.011 to 0.035 in)

39
 TORQUE SPECIFICATIONS
ITEM TORQUE SPECIFICATION
CAMSHAFT GEAR NUT 68 N.m (50 ft lb)
CRANKSHAFT PULLEY CAPSCREWS 88 N.m (65 ft lb)
COOLING JET CAPSCREWS 27 N.m (20 ft lb)
CYLINDER HEAD See FIGURE 5.
FLYWHEEL CAPSCREWS 122 N.m (90 ft lb)
FLYWHEEL HOUSING CAPSCREWS 41 to 68 N.m (30 to 50 ft lb)
FUEL INJECTOR NUTS 16 N.m (12 ft lb)
FUEL PUMP CAPSCREWS 27 N.m (20 ft lb)
INLET MANIFOLD NUTS 33 N.m (24 ft lb)
MAIN BEARING CAP CAPSCREWS 271 N.m (200 ft lb)
OIL SUMP CAPSCREWS 20 N.m (15 ft lb)
ROCKER ARM NUTS 75 N.m (55 ft lb)
TURBOCHARGER
Cover Plate Capscrews 8.9 N.m (79 in lb)
Impeller Housing Capscrews 14.7 N.m (130 in lb)
Impeller Locknut 2.3 N.m (20 in lb)
Turbine Housing Capscrews 14.7 N.m (130 in lb)

40