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珀金斯Perkins1204F-E44TA(TTA)技術(shù)資料（英文）
詳細描述
Specifications
1204F-E44TA and 1204F-E44TTA
Industrial Engines
MT (Engine)
MU(Engine)
This document is printed from SPI2. NOT FOR RESALE
Important Safety Information
Most accidents tha t involve produc t op eration, ma intena nc e and repair are caus ed by failure to
ob serve basic safety rules or precautions . An accident can often be avoided by recog nizing pote ntially
ha za rdous situations before an accident oc curs . A person mus t be alert to pote ntial ha za rds. This
person should also ha ve the ne cessary training, skills and tools to perform the se func tions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Sa fety precautions and warning s are provided in this ma nua l and on the produc t. If the se ha za rd
warning s are not he eded, bod ily injury or death could oc cur to you or to othe r persons .
The ha za rds are identified by the “Safety Alert Symb ol” and followed by a “Signa l Word” suc h as
“DANGER”, “WARNING” or “CAUTION”. The Sa fety Alert “WARNING” label is shown below.
The me aning of this safety alert symb ol is as follows:
Attention! Become Alert! Your Safety is Involved.
The me ssage tha t appears und er the warning explains the ha za rd and can be either written or
pictorially presente d.
Op erations tha t ma y caus e produc t dama ge are identified by “NOTICE” labels on the produc t and in
this pub lication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The informa tion, specifications , and illustrations in this pub lication are on the basis of informa tion tha t
was available at the time tha t the pub lication was written. The specifications , torque s, pressure s,
me asure me nts , adjustme nts , illustrations , and othe r items can cha ng e at any time. These cha ng es can
affect the service tha t is given to the produc t. Ob tain the comp lete and mos t current informa tion before
you start any job. Pe rkins dealers or Pe rkins distributors ha ve the mos t current informa tion available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
This document is printed from SPI2. NOT FOR RESALE
UENR4489
3
Table of Contents
Table of Contents
Accessory Drive (SAE “B” ).............. ............. 38
Accessory Drive....................... ....................... 39
Front Housing and Covers............... ............... 39
Gear Group (Front)..................... .................... 40
Flywheel .......................................................... 41
Flywheel Housing...................... ..................... 41
Crankshaft Pulley ...................... ..................... 42
Belt Tensioner......................... ........................ 42
Refrigerant Compressor................. ................ 42
Fan Drive............................ ............................ 43
Engine Lifting Bracket................... .................. 43
Alternator............................ ............................ 43
Starter Motor.......................... ......................... 44
Nitrogen Oxide Sensor .................. ................. 45
Coolant Temperature Sensor............. ............. 45
Engine Oil Pressure Sensor.............. ............. 46
Boost Pressure Sensor.................. ................. 46
Ammonia Sensor (If equipped)............ ........... 46
Atmospheric Pressure Sensor............ ............ 47
Inlet Manifold Temperature Sensor......... ........ 47
Temperature Sensor (DPF Inlet)........... .......... 48
Temperature Sensor (DOC Inlet).......... .......... 48
Temperature Sensor (Exhaust) (Selective
SpecificationsSection
Engine Design ......................... ......................... 4
Fuel Injection Lines...................... ..................... 4
Fuel Injection Pump..................... ..................... 5
Fuel Injectors.......................... .......................... 6
Fuel Transfer Pump..................... ..................... 6
Fuel Filter Base (Single Secondary Fuel Filter
Base) ............................... ............................... 7
Fuel Filter Base (Twin Secondary Fuel Filter
Base) ............................... ............................... 7
Fuel Filter Base (Primary Fuel Filter Base)... ... 8
Fuel Manifold (Rail)...................... ..................... 8
Lifter Group............................ ........................... 9
Rocker Shaft........................... .......................... 9
Valve Mechanism Cover................. .................11
Cylinder Head Valves ................... ...................11
Cylinder Head......................... ........................ 12
Turbocharger (Single Turbocharger)....... ....... 14
Turbocharger (Series Turbochargers)...... ...... 16
Exhaust Gas Valve (NRS) ............... ............... 18
Injector (Diesel Exhaust Fluid)............ ............ 19
Manifold (Diesel Exhaust Fluid)........... ........... 19
Diesel Exhaust Fluid Tank ............... ............... 20
Diesel Exhaust Fluid Pump .............. .............. 20
Solenoid Valve (DEF Heater Coolant)...... ...... 21
Exhaust Cooler (NRS).................. .................. 21
Exhaust Manifold...................... ...................... 24
Flexible Exhaust Pipe................... .................. 25
Camshaft............................ ............................ 25
Camshaft Bearings..................... .................... 26
Engine Oil Filter Base................... .................. 27
Engine Oil Cooler...................... ...................... 27
Engine Oil Pump....................... ...................... 28
Engine Oil Pressure.................... .................... 28
Engine Oil Pan........................ ........................ 29
Crankcase Breather.................... .................... 30
Water Temperature Regulator and Housing.. . 30
Water Pump.......................... .......................... 31
Cylinder Block......................... ........................ 31
Crankshaft........................... ........................... 32
Crankshaft Seals ...................... ...................... 33
Connecting Rod Bearing Journal.......... .......... 34
Main Bearing Journal................... ................... 34
Connecting Rod....................... ....................... 35
Piston and Rings ...................... ...................... 36
Piston Cooling Jet...................... ..................... 37
Balancer .......................................................... 38
Catalytic Reduction (SCR) Temperature
Sensor)............................. ............................ 48
Pressure Sensor (NOx Reduction System)
(Differential Pressure Sensor) ........... ........... 49
Pressure Sensor (NOx Reduction System).. .. 49
Temperature Sensor (NOx Reduction System)49
Soot Antenna......................... ......................... 50
Speed/Timing Sensor................... .................. 50
Electronic Control Module ............... ............... 51
Glow Plugs .......................... ........................... 51
Air Compressor (Twin Cylinder Compressor) 52
Air Compressor (Single Cylinder)......... ......... 53
Index Section
Index................................ ............................... 55
This document is printed from SPI2. NOT FOR RESALE
4
UENR4489
Specifications Section
SpecificationsSection
When the camshaft is viewed from the front of the
engine, the camshaft rotates in the following direction:
.....................................................................Clockwise
i05937832
The front of the engine is opposite the flywheel end.
The left side and the right side of the engine are
viewed from the flywheel end. The No. 1 cylinder is
the front cylinder.
Engine Design
i05847993
Fuel Injection Lines
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
Refer to Operation and Maintenance Manual,
“General Hazard Information and High Pressure Fuel
Lines” before adjustments and repairs are performed.
NOTICE
Refer to Systems Operation, Testing, and Adjust-
ing, “Cleanliness of Fuel System Components”
for detailed information on the standards of clean-
liness that must be observed during ALL work on
the fuel system.
Illustration 1
g01335181
Cylinder and valve location
(A) Exhaust valve
(B) Inlet valve
Bore ............................................105 mm (4.133 inch)
Stroke .........................................127 mm (5.000 inch)
Displacement........................................4.4 L (269 in3)
Cylinder arrangement ........................................In-line
Type of combustion ..............................Direct injection
Compression ratio
Ensure that all adjustments and repairs are
performed by authorized personnel that have had the
correct training.
Turbocharged engines and turbocharged charge
cooled engines ...........................................16.5:1
Number of cylinders .................................................. 4
Valves per cylinder .................................................... 4
Firing order .....................................................1, 3, 4, 2
When the crankshaft is viewed from the front of the
engine, the crankshaft rotates in the following
direction: .....................................................Clockwise
This document is printed from SPI2. NOT FOR RESALE
UENR4489
5
Specifications Section
Illustration 2
g02334261
Typical example
(1) (2) Torque for the nuts on the high-pressure fuel
lines.....................................................55 N·m (41 lb ft)
i04138513
Fuel Injection Pump
Note: The timing of the fuel injection pump will need
to be checked by trained personnel. In order to check
the timing of the fuel injection pump, refer to Systems
Operation, Testing, and Adjusting, “Fuel Injection
Pump Timing - Check”.
NOTICE
Refer to Systems Operation, Testing, and Adjust-
ing, “Cleanliness of Fuel System Components”
for detailed information on the standards of clean-
liness that must be observed during ALL work on
the fuel system.
Illustration 3
g02335956
Typical example
(1) Tighten the studs to the following torque.....11 N·m
(97 lb in)
(2) Tighten the mounting nut to the following torque.
............................................................22 N·m (16 lb ft)
This document is printed from SPI2. NOT FOR RESALE
6
UENR4489
Specifications Section
(3) Tighten the setscrews to the following torque.
(2) Torque for the bolt in the clamp for the fuel
............................................................22 N·m (16 lb ft)
injection nozzle................................21 N·m (15.5 lb ft)
(4) Tighten the screws for the suction control valve to
the following torque..............................9 N·m (80 lb in)
i05847994
Fuel Transfer Pump
(5) Tighten the fuel temperature sensor to the
following torque...................................22 N·m (16 lb ft)
(6) Tighten the screw to the following torque.
............................................................14 N·m (10 lb ft)
i03631793
Fuel Injectors
NOTICE
Refer to Systems Operation, Testing and Adjust-
ing, “Cleanliness of Fuel System Components”
for detailed information on the standards of clean-
liness that must be observed during ALL work on
the fuel system.
Illustration 5
g02337197
Typical example
(1) Tighten the allen head screws to the following
torque...................................................9 N·m (80 lb in)
(2) Tighten the connection to the following torque.
.........................................................21.5 N·m (16 lb ft)
Illustration 4
g01862457
Typical example
(3) Clamp
(4) Washer
(5) O ring seal
(1) Torque for the nuts..........................2 N·m (18 lb in)
This document is printed from SPI2. NOT FOR RESALE
UENR4489
7
Specifications Section
Illustration 6
g02337198
Illustration 7
g02484376
Typical example
Typical example
(3) (4) Tighten the bolts to the following torque.
............................................................22 N·m (16 lb ft)
(3) Tighten the bolts to the following torque......44 N·m
(33 lb ft)
(4) Tighten the bolt to the following torque. ......17 N·m
(13 lb ft)
i04325509
Fuel Filter Base
(Single Secondary Fuel Filter
Base)
i04330369
Fuel Filter Base
(Twin Secondary Fuel Filter
Base)
NOTICE
Refer to Systems Operation, Testing and Adjust-
ing, “Cleanliness of Fuel System Components”
for detailed information on the standards of clean-
liness that must be observed during ALL work on
the fuel system.
NOTICE
Refer to Systems Operation, Testing and Adjust-
ing, “Cleanliness of Fuel System Components”
for detailed information on the standards of clean-
liness that must be observed during ALL work on
the fuel system.
If necessary, install a new fuel filter (2) to canister (1).
Refer to Operation and Maintenance Manual, “Fuel
System Secondary Filter - Replace” for the correct
procedure.
If necessary, install a new fuel filter (2) to canister (1).
Refer to Operation and Maintenance Manual, “Fuel
System Secondary Filter - Replace” for the correct
procedure.
This document is printed from SPI2. NOT FOR RESALE
8
UENR4489
Specifications Section
Illustration 9
g03084516
Typical example
Tighten water in fuel switch (1) hand tight.
(3) Tighten the connection to the following torque.
............................................................17 N·m (13 lb ft)
Illustration 8
g02485877
Typical example
(4) Tighten the bolts to the following torque......44 N·m
(32 lb ft)
(3) Tighten the bolts to the following torque......44 N·m
(33 lb ft)
(5) Tighten the connection to the following torque.
............................................................17 N·m (13 lb ft)
(4) Tighten the bolt to the following torque. ......20 N·m
(15 lb ft)
i04139570
Fuel Manifold (Rail)
i04916708
Fuel Filter Base
(Primary Fuel Filter Base)
Refer to Operation and Maintenance Manual,
“General Hazard Information and High Pressure Fuel
Lines” before adjustments and repairs are performed.
NOTICE
NOTICE
Refer to Systems Operation, Testing and Adjust-
ing, “Cleanliness of Fuel System Components”
for detailed information on the standards of clean-
liness that must be observed during ALL work on
the fuel system.
Refer to Systems Operation, Testing and Adjust-
ing, “Cleanliness of Fuel System Components”
for detailed information on the standards of clean-
liness that must be observed during ALL work on
the fuel system.
If necessary, install a new fuel filter element to
canister (2). Refer to Operation and Maintenance
Manual, “Fuel System Primary Filter (Water
Separator) Element - Replace” for the correct
procedure.
This document is printed from SPI2. NOT FOR RESALE
UENR4489
9
Specifications Section
Illustration 10
g02337196
Illustration 11
g01344742
Typical example
Typical example
(1) Tighten the bolts to the following torque......22 N·m
(16 lb ft)
(A) Diameter of the lifter body....21.938 to 21.963 mm
(0.86370 to 0.86468 inch)
(2) Tighten the bolts to the following torque......10 N·m
(89 lb in)
Bore diameter in the cylinder block
.........22.000 to 22.032 mm (0.86614 to 0.86740 inch)
(3) Tighten the fuel pressure relief valve to the
Clearance
following torque...................................30 N·m (22 lb ft)
Clearance of the lifter..............0.038 to 0.095 mm
(0.0015 to 0.0037 inch)
Note: The fuel pressure relief valve (3) should be
tightened an additional 24 degrees.
i03916469
i04381710
Rocker Shaft
Lifter Group
This document is printed from SPI2. NOT FOR RESALE
10
UENR4489
Specifications Section
(9) Spring
Illustration 13
g02150797
Tightening sequence
Tighten the fasteners in the sequence that is in
illustration 13 . Tighten the fasteners to the following
torque..................................................35 N·m (26 lb ft)
Illustration 12
g02150799
Typical example
(1) Tighten the threaded inserts to the following
torque..................................................30 N·m (22 lb ft)
(2) Retaining clip
(3) Spring
(4) Inlet rocker arm
Diameter of the rocker arm bore
......25.013 to 25.051 mm (0.9848 to 0.9863 inch)
(5) Exhaust rocker arm
Diameter of the rocker arm bore
......25.013 to 25.051 mm (0.9848 to 0.9863 inch)
Clearance
Maximum clearance of both the rocker arm
bores. ..............................0.089 mm (0.0035 inch)
The service limit for both rocker arm bores
..........................................0.17 mm (0.0067 inch)
(6) Guide
(7) Rocker shaft
Diameter of the rocker shaft
............................................24.962 to 24.987 mm
(0.98275 to 0.98374 inch)
(8) Retaining clip
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UENR4489
11
Specifications Section
i04351269
Valve Mechanism Cover
Illustration 14
g02161123
Typical example
Tighten the fasteners for the valve mechanism cover
in the sequence that is shown in illustration 14 to the
following torque...................................22 N·m (16 lb ft)
i05800591
Cylinder Head Valves
Illustration 15
g01335203
Typical example
When the valve springs (1) are replaced the valve
springs must be replaced in pairs.
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12
UENR4489
Specifications Section
Table 1
Inlet valve.............................109.82 to 110.27 mm
(4.32361 to 4.34133 inch)
Exhaust valve.................. 109.853 to 110.303 mm
(4.32491 to 4.34263 inch)
The load for the inlet valve
spring
The length of the inlet valve
spring
209 to 231 N (47 to 52 lb)
31.5 mm (1.2402 inch)
(5) Valve head
389.5 to 430.5 N (87.5 to 97 lb) 22.2 mm (0.87401 inch)
Diameter of inlet valve head ...................... 35 mm
(1.3780 inch)
Table 2
The load for the exhaust valve
spring
The length of the exhaust valve
spring
Diameter of exhaust valve head ................ 33 mm
(1.2992 inch)
285 to 315 N
31.5 mm (1.2402 inch)
(64.07085 to 70.81515 lb)
i05800598
408.5 to 451.5 N
(91.83488 to 101.50172 lb)
22.3 mm (0.87795 inch)
Cylinder Head
Illustration 16
g01335204
(2) Valve face angle
Illustration 17
g01250785
Typical example
Inlet .....................................................30 degrees
Exhaust ..............................................45 degrees
Lubricate the threads and the underside of the head
bolts with clean engine oil.
(3) Valve stem diameter
Inlet....6.970 to 6.985 mm (0.2744 to 0.2750 inch)
Exhaust...................................6.945 to 6.960 mm
(0.2734 to 0.2740 inch)
Tighten the bolts in the sequence that is shown in
illustration 17 to the following torque.........50 N·m
(37 lb ft)
Tighten the bolts again to the following torque.
...................................................100N·m (74 lb ft)
Tighten the head bolts to the additional amount.
..........................................................225 degrees
Clearance
Maximum clearance of the inlet valve stem
..........................................0.05 mm (0.0020 inch)
The service limit for the inlet valve stem
Minimum thickness of cylinder head ...........150.8 mm
(5.93700 inch)
..........................................0.08 mm (0.0031 inch)
Clearance
Maximum clearance of the exhaust valve stem
......................................0.075 mm (0.00295 inch)
The service limit for the exhaust valve stem
........................................0.10 mm (0.00394 inch)
(4) Length of valve
This document is printed from SPI2. NOT FOR RESALE
UENR4489
13
Specifications Section
Illustration 18
g01455374
Note: The maximum distortion of the bottom face of
the cylinder head is given in table 3 .
Table 3
Maximum Permissible
Dimension
Distortion
Illustration 19
g02328933
Typical example
Width (A)
Length (B)
0.08 mm (0.0032 inch)
0.08 mm (0.0032 inch)
0.08 mm (0.0032 inch)
(D) Valve guide height from the top of the valve guide
to the valve spring seat...................10.85 to 11.15 mm
(0.42716 to 0.43898 inch)
Diagonal Line (C)
(E) Outside diameter of the valve guides
......... 11.029 to 11.040 mm (0.43421 to 0.43464 inch)
(F) Length of the valve guides.......43.75 to 44.25 mm
(1.72244 to 1.74212 inch)
(G) Internal diameter of the valve guides
.............7.007 to 7.020 mm (0.27587 to 0.27638 inch)
(H) Valve depths
Inlet....0.905 to 1.163 mm (0.0356 to 0.0458 inch)
The service limit for the depth of the inlet valve
.......................................... 1.41 mm (0.0555 inch)
Exhaust...................................0.876 to 1.131 mm
(0.0345 to 0.0445 inch)
The service limit for the exhaust valve depth
.......................................... 1.38 mm (0.0543 inch)
This document is printed from SPI2. NOT FOR RESALE
14
UENR4489
Specifications Section
(L) Seat surface finish .........................Ra 0.8 microns
(M) Concentricity of valve seat to valve guide parent
bore Maximum Total Indicated Reading (TIR)
...............................................0.08 mm (0.00315 inch)
i05847995
Turbocharger
(Single Turbocharger)
Illustration 20
g02474819
Typical example
(J) Diameter of the parent bore in the cylinder head
......... 11.000 to 11.022 mm (0.43307 to 0.43394 inch)
(K) Seat angle
Inlet .............................................. 119.25 degrees
Exhaust .........................................89.25 degrees
Illustration 22
g03696193
Typical example
(1) Actuator
The test pressure for the wastegate actuator
.................................................100 kPa (14.5 psi)
The movement for the rod actuator..............1 mm
(0.0394 inch)
(2) Tighten the studs to the following torque.
............................................................18 N·m (13 lb ft)
(3) Tighten the nuts to the following torque. .....44 N·m
(32 lb ft)
(4) Tighten the studs to the following torque.
............................................................18 N·m (13 lb ft)
(5) Tighten the nuts to the following torque. .....44 N·m
(32 lb ft)
Illustration 21
g02475018
Typical example
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UENR4489
15
Specifications Section
(9) Tighten the bolts to the following torque......18 N·m
(13 lb ft)
(10) Tighten the bolt to the following torque. ....40 N·m
(30 lb ft)
(11) Tighten the bolts to the following torque.
............................................................22 N·m (16 lb ft)
Illustration 23
g02469717
Typical example
(6) Tighten the bolt to the following torque. ......22 N·m
(16 lb ft)
(7) Tighten the bolt to the following torque. ........9 N·m
(80 lb in)
Illustration 25
g02469836
Typical example
(12) Tighten the bolt to the following torque. ....22 N·m
(16 lb ft)
(13) Tighten the bolt to the following torque. ....15 N·m
(11 lb ft)
Illustration 24
g02469740
Typical example
Illustration 26
g03696194
Typical example
(8) Tighten the bolt to the following torque. ......22 N·m
(16 lb ft)
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16
UENR4489
Specifications Section
(14) Tighten the clamps to the following torque.
.........................................................12 N·m (106 lb in)
i05848007
Turbocharger
(Series Turbochargers)
Note: For the correct procedure to install the
turbochargers, refer to Disassembly and Assembly,
“Turbocharger - Install”.
Illustration 28
g02467764
Typical example
(4) Tighten the studs to the following torque.
............................................................18 N·m (13 lb ft)
(5) Tighten the bolts to the following torque......44 N·m
(32 lb ft)
(6) Tighten the nuts to the following torque. .....44 N·m
(32 lb ft)
Illustration 27
g03696205
Typical example
(1) Actuator
The test pressure for the wastegate actuator
.................................................100 kPa (14.5 psi)
The movement for the rod actuator..............1 mm
(0.0394 inch)
(2) Tighten the studs to the following torque.....11 N·m
(97 lb in)
Illustration 29
g02467778
Typical example
(3) Tighten the nuts to the following torque. .....24 N·m
(18 lb ft)
(7) Tighten the bolt to the following torque. ......22 N·m
(16 lb ft)
(8) Tighten the bolts to the following torque........9 N·m
(80 lb in)
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UENR4489
17
Specifications Section
(17) Tighten the clamps to the following torque.
.............................................................6 N·m (53 lb in)
Illustration 30
g02467817
Typical example
Illustration 32
g03696203
(9) Tighten the nut to the following torque........30 N·m
(22 lb ft)
Typical example
(18) Tighten the bolts to the following torque.
............................................................22 N·m (16 lb ft)
(10) (14) (15) Tighten the bolts to the following torque.
............................................................22 N·m (16 lb ft)
(19) Tighten the bolt to the following torque. ....15 N·m
(11 lb ft)
(11) (12) Tighten the bolt to the following torque.
............................................................18 N·m (13 lb ft)
(13) Tighten the bolt to the following torque. ....40 N·m
(29 lb ft)
Illustration 33
g02469676
Typical example
(20) Tighten the bolts to the following torque.
............................................................22 N·m (16 lb ft)
Illustration 31
g02469656
Typical example
(21) Tighten the clamps to the following torque.
.........................................................12 N·m (106 lb in)
(16) Tighten the clamps to the following torque.
.........................................................12 N·m (106 lb in)
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18
UENR4489
Specifications Section
i04138516
Exhaust Gas Valve (NRS)
Illustration 35
g02337116
Typical example
(2) Tighten the stud to the following torque. .....11 N·m
(97 lb in)
(3) Tighten the plug to the following torque. .....35 N·m
(26 lb ft)
Illustration 34
g02337096
Typical example
(1) Tighten the bolts to the following torque......22 N·m
(16 lb ft)
Illustration 36
g02337117
Typical example
(4) Tighten the bolts to the following torque........9 N·m
(80 lb in)
(5) Tighten the plug to the following torque. ....9.5 N·m
(84 lb in)
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UENR4489
19
Specifications Section
i05882350
Injector (Diesel Exhaust Fluid)
Illustration 37
g02337118
Typical example
(6) Tighten the nut to the following torque........18 N·m
(13 lb ft)
(7) Tighten the bolts to the following torque......18 N·m
(13 lb ft)
Illustration 39
g03729126
Typical example
(1) Tighten the bolt for the clamp to the following
torque...................................................4 N·m (35 lb in)
i05882355
Manifold (Diesel Exhaust Fluid)
Illustration 38
g02337119
Typical example
(8) Tighten the bolts to the following torque........9 N·m
(80 lb in)
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UENR4489
Specifications Section
Illustration 41
g03719679
Typical example
(1) Tighten the plug to the following torque. .......6 N·m
(53 lb in)
Note: The Original Equipment Manufacturer (OEM)
may supply the Diesel Exhaust Fluid (DEF) tank.
Refer to the OEM for more information if the DEF tank
has been supplied by the OEM.
Illustration 40
g03722372
Typical example
(1) Tighten the screws to the following torque.
.............................................................3 N·m (27 lb in)
i05882416
Diesel Exhaust Fluid Pump
i05882407
Diesel Exhaust Fluid Tank
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21
Specifications Section
Illustration 42
g03722354
Illustration 43
g03722361
Typical example
(2) M8 mounting holes
Typical example
(2) M8 mounting holes
Note: The diesel exhaust fluid pump (1) is mounted to
the application.
Note: The coolant diverter valve (1) is mounted to the
application. The coolant diverter valve must be
mounted with three M8 bolts.
Tighten the recommended M8 fasteners to the
following torque................................16 N·m (142 lb in)
Tighten the recommended M8 fasteners to the
following torque................................22 N·m (195 lb in)
i05914961
Solenoid Valve (DEF Heater
Coolant)
i04138514
Exhaust Cooler (NRS)
Note: When the pipes for the exhaust cooler are
removed or installed, care must be taken so that the
pipes are not bent or the pipes are not damaged.
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UENR4489
Specifications Section
Illustration 44
g02337136
Typical example
(1) Tighten the bolts to the following torque........9 N·m
(80 lb in)
(2) Tighten the bolts to the following torque......22 N·m
(16 lb ft)
(3) Tighten the bolts to the following torque......22 N·m
(16 lb ft)
(4) Tighten the bolts to the following torque......22 N·m
(16 lb ft)
(5) Tighten the bolts to the following torque......22 N·m
(16 lb ft)
(6) Tighten the bolt to the following torque. ......22 N·m
(16 lb ft)
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23
Specifications Section
Illustration 45
g02337137
Typical example
(7) (8) Tighten the bolts to the following torque.
............................................................22 N·m (16 lb ft)
(9) Tighten the bolts to the following torque......22 N·m
(16 lb ft)
(10) Tighten the bolts to the following torque.
............................................................22 N·m (16 lb ft)
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UENR4489
Specifications Section
i03914512
Exhaust Manifold
Illustration 46
g02150456
Typical example
Tighten the exhaust manifold bolts in the sequence
that is shown in illustration 46 to the following torque.
............................................................44 N·m (32 lb ft)
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25
Specifications Section
i03936932
Flexible Exhaust Pipe
Illustration 47
g02155429
Typical example
(1) Tighten the clamp to the following torque.
............................................................35 N·m (26 lb ft)
(2) Tighten the clamp to the following torque.
............................................................55 N·m (41 lb ft)
Refer to Disassembly and Assembly for the correct
procedure to install the flexible exhaust pipe.
i04156670
Camshaft
Illustration 48
g01927854
Checking the end play of the camshaft
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UENR4489
Specifications Section
(1) End play of a camshaft.............0.106 to 0.558 mm
(0.00417 to 0.02197 inch)
Maximum permissible end play of a worn camshaft
.................................................0.62 mm (0.0244 inch)
Illustration 50
g02474757
Typical example
(4) Camshaft thrust washer
Illustration 49
g02150828
Outer diameter (X) ..............72.949 to 73.000 mm
(2.872 to 2.874 inch)
Typical example
Thickness (Y) ......................... 5.486 to 5.537 mm
(0.21598 to 0.21799 inch)
(2) Bolt
Torque for the 8.8 graded bolt......95 N·m (70 lb ft)
Torque for the 10.9 graded bolt................120 N·m
(89 lb ft)
i03916857
Camshaft Bearings
(3) The diameters of the camshaft journals are given
in the following tables.
Table 4
Camshaft Journals from
the Front End of the
Engine
Standard Diameter
1
Front
50.711 to 50.737 mm
(1.9965 to 1.9975 inch)
50.457 to 50.483 mm
(1.9865 to 1.9875 inch)
2
3
Rear
49.949 to 49.975 mm
(1.9665 to 1.9675 inch)
Maximum wear on the camshaft journals...... 0.05 mm
(0.0021 inch)
Check the camshaft lobes for visible damage. If a
new camshaft is installed, you must install new lifters.
Illustration 51
g02150875
Typical example
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Specifications Section
(1) The diameter of the installed camshaft bearing
.............50.787 to 50.848 mm (1.9995 to 2.0019 inch)
i03914549
Engine Oil Filter Base
Illustration 53
g02600976
Typical example
Tighten the setscrews in the sequence that is in
illustration 53 to the following torque. ..............10 N·m
(89 lb in)
Illustration 52
g02150462
Typical example
(1) Setscrew
Torque for the setscrews..............22 N·m (16 lb ft)
(2) Dust cap
(3) Oil sampling valve
Torque for the Oil sampling valve...............12 N·m
(106 lb in)
Torque for the plug (if equipped)......12 N·m (106 lb in)
(4) Engine oil filter
Illustration 54
g02600977
Torque for the engine oil filter....12 N·m (106 lb in)
Typical example
i04406752
Tighten the setscrews in the sequence that is in
illustration 54 to the following torque. ..............26 N·m
(19 lb ft)
Engine Oil Cooler
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UENR4489
Specifications Section
i04346632
Engine Oil Pump
Type ...............................Gear-driven differential rotor
Number of lobes
Inner rotor ........................................................... 6
Outer rotor ..........................................................7
Illustration 57
g00938799
Checking the end play
(3) End play of rotor assembly
Inner rotor................................0.050 to 0.180 mm
(0.0020 to 0.0071 inch)
Outer rotor...............................0.050 to 0.180 mm
(0.0020 to 0.0071 inch)
Illustration 55
g00938064
Typical example
(1) Clearance of the outer rotor to the body
.................0.050 to 0.330 mm (0.0020 to 0.0130 inch)
Illustration 58
g02501636
Typical example
Illustration 56
g00938061
(4) Tighten the bolts to the following torque......44 N·m
(32 lb ft)
Checking the clearance
(2) Service limit of inner rotor to outer rotor
.................0.080 to 0.250 mm (0.0031 to 0.0098 inch)
(5) Tighten the bolts to the following torque......22 N·m
(16 lb ft)
i03994212
Engine Oil Pressure
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Specifications Section
The minimum oil pressure at a maximum engine
speed of 2200 rpm and at normal operating
temperature is the following value.....280 kPa (40 psi)
i04315734
Engine Oil Pan
Table 5
Required Tools
Tool
Part Number
Part Description
Loctite 5900
Qty
A
-
1
Front sealant
Illustration 60
g01254887
Applying sealant
ApplyTooling (A) to the bridge. The sealant must not
protrude more than 5 mm (0.1969 inch) above the
bridge.
Illustration 59
g01254690
Applying sealant
Apply Tooling (A) to the cylinder block and to the
timing case.
Note: Apply a sealant bead of 3.5 mm (0.1378 inch)
that is shown in illustration 59 .
Rear sealant
Note: Install the rear oil seal before sealant is applied
to the bridge.
Illustration 61
g01255016
Typical example
(1) Tighten the four front bolts in position (X) to the
following torque...................................22 N·m (16 lb ft)
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UENR4489
Specifications Section
Tighten the remaining bolts to the following torque.
............................................................22 N·m (16 lb ft)
(2) Drain plug
Tighten the drain plug for the engine oil pan to the
following torque............................34 N·m (25 lb ft)
i03969629
Crankcase Breather
Illustration 63
g02150761
Typical example
(3) Water temperatureregulator housing
(1) Torque for the vent plug........... 22 N·m (16.22 lb ft)
(2) Torque for the bolts that fasten the housing to the
cylinder head ......................................22 N·m (16 lb ft)
Illustration 62
g02162137
Typical example
(1) (2) (3) Tighten the setscrews to the following
torque..................................................22 N·m (16 lb ft)
i03916250
Water Temperature Regulator
and Housing
Illustration 64
g02150762
Typical example
(4) Water temperature regulator
Opening temperature..........................80° to 84°C
(151° to 176°F)
Maximum open length of 11 mm (0.43307 inch)
is achieved at the following temperature. .... 94° C
(201° F)
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Specifications Section
i03916132
Water Pump
Illustration 66
g02150944
Typical example
(1) Cylinder block
(2) Cylinder bore....................105.000 to 105.025 mm
(4.1338 to 4.1348 inch)
Illustration 65
g02150757
The maximum permissible wear for the cylinder bore
.................................................0.15 mm (0.0059 inch)
Tightening sequence
Tighten the setscrews in the numerical sequence that
is shown in illustration 65 to the following torque.
............................................................22 N·m (16 lb ft)
(3) Camshaft bearings
Diameter of the bushing in the cylinder block for
the number 1 camshaft bearing
......55.563 to 55.593 mm (2.1875 to 2.1887 inch)
i05800601
Cylinder Block
Diameter of the bore in the cylinder block for the
number 2 camshaft journal
......50.546 to 50.597 mm (1.9900 to 1.9920 inch)
Diameter of the bore in the cylinder block for the
number 3 camshaft journal
......50.038 to 50.089 mm (1.9700 to 1.9720 inch)
(4) Main bearings
Bore in the cylinder block for the main bearings
......88.246 to 88.272 mm (3.4742 to 3.4753 inch)
(5) Main bearing cap bolts
Use the following procedure in order to install the
main bearing cap bolts:
1. Apply clean engine oil to the threads of the main
bearing cap bolts.
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UENR4489
Specifications Section
2. Put the main bearing caps in the correct position
that is indicated by a number on the top of the main
bearing cap. Install the main bearing caps with the
locating tabs in correct alignment with the recess in
the cylinder block.
Standard thickness of thrust washer
.................2.69 to 2.75 mm (0.10591 to 0.10827 inch)
Oversize thickness of thrust washer
..................2.89 to 2.95 mm (0.11378 to 0.11614 inch)
3. Evenly tighten the main bearing cap bolts.
Torque for the main bearing cap bolts. ...........245 N·m
(181 lb ft)
Note: Ensure that the crankshaft can rotate freely.
i04129189
Crankshaft
Illustration 67
g02155393
Typical example
(1) Crankshaft gear
(2) Crankshaft
(3) Crankshaft thrust washers
Maximum permissible temperature of the gear for
installation on the crankshaft..............180 °C (356 °F)
Maximum permissible temperature of the drive gear
for the balancer (if equipped) for installation on the
crankshaft...........................................180 °C (356 °F)
Note: Refer to Disassembly and Assembly for the
correct procedure to remove and install the drive gear
for the balancer.
The end play of a new crankshaft........ 0.1 to 0.41 mm
(0.00394 to 0.01614 inch)
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Specifications Section
Illustration 68
g02155394
i02934550
Typical example
(4) Journal 1
(5) Journal 2
(6) Journal 3
(7) Journal 4
(8) Journal 5
Refer to table 6 for the run out of the crankshaft
journals.
Crankshaft Seals
Table 6
Journal
Run out of the Journals
(1)
Mounting
(2)
(3)
(4)
(5)
0.08 mm (0.0031 inch)
0.15 mm (0.0059 inch)
0.08 mm (0.0031 inch)
Mounting
Inspect the crankshaft for wear or for damage. For
more information regarding the servicing of the
crankshaft, contact the Global Technical Support
Center.
Refer to Specifications, “Connecting Rod Bearing
Journal” for more information on the connecting rod
bearing journals and connecting rod bearings.
Refer to Specifications, “Main Bearing Journal” for
information on the main bearing journals and for
information on the main bearings.
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Specifications Section
i03996317
Connecting Rod Bearing
Journal
The original size of the connecting rod bearing journal
on the crankshaft........................... 67.99 to 68.01 mm
(2.67677 to 2.67755 inch)
Maximum permissible wear of a bearing journal on
the crankshaft when a new connecting rod is installed
.................................................0.04 mm (0.0016 inch)
Width of the connecting rod bearing journals on the
crankshaft..................................40.305 to 40.455 mm
(1.58681 to 1.59271 inch)
Surface finish of connecting rod bearing journals
Illustration 69
g01455434
...........................................................Ra 0.25 microns
Typical example
(1) Crankshaft
i05800602
(2) Crankshaft seal
(3) Plastic sleeve
(4) Alignment tool
Main Bearing Journal
The original size of the main bearing journal
.........83.980 to 84.000 mm (3.30629 to 3.30708 inch)
Maximum permissible wear of the main bearing
journals..................................0.040 mm (0.0016 inch)
Surface finish of bearing journals and crank pins
...........................................................Ra 0.25 microns
Width of new main bearing journal where the thrust
washer is installed ..................... 39.765 to 39.835 mm
(1.56555 to 1.56830 inch)
Width of new main bearing journal where the thrust
washer is not installed ................... 39.19 to 39.39 mm
(1.54291 to 1.55078 inch)
The shell for the main bearings
The shells for the main bearings are available for
remachined journals which have the following
oversize dimensions.
Illustration 70
g00915076
(5) Tighten bolts 1, 2, 3, 4, 5, 6, 7, and 10 in the
sequence that is shown in Illustration 70 to the
following torque...................................22 N·m (16 lb ft)
Oversize bearing shell ........0.25 mm (0.010 inch)
Oversize bearing shell ........0.51 mm (0.020 inch)
Oversize bearing shell ........0.76 mm (0.030 inch)
Remove the alignment tool.
Thickness at center of the shells of oversize bearing
shell 0.25 mm (0.010 inch) ...........2.226 to 2.232 mm
(0.08764 to 0.08787 inch)
Tighten bolts 8 and 9 in the sequence that is shown in
Illustration 70 to the following torque...............22 N·m
(16 lb ft)
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Specifications Section
Thickness at center of the shells of oversize bearing
shell 0.50 mm (0.020 inch) ...........2.353 to 2.359 mm
(0.09264 to 0.09287 inch)
Thickness at center of the shells of oversize bearing
shell 0.76 mm (0.030 inch) ...........2.480 to 2.486 mm
(0.09764 to 0.09787 inch)
Width of the main bearing shells ... 26.32 to 26.58 mm
(1.03622 to 1.04645 inch)
Clearance between the bearing shell and the main
bearing journals.............................0.036 to 0.094 mm
(0.00142 to 0.00370 inch)
i05380410
Connecting Rod
Illustration 72
g01950657
Typical example
(U) Day code
(V) Code for the connecting rod
(X) Code for the Connecting rod cap
(Y) Year code
(Z) Code for the grade of connecting rod
Note: The day code is from the first day in the year.
For example, “001” will be the first day of the
appropriate year.
The mating surfaces of the connecting rod are
produced by hydraulically fracturing the forged
connecting rod. Ensure that the correct cap for the
connecting rod is installed with the correct connecting
rod. Ensure that the serial numbers for both
components match.
Illustration 71
g01254512
Typical example
(2) Torque of the setscrews for the connecting rod
............................................................40 N·m (30 lb ft)
(1) The bearing shell for the connecting rod
Tighten the setscrews for the connecting rod for an
additional 120 degrees. The setscrews for the
connecting rod (2) must be replaced after this
procedure.
For the correct procedure to install the bearing shell
for the connecting rod, refer to Disassembly and
Assembly, “Pistons and Connecting Rods -
Assemble”.
Table 7
Note: Always tighten the connecting rod cap to the
connecting rod, when the assembly is out of the
engine. Tighten the assembly to the following torque
20 N·m (14 lb ft).
Thickness of ConnectingRod
Bearing at the Center
1.995 to 2.002 mm
(0.07854 to 0.07882 inch)
0.031 to 0.078 mm
(0.00122 to 0.00307 inch)
Bearing Clearance
Table 8
Oversize Connecting Rod Bearing
0.25 mm (0.010 inch)
0.51 mm (0.020 inch)
0.76 mm (0.030 inch)
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Specifications Section
Illustration 74
g03120776
Typical example
(1) Top compression ring
The shape of the top compression ring
...............................................................Keystone
Illustration 73
g01254518
Typical example
Ring gap......................................0.25 to 0.35 mm
(0.00984 to 0.01378 inch)
(3) Diameter of the finished bore for the piston pin
.............39.738 to 39.723 mm (1.5645 to 1.5639 inch)
Note: When you install a new top compression ring,
make sure that the word “TOP” is facing the top of
the piston. New top piston rings have a black
identification mark. The identification mark must be
on the left of the ring end gap when the top piston ring
is installed on an upright piston.
(4) Distance between the parent bores
...............219.05 to 219.1 mm (8.6240 to 8.6260 inch)
(5) Diameter for the finished bore for the connecting
rod bearing.................................72.045 to 72.058 mm
(2.83641 to 2.83692 inch)
(2) Intermediate compression ring
The connecting rod is color coded. The color code is
a reference for the length of the connecting rod. Refer
to table 9 for the length of connecting rod.
The shape of the intermediate compression ring
...............Internal bevel in the bottom edge with a
tapered face
Table 9
Width of intermediate compression ring
............2.47 to 2.495 mm (0.0972 to 0.0982 inch)
Specificationsfor the Connecting Rod
Length Of The Connect-
Grade Letter Color Code
ing Rod
The clearance between a new intermediate
compression ring and the piston groove in a new
piston........................................0.065 to 0.110 mm
(0.00256 to 0.00433 inch)
163.081 to 163.114 mm
B
Blue
(6.42050 to 6.42180 inch)
i04939374
Ring gap......................................0.65 to 0.85 mm
(0.0256 to 0.0335 inch)
Piston and Rings
Note: When you install a new intermediate
compression ring, make sure that the word “TOP” is
facing the top of the piston. New intermediate rings
have a blue identification mark. The identification
mark must be on the left of the ring end gap when the
top piston ring is installed on an upright piston.
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37
Specifications Section
(3) The oil control ring
Width of oil control ring................2.79 to 3.00 mm
(0.10984 to 0.11811 inch)
The clearance between a new oil control ring and
the groove in a new piston..........0.05 to 0.10 mm
(0.00197 to 0.00394 inch)
Ring gap......................................0.30 to 0.55 mm
(0.0118 to 0.0216 inch)
Note: When you install a new oil control ring, make
sure that the word “TOP” is facing the top of the
piston. New oil control rings have a red identification
mark. The identification mark must be on the left of
the ring end gap when the top piston ring is installed
on an upright piston. The oil control ring is a two-
piece ring that is spring loaded. A pin is used in order
to hold both ends of the spring of the oil control ring in
position. The ends of the spring of the oil control ring
must be installed opposite the end gap of the oil
control ring.
Illustration 75
g01352576
(1) Installed piston cooling jets
The valve must move freely. Tighten the bolt to the
following torque.......................................9 N·m (7 lb ft)
Piston Cooling Jet Alignment
Note: Ensure that the ring end gaps of the piston
rings are spaced 120 degrees from each other.
Piston
Note: An arrow which is marked on the piston crown
must be toward the front of the engine.
Piston height above cylinder block.... 0.55 to 0.20 mm
(0.02165 to 0.00787 inch)
Width of top groove in the piston ................... Tapered
Width of second groove in new piston
.....................2.56 to 2.58 mm (0.1008 to 0.1016 inch)
Width of third groove in new piston.... 3.05 to 3.07 mm
(0.12008 to 0.12087 inch)
Piston pin
Diameter of a new piston pin
......39.694 to 39.700 mm (1.5628 to 1.5630 inch)
Illustration 76
g01352578
(2) Piston cooling jet
(3) Rod
(4) Cylinder block
i02696381
Piston Cooling Jet
Use the following procedure in order to check the
alignment of the piston cooling jet.
1. Insert rod (3) into the end of the piston cooling jet
(2). Rod (3) has a diameter of 1.70 mm
(0.067 inch). Rod (3) must protrude out of the top
of the cylinder block.
2. Dimension (A) is 50.75 mm (1.9980 inch) and
dimension (B) is 9.35 mm (0.3681 inch).
Dimension (A) and dimension (B) are tangential to
the cylinder bore (4).
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UENR4489
Specifications Section
3. The position of the rod (3) must be within
dimension (C). Dimension (C) is 14 mm
(0.5512 inch).
Note: Ensure that the rod (3) can not damage the
piston cooling jet when the alignment is checked. The
piston cooling jets can not be adjusted. If a piston
cooling jet is not in alignment the piston cooling jet
must be replaced.
i04555039
Balancer
Illustration 78
g02148374
Typical example
(1) Tighten allen head screws to the following torque.
............................................................22 N·m (16 lb ft)
(2) Tighten the allen head screw to the following
torque..................................................78 N·m (58 lb ft)
Illustration 77
g02150753
Typical example
Tighten the bolts in the sequence that is shown in
illustration 77 to the following torque. ..............54 N·m
(40 lb ft)
Backlash values
Backlash between crankshaft ring gear and the
balancer intermediate gear..... 0.020 to 0.240 mm
(0.0008 to 0.009 inch)
Backlash between the balancer shaft gears
..........0.020 to 0.160 mm (0.0008 to 0.0063 inch)
Illustration 79
g02148375
i03907005
Typical example
Accessory Drive
(SAE “B” )
(3) Tighten bolts to the following torque............44 N·m
(33 lb ft)
This document is printed from SPI2. NOT FOR RESALE
UENR4489
39
Specifications Section
i03907004
Accessory Drive
Illustration 81
g01860874
Typical example
Tighten the setscrew to the sequence that is shown in
illustration 81 to the following torque. ..............28 N·m
(20 lb ft)
Illustration 80
g02148372
Typical example
(1) Tighten the allen head screws to the following
torque..................................................22 N·m (16 lb ft)
(2) Tighten the allen head screws to the following
torque..................................................78 N·m (58 lb ft)
i03917090
Front Housing and Covers
Illustration 82
g02150954
Typical example
(1) Tighten the bolts that fasten the front cover to the
front housing to the following torque.................22 N·m
(16 lb ft)
(2) Tighten the bolts that fasten the water pump to the
front housing to the following torque.................22 N·m
(16 lb ft)
Note: Refer to Specifications, “Water Pump” for the
correct bolt tightening sequence for the water pump.
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UENR4489
Specifications Section
i05805182
The end play of the medium duty and heavy duty
idler gear .....................................0.05 to 0.15 mm
(0.00197 to 0.00591 inch)
Gear Group (Front)
Number of teeth ................................................ 97
(3) Fuel injection pump drive gear
Torque for the nut.........................64 N·m (47 lb ft)
Number of teeth ................................................ 36
(4) Oil pump gear
The number of teeth on the oil pump gear ....... 18
Backlash values
Backlash between the oil pump idler gear (5) and
the oil pump drive gear (4) ......... 0.05 to 0.15 mm
(0.0020 to 0.0059 inch)
Backlash between the oil pump idler gear (5) and
the crankshaft gear (6) ...........0.025 to 0.210 mm
(0.00098 to 0.00827 inch)
Backlash between the idler gear (2) and the
crankshaft gear (6) .....................0.05 to 0.15 mm
(0.0020 to 0.0059 inch)
Illustration 83
g01857156
Backlash between the camshaft gear (1) and the
idler gear (2) ............................... 0.05 to 0.15 mm
(0.0020 to 0.0059 inch)
Gear train
(1) Camshaft gear
Backlash between the fuel injection pump gear
(3) and the idler gear (2) .............0.05 to 0.15 mm
(0.0020 to 0.0059 inch)
Torque for the 8.8 graded bolt for the camshaft
gear..............................................95 N·m (70 lb ft)
Torque for the 10.9 graded bolt for the camshaft
gear............................................120 N·m (89 lb ft)
Backlash between the water pump gear (not
shown) and the fuel injection pump gear (3)
..............0.05 to 0.15 mm (0.0020 to 0.0059 inch)
Backlash between the power take-off drive (if
equipped) and the idler gear (2)
Number of teeth ................................................ 72
(2) Idler gear and hub
Torque for the bolts for the idler gear .........44 N·m
(33 lb ft)
............0.05 to 0.250 mm (0.0020 to 0.0098 inch)
(5) Oil pump idler gear
Width of medium duty and heavy duty idler gear
bearing....................................25.45 to 25.55 mm
(1.00197 to 1.00590 inch)
Inside diameter of oil pump idler gear bearing
......16.012 to 16.038 mm (0.6304 to 0.6314 inch)
Inside diameter of medium duty and heavy duty
idler gear bearings .................. 56.00 to 56.03 mm
(2.20472 to 2.20590 inch)
Outside diameter of oil pump idler gear shaft
......15.966 to 15.984 mm (0.6286 to 0.6293 inch)
Clearance of oil pump idler gear bearing on shaft
..........0.028 to 0.072 mm (0.0011 to 0.0028 inch)
Outside diameter of medium duty and heavy duty
idler gear hub .......................... 55.95 to 55.97 mm
(2.20275 to 2.20354 inch)
End play of the oil pump idler gear
..........0.050 to 0.275 mm (0.0019 to 0.0108 inch)
Clearance of medium duty and heavy duty idler
gear bearing on hub....................0.03 to 0.08 mm
(0.00118 to 0.00315 inch)
End play of the oil pump drive gear
......0.005 to 0.090 mm (0.00020 to 0.00354 inch)
(6) Crankshaft gear
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UENR4489
41
Specifications Section
Bore diameter of crankshaft gear
i04315754
..........51.00 to 51.03 mm (2.0079 to 2.0091 inch)
Flywheel Housing
Outside diameter of crankshaft hub
......51.021 to 51.002 mm (2.0087 to 2.0079 inch)
Clearance of gear on crankshaft
............................................−0.021 to +0.028 mm
(−0.00083 to 0.00110 inch)
Table 10
Required Tools
Part Description
Loctite 575
Number of teeth ................................................ 36
Tool
Part Number
Qty
A
-
1
i03520340
Flywheel
Illustration 84
g00584712
Typical example
Illustration 85
g01254486
Typical example
(1) Flywheel ring gear
Setscrew
Heat the flywheel ring gear to the following
temperature..................................250 °C (480 °F)
(1)Tighten the setscrew to the following torque.
.....................................................75 N·m (55 lb ft)
Note: Do not use an oxyacetylene torch to heat the
flywheel ring gear.
Setscrew
(2) Flywheel
(3) Bolt
(2)Tighten the setscrew to the following torque.
.....................................................63 N·m (46 lb ft)
Note: If 12.9 setscrews are installed, apply Tooling
(A) to the setscrews. Tighten the 12.9 setscrews to a
torque of 70 N·m (52 lb ft).
Tighten the flywheel bolts to the following torque.
................................................ 140 N·m (103 lb ft)
This document is printed from SPI2. NOT FOR RESALE
42
UENR4489
Specifications Section
i05800618
Crankshaft Pulley
Illustration 87
g02291813
Typical example
(1) Tighten the bolt to the following torque. ......45 N·m
(33 lb ft)
Note: To install the belt tensioner, refer to
Disassembly and Assembly, “Belt Tensioner -
Remove and Install” for the correct procedure.
Illustration 86
g02155003
Typical example
(1) Tighten the bolts to the following torque......78 N·m
(58 lb ft)
i03629003
Refrigerant Compressor
(3) Bolts
Tighten the bolts to the following torque.
..................................................22.5 N·m (17 lb ft)
Tighten the bolts to the additional amount. .... 120
degrees
(2) Auxiliary pulley
(4) Crankshaft pulley
i04083729
Belt Tensioner
Illustration 88
g01946810
Typical example
This document is printed from SPI2. NOT FOR RESALE
