Perkins Engine 1104D 80CV, 1104D 100CV Repair Manual

647016EN (16/06/2008)

ENGINE

1104D EURO 3 - 80CV / 100CV

Repair manualRepair manual

MANITOU BF
B.P 249 - 44158 ANCENIS Cedex Tél. [phone]
Fax commercial France : 02 40 09 10 96 // Export : 33 2 40 09 10 97
www.manitou.com

647016EN

ISSUE

st

16 / 06 / 2008 - 1
Engine 1104D E3 - 80CV/ 100CV

ISSUE

1st DATE OF ISSUE

16 / 06 / 2008

THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED EITHER TOTALLY OR PARTLY.

Specifications

1104D (Me

NK (Engine)

Engine)

NL

(

K (Engine)

N

ch) Industrial Engine

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or
pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.

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 information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this
product Perkins recommends using Perkins

replacement parts.

Failure to heed this warning can lead to prema­ture failures, product damage, personal injury or
death.

KENR6245 3

Table of Contents

Table o f Contents

Specifications Section

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

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

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

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

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

Lifter Group ........................................................... 7

Rocker Shaft ........................................................ 7

Valve Mechanism Cover ...................................... 8

Cylinder Head Valves ........................................... 8

Cylinder Head ...................................................... 10

Turbocharger ....................................................... 11

Exhaust Manifold ................................................. 12

Camshaft ............................................................. 12

Camshaft Bearings .............................................. 14

Engine Oil Filter ................................................... 14

Engine Oil Cooler ................................................. 15

Engine Oil Pump .................................................. 16

Engine Oil Pressure ........................... .................. 18

Engine Oil Bypass Valve ...................................... 18

Engine Oil Pan ..................................................... 19

Crankcase Breather ............................................. 20

Water Temperature Regulator and Housing ......... 22

Water Pump ......................................................... 22

Cylinder Block ...................................................... 22

Crankshaft ........................................................... 24

Crankshaft Seals ................................................. 26

Connecting Rod Bearing Journal ......................... 26

Main Bearing Journal ................................ ............ 27

Connecting Rod ................................................... 27

Piston and Rings .................................................. 29

Piston Cooling Jet ................................................. 30

Front Housing and Covers ................................... 31

Gear Group (Front) ............................................... 31

Flywheel ............................................................... 33

Flywheel Housing ................................................ 34

Crankshaft Pulley ................................................. 34

Fan Drive ............................................................. 35

Engine Lifting Bracket ........................................... 36

Alternator ............................................................. 36

Starter Motor ........................................................ 37

Glow Plugs ........................................................... 38

Index Section

Index ..................................................................... 40

4 KENR6245
Specifications Section

Specifications Section

Engine Design

Illustration 1

Cylinder and valve location

(A) Inlet v alve
(B) Exhaust valve

i02655068

g01333480

When the camshaft is viewed from the front of
the engine, the

camshaft rotates in the following

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

The front of th

e engine is opposite the flywheel end.
Theleftsideandtherightsideoftheengineare
viewed from the flywheel end. The No. 1 cylinder is
the front cyl

inder.

i02656438

Fuel Injection Lines

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

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

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

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

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

Compression ratio

Naturally aspirated engines ...................... 19.3:1

Turbocharged engines .............................. 18.2:1

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

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

Val v e lash

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

3

)

Illustration 2

Typical exam ple

g01334606

(1) Tighten the union nuts for the fuel injector nozzles

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

Tighten the union nuts for the fuel injection pump (not

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

KENR6245 5

Specifications Section

i02663071

Fuel Injection Pump

Note: Before the fuel injection pump is removed from

the engine the fuel injection pump shaft must be
locked. Posit
of number one cylinder before tightening the locking
screw. The locking screw will prevent the shaft from
rotating. If t
prior to correctly timing the engine and locking the
shaft, the fuel injection pump will need to be timed by
trained pers

ion the engine to TC compression stroke

he fuel injection pump was removed

onnel.

Unlocking the shaft

Loosen locking screw (2) and install the washer
(3) to the unlocked position. Tighten the bolt to
the following t

Illustration 4

Typical example of a support bracket

orque. ................... 12 N·m (9 lb ft)

g01352239

Illustration 3

Typical example

g01352237

Note: The solenoid on the fuel injection pump is
a serviceable item. The fuel injection pump is a
nonserviceable item.

(1) O-ring

(2) Locking screw

(3) Washer

(4) Tighten the mounting bolt to the following

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

(5) Tighten the mounting bolt and the nut to the

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

Note: The support bracket must be installed after
the coolant pump is installed. In order to stop the
distortion of the timing case, finger tighten the bolt
(4) and then tighten the nut and bolt (5). Tighten the
bolt (4).

Tighten the bolts that hold the fuel pump to the front

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

Locking the shaft

Loosen locking screw (2) and move the washer
(3) to the locked position. Tighten the bolt to the

following torque. ...................... 17 N·m (12 lb ft)

6 KENR6245
Specifications Section

i02662510

Fuel Injectors

Illustratio

Fuel injector clamp

n5

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

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

g00908211

i02661897

Fuel Transfer Pump

The fuel injector should be tested at the pressure in
table 1.

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

Table 1

Service setting for the Fuel Injector

Injection Pressure

29.4+0.8MPa(4264+116psi)

Illustration 6

g00986823

(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

(7) Fuel filter bowl

Note: Tighten the fuel filter bowl by hand. Rotate the
bowl 1/8 of a turn more by hand.

KENR6245 7

Specifications Section

i02677369

Lifter Group

Illustratio

n7

g00629433

(1) Diameter of the lifter body .. 18.987 to 19.012 mm

(0.7475to0.

7485 inch)

Clearance of the lifter in the cylinder block

bore ....... 0.038 to

0.095 mm (0.0015 to 0.0037 inch)

i02655105

Rocker Shaft

Table 2

Required Tools

Part

Tool

A 27610227

Number Part Description Qty

Spacing Tool

4

Illustration 8

The rocker shaft

g01345401

Note: In order to install the rocker shaft assembly,
Tooling (A) is required.

(1) Snap ring

(2) Washer

(3) Rocker arm

(4) Rocker arm bore

Diameter of the rocker arm

bore .................................. 25.013 to 25.051 mm

(0.9848 to 0.9863 inch)

Rocker arm

Clearance between the rocker arm and the rocker

shaft ...................................... 0.026 to 0.089 mm

(0.0010 to 0.0035 inch)
Maximum permissible clearance between the

rocker arm 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 .................................. 24.962 to 24.987 mm

(0.9828 to 0.9837 inch)

8 KENR6245
Specifications Section

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

ensure that the

machined square is to the top of

the rocker shaft.

(9) Locknut

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

i02551219

Valve Mechanism Cover

i02662486

Cylinder Head Valves

Illustration 9

g01277221

Tighten the bolts for the valve mechanism cover
in the sequence that is shown to the following

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

Illustration 10

Cross section of cylinder head

(1) Valve spring

Naturally aspirated engines

The installed length of the valve

springs .......................... 35.17 mm (1.3846 inch)

The load for the installed valve springs ..... 335 N

Turbocharged engines

The installed length of the inlet valve springs

(high ratings) ................. 35.17 mm (1.3846 inch)

The load for the installed inlet valve

springs ........................................... 335 N (75 lb)

The installed length of the inlet valve springs (low

ratings) .......................... 36.17 mm (1.4240 inch)

The load for the installed inlet valve

springs ........................................... 312 N (70 lb)

The installed length of the exhaust valve springs

(all ratings) .................... 36.17 mm (1.4240 inch)

The load for the installed exhaust valve

spring ............................................. 312 N (70 lb)

g01345407

(75 lb)

KENR6245 9

Specifications Section

Turbocharged aftercooled engines

The installed length of the valve

springs .......................... 36.17 m

The load for the installed valve springs ..... 312 N

(2) Valve spring recess

(3) The finishe

Inside diameter of valve

guide ..................................... 9.000 to

Outside diame

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

Interference fit of valve guide in cylinder

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

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

Projection of the valve guide above the valve
spring reces

d valve guides

(0.3543 to 0.3552 inch)

ter of the valve

(0.5131 to 0.5137 inch)

(0.0003to0.

s (2) ................... 12.35 to 12.65 mm

m (1.4240 inch)

9.022 mm

0019 inch)

(2.018 to 2.0

(0.486 to 0.498 inch)

(70 lb)

27 inch)

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

Turbocharged aftercooled engines .. 1.55 to 1.81 mm

(0.0610 to 0.0713 inch)

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

(5) Inlet valv

Diameter of the inlet valve

stem ...................................... 8.953 to 8

Clearance of valve in valve
guide .. 0.025 to

Overall length of the inlet

valve ................................... 128.838

Thefaceofthe
cylinder head by the following amount.

Naturally as

Turbocharge

e

.975 mm

(0.3525 to 0.3533 inch)

0.069 mm (0.001 to 0.0027 inch)

to 129.288 mm

(5.0724 to 5.0901 inch)

inlet valve is recessed below the

pirated engines ............ 0.60 to 0.85 mm

(0.0236 to 0.0335 inch)

d engines (high rating) .. 0.60 to 0.85 mm

(0.0236 to 0.0335 inch)

Note: When ne
valves and new valve seat inserts must be installed.
The valve guides and the valve seat inserts are
supplied as
valve guides and unfinished valve seat inserts are
installed in the cylinder head. The guides and inserts
are then cut
tooling. This procedure ensures the concentricity of
the valve seat to the valve guide in order to create a
seal that i
for removal and installation procedures.

(4) Exhaus

Diameter of the exhaust valve

stem ...................................... 8.938

Clearanc

guide ..... 0.040 to 0.062 mm (0.0016 to 0.0024 inch)

Overall l

valve ................................... 128.184 to 128.634 mm

The face of the exhaust valve is recessed below the
cylinder head by the following amount.

Naturally aspirated engines ............ 0.55 to 0.81 mm

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

ength of the exhaust

w valve guides are installed, new

partially finished parts. The unfinished

and reamed in one operation with special

s tight. Refer to Disassembly and Assembly

tvalve

to 8.960 mm

(0.3519 to 0.3528 inch)

e of valve in valve

(5.0466 to 5.0643 inch)

(0.0217 to 0.0319 inch)

Service limi

Turbocharged engines (low rating) .. 1.60 to 1.85 mm

Turbocharged aftercooled engines .. 1.60 to 1.85 mm

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

(6) Exhaust valve face angle from the horizontal axis

Val v e f ace a

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

(7) Diamete

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

(8) Diameter of the head of the inlet

valve ..................................... 46.28 to 46.53 mm

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

Valve face angle ............................... 45 degrees

Valve seat angle ............................... 45 degrees

The valve lash is the following value when the engine
is cold:

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

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

t ............................ 1.09 mm (0.043 inch)

(0.0630to0.

(0.0630to0

ngle ............................... 30 degrees

r of the exhaust

(1.634 to 1.643 inch)

(1.8220 to 1

0728 inch)

.0728 inch)

.8319 inch)

Turboch

arged engines .................... 1.55 to 1.81 mm

(0.0610 to 0.0713 inch)

10 KENR6245
Specifications Section

i02662502

Cylinder Head

Table 3

Required Tools

Tool

A

Part

Number Part Description Qty

21825607

Angle gauge 1

Illustration 11

Recess for the valve s ea t insert

g00809016

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

inserts to the following dimensions.

Recess for Inlet Valve Seat for Naturally Aspirated
Engines and high rated turbocharged engines

(A) ..... 9.84 to 10.04 mm (0.3874 to 0.3953 inch)

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

(1.8827 to 1.8837 inch)

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

Recess for Exhaust Valve Seat for Naturally
Aspirated Engines and high rated turbocharged
engines

(A) ..... 9.84 to 10.04 mm (0.3874 to 0.3953 inch)

(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 low rated
turbocharged engines and turbocharged
aftercooled engines

(A) .... 10.84 to 11.04 mm (0.4268 to 0.4346 inch)

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

(1.8827 to 1.8837 inch)

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

Recess for Exhaust Valve Seat for turbocharged
engines and turbocharged aftercooled engines

(A) .... 10.84 to 11.04 mm (0.4268 to 0.4346 inch)

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

(1.6701 to 1.6711 inch)

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

The maximum dis

tortion of the cylinder head is given

in table 4.

The cylinder h

ead bolts are two different lengths. The
following information provides the proper torque for
the cylinder head bolts.

Illustration 12

The tightening sequence

g00987480

Lubricate the threads and the underside of the head
bolts with clean engine oil.

Tighten the bolts in the sequence that is shown in

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

(37lbft)
Tighten the bolts again to the following

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

KENR6245 11

Specifications Section

i02662519

Turbo charger

Illustration 13

g00905621

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)

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

(4.614 inch)

Note: The maximum distortion of the cylinder head
isgivenintable4.

Illustration 15

Typical turbocharger

g00991357

(1) Actuator rod

(2) Actuator

(3) Turbocharger

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

(32lbft)

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

(80 lb in)

ation 14

Illustr

Table 4

Dimension

Width (A) 0.03 mm (0.0012 inch)

Length (B) 0.05 mm (0.0019 inch)

Diagonal Line (C) 0.05 mm (0.0019 inch)

Maximum Permissible

Distorti

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

(16lbft)

The maximum test pressure for the

wastegate ....................................... 205 kPa (30 psi)

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

(0.0394 inch)

g01006568

on

12 KENR6245
Specifications Section

Table 5

The part number for

the turbocharger

2674A835

2674A841

2674A843

2674A816

2674A817

2674A836

2674A818

2674A844

2674A819

2674A821

2674A837

2674A822

2674A838

2674A825

2674A845

2674A826

2674A827

2674A842

The pressure for the

wastegate

138±3kPa
(20.0155 ± 0.4351 psi)

123±3kPa
(17.8399 ± 0.4351 psi)

138±3kPa
(20.0155 ± 0.4351 psi)

131±3kPa
(19.0002 ± 0.4351 psi)

100±3kPa
(14.5040 ± 0.4351 psi)

138±3kPa
(20.0155 ± 0.4351 psi)

123±3kPa
(17.8399 ± 0.4351 psi)

138±3kPa
(20.0155 ± 0.4351 psi)

131±3kPa
(19.0002 ± 0.4351 psi)

100±3kPa
(14.5040 ± 0.4351 psi)

138±3kPa
(20.0155 ± 0.4351 psi)

123±3kPa
(17.8399 ± 0.4351 psi)

138±3kPa
(20.0155 ± 0.4351 psi)

123±3kPa
(17.8399 ± 0.4351 psi)

138±3kPa
(20.0155 ± 0.4351 psi)

131±3kPa
(19.0002 ± 0.4351 psi)

100±3kPa
(14.5040 ± 0.4351 psi)

138±3kPa
(20.0155 ± 0.4351 psi)

i02662527

Exhaust Manifold

Illustration 16

Typical exam

ple

g01337856

Tighten the exhaust manifold bolts in the sequence
that is shown

in illustration 16 to the following

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

i02662539

Camshaft

Illustration 17

Checking the end play of the camshaft

g01277351

KENR6245 13

Specifications Section

(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)

Illustration 18

Typical camshaft

g01277354

(2) Bolt

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

(70 lb ft)

(3) Camshaft thrust washer

Thickness of the thrust washer .. 5.49 to 5.54 mm

(0.216 to 0.218 inch)

Depth of the recess in the cylinder block for the

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

(0.218 to 0.222 inch)

Tolerance of the thrust washer in cylinder block

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

(−0.0006 to −0.0001 inch)

(4) The diameters of the camshaft journals are given

in the following table.

Table 6

Diameters of Camshaft Journals

Camshaft Journals Standard Diameter

1

2

3

50.711 to 50.737 mm

(1.9965 to

50.457 to 50.483 mm

(1.9865 to 1.9875 inch)

49.949to4

(1.9665 to 1.9675 inch)

1.9975 inch)

9.975 mm

ion 19

Illustrat

Typical exam ple

(5) Camshaft lobe lift

Naturally

Inlet lobe

aspirated

............................... 7.201 to 7.301 mm

(0.2835 to 0.2874 inch)

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

(0.2914 t

o0.2954inch)

Turbocharged

Inlet lobe ............................... 7.527 to 7.627 mm

(0.2963 t

o0.3003inch)

Exhaust lobe ......................... 7.363 to 7.463 mm

(0.2899 to 0.2938 inch)

Turbocharged aftercooled

Inlet lobe ............................... 7.031 to 7.131 mm

(0.2768 to 0.2807 inch)

Exhaust lo

be ......................... 7.363 to 7.463 mm

(0.2899 to 0.2938 inch)

(6) Camsh

aft lobe height

(7) Base circle

g01345411

Maximum wear on the camshaft journals ... 0.05 mm

(0.0021 i

nch)

To determine the lobe lift, use the procedure that
follows:

1. Mount the camshaft between centers.

2. By using a

dial indicator in contact with the surface
of the lobe, rotate the camshaft and record the
maximum and minimum lift.

14 KENR6245
Specifications Section

Note: There may be two lobes on the camshaft.
Refer to illust

ration 19. The surface between the
lobes may not return to the radius of the base circle.
Usingamicrometertomeasurethediameterofthe
base circle ma

y give a inaccurate result.

3. Subtract the smallest dimension from the largest

dimension. T

he difference is the actual camshaft

lobe lift.

Maximum perm

issible deviation between the
actual lobe lift and the specified lobe lift of a new

camshaft ................................. 0.05 mm (0.002 inch)

i02656416

Camshaft Bearings

i02663064

Engine Oil F ilter

Illustration 20

Typical example

(1) The d

iameter of the installed camshaft

bearing .............................. 50.787 to 50.848 mm

(1.9995 to 2.0019 inch)

g01334

592

Illustration 21

Typical exam ple

(1) Setscrew

Tighten the setscrews to the following

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

(2) Engine oil filter

Tighten the engine oil filter to the following

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

g01338237

KENR6245 15

Specifications Section

i02657143

Engine Oil Coo ler

ion 22

Illustrat

Typical example

(3) Setscrew

Tighten th

e setscrews to the following

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

(4) Engin

eoilfilter

Tighten the engine oil filter to the following

torque. .................................... 1

2 N·m (106 lb in)

(5) Plug

Tighten the plug to the following torque. .. 12 N·m

(106 lb in)

g01338238

Illustratio

Typical exam ple

(1) Joint
(2) Oil cooler
(3) Housing
(4) Setscrew
(5) Seal
(6) Setscrew
(7) Setscrew

n23

g00952614

Illustration 24

Setscrews

Tighten the setscrews (7) to the following

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

Setscrews

Tighten the setscrews (4) and (6) in the
sequence that is in illustration 24 to the following

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

g01334858

16 KENR6245
Specifications Section

i02656269

Engine Oil Pump

Engines with Balancer Group

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

Number of lobe

s

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

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

Illustration 25

The oil pump for the balancer

g01334408

Illustration 26

Inner rotor

(2) Clearance of inner rotor to outer

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

(0.0020 to 0.0079 inch)

g01334410

(1) Clearance of the outer rotor to the

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

Illustration 27

The end play for the rotor

(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 0.11 mm

(0.0016 to 0.0043 inch)

g01334412

KENR6245 17

Specifications Section

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

(70lbft)

Tighten the bolts that hold the balancer to the cylinder
block to the fo

llowing torque. .......... 54 N·m (40 lb ft)

Illustration 28

The end cover

g01334415

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

(19 lb ft)

Engines witho

ut Balancer Group

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

Number of lobes

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

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

Illustration 30

The oil pump

g00938064

(1) Clearance of the outer rotor to the

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

(0.0059 to 0.0129 inch)

Illustration 29

Idler gear and pump gear

g01334416

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)

Note: Set the engine to the TC position. Refer to
Systems Operation, Testing and Adjusting Manual,
“Finding Top Center Position for No. 1 Piston”. Install
the balancer. Refer to Disassembly and Assembly,
“Balancer - Install”. Install the gear for the oil pump
and tighten the nut (6).

tion 31

Illustra

Checking the clearance

(2) Clearance of inner rotor to outer

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

(0.0015 t

o0.0050inch)

g00938061

18 KENR6245
Specifications Section

i02505676

Engine Oil Bypass Valve

Installed in the Oil Pump

Illustration 32

Checking the end play

g00938799

(3) End play of rotor assembly

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

(0.0014 to 0.0035 inch)

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

(0.0010 to 0.0029 inch)

Tighten the bolts that hold the front cover of the oil

pump assembly to the following torque. ........ 10 N·m

(89lbin)

i02731019

Engine O il Pressure

The minimum oil pressure at the maximum engine
speed and at

following value. ............................... 280 kPa (41 psi)

normal operating temperature is the

Illustration 33

Typical engi

Illustrat

Relief valve and spring

ne oil pump

ion 34

g00919893

g00921377

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

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

(2) Plunger

Diameter o

f the plunger ..... 19.186 to 19.211 mm

(0.7554 to 0.7563 inch)

Clearance

of plunger in bore .. 0.039 to 0.114 mm

(0.0015 to 0.0045 inch)

(3) Spring

Length of the spring ...... 80.94 mm (3.1866 inch)

KENR6245 19

Specifications Section

Installed in th

Illustration 35

Plug

e Balancer

g00919890

Engine Oil Pan

Table 7

Required Tools

Tool Part Number Part Description

A

21826038

Front sealant

POWERPART
Retainer

i02662550

Qty

1

Illustration 36

The relief valve for the balancer

(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)

(3) Spring

Length of the spring ........... 67 mm (2.6378 inch)

g00921379

Illustration 37

Applying sealant

g01254690

If the gasket that is between the front housing and
the cylinder block is not renewed, apply Tooling (A) to
the cylinder block and to the front housing. If a new
gasket is installed, Tooling (A) is not required.

Note: Apply a sealant bead of 3.5 mm (0.1378 inch)
that is shown in illustration 37.

Rear sealant

Note: Install the rear oil seal before sealant is applied

to the bridge.

20 KENR6245
Specifications Section

Tighten the remaining bolts to the following

torque. ............................................. 22 N·m (

16 lb ft)

(2) Drain plug

Tighten the drain plug for the engine oil pan to

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

i02662638

Crankcase Breather

Table 8

Required Tools

Part

Number Part Description Qty

POWERPART red rubber
grease

1

Illustration 38

Applying sealant

g01254887

Tool

A 21820221

Apply Tooling (A) to the bridge. The sealant must
not protrude more than 5 mm (0.1969 inch) above
the bridge.

Illustration 40

Breather valve

(1) Cover

(2) Cover plate

g00926199

Illustration 39

Typical example

g01255016

(1) Tighten the four front bolts in position (X) to the

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

(3) Screws

Tighten the screws for the cover plate with
a composite valve mechanism cover to the

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

(4) Diaphragm

(5) Cap

KENR6245 21

Specifications Section

(6) Spring

Illustration 41

Typical example

(7) O-ring

Breather Canister

g00926200

Note: Apply Tooling (A) 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

(80lbin)

Illustration 42

Typical exam ple

(1) Conn ection
(2) Clamp
(3) Hose
(4) F ilter base
(5) Bolts
(6) Clamp
(7) Hose
(8) C anister

g01277902

(2) Tighten the clamps to the following

torque. ........................................ 3 N·m (26 lb in)

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

(16lbft)

(6) Tighten the clamp to the following torque. .. 3 N·m

(26 lb in)

(8) Tighten the canister to the following

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

22 KENR6245
Specifications Section

i02504533

Water Temperature Regulator
and Housing

Table 9

Required Tools

Tool Part Number Part Description Qty

A

21820221

POWERPART Red
Rubber Grease

1

i02363605

Water Pump

Illustration 43

Typical example

g01253716

Note: Apply Tooling (A) to the O-ring (4) in order to
install the water temperature regulator housing (2).

(1) Tighten the bolts that fasten the housing to the

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

(2) Water temperature regulator housing

(3) Water temperature regulator

Opening temperature ........................ 82° to 87°C

(179.6000° to 156.6000°F)

Full opening temperature .... 95 °C (203.0000 °F)

Minimum stroke at full temperature ........... 9 mm

(0.3543 inch)

Illustration 44

Tightening sequence

g01183807

Tighten the setscrews in the numerical sequence
that is shown in illustration 44 to the following

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

i02663067

Cylinder Block

Table 10

Required Tools

Tool Part Number Part Description Qty

A

21826038

POWERPART
Retainer

1

KENR6245 23

Specifications Section

Use the following procedure in order to install the
main bearing ca

p bolts:

1. Apply clean engine oil to the threads of the main
bearing cap bo

lts.

2. Put the main bearing caps in the correct position
that is indica

ted 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)

Illustration 45

Typical example

g00924764

(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)

The maximum permissible wear for the cylinder bore

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

(3) Camshaft bearings

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)

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)

Illustration 46

g00938203

Use the following procedure in order to install the
allen head bolts for the bridge.

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.

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

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

3. When the bridge is installed on the cylinder block,
apply Tooling (A) 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.

Diameter of the bore in the cylinder
block for the number 3 camshaft

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

(1.9700 to 1.9720 inch)

(4) Main bearings

Bore in the cylinder block for the main

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

(3.1660 to 3.1670 inch)

(5) Main bearing cap bolts

Note: Theoilpanmustbeinstalledwithin10minutes
of applying the sealant.

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)

24 KENR6245
Specifications Section

Crankshaft

i02663072

Note: All new turbocharged engines and
turbocharged a

ftercooled 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 mac

hining. Naturally aspirated engines

have induction hardened crankshafts.

Illustration 47

Typical example

g01338264

(1) Crankshaft

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)

Note: The timing mark is toward the outside of
the crankshaft when the gear is installed on the
crankshaft.

KENR6245 25

Specifications Section

ion 48

Illustrat

Note: Refer to illustration 48 in order to use table 11.

Table 11

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)

1

2

3

4

5

6

7 Do not machine this diameter. N/A N/A

8

9

75.905 to 75.926 mm
(2.9884 to 2.9892 inch)

63.216 to 63.236 mm
(2.4888 to 2.4896 inch)

39.47 mm (1.5539 inch)
maximum

37.44 mm (1.4740 inch)
maximum

44.68 mm (1.7591 inch)
maximum

40.55 mm (1.5965 inch)
maximum

3.68 mm

3.96 mm (0.1559 inch)

4.36 to 4.60 mm
(0.171

(0.1449 inch) to

7to0.1811inch)

75.651 to 75.672 mm
(2.9784 to 2.9792 inch)

62.962 to 62.982 mm
(2.4788 to 2.4796 inch)

N/A N/A

N/A N/A

N/A N/A

N/A N/A

N/A N/A

N/A N/A

g01338265

75.397 to 75.418 mm
(2.9684 to 2.9692 inch)

62.708 to 62.728 mm
(2.4688 to 2.4696 inch)

Refer t

o table 12 for the maximum run out of the

crankshaft journals.

26 KENR6245
Specifications Section

Table 12

Journal Excessive run out

(1)

(2) 0.08 mm (0.0031 inch)

(3) 0.15 mm (0.0059 inch)

(4) 0.08 mm (0.0031 inch)

(5) Mounting

Mounting

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.

Crankshaft Seals

Illustration 49

Typical example

(1) Crankshaft

(2) Crankshaft seal

(3) Plastic sleeve

(4) Alignment tool

i02658811

g01335894

Illustration 50

g00915076

(5) Tightenbolts1,2,3,4,5,6,7,and10inthe

sequence that is shown in Illustration 50 to the

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

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

(16lbft)

i02504771

Connecting Rod B earing
Journal

Refer to Specifications, “Crankshaft” 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 a bearing journal on a

new connecting rod .............. 0.04 mm (0.0016 inch)

Width of the connecting rod bearing

journals ................................... 40.348 to 40.424 mm

(1.5885 to 1.5915 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 ............................................. Ra 0.4 microns

KENR6245 27

Specifications Section

Surface finish of radii ........................ Ra 1.3 microns

i02656267

Main Bearing Journal

Refer to Specifications, “Crankshaft” for information
on the undersi
information on the width of main bearing journals.

The original s

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

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)

ze main bearing journals, and

ize of the main bearing

(2.9984 to 2.9992 inch)

i02662161

Connecting Rod

The shell for the main bearings

The shells for the main bearings are available
for remachined journals which have the following
undersize d

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

Undersize be

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

Thickness a

Width of the

Clearance b

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

imensions.

aring shell .... 0.51 mm (0.020 inch)

t center of the shells .. 2.083 to 2.089 mm

(0.0820 to 0.0823 inch)

main bearing shells .. 31.62 to 31.88 mm

(1.244 to 1.255 inch)

etween the bearing shell and the main

(0.0022 to 0.0046 inch)

Illustration 51

The mating surfaces of the connecting rod are
produced by hydraulically fracturing the forged
connecting rod.

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

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

Tighten the torx screws for the connecting rod again

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

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.

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).

(2) The bearing shell for the connecting rod

g00907738

28 KENR6245
Specifications Section

Illustration 52

Alignment of the bearing shell

g00995584

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 Disassembly
and Assembly for information on the alignment tool.

Table 13

Bearing Width for the

Connecting Rod

Bearing Wid

Connecting Rod Cap

Thickness of Connecting

Rod Bearing at the

Thickness of Connecting

Rod Bearing for the Cap

at the Center

Bearing Clearance

Table 14

th for the

Center

Undersized Connecting Rod Bearing

31.62 to 31.88 mm

(1.245 to 1.255 inch)

31.62 to 31.88 mm

(1.2449 to 1.2551 inch)

1.835 to 1.842 mm

(0.0723 to 0.0725 inch)

1.835 to 1.842 mm

(0.0722 to 0.0725 inch)

0.034 to 0.081 mm

(0.0013 to 0.0032 inch)

Illustrat

ion 53

g00907744

(3)Insidediameterofthesmall

bush .................................. 39.7

23 to 39.738 mm

(1.5639 to 1.5645 inch)

(4) Dista

nce 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)

0.25 mm (0.010 inch)

0.51 mm (0.020 inch)

0.76 mm (0.030 inch)

Illustration 54

g00915056