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

647016EN (16/06/2008)	ENGINE
	1104D EURO 3 - 80CV / 100CV
	Repair 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	1st DATE OF ISSUE
	16 / 06 / 2008

ISSUE

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

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

Specifications

1104D (Mech) Industrial Engine

NK (Engine)

NL (Engine)

NK (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 of 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

When the camshaft is viewed from the front of the engine, the camshaft rotates in the following

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

Engine Design

i02655068

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.

i02656438

Fuel Injection Lines

Illustration 1	g01333480
Cylinder and valve location
(A) Inlet valve
(B) Exhaust valve
Bore .........................................	105 mm (4.133 inch)
Stroke ......................................	127 mm (5.000 inch)
Displacement ......................................	4.4 L (269 in3)
Cylinder arrangement .....................................	In-line
Type of combustion ............................	Direct injection
Compression ratio
Naturally aspirated engines	...................... 19.3:1
Turbocharged engines ..............................	18.2:1
Number of cylinders ................................................	4
Valves per cylinder ..................................................	2
Valve 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

Illustration 2	g01334606
Typical example

(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. Position the engine to TC compression stroke of number one cylinder before tightening the locking screw. The locking screw will prevent the shaft from rotating. If the fuel injection pump was removed prior to correctly timing the engine and locking the shaft, the fuel injection pump will need to be timed by trained personnel.

Illustration 3	g01352237
Typical example

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

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)

Unlocking the shaft

Loosen locking screw (2) and install the washer

(3) to the unlocked position. Tighten the bolt to the following torque. ................... 12 N·m (9 lb ft)

Illustration 4		g01352239
Typical example of a support bracket
(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)

6		KENR6245
Specifications Section
i02662510		i02661897
Fuel Injectors		Fuel Transfer Pump

Illustration 5	g00908211
Fuel injector clamp

(1) Tighten the bolt in the clamp for the fuel injector to the following torque. ............. 35 N·m (26 lb ft)

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 + 0.8 MPa (4264 + 116 psi)

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

Illustration 7	g00629433

(1) Diameter of the lifter body .. 18.987 to 19.012 mm (0.7475 to 0.7485 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	Number	Part Description	Qty
A	27610227	Spacing Tool	4

Illustration 8	g01345401
The rocker shaft

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	g01345407
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
		(75 lb)

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)

KENR6245	9
	Specifications Section

Turbocharged aftercooled engines
The installed length of the valve
springs ..........................	36.17 mm (1.4240 inch)
The load for the installed valve springs .....		312 N
		(70 lb)

(2)Valve spring recess

(3)The finished valve guides

Inside diameter of valve	9.000 to 9.022 mm
guide .....................................
	(0.3543 to 0.3552 inch)
Outside diameter of the valve
guide .................................	13.034 to 13.047 mm
	(0.5131 to 0.5137 inch)
Interference fit of valve guide in cylinder
head ......................................	0.007 to 0.047 mm
	(0.0003 to 0.0019 inch)
Length of Valve guide ..........	51.00 to 51.50 mm
	(2.018 to 2.027 inch)
Projection of the valve guide above the valve
spring recess (2) ...................	12.35 to 12.65 mm
	(0.486 to 0.498 inch)

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 Disassembly and Assembly for removal and installation procedures.

(4) Exhaust valve

Diameter of the exhaust valve

stem	...................................... 8.938 to 8.960 mm
	(0.3519 to 0.3528 inch)
Clearance of valve in valve
guide .....	0.040 to 0.062 mm (0.0016 to 0.0024 inch)
Overall length of the exhaust
valve ...................................	128.184 to 128.634 mm
	(5.0466 to 5.0643 inch)

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
	(0.0217 to 0.0319 inch)
Service limit ............................	1.06 mm (0.042 inch)
Turbocharged engines ....................	1.55 to 1.81 mm
	(0.0610 to 0.0713 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 valve

Diameter of the inlet valve

stem ......................................	8.953 to 8.975 mm
	(0.3525 to 0.3533 inch)
Clearance of valve in valve
guide ..	0.025 to 0.069 mm (0.001 to 0.0027 inch)
Overall length of the inlet
valve ...................................	128.838 to 129.288 mm
	(5.0724 to 5.0901 inch)

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

Naturally aspirated engines	............ 0.60 to 0.85 mm
	(0.0236 to 0.0335 inch)

Turbocharged engines (high rating) .. 0.60 to 0.85 mm (0.0236 to 0.0335 inch)

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

Turbocharged engines (low rating) .. 1.60 to 1.85 mm (0.0630 to 0.0728 inch)

Turbocharged aftercooled engines .. 1.60 to 1.85 mm (0.0630 to 0.0728 inch)

Service limit ..........................		2.09 mm (0.0823 inch)
(6)	Exhaust valve face angle from the horizontal axis
	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 .....................................	46.28 to 46.53 mm
		(1.8220 to 1.8319 inch)
(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)

10	KENR6245
Specifications Section

Illustration 11	g00809016
Recess for the valve seat insert

(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)

i02662502

Cylinder Head

Table 3

Required Tools

	Part
Tool	Number	Part Description	Qty
A	21825607	Angle gauge	1

The maximum distortion of the cylinder head is given in table 4.

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

Illustration 12	g00987480
The tightening sequence

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
Tighten the bolts again to the following		(37 lb ft)
torque. ....................................	100 N·m (74 lb ft)

KENR6245	11
	Specifications Section

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 is given in table 4.

	Illustration 14	g01006568
	Table 4
	Dimension	Maximum Permissible
		Distortion
	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)

i02662519

Turbocharger

Illustration 15	g00991357
Typical turbocharger

(1)Actuator rod

(2)Actuator

(3)Turbocharger

(4)	Tighten the nuts to the following torque. .. 44 N·m
			(32 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
wastegate .......................................		205 kPa (30 psi)
The movement for the rod actuator .................			1 mm
		(0.0394 inch)

12	KENR6245
Specifications Section

Table 5

The part number for	The pressure for the
the turbocharger		wastegate
2674A835	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A841	123	± 3 kPa
	(17.8399 ± 0.4351 psi)
2674A843	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A816	131	± 3 kPa
	(19.0002 ± 0.4351 psi)
2674A817	100	± 3 kPa
	(14.5040 ± 0.4351 psi)
2674A836	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A818	123	± 3 kPa
	(17.8399 ± 0.4351 psi)
2674A844	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A819	131	± 3 kPa
	(19.0002 ± 0.4351 psi)
2674A821	100	± 3 kPa
	(14.5040 ± 0.4351 psi)
2674A837	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A822	123	± 3 kPa
	(17.8399 ± 0.4351 psi)
2674A838	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A825	123	± 3 kPa
	(17.8399 ± 0.4351 psi)
2674A845	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A826	131	± 3 kPa
	(19.0002 ± 0.4351 psi)
2674A827	100	± 3 kPa
	(14.5040 ± 0.4351 psi)
2674A842	138	± 3 kPa
	(20.0155 ± 0.4351 psi)

i02662527

Exhaust Manifold

Illustration 16	g01337856
Typical example

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	g01277351
Checking the end play of the camshaft

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	g01277354
Typical camshaft

(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	50.711 to 50.737 mm
		(1.9965 to 1.9975 inch)
	2	50.457 to 50.483 mm
		(1.9865 to 1.9875 inch)
	3	49.949 to 49.975 mm
		(1.9665 to 1.9675 inch)

Maximum wear on the camshaft journals ... 0.05 mm (0.0021 inch)

Illustration 19	g01345411
Typical example
(5) Camshaft lobe lift
Naturally aspirated
Inlet lobe ...............................	7.201 to 7.301 mm
	(0.2835 to 0.2874 inch)
Exhaust lobe .........................	7.404 to 7.504 mm
	(0.2914 to 0.2954 inch)
Turbocharged
Inlet lobe ...............................	7.527 to 7.627 mm
	(0.2963 to 0.3003 inch)
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 lobe .........................	7.363 to 7.463 mm
	(0.2899 to 0.2938 inch)

(6)Camshaft lobe height

(7)Base circle

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 illustration 19. The surface between the lobes may not return to the radius of the base circle. Using a micrometer to measure the diameter of the base circle may give a inaccurate result.

3.Subtract the smallest dimension from the largest dimension. The difference is the actual camshaft lobe lift.

Maximum permissible 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 Filter

Illustration 20 Typical example

Illustration 21		g01338237
Typical example
(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)

g01334592

(1) The diameter of the installed camshaft

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

KENR6245	15
	Specifications Section

Illustration 22		g01338238
Typical example
(3)	Setscrew
	Tighten the setscrews to the following
	torque. ......................................	22 N·m (16 lb ft)
(4)	Engine oil filter
	Tighten the engine oil filter to the following
	torque. ....................................	12 N·m (106 lb in)
(5)	Plug
	Tighten the plug to the following torque. .. 12 N·m
		(106 lb in)

i02657143

Engine Oil Cooler

Illustration 23		g00952614
Typical example
(1)	Joint
(2)	Oil cooler
(3)	Housing
(4)	Setscrew
(5)	Seal
(6)	Setscrew
(7)	Setscrew

Illustration 24	g01334858

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)

16	KENR6245
Specifications Section

i02656269

Engine Oil Pump

Engines with Balancer Group

Type .............................	Gear-driven differential rotor
Number of lobes
Inner rotor .........................................................	6
Outer rotor ........................................................	7

Illustration 25	g01334408
The oil pump for the balancer

(1) Clearance of the outer rotor to the

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

Illustration 26	g01334410
Inner rotor
(2) Clearance of inner rotor to outer
rotor ......................................	0.050 to 0.200 mm
	(0.0020 to 0.0079 inch)

Illustration 27	g01334412
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)

KENR6245	17
	Specifications Section

Illustration 28	g01334415
The end cover

(4) Torque for cover bolts for oil pump .......... 26 N·m (19 lb ft)

Illustration 29	g01334416
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)

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).

(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

Illustration 30	g00938064
The oil pump
(1) Clearance of the outer rotor to the
body ......................................	0.152 to 0.330 mm
	(0.0059 to 0.0129 inch)

Illustration 31	g00938061
Checking the clearance
(2) Clearance of inner rotor to outer
rotor ......................................	0.040 to 0.127 mm
	(0.0015 to 0.0050 inch)

18	KENR6245
Specifications Section

Illustration 32	g00938799
Checking the end play
(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
	(89 lb in)
	i02731019

Engine Oil Pressure

The minimum oil pressure at the maximum engine speed and at normal operating temperature is the following value. ............................... 280 kPa (41 psi)

i02505676

Engine Oil Bypass Valve

Installed in the Oil Pump

Illustration 33	g00919893
Typical engine oil pump

Illustration 34	g00921377
Relief valve and spring

(1)Tighten the plug for the relief valve to the following torque. ....................... 35 N·m (26 lb ft)

(2)Plunger

Diameter of 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 the Balancer

Illustration 35	g00919890
Plug

Illustration 36			g00921379
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)

i02662550

Engine Oil Pan

Table 7

Required Tools

	Tool	Part Number	Part Description	Qty
	A	21826038	POWERPART	1
			Retainer

Front sealant

Illustration 37	g01254690
Applying sealant

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
			Tool	Number		Part Description	Qty
						POWERPART red rubber
Illustration 38	g01254887		A	21820221			1
						grease
Applying sealant

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

Illustration 39	g01255016
Typical example

(1) Tighten the four front bolts in position (X) to the following torque. ....................... 22 N·m (16 lb ft)

Illustration 40	g00926199
Breather valve

(1)Cover

(2)Cover plate

(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		Breather Canister

Illustration 41	g00926200
Typical example

(7) O-ring

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

(80 lb in)

Illustration 42		g01277902
Typical example
(1)	Connection
(2)	Clamp
(3)	Hose
(4)	Filter base
(5)	Bolts
(6)	Clamp
(7)	Hose
(8)	Canister

(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 (16 lb ft)

(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	1
			Rubber Grease

Illustration 43	g01253716
Typical example

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)

i02363605

Water Pump

Illustration 44	g01183807
Tightening sequence

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	1
			Retainer

KENR6245	23
	Specifications Section

Illustration 45	g00924764
Typical example
(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)

	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

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)

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.

Note: The oil pan must be installed within 10 minutes 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 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.

Illustration 47	g01338264
Typical example

(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

Illustration 48	g01338265

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	75.905 to 75.926 mm	75.651 to 75.672 mm	75.397 to 75.418 mm
		(2.9884 to 2.9892 inch)	(2.9784 to 2.9792 inch)	(2.9684 to 2.9692 inch)
	2	63.216 to 63.236 mm	62.962 to 62.982 mm	62.708 to 62.728 mm
		(2.4888 to 2.4896 inch)	(2.4788 to 2.4796 inch)	(2.4688 to 2.4696 inch)
	3	39.47 mm (1.5539 inch)	N/A	N/A
		maximum
	4	37.44 mm (1.4740 inch)	N/A	N/A
		maximum
	5	44.68 mm (1.7591 inch)	N/A	N/A
		maximum
	6	40.55 mm (1.5965 inch)	N/A	N/A
		maximum
	7	Do not machine this diameter.	N/A	N/A
	8	3.68 mm (0.1449 inch) to	N/A	N/A
		3.96 mm (0.1559 inch)
	9	4.36 to 4.60 mm	N/A	N/A
		(0.1717 to 0.1811 inch)

Refer to table 12 for the maximum run out of the crankshaft journals.

26	KENR6245
Specifications Section

Table 12

Journal	Excessive run out
(1)	Mounting
(2)	0.08 mm (0.0031 inch)
(3)	0.15 mm (0.0059 inch)
(4)	0.08 mm (0.0031 inch)
(5)	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.

i02658811

Crankshaft Seals

Illustration 49	g01335894
Typical example

(1)Crankshaft

(2)Crankshaft seal

(3)Plastic sleeve

(4)Alignment tool

Illustration 50	g00915076

(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)
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)
	i02504771

Connecting Rod Bearing

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 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)

The shell for the main bearings

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

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)

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)

i02662161

Connecting Rod

Illustration 51	g00907738

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

28		KENR6245
Specifications Section

Illustration 52	g00995584
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 Disassembly and Assembly for information on the alignment tool.

Table 13

	Bearing Width for the	31.62	to 31.88 mm
	Connecting Rod	(1.245 to 1.255 inch)
	Bearing Width for the	31.62	to 31.88 mm
	Connecting Rod Cap	(1.2449 to 1.2551 inch)
	Thickness of Connecting	1.835	to 1.842 mm
	Rod Bearing at the
		(0.0723 to 0.0725 inch)
	Center
	Thickness of Connecting	1.835	to 1.842 mm
	Rod Bearing for the Cap
		(0.0722 to 0.0725 inch)
	at the Center
	Bearing Clearance	0.034	to 0.081 mm
		(0.0013 to 0.0032 inch)

Table 14

Undersized Connecting Rod Bearing

0.25 mm (0.010 inch)

0.51 mm (0.020 inch)

0.76 mm (0.030 inch)

Illustration 53		g00907744
(3)	Inside diameter of the small
	bush ..................................	39.723 to 39.738 mm
		(1.5639 to 1.5645 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)

Illustration 54	g00915056