C9 Specifications PDF

SENR9912-01
January 2013
Specifications
C9 Petroleum Engines
P9L 1-Up (Engine)
KLW 1-Up (Engine)
P7Z 1-Up (Engine)
SAFETY.CAT.COM
i05086812
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, including human factors
that can affect safety. 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 verify
that you are authorized to perform this work, and 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.
A non-exhaustive list of 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. You must not
use this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of the
product in the location of use, including site-specific rules and precautions applicable to the
worksite. 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 you are authorized to perform this work, and that the product will not be
damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
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. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury
or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SENR9912 3
Table of Contents
Table of Contents Crankshaft Seals ...................... ...................... 38

Connecting Rod Bearing Journal.......... .......... 39
Specifications Section Main Bearing Journal................... ................... 39
Connecting Rod....................... ....................... 40
Engine Design ......................... ......................... 4 Piston and Rings ...................... ...................... 41
Fuel Filter Base......................... ........................ 4 Piston Cooling Jet...................... ..................... 42
Fuel Filter Base......................... ........................ 5 Front Housing and Covers............... ............... 42
Fuel Filter Base......................... ........................ 6 Gear Group (Front)..................... .................... 43
Unit Injector Hydraulic Pump .............. .............. 6 Rear Power Take-Off (RPTO)............. ............ 44
Unit Injector............................ ........................... 8 Rear Power Take-Off (RPTO)............. ............ 44
Lifter Group............................ ........................... 9 Rear Power Take-Off (RPTO)............. ............ 45
Valve Mechanism ............................................ 10 Flywheel .......................................................... 45
Valve Mechanism Cover................. .................11 Flywheel .......................................................... 46
Cylinder Head Valves ................... ...................11 Flywheel .......................................................... 46
Cylinder Head......................... ........................ 14 Flywheel .......................................................... 47
Turbocharger ......................... ......................... 16 Flywheel Housing ...................... ..................... 47
Turbocharger ......................... ......................... 17 Belt Tension Chart ..................... ..................... 48
Air Inlet Elbow......................... ........................ 17 Fan Drive ............................ ............................ 49
Air Inlet Elbow......................... ........................ 17 Alternator and Regulator................. ................ 50
Exhaust Manifold...................... ...................... 19 Alternator and Regulator................. ................ 57
Camshaft ............................ ............................ 21 Alternator and Regulator................. ................ 61
Engine Oil Filter Base ................... .................. 22 Alternator and Regulator................. ................ 63
Engine Oil Filter Base ................... .................. 22 Alternator and Regulator................. ................ 63
Engine Oil Filter Base ................... .................. 23 Electric Starting Motor .................. .................. 64
Engine Oil Pan........................ ........................ 24
Engine Oil Pan........................ ........................ 24 Index Section
Engine Oil Pan........................ ........................ 25
Index................................ ............................... 65
Engine Oil Pan........................ ........................ 26
Water Temperature Regulator Housing ..... ..... 27
Water Temperature Regulator ............ ............ 29
Water Pump.......................... .......................... 31
Water Pump.......................... .......................... 32
Water Pump.......................... .......................... 34
Cylinder Block Cover Group .............. ............. 35
Cylinder Block Cover Group .............. ............. 35
Cylinder Block......................... ........................ 36
Cylinder Liner......................... ......................... 37
Cylinder Liner Projection ................ ................ 38
Crankshaft ........................... ........................... 38
4 SENR9912
Specifications Section
Specifications Section i02701484
i02841820
Fuel Filter Base
SMCS Code: 1261; 1262
Engine Design
SMCS Code: 1201
Illustration 1 g01101255
Cylinder and valve location
(A) Exhaust valves
(B) Inlet valves
Bore ............................................112.0 mm (4.41 inch)

(A) Length for applying 154-9731 Thread Lock
Stroke ........................................ 149.0 mm (5.87 inch) Compound to the threads on the tapered end of the
fuel filter insert............ 7.6 ± 1.5 mm (0.30 ± 0.06 inch)
Displacement..................................... 8.8 L (537 cu in)
(B) Distance from the sealing surface of the fuel filter
Cylinder arrangement .....................In-line six cylinder base assembly to the end of the fuel filter insert
................................. 24.7 ± 2.3 mm (0.97 ± 0.09 inch)
Valves per cylinder .................................................... 4
(1) Torque for the fuel filter insert................68 ± 7 N·m
Type of combustion ..............................Direct injection (50 ± 5 lb ft)
Valve lash with engine stopped (cold)
Inlet.............. 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

Exhaust ....... 0.64 ± 0.08 mm (0.025 ± 0.003 inch)
Note: The front of the engine is opposite of the
flywheel end of the engine. The left side and the right
side of the engine are viewed from the flywheel end of
the engine. The no. 1 cylinder is the front cylinder.
Crankshaft rotation direction (view from the flywheel

end) .................................................Counterclockwise
Firing order (injection sequence) ...........1, 5, 3, 6, 2, 4

SENR9912 5
i04374373
Fuel Filter Base

SMCS Code: 1261; 1262
(A) Length 11 mm (0.4 inch)
Table 1
Specification for 177-9778 Base As
Item Qty Part Specification Description
Apply red Loctite 271 on the tapered end of the hollow stud for the length of (A).
1 1 9S-4167 Hollow Stud
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
6 SENR9912
i02701489 i03251321
Fuel Filter Base Unit Injector Hydraulic Pump

SMCS Code: 1261; 1262 SMCS Code: 1714
Illustration 4 g01445336 Illustration 6 g01411601
(A) Length for applying 154-9731 Thread Lock Note: The bolts need to be replaced when the fuel
Compound from the tapered end of the hollow stud transfer pump group (5) is replaced.
....................................................... 7.6 mm (0.30 inch)
(1) Torque for four bolts......33 ± 5 N·m (290 ± 45 lb in)
(2) Torque for three screws....10 ± 1 N·m (90 ± 9 lb in)
(3) Torque for the fitting for the fuel inlet port
...........................................23 ± 2 N·m (205 ± 18 lb in)
(4) Torque for the fitting for the fuel outlet port
...........................................23 ± 2 N·m (205 ± 18 lb in)
(B) Distance from the sealing surface of the fuel filter

base assembly to the end of the hollow stud
................................. 24.6 ± 1.3 mm (0.97 ± 0.05 inch)
(1) Torque for the hollow stud ...................70 ± 15 N·m

(50 ± 11 lb ft)
SENR9912 7
(A) Installation depth for the needle bearing assembly

in the barrel .............. 28.9 ± 0.2 mm (1.14 ± 0.01 inch)
(6) Torque for the retainer nut .................5.5 ± 0.5 N·m

(50 ± 4 lb in)
(7) Torque for the nut ...............8 ± 1 N·m (70 ± 9 lb in)
Note: Install needle bearing assembly (8) so that the

end of the bearing with the identification number is
oriented, as shown. Refer to Illustration 7 .
Note: Install the spool (9) until the spool is fully

seated against the shoulder of the block.
8 SENR9912
i02820444
Unit Injector
SMCS Code: 1290
View A-A
Note: Lubricate the bore in the cylinder head lightly

with the lubricant that is being sealed.
Note: Install the fuel injector group (1) so the
electrical connector is facing toward the exhaust side
of the cylinder head.
Use the following procedure to install the fuel injector
group:
1. Seat the fuel injector group in the bore.
2. Tighten the bolt (2) which is closest to the exhaust

side (5) of the cylinder head until the bolt is seated.
3. Tighten the bolt (3) which is closest to the inlet side

Illustration 9 g01407502 (6) of the cylinder head to 12 ± 1 N·m
(4) O-ring seal (105 ± 9 lb in).
SENR9912 9
i02820477
Lifter Group
SMCS Code: 1209
Illustration 11 g01407507 (1) Valve lifter insert
View B-B (3) Valve lifter roller
(7) Backup ring
(8) O-ring seal (A) Diameter of a new valve lifter body
(9) O-ring seal .................29.464 ± 0.013 mm (1.1600 ± 0.0005 inch)
(10) Backup ring
(2)Lubricate the roller pin with clean engine oil.
Top view of fuel injector group
Note: The top of the fuel injector group has four bolts
(11) that are used for securing the top cover on the
fuel injector group. There are two holes (12) in the top
of the fuel injector group that are used for assembly
purposes only. Do not install bolts in the two bolt
holes (12).
10 SENR9912
i02843166
Valve Mechanism
SMCS Code: 1102
(B) Diameter of the new rocker arm shaft

.................28.000 ± 0.013 mm (1.1024 ± 0.0005 inch)
(C) Depth of installation of the two cup plugs from the

end of the rocker arm shaft to the top edge of the cup
plugs .................. 1.25 ± 0.25 mm (0.049 ± 0.010 inch)
(1) Valve bridge
(3) Valve pushrod
Valve lash
Inlet valve .... 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

Exhaust valve............................... 0.64 ± 0.08 mm
(0.025 ± 0.003 inch)
Note: Tighten the nut (2) after you set the valve lash.
(2) Torque for the nut ..............30 ± 7 N·m (22 ± 5 lb ft)

(4)Lubricate the bore in the cylinder block for the
valve lifter assemblies with a 50/50 mixture of clean
engine oil and 8T-2998 Lubricant before installation.
(A) Bore diameter of the valve rocker arm

.................28.050 ± 0.013 mm (1.1043 ± 0.0005 inch)
SENR9912 11
Note: Tighten the bolts in a numerical sequence that Tighten bolt (1) through bolt (11) in a numerical
is shown in Illustration 16 to standard torque. sequence to the following torque................28 ± 7 N·m
(248 ± 62 lb in)
(5) 163-2459 Spring
Quantity ..............................................................6 i03894192
Length under test force ......... 14.5 mm (0.57 inch)

Test force.....................65.0 ± 3.5 N (14.6 ± 0.8 lb) Cylinder Head Valves
Approximate free length after test......... 30.75 mm SMCS Code: 1105
(1.211 inch)
Outside diameter............... 34.80 mm (1.370 inch)
i04348429
Valve Mechanism Cover

SMCS Code: 1107
Section view of cylinder head valves
(1) Torque for the filler cap assembly............5 ± 1 N·m Note: Fully coat the assembled valve guide inner
diameter with engine oil prior to valve installation.
(45 ± 9 lb in)
(1) Inlet valve
12 SENR9912
Valve stem diameter................. 8.000 ± 0.010 mm Bore in the cylinder head for the valve guide
(0.3150 ± 0.0004 inch) .......... 15.970 ± 0.013 mm (0.6287 ± 0.0005 inch)
Diameter of valve head .............. 39.00 ± 0.13 mm
(1.535 ± 0.005 inch)
(2) Exhaust valve
Valve stem diameter................. 9.441 ± 0.010 mm

(0.3717 ± 0.0004 inch)
Diameter of valve head .............. 36.00 ± 0.13 mm
(1.417 ± 0.005 inch)
(3) 241-8386 Spring
Length under test force ......... 42.8 mm (1.69 inch)

Test force...................152.5 ± 7.0 N (34.3 ± 1.6 lb)
Approximate free length after test......... 56.68 mm
(2.231 inch)
Outside diameter................. 21.33 mm (0.84 inch) Detail B
(4) 190-6117 Spring Note: Shrink the valve seat inserts by reducing the
temperature. Shrinking the valve seat inserts allows
Length under test force ..... 37.70 mm (1.484 inch) placement into the counterbore.
Test force.......................350 ± 17 N (78.7 ± 3.8 lb)
Approximate free length after test......... 57.80 mm (C) Depth of the bore in the cylinder head for the
(2.276 inch) valve seat insert
Outside diameter............... 31.79 mm (1.252 inch) Depth (inlet).................................. 9.30 ± 0.05 mm
(5) 190-6115 Spring (0.366 ± 0.002 inch)
Depth (exhaust).......................... 10.40 ± 0.05 mm
Length under test force ......... 36.5 mm (1.44 inch) (0.409 ± 0.002 inch)
Test force.........................187 ± 8 N (42.0 ± 1.8 lb)
Approximate free length after test......... 57.80 mm (D) Outside diameter of the valve seat insert
(2.276 inch) Diameter (inlet)....................... 40.060 ± 0.013 mm
Outside diameter............... 23.18 mm (0.913 inch) (1.5772 ± 0.0005 inch)
(6) 241-8385 Spring Bore in the cylinder head for the valve seat insert
(inlet) ...................................... 40.000 ± 0.015 mm
Length under test force ......... 44.0 mm (1.73 inch) (1.5748 ± 0.0006 inch)
Test force.......................305 ± 15 N (68.6 ± 3.3 lb)
Approximate free length after test......... 67.69 mm Diameter (exhaust) ................ 37.560 ± 0.013 mm
(2.665 inch) (1.4787 ± 0.0005 inch)
Outside diameter............... 28.56 mm (1.124 inch) Bore in the cylinder head for the valve seat insert
(exhaust) ................................ 37.500 ± 0.015 mm
Note: Lubricate the bores in the cylinder head for the (1.4764 ± 0.0006 inch)
valve guides with clean engine oil prior to installation.
(A) Height of the valve guides above the top of the

cylinder head ........... 12.0 ± 0.5 mm (0.47 ± 0.02 inch)
(7) Valve guide (inlet)
Outside diameter.................... 13.030 ± 0.008 mm

(0.5130 ± 0.0003 inch)
Bore in the cylinder head for the valve guide
.......... 13.000 ± 0.013 mm (0.5118 ± 0.0005 inch)
(8) Valve guide (exhaust)
Outside diameter.................... 16.000 ± 0.008 mm

(0.6299 ± 0.0003 inch) Illustration 20 g02137776
View E-E of Detail B
SENR9912 13
(G) Angle of the face of the valve seat insert
Angle (inlet) ........................30.25 ± 0.25 degrees
View E-E of Detail B
(H) Angle of the face of the valve seat insert Illustration 23 g02137996
View F-F of Detail B
Angle (exhaust) ..................45.00 ± 0.25 degrees
(K) Angle of the face of the valve
Angle (exhaust) ..................45.75 ± 0.25 degrees
View F-F of Detail B
(J) Angle of the face of the valve
Angle (inlet) .......................... 60.5 ± 0.25 degrees

14 SENR9912
i02843388
Cylinder Head
SMCS Code: 1100
Note: The top face of the gasket and the top face of
the cylinder block, cylinder liners and the bottom face
of the gasket and the bottom face of the cylinder head
must be free of oil, fuel, water and other contaminants
before assembly.
Note: Use clean engine oil to lubricate the threads of

the cylinder head bolts before assembly.
Use the following procedure to tighten the cylinder
head bolts:
1. Torque the bolt (1) through bolt (26) in a numerical
sequence to 130 ± 15 N·m (95 ± 11 lb ft).
2. Again torque the bolt (1) through bolt (26) in a

numerical sequence to 130 ± 15 N·m (95 ± 11 lb ft)
.
3. Place a mark on bolt (1) through bolt (26). Rotate
the bolt (1) through bolt (26) in the clockwise
direction in a numerical sequence to 90 degrees
(1/4 turn).
4. Loosen the bolt (1) through bolt (26) in a numerical

sequence to 0 N·m (0 lb ft).
5. Repeat Step 1 through Step 3.
6. Torque the bolt (27) through bolt (31) in a numerical

sequence to 28 ± 7 N·m (21 ± 5 lb ft).
SENR9912 15
16 SENR9912
Note: Apply 6V-6640 Sealant to the bore of the cup i02847495

plugs before assembly.
Turbocharger
(C) The cup plugs (Y) are measured from the head
face to the top edge of the plug. Depth of installation SMCS Code: 1052
................................... 2.0 ± 0.5 mm (0.08 ± 0.02 inch)
(D) The cup plugs (X) are measured from the head
face to the top edge of the plug. Depth of installation
................................... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)
(32) Torque for the plugs.........................350 ± 30 N·m Illustration 27 g01419635

(260 ± 22 lb ft)
(1) Torque for the six bolts of the turbine clamp plate
(E) Height of new cylinder head ..... 130.00 ± 0.15 mm .....................................21.6 ± 1.1 N·m (190 ± 10 lb in)
(5.118 ± 0.006 inch)
(2) Torque for the eight bolts of the compressor clamp
Note: The flatness of the cylinder head should be plate .............................13.6 ± 1.1 N·m (120 ± 10 lb in)
within 0.15 mm (0.006 inch). The flatness should
also be a maximum of 0.05 mm (0.002 inch) for any (3) Opening pressure of the wastegate ..........210 kPa
150.00 mm (5.906 inch) span. (30 psi)
Front view
Note: Apply 4C-5599 Anti-Seize Compound to the
threads of the locknuts.
SENR9912 17
(4) Torque for the four locknuts...................54 ± 5 N·m i02843181

(40 ± 4 lb ft)
Air Inlet Elbow
i02703347 SMCS Code: 1071
Turbocharger
SMCS Code: 1052
Left side view of engine
(1)Apply 1U-8846 Gasket Sealant to the face of the

mounting flange of the elbow. Spread the gasket
sealant uniformly. The elbow must be assembled and
tightened within ten minutes.
(2) Torque for the eight studs......................30 ± 7 N·m

(22 ± 5 lb ft)
i02182363
Air Inlet Elbow

SMCS Code: 1071
(1) Torque for the compressor clamp assembly

.......................................13.5 ± 1.0 N·m (120 ± 9 lb in)
Note: Apply 4C-5599 Anti-Seize Compound to the

(2) Torque for the four locknuts...................54 ± 5 N·m

(40 ± 4 lb ft)
(3)Use the following procedure to tighten the turbine
clamp assembly:
1. Tighten the clamp assembly to 18.1 N·m

(160 lb in).
2. Loosen the clamp assembly to 5.6 N·m (50 lb in). (1)Air Inlet Elbow
3. Again tighten the clamp assembly to Apply 1U-8846 Gasket Sealant to the face of the
13.5 ± 1.0 N·m (120 ± 9 lb in). mounting flange of the inlet elbow. Spread the sealant
uniformly. The elbow must be assembled and
(4) Opening pressure of the wastegate ..........210 kPa tightened within ten minutes.
(30 psi)
18 SENR9912
i02182321 i02182101
Air Inlet Elbow Air Inlet Elbow

SMCS Code: 1071 SMCS Code: 1071
(1)Air Inlet Elbow

Apply 1U-8846 Gasket Sealant to the face of the
mounting flange of the inlet elbow. Spread the sealant
tightened within ten minutes. Illustration 34 g01104053
i02843193
(1)Air Inlet Elbow
Air Inlet Elbow mounting flange of the inlet elbow. Spread the sealant
SMCS Code: 1071 uniformly. The elbow must be assembled and
Typical example
(1)Apply 1U-8846 Gasket Sealant to the face of the

mounting flange of the elbow. Spread the gasket
sealant uniformly. The elbow must be assembled and
SENR9912 19
i02496546 i02843280
Air Inlet Elbow Exhaust Manifold

Typical example
(1)Air Inlet Elbow

mounting flange of the inlet elbow. Spread the sealant
View A-A
(1) Torque for the taperlock studs ...............35 ± 5 N·m

(26 ± 4 lb ft)
(2)Apply 4C-5599 Anti-Seize Compound to the
(3)Install the gasket with the tab upward.
20 SENR9912
i02843259 i02881149
Exhaust Manifold Exhaust Manifold


Typical example (1) Cylinder head
(1) Cylinder head
(2) Torque for the 12 taperlock studs ..........35 ± 5 N·m
(2) Torque for 12 taperlock studs ................35 ± 5 N·m (26 ± 4 lb ft)
(26 ± 4 lb ft)
(3) Torque for the four taperlock studs........35 ± 5 N·m
(3) Torque for four taperlock studs..............35 ± 5 N·m (26 ± 4 lb ft)
(26 ± 4 lb ft)
(4)Install the six gaskets with the tabs upward, as
(4)Install the gasket with the tab upward, as shown. shown.
(5)Apply 4C-5599 Anti-Seize Compound to the (5)Apply 4C-5599 Anti-Seize Compound to the
threads of the locknuts and the bearing surface of the bearing surfaces and the threads of the 12 locknuts
locknuts and the washers before assembly. before assembly.
SENR9912 21
i02881184 i02843361
Exhaust Manifold Camshaft


(1) Cylinder head
(A) Diameter of the four camshaft journals
(2) Torque for the 12 taperlock studs ..........35 ± 5 N·m .................65.126 ± 0.013 mm (2.5640 ± 0.0005 inch)
(26 ± 4 lb ft)
(B) Thickness of new thrust plate .................... 4.7 mm
(3) Torque for the four taperlock studs........35 ± 5 N·m (0.19 inch)
(26 ± 4 lb ft)
End play of a new camshaft................ 0.10 ± 0.08 mm
(4)Install the six gaskets with the tabs upward, as (0.004 ± 0.003 inch)
shown.
Maximum permissible end play of a worn camshaft
(5)Apply 4C-5599 Anti-Seize Compound to the
bearing surfaces and the threads of the 12 locknuts ................................................... 0.46 mm (0.018 inch)
before assembly.
(C) Specified camshaft lobe lift
Exhaust lobe ...................6.858 mm (0.2700 inch)

Inlet lobe.......................... 8.655 mm (0.3407 inch)
22 SENR9912
To find the actual camshaft lobe lift, use the following i02841642
procedure:
Engine Oil Filter Base
1. Measure the camshaft lobe height (D).
SMCS Code: 1306
2. Measure the base circle (E).
3. Subtract the base circle (E) from the camshaft lobe

height (D). The difference is the actual camshaft
lobe lift (C).
Maximum permissible difference between the actual

lobe lift and the specified lobe lift of a new camshaft
................................................ ± 0.10 mm (0.004 inch)
i03094842
Engine Oil Filter Base

SMCS Code: 1306
Bolt tightening sequence for oil filter base
Use the tightening sequence that is shown in

Illustration 44 in order to torque the bolts for the oil
filter base.
(A) Length for applying 154-9731 Thread Lock

Compound to the threads of the hollow stud
..................................................... 10.0 mm (0.39 inch)

(60 ± 11 lb ft)
(13) Oil cooler bypass valve
(14) Oil filter bypass valve
(17) Engine oil filter assembly
(15) 242-3864 Spring
Length under test force ..... 43.18 mm (1.700 inch)

Test force.........................................43.7 N (9.8 lb)
SENR9912 23
Free length after test .................. 58.50 ± 0.50 mm i02841054

(2.303 ± 0.020 inch)
Outside diameter.........................11 mm (0.4 inch) Engine Oil Filter Base
SMCS Code: 1306
(A) Length for applying 154-9731 Thread Lock Illustration 47 g01417027

Compound to the threads of the hollow stud
................................. 10.0 ± 1.5 mm (0.39 ± 0.06 inch)

(50 ± 5 lb ft)
(1) Torque for the hollow stud .....................68 ± 7 N·m

(50 ± 5 lb ft)
24 SENR9912
Note: The 242-3864 Spring is located in each of the Note: The sealing surfaces of the oil pan shall be free
bypass valves. of oil, debris, gasket material that is protruding, or any
other sealant. The oil pan must be assembled and
(2) 242-3864 Spring tightened to the cylinder block within ten minutes of
applying sealant.
Length under test force ..... 43.18 mm (1.700 inch)
Test force.........................................43.7 N (9.8 lb) Use the following procedure in order to tighten the
Free length after test .................. 58.50 ± 0.50 mm bolts for the oil pan:
(2.303 ± 0.020 inch)
1. Apply 4C-9612 Silicone Sealant to a bead of
Outside diameter.........................11 mm (0.4 inch)
5 mm (0.2 inch) at four places (3) on the sealing
surface of the oil pan. The sealing surfaces are the
following areas:
• Connecting joint of the flywheel housing (4) and

the rear of the cylinder block
• Connecting joint of the front housing (5) and the

front of the cylinder block
2. Tighten the four bolts (1) to standard torque.
3. Start with bolt (2) and tighten all the bolts in a

counterclockwise sequence to standard torque.
4. Again, start with bolt (2) and tighten all the bolts in
a counterclockwise sequence to 31 ± 3 N·m
View of area D
(23 ± 2 lb ft).
(E) Length for applying 154-9731 Thread Lock
Compound to the threads of the hollow stud i02916163
................................. 10.0 ± 1.5 mm (0.39 ± 0.06 inch)

Engine Oil Pan
i03017954 SMCS Code: 1302
Engine Oil Pan

SMCS Code: 1302
Typical example
Note: The sealing surfaces shall be free of oil, debris,

gasket material that is protruding, or any other
Typical example sealant.
SENR9912 25
Use the following procedure to install the oil pan: • Connecting joint of the front housing and the
front of the cylinder block
1. Apply 1U-8846 Gasket Sealant to four places (3)
on the sealing surface of the oil pan. The sealing 2. Tighten four bolts (1) to standard torque.
surfaces are the following areas:
3. Start with bolt (3) and tighten all the remaining bolts
• Connecting joint of the front housing (4) and the in a counterclockwise sequence to standard
front of the cylinder block torque.
• Connecting joint of the flywheel housing (5) and 4. Again start with bolt (3) and tighten all the bolts in a
the rear of the cylinder block counterclockwise sequence to 31 ± 3 N·m
(23 ± 2 lb ft).
2. The oil pan must be assembled and tightened to
the cylinder block within five minutes.
3. Tighten the four bolts (1).
4. Start with bolt (2) and tighten all the bolts in a

counterclockwise sequence.
5. Again start with bolt (2) and tighten all the bolts in a
counterclockwise sequence to 31 ± 3 N·m
(23 ± 2 lb ft).
i03005528
Engine Oil Pan

SMCS Code: 1302
Typical example
Note: The sealing surfaces of the oil pan shall be free

of oil, debris, gasket material that is protruding, or any
other sealant. The oil pan must be assembled and
tightened to the cylinder block within ten minutes of
applying sealant.
Use the following procedure to install the oil pan:
1. Apply 4C-9612 Silicone Sealant to a bead of

5 mm (0.2 inch) at four places (2) on the sealing
surface of the oil pan. The sealing surfaces are the
following areas:
• Connecting joint of the flywheel housing and

the rear of the cylinder block
26 SENR9912
i05198782
Engine Oil Pan

SMCS Code: 1302
Typical example
Table 2
Specification for 198-6368 Oil Pan Gp and 197-6354 Oil Pan Gp
The sealing surfaces of the oil pan shall be free of oil, debris, gasket material that is protruding, or any other sealant. The oil pan must be as-
sembled and tightened to the cylinder block within 10 minutes of applying sealant.
Apply, Loctite RTV silicone to a bead of 5 mm (0.2 inch) at two places:

- - - To the connecting joint of the front housing (3). and to the connecting joint of the flywheel hous-
ing (4).
Use the following tightening procedure for oil pan bolts:
Tighten the four bolts (1).

- - -
Start with bolt (2) and tighten rest all bolts in a counterclockwise sequence.
Again, start with bolt (2) and tighten all the bolts in a counterclockwise sequence to 31 ± 3 N·m
(274 ± 27 lb in).
SENR9912 27
i02822670 i02822671
Water Temperature Regulator Water Temperature Regulator

Housing Housing
(1)Lubricate the sealing lip of the lip type seal lightly

with glycerin or an approved equivalent.

28 SENR9912
i02843384
Water Temperature Regulator

Housing
SMCS Code: 1393

SENR9912 29
i04907651

SMCS Code: 1355
Table 3
Specification for 248-5513 Temperature Regulator
A - - Minimum opening distance at fully open temperature is 10.4 mm (0.41 inch).
- - - Opening temperature is 81 to 84 °C (178 to 183 °F).
- - - Fully open temperature is 92 °C (198 °F).
- - - Leakage at the seat and sleeve shall not exceed minimum 10.0 cc (0.6 cubic inch) at 207 kPa (30 psi).
Force required to separate valve from seat is 165 ± 9 N (37 ± 2 lb), measured at temperature 75 °C
- - -
(167 °F).
30 SENR9912
i04377217

SMCS Code: 1355
Table 4
Specification for the 247-7133 Water Temperature Regulator
247-7133 Water Minimum opening distance at fully open temperature is 10.4 mm (0.41 inch).
A - Temperature
Regulator
Start to open temperature is 86 to 90 °C (187 to 194 °F).

- - -
Fully open temperature is 98 °C (208 °F).
SENR9912 31
i02843440 (B) Minimum stroke at fully open temperature.... 8 mm

(0.3 inch)
SMCS Code: 1355 i02843453
Water Pump
SMCS Code: 1361
(1)Apply 4C-9509 Wicking Sealant to the retainer

tab all around.
(1) Shaft assembly
(2)The bearing must be flush with the edge of the

housing.
(3)The plug must be flush with the edge of the
housing. Refer to Illustration 61 for the correct
orientation of the plug. If necessary, adjust the
orientation of the plug.
(A) Clearance between the pump impeller and the

housing .............. 0.75 ± 0.25 mm (0.030 ± 0.010 inch)
(C) Operating height of the water pump seal

assembly.......... 12.19 ± 0.13 mm (0.480 ± 0.005 inch)
(D) Distance from the front face of the pulley to the

face of the housing ......................... 132.88 ± 0.30 mm
(5.232 ± 0.012 inch)
Note: Refer to Disassembly and Assembly for the
complete procedure for installing the shaft assembly
and the water pump seal assembly.
Start to open temperature.......................... 86 to 89 °C
(187 to 192 °F)
Fully open temperature......................... 97 °C (207 °F)
(A) Closed dimension of the water temperature

regulator................... 29.5 ± 0.5 mm (1.16 ± 0.02 inch)
32 SENR9912
i04338151
Water Pump
SMCS Code: 1361
(2) Shaft assembly

SENR9912 33
(1) Torque for four bolts.........55 ± 10 N·m (41 ± 7 lb ft)

(3)Flush the bearing with the water pump housing
assembly.
(B) Clearance between the pump impeller and the

pump housing .... 0.75 ± 0.25 mm (0.030 ± 0.010 inch)
(C) Operating height of the water pump seal

assembly.......... 12.19 ± 0.13 mm (0.480 ± 0.005 inch)
(D) Distance from the front face of the pulley to the

face of the pump housing ................... 132.9 ± 0.3 mm
(5.23 ± 0.01 inch)
(4) Torque for bolts.............30 ± 7 N·m (266 ± 62 lb in)

complete procedure for installing the shaft assembly
and the water pump seal assembly.
34 SENR9912
i02746324
Water Pump
SMCS Code: 1361
(1) Shaft assembly
(2)The bearing must be flush with the edge of the

housing.
(3)The plug must be flush with the edge of the
housing. Refer to Illustration 64 for the correct
orientation of the plug. If necessary, adjust the
orientation of the plug.
(B) Clearance between the pump impeller and the

housing .............. 0.75 ± 0.25 mm (0.030 ± 0.010 inch)
(C) Working height of the installed water pump seal

assembly.......... 12.19 ± 0.13 mm (0.480 ± 0.005 inch)
(D) Distance from the front of the hub to the face of

the housing .... 122.79 ± 0.30 mm (4.834 ± 0.012 inch)

complete procedure for installing the shaft and seal.
SENR9912 35
i02843502 i02906652
Cylinder Block Cover Group Cylinder Block Cover Group


Left side view
Use the following procedure to tighten the bolts for
the cylinder block cover group: Use the following procedure to tighten the bolts for
the cylinder block cover group:
1. Tighten bolt (1) through bolt (11) in the numerical
sequence that is shown. 1. Tighten the bolts in the numerical sequence that is
shown.
2. Again tighten the bolt (1) through bolt (11) in the
numerical sequence that is shown. 2. Again tighten the bolts in the numerical sequence
that is shown.
(12) Torque for the bolt............15 ± 3 N·m (11 ± 2 lb ft)
(1) Torque for the bolt...........10 ± 3 N·m (90 ± 27 lb in)
36 SENR9912
i02845073
Cylinder Block
SMCS Code: 1201
View C-C
(G) Distance from the centerline of the crankshaft

bore to the top surface of the cylinder block
Illustration 67 g01418207 .....................356.50 ± 0.15 mm (14.035 ± 0.006 inch)
Right side view
(J) Camshaft bores
Bore diameters in the cylinder block for the

camshaft bearings except for the front camshaft
bearing. ..................................70.000 ± 0.038 mm
(2.7559 ± 0.0015 inch)
Bore diameter in the cylinder block for the front
camshaft bearing. .................. 70.000 ± 0.025 mm
(2.7559 ± 0.0010 inch)
(K) Distance from the centerline of the crankshaft to

the bottom surface of the cylinder block .....110.00 mm
(4.331 inch)
(L) Bore in the cylinder block for the seven main

bearings .......................................112.000 ± 0.013 mm
Illustration 68 g01418249 (4.4094 ± 0.0005 inch)
View B-B
(M) Width of the main bearing cap
(A) Distance from the top of the cylinder block to the ...............175.000 ± 0.020 mm (6.8898 ± 0.0008 inch)
top of the dowel........ 14.0 ± 0.5 mm (0.55 ± 0.02 inch)
Use the following procedure in order to tighten the
(D) Distance from the rear face of the cylinder block main bearing cap bolts (1):
to the end of dowels.............................. 12.0 ± 0.5 mm
1. Orient the main bearing cap correctly. The part
(0.47 ± 0.02 inch)
number on the main bearing cap must face to the
(E) Distance from the front face of the cylinder block right and to the front face of the block.
to the end of dowels.................................8.0 ± 0.5 mm Note: The main bearing caps are marked with
(0.31 ± 0.02 inch) identification numbers “1” through “7” . Install the
main bearing caps into the correct positions.
(F) Installation depth of the cup plug from the block
face to the top edge of the plug .......... 1.25 ± 0.25 mm
(0.049 ± 0.010 inch)
SENR9912 37
2. Lubricate the main bearing cap bolts. Use SAE

30W oil or molybdenum grease to lubricate the
threads and the washer face.
3. Torque the main bearing cap bolts to 95 ± 5 N·m
(70 ± 4 lb ft).
4. Put an alignment mark on each cap and bolt.
5. Rotate the bolts in the clockwise direction to an

angle of 90 ± 5 degrees.
View R-R
(2)The oil hole in the bearing must be in alignment

with the oil hole in the block.
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.
i02844254
Cylinder Liner
View H-H
SMCS Code: 1216
NOTICE
Camshaft bearings must be installed into their correct
position. Failure to do so will result in engine damage.
The camshaft bearings are installed into the cylinder

block at the following positions:
Position (N) .............................. 816.50 ± 0.80 mm

(32.146 ± 0.031 inch)
Position (P) .............................. 536.50 ± 0.80 mm
(21.122 ± 0.031 inch)
Position (S) .............................. 294.50 ± 0.80 mm
(11.594 ± 0.031 inch)
Position (T) .................................. 0.50 ± 0.25 mm
(0.020 ± 0.010 inch)
(U) Installation depth of the cup plug from the block

face to the top edge of the plug .......... 1.25 ± 0.25 mm
(0.049 ± 0.010 inch)
Note: Apply 5P-3975 Rubber Lubricant to the

cylinder liner seal prior to assembly.
38 SENR9912
Outside diameters of the cylinder liner (A) Average diameter of gear after assembly
........................112.48 ± 0.10 mm (4.428 ± 0.004 inch)
Position (A) .............................. 128.95 ± 0.03 mm
(5.077 ± 0.001 inch) Maximum diameter of gear after assembly
Position (B) .............................. 123.80 ± 0.30 mm ............................................... 112.63 mm (4.434 inch)
(4.874 ± 0.012 inch)
Position (C) .............................. 123.95 ± 0.13 mm Crankshaft end play after assembly into cylinder
(4.880 ± 0.005 inch) block ................0.21 to 0.60 mm (0.008 to 0.024 inch)
Position (D) .............................. 126.00 ± 0.27 mm
(4.961 ± 0.011 inch) i02844263
Position (E) .............................. 126.24 ± 0.03 mm
(4.970 ± 0.001 inch) Crankshaft Seals
Position (F) .............................. 120.34 ± 0.08 mm SMCS Code: 1160; 1161
(4.738 ± 0.003 inch)
Bore diameter for the cylinder liner

............... 112.025 ± 0.025 mm (4.4104 ± 0.0010 inch)
i02084820
Cylinder Liner Projection

SMCS Code: 1216
Table 5
Specifications
0.060 to −0.060 mm
Liner projection
(0.0024 to −0.0024 inch)
Maximum variation in each liner 0.051 mm (0.0020 inch)
Maximum average variation be-

0.080 mm (0.0031 inch)
tween adjacent liners
Maximum variation between all

0.102 mm (0.0040 inch)
six liners
i02765209 (4) O-ring seal
(5) Bolt
Crankshaft
SMCS Code: 1202
(1) Main bearing journals
(2) Connecting rod bearing journals
SENR9912 39

Detail A Detail B
(7) Rear crankshaft seal group with dust lip
complete procedure that is used for information that Note: The rear crankshaft seal group (6) is a double
relates to the removal and the installation of the front lipped seal that is used for wet flywheel housing
and the rear crankshaft seals. applications.
Note: The crankshaft seal excluder (1) can be
installed with the front seal for use in applications that i02741422
operate in harsh environments. If the extruder is used
on your application, lubricate the inside diameter of Connecting Rod Bearing
the crankshaft seal excluder with liquid soap prior to
assembly to the crankshaft pulley.
Journal
SMCS Code: 1202; 1219; 1225
When the front crankshaft seal (3) is installed, the
front face of the seal must be 2.5 mm (0.10 inch) Table 6
from the face of the front housing (2). Connecting Rod Bearing Journal
Original size journal 80.000 ± 0.020 mm

(3.1496 ± 0.0008 inch)
Reuse And Salvage Guidelines, SEBF8041

Note: No undersized bearings exist for the
connecting rod bearing journals.
i04041250
Main Bearing Journal

SMCS Code: 1202; 1203
Table 7
Diameter of Crankshaft Journal (Bearing Surface) for Main
Bearings
104.000 ± 0.020 mm
Original size journal
(4.0945 ± 0.0008 inch)
(continued)
40 SENR9912
(Table 7, contd) (B) Bore in the connecting rod for the piston pin
Undersized journal 0.25 mm 103.75 ± 0.02 mm bearing..... 50.640 ± 0.013 mm (1.9937 ± 0.0005 inch)
(0.00984 inch) (4.08464 ± 0.00079 inch)
(C)The bearing joint must be within ± 5 degrees of
Undersized journal 103.49 ± 0.02 mm either location.
0.51 mm (0.02008 inch) (4.07440 ± 0.00079 inch)
Note: The connecting rod must be heated for the
installation of the piston pin bearing. Do not use a
Reuse And Salvage Guidelines, SEBF8041
torch.
Table 8
Main Bearing Bore (D) The connecting rod may be heated from
175 to 260 °C (347 to 500 °F) for the installation of
Main bearing bore (original size) 112.000 ± 0.013 mm
(4.4094 ± 0.0005 inch)
the piston pin bearing. Maximum distance for heating
the connecting rod ....................... 83.0 mm (3.27 inch)
Reuse And Salvage Guidelines, SEBF8735 Note: Thoroughly lubricate the piston pin with clean
engine oil prior to assembly of the piston and
Note: No oversized bearings exist for the main bore connecting rod.
of the cylinder block.
(E) Distance between the center of the bearings
i02840023 ...............................................217.00 mm (8.543 inch)
Connecting Rod (G) Bore in the connecting rod for the crankshaft
bearing..... 85.000 ± 0.013 mm (3.3465 ± 0.0005 inch)
SMCS Code: 1218
View F-F
(1)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 (3).
Note: Install the rod and piston group in the engine

with the part number of the forging for the rod
assembly to the rear of the engine. The rear of the
engine is the flywheel end of the engine. Lubricate
the rod and piston group with clean engine oil before
you insert the rod and piston group into the block.
(2)Use the following procedure to tighten the
connecting rod bolts:
Note: Handle the fractured connecting rod with care.
Use a soft jawed vise in order to hold the connecting 1. Torque the bolts to 50 ± 5 N·m (37 ± 4 lb ft).
rod when you are loosening the connecting rod cap
bolts. Use a soft faced hammer in order to tap the 2. Rotate each bolt in a clockwise direction for 90 ± 5
connecting rod cap, if necessary. degrees (1/4 of a turn).
(A) Bore in the bearing for the piston pin
.................46.035 ± 0.008 mm (1.8124 ± 0.0003 inch)
SENR9912 41
i02765702 Top Piston Ring

Piston and Rings (3) The top ring has the mark “UP-1” .
SMCS Code: 1214; 1215 Install the piston ring with the side marked “UP-
1” toward the top of the piston. The colored stripe
Two-Piece Articulated Piston faces to the right of the ring end gap.
Piston ring end gap ...................... 0.40 ± 0.10 mm
(0.016 ± 0.004 inch)
Minimum depth of the groove in new piston for
the top ring ......................4.947 mm (0.1948 inch)
Thickness of new top piston ring........... 3.453 mm
(0.1359 inch)
Intermediate Piston Ring

(4) The intermediate ring has the mark “UP-2” .
Install the piston ring with the side marked “UP-

2” toward the top of the piston. The colored stripe
faces to the right of the piston ring end gap.
(0.059 ± 0.004 inch)
Width of groove in new piston for intermediate
piston ring............................ 3.06 mm (0.120 inch)
Minimum depth of the groove in new piston for
the intermediate ring ....... 4.948 mm (0.1948 inch)
Thickness of new intermediate piston ring
.....................2.98 ± 0.01 mm (0.117 ± 0.001 inch)
(1) Piston crown assembly
(2) Rod assembly Oil Control Piston Ring
(5) Oil control piston ring
The oil control piston ring has a spring that is
installed with the ring. The gap in the spring
should be a distance of 180 degrees from the ring
end gap when the oil control piston ring is
assembled. The colored portion can be to the
right or to the left of the ring end gap.
(0.018 ± 0.006 inch)
Width of groove in new piston for the oil control
piston ring.... 4.03 ± 0.01 mm (0.159 ± 0.001 inch)
Minimum depth of groove in new piston for the oil
control piston ring............ 4.725 mm (0.1860 inch)
Thickness of new oil control piston ring
.................... 3.98 ± 0.01 mm (0.157 ± 0.001 inch)
Note: After the piston rings have been installed,
rotate the piston rings so that the end gaps are 120
degrees from each other.
Piston Skirt
(6)Piston skirt
Note: Install the rod and piston group in the engine
with the part number of the forging for the rod Note: Lubricate the entire piston in zone (A) prior to
assembly to the rear of the engine. The rear of the assembly into the cylinder block. Use clean engine
engine is the flywheel end of the engine. Lubricate oil.
the rod and piston group with clean engine oil before
you insert the rod and piston group into the block.
42 SENR9912
Piston Pin i02818173
(7) Piston pin Front Housing and Covers

Piston pin diameter ................ 46.000 ± 0.005 mm SMCS Code: 1162; 1166
(1.8110 ± 0.0002 inch)
Length of piston pin.................... 91.50 ± 0.15 mm
(3.602 ± 0.006 inch)
Note: Thoroughly lubricate the piston pin with clean
engine oil prior to assembly.
i02833773
Piston Cooling Jet

SMCS Code: 1331
(1) Cylinder block
(2) Front housing
Apply 1U-8846 Gasket Sealant to the front housing

sealing surfaces before assembling the front housing
Illustration 81 g01412616 to the cylinder block. The front housing must be
assembled and the front housing must be tightened to
The piston cooling jet must be checked for the the cylinder block within ten minutes.
location of the stream of oil. Insert a drill rod with a
diameter of 2 mm (0.1 inch) into the orifice. The drill (3) Length of the bolts that are marked for location
rod simulates the stream of oil under normal “A” .............................................. 20.0 mm (0.79 inch)
operating pressure. The drill rod must pass through a
circle with a diameter of 5.0 mm (0.20 inch) at point
(1). (4) Length of the bolts that are marked for location
“B” .............................................. 50.0 mm (1.97 inch)
Use the following dimensions in order to locate point
(1).
Dimension (A) ........................... 71.88 ± 0.25 mm

(2.830 ± 0.010 inch)
Dimension (B) ........................... 16.07 ± 0.25 mm
(0.633 ± 0.010 inch)
Dimension (C) ......................... 120.00 ± 0.25 mm
(4.724 ± 0.010 inch)
Dimension (D) ......................... 120.00 ± 0.25 mm
(4.724 ± 0.010 inch)
Dimension (E) ........................... 42.20 ± 0.25 mm
(1.661 ± 0.010 inch)
SENR9912 43
i03869699
Gear Group (Front)

SMCS Code: 1206
(5) Front housing cover
(6) Length of the bolts that are marked for location

“C” .............................................. 30.0 mm (1.18 inch)
(7) Length of the bolt that is marked for location “D”
(6) Oil pump idler gear
..................................................... 60.0 mm (2.36 inch) (7) Bolt
(8) Oil pump idler gear
(8)Apply 154-9731 Thread Lock Compound to the
serrations of the studs before installing the studs into
the front housing cover (5). (A) Diameter of the idler shaft....... 74.000 ± 0.013 mm
(2.9134 ± 0.0005 inch)
(B)Installation depth of the bearing..... 1.08 ± 0.25 mm

(0.043 ± 0.010 inch)
(3) Torque for the bolts for the camshaft idler gear
............................................70 ± 15 N·m (52 ± 11 lb ft)
(4)Align the timing marks on the camshaft idler gear
(2) with the holes on the camshaft gear (1) and the
crankshaft gear (5).
44 SENR9912
i02825056 i02825057
Rear Power Take-Off (RPTO) Rear Power Take-Off (RPTO)

SMCS Code: 1165-RE SMCS Code: 1165-RE
(A) Travel of the hand lever assembly ...... 18 degrees
Note: Once the clutch has been installed onto the

engine, hit the output shaft sharply on the end. This is
done in order to relieve any preload.
Use the following procedure to adjust the bearing:
(A) Travel of the hand lever assembly ............... 17.75
1. Tighten the bearing retainer until there is no degrees
clearance between the cup and the cone.
2. Loosen the bearing retainer. Loosen approximately engine, hit the output shaft sharply on the end. This is
three notches. done in order to relieve any preload.
3. Assemble the lock. Use the following procedure to adjust the bearing:
4. Strike the output end of the shaft in order to seat 1. Tighten the bearing retainer until there is no
the inner bearing cup against the bearing retainer. clearance between the cup and the cone.
5. The end play (B) should be 0.15 to 0.25 mm 2. Loosen the bearing retainer. Loosen approximately
(0.006 to 0.010 inch). three notches.
Note: A torque of 295 to 392 N·m (220 to 290 lb ft) 3. Assemble the lock.
on the splined clutch shaft is required in order to
engage the clutch. 4. Strike the output end of the shaft in order to seat
the inner bearing cup against the bearing retainer.
5. The end play (B) should be 0.15 to 0.25 mm

(0.006 to 0.010 inch).
Note: A torque of 325 to 435 N·m (240 to 320 lb ft)
engage the clutch.
SENR9912 45
i02825058 i02844272
Rear Power Take-Off (RPTO) Flywheel

SMCS Code: 1165-RE SMCS Code: 1156

(2) Flywheel gear
(A) Travel of the lever assembly ............ 15.5 degrees
(1) Torque for the eight bolts...................300 ± 40 N·m
(220 ± 30 lb ft)
engine, hit the output shaft sharply on the end. This is
done in order to relieve any preload.
Use the following procedure to adjust the bearing:
1. Tighten the bearing retainer until there is no

clearance between the cup and the cone.
2. Loosen the bearing retainer. Loosen approximately

three notches.
3. Assemble the lock.
4. Strike the output end of the shaft in order to seat
the inner bearing cup against the bearing retainer.
5. The end play (B) should be 0.27 to 0.34 mm

(0.011 to 0.013 inch).
Note: A torque of 182 to 240 N·m (135 to 175 lb ft)

engage the clutch.
46 SENR9912
i02844273 i02888012
Flywheel Flywheel

(220 ± 30 lb ft)
Note: The gear must be installed against the
shoulder of the flywheel.
(2) Maximum temperature for the gear installation (1) Flywheel ring gear
(2) Flywheel
............................................................ 315 °C (599 °F)
Refer to the Testing And Adjusting, “Basic Block”
topic for the proper procedure to check flywheel
runout.
(3) Bolt
Apply 7M-7456 Compound to the bolt threads.

Tighten the bolts to the following torque.
.................................300 ± 40 N·m (220 ± 30 lb ft)
SENR9912 47
i02844274 i02505483
Flywheel Flywheel Housing


Typical example
(1)Apply 8C-8422 Sealant to all sealing surfaces of
the flywheel housing.
(220 ± 30 lb ft) Note: The flywheel housing must be assembled and
tightened to the cylinder block within ten minutes.
Note: The gear must be installed against the
shoulder of the flywheel.
(2) Maximum temperature for the gear installation

............................................................ 300 °C (572 °F)
48 SENR9912
i05084397
Belt Tension Chart

SMCS Code: 1357
Table 9
Specification for the 7N-9693 Tension Chart
The new belt tension chart has been standardized. The belt tension chart eliminates confusion about the
correct belt tension to use. Studies were completed with different belt suppliers and the information that
was gathered from the studies was developed into a new belt tension for each belt size .
The chart does not apply to belts that use a spring loaded tensioner .
For more accurate results, a Clavis frequency gauge should be used in order to measure the natural fre-
quency of the belt. By the use of a formula, the natural frequency is converted into the belt tension force. If
the Clavis frequency gauge cannot be used, then use the appropriate Kent-Moore belt tension gauge to
- - -
measure the belt tension force.
When matched sets of belts are used, check the tension of all the belts in order to verify that the lowest belt
is in the acceptable tolerance range. Variations in tension between the belts can vary by as much as 65
pounds.
In order to determine the tension of a “banded” belt, refer to the chart above. Multiply the tension value of
the belt by the number of belts that are banded together.Two 1/2 inch belts would require a used belt ten-
sion equal to twice the value of the used belt tension for one 1/2 inch belt (2 X 80 = 160 lb).
Table 10
Belt Tension Chart
SAE or RMA Belt SIze Width of Belt (Top Belt Tension “Initial”” (1) Belt Belt Tension “Used”” (3) (4)
Reference) Tension
Used(2)
IN MM IN MM LB N LB N LB N
3/8 (0.380) 10A 0.42 10.72 145±10 645±44 115±10 510±44 70±10 311±44
7/16 (0.440) 11A 0.46 11.68 155±10 689±44 125±10 560±10 75±10 333±44
1/2 (0.500) 13A 0.55 13.89 165±10 734±44 130±10 580±10 80±10 356±44
5V/5VX 5V 0.63 15.88 180±10 801±44 145±10 645±10 85±10 378±44

11/16 (0.600) 15A 0.69 17.48 180±10 801±44 145±10 645±10 85±10 378±44
3/4 (0.660) 17A 0.75 19.05 205±10 912±44 165±10 730±44 95±10 422±44
7/8 (0.790) 20A 0.88 22.23 205±10 912±44 165±10 730±44 95±10 422±44
15/16 N/A 0.98 23.83 205±10 912±44 165±10 730±44 95±10 422±44
4K 4PK 0.54 13.72 145±10 645±44 115±10 510±44 60±10 267±44
6K 6PK 0.82 20.94 215±10 956±44 170±10 755±10 90±10 400±44
8K 8PK 1.1 27.82 285±10 1179±44 230±10 1025±10 115±10 511±44
10K 10PK 1.38 35.05 355±10 1579±44 285±10 1270±10 145±10 645±44
12K 12PK 1.66 42.16 425±10 1891±44 340±10 1510±10 175±10 778±44
14K 14PK 1.94 49.28 495±10 2202±44 395±10 1755±10 205±10 912±44
15K 15PK 2.08 52.83 530±10 2358±44 425±10 1890±44 215±10 956±44
(1) Belt Tension “Initial ” is for a new belt.
(2) Belt tension with less than 10 hours of operation
(3) Belt tension “Used” is for a belt that has operated for more than 30 minutes of operation at the rated speed..
(4) If a belt falls below the “Used” belt tension, the belt should be tightened again to 80% of the “Initial” belt tension.
SENR9912 49
i02844292
Fan Drive
SMCS Code: 1359
(1)Add 10 g (0.4 oz) of 2S-3230 Bearing Lubricant

in the cavity between the two bearing cups.
Note: Apply 4C-4030 Thread Lock Compound to
the threads of the bolt.
(2) Torque for the bolt........ 115 ± 15 N·m (85 ± 11 lb ft)

(3)Add 30 g (1.1 oz) of 2S-3230 Bearing Lubricant
in the fan adapter cavity.
(4)Hand pack the two bearing cups and the two
bearing cones with 5 g (0.2 oz) of 2S-3230 Bearing
Lubricant prior to assembly.
Note: Install the lip type seal with the lip in the
specified position. The lip should be facing toward the
front of the engine.
(5)Lightly lubricate the sealing lip of the lip type seal
with 2S-3230 Bearing Lubricant.
50 SENR9912
i04375781
Alternator and Regulator

SMCS Code: 1405; 1410
Note: Load the battery with a carbon pile 4C-4911

Battery Load Tester in order to get the maximum
alternator output.
SENR9912 51
Table 11
Specification for 185-5294 Charging Alternator Gp
1 1 2K-4821 Locknut Torque to 127 ± 10 N·m (94 ± 8 lb ft).
2 1 5S-7349 Bolt (B-) terminal. Torque to 4.4 ± 1.0 N·m (38.9 ± 8.9 lb in).
185-2648 Voltage Regula- Voltage setting requires no adjustment.

3 1
tor As Permissible voltage range is 27 to 29 V.
4 - - (R) terminal is the AC tap from stator and is not to be used for diagnostics.
Use a 7/16 ring terminal for (B+) terminal.

5 1 6V-8189 Nut
(B+) terminal. Torque to 18.2 ± 2.4 N·m (161.1 ± 21.2 lb in).
- - - Voltage is 24 V.
- - - Amperage is 65 Amp.
- - - Polarity is negative ground.
- - - Rotation is clockwise.
- - - Minimum full load current at 5000 rpm is 65 Amp.
- - - Output voltage is 28 ± 1 V.
52 SENR9912
i04399189

SMCS Code: 1405; 1410
SENR9912 53
Table 12
Specification for 5N-5692 Charging Alternator Gp
Load the battery with a carbon pile 4C-4911 Battery Load Tester in order to get the maximum alternator output
1 1 187-2034 Flange Nut Torque to 102 ± 7 N·m (75 ± 5 lb ft).
2 1- 9S-2011 Screw (B-) terminal. Torque to 6.2 ± 0.6 N·m (55.0 ± 5.0 lb in).
3 1 9S-2389 Stud As (B+) terminal. Torque to 13.5 ± 1.3 N·m (120 ± 11.50597 lb in).
3T-6354 Voltage Regulator No adjustment for voltage setting.

4 1-
As Permissible voltage range is 27 to 29 V.
The peak voltage for (R) terminal must not be less than the output voltage for (B+)
5 - -
terminal.
- - - Amperage is 75 amp.
- - - Rotation is Either direction.

Minimum full load current at 5000 rpm is 67 amp.
Alternator performance at 25 °C (77 °F) Minimum full load current at 2000 rpm is 29 amp.
Output voltage is 28 ± 1 V.
54 SENR9912
i04375724

SMCS Code: 1405; 1410

alternator output.
Table 13

4 1 6V-8189 Nut
SENR9912 55
i02927771 Minimum full load current at 5000 rpm ......... 112 Amp
Alternator and Regulator Minimum full load current at 2000 rpm ...........63 Amp
SMCS Code: 1405; 1410 Output voltage ............................................... 28 ± 1 V
(1) Final installation torque for the flange nut

..............................................102 ± 7 N·m (75 ± 5 lb ft)
(2) (B+) terminal. Final installation torque for the nut

...........................................6.2 ± 0.6 N·m (55 ± 5 lb in)
Note: Use a 7/16 ring terminal for (B+) terminal.

(3)The peak voltage for (R) terminal must not be less
than the output voltage for (B+) terminal.
(4) (D+) terminal. Final installation torque for the nut

.......................................2.25 ± 0.25 N·m (20 ± 2 lb in)
(5) Voltage regulator assembly
Voltage setting ...............................No adjustment

Permissible voltage range ....................27 to 29 V
Voltage .................................................................24 V
Amperage .......................................................60 Amp

alternator output.
Polarity ..............................................Negative ground
Rotation ............................................... Either direction

56 SENR9912
i04390205

SMCS Code: 1405; 1410
Table 14
Load the battery with a carbon pile 4C-4911 Battery Load Tester in order to
- - -
get the maximum alternator output
2 - 6V-8189 Nut (B+) terminal. Torque to 11.3 ± 2.3 N·m (100.0 ± 20.0 lb in).
3E-5451 Voltage Regula-

3 1 Voltage setting is not adjustable.
tor As
4 - 4M-5281 Bolt (B-) terminal. Torque to 6.2 ± 0.6 N·m (55.0 ± 5.0 lb in).
- - - Rotation is either direction.
- - - Maximum turn on speed is 2300 rpm.
- - Alternator performance at 25 °C (77 °F)
- - - Minimum full load current at 5000 rpm is 107 amp.
- - - Output voltage is 14.0 ± 0.5 V.

SENR9912 57
i04390212

SMCS Code: 1405; 1410
Table 15
Specification for 7G-7889 Charging Alternator Gp
- - -
Tighten bolt before tightening the mounting bolt for the alternator.
1 1 -
Torque to 88.4 ± 6.8 N·m (65.0 ± 5.0 lb ft)
3 - 6V-8187 Nut (B+) terminal. Torque to 6.2 ± 0.6 N·m (55.0 ± 5.0 lb in).
The peak voltage for (R) terminal must not be less than the output voltage for
4 - -
(B+) terminal.
5 - 030-9612 Screw (B-) terminal. Torque to 2.25 ± 0.25 N·m (20.00 ± 2.00 lb in).
Voltage setting is not adjustable.

3E-5451 Voltage Regulator
6 1
As Permissible voltage range is 13.7 to 14.3 V.
- - - Rotation is either direction.
- - - Maximum turn on speed is 2000 rpm
- - - Output voltage is 14.0 ± 0.3 V.

58 SENR9912
i02844357 Minimum full load current at 5000 rpm .........137 Amp
Alternator and Regulator Minimum full load current at 2000 rpm ...........75 Amp
SMCS Code: 1405; 1410 Output voltage .........................................14.0 ± 0.5 V
(1) Final installation torque for the locknut

..............................................102 ± 7 N·m (75 ± 5 lb ft)

.....................................11.3 ± 2.3 N·m (100 ± 20 lb in)

(4) (B-) terminal. Final installation torque for the bolt

...........................................6.2 ± 0.6 N·m (55 ± 5 lb in)
Voltage .................................................................12 V
Amperage .....................................................145 Amp

alternator output.
Polarity ..............................................Negative ground
Rotation .......................................................Clockwise
SENR9912 59
i04390224

SMCS Code: 1405; 1410
Table 16
- - -
2 - 5S-7349 Bolt (B-) terminal. Torque to4.4 ± 1.0 N·m (40.0 ± 9.0 lb in).
3 - -
(B+) terminal.

4 - 6V-8189 Nut
Voltage setting is not adjustable.

185-2648 Voltage Regula-
5 1
Maximum turn on speed is 2000 rpm
Alternator performance at 25 °C (77 °F)
60 SENR9912
i04392851

SMCS Code: 1405; 1410
Table 17
Specification for 5N-5692 Charging Alternator Gp
- - -
Tighten the bolt before you tighten the mounting bolt for the alternator.
1 1 -
Torque to 88.4 ± 6.8 N·m (65.0 ± 5.0 lb ft)

3 - 6V-8187 Nut
4 - -
(B+) terminal.
5 - - (B-) terminal. Torque to 2.25 ± 0.25 N·m (20.00 ± 2.00 lb in).
- - - Rotation is Either direction.
- - - Maximum turn on speed is 2500 rpm
- - - Minimum full load current at 5000 rpm is 42.3 amp.
- - - Minimum full load current at 2000 rpm is 15.8 amp.
SENR9912 61
i04380836

SMCS Code: 1405; 1410

alternator output.
62 SENR9912
Table 18
185-2648 Voltage Regula- Voltage setting requires no adjustment.

3 1

5 1 6V-8189 Nut
SENR9912 63
i02839280 (1) Final installation torque for the locknut

..............................................102 ± 7 N·m (75 ± 5 lb ft)
SMCS Code: 1405; 1410
...........................................7.1 ± 0.9 N·m (65 ± 8 lb in)
(3) Final installation torque for the nut

.......................................2.26 ± 0.57 N·m (20 ± 5 lb in)
(4) (B-) terminal. Final installation torque for the bolt

...........................................6.2 ± 0.6 N·m (55 ± 5 lb in)

i02906667

SMCS Code: 1405; 1410

(2) Positive output
(3) Negative output

Illustration 108 g01416074 alternator output.
Voltage .................................................................24 V Voltage ................................................................. 12 V
Amperage .......................................................70 Amp Amperage .....................................................160 Amp
Note: Load the battery with a carbon pile 4C-4911 Polarity ..............................................Negative ground
alternator output. Rotation .......................................................Clockwise
Polarity ..............................................Negative ground (1) Torque for the pulley nut...................95 to 110 N·m
(70 to 80 lb ft)
Rotation of the alternator pulley from the pulley end
..................................................................... Clockwise
Minimum full load current at 5000 rpm ...........68 Amp
Minimum full load current at 2000 rpm ...........31 Amp
Output voltage ............................................... 28 ± 1 V

64 SENR9912
i02909979 (3) Final installation torque for the battery terminal nut
.....................................30.5 ± 3.5 N·m (270 ± 30 lb in)
Electric Starting Motor
Note: The switch terminal must be insulated with heat
SMCS Code: 1453 shrink tubing. Do not use molded terminals.
(4) Final installation torque for the switch terminal nut

.......................................2.25 ± 0.25 N·m (20 ± 2 lb in)
(5) Final installation torque for the motor terminal nut

.....................................30.5 ± 3.5 N·m (270 ± 30 lb in)
(6) Final installation torque for the motor frame

terminal nut ............................8 ± 3 N·m (70 ± 27 lb in)
Solenoid assembly
Current consumption at 10 V and 25 °C (77 °F)
Pull-in windings ............................92.5 ± 7.5 Amp

Hold-in windings .......................................23 Amp

View A-A
Direction of rotation for the electric starting motor from

the pinion end .............................................Clockwise
No load conditions at 25 °C (77 °F)
Speed ........................................6900 ± 1800 rpm

Current draw .............................127.5 ± 27.5 Amp
Voltage .......................................................... 11 V
(B) Clearance between the pinion and the housing

....................................................... 9.1 mm (0.36 inch)
(1) Final installation torque for the ground terminal nut

.....................................30.5 ± 3.5 N·m (270 ± 30 lb in)
(2) Final installation torque for the ground terminal nut

.......................................2.25 ± 0.25 N·m (20 ± 2 lb in)
Note: A maximum of three cable terminals or wire
terminals may be used with the battery terminal nut
(3). A maximum of two of the cable terminals may be
equal to or greater than 0 AWG.
SENR9912 65
Index Section
Index
A L
Air Inlet Elbow............................................ 17–19 Lifter Group........................................................ 9
Alternator and Regulator...........50, 52, 54–61, 63
M
B Main Bearing Journal....................................... 39
Belt Tension Chart ........................................... 48
P
C Piston and Rings ............................................. 41
Camshaft ......................................................... 21 Intermediate Piston Ring.............................. 41
Connecting Rod............................................... 40 Oil Control Piston Ring................................. 41
Connecting Rod Bearing Journal..................... 39 Piston Pin..................................................... 42
Crankshaft ....................................................... 38 Piston Skirt................................................... 41
Crankshaft Seals ............................................. 38 Top Piston Ring............................................ 41
Cylinder Block.................................................. 36 Two-Piece Articulated Piston ....................... 41
Cylinder Block Cover Group ............................ 35 Piston Cooling Jet............................................ 42
Cylinder Head.................................................. 14
Cylinder Head Valves .......................................11
Cylinder Liner................................................... 37 R
Cylinder Liner Projection ................................. 38 Rear Power Take-Off (RPTO).................... 44–45
E S
Electric Starting Motor ..................................... 64 Specifications Section ....................................... 4
Engine Design ................................................... 4
Engine Oil Filter Base ................................ 22–23
Engine Oil Pan........................................... 24–26 T
Exhaust Manifold....................................... 19–21 Table of Contents............................................... 3
Turbocharger ............................................. 16–17
F
Fan Drive ......................................................... 49 U
Flywheel .................................................... 45–47 Unit Injector........................................................ 8
Flywheel Housing ............................................ 47 Unit Injector Hydraulic Pump ............................. 6
Front Housing and Covers............................... 42
Fuel Filter Base.............................................. 4–6
V
G Valve Mechanism ............................................ 10
Valve Mechanism Cover...................................11
Gear Group (Front).......................................... 43
W
I
Water Pump......................................... 31–32, 34
Important Safety Information ............................. 2 Water Temperature Regulator ................... 29–31
Water Temperature Regulator Housing ..... 27–28
©2013 Caterpillar CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
All Rights Reserved dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.

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SENR9912-01

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Crankshaft Seals ...................... ...................... 38

Specifications Section i02701484

Bore ............................................112.0 mm (4.41 inch)

Inlet.............. 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

Crankshaft rotation direction (view from the flywheel

Firing order (injection sequence) ...........1, 5, 3, 6, 2, 4

Fuel Filter Base

(A) Length 11 mm (0.4 inch)

Item Qty Part Specification Description

Fuel Filter Base Unit Injector Hydraulic Pump

Illustration 4 g01445336 Illustration 6 g01411601

(2) Torque for three screws....10 ± 1 N·m (90 ± 9 lb in)

(B) Distance from the sealing surface of the fuel filter

(1) Torque for the hollow stud ...................70 ± 15 N·m

(A) Installation depth for the needle bearing assembly

(6) Torque for the retainer nut .................5.5 ± 0.5 N·m

(7) Torque for the nut ...............8 ± 1 N·m (70 ± 9 lb in)

Note: Install needle bearing assembly (8) so that the

Note: Install the spool (9) until the spool is fully

Note: Lubricate the bore in the cylinder head lightly

1. Seat the fuel injector group in the bore.

2. Tighten the bolt (2) which is closest to the exhaust

3. Tighten the bolt (3) which is closest to the inlet side

(B) Diameter of the new rocker arm shaft

(C) Depth of installation of the two cup plugs from the

Inlet valve .... 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

(2) Torque for the nut ..............30 ± 7 N·m (22 ± 5 lb ft)

(A) Bore diameter of the valve rocker arm

Quantity ..............................................................6 i03894192

Length under test force ......... 14.5 mm (0.57 inch)

Valve Mechanism Cover

(2) Exhaust valve

Valve stem diameter................. 9.441 ± 0.010 mm

(3) 241-8386 Spring

Length under test force ......... 42.8 mm (1.69 inch)

(A) Height of the valve guides above the top of the

(7) Valve guide (inlet)

Outside diameter.................... 13.030 ± 0.008 mm

(8) Valve guide (exhaust)

Outside diameter.................... 16.000 ± 0.008 mm

(G) Angle of the face of the valve seat insert

Angle (inlet) ........................30.25 ± 0.25 degrees

Angle (exhaust) ..................45.75 ± 0.25 degrees

(J) Angle of the face of the valve

Angle (inlet) .......................... 60.5 ± 0.25 degrees

Note: Use clean engine oil to lubricate the threads of

2. Again torque the bolt (1) through bolt (26) in a

4. Loosen the bolt (1) through bolt (26) in a numerical

5. Repeat Step 1 through Step 3.

6. Torque the bolt (27) through bolt (31) in a numerical

Note: Apply 6V-6640 Sealant to the bore of the cup i02847495

(32) Torque for the plugs.........................350 ± 30 N·m Illustration 27 g01419635

(4) Torque for the four locknuts...................54 ± 5 N·m i02843181

(1)Apply 1U-8846 Gasket Sealant to the face of the

(2) Torque for the eight studs......................30 ± 7 N·m

Air Inlet Elbow

(1) Torque for the compressor clamp assembly

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

(2) Torque for the four locknuts...................54 ± 5 N·m