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        珀金斯Perkins1206F-E70TA(TTA)技術資料(英文)

        詳細描述

        Specifications

        1206F-E70TA and 1206F-E70TTA

        Industrial Engines

        BM (Engine)

        BN (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


         

        UENR0675

        3

        Table of Contents

        Table of Contents

        Accessory Drive....................... ....................... 42

        Front Housing and Covers............... ............... 42

        Gear Group (Front)..................... .................... 43

        Flywheel .......................................................... 44

        Flywheel Housing...................... ..................... 44

        Belt Tensioner......................... ........................ 45

        Refrigerant Compressor................. ................ 45

        Fan Drive............................ ............................ 46

        Engine Lifting Bracket................... .................. 46

        Alternator............................ ............................ 46

        Starter Motor.......................... ......................... 48

        Nitrogen Oxide Sensor .................. ................. 50

        Coolant Temperature Sensor............. ............. 51

        Engine Oil Pressure Sensor.............. ............. 51

        Boost Pressure Sensor.................. ................. 51

        Atmospheric Pressure Sensor............ ............ 52

        Inlet Manifold Temperature Sensor......... ........ 52

        Turbocharger Exhaust Temperature Sensor . . 53

        Temperature Sensor (DPF Inlet)........... .......... 53

        Temperature Sensor (Exhaust)............ ........... 54

        Pressure Sensor (NOx Reduction System).. .. 54

        Temperature Sensor (NOx Reduction System)55

        Soot Antenna......................... ......................... 55

        Speed/Timing Sensor................... .................. 56

        Electronic Control Module ............... ............... 56

        Electronic Control (Diesel Exhaust Fluid).... ... 57

        Glow Plugs .......................... ........................... 57

        Air Compressor (Twin Cylinder Compressor)  58

        Air Compressor (Single Cylinder)......... ......... 59

        SpecificationsSection

        Engine Design ......................... ......................... 4

        Fuel Injection Lines...................... ..................... 4

        Fuel Injection Pump..................... ..................... 5

        Fuel Injectors.......................... .......................... 6

        Fuel Transfer Pump (Electric 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)...................... ..................... 9

        Lifter Group............................ ........................... 9

        Rocker Shaft........................... .......................... 9

        Valve Mechanism Cover................. .................11

        Cylinder Head Valves ................... ...................11

        Cylinder Head......................... ........................ 12

        Turbocharger (Series Turbochargers)...... ...... 14

        Turbocharger (Single Turbocharger)....... ....... 17

        Injector (Diesel Exhaust Fluid)............ ............ 18

        Manifold (Diesel Exhaust Fluid)........... ........... 20

        Diesel Exhaust Fluid Tank ............... ............... 20

        Diesel Exhaust Fluid Pump .............. .............. 21

        Exhaust Gas Valve (NRS) ............... ............... 21

        Exhaust Cooler (NRS).................. .................. 23

        Exhaust Manifold...................... ...................... 25

        Flexible Exhaust Pipe................... .................. 26

        Camshaft............................ ............................ 26

        Camshaft Bearings..................... .................... 27

        Engine Oil Filter Base................... .................. 28

        Engine Oil Cooler...................... ...................... 28

        Engine Oil Pump....................... ...................... 29

        Engine Oil Pressure.................... .................... 30

        Engine Oil Pan........................ ........................ 31

        Crankcase Breather.................... .................... 33

        Water Temperature Regulator and Housing.. . 34

        Water Pump.......................... .......................... 34

        Cylinder Block......................... ........................ 35

        Crankshaft........................... ........................... 35

        Crankshaft Seals ...................... ...................... 36

        Vibration Damper and Pulley............. ............. 37

        Connecting Rod Bearing Journal.......... .......... 37

        Main Bearing Journal................... ................... 38

        Connecting Rod....................... ....................... 38

        Piston and Rings ...................... ...................... 39

        Piston Cooling Jet...................... ..................... 40

        Accessory Drive (SAE  “B” ).............. ............. 41

        Index Section

        Index................................ ............................... 61

        This document is printed from SPI². Not for RESALE


         

        4

        UENR0675

        Specifications Section

        SpecificationsSection

        i04928625

        Fuel Injection Lines

        i03519906

        Engine Design

        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

        g01284058

        Cylinder and valve location

        (A) Exhaust valve

        (B) Inlet valve

        Ensure that all adjustments and repairs are

        performed by authorized personnel that have had the

        correct training.

        Bore ............................................105 mm (4.133 inch)

        Stroke .........................................135 mm (5.315 inch)

        Displacement......................7.01 L (427.78 cubic inch)

        Cylinder arrangement ........................................In-line

        Type of combustion ..............................Direct injection

        Compression ratio

        Turbocharged charge cooled  ....................16.5:1

        Number of cylinders .................................................. 6

        Valves per cylinder .................................................... 4

        Firing order .............................................1, 5, 3, 6, 2, 4

        When the crankshaft is viewed from the front of the

        engine, the crankshaft rotates in the following

        direction: .....................................................Clockwise

        When the camshaft is viewed from the front of the

        engine, the camshaft rotates in the following direction:

        .....................................................................Clockwise

        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.

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        5

        Specifications Section

        Illustration 2

        g02293673

        Typical example

        (1) (2) Tighten the nuts on the high-pressure fuel lines

        to the following torque.........................55 N·m (41 lb ft)

        i04085749

        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

        g02293713

        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

        UENR0675

        Specifications Section

        (3) Tighten the fuel temperature sensor to the

        (2) Torque for the bolt in the clamp for the fuel

        following torque...................................22 N·m (16 lb ft)

        injection nozzle................................21 N·m (15.5 lb ft)

        (4) Tighten the setscrews to the following torque.

        ............................................................22 N·m (16 lb ft)

        i05449450

        Fuel Transfer Pump

        (Electric Transfer Pump)

        (5) Tighten the screws for the suction control valve to

        the following torque..............................9 N·m (80 lb in)

        (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

        g02291814

        Typical example

        (1) Tighten the connection to the following torque.

        ............................................................20 N·m (15 lb ft)

        Illustration 4

        g01862457

        Typical example

        (3) Clamp

        (4) Washer

        (5) O ring seal

        Illustration 6

        g02291815

        (1) Torque for the nuts..........................2 N·m (18 lb in)

        Typical example

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        7

        Specifications Section

        (2) (3) Tighten the bolts to the following torque.

        ............................................................22 N·m (16 lb ft)

        i05365831

        Fuel Filter Base

        (Single 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.

        Illustration 8

        g03396250

        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.

        Typical example

        (5) Tighten the screw to the following torque.

        ..........................................................2.5 N·m (22 lb in)

        i05371617

        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.

        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.

        Illustration 7

        g02516539

        Typical example

        (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)

        This document is printed from SPI². Not for RESALE


         

        8

        UENR0675

        Specifications Section

        i04916708

        Fuel Filter Base

        (Primary 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.

        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.

        Illustration 9

        g02518537

        Typical example

        (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)

        Illustration 11

        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)

        (4) Tighten the bolts to the following torque......44 N·m

        (32 lb ft)

        (5) Tighten the connection to the following torque.

        ............................................................17 N·m (13 lb ft)

        Illustration 10

        g03398925

        Typical example

        (5) Tighten the screws to the following torque.

        ..........................................................2.5 N·m (22 lb in)

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        9

        Specifications Section

        i04084390

        Fuel Manifold (Rail)

        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 13

        g01866794

        Typical example

        (A) Diameter of the lifter body....21.938 to 21.963 mm

        (0.86370 to 0.86468 inch)

        Bore diameter in the cylinder block

        .........22.000 to 22.032 mm (0.86614 to 0.86740 inch)

        Clearance

        Clearance of the lifter..............0.037 to 0.094 mm

        (0.00146 to 0.00370 inch)

        i03519944

        Rocker Shaft

        Illustration 12

        g02293653

        Typical example

        (1) Tighten the bolts to the following torque......22 N·m

        (16 lb ft)

        (2) Tighten the bolts to the following torque......10 N·m

        (89 lb in)

        (3) Tighten the fuel pressure relief valve to the

        following torque...................................30 N·m (22 lb ft)

        Note: The fuel pressure relief valve (3) should be

        tightened an additional 24 degrees.

        i03537811

        Lifter Group

        This document is printed from SPI². Not for RESALE


         

        10

        UENR0675

        Specifications Section

        (9) Spring

        Illustration 15

        g01850497

        Tightening sequence

        Tighten the fasteners in the sequence that is in

        illustration 15 . Tighten the fasteners to the following

        torque..................................................35 N·m (26 lb ft)

        Illustration 14

        g02113434

        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

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        11

        Specifications Section

        i03532881

        Valve Mechanism Cover

        Illustration 16

        g01861234

        Typical example

        Tighten the bolts for the valve mechanism cover in

        the sequence that is shown in illustration 16 . Torque

        for the bolts..........................................9 N·m (80 lb in)

        i03538600

        Cylinder Head Valves

        Illustration 17

        g01927355

        Typical example

        (1) Exhaust valve spring

        (2) Inlet valve spring

        When the valve springs are replaced the valve

        springs must be replaced in pairs.

        This document is printed from SPI². Not for RESALE


         

        12

        UENR0675

        Specifications Section

        Refer to table 1 and table 2 for information on the

        length of the valve spring and the load of the valve

        spring.

        Clearance

        Maximum clearance of the exhaust valve stem

        Table 1

        ......................................0.075 mm (0.00295 inch)

        The service limit for the exhaust valve stem

        ........................................0.10 mm (0.00394 inch)

        The load for the inlet valve

        spring

        The length of the inlet valve

        spring

        161.5 to 178.5 N

        (36.30682 to 40.12859 lb)

        31.5 mm (1.2402 inch)

        (5)  Length of valve

        Inlet valve.............................109.82 to 110.27 mm

        (4.32361 to 4.34133 inch)

        337.9 to 373.5 N

        (75.96330 to 83.96654 lb)

        21.5 mm (0.84646 inch)

        Exhaust valve.................. 109.853 to 110.303 mm

        (4.32491 to 4.34263 inch)

        Note: The free length for the inlet valve spring is

        40.65 mm (1.60039 inch).

        (6) Valve head

        Table 2

        Diameter of inlet valve head ...................... 35 mm

        (1.37795 inch)

        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

        (64.07085 to 70.81515 lb)

        31.5 mm (1.2402 inch)

        408.5 to 451.5 N

        (91.83488 to 101.50172 lb)

        22.3 mm (0.87795 inch)

        i04314230

        Cylinder Head

        Note: The free length for the exhaust valve spring is

        52.73 mm (2.07598 inch).

        Illustration 18

        g01927357

        Typical example

        (3) Valve face angle

        Inlet .....................................................30 degrees

        Exhaust ..............................................45  degrees

        (4) Valve stem diameter

        Illustration 19

        g01852017

        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)

        Typical example

        Lubricate the threads and the underside of the head

        bolts with clean engine oil.

        Clearance

        Tighten the bolts in the sequence that is shown in

        illustration 19 . Torque for the bolts............50 N·m

        (37 lb ft)

        Tighten the bolts again to the following torque.

        ...................................................100N·m (74 lb ft)

        Maximum clearance of the inlet valve stem

        ..........................................0.05 mm (0.0020 inch)

        The service limit for the inlet valve stem

        ..........................................0.08 mm (0.0031 inch)

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        13

        Specifications Section

        Tighten the head bolts to the additional amount.

        ..........................................................225 degrees

        Minimum thickness of cylinder head ...........150.8 mm

        (5.93700 inch)

        Illustration 20

        g01854993

        Typical example

        Illustration 21

        g02328933

        Typical example

        Note: The maximum distortion of the cylinder head is

        given in table 3 .

        (D) Valve guide height from the top of the valve guide

        to the valve spring seat...................10.75 to 11.25 mm

        (0.42323 to 0.44291 inch)

        Table 3

        Maximum Permissible

        Dimension

        Distortion

        (E) Outside diameter of the valve guides

        ......... 11.029 to 11.040 mm (0.43421 to 0.43464 inch)

        Width (A)

        Length (B)

        0.03 mm (0.0012 inch)

        0.05 mm (0.0020 inch)

        0.05 mm (0.020 inch)

        (F) Length of the valve guides.......43.75 to 44.25 mm

        (1.72244 to 1.74212 inch)

        Diagonal Line (C)

        (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

        UENR0675

        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)

        i05365854

        Turbocharger

        (Series Turbochargers)

        Note: For the correct procedure to install the

        turbochargers, refer to Disassembly and Assembly,

        “Turbocharger - Install”.

        Illustration 22

        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 .............................................. 119.15 degrees

        Exhaust .........................................89.15  degrees

        Illustration 24

        g03097997

        Typical example

        (1) Actuator

        The test pressure for the wastegate actuator

        ...............................................................60 kPa (9 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)

        Illustration 23

        g02475018

        Typical example

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        15

        Specifications Section

        Illustration 25

        g03098036

        Illustration 27

        g02352719

        Typical example

        Tightening sequence for the nuts that secure the

        turbocharger to the bracket

        (4) (6) Tighten the studs to the following torque.

        ............................................................18 N·m (13 lb ft)

        (5) (7) Tighten the nuts to the following torque.

        ............................................................44 N·m (32 lb ft)

        Illustration 26

        g03396277

        Tightening sequence for the nuts that secure the

        bracket to the cylinder block

        This document is printed from SPI². Not for RESALE


         

        16

        UENR0675

        Specifications Section

        Illustration 28

        g03098058

        Typical example

        (8) Tighten the bolt to the following torque. ......15 N·m

        (11 lb ft)

        (9) Tighten the bolts to the following torque........9 N·m

        (80 lb in)

        (10) (11) (17) Tighten the bolt to the following torque.

        ............................................................18 N·m (13 lb ft)

        (12) (14) (15) (16) Tighten the bolts to the following

        torque..................................................22 N·m (16 lb ft)

        (13) Tighten the bolt to the following torque. ....33 N·m

        (24 lb ft)

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        17

        Specifications Section

        Illustration 29

        g03120317

        i04928651

        Typical example

        (18) Tighten the band clamps for the turbochargers to

        the following torque..........................12 N·m (106 lb in)

        Turbocharger

        (Single Turbocharger)

        (19) Tighten the band clamps for the ducts to the

        following torque....................................6 N·m (53 lb in)

        Illustration 30

        g03120696

        Typical example

        (20) Tighten the band clamps for the turbochargers to

        the following torque..........................12 N·m (106 lb in)

        This document is printed from SPI². Not for RESALE


         

        18

        UENR0675

        Specifications Section

        Illustration 32

        g03097926

        Typical example

        (8) Tighten the bolts to the following torque........9 N·m

        (80 lb in)

        (9) Tighten the bolt to the following torque. ......33 N·m

        (24 lb ft)

        Illustration 31

        g03097898

        Typical example

        (10) Tighten the bolt to the following torque. ....22 N·m

        (16 lb ft)

        (1) Tighten the studs to the following torque.

        ............................................................18 N·m (13 lb ft)

        (2) Tighten the nuts to the following torque. .....44 N·m

        (32 lb ft)

        i05380879

        Injector (Diesel Exhaust Fluid)

        (3) Tighten the bolt to the following torque. ......15 N·m

        (11 lb ft)

        (4) Tighten the studs to the following torque.

        ............................................................18 N·m (13 lb ft)

        Table 4

        Required Tools

        (5) Tighten the nuts to the following torque. .....44 N·m

        (32 lb ft)

        Tool

        Part Number

        Part Description

        Qty

        Bostik Pure Nickel

        Anti-Seize Compound

        (6) Actuator

        A

        -

        1

        The test pressure for the wastegate actuator

        ...............................................................60 kPa (9 psi)

        The movement for the rod actuator .................... 1 mm

        (0.0394 inch)

        (7) Tighten the band clamps to the following torque.

        .........................................................12 N·m (106 lb in)

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        19

        Specifications Section

        Illustration 33

        g03404738

        Typical example

        (1) Injector (Diesel Exhaust Fluid)

        (2) Stud

        (3) Washer

        Lightly lubricate the thread of the studs (2) and nuts

        (4) with Tooling (A) before installation.

        (2) Tighten the studs to the following torque.......5 N·m

        (44 lb in)

        (4) Tighten the nuts to an initial torque. ..............5 N·m

        (44 lb in)

        (4) Tighten the nuts to a final torque...................5 N·m

        (44 lb in)

        Tighten the nuts to the additional amount. ..............90

        degrees

        This document is printed from SPI². Not for RESALE


         

        20

        UENR0675

        Specifications Section

        i05380938

        Manifold (Diesel Exhaust Fluid)

        Illustration 34

        g03404759

        Typical example

        (1) Tighten the screws in the tightening sequence as

        shown in illustration 34 to an initial torque.........5 N·m

        (44 lb in)

        (1) Tighten the screws in the tightening sequence as

        shown in illustration 34 to a final torque.............5 N·m

        (44 lb in)

        i05380903

        Diesel Exhaust Fluid Tank

        Illustration 35

        g03404743

        Typical example

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        21

        Specifications Section

        (1) Tighten the cap adapter or hose adapter to the

        following torque...................................15 N·m (11 lb ft)

        Tighten the self-taping screws to the following torque.

        ..........................................................2.8 N·m (25 lb in)

        (2) Tighten the plug to the following torque. .....11 N·m

        (97 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.

        i05380925

        Diesel Exhaust Fluid Pump

        Illustration 37

        g01946893

        Typical example

        (1) Tighten the bolts to the following torque......22 N·m

        (16 lb ft)

        Illustration 36

        g03404752

        Typical example

        (1) Tighten the bolts to the following torque......19 N·m

        (14 lb ft)

        Note: The maximum wrench speed is 60 rpm.

        i04928588

        Exhaust Gas Valve (NRS)

        This document is printed from SPI². Not for RESALE


         

        22

        UENR0675

        Specifications Section

        Illustration 38

        g02295533

        Typical example

        (2) Tighten the bolts to the following torque......18 N·m

        (13 lb ft)

        (3) Tighten the bolts to the following torque......22 N·m

        (16 lb ft)

        (4) Tighten the clamps to the following torque.

        ...........................................................11 N·m (97 lb in)

        (5) Tighten the bolt to the following torque. ......18 N·m

        (13 lb ft)

        Illustration 39

        g03097576

        Typical example

        (6) Tighten the bolt to the following torque. ......15 N·m

        (11 lb ft)

        (7) (8) Tighten the fasteners to the following torque.

        ............................................................18 N·m (13 lb ft)

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        23

        Specifications Section

        i04928620

        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 damaged.

        Illustration 40

        g02295833

        Typical example

        (1) (2) Tighten the setscrews to the following torque.

        ............................................................22 N·m (16 lb ft)

        This document is printed from SPI². Not for RESALE


         

        24

        UENR0675

        Specifications Section

        Illustration 41

        g02295755

        Typical example

        (3) (6) (7) (9) Tighten the setscrews to the following

        torque..................................................22 N·m (16 lb ft)

        (4) Tighten the setscrews to, the following torque.

        ............................................................18 N·m (13 lb ft)

        (5) (8) Tighten the setscrews to the following torque.

        ............................................................44 N·m (32 lb ft)

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        25

        Specifications Section

        i04364975

        Exhaust Manifold

        Illustration 42

        g02330776

        Typical example

        Tighten the exhaust manifold bolts in the sequence

        that is shown in illustration 42 to the following torque.

        ............................................................44 N·m (32 lb ft)

        To measure the flatness of the exhaust manifold,

        follow step 1 to step 4.

        1. Remove all bolts and spacers from the exhaust

        manifold.

        2. Install two spacers and bolts into holes eleven and

        twelve of port one of the exhaust manifold.

        3. Tighten the bolts to a torque of 44 N·m  (32 lb ft).

        4. Use a suitable feeler gauge to measure the gap

        that is between port six (holes nine and ten) of the

        exhaust manifold and the cylinder head.

        The maximum amount that the gap should be is

        .................................................1.4 mm (0.05512 inch)

        For the correct procedures to remove and install the

        exhaust manifold, refer to Disassembly and

        Assembly.

        This document is printed from SPI². Not for RESALE


         

        26

        UENR0675

        Specifications Section

        i05365841

        Flexible Exhaust Pipe

        Illustration 43

        g03396256

        i05452413

        Typical example

        (1) Tighten the clamp to the following torque.

        ............................................................55 N·m (41 lb ft)

        Camshaft

        (2) Tighten the clamp to the following torque.

        ............................................................35 N·m (26 lb ft)

        (3) Tighten the clamp to the following torque.

        .........................................................12 N·m (106 lb in)

        Refer to Disassembly and Assembly for the correct

        procedure to install the flexible exhaust pipe.

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        27

        Specifications Section

        Table 5

        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

        50.203 to 50.229 mm

        (1.9765 to 1.9775 inch)

        4

        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 44

        g01927854

        Checking the end play of the camshaft

        (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 46

        g02474757

        Typical example

        (4) Camshaft thrust washer

        Outer diameter (X) ..............72.949 to 73.000 mm

        (2.872 to 2.874 inch)

        Thickness (Y) ......................... 5.486 to 5.537 mm

        (0.21598 to 0.21799 inch)

        Illustration 45

        g03442257

        Typical example

        i03530782

        Camshaft Bearings

        (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)

        (3) The diameters of the camshaft journals are given

        in the following tables.

        This document is printed from SPI². Not for RESALE


         

        28

        UENR0675

        Specifications Section

        Torque for the engine oil filter....12 N·m (106 lb in)

        (3) Engine oil sampling valve

        Torque for the engine oil sampling valve (if

        equipped)..................................12 N·m (106 lb in)

        Torque for the plug (if equipped)......12 N·m (106 lb in)

        (4) Setscrew

        Torque for the setscrews that retain the oil filter

        base .............................................22 N·m (16 lb ft)

        i04916915

        Engine Oil Cooler

        Illustration 47

        g01859293

        Engine Oil Cooler with a Low

        Mounted Filter Base

        Typical example

        (1) The diameter of the installed camshaft bearing

        .............50.787 to 50.848 mm (1.9995 to 2.0019 inch)

        i03551117

        Engine Oil Filter Base

        Illustration 49

        g03084977

        Typical example

        Setscrews

        Tighten the setscrews in the sequence that is in

        illustration 49 to the following torque.........22 N·m

        (16 lb ft)

        Illustration 48

        g01877935

        Typical example

        (1) Dust cap

        (2) Engine oil filter

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        29

        Specifications Section

        Engine Oil Cooler with a High

        Mounted Filter Base

        Illustration 51

        g00938064

        (1) Clearance of the outer rotor to the body

        .................0.050 to 0.330 mm (0.0020 to 0.0130 inch)

        Illustration 50

        g01854213

        Typical example

        Setscrews

        Tighten the setscrews in the sequence that is in

        illustration 50 to the following torque.........22 N·m

        (16 lb ft)

        Illustration 52

        g00938061

        i04363634

        Checking the clearance

        Engine Oil Pump

        (2) Service limit of inner rotor to outer rotor

        .................0.080 to 0.250 mm (0.0031 to 0.0098 inch)

        Type ...............................Gear-driven differential rotor

        Number of lobes

        Inner rotor ........................................................... 6

        Outer rotor ..........................................................7

        Illustration 53

        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)

        This document is printed from SPI². Not for RESALE


         

        30

        UENR0675

        Specifications Section

        Outer rotor............................... 0.050 to 0.180 mm

        (0.0020 to 0.0071 inch)

        Illustration 54

        g02293754

        Typical example

        (4) Suction Pipe

        (6) Bracket for the Suction Pipe

        (5) (8) (9) (10) Tighten the bolts to the following

        torque..................................................22 N·m (16 lb ft)

        (7) Tighten the bolt to the following torque. ......44 N·m

        (32 lb ft)

        i03540441

        Engine Oil Pressure

        The minimum oil pressure at a maximum engine

        speed of 2200 rpm and at normal operating

        temperature is the following value.....315 kPa (45 psi)

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        31

        Specifications Section

        i04129089

        Engine Oil Pan

        Illustration 55

        g01856874

        (X) Guide studs

        (Y) Short fastener

        Tighten the fasteners in the sequence that is shown in

        illustration 55 . Torque for the fasteners ...........22 N·m

        (16 lb ft)

        This document is printed from SPI². Not for RESALE


         

        32

        UENR0675

        Specifications Section

        Illustration 56

        g01857014

        Remove the guide studs. Install the fasteners (27),

        (28), (29) and (30).

        Tighten the fastener in the sequence that is shown in

        illustration 56 . Torque for the fasteners ...........22 N·m

        (16 lb ft)

        Tighten the oil drain plug to the following torque.

        ............................................................34 N·m (25 lb ft)

        Tighten the oil level switch (if equipped) to the

        following torque...................................34 N·m (25 lb ft)

        Refer to the Disassembly and Assembly, “Engine Oil

        Pan” for the correct procedure to install the engine oil

        pan.

        The Cast Iron Oil Pan

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        33

        Specifications Section

        Illustration 57

        g01397669

        Tightening sequence

        Tighten the fasteners in the sequence that is shown in

        illustration 57 to the following torque. ..............22 N·m

        (16 lb ft)

        Tighten the oil drain plug to the following torque.

        ............................................................34 N·m (25 lb ft)

        Tighten the oil level switch (if equipped) to the

        following torque...................................34 N·m (25 lb ft)

        i04085789

        Crankcase Breather

        Illustration 58

        g02295333

        Typical example

        This document is printed from SPI². Not for RESALE


         

        34

        UENR0675

        Specifications Section

        (1) (2) (3) Tighten the setscrews to the following

        torque..................................................22 N·m (16 lb ft)

        (4) Tighten the setscrews to the following torque.

        ............................................................44 N·m (32 lb ft)

        Note: If a hexagonal pillar spacer is required, install

        the spacer to the engine oil cooler. Tighten the spacer

        to a torque of 22 N·m (16 lb ft).

        i03520180

        Water Temperature Regulator

        and Housing

        Illustration 60

        g01854133

        (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)

        i03520301

        Water Pump

        Illustration 59

        g01853873

        Typical example

        Water temperature regulator housing

        (1) Torque for the bolts that fasten the housing to the

        cylinder head ......................................22 N·m (16 lb ft)

        (2) Torque for the vent plug........... 22 N·m (16.22 lb ft)

        Illustration 61

        g01850741

        Tightening sequence

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        35

        Specifications Section

        Tighten the setscrews in the numerical sequence that

        is shown in illustration 61 to the following torque.

        ............................................................22 N·m (16 lb ft)

        (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

        i04117792

        bearing cap bolts.

        Cylinder Block

        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.

        3. Evenly tighten the main bearing cap bolts.

        Torque for the main bearing cap bolts. .............80 N·m

        (59 lb ft)

        4. After torquing the bolts for the main bearing caps,

        the bolts must be rotated for an additional 90

        degrees.

        Note: Ensure that the crankshaft can rotate freely.

        i04029133

        Crankshaft

        Illustration 62

        g01855114

        Cylinder block

        (1) Cylinder block

        (2) Cylinder bore....................105.000 to 105.025 mm

        (4.1338 to 4.1348 inch)

        (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)

        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

        ......50.292 to 50.343 mm (1.9800 to 1.9820 inch)

        Diameter of the bore in the cylinder block for the

        number 4 camshaft journal

        Illustration 63

        g01862538

        Typical example

        (1) Crankshaft gear

        (2) Crankshaft

        ......50.038 to 50.089 mm (1.9700 to 1.9720 inch)

        (3) Crankshaft thrust washers

        (4) Main bearings

        Maximum permissible temperature of the gear for

        installation on the crankshaft..............180 °C (356 °F)

        Bore in the cylinder block for the main bearings

        ......88.246 to 88.272 mm (3.4742 to 3.4753 inch)

        This document is printed from SPI². Not for RESALE


         

        36

        UENR0675

        Specifications Section

        The end play of a new crankshaft........ 0.1 to 0.41 mm

        (0.00394 to 0.01614 inch)

        Standard thickness of thrust washer

        .....................2.69 to 2.75 mm (0.1059 to 0.1083 inch)

        Oversize thickness of thrust washer

        ......................2.89 to 2.95 mm (0.1138 to 0.1161 inch)

        Illustration 64

        g01869273

        i03520221

        (4) Journal 1

        (5) Journal 2

        (6) Journal 3

        (7) Journal 4

        (8) Journal 5

        (9) Journal 6

        (10) Journal 7

        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)

        (6)

        (7)

        0.05 mm (0.0020 inch)

        0.1 mm (0.0039 inch)

        0.15 mm (0.0059 inch)

        0.1 mm (0.0039 inch)

        0.05 mm (0.0020 inch)

        Mounting

        You do not need to remove the engine oil pan in order

        to install the oil seal.

        Note: Some engines also have an oil seal that is

        installed in the flywheel housing. Refer to

        Specifications, “Flywheel Housing” for more

        information.

        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.

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        37

        Specifications Section

        The sequence for installationof the

        rear oil seal

        Illustration 66

        g02282353

        Typical example

        (1) Tighten the setscrews for the adapter to the

        following torque...................................40 N·m (30 lb ft)

        The setscrews must be tightened through an angle of

        120 degrees.

        (2) Tighten the bolts for the damper and pulley to the

        following torque.................................115 N·m (85 lb ft)

        Illustration 65

        g01863635

        Typical example

        (3) Vibration damper

        (4) Crankshaft pulley

        (5) Crankshaft adapter

        (11) (12) Torque for the fasteners.......15 N·m (11 lb ft)

        (1) (2) Torque for the fastener.............22 N·m (16 lb ft)

        Loosen fastener (11) and (12) by one complete turn.

        i05197127

        Tighten the fasteners in the sequence that is in

        illustration 65 . Torque for the fasteners ...........22 N·m

        (16 lb ft)

        Connecting Rod Bearing

        Journal

        The maximum out of concentricity between the

        crankshaft flange and the outside diameter of the rear

        seal for the crankshaft. ............0.4 mm (0.01575 inch)

        The original size of the connecting rod bearing journal

        on the crankshaft.......................71.970 to 71.990 mm

        (2.83346 to 2.83425 inch)

        i04067351

        Vibration Damper and Pulley

        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..................................37.962 to 38.038 mm

        (1.4946 to 1.4976 inch)

        This document is printed from SPI². Not for RESALE


         

        38

        UENR0675

        Specifications Section

        Radius of the fillet of the connecting rod bearing

        journals..........................................3.875 to 4.125 mm

        (0.15256 to 0.16240 inch)

        Clearance between the bearing shell and the main

        bearing journals.............................0.036 to 0.094 mm

        (0.00142 to 0.00370 inch)

        Surface finish of connecting rod bearing journals

        ...........................................................Ra 0.25 microns

        i04234795

        Connecting Rod

        Surface finish of radii ..........................Ra 0.4 microns

        i05197134

        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)

        Radius of the fillet of the main bearing journals

        .............3.875 to 4.125 mm (0.15256 to 0.16240 inch)

        Surface finish of bearing journals and crank pins

        ...........................................................Ra 0.25 microns

        Surface finish of radii ..........................Ra 0.4 microns

        Width of new main bearing journal where the thrust

        washer is installed .....................35.235 to 35.165 mm

        (1.3872 to 1.3844 inch)

        Illustration 67

        g01860862

        Typical example

        Width of new main bearing journal where the thrust

        washer is not installed ...................35.25 to 35.15 mm

        (1.38779 to 1.38386 inch)

        (1) The bearing shell for the connecting rod

        For the correct procedure to install the bearing shell

        for the connecting rod, refer to Disassembly and

        Assembly, “Pistons and Connecting Rods -

        Assemble”.

        The shell for the main bearings

        The shells for the main bearings are available for

        remachined journals which have the following

        oversize dimensions.

        Table 7

        Thickness of Connecting Rod

        Bearing at the Center

        1.994 to 2.000 mm

        (0.0785 to 0.0787 inch)

        Oversize bearing shell ........0.25 mm (0.010 inch)

        Oversize bearing shell ........0.50 mm (0.020 inch)

        Oversize bearing shell ........0.76 mm (0.030 inch)

        Thickness of Bearing Cap at

        the Center

        1.994 to 2.000 mm

        (0.0785 to 0.0787 inch)

        0.080 to 0.035 mm

        (0.00315 to 0.00138 inch)

        Bearing Clearance

        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)

        Table 8

        Oversize Connecting Rod Bearing

        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)

        0.25 mm (0.010 inch)

        0.51 mm (0.020 inch)

        0.76 mm (0.030 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)

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        39

        Specifications Section

        Illustration 68

        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

        Illustration 69

        g01860878

        Note: The day code is from the first day in the year.

        For example, “001”  will be the first day of the

        appropriate year.

        Typical example

        (3) Diameter of the finished bore for the piston pin

        .............39.738 to 39.723 mm (1.5645 to 1.5639 inch)

        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.

        (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.................................76.025 to 76.038 mm

        (2.99310 to 2.99362 inch)

        (2) Torque of the setscrews for the connecting rod

        ............................................................40 N·m (30 lb ft)

        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.

        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.

        Table 9

        Specificationsfor the Connecting Rod

        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).

        Length Of The Connect-

        Grade Letter    Color Code

        ing Rod

        161.107 to 161.140 mm

        (6.3428 to 6.3441 inch)

        B

        Blue

        i04939374

        Piston and Rings

        This document is printed from SPI². Not for RESALE


         

        40

        UENR0675

        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 70

        g03120776

        Typical example

        Note: Ensure that the ring end gaps of the piston

        rings are spaced 120 degrees from each other.

        (1) Top compression ring

        Piston

        The shape of the top compression ring

        ...............................................................Keystone

        Note: An arrow which is marked on the piston crown

        must be toward the front of the engine.

        Ring gap......................................0.25 to 0.35 mm

        (0.00984 to 0.01378 inch)

        Piston height above cylinder block.... 0.55 to 0.20 mm

        (0.02165 to 0.00787 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.

        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)

        (2) Intermediate compression ring

        The shape of the intermediate compression ring

        ...............Internal bevel in the bottom edge with a

        tapered face

        Piston pin

        Diameter of a new piston pin

        ......39.694 to 39.700 mm (1.5628 to 1.5630 inch)

        Width of intermediate compression ring

        ............2.47 to 2.495 mm (0.0972 to 0.0982 inch)

        i03520280

        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)

        Piston Cooling Jet

        Ring gap......................................0.65 to 0.85 mm

        (0.0256 to 0.0335 inch)

        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.

        This document is printed from SPI². Not for RESALE


         

        UENR0675

        41

        Specifications Section

        3. The position of the rod (3) must be within

        dimension (C). Dimension (C) is 10 mm

        (0.39370 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.

        i03907005

        Accessory Drive

        (SAE  “B”  )

        Illustration 71

        g01352576

        (1) Installed piston cooling jets

        The valve must move freely. Torque for the bolt

        ................................................................9 N·m (7 lb ft)

        Piston Cooling Jet Alignment

        Illustration 73

        g02148374

        Typical example

        (1) Tighten allen head screws to the following torque.

        ............................................................22 N·m (16 lb ft)

        Illustration 72

        g01352578

        (2) Piston cooling jet

        (3) Rod

        (4) Cylinder block

        (2) Tighten the allen head screw to the following

        torque..................................................78 N·m (58 lb ft)

        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 58.5 mm (2.30315 inch) and

        dimension (B) is 13.5 mm (0.53150 inch).

        Dimension (A) and dimension (B) are tangential to

        the cylinder bore (4).

        This document is printed from SPI². Not for RESALE


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