Specifications

1103D Industrial Engine

XK (Engine)

XL (Engine)

XM (Engine)

This document has been printed from SPI². Not for Resale

 

Important Safety Information

Most  accidents    tha t involve  produc  t  op eration,  ma intena nc e and   repair   are  caus  ed  by  failure  to

ob serve  basic   safety   rules  or  precautions  .  An accident    can   often  be  avoided   by  recog nizing  pote ntially

ha za rdous  situations   before   an  accident    oc curs . A person    mus t be  alert   to pote ntial  ha za rds.  This

person   should   also  ha ve  the  ne cessary   training,  skills  and   tools  to perform   the se  func tions properly.

Improper operation, lubrication, maintenance or repair  of this product can be dangerous and

could result in injury  or death.

Do not operate or perform any lubrication, maintenance or repair on this  product, until you have

read and understood the operation, lubrication, maintenance and repair information.

Sa fety precautions     and  warning s  are   provided   in this  ma nua l and   on  the  produc t.  If the se  ha za rd

warning s  are  not  he eded,   bod ily injury  or death   could   oc cur to  you  or to  othe r persons  .

The  ha za rds are   identified   by  the  “Safety  Alert  Symb ol”  and  followed  by  a  “Signa l  Word” suc h  as

“DANGER”, “WARNING”  or “CAUTION”.  The Sa fety  Alert  “WARNING” label  is  shown   below.

The  me aning  of  this safety   alert   symb ol is  as  follows:

Attention! Become Alert! Your Safety is  Involved.

The  me ssage   tha t appears     und er the   warning  explains    the  ha za rd and   can  be   either  written  or

pictorially   presente  d.

Op erations  tha t  ma y caus e  produc  t dama  ge  are  identified   by  “NOTICE” labels   on  the  produc  t and   in

this  pub lication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The

warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,

work method or operating technique that is not specifically recommended by Perkins is used,

you must satisfy yourself that it is safe  for you and for others. You should also ensure that the

product will not be damaged or be  made unsafe by the operation, lubrication, maintenance or

repair procedures that you choose.

The  informa tion, specifications   ,  and  illustrations   in  this  pub lication  are   on the  basis    of informa tion tha t

was  available    at  the  time  tha t the  pub lication   was  written.   The  specifications   , torque  s,  pressure  s,

me asure me nts , adjustme  nts , illustrations ,  and  othe r  items  can  cha  ng e at  any  time.  These  cha ng es  can

affect   the  service   tha t is given   to the  produc  t.  Ob tain the  comp  lete  and  mos t current   informa tion before

you  start any   job. Pe  rkins  dealers   or   Pe rkins  distributors     ha ve  the  mos t current   informa tion  available.

When  replacement  parts  are  required  for  this

product Perkins recommends using Perkins

 replacement  parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

This document has been printed from SPI². Not for Resale

 

KENR6911

3

Table of  Contents

Table of Contents

Specifications Section

Engine Design  .....................................................

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

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

Fuel Injectors  .......................................................

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

Lifter Group ...........................................................

Rocker Shaft  ........................................................

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

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

4

4

5

6

6

7

7

8

8

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

Turbocharger  .......................................................  12

Exhaust Manifold  .................................................  13

Camshaft  .............................................................  13

Camshaft Bearings  ..............................................  15

Engine Oil Filter  ...................................................  15

Engine Oil Pump  .................................................. 15

Engine Oil Pressure  ............................................. 16

Engine Oil Bypass Valve  ...................................... 17

Engine Oil Pan  ..................................................... 17

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

Water Temperature Regulator and Housing .........  19

Water Pump  ......................................................... 20

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

Crankshaft  ...........................................................  22

Crankshaft Seals  .................................................  24

Connecting Rod Bearing Journal  ......................... 25

Main Bearing Journal ............................................ 25

Connecting Rod  ................................................... 26

Piston and Rings  .................................................. 27

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

Front Housing and Covers  ................................... 29

Gear Group (Front) ............................................... 30

Flywheel  ............................................................... 31

Flywheel Housing  ................................................  32

Crankshaft Pulley  ................................................. 32

Fan Drive  .............................................................  32

Engine Lifting Bracket ........................................... 33

Alternator  .............................................................  33

Starter Motor  ........................................................ 34

Glow Plugs  ........................................................... 35

Index Section

Index .....................................................................  36

This document has been printed from SPI². Not for Resale

 

4

KENR6911

Specifications  Section

Specifications Section

When the camshaft is  viewed from the front of

the engine, the camshaft rotates in  the following

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

i02801123

The front of the engine is opposite the flywheel end.

The left side and the right  side of the engine are

viewed from the flywheel end. The No. 1 cylinder is

the front cylinder.

Engine Design

Part No.:  290-8866

i02801124

Fuel Injection Lines

Part No.:  290-8866

g01223241

Illustration 1

Cylinder and valve location

(A) Exhaust valve

(B) Inlet valve

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

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

g01419468

Illustration 2

A typical fuel line

Displacement ...................................... 3.3 L (201 in )

3

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

following torque. .......................  27 N·m (20 lb ft)

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

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

Compression ratio

Note: Tighten the union nuts at  the fuel injection

pump to the following torque 27 N·m (20 lb ft).

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

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

Turbocharged engines .............................. 17.2:1

Number of cylinders ................................................ 3

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, 2, 3

When the crankshaft is viewed  from the front of

the engine, the crankshaft rotates in the following

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

This document has been printed from SPI². Not for Resale

 

KENR6911

5

Specifications Section

i02801125

Fuel Injection Pump

  

Delphi DP210 and Delphi DP310

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.

g01421823

Illustration 4

The Delphi DP 310 fuel injection pump

Note: The solenoid on the fuel  injection pump is

a serviceable item. The fuel  injection pump is a

nonserviceable item.

Note: A DP210 fuel injection pump is installed on the

naturally aspirated engine. A DP310 fuel injection

pump is installed on the turbocharged engine.

(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.  .................... 14.5 N·m (11 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)

g01419475

Illustration 3

The Delphi DP 210 fuel injection pump

Note: The solenoid on the fuel  injection pump is

a serviceable item. The fuel  injection pump is a

nonserviceable item.

(1)  O-ring

g00986531

(2)  Locking screw

Illustration 5

Support bracket

(3)  Washer

This document has been printed from SPI². Not for Resale

 

6

KENR6911

Specifications  Section

(4)  Tighten the mounting bolt  to the following

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

i02801146

Fuel Transfer Pump

(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)

i02801141

Fuel Injectors

g00986823

Illustration 7

g00908211

Illustration 6

(1)  Retaining bolts

(2)  Clip

Fuel injector clamp

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

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

(3)  Spacer

The fuel injector should be tested at the pressure in

Table 1.

(4)  Fuel transfer pump

Type ................................... 12 volt electric motor

(5)  Fuel filter element

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

Table 1

(6)  O ring

Service setting for  the Fuel Injector

Injection Pressure

(7)  Fuel filter bowl

29.4 + 0.8  MPa (4264 + 116  psi)

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

bowl 1/8 of a turn more by hand.

This document has been printed from SPI². Not for Resale

 

KENR6911

7

Specifications Section

i02801148

Lifter Group

SMC S  Code:  1209

Part No.:  290-8866

S/N:  XK11-Up

Part No.:  280-8866

S/N:  XL11-Up

Part No.:  280-8866

S/N:  XM11-Up

g01418665

Illustration 9

Note: In order to install the rocker shaft assembly,

Tooling (A) is required.

(1)  Snap ring

g00629433

Illustration 8

(2)  Washer

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

(0.7475 to 0.7485 inch)

(3)  Rocker arm

(4)  Rocker arm bore

Clearance of  the lifter in the  cylinder block

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

Diameter of the  rocker arm bore  for the

bushing ............................. 25.013 to 25.051 mm

(0.9848 to 0.9863 inch)

i02801152

Rocker Shaft

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 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.

Table 2

Required Tools

(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)

Tool

Part Number

Part Description

Qty

A

27610227

Spacing Tool

1

(7)  Rocker shaft

Diameter  of  the  rocker

shaft .................................. 24.962 to 24.987 mm

(0.9828 to 0.9837 inch)

This document has been printed from SPI². Not for Resale

 

8

KENR6911

Specifications  Section

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

ensure that the machined square is to the top of

the rocker shaft.

i02830703

Cylinder Head Valves

(9)  Locknut

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

Turbocharged Engines  and

Turbocharged Aftercooled Engines

i02801157

Valve Mechanism Cover

g01345407

Illustration 11

A cross section of a cylinder head for a turbocharged engine and

turbocharged aftercooled engines

(1)  Valve spring

g01018519

Illustration 10

Typical example

The installed  length  of the  valve

springs .......................... 36.17 mm (1.4240 inch)

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

(70 lb)

Tighten the bolts for the valve  mechanism cover

in the sequence that  is shown to the following

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

(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 valve

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

(0.5131 to 0.5137 inch)

This document has been printed from SPI². Not for Resale

 

KENR6911

9

Specifications Section

Interference fit of  valve guide in  cylinder

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

(0.0003 to 0.0019 inch)

(6)  Exhaust valve face angle from the horizontal axis

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

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

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

(2.018 to 2.027 inch)

(7)  Diameter of  the  exhaust

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

Projection of the valve guide above  the valve

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

(0.486 to 0.498 inch)

(1.634 to 1.643 inch)

(8)  Diameter of  the head  of the  inlet

valve .....................................  46.20 to 46.45 mm

(1.8189 to 1.8287 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.

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

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

Valve seat angle ...............................  30 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)

(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.

g00809016

Illustration 12

Turbocharged engines and turbocharged aftercooled

engines .....  1.55 to 1.81 mm (0.0610 to 0.0713 inch)

Recess for the valve seat insert

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

inserts to the following dimensions.

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

(5)  Inlet valve

Recess for inlet valve  seat for turbocharged

engines and turbocharged aftercooled engines

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)

(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

Overall  length  of  the inlet

valve ...................................  128.838 to 129.288 mm

(5.0724 to 5.0901 inch)

(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)

The face of the inlet valve  is recessed below the

cylinder head by the following amount.

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

Turbocharged engines and turbocharged aftercooled

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

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

This document has been printed from SPI². Not for Resale

 

10

KENR6911

Specifications  Section

Naturally Aspirated Engines

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.

(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 0.840 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)

g00294082

Illustration 13

Cross section of naturally aspirated cylinder head

The face of the exhaust valve is recessed below the

cylinder head by the following amount.

(1)  Valve spring

The installed  length  of the  valve

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

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

(0.021 to 0.032 inch)

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

(57.1 lb)

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

(5)  Inlet valve

(2)  Valve spring recess

Diameter  of the  inlet  valve

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

(3)  The finished valve guides

(0.3525 to 0.3533 inch)

Clearance  of valve  in  valve

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

Inside  diameter  of valve

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

(0.3543 to 0.3552 inch)

Overall  length  of  the inlet

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

Outside diameter  of the exhaust  valve

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

(0.5131 to 0.5137 inch)

The face of the inlet valve  is recessed below the

cylinder head by the following amount.

Outside diameter  of the  inlet 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)

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

(0.023 to 0.033 inch)

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

(6)  Exhaust valve face angle from the vertical axis

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

(2.018 to 2.027 inch)

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

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

Projection of the valve guide above  the valve

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

(0.486 to 0.498 inch)

(7)  Diameter of  the  exhaust

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

(1.634 to 1.643 inch)

This document has been printed from SPI². Not for Resale

 

KENR6911

11

Specifications Section

(8)  Diameter of  the head  of the  inlet

i02801177

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

Cylinder Head

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

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

Valve seat angle ...............................  30 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)

The cylinder head bolts are two different lengths. The

following information provides the proper torque for

the cylinder head bolts.

g00809016

Illustration 14

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

(A) ..... 9.84 to 10.04 mm (0.3874 to 0.3952 inch)

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

(1.8826 to 1.8836 inch)

g01017007

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

Illustration 15

The tightening sequence

Recess for exhaust valve  seat for naturally

aspirated engines

Lubricate the threads and the underside of the head

bolts with clean engine oil.

(A) ..... 9.84 to 10.04 mm (0.3874 to 0.3952 inch)

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

(1.6701 to 1.6711 inch)

Tighten the bolts in the sequence that is shown in

illustration 15 to the following torque. ...... 50 N·m

(37 lb ft)

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

Tighten the  bolts again to  the following

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

This document has been printed from SPI². Not for Resale

 

12

KENR6911

Specifications  Section

Table 3

Maximum Permissible

Distortion

Dimension

Width (A)

Height (B)

0.03 mm (0.0012 inch)

0.05 mm (0.0019 inch)

0.05 mm (0.0019 inch)

Diagonal Line (C)

i02801182

Turbocharger

g00905621

Illustration 16

Head bolts

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 illustration 15.

Place an index mark on  the top of each bolt

head. Tighten the short bolts for the additional

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

Place an index mark 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)

The maximum distortion of the cylinder head is given

in table 3.

g00991357

Illustration 18

Typical turbocharger

(1)  Actuator rod

(2)  Actuator

(3)  Turbocharger

g01017008

Illustration 17

Cylinder head

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

(32 lb ft)

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

(80 lb in)

This document has been printed from SPI². Not for Resale

 

KENR6911

13

Specifications Section

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

(16 lb ft)

i02831537

Camshaft

The maximum  test pressure  for  the

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

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

(0.0394 inch)

Table 4

The part number  for

the turbocharger

The pressure for  the

wastegate

2674A715

2674A721

2674A722

101.5  ± 3  kPa

(14.7216 ± 0.4351 psi)

127  ±  3  kPa

(18.4201 ± 0.4351 psi)

154  ±  3  kPa

(22.3362 ± 0.4351 psi)

g01277351

Illustration 20

i02801183

Exhaust Manifold

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)

g01277354

Illustration 21

Typical camshaft

(2)  Bolt

g01017009

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

(70 lb ft)

Illustration 19

Note: The exhaust manifold must be aligned to the

cylinder head. Refer to Disassembly and Assembly

Manual for the correct procedure.

(3)  Camshaft thrust washer

Thickness  of  the  thrust

washer .................................. 5.486 to 5.537 mm

(0.2160 to 0.2180 inch)

Tighten the exhaust manifold bolts in the sequence

that is shown  illustration 19 to  the following

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

Depth of the recess in the cylinder block for the

thrust washer ........................ 5.560 to 5.640 mm

(0.2189 to 0.2220 inch)

This document has been printed from SPI². Not for Resale

 

14

KENR6911

Specifications  Section

Tolerance of the thrust washer in cylinder block

front face ........................... −0.154 to −0.023 mm

(−0.0061 to −0.0009 inch)

Turbocharged engines and  turbocharged

aftercooled engines

Inlet lobe ............................... 7.266 to 7.366 mm

(0.2861 to 0.2900 inch)

Exhaust lobe ......................... 8.081 to 8.181 mm

(4)  The diameters of the camshaft journals are given

in the following table.

(0.3181 to 0.3221 inch)

Table 5

(6)  Camshaft lobe height

(7)  Base circle

Diameters of Camshaft  Journals

Camshaft Journals

Standard Diameter

50.711 to  50.737  mm

(1.9965 to 1.9975 inch)

To determine the lobe lift, use the  procedure that

follows:

1

50.457 to  50.483 mm

(1.9865 to 1.9875 inch)

2 and  3

4

1.  Mount the camshaft between centers.

49.949 to  49.975 mm

(1.9665 to 1.9675 inch)

2.  By using a dial indicator in contact with the surface

of the lobe, rotate the camshaft and record the

maximum and minimum lift.

Maximum wear on the camshaft journals ... 0.05 mm

(0.0021 inch)

Note: There may be two lobes  on the camshaft.

Refer to illustration 22. 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)

g01345411

Illustration 22

Typical example

(5)  Camshaft lobe lift

Naturally aspirated engines

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

(0.2906 to 0.2946 inch)

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

(0.2915 to 0.2954 inch)

This document has been printed from SPI². Not for Resale

 

KENR6911

15

Specifications Section

i02801188

i02801189

Camshaft Bearings

Engine Oil Filter

Spin-on Oil Filter

g00915984

Illustration 24

(1)  Seal

g01017012

Note: Lubricate the top of the seal with clean engine

Illustration 23

oil before installation.

Typical example

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

(1)  Camshaft bearing

The diameter  for the installed camshaft

Pressure to  open engine oil  filter bypass

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

(1.9995 to 2.0019 inch)

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

i02801191

Engine Oil Pump

Three Cylinder Engines without

Balancer Group

Type .............................  Gear-driven differential ro

This document has been printed from SPI². Not for Resale

 

16

KENR6911

Specifications  Section

Number of lobes

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

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

g00938799

Illustration 27

Checking the end play

(3)  End play of rotor assembly

g00938064

Illustration 25

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

(0.0014 to 0.0035 inch)

The oil pump

(1)  Clearance of  the outer rotor  to the

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

(0.0059 to 0.0129 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. ........ 26 N·m

(19 lb ft)

i02807662

Engine Oil Pressure

g00938061

Illustration 26

Checking the clearance

The minimum oil pressure at the maximum engine

speed and at normal operating temperature is the

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

(2)  Clearance of  inner rotor  to outer

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

(0.0015 to 0.0050 inch)

This document has been printed from SPI². Not for Resale

 

KENR6911

17

Specifications Section

i02807665

i02807666

Engine Oil Bypass Valve

Engine Oil Pan

Installed in the Oil Pump

Table 6

Required Tools

Tool

Part Number

Part Description

Qty

POWERPART Rubber

Sealant

A

21826038

1

POWERPART

Threadlock and

Nutlock

B

21820117

1

Front sealant

g00919893

Illustration 28

Typical example

g00990254

Illustration 30

Applying sealant

(1)  Apply Tooling (A) to the cylinder block and to the

timing case.

g00921377

Note: Apply a sealant bead of 3.5 mm (0.1378 inch)

that is shown in illustration 30.

Illustration 29

(2) Plunger

(3) Spring

Rear sealant

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

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

Note: Install the rear oil seal before sealant is applied

to the bridge.

(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)

This document has been printed from SPI². Not for Resale

 

18

KENR6911

Specifications  Section

(6)  Tighten the remaining bolts to the  following

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

Note: The rear face of the cast iron oil pan must be

aligned to the rear face of the cylinder block.

The maximum allowed  value of the rear face

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

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

reuse the bolts, apply Tooling (B) to the first  three

threads of the used bolts.

(5)  Tighten the drain plug for the engine oil pan to

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

g00990255

Illustration 31

Applying sealant

(8)  Tighten the nut for the dipstick (not shown) to the

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

(2)  ApplyTooling (A) to the bridge. The sealant must

not protrude more than  5 mm (0.1969 inch)

above the bridge.

i02807667

Crankcase Breather

Note: The oil pan must be installed within 10 minutes

of applying the sealant.

Table 7

Required Tools

Tool

Part Number

Part Description

Qty

POWERPART Rubber

Grease

A

21820221

1

g01236729

Illustration 32

Tighten the two nuts (4) to the studs (3).

Tighten the  two nuts (4)  to the  following

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

(7)  Tighten the four front bolts  to the following

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

This document has been printed from SPI². Not for Resale

 

KENR6911

19

Specifications Section

g01410651

g01410612

Illustration 33

Breather valve

Illustration 34

(7)  O-ring

(1)  Plastic cover

(2)  Cover plate

(3)  Screws

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)

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)

i02807668

,

Water Temperature Regulator

and Housing

(4)  Diaphragm

(5)  Cap

(6)  Spring

Table 8

Required Tools

Tool

Part Number

Part Description

Qty

POWERPART

Rubber Grease

A

21820221

1

Tighten the bolts (not shown) that fasten the housing

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

This document has been printed from SPI². Not for Resale

 

20

KENR6911

Specifications  Section

g00997234

g00915951

Illustration 35

O ring

Illustration 36

Tightening sequence

Note: Apply Tooling (A) to the O-ring (1) in order to

install the thermostat housing.

Note: Apply Tooling (A) to the first three threads of

the bolts before installation.

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

(174 ° to 151 °F)

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)

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

Note: Refer to the  Disassembly and Assembly

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

(0.3937 inch)

Manual in order to service the water pump.

i02807670

i02807669

Cylinder Block

Water Pump

Table 10

Required Tools

Part

Tool

A

Part Name

Qty

Number

21826038

Silicone Sealant

1

Table 9

Required Tools

Part

Tool

A

Part Name

Qty

Number

21820117

Thread Lock

1

This document has been printed from SPI². Not for Resale

 

KENR6911

21

Specifications Section

Bore in  the cylinder block  for the main

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

(3.1660 to 3.1670 inch)

(12)  Main bearing cap bolts for the four cylinder and

three cylinder engines

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)

g01018250

Illustration 37

Typical example

(8)  Cylinder block

(9)  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)

g01018262

Illustration 38

Use the following procedure in order to install  the

Allen head bolts for the bridge.

(10)  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 (13) for the bridge.

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

Diameter of  the bore  in the cylinder

block for  the number  3  camshaft

journal ............................... 50.546 to 50.597 mm

(1.9900 to 1.9920 inch)

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

applyTooling (A) into groove (14) 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  4  camshaft

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

(1.9700 to 1.9720 inch)

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)

(11)  Main bearings for the three cylinder engine

This document has been printed from SPI². Not for Resale

 

22

KENR6911

Specifications  Section

i02807671

Crankshaft

g01427697

Illustration 39

The crankshaft for the three cylinder engine

(1)  Crankshaft for the three 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)

Note: The timing mark is  toward the outside of

the crankshaft when the gear  is installed on the

crankshaft.

Note: All fillets on the 1103D engines are induction

hardened. No additional hardening is required when

the crankshaft has been reground.

This document has been printed from SPI². Not for Resale

 

KENR6911

23

Specifications Section

g01017747

Illustration 40

The crankshaft for the  three cylinder engine

The crankshaft for the three Cylinder engine

This document has been printed from SPI². Not for Resale

 

24

KENR6911

Specifications  Section

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)

75.926 mm (2.9892 inch) to

75.905 mm (2.9884 inch)

75.672 mm (2.9792 inch) to

75.651 mm (2.9784 inch)

75.418 mm (2.9692 inch) to

75.397 mm (2.9684 inch)

1

63.236 mm (2.4896 inch) to

63.216 mm (2.4888 inch)

62.982 mm (2.4796 inch) to

62.962 mm (2.4788 inch)

62.728 mm (2.4696 inch) to

62.708 mm (2.4688 inch)

2

3

4

5

6

7

39.47  mm

(1.5539 inch)maximum

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

44.68  mm

(1.7591 inch)maximum

40.551  mm

(1.5965 inch)maximum

133.17 mm (5.2429 inch) Do

not machine this diameter.

3.68 mm (0.1449  inch) to

3.96 mm (0.1559 inch)

Refer to table 12 for the  maximum run out of the

crankshaft journals.

i02847193

Crankshaft Seals

The maximum difference in value  between one

crankshaft journal and the next crankshaft journal

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

Table 12

Journal

(1)

Excessive run out

Mounting Dia

(2)

0.08 mm (0.0031 inch)

0.08 mm (0.0031 inch)

Mounting Dia

(3)

(4)

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 41

Refer to the Specifications Module, “Main Bearing

Journal” topic for information on the main bearing

journals and for information on the main bearings.

(1)  Crankshaft

(2)  Plastic sleeve

(3)  Crankshaft seal

(4)  Alignment tool

This document has been printed from SPI². Not for Resale

 

KENR6911

25

Specifications Section

i02807674

Main Bearing Journal

Refer to Specifications Manual, “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)

g00915076

Illustration 42

Surface finish of bearing journals, crank pins  and

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

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

sequence that is shown in Illustration 42 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 42 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)

i02807673

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)

This document has been printed from SPI². Not for Resale

 

26

KENR6911

Specifications  Section

i02807675

Connecting Rod

g00995584

Illustration 44

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 44. Refer to the

Disassembly and assembly manual for information

on the alignment tool.

Table 13

Bearing Width for  the

Connecting Rod

31.62 to  31.88 mm

(1.245 to 1.255 inch)

g00907738

Bearing Width for  the

Connecting Rod Cap

31.62 to  31.88 mm

(1.245 to 1.255 inch)

Illustration 43

The mating surfaces of  the connecting rod are

produced by hydraulically fracturing  the forged

connecting rod.

Thickness of Connecting

Rod Bearing  at the

Center

1.835 to  1.842 mm

(0.0723 to 0.0725 inch)

Thickness of Connecting

Rod Bearing for the Cap

at the  Center

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

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

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

(0.0012 to 0.0032 inch)

Bearing Clearance

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 14

Undersized Connecting Rod Bearing

0.25 mm  (0.010 inch)

0.51 mm  (0.020 inch)

0.76 mm  (0.030 inch)

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

This document has been printed from SPI². Not for Resale

 

KENR6911

27

Specifications Section

Table 15

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)

i02807676

Piston and Rings

g00907744

Illustration 45

(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 47

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)

g00915056

Clearance between the top compression ring and

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

(0.0035 to 0.0059 inch)

Illustration 46

Connecting rods are color coded. The color code

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

rod. Refer to table 15  for the different lengths of

connecting rods.

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

(0.0118 to 0.0216 inch)

Turbocharged

The shape  of the  top compression

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

This document has been printed from SPI². Not for Resale

 

28

KENR6911

Specifications  Section

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

The combustion bowl  re-entrant angle for the

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

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

(0.0118 to 0.0216 inch)

The combustion bowl  re-entrant angle for the

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

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.

Piston height above cylinder block .. 0.21 to 0.35 mm

(0.008 to 0.014 inch)

Width of top  groove in piston for the  naturally

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

(0.1016 to 0.1024 inch)

(2)  Intermediate compression ring

Width of top groove in piston for the turbocharged

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

The shape of the intermediate  compression

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

bottom edge with a tapered face

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

(0.1000 to 0.1008 inch)

Width of  intermediate compression

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

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

(0.1386 to 0.1394 inch)

Clearance between the intermediate compression

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

(0.002 to 0.003 inch)

Piston pin

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

(0.0275 to 0.0374 inch)

Diameter  of  a new  piston

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

(1.5628 to 1.5630 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.

Diameter of  the bore  for the  piston

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

(1.5631 to 1.5633 inch)

i02807678

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)

Note: The three cylinder naturally aspirated engine

may have installed piston cooling jets as an option.

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.

Note: Ensure that the ring end gaps  of the piston

rings are spaced 120 degrees from each other.

Piston

g00942652

Illustration 48

Note: An arrow which is marked on the piston crown

must be toward the front of the engine.

(1) Installed piston cooling jets

This document has been printed from SPI². Not for Resale

 

KENR6911

29

Specifications Section

The valve that is spring loaded must  move freely.

Tighten the bolt to the following torque. ........... 9 N·m

(7 lb ft)

Piston Cooling Jet Alignment

g01224872

Illustration 50

Alignment

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

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

(16 lb ft)

g01006929

Illustration 49

(2) Piston cooling jet

(3) Rod

(4) Cylinder block

Use the following procedure in order to check  the

alignment of the piston cooling jet.

1.  Insert rod (3) into the end of the piston cooling

jet (2). Rod  (3) has a diameter of  1.70 mm

(0.067 inch). Rod (3) must protrude out of the top

of the cylinder block.

2.  Dimension (A) is 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).

g00918672

Illustration 51

i02807679

Front cover

Front Housing and Covers

(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.

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 )

This document has been printed from SPI². Not for Resale

 

30

KENR6911

Specifications  Section

i02807680

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

(3)  Idler gear and hub

Gear Group (Front)

Tighten the bolts for the idler gear to the following

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

Bore diameter  of  the idler  gear

The 1103D mechanical engine may use two types

of fuel injection pump. The fuel injection pump may

be a Delphi 210 fuel injection pump or a Delphi 310

fuel injection pump.

.... 57.137 to 57.175 mm (2.2495 to 2.2510 inch)

Bore diameter of  the idler gear with  roller

bearings ............................ 72.345 to 72.364 mm

(2.8482 to 2.8490 inch)

Width of  idler gear  and split bearing

assembly ..........................  30.135 to 30.165 mm

(1.186 to 1.188 inch)

Inside diameter of  idler gear bearings with

flanges ..............................  50.797 to 50.818 mm

(1.9999 to 2.0007 inch)

Outside  diameter of  idler gear

hub .................................... 50.716 to 50.737 mm

(1.9967 to 1.9975 inch)

Outside diameter of idler gear hub  with roller

bearings ............................. 59.100 to 59.115 mm

(2.3268 to 2.3274 inch)

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

(0.004 to 0.008 inch)

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

(0.015 inch)

Idler  gear end  play with  roller

g00995886

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

(0.0039 to 0.0295 inch)

Illustration 52

Gear train

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

(1)  Fuel injection pump drive gear

Tighten the nut to the following torque. ... 24 N·m

(18 lb ft)

Release the lock on the fuel injection pump shaft.

Torque the nut to the following torque. .... 90 N·m

(66 lb ft)

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

Note: Refer to the Specifications, “Fuel  Injection

Pump” for the locking torque for the  fuel injection

pump shaft.

(2)  Camshaft gear

Tighten the bolt for the  camshaft gear to the

g00996214

Illustration 53

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

The gear train for the oil pump

Bore  diameter of  the camshaft

gear ......................................  34.92 to 34.95 mm

(1.3748 to 1.3760 inch)

(4)  Crankshaft gear

Bore diameter  of crankshaft  gear

.... 47.625 to 47.650 mm (1.8750 to 1.8760 inch)

Outside diameter  of the  camshaft

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

This document has been printed from SPI². Not for Resale

 

KENR6911

31

Specifications Section

Outside diameter  of  crankshaft

i02807681

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

(1.8750 to 1.8758 inch)

Flywheel

Clearance  of  gear  on

crankshaft ......................... −0.020 to +0.025 mm

(−0.0008 to +0.0010 inch)

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

(5)  Oil pump idler gear

Inside diameter  of oil pump  idler gear

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

(0.6304 to 0.6314 inch)

Outside diameter of  oil pump idler  gear

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

(0.6286 to 0.6293 inch)

Clearance of oil pump idler  gear bearing on

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

(0.0011 to 0.0028 inch)

End  play of  the oil  pump  idler

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

(0.0019 to 0.0108 inch)

(6)  Oil pump gear

g00584712

Illustration 54

The number of teeth on the oil pump gear .....  17

Standard flywheel

Backlash values

(1)  Flywheel ring gear

Backlash between the idler gear (5) and the oil

pump drive gear (6) ..............  0.046 to 0.106 mm

(0.0018 to 0.0041 inch)

Heat the flywheel ring  gear to the following

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

Backlash between the oil pump idler gear (5) and

the crankshaft gear (4) .........  0.095 to 0.160 mm

(0.0037 to 0.0063 inch)

Note: Do not use an oxyacetylene torch to heat the

flywheel ring gear.

(2)  Flywheel

(3)  Bolt

Backlash between the idler gear  (3) and the

crankshaft gear (4) ...............  0.064 to 0.124 mm

(0.0025 to 0.0049 inch)

Tighten the flywheel  bolts to the following

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

Backlash between the camshaft gear (2) and the

idler gear (3) .........................  0.052 to 0.107 mm

(0.0020 to 0.0042 inch)

Non-standard flywheel

Backlash between the fuel injection pump gear

(1) and the idler gear (3) ....... 0.054 to 0.109 mm

(0.0021 to 0.0043 inch)

Note: A special flywheel is aligned to a dowel on the

crankshaft.

Backlash between the water pump  gear (not

shown) and the  fuel injection pump gear

(1) ...  0.073 to 0.133 mm (0.0028 to 0.0052 inch)

Backlash between  the power take-off

drive (  if equipped) and  the idler gear

(3) .... 0.112 to 0.172 mm (0.0044 to 0.0068 inch)

This document has been printed from SPI². Not for Resale

 

32

KENR6911

Specifications  Section

i02807682

i02807684

Flywheel Housing

Crankshaft Pulley

g00915497

Illustration 56

Typical example

(1)  Tighten the three bolts  progressively for

the crankshaft  pulley to the  following

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

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

(2)  Thrust block

(3)  Crankshaft pulley

g01338247

Illustration 55

i02830701

Typical example

Fan Drive

(1)  Bolt

Tighten the bolts for the 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)

Tighten the studs (not  shown) that support the

extension for the fan to 11 N·m (8 lb ft).

Note: Certain engines may be equipped with a back

plate.

This document has been printed from SPI². Not for Resale

 

KENR6911

33

Specifications Section

i02807693

Alternator

12 Volt Alternator

g00926178

Illustration 57

A typical fan drive

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

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

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)

Maximum permissible end play of the shaft .. 0.20 mm

(0.0079 inch)

g00959541

Illustration 58

i02807686

A typical alternator

Engine Lifting Bracket

(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)

All engines are equipped with  two engine lifting

brackets.

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

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

Tighten the two bolts  on each engine lifting

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

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

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

V-Belt

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

to Operation and Maintenance Manual, “Alternator

and Fan Belts -  Inspect/Adjust/Replace” for the

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

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

Used V-belt tension .............................  355 N (80 lb)

This document has been printed from SPI². Not for Resale

 

34

KENR6911

Specifications  Section

i02807694

Starter Motor

12 Volt Starting Motor

g00977365

Illustration 59

The 12 volt starting 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

This document has been printed from SPI². Not for Resale

 

KENR6911

35

Specifications Section

i02807695

Glow Plugs

g01224881

Illustration 60

Typical example

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

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

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

Note: Glow plugs are not installed on all engines.

Engines that do not have glow plugs are  installed

with threaded plugs.

This document has been printed from SPI². Not for Resale

 

Index

A

G

Alternator...............................................................  33

12 Volt Alternator ............................................... 33

V-Belt ................................................................. 33

Gear Group (Front)................................................ 30

Glow Plugs ............................................................ 35

I

C

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

2

7

Camshaft...............................................................  13

Camshaft Bearings................................................  15

Connecting Rod.....................................................  26

Connecting Rod Bearing Journal........................... 25

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

Crankshaft ............................................................  22

Crankshaft Pulley .................................................. 32

Crankshaft Seals...................................................  24

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

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

L

Lifter Group............................................................

M

Main Bearing Journal............................................. 25

The shell for the main bearings.......................... 25

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

8

Naturally Aspirated Engines............................... 10

Turbocharged Engines and  Turbocharged

Aftercooled Engines.........................................

8

P

Piston and Rings ................................................... 27

Piston.................................................................  28

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

Piston Cooling Jet Alignment.............................  29

E

Engine Design.......................................................

4

Engine Lifting Bracket............................................ 33

Engine Oil Bypass Valve ....................................... 17

Installed in the Oil Pump....................................  17

Engine Oil Filter.....................................................  15

Spin-on Oil Filter ................................................ 15

Engine Oil Pan....................................................... 17

Front sealant......................................................  17

Rear sealant....................................................... 17

Engine Oil Pressure............................................... 16

Engine Oil Pump.................................................... 15

Three Cylinder Engines  without Balancer

R

Rocker Shaft..........................................................

7

4

S

Specifications Section ...........................................

Starter Motor.......................................................... 34

Group...............................................................  15

Exhaust Manifold...................................................  13

12 Volt Starting Motor ........................................ 34

T

F

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

Turbocharger.........................................................  12

3

Fan Drive...............................................................  32

Fan drive housing .............................................. 33

Flywheel ................................................................ 31

Non-standard flywheel ....................................... 31

Flywheel Housing..................................................  32

Front Housing and Covers..................................... 29

V

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

8

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

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

Delphi DP210 and Delphi DP310.......................

Fuel Injectors.........................................................

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

4

5

5

6

6

W

Water Pump........................................................... 20

Water Temperature Regulator and Housing..........  19

©2008 Perkins Engines Company Limited

All Rights Reserved

Printed in U. K.

This document has been printed from SPI². Not for Resale