Specifications

1104E Engine

R F ( Engine)

RH (Engine)

R K ( Engine)

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i01658146

ImportantSafetyInformation

Mostaccidentsthatinvolveproductoperation,maintenanceandrepairarecausedbyfailuretoobserve

basicsafetyrulesorprecautions.Anaccidentcanoftenbeavoidedbyrecognizingpotentiallyhazardous

situationsbeforeanaccidentoccurs.Apersonmustbealerttopotentialhazards.Thispersonshouldalso

havethenecessarytraining,skillsandtoolstoperformthesefunctionsproperly.

Improperoperation,lubrication,maintenanceorrepairofthisproductcanbedangerousand

couldresultininjuryordeath.

Donotoperateorperformanylubrication,maintenanceorrepaironthisproduct,untilyouhave

readandunderstoodtheoperation,lubrication,maintenanceandrepairinformation.

Safetyprecautionsandwarningsareprovidedinthismanualandontheproduct.Ifthesehazardwarnings

arenotheeded,bodilyinjuryordeathcouldoccurtoyouortootherpersons.

Thehazardsareidentifiedbythe“SafetyAlertSymbol”andfollowedbya“SignalWord”suchas

“DANGER”,“WARNING”or“CAUTION”.TheSafetyAlert“WARNING”labelisshownbelow.

Themeaningofthissafetyalertsymbolisasfollows:

Attention!BecomeAlert!YourSafetyisInvolved.

Themessagethatappearsunderthewarningexplainsthehazardandcanbeeitherwrittenorpictorially

presented.

Operationsthatmaycauseproductdamageareidentifiedby“NOTICE”labelsontheproductandin

thispublication.

Perkins cannot anticipa te e ver y p os sible c irc u mstance t hat m ight invol ve a pote n ti al hazard .

Thewarningsinthispublicationandontheproductare,therefore,notallinclusive.Ifatool,

proc edure, work me thod or ope rating technique tha t is not s pecific ally rec ommended by Perkins

isused,youmustsatisfyyourselfthatitissafeforyouandforothers.Youshouldalsoensurethat

theproductwillnotbedamagedorbemadeunsafebytheoperation,lubrication,maintenanceor

repairproceduresthatyouchoose.

Theinformation,specifications,andillustrationsinthispublicationareonthebasisofinformationthat

wasavailableatthetimethatthepublicationwaswritten.Thespecifications,torques,pressures,

measurements,adjustments,illustrations,andotheritemscanchangeatanytime.Thesechangescan

affecttheservicethatisgiventotheproduct.Obtainthecompleteandmostcurrentinformationbeforeyou

s t ar t any jo b . Perkins dea le rs hav e t he m os t c ur r en t i nfo rm ati on a va il abl e.

When replacement parts are required for this

product Perkinsre comme nds usi ng Perkins

re pl ace ment parts or parts w ith equiva lent

specificationsincluding,butnotlimitedto,  phys-

icaldimensions,type,strengthandmaterial.

Failuretoheedthiswarningcanleadtoprema-

turefailures,productdamage,personalinjuryor

death.

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SENR9976

3

Table of  Contents

Table of Contents

Specifications Section

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

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

Fuel Injection Pump  .............................................   4

Fuel Injectors  .......................................................    5

Fuel Transfer Pump  .............................................   6

Lifter Group ...........................................................   6

Rocker Shaft  ........................................................   6

Valve Mechanism Cover  ......................................   7

Cylinder Head Valves ...........................................    7

Cylinder Head  ......................................................   9

Turbocharger  .......................................................  10

Exhaust Manifold  .................................................  11

Camshaft  .............................................................  11

Camshaft Bearings  ..............................................  12

Engine Oil Filter  ...................................................  12

Engine Oil Pump  .................................................. 13

Engine Oil Pressure  ............................................. 15

Engine Oil Bypass Valve  ...................................... 15

Engine Oil Pan  ..................................................... 16

Crankcase Breather  ............................................. 18

Water Temperature Regulator and Housing .........  18

Water Pump  ......................................................... 19

Cylinder Block  ...................................................... 20

Crankshaft  ...........................................................  21

Crankshaft Seals  .................................................  23

Connecting Rod Bearing Journal  ......................... 24

Main Bearing Journal ............................................ 24

Connecting Rod  ................................................... 25

Piston and Rings  .................................................. 26

Piston Cooling Jet ................................................. 27

Front Housing and Covers  ................................... 28

Gear Group (Front) ............................................... 29

Flywheel  ............................................................... 30

Flywheel Housing  ................................................  31

Crankshaft Pulley  ................................................. 31

Fan Drive  .............................................................  31

Engine Lifting Bracket ........................................... 32

Alternator  .............................................................  32

Starter Motor  ........................................................ 33

Coolant Temperature Sensor  ............................... 34

Engine Oil Pressure Sensor .................................  35

Boost Pressure Sensor ......................................... 35

Inlet Manifold Temperature Sensor ....................... 36

Speed/Timing Sensor  ..........................................  36

Voltage Load Protection Module ........................... 37

Electronic Control Module ..................................... 37

Glow Plugs  ........................................................... 37

Index Section

Index .....................................................................  38

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4

SENR9976

Specifications Section

Specifications Section

Engine Design

When the camshaft is  viewed from the front of

the engine, the camshaft rotates in  the following

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

i02242466

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.

Four Cylinder Engine

i01914111

Fuel Injection Lines

g00984281

Illustration 1

Cylinder and valve location

(A) Inlet valve

(B) Exhaust valve

g00923498

Illustration 2

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

Stroke ......................................  127 mm (5.000 inch)

A typical fuel line

(1)  Tighten

the union nuts for the fuel injector to the

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

Displacement ...................................... 4.4 L (269 in )

3

Note: Tighten the union nuts at  the fuel injection

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

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

Compression ratio

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

i02242475

Fuel Injection Pump

Naturally aspirated engines .................... 19.25:1

Turbocharged engines ............................ 18.23:1

Bosch VP30

Number of cylinders ................................................ 4

Valves per cylinder .................................................. 2

Valve lash

Note: Parts that are inside of the fuel injection pump

are only serviceable by an authorized Bosch dealer.

Please consult your parts book for availability of parts

on the outside of the pump that are not related to the

settings of the fuel pump and for  the possibility of

remanufacturing options.

Inlet valve .........................  0.20 mm (0.008 inch)

Exhaust valve ...................  0.45 mm (0.018 inch)

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

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SENR9976

5

Specifications Section

i02207945

Fuel Injectors

g00925395

Illustration 3

(1)  O-ring

Note: Lubricate the O-ring with  clean engine oil

before installing the fuel injection pump in the timing

case.

g00908211

Illustration 5

Fuel injector clamp

(2)  Locking screw

(1)  Tighten the bolt in the clamp for the fuel injector

to the following torque. .............  35 N·m (26 lb ft)

Unlocked pump shaft

Tighten the locking screw when the spacer  is

The fuel injector should be tested at the pressure in

Table 1.

installed to the following torque. .. 12 N·m (9 lb ft)

Locked pump shaft

Leakage in 10 seconds ................................. 0 drops

Tighten the locking screw when the spacer is not

installed to the following torque. .............. 31 N·m

(23 lb ft)

Table 1

Service setting for the  Fuel Injector

Injection Pressure

(3)  Spacer

29.4 + 0.8  MPa (4264 + 116  psi)

g00925394

Illustration 4

(4)  Tighten the bolt for the support bracket to the

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

Note: Ensure that force is not  applied to the fuel

injection pump when you are tightening the bolt for

the support bracket.

Tighten the three mounting bolts for the fuel injection

pump to the following torque. .......... 25 N·m (18 lb ft)

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6

SENR9976

Specifications Section

i01957629

i01714153

Fuel Transfer Pump

Lifter Group

g00629433

Illustration 7

(1)  Diameter of the lifter body .... 18.99 to 19.01 mm

(0.7475 to 0.7485 inch)

Clearance of  the lifter in the  cylinder block

bore ........... 0.04 to 0.09 mm (0.0015 to 0.0037 inch)

i02242607

Rocker Shaft

g00986823

Illustration 6

(1)  Retaining bolts

(2)  Clip

(3)  Spacer

(4)  Fuel transfer pump

Type .......................... 12 or 24 volt electric motor

(5)  Fuel filter element

(6)  O ring

g00985174

Illustration 8

The rocker shaft

(7)  Fuel filter bowl

Note: Tighten the fuel filter bowl by hand. Rotate the

Note: In order to install the rocker shaft assembly,

the tool 27610227 Spacing Tool is required.

bowl 1/8 of a turn more by hand.

(1)  Snap ring

(2)  Washer

(3)  Rocker arm

(4)  Rocker arm bore

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SENR9976

7

Specifications Section

Diameter of the  rocker arm bore  for the

i01958092

bushing .................................  25.01 to 25.05 mm

(0.9847 to 0.9862 inch)

Cylinder Head Valves

Rocker arm bushing

Clearance between the rocker arm bushing and

the rocker shaft ......................... 0.03 to 0.09 mm

(0.0010 to 0.0035 inch)

Maximum permissible clearance  between

the rocker arm  bushing and the  rocker

shaft .................................. 0.17 mm (0.007 inch)

(5)  Spring

Note: Install the longest screw at  the front of the

rocker shaft assembly.

(6)  Tighten the screws evenly. Begin in the center

and work toward the outside. Tighten the screws

to the following torque. .............  35 N·m (26 lb ft)

(7)  Rocker shaft

Diameter of the rocker shaft .. 24.96 to 24.99 mm

(0.9827 to 0.9839 inch)

g00294082

Illustration 10

Cross section of cylinder head

(8)  In order to install the rocker shaft  assembly,

ensure that the machined square is to the top

of the rocker shaft.

(1)  Valve spring

(9)  Locknut

Naturally aspirated engines

The installed  length of  the  valve

Torque for the locknut ...............  27 N·m (20 lb ft)

springs ..............................  33.5 mm (1.318 inch)

i01776124

The load for the installed valve springs ..... 254 N

(57.1 lb)

Valve Mechanism Cover

Turbocharged engines

The installed  length of  the  valve

springs ..............................  34.5 mm (1.358 inch)

The load for the installed valve spring ....... 229 N

(51.4 lb)

(2)  Valve spring recess

(3)  The finished valve guides

Inside  diameter of  valve

guide ..................................... 9.000 to 9.022 mm

(0.3543 to 0.3552 inch)

Outside diameter  of the exhaust valve

guide ................................. 13.034 to 13.047 mm

(0.5131 to 0.5137 inch)

g00908011

Illustration 9

Outside diameter  of the  inlet valve

guide ................................. 13.034 to 13.047 mm

(0.5131 to 0.5137 inch)

Tighten the bolts for the valve  mechanism cover

in the sequence that  is shown to the following

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

Interference fit of  valve guide in cylinder

head ...................................... 0.007 to 0.047 mm

(0.0003 to 0.0019 inch)

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8

SENR9976

Specifications Section

Length of Valve guide  .......... 51.00 to 51.50 mm

(2.018 to 2.027 inch)

Service limit ............................  1.09 mm (0.043 inch)

Turbocharged engines .................... 1.58 to 1.84 mm

(0.062 to 0.072 inch)

Projection of the valve guide above the  valve

spring recess (2) ................... 12.35 to 12.65 mm

(0.486 to 0.498 inch)

Service limit ..........................  2.09 mm (0.0823 inch)

(6)  Exhaust valve face angle from the vertical axis

Note: When new valve guides are installed,  new

valves and new valve seat inserts must be installed.

The valve guides and the  valve seat inserts are

supplied as partially finished parts. The unfinished

valve guides and unfinished valve seat inserts are

installed in the cylinder head. The guides and inserts

are then cut and reamed in one operation with special

tooling. This procedure ensures the concentricity

of the valve seat  to the valve guide in order  to

create a seal that is tight. Refer to the Disassembly

and Assembly Manual for removal and installation

procedures.

Valve face angle ...............................  30 degrees

Valve seat angle ...............................  30 degrees

(7)  Diameter of  the  exhaust

valve head ............................  41.51 to 41.75 mm

(1.634 to 1.643 inch)

(8)  Diameter of  the head  of the  inlet

valve ...  46.20 to 46.45 mm (1.818 to 1.828 inch)

(9)  Angle of the inlet valve face from the vertical axis

(4)  Exhaust valve

Valve face angle ...............................  30 degrees

Valve seat angle ...............................  30 degrees

Diameter of  the  exhaust valve

stem ...................................... 8.938 to 8.960 mm

(0.3519 to 0.3528 inch)

The valve lash is the following value when the engine

is cold:

Clearance  of  valve in  valve

Inlet valves ........................ 0.20 mm (0.008 inch)

Exhaust valves .................  0.45 mm (0.018 inch)

guide ....... 0.040 to 0.840 mm (0.0016 to 0.033 inch)

Overall  length of  the  exhaust

valve .....  128.92 to 129.37 mm (5.075 to 5.093 inch)

The face of the exhaust valve is recessed below the

cylinder head by the following amount.

Naturally aspirated engines ............  0.53 to 0.81 mm

(0.021 to 0.032 inch)

Service limit ............................  1.06 mm (0.042 inch)

Turbocharged engines .................... 1.53 to 1.81 mm

(0.060 to 0.071 inch)

Service limit ........................... 2.06 mm (0.0811 inch)

(5)  Inlet valve

g00809016

Illustration 11

Recess for the valve seat insert

Diameter  of the  inlet  valve

(10)  Machine the recess in the head for valve seat

inserts to the following dimensions.

stem ...................................... 8.953 to 8.975 mm

(0.3525 to 0.3533 inch)

Recess for Inlet  Valve Seat for Naturally

Aspirated Engines

Clearance  of valve  in  valve

guide .. 0.025 to 0.069 mm (0.001 to 0.0027 inch)

(A) .. 9.910 to 10.040 mm (0.3901 to 0.3952 inch)

(B) ..................................... 47.820 to 47.845 mm

(1.8826 to 1.8836 inch)

Overall  length  of  the inlet

valve .....  128.92 to 129.37 mm (5.075 to 5.093 inch)

(C) Maximum radius .........  0.38 mm (0.015 inch)

The face of the inlet valve  is recessed below the

cylinder head by the following amount.

Recess for Exhaust Valve Seat  for Naturally

Aspirated Engines

(A) .. 9.910 to 10.040 mm (0.3901 to 0.3952 inch)

Naturally aspirated engines ............  0.58 to 0.84 mm

(0.023 to 0.033 inch)

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SENR9976

9

Specifications Section

(B) ..................................... 42.420 to 42.445 mm

(1.6701 to 1.6711 inch)

(C) Maximum radius .........  0.38 mm (0.015 inch)

Recess for Inlet Valve Seat for Turbocharged

Engines

(A) ...................................... 10.910 to 11.040 mm

(0.4295 to 0.4346 inch)

(B) ..................................... 47.820 to 47.845 mm

(1.8826 to 1.8836 inch)

(C) Maximum radius .........  0.38 mm (0.015 inch)

Recess for Exhaust Valve Seat for Turbocharged

Engines

(A) ...................................... 10.910 to 11.040 mm

(0.4295 to 0.4346 inch)

(B) ..................................... 42.420 to 42.445 mm

(1.6700 to 1.6710 inch)

(C) Maximum radius .........  0.38 mm (0.015 inch)

i01899306

g00987480

Illustration 12

Cylinder Head

The tightening sequence

Lubricate the threads and the underside of the head

bolts with clean engine oil.

The maximum distortion of the cylinder head is given

in table 3.

Tighten the bolts in the sequence that is shown in

Illustrations to the following torque. ......... 50 N·m

(37 lb ft)

Table 2

Tighten the bolts  again to the  following

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

Required Tools

Part

Part Description

Qty

Number

21825607

Angle gauge

1

The cylinder head bolts are two different lengths. The

following information provides the proper torque for

the cylinder head bolts.

g00905621

Illustration 13

The head bolts require an  additional torque turn

procedure. The numbers (1, 3, 4)  are three long

cylinder head bolts. All the other bolts are short bolts.

The tightening sequence is shown in the Illustrations .

Place the angle gauge on the top of each bolt

head. Tighten the short bolts to the additional

amount. ........................................... 225 degrees

Place the angle gauge on the top of each bolt

head. Tighten the long bolts for the  additional

amount. ........................................... 270 degrees

Thickness of the cylinder head .. 117.95 to 118.05 mm

(4.643 to 4.647 inch)

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10

SENR9976

Specifications Section

Minimum thickness of cylinder head ........ 117.20 mm

(4.614 inch)

(1)  Actuator rod

(2)  Actuator

Note: The maximum distortion of the cylinder head

is given in table 3.

(3)  Turbocharger

(4)  Tighten the nuts to the following torque. .. 47 N·m

(34 lb ft)

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

(80 lb in)

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

(16 lb ft)

The maximum  test pressure for the  waste

gate ................................................. 205 kPa (30 psi)

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

(0.0394 inch)

g01006568

Illustration 14

Four Cylinder Engine

Table 3

Maximum Permissible

Table 4

Dimension

Distortion

The part number  for

the turbocharger

The pressure for  the

waste gate

Width (A)

Length (B)

0.03 mm (0.0018 inch)

0.05 mm (0.0019 inch)

0.05 mm (0.0019 inch)

2674A200

2674A201

2674A202

2674A209

2674A211

2674A215

2674A223

2674A224

2674A225

2674A226

2674A227

100  ±  5 kPa

(14.5040 ± 0.7252 psi)

Diagonal Line (C)

110  ±  5  kPa

(15.9544 ± 0.7252 psi)

i02242611

128  ±  5 kPa

Turbocharger

(18.5651 ± 0.7252 psi)

100  ±  5 kPa

(14.5040 ± 0.7252 psi)

128  ±  5 kPa

(18.5651 ± 0.7252 psi)

128  ±  5 kPa

(18.5651 ± 0.7252 psi)

136  ±  5 kPa

(19.7254 ± 0.7252 psi)

136  ±  5 kPa

(19.7254 ± 0.7252 psi)

136  ±  5 kPa

(19.7254 ± 0.7252 psi)

100  ±  5 kPa

(14.5040 ± 0.7252 psi)

128  ±  5 kPa

(18.5651 ± 0.7252 psi)

g00991357

Illustration 15

Typical turbocharger

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SENR9976

11

Specifications Section

i02242613

Exhaust Manifold

Four Cylinder Engine

g00976195

Illustration 18

Typical camshaft

(2)  Bolt

Tighten the bolt to the following torque. ... 95 N·m

(70 lb ft)

g00907527

Illustration 16

Tightening sequence

(3)  Camshaft thrust washer

Thickness of the thrust washer .. 5.49 to 5.54 mm

(0.216 to 0.218 inch)

Note: The exhaust manifold must  be aligned to

the cylinder head. Refer to the  Disassembly and

Assembly manual.

Depth of the recess in the cylinder block for the

thrust washer ............................ 5.54 to 5.64 mm

(0.218 to 0.222 inch)

Tighten the exhaust manifold bolts in the sequence

that is shown in  illustration 16 to the following

torque. ............................................. 33 N·m (24 lb ft)

Tolerance of the thrust washer in cylinder block

front face ........................... −0.154 to −0.003 mm

(−0.0006 to −0.0001 inch)

i02242614

(4)  The diameters of the camshaft journals are given

in the following tables.

Camshaft

Table 5

1104 Diameters of Camshaft  Journals

Camshaft Journals

Standard Diameter

50.71  to 50.74  mm

1

(1.9965 to 1.9975 inch)

50.46  to 50.48  mm

2

3

(1.9865 to 1.9875 inch)

49.95  to 49.98  mm

(1.9665 to 1.9675 inch)

Maximum wear on the camshaft journals ...  0.05 mm

(0.0021 inch)

g00987750

Illustration 17

Checking the end play of the camshaft

(1)  End play of a new camshaft ..... 0.10 to 0.55 mm

(0.004 to 0.022 inch)

Maximum permissible  end play of  a worn

camshaft .................................  0.60 mm (0.023 inch)

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12

SENR9976

Specifications Section

i02242618

Camshaft Bearings

g00629702

Illustration 19

(5)  Camshaft lobe lift

Naturally aspirated

Inlet lobe ............................... 7.382 to 7.482 mm

g00997348

Illustration 20

A typical four cylinder engine

(0.2906 to 0.2946 inch)

Exhaust lobe ......................... 7.404 to 7.504 mm

(0.2914 to 0.2954 inch)

(1)  Camshaft bearing

Turbocharged

Inlet lobe ............................... 7.031 to 7.130 mm

The diameter for  the installed camshaft

bearing .............................. 50.790 to 50.850 mm

(1.9996 to 2.0020 inch)

(0.2768 to 0.2807 inch)

Exhaust lobe ......................... 7.963 to 8.063 mm

(0.3135 to 0.3174 inch)

i01958095

Engine Oil Filter

(6)  Camshaft lobe height

(7)  Base circle

To determine the lobe lift, use the  procedure that

follows:

Spin-on Oil Filter

1.  Measure the camshaft lobe height (6).

2.  Measure the base circle (7).

3.  Subtract the base circle that is found in Step 2

from the camshaft lobe height that is found in Step

1. The difference is the actual camshaft lobe lift.

Maximum permissible clearance  between the

actual lobe lift and the specified lobe  lift of a new

camshaft .................................  0.05 mm (0.021 inch)

g00915984

Illustration 21

(1)  Seal

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SENR9976

13

Specifications Section

Note: Lubricate the top of the seal with clean engine

oil before installation.

Type ............................................................. Full flow

Pressure to  open engine oil  filter bypass

valve .............................  80 to 120 kPa (12 to 18 psi)

Replaceable Element

g00989248

Illustration 23

The oil pump for the balancer

g00915985

(1)  Clearance of the  outer rotor  to the

Illustration 22

body .. 0.130 to 0.24 mm (0.0050 to 0.0094 inch)

Note: Lubricate the seal on the oil filter housing with

clean engine oil before installation.

Type ............................................................. Full flow

Pressure to  open engine oil  filter bypass

valve ...........................  130 to 170 kPa (19 to 25 psi)

(1)  Tighten the oil filter housing to the oil filter base

to the following torque. .............  25 N·m (18 lb ft)

(2)  Tighten the drain plug on the oil filter housing to

the following torque. ...................  12 N·m (9 lb ft)

Note: The horizontal filter as a drain plug in the filter

head

(3)  Recess for 1/2 inch square drive

i02242623

Engine Oil Pump

g00989236

Illustration 24

Inner rotor

(2)  Clearance of  inner rotor  to outer

rotor ......................................  0.050 to 0.200 mm

(0.0020 to 0.0079 inch)

Engines with Balancer Group

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

Number of lobes

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

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

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14

SENR9976

Specifications Section

g00989519

Illustration 27

Idler gear and pump gear

Note: Replace the idler gear bolt (5) and the nut for

the oil pump gear (6).

(5)  Tighten the idler gear bolt  to the following

torque. ......................................  26 N·m (19 lb ft)

g00989217

Illustration 25

The end play for the  rotor

Note: Set the engine to the TC  position. Refer to

Testing and Adjusting , “Finding Top Center Position

for No. 1 Piston”. Install the balancer. Refer to the

Disassembly and Assembly manual. Install the gear

for the oil pump and tighten the nut (6).

(3)  End play of rotor assembly

Inner rotor .................................. 0.04 to 0.11 mm

(0.0016 to 0.0043 inch)

Outer rotor ................................  0.04 to 0.00 mm

(0.0016 to 0.0043 inch)

(6)  Tighten the nut to the following torque. .... 95 N·m

(70 lb ft)

Tighten the bolts that hold the balancer to the cylinder

block to the following torque. ..........  54 N·m (40 lb ft)

Engines without Balancer Group

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

Number of lobes

Inner rotor ......................................................... 5

Outer rotor ........................................................  6

g00938724

Illustration 26

The end cover

(4)  Torque for cover bolts for oil pump .......... 26 N·m

(19 lb ft)

g00938064

Illustration 28

The oil pump

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SENR9976

15

Specifications Section

(1)  Clearance of  the outer rotor  to the

body ...................................... 0.152 to 0.330 mm

(0.0059 to 0.0129 inch)

i02242638

Engine Oil Bypass Valve

Installed in the Oil Pump

g00938061

Illustration 29

Checking the clearance

(2)  Clearance of  inner rotor  to outer

rotor ......................................  0.040 to 0.127 mm

(0.0015 to 0.0050 inch)

g00919893

Illustration 31

Typical engine oil pump

g00938799

Illustration 30

Checking the end play

g00921377

Illustration 32

Relief valve and spring

(3)  End play of rotor assembly

(1)  Tighten the plug for the  relief valve to the

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

Inner rotor ............................. 0.038 to 0.089 mm

(0.0014 to 0.0035 inch)

(2)  Plunger

Outer rotor ............................  0.025 to 0.076 mm

(0.0010 to 0.0029 inch)

Diameter of the plunger ..... 19.186 to 19.211 mm

(0.7554 to 0.7563 inch)

Tighten the bolts that hold the front cover of the oil

pump assembly to the following torque. ........ 26 N·m

(19 lb ft)

Clearance of plunger in bore .. 0.039 to 0.114 mm

(0.0015 to 0.0045 inch)

i01958104

Engine Oil Pressure

The minimum oil pressure at the maximum engine

speed and at normal operating temperature is the

following value. ............................... 300 kPa (43 psi)

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16

SENR9976

Specifications Section

Installed in the Balancer

i02242687

Engine Oil Pan

Front sealant

g00919890

Illustration 33

Plug

g00990254

Illustration 35

Applying sealant

(1)  Apply 1861108  Powerpart silicone rubber

sealant 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 35.

Rear sealant

g00921379

Illustration 34

The relief valve for the balancer

Note: Install the rear oil seal before sealant is applied

to the bridge.

(1)  Tighten the plug for  the relief valve to the

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

(2)  Plunger

Diameter of the plunger ........ 14.46 to 14.48 mm

(0.5692 to 0.5700 inch)

Clearance of  the  plunger in  the

bore ....  0.04 to 0.08 mm (0.0015 to 0.0031 inch)

g00990255

Illustration 36

Applying sealant

(2)  Apply 1861108  Powerpart silicone rubber

sealant to the bridge. The  sealant must not

protrude more than 5 mm (0.1969 inch) above

the bridge.

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SENR9976

17

Specifications Section

Note: The oil pan must be installed within 10 minutes

The cast iron oil pan

of applying the sealant.

g00990249

Illustration 38

g00990252

Illustration 37

Typical oil pan

The cast iron oil pan

Note: The rear face of the cast iron oil pan (5) must

(3)  Tighten the four front bolts  to the following

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

be aligned to the rear face of the cylinder block.

(5)  The maximum allowed value of the rear face

misalignment.  .................  0.1 mm (0.0039 inch )

(4)  Tighten the remaining bolts to the  following

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

(6)  Bolt

Tighten the front four bolts. Refer to illustration

37. Tighten the remaining bolts and the nuts that

fasten the engine oil pan to the cylinder block to

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

Note: The sealant is applied to new bolts. In order

to reuse the bolts,  apply 21820117  Powerpart

threadlock and nutlock to the first three threads of

the used bolts.

Note: The engine may be equipped with an oil drain

plug or the engine may be  equipped with a drain

valve.

(7)  Drain plug

Tighten the drain plug for the engine oil pan to

the following torque. ...... 34 ± 5 N·m (25 ± 4 lb ft)

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18

SENR9976

Specifications Section

(3)  Screws

Tighten the screws for the  cover plate with a

plastic valve mechanism cover to the following

torque. ..................................  1.3 N·m (11.5 lb in)

Tighten the screws for the  cover plate with a

metal valve mechanism cover to the following

torque. ..................................... 1.8 N·m (16 lb in)

(4)  Diaphragm

(5)  Cap

(6)  Spring

g00990677

Illustration 39

The drain valve

(8)  Drain valve

Tighten the drain valve into the adapter to the

following torque. ............ 34 ± 5 N·m (25 ± 4 lb ft)

(9)  Adapter

Tighten the adapter into the engine oil pan to the

following torque. ............ 34 ± 5 N·m (25 ± 4 lb ft)

i02242678

Crankcase Breather

g00926200

Illustration 41

(7)  O-ring

Note: Apply 21820221 Powerpart red rubber grease

to the O-ring before installing the breather pipe in the

valve mechanism cover.

(8)  Tighten the bolts that secure the breather pipe to

the cylinder head to the following torque. .. 9 N·m

(80 lb in)

i01914256

Water Temperature Regulator

and Housing

g00926199

Illustration 40

Tighten the bolts (not shown) that fasten the housing

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

Breather valve

(1)  Plastic cover

(2)  Cover plate

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SENR9976

19

Specifications Section

i01904883

Water Pump

g00997234

Illustration 42

O ring

Note: Apply 21820221 Powerpart red rubber grease

to the O-ring (1) in order  to install the thermostat

housing.

g00915951

Illustration 44

Tightening sequence

Water Temperature Regulator

Note: Apply 21820117  Powerpart  threadlock

nutlock to the first three threads of the bolts before

installation.

Tighten the nine bolts that secure the water pump to

the front housing in the numerical sequence that is

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

Note: Refer to the  Disassembly and Assembly

manual in order to service the water pump.

g00906121

Illustration 43

A typical water temperature regulator

Opening temperature ............................ 79 ° to 84 °C

(174 ° to 151 °F)

Full opening temperature ................... 93 °C (199 °F)

Minimum stroke at full open temperature ......  10 mm

(0.3937 inch)

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20

SENR9976

Specifications Section

i02242732

Diameter of  the bore in  the cylinder

block for  the number  3 camshaft

Cylinder Block

journal ............................... 50.038 to 50.089 mm

(1.9700 to 1.9720 inch)

(4)  Main bearings for the four cylinder engine

Four Cylinder Engine

Bore in  the cylinder block for  the main

bearings ............................ 80.416 to 80.442 mm

(3.1660 to 3.1670 inch)

(5)  Main bearing cap bolts for the four  cylinder

engine

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.

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. .... 245 N·m

(180 lb ft)

g00924764

Illustration 45

Cylinder block

(1)  Cylinder block

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

(4.1338 to 4.1348 inch)

The  first  oversize  bore

diameter .................................. 105.5 to 105.525 mm

(4.1535 to 4.1545 inch)

The  second  oversize bore

diameter .............................. 106.000 to 106.025 mm

(4.1732 to 4.1742 inch)

g00938203

The maximum permissible wear for the cylinder bore

................................. 0 to 0.15 mm (0 to 0.0059 inch)

Illustration 46

Use the following procedure in order to install  the

Allen head bolts for the bridge.

(3)  Camshaft bearings for the four cylinder engine

Diameter of  the bore in  the cylinder

block for  the number  1 camshaft

bearing .............................. 55.563 to 55.593 mm

(2.1875 to 2.1887 inch)

Note: Install the rear seal before sealant is applied.

1.  Use a straight edge in order to ensure that the

bridge is aligned with the rear face of the 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)

2.  Tighten the Allen head bolts (6) for the bridge.

Torque for the Allen head bolts ..  16 N·m (12 lb ft)

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SENR9976

21

Specifications Section

3.  When the bridge is installed on the cylinder block,

apply 21826038 POWERPART Silicon Adhesive

into groove (7) at each end of the bridge. Apply the

sealant into the groove until the sealant is forced

through the bottom end of the groove in the bridge.

Note: The timing mark  is toward the outside of

the crankshaft when the gear  is installed on the

crankshaft.

Note: All  new turbocharged engines  and

turbocharged aftercooled engines have crankshafts

that are nitrocarburised. The crankshaft can  also

be nitrided for  20 hours, if the nitrocarburised

process is not available.  After a crankshaft has

been machined, the crankshaft must be rehardened.

Inspect the crankshaft for cracks before machining

and after machining. Naturally aspirated engines

have induction hardened crankshafts.

Total height of the cylinder block between the top and

the bottom faces. ................  441.173 to 441.274 mm

(17.3689 to 17.3729 inch)

i02242736

Crankshaft

g00992214

Illustration 47

The crankshaft for the four cylinder engine

(1)  Crankshaft for the four cylinder engine

The maximum end play of the crankshaft ... 0.51 mm

(0.0201 inch)

(2)  Thrust washers

Standard thickness ................... 2.26 to 2.31 mm

(0.089 to 0.091 inch)

Oversize thickness ...................  2.45 to 2.50 mm

(0.097 to 0.098 inch)

(3)  The crankshaft gear

Maximum permissible temperature of the gear for

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

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22

SENR9976

Specifications Section

g01017233

Illustration 48

The 1104 engine crankshaft

Note: Refer to illustration 48 in order to use table 6.

The four cylinder engine.

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SENR9976

23

Specifications Section

Table 6

The undersize  diameter of the  Crankshaft Journals

NUMBER

0.25 mm (0.010 inch)

0.51 mm (0.020 inch)

0.76 mm (0.030 inch)

75.909 mm (2.9885 inch) to

75.930 mm (2.9894 inch)

75.649 mm (2.9783 inch) to

75.670 mm (2.9791 inch)

75.399 mm (2.9685 inch) to

75.420 mm (2.9693 inch)

1

2

3

4

5

63.220 mm (2.4890 inch) to

63.240 mm (2.4898 inch)

62.960 mm (2.4787 inch) to

62.982 mm (2.4796 inch)

62.708 mm (2.4688 inch) to

62.728 mm (2.4696 inch)

39.47  mm

N/A

N/A

N/A

N/A

N/A

N/A

(1.5539 inch)maximum

37.44  mm

(1.4740 inch)maximum

44.68  mm

(1.7591 inch)maximum

40.55  mm

6

7

8

N/A

N/A

N/A

N/A

N/A

N/A

(1.5965 inch)maximum

Do not machine this diameter.

3.68 mm (0.1449  inch) to

3.96 mm (0.1559 inch)

Refer to table 7 for  the maximum run out of the

crankshaft journals.

i01958114

Crankshaft Seals

The maximum difference in value  between one

crankshaft journal and the next crankshaft journal

............................................... 0.10 mm (0.0039 inch)

Table 7

Journal

(1)

Excessive run out

Mounting

(2)

0.08 mm (0.0031 inch)

0.15 mm (0.0059 inch)

0.08 mm (0.0031 inch)

Mounting

(3)

(4)

(5)

Refer to the Specifications Module, “Connecting Rod

Bearing Journal” topic for more information on the

connecting rod bearing journals and connecting rod

bearings.

g00915078

Illustration 49

(1)  Crankshaft

(2)  Plastic sleeve

(3)  Crankshaft seal

(4)  Alignment tool

Refer to the Specifications Module, “Main Bearing

Journal” topic for information on the main bearing

journals and for information on the main bearings.

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24

SENR9976

Specifications Section

i01958141

Main Bearing Journal

Refer to the Specifications module,  “Crankshaft”

topic for information on the undersize main bearing

journals, and information on the width of main bearing

journals.

The original  size of  the main  bearing

journal .....................................  76.159 to 76.180 mm

(2.9984 to 2.9992 inch)

Maximum permissible wear of the  main bearing

journals ...............................  0.040 mm (0.0016 inch)

Radius of  the fillet  of the main  bearing

journals .....  3.68 to 3.69 mm (0.1448 to 0.1452 inch)

Surface finish of bearing journals, crank pins and

radii ................................... 0.4 microns (16 µ inches)

g00915076

Illustration 50

(5)  Tighten bolts 1, 2, 3, 4, 5, 6, 7,  and 10 in the

sequence that is shown in Illustration 50 to the

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

The shell for the main bearings

The shells for the  main bearings are available

for remachined journals which have the  following

undersize dimensions.

Remove the alignment tool.

Tighten bolts 8 and 9 in the sequence that is shown

in Illustration 50 to the following torque. ........ 22 N·m

(16 lb ft)

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

Undersize bearing shell .... 0.51 mm (0.020 inch)

Undersize bearing shell .... 0.75 mm (0.030 inch)

i01958137

Connecting Rod  Bearing

Journal

Thickness at center of the shells .. 2.083 to 2.089 mm

(0.0820 to 0.0823 inch)

Width of the main bearing shells .. 31.62 to 31.88 mm

(1.244 to 1.255 inch)

Clearance between the bearing shell and the main

bearing journals ........................... 0.057 to 0.117 mm

(0.0022 to 0.0046 inch)

Refer to the Specifications Module, “Crankshaft” topic

for information on the undersize crankshaft journals.

The original size of  the connecting rod bearing

journal ... 63.47 to 63.49 mm (2.4988 to 2.4996 inch)

Maximum permissible wear of the connecting rod

bearing journals ....................  0.04 mm (0.0016 inch)

Width of  the connecting  rod bearing

journals .....  40.35 to 40.42 mm (1.589 to 1.591 inch)

Radius of the fillet of the  connecting rod bearing

journals .........  3.68 to 3.96 mm (0.145 to 0.156 inch)

Surface finish of connecting rod bearing journals and

radii ................................. Ra 0.4 microns (16 µ inch)

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SENR9976

25

Specifications Section

i01958156

Connecting Rod

g00995584

Illustration 52

Alignment of the bearing shell

Note: The bearing shell  for the connecting rod

must be aligned equally  from both ends of the

connecting rod. Refer to (A) in figure 52. Refer to the

Disassembly and assembly manual for information

on the alignment tool.

Table 8

Bearing Width for  the

Connecting Rod

31.62 to  31.88 mm

(1.245 to 1.255 inch)

g00907738

Illustration 51

Bearing Width for  the

Connecting Rod Cap

31.55 to  31.88 mm

The mating surfaces of  the connecting rod are

produced by hydraulically fracturing  the forged

connecting rod.

(1.2405 to 1.255 inch)

Thickness of Connecting

Rod Bearing  at the

Center

1.835 to  1.842 mm

(0.0723 to 0.0725 inch)

(1)  Tighten the torx screws for the connecting rod to

the following torque. .................  18 N·m (13 lb ft)

Thickness of Connecting

Rod Bearing for the Cap

at the  Center

1.835 to  1.842 mm

(0.0722 to 0.0725 inch)

Tighten the torx screws for the connecting rod again

to the following torque. .................... 70 N·m (52 lb ft)

0.030 to  0.081 mm

Bearing Clearance

(0.0012 to 0.0032 inch)

Tighten the torx screws for the connecting rod  for

an additional 120 degrees.  The torx screws for

the connecting rod (1) must be replaced after this

procedure.

Table 9

Undersized Connecting Rod Bearing

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).

0.25 mm  (0.010 inch)

0.51 mm  (0.020 inch)

0.76 mm  (0.030 inch)

(2)  The bearing shell for the connecting rod

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26

SENR9976

Specifications Section

Table 10

Length Grades for Connecting  Rods

Grade Letter    Color Code               Length (Y)

165.728 to 165.761 mm

(6.5247 to 6.5260 inch)

F

G

H

J

Red

Orange

White

Green

Purple

Blue

165.682 to 165.715 mm

(6.5229 to 6.5242 inch)

165.637 to 165.670 mm

(6.5211 to 6.5224 inch)

165.591 to 165.624 mm

(6.5193 to 6.5206 inch)

165.545 to 165.578 mm

(6.5175 to 6.5188 inch)

K

L

165.499 to 165.532 mm

(6.5157 to 6.4961 inch)

i01958185

Piston and Rings

g00907744

Illustration 53

(3)  Diameter of the parent bore  for the piston

pin ....... 43.01 to 43.04 mm (1.693 to 1.694 inch)

(4)  Distance between the  parent bores

........ 219.05 to 219.10 mm (8.624 to 8.626 inch)

(5)  Diameter for the parent bore for the connecting

rod bearing ...........................  67.21 to 67.22 mm

(2.6460 to 2.6465 inch)

g00888215

Illustration 55

A typical example of a piston and rings

(1)  Top compression ring

Naturally Aspirated

The shape  of the  top compression

ring ...................... Rectangular with a barrel face

Width of  the  top compression

ring ........ 2.475 to 2.49 mm (0.097 to 0.098 inch)

Clearance between the top compression ring and

the piston groove ........................ 0.09 to .15 mm

(0.0035 to 0.0059 inch)

g00915056

Illustration 54

Ring gap ...................................  0.30 to 0.55 mm

(0.0118 to 0.0216 inch)

Connecting rods are color coded. The color code

is a reference for the length (Y) of  the connecting

rod. Refer to table 10  for the different lengths of

connecting rods.

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SENR9976

27

Specifications Section

Turbocharged

The combustion bowl  re-entrant angle for the

turbocharged engine ............................... 80 degrees

The shape  of the  top compression

ring ........................... Keystone with a barrel face

The combustion bowl  re-entrant angle for the

Width of the top compression ring .......... tapered

naturally aspirated engine ....................... 70 degrees

Ring gap ...................................  0.30 to 0.55 mm

(0.0118 to 0.0216 inch)

Piston height above cylinder block .. 0.21 to 0.35 mm

(0.008 to 0.014 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 red identification

mark which 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 piston for the  naturally

aspirated engine .............................  2.58 to 2.60 mm

(0.1016 to 0.1024 inch)

Width of top groove in piston for the turbocharged

engine .......................................................... Tapered

(2)  Intermediate compression ring

Width of second groove in piston .... 2.54 to 2.56 mm

(0.1000 to 0.1008 inch)

The shape of the intermediate  compression

ring ......................................... Internal step in the

bottom edge with a tapered face

Width of third groove in piston ........  3.52 to 3.54 mm

(0.1386 to 0.1394 inch)

Width of  intermediate compression

Piston pin

ring .......... 2.47 to 2.49 mm (0.097 to 0.098 inch)

Diameter  of a  new  piston

Clearance between the intermediate compression

ring and the piston groove ........ 0.05 to 0.09 mm

(0.002 to 0.003 inch)

pin ..................................... 39.694 to 39.700 mm

(1.5628 to 1.5630 inch)

Diameter of  the bore  for the piston

pin ..................................... 39.703 to 39.709 mm

(1.5631 to 1.5633 inch)

Ring gap ...................................  0.70 to 0.95 mm

(0.0275 to 0.0374 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 green identification mark which must be on

the left of the ring end gap when the top piston ring is

installed on an upright piston.

i02242750

Piston Cooling Jet

(3)  Oil control ring

Shape  of  oil  control

ring ............... two-piece coil that is spring loaded

Width of oil control ring ............. 3.47 to 3.49 mm

(0.1366 to 0.1374 inch)

Clearance between the oil control ring and the

groove in the piston ..................  0.03 to 0.07 mm

(0.0011 to 0.0027 inch)

Ring gap ...................................  0.30 to 0.55 mm

(0.0118 to 0.0216 inch)

Note: 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.

g00942652

Illustration 56

(1) Installed piston cooling jets

The spring loaded valve must move freely. Tighten

the bolt to the following torque. ........... 9 N·m (7 lb ft)

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.

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28

SENR9976

Specifications Section

Piston Cooling Jet Alignment

g01006929

Illustration 57

(2) Piston cooling jet

(3) Rod

(4) Cylinder block

Use the following procedure in order to check  the

alignment of the piston cooling jet.

g00995663

Illustration 58

Alignment

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.

(1)  Tighten the bolts that fasten the front cover to the

front housing to the following torque. ....... 22 N·m

(16 lb ft)

2.  Dimension (A) is 55.25 mm (2.1752 inch) and

dimension (B) is 14 mm (0.5512 inch). Dimension

(A) and dimension (B) are tangent to the cylinder

bore (4).

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

dimension (C). Dimension  (C) is 14  mm

(0.5512 inch).

i01957083

Front Housing and Covers

The front housing must be aligned to the  cylinder

block face. ......................... + 0.05 to minus 0.05 mm

(+ 0.0020 to minus 0.0020 inch )

g00918672

Illustration 59

Front cover

(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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SENR9976

29

Specifications Section

i01794692

Bore diameter  of  the idler  gear

.............................................. 57.14 to 57.18 mm

(2.2495 to 2.2512 inch)

Gear Group (Front)

Bore diameter  of idler gear  with roller

bearings ................................ 72.35 to 72.36 mm

(2.8484 to 2.8488 inch)

Width of  idler gear and  split bearing

assembly ..............................  30.14 to 30.16 mm

(1.186 to 1.187 inch)

Inside diameter of idler  gear bearings with

flanges ..................................  50.78 to 50.80 mm

(1.999 to 2.000 inch)

Outside diameter  of  idler gear

hub .. 50.70 to 50.74 mm (1.9961 to 1.9976 inch)

Outside diameter of idler gear hub  with roller

bearings ............................ 49.975 to 49.988 mm

(1.9675 to 1.9680 inch)

Clearance of  idler gear  bearing on

hub ...... 0.04 to 0.10 mm (0.0016 to 0.0039 inch)

Idler gear end play .................... 0.10 to 0.20 mm

(0.004 to 0.008 inch)

g00918708

Idler  gear end  play with  roller

Illustration 60

bearings .................................... 0.10 to 0.75 mm

(0.0039 to 0.0295 inch)

(1)  Fuel injection pump drive gear

Tighten the bolts for the fuel injection pump drive

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

Maximum permissible end play ............  0.38 mm

(0.015 inch)

Bore diameter of the fuel injection pump drive

gear  .................................  29.995 to 30.021 mm

(1.1809 to 1.1819 inch)

Number of teeth .............................................. 73

Clearance between the fuel injection pump drive

gear and the drive gear hub .. 0.005 to 0.141 mm

(0.0002 to 0.0060 inch)

Number of teeth .............................................. 68

(2)  Camshaft gear

Tighten the bolt for the  camshaft gear to the

following torque. .......................  95 N·m (70 lb ft)

Bore diameter  of  the camshaft

gear ......................................  34.93 to 34.95 mm

(1.3750 to 1.3760 inch)

g00918756

Illustration 61

Outside diameter  of  camshaft

(4)  Crankshaft gear

hub .. 34.90 to 34.92 mm (1.3741 to 1.3747 inch)

Bore diameter  of crankshaft  gear

.......................................... 47.625 to 47.650 mm

(1.8750 to 1.8760 inch)

Clearance between camshaft gear and camshaft

hub .. 0.003 to 0.048 mm (0.0001 to 0.0019 inch)

Number of teeth .............................................. 68

(3)  Idler gear and hub

Outside  diameter of  crankshaft

hub .................................... 47.625 to 47.645 mm

(1.8750 to 1.8758 inch)

Tighten the bolts for the idler gear to the following

torque. ......................................  44 N·m (33 lb ft)

Clearance  of  gear  on

crankshaft ......................... −0.020 to +0.020 mm

(−0.0008 to +0.0008 inch)

This document has been printed from SPI². Not for Resale

 

30

SENR9976

Specifications Section

Number of teeth .............................................. 34

(5)  Idler gear

i02253807

Flywheel

Engines with balancer group

Inside  bore diameter  of idler

gear ..................................  37.197 to 37.212 mm

(1.5431 to 1.5437 inch)

Outside diameter  of  idler gear

hub .................................... 37.152 to 37.162 mm

(1.4626 to 1.4630 inch)

End play  of  the oil  pump idler

gear ......................................  0.120 to 0.270 mm

(0.0047 to 0.0108 inch)

Engines without the balancer group

Inside diameter  of oil pump  idler gear

bearing .............................. 16.012 to 16.038 mm

(0.6303 to 0.6314 inch)

Outside diameter of  oil pump idler  gear

shaft .................................. 15.966 to 15.984 mm

(0.6285 to 0.6292 inch)

Clearance of oil pump idler  gear bearing on

shaft ...................................... 0.028 to 0.072 mm

(0.0011 to 0.0028 inch)

g00584712

Illustration 62

Standard flywheel

End play  of  the oil  pump idler

gear ......................................  0.050 to 0.275 mm

(0.0019 to 0.0108 inch)

(1)  Flywheel ring gear

Backlash values

Heat the flywheel ring gear  to the following

temperature. ..............................  250 °C (480 °F)

Backlash between drive gear and idler gear of

balancer (if equipped) ........... 0.097 to 0.170 mm

(0.0038 to 0.0066 inch)

Note: Do not use an oxyacetylene torch to heat the

flywheel ring gear.

Backlash between idler gear and oil pump drive

gear ......................................  0.046 to 0.106 mm

(0.0018 to 0.0041 inch)

(2)  Flywheel

(3)  Bolt

Backlash between oil pump  idler gear and

crankshaft gear ..................... 0.095 to 0.160 mm

(0.0037 to 0.0063 inch)

Tighten the flywheel  bolts to the following

torque. ....................................  105 N·m (77 lb ft)

Backlash between the  idler gear and the

crankshaft gear ..................... 0.064 to 0.124 mm

(0.0025 to 0.0049 inch)

Backlash between camshaft gear  and idler

gear ......................................  0.052 to 0.107 mm

(0.0020 to 0.0042 inch)

Backlash between fuel injection pump gear and

idler gear ............................... 0.054 to 0.109 mm

(0.0021 to 0.0043 inch)

Backlash between water pump gear and  fuel

injection pump gear ..............  0.073 to 0.133 mm

(0.0028 to 0.0052 inch)

This document has been printed from SPI². Not for Resale

 

SENR9976

31

Specifications Section

i02243052

Note: Recheck the torque of the bolts (1) twice.

(2)  Thrust block

Flywheel Housing

(3)  Crankshaft pulley

Four cylinder

i01958344

Fan Drive

g00631781

Illustration 63

(1)  Bolt

Tighten the bolts for  the cast iron flywheel

housing to the following torque:

M10 “8.8” ..................................  44 N·m (33 lb ft)

M10 “10.9” ................................  63 N·m (47 lb ft)

M12 “8.8” ..................................  75 N·m (55 lb ft)

M12 “10.9” ............................... 115 N·m (85 lb ft)

g00926178

Illustration 65

A typical fan drive

(1)  Tighten the bolts for the fan to  the following

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

Tighten the bolts that secure the fan drive pulley to

the hub to the following torque (not shown). .. 22 N·m

(16 lb ft)

i02253806

Crankshaft Pulley

Fan drive housing

Tighten the bolts that secure the fan drive housing

to the cylinder head to  the following torque (not

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

Bearing bore for the housing ..  61.986 to 62.005 mm

(2.4404 to 2.4411 inch)

Outer bearing diameter ........... 61.987 to 62.000 mm

(2.4404 to 2.4409 inch)

Interference  fit  for  the

bearing .............................. 0.014 to minus 0.018 mm

(0.0006 to minus 0.0007 inch)

The  outer  diameter of  the

g00915497

Illustration 64

A standard pulley

shaft ... 25.002 to 25.011 mm (0.9843 to 0.9847 inch)

Maximum permissible end play of the shaft .. 0.20 mm

(0.0079 inch)

Note: Lubricate the threads of the bolts with clean

engine oil before installation.

(1)  Tighten the three bolts for the crankshaft pulley

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

This document has been printed from SPI². Not for Resale

 

32

SENR9976

Specifications Section

i01721280

Polarity ............................................... Negative earth

Engine Lifting Bracket

V-Belt

Note: The V-belt must be checked by a gauge. Refer

to the Testing and Adjusting, “V-Belt-Test” for  the

correct type of gauge in order to check the V-belt.

All engines are equipped with  two engine lifting

brackets.

Tighten the two bolts  on each engine lifting

V-belt tension ..................................... 535 N (120 lb)

bracket to the following torque. .. 44 N·m (32 lb ft)

i01958367

Alternator

12 Volt and 24 Volt Alternator

g00959541

Illustration 66

A typical alternator

(1)  Tighten terminal nut “W”  to the following

torque. ........................................ 2 N·m (17 lb in)

(2)  Tighten terminal nut “D+”  to the following

torque. ..................................... 4.3 N·m (38 lb in)

(3)  Tighten terminal nut “B+”  to the following

torque. ..................................... 4.3 N·m (38 lb in)

Tighten the pulley nut (not shown) to the following

torque. ............................................. 80 N·m (59 lb ft)

Alignment of the alternator pulley to the crankshaft

pulley ..............................   ± 2.4 mm ( ± 0.0945 inch)

Rotation  .................................................... clockwise

This document has been printed from SPI². Not for Resale

 

SENR9976

33

Specifications Section

i01958653

Starter Motor

24 Volt Starter Motor

g00974968

Illustration 67

The 24 volt starter motor which  shows the electrical connections

(1)  Tighten the negative terminal nut to the following

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

(2)  Tighten the positive terminal nut to the following

torque. ......................................  21 N·m (15 lb ft)

(3)  Tighten the solenoid terminal to the following

torque. ..................................... 3.5 N·m (31 lb in)

Rated voltage ................................................ 24 volts

Pull in voltage ............................................... 16 volts

This document has been printed from SPI². Not for Resale

 

34

SENR9976

Specifications Section

12 Volt Starter Motor

g00977365

Illustration 68

The 12 volt starter motor which  shows the electrical connections

(1)  Tighten the solenoid terminal to the following

torque. ....................................... 8 N·m ( 70 lb in)

(2)  Tighten the positive terminal nut to the following

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

(3)  Tighten the negative terminal nut to the following

torque.  ....................................... 8 N·m (70 lb in)

Rated voltage ................................................ 12 volts

Pull in voltage ................................................. 8 volts

i02245817

g00884683

Coolant Temperature Sensor

Illustration 70

(1)  Tighten the coolant temperature sensor to the

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

g01131749

Illustration 69

Location of the coolant temperature sensor

This document has been printed from SPI². Not for Resale

 

SENR9976

35

Specifications Section

i02245818

Engine Oil Pressure Sensor

i02245819

Boost Pressure Sensor

g01131721

Illustration 71

g01130928

Illustration 73

Location of the engine oil pressure sensor

Location of the boost pressure sensor

g00884723

Illustration 72

g00884730

Illustration 74

(1)  Tighten the engine oil pressure sensor to the

following torque. .........................  10 N·m (7 lb ft)

(1)  Tighten the boost pressure sensor to the following

torque. ........................................  10 N·m (7 lb ft)

This document has been printed from SPI². Not for Resale

 

36

SENR9976

Specifications Section

i02245820

Inlet Manifold Temperature

i02245821

Speed/Timing Sensor

Sensor

g01131722

Illustration 77

Location of the speed/timing sensor

g01131036

Illustration 75

Location of the inlet manifold temperature sensor

g00884736

Illustration 78

g00884683

Illustration 76

(1)  Tighten the bolt for the speed/timing sensor to

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

(1)  Tighten the inlet manifold temperature sensor to

the following torque. .................  20 N·m (15 lb ft)

This document has been printed from SPI². Not for Resale

 

SENR9976

37

Specifications Section

i02245822

i02253813

Voltage Load  Protection

Module

Glow Plugs

g00955714

Illustration 81

g00915868

Typical example

Illustration 79

(1)  Tighten the glow plugs (3) in the cylinder head to

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

(3)  Tighten the bolts for the clips that hold the VLPM

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

Tighten the nuts  (2) for the bus bar  (1) that is

installed on top of the glow plugs  to the following

torque. ............................................... 2 N·m (18 lb in)

i02246071

Electronic Control Module

Voltage ................................................. 12 or 24 volts

g00915338

Illustration 80

(1)  Tighten the allen head screw that secures the

harness connector to the ECM to the following

torque. ..................................... 2.3 N·m (20 lb in)

(2)  Tighten the bolts that hold the ECM to the engine

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

This document has been printed from SPI². Not for Resale

 

38

SENR9976

Index  Section

Index

A

Flywheel ................................................................ 30

Flywheel Housing .................................................. 31

Four cylinder......................................................  31

Front Housing and Covers..................................... 28

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

Fuel Injection Pump...............................................   4

Bosch VP30 .......................................................   4

Fuel Injectors.........................................................    5

Fuel Transfer Pump...............................................   6

Alternator...............................................................  32

12 Volt and 24 Volt Alternator ............................ 32

V-Belt ................................................................. 32

B

Boost Pressure Sensor.......................................... 35

G

C

Gear Group (Front)................................................ 29

Glow Plugs ............................................................ 37

Camshaft...............................................................  11

Camshaft Bearings................................................  12

Connecting Rod.....................................................  25

Connecting Rod Bearing Journal........................... 24

Coolant Temperature Sensor................................. 34

Crankcase Breather............................................... 18

Crankshaft ............................................................  21

Crankshaft Pulley .................................................. 31

Crankshaft Seals...................................................  23

Cylinder Block........................................................ 20

Four Cylinder Engine ......................................... 20

Cylinder Head........................................................   9

Cylinder Head Valves ............................................   7

I

Important Safety Information.................................    2

Inlet Manifold Temperature Sensor........................ 36

L

Lifter Group............................................................   6

M

E

Main Bearing Journal............................................. 24

The shell for the main bearings.......................... 24

Electronic Control Module ..................................... 37

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

Four Cylinder Engine .........................................   4

Engine Lifting Bracket............................................ 32

Engine Oil Bypass Valve ....................................... 15

Installed in the Balancer..................................... 16

Installed in the Oil Pump....................................  15

Engine Oil Filter.....................................................  12

Replaceable Element.........................................  13

Spin-on Oil Filter ................................................ 12

Engine Oil Pan....................................................... 16

Front sealant......................................................  16

Rear sealant....................................................... 16

The cast iron oil pan........................................... 17

Engine Oil Pressure............................................... 15

Engine Oil Pressure Sensor..................................  35

Engine Oil Pump.................................................... 13

Engines with Balancer Group ............................ 13

Engines without Balancer Group ....................... 14

Exhaust Manifold...................................................  11

Four Cylinder Engine ......................................... 11

P

Piston and Rings ................................................... 26

Piston.................................................................  27

Piston Cooling Jet.................................................. 27

Piston Cooling Jet Alignment.............................  28

R

Rocker Shaft..........................................................   6

S

Specifications Section ...........................................   4

Speed/Timing Sensor............................................  36

Starter Motor.......................................................... 33

12 Volt Starter Motor..........................................  34

24 Volt Starter Motor........., .................................  33

F

Fan Drive...............................................................  31

Fan drive housing .............................................. 31

This document has been printed from SPI². Not for Resale

 

SENR9976

39

Index  Section

T

Table of Contents...................................................   3

Turbocharger.........................................................  10

Four Cylinder Engine ......................................... 10

V

Valve Mechanism Cover........................................   7

Voltage Load Protection Module............................ 37

W

Water Pump........................................................... 19

Water Temperature Regulator and Housing..........  18

Water Temperature Regulator............................ 19

This document has been printed from SPI². Not for Resale