S6D114 E1 Engine PDF

CEBM000601
Shop
Manual
SGD114E=i
SAID1
14E=l
SAAGD114E=i
SERIES ENGINE
SERIAL NUMBERS 45241940andw

This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
May 1997 Copyright 1997 Komatsu America International Company

CONTENTS
SHOP MANUAL ....................................... 01
TROUBLESHOOTING & REPAIR MANUAL .................... 02

PRODUCT PUBLICATIONS INFORMATION
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MANUALS ARE ALSO AVAIlABLE AS WELL AS SELECTED OPERATION & SERVICE MANUALS IN FOREIGN
LANGUAGES.
THE PUBLICATION LISTED BELOW ARE AVAILABLE FOR THE 6D114E-1 SERIES ENGINE.
DESCRIPTION FORM NUMBER
SHOP MANUAL SET: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM000601
Troubleshooting & Repair Manual
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Shop Manual
S6D114E-1
SAGDI 14E-1
SAAGDI 14E-1
Series Engine
6D114E-I Series Engine

Foreword
This manual contains complete rebuild specifications and information for the 6D114E-1 Series engines.
The repair procedures in this manual are based on the engine being installed on an approved engine stand. Some rebuild
procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures.
When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used
in place of the recommended item.
A series of specific service manuals (Shop, Specification, Alternative Repair, and so forth) are available and can be
ordered through your distributor using the form in the front of this book.
The specifications and rebuild information in this manual is based on the information in effect at the time of printing.
Komatsu America International Company reserves the right to make any changes at any time without obligation. If
differences are found between your engine and the information in this manual, contact your Komatsu Distributor.
The latest technology and the highest quality components are used to manufacture Komatsu engines. When replacement
parts are needed, we recommend using only genuine Komatsu exchange parts.
Engine - Exploded View by Groups
GROUP 02
GROUP b9
‘GROUP 16
Table of Contents
Page
Introduction ................................................................. 1
Engine Identification ........................................................... E
Engine Disassembly and Assembly - Group 00 .......................................... 0
Cylinder Block - Group 01 ....................................................... 1
Cylinder Head - Group 02 ..................................... . . . . . . . . . . . . . . . . . 2
Rocker Levers - Group 03 ..................................... . . . . . . . . . . . . . . . . . 3
Cam Followers - Group 04 ....................................................... 4
Fuel System - Group 05 ......................................................... 5
Injectors and Fuel Lines - Group 06 ................................................. 6
Lubricating Oil System - Group 07 ...... . . . .................. 7
Cooling System - Group 08 .......... . . . .................. 8
Drive Units - Group 09 .............. . . . .................. 9
Air Intake System - Group 10 ......... . . . ................. 10
Exhaust System - Group 11 ..................................................... 11
Air Equipment - Group 12 ...................................................... 12
Electrical Equipment - Group 13 .................................................. 13
Engine Testing - Group 14 ...................................................... 14
Instruments and Controls - Group 15 ............................................... 15
Mounting Adaptations - Group 16 ................................................. 16
Specifications and Torque Values - Group 18 .......................................... 18
Index ..................................................................... X
Section i - Introduction Page i-l
Section i - Introduction
Section Contents
Page
Aboutthe Manual .......................................................... i-2
General Cleaning instructions .................................................. i-8

Solvent and Acid Cleaning .................................................... i-8
Steam Cleaning . . . . . . . .................................................... i-8
General Repair Instructions .................................................... i-7
General Safety Instructions .................................................... i-6
Generic Symbols . . . . . . . .................................................... i-4
Glossary of Terms . . . . . . .................................................... i-9
How To Use This Manual . .................................................... i-3

Group Contents . . . . . . . .................................................... i-3
Index . . . . . . . . . . . . . . .................................................... i-3
Metric Information, . . . . . .................................................... i-3
Table of Contents . . . . . .................................................... i-3
Illustrations . . . . . . . . . . . .................................................... i-5

Page i-2 Section i - Introduction
About the Manual

This 6D114E-1 Series Shop Manual is intended to aid mechanics in disassembly, inspecting parts for reuse, rebuilding
and assembly of components of the 6D114E-1 Series engines. The manual is divided into sections. Section 00 outlines
the disassembly and assembly of the engine while the other section detail specific components.
The procedures in this manual were developed for a shop environment with engine disassembly and assembly being
performed on a rollover stand. A Group System has been used to subdivide the instructions by major components and
systems. Refer to the Table of Contents (page i-l) for the various groups. The information is presented in very basic terms
to make sure the instructions are easily understood. Wrench sizes and shop tooling are identified in the procedure when
needed.
Each group contains the following in sequence:
l An Alphabetical Table of Contents (Index).
l Exploded view(s) of all the components -in the group.
l General Information Section(s) containing the basic service, maintenance, and design information necessary to assist
in the rebuild of the engine or a component.
l Procedural instructions for the disassembly, inspection, repair, and assembly that can be required to rebuild an
engine. Additional repairs that are not essential during every rebuild, but can be necessary, are included. These
repairs depend on the length of time an engine has been in service and the condition of the parts.
Section i - Introduction Page i-3
How To Use This Manual

Table of Contents
The Table of Contents in the front of the manual contains a quick page reference for each group number.
Group Contents
Each group contains the following information:
l A group index page at the beginning of each group to quickly aid in locating the information desired.
l General information to aid in rebuilding the component and an explanation of design change differences.
l Step-by-step rebuild instructions for disassembly, cleaning, inspection, and assembly of the component.
l Symbols which represent the action outlined in the instructions. The definitions of the symbols, appear on pages
i-5 through i-8.
Index
An alphabetical index is in the back of the manual to aid in locating specific information.
Metric Information,
Both metric and U.S. customary values,are used in this manual. The metric value is listed first, followed by the U.S.
customary in brackets. An example is 60°C [14O”F].
Illustrations
The illustrations used in the “Repair Sections” of this manual

are intended to give an example of a problem, and to show
what to look for and where the problem can be found. Some
0+B
of the illustrations are “generic” and might not look exactly
like the engine or parts used in your application. The
illustrations can contain symbols to indicate an action
required, and an acceptable or not acceptable condition.
/
ca9OOsh
The illustrations are intended to show repair or replacement

procedures. The illustration can differ from your application,
but the procedure given will be the same.
kn9cswt
Page i-6 Section i - introduction
General Safety Instructions

Important Safety Notice
A WARNING A
Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation or other bodily injury or death.
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the
general safety precautions that must be followed to provide personal safety. Special safety precautions are included in
the procedures when they apply.
Make sure the work area surrounding the product is safe. Be aware of hazardous conditions that can exist.
Always wear protective glasses and protective shoes when working.
Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air starting
motor if equipped to prevent accidental engine starting. Put a “Do Not Operate” tag in the operator’s compartment
or on the controls.
Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the
engine by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or
damage to the fan blade(s) causing premature fan failure.
If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the filler
cap and relieve the pressure from the cooling system.
Do not work on any thing that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.
Relieve all pressure in the air, oil, and the cooling systems before any lines, fiiings, or related items are removed
or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure,
Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.
To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon) lines
in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled
using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere. Federal law
requires capture and recycling refrigerant.
To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more.
Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity.
Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not
be side-loaded.
Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact with
skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact,
immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A
PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.
To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes
and compartments.
Always use tools that are in good condition, Make sure you understand how to use them before performing any
service work. Use ONLY genuine replacement parts.
Always use the same fastener part number (or equivalent) when replacing fasteners, Do not use a fastener, of
lessor quality if replacements are necessary.
Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
General Repair Instructions

This engine incorporates the latest diesel technology; yet, it is designed to be repaired using normal repair practices
performed to quality standards.
Komatsu America International Company does not recommend or authorize any modifications or repairs to
engines or components except for those detailed in Komatsu Service Information. In particular, unauthorized
repair to safety-related components can cause personal injury. Below is a partial listing of components
classified as safety-related:
Air Compressor
Air Controls
Air Shutoff Assemblies
Balance Weights
Cooling Fan
Fan Hub Assembly
Fan Mounting Bracket(s)
Fan Mounting Capscrews
Fan Hub Spindle
Flywheel
Flywheel Crankshaft Adapter
Flywheel Mounting Capscrews
Fuel Shutoff Assemblies
Fuel Supply Tubes
Lifting Brackets
Throttle Controls
Turbocharger Compressor Casing
Turbocharger Oil Drain tine(s)
Turbocharger Oil Supply Line(s)
Turbocharger Turbine Casing
Vibration Damper Mounting Capscrews
Follow All Safety Instructions Noted In the Procedures.
Follow the manufacturer’s recommendations for cleaning solvents and there substances used during the repair of
the engine. Some solvents and used engine oil have been identified by government agencies as toxic or
carcinogenic. Avoid excessive breathing, ingestion and contact with such substances. Always use good safety
practices with tools and equipment.
Provide A Clean Environment and Follow the Cleaning Instructions Specified in the Procedures
The engine and its components must be kept clean during any repair. Contamination of the engine and
components will cause premature wear.
Perform the Inspections Specified in the Procedures.
Use Genuine Komatsu Service Parts and Assemblies
Replace all Components or Assemblies Which are Damaged or Worn Beyond the Specifications
- The assembly instructions have been written to use again as many components and assemblies as possible. When
it is necessary to replace a component or assembly, the procedure is based on the use of new Komatsu
components. All of the repair services described in this manual are available from all Komatsu Distributors.
0 Follow The Specified Disassembly and Assembly Procedures to Avoid Damage to the Components.
Complete rebuild instructions are available in the shop manual which can be ordered or purchased from your Komatsu
Distributor. Refer to Section L, Literature, for ordering instructions.
Page i-8 Section i - Introduction
General Cleaning Instructions

Solvent and Acid Cleaning
Several solvent and acid-type cleaners can be used to clean the engine parts. Komatsu America International
Company does not recommend any specific cleaners. Always follow the cleaner manufacturer’s instructions.
Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95”
Celsius 1160 to 200” Fahrenheit]. A cleaning tank that provides a constant mixing and filtering of the cleaning
solution will give the best results.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper
before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam
clean the parts before putting them in the cleaning tank.
Warning: The use of acid can be extremely dangerous to personnel and can damage the machinery. Always
provide a tank of strong soda water as a neutralizing agent.
Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from
all of the capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rust-proofing compound. The rust-
proofing compound must be removed from the parts before installation on the engine.
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good way
to clean the oil drillings.
Warning: Wear protective clothing to prevent personal Injury from the high pressure and extreme heat.
Do not steam clean the following parts:
1. Electrical Components
2. Wiring
3. Injectors
4. Fuel Pump
5. Belts and Hoses
6. Bearings
Glass or Plastic Bead Cleaning
Glass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning
process is controlled by the size of the glass or plastic beads, the operating pressure, and the cleaning time.
Caution: Do not use glass or plastic bead cleaning on aluminum piston skirts. Do not use glass bead
cleaning on aluminum ring grooves. Small particles of glass or plastic will embed in the
aluminum and result in premature wear. Valves, turbocharger shafts, etc. can also be damaged.
follow the cleaning directions listed in the procedures.
Follow the equipment manufacturer’s cleaning instructions. The following guidelines can be used to adapt to
manufacture’s instruction:
1. Bead size: Use U.S. size No. 60 for general purpose cleaning with glass media.
2. Operating Pressure: Glass: Use 620 Kpa 190 psi] for general purpose cleaning.
3. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic beads
after cleaning. Rinse with hot water. Dry with compressed air.
4. Do not contaminate the wash tanks with glass or plastic beads.
Glossary of Terms
Definition
A. C.: Alternating Current
AFC: Air Fuel Control; a device in the fuel pump that limits the fuel delivery until there is
sufficient intake manifold pressure to allow for complete combustion.
ATDC: After Top Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is moving downward on the power stroke or intake stroke.
BDC: Bottom Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is at its lowest position in the cylinder.
BTDC: Before Top Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is moving upward on the compression stroke or exhaust stroke.
Circumferential Direction: In the direction of a circle in respect to the centerline of a round part or a bore.
Concentricity: A measurement of the difference between the centers of either two or more parts or the
bores In one part.
Silicone Sealant: This is a one part Room Temperature Vulcanizing (RTV) silicone rubber, adhesive and
sealant material having high heat and oil resistance, and low compression set.
Some of the equivalent products are Marston Lubricants, Hylosil, Dow Corning, Silastic
732, Loctite Supetflex, General Electric RTV108 and Three Bond Sealant.
D. C.: Direct Current
Dye Penetrant Method: A method used to check for cracks in a part by using a dye penetrant and a developer.
Use crack detection kit, Part No. 3375432, or its equivalent.
End Clearance: The clearance in an assembly determined by pushing the shaft in an axial direction one
way and then pushing the shaft the other way.
E. S. N. Engine Serial Number
Hammer: A hand tool consisting of a hard steel head on a handle.
I. D.: Inside Diameter
Loctite 290: A single component, anaerobic, polyester resin, liquid sealant compound that hardens
between closely fitted metal surfaces producing a tough. hard bond. Equivalent products
are Komatsu 1232 273 Hl and Perma-Lok HL 126.
Loctite 609: A single component anaerobic, liquid adhesive that meets or exceeds the requirements
of MIL-R-46082A (MN) TYPEl.
Some of the equivalent products are Komatsu 634 018 Cl, Loctite 601 and Permabond
HL 138.
Lubriplate 105: A mineral oil base grease with calcium soap (2 percent to 6 percent), and zinc oxide (2
percent to 4 percent) additives.
Magnetic Particle Inspection: A method of checking for cracks in either steel or iron parts. This method requires a
Magnaflux or equivalent machine that imparts a magnetic field on the part being checked.
Mallet: A hand tool consisting of a sofi head, either wood, plastic, lead, brass, or rawhide, on
a handle.
Page i-10 Section i - introduction
Definition
MAX: Maximum allowed
MIN: Minimum allowed
No.: Number
O.D.: Outside Diameter
OS: Oversize
Protrusion: The difference in the height between two parts in the assembled state.
STD: Standard
TC: Torque Converter; used when referring to the torque converter cooler.
TDC: Top Dead Center; refers to the position of the piston or the crankshaft rod journal. The
piston is at its highest position in the cylinder. The rod journal is pointing straight up
toward the piston.
T.I.R.: Total Indicator Runout; used when measuring the concentricity or the runout. The T.I.R.
refers to the total movement of the needle on a dial indicator, from the most negative
reading to the most positive reading.
Water Pump Grease: A premium high temperature grease that will lubricate anti-friction bearings continually
from minus 40” C [minus 40” F] to plus 150” C [plus 350” F]. Some of the greases
meeting this requirement are Aeroshell No. 5, Chevron SRI, Amoco Rykon Premium No.
2, Texaco Premium RB, and Shell Dolium R. Aeroshell No. 5 is not compatible with the
other greases and must not be mixed. Aeroshell No. 5 is used on new engines and
components.
Section E - Enaine and Component Identification
Page E-l
Section E - Engine and Component Identification

Section Contents
Page
Engine Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine Identification ......................................................... 2

Engine Dataplate ........................................................... 2
Fuel Injection Pump Dataplate .................................................. 3
General Engine Specifications ................................................... 4

Cooling System ............................................................ 5
Fuel System .............................................................. 5
General Engine Data ........................................................ 4
Intake Air and Exhaust System .................................................. 5
Lubrication System.. ........................................................ 4
Engine Identification Section E - Engine and Component Identification
Page E-2
Engine Identification
Engine Dataplates
The engine dataplates show specific information about your
engine. The engine serial number provides information for
ordering parts and service needs.
The engine dataplates are located on the front gear cover
housing, on the fuel pump side of the engine, oriented 90
degrees from horizontal. See drawing at left.
NOTE: The engine dataplate must not be changed unless
approved by Komatsu.
6Cl
C.I.D/L CPL EUXN

KOMATSU FAMILY
-!3ERIAL ND.
Lmo.Lruhcr., Illcmr.,6W69 U.S.A.
TIMING EC %a?
KCMATSU
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Vo1d.d If b u.1 Rar. Rpy 0, Allrrudm c xemd RAE0 l+vKw AT m
PubLImhsd km,.“. Vm1u.s For Tht. Med.1 And nRING _
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“md&!!.A. LOU IDLE RANGE FUEL RATE AT RATED IP MM3/STROKE
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Engine Dataplates
The. Komatsu model designation represent the

basrc desrgn and confrguratron of your engine. (1) Turbocharged
Example Engine Model Name: (2) Jacket water aftercooled (JWAC)
(2) or (3)
6D114E-1, S6D114E-1, SAGD114E-1 or SAAGD114E-1
(3) Charged air cooled (CAC)
S A (AA) 6 D114 E -1 (4) Number of cylinders

(1) (2) (3) (4) (8) (6) (7) (8) (5) Diesel
(6) Cylinder Bore Dia. in mm
(7) Emission&d
(8) Engine Series
Section E - Engine and Component Identification Injection Pump Dataplate
Page E-3
Fuel Injection Pump Dataplate

The injection pump dataplate is located on the side of the
injection pump. It provides information for fuel pump
calibration.
The Bosch Injection pump dataplate contains:

1. Pump Serial Number
2. Bosch Ten Digit Number
3. Bosch Designation Code
PES6AlOOD32
The vendor part number for the fuel pump-governor

combination is located on the governor dataplate.
The Bosch governor dataplate contains:

1. Bosch Governor Designation Code.
2. Vendor Pump Part Number
-
S/RSV425 llOOAOC2190-8Ri
CDC-NO 390 6541
\ Made In USA
fp901g
General Engine Specifications Section E - Engine Component Identification
Page E-4
General Engine Specifications
General Engine Data

Bore ................................................................ 114 mm [4.49 in]
Stroke ............................................................... 135 mm 15.32 in]
Displacement ........................................................ 8.27 liters 1504.5 in31
Compression ratio
6D114E-1 .................................................................. 16.4:1
S6D114E-1 ................................................................. 17.3:1
SAGD114E-1 ................................................................ 16.5:1
SAAGD114E-l *
High Torque ............................................................. 17.3:1
LowTorque.. ............................................................. 18:l
Firing order ................................................................ l-53-6-24
Valve clearance
Intake ........................................................... 0.30 mm [0.012 in]
Exhaust .......................................................... .0.61 mm [0.024 in]
Engine rotation (viewed from front of engine) .......................................... Clockwise
Aspiration
6D114E-1 ......................................................... Naturally Aspirated
S6D114E-1 ........................................................... Turbocharged
SAGD114E-1 ......................................... Turbocharged and Jacket Water Cooled
SAAGD114E-1 .................................... Turbocharged and Charged Air Cooled (CAC)
Engine weight (with standard accessories)
Dry weight ............................................... 603 to 612 kg [1330 to 1380 lb]
Wet weight ............................................... 635 to 658 kg [1400 to 1450 lb]
Lubrication System
Oil pressure
At idle (minimum allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa [lo psi]
At rated speed (minimum allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 kPa [30 psi]
Differential pressure to open oil filter bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa [25 psi]
Oil flow at rated speed (less flow though pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . 106.8 Ipm [28.2 gpm]
Oil temperature at rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.9” to 126.6”C [210” to 26O”F]
Oil temperature thermostat
Fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116°C [241”F]
Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104°C [219”F]
Oil pan capacity (all engines) (high - low) . . . . . . . . . . . . . . . . . . . . . . . . 18.9 to 15.1 liters [20 to 16 U.S. Qts.]
Total system capacity
6D114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.6 liters [25.0 U.S. Qts.]
S6D114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.8 liters [25.2 U.S. Qts]
* All emission&d engines with Charged Air Cooling are designed as “AA”.
Section E - Engine Component Identification General Engine Specifications
Page E-5
Cooling System
Thermostats
Begins to open .............................................. 81” to 83°C [178” to 182”F]
Fully open ............................................................ 95°C [203”F]
Top tank temperature
Maximum allowable ..................................................... 100°C [212’F]
Minimum recommended ................................................... 70” C [158” F]
Pressure cap for 99°C [210” F] system ........................................... 50 kPa [7 psi]
Pressure cap for 104°C [220” F] system ......................................... 103 kPa [15 psi]
Water Pressure (Upper manifold) at 2000 RPM engine speed .................. 103 to 276 kPa 115 to 40 psi]
Coolant flow (thermostats fully opened, engine speed 2000 RPM) ....................... 258 Ipm 168 gpm]
Coolant capacity (engine only)
6D114E-1, S6D114E-1, SAAGD114E-1* .................................. 9.9 liters [lo.5 U.S. Qts.]
SAGD114E-1 .................................................. 10.9 liters Ill.5 U.S. Qts.]
Intake Air and Exhaust System

Maximum allowable intake restriction at rated speed and load (with dirty air filter element)
6D114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.8 cm H,O 120 in H,O]
S6D114E-1, SAGD114E-1, SAAGD114E-l* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 cm H,O [25 in H,O]
Maximum turbocharger outlet restriction at rated speed and load
6D114E-1, S6D114E-1, SAAGD114E-l* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.2 mm Hg [3 in Hg]
6D114E-1, SAAGD114E-1* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.6 cm H,O [40 in H,O]
SAGD114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 in H,O [S in Hg]
Fuel System
Fuel transfer pump maximum inlet restriction
6D114E-1, S6D114E-1, SAGD114E-1, SAAGD114E-l* . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Hg [4.0 in Hg]
Fuel transfer pump maximum output pressure
6D114E-1, S6D114E-1, SAGD114E-1 Low Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 kPa [12 psi]
SAAGD114E-l* High Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa 125 psi]
Fuel filter restriction (maximum pressure drop across filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 kPa [5 psi]
Fuel pump gallery pressure minimum at rated speed high flow . . . . . . . . . . . . . . . . . . . . . . . . . . 140 kPa 120 psi]
Fuel pump gallery pressure minimum at rated speed low Row . . . . . . . . . . . . . . . . . . . . . . . . . 48 kPa [7 psi]
Fuel return restriction (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 mm Hg [20.4 in Hg]
* All emissionized engines with Charged Air Cooling are designed as “AA”.
Engine Diagram Section E - Engine Component Identification
Page E-6
Engine Diagrams
The illustration which follow show the locations of the major external engine components, the filters, and other service
and maintenance points. Some external components will be at different location for different engines.
High Pressure
%[inch]NPTF (Air)
Fuel Lines
Front Lifting I
Fuel/Water
Fuel Transfer
’ %x lB(inch]UNF
Tap for Magnetic
Pick-up
Air /Il7II IHtl II II I I HII II II II II I IE--+d
Front Engine
Mounting Bracket
FUEL PUMP SIDE VIEW

Section E - Engine Component Identification Engine Diagram
Page E-7
Crsnkcase Westha
Vent Tubs
I / PilotBesrina
M&tin9 Holes
Housing
Rear View
Turbocha~e~ Engine Air

Turbochar9er bi. lnkt
Inlet
/
Filter
Front View
Engine Diagram Section E - Engine Component Identification
Page E-8
Turbocharger Turbocharger
Wastegate Actuator. Air Outlet
Turbocharger
Water Outlet
Exhaust Outlet
Connection
Lubricating Oil
Provision for
Coolant Heater
Provision for
Pressure (before
Cab Heater
Turbocharger
Oil Drain
Coolant Inlet
Turbocharger Side View

Engine Disassembly and Assembly - Group 00
Page O-l

Section Contents
Page
Engine - Assembly .......................................................... O-39

AFC Tube - Installation ..................................................... O-l 12 -
Aftercooler - Installation ..................................................... O-97 -
Air Compressor - Installation ................................................. O-l 19
Air Crossover Tube - Installation ............................................... O-101
Alternator Brace - Installation ................................................. O-104
Alternator - Installation ..................................................... O-l 03
Alternator Mounting Bracket - Installation ......................................... O-l 03
Belt Tensioner Bracket - Installation ............................................ O-105
Belt Tensioner - Installation .................................................. O-105
Camshaft - Installation ...................................................... O-65
Connecting Rod Bolt - Installation ............................................... O-54
Coolant Filter - Installation ................................................... O-102
Coolant Heater - Installation ................................................... O-82
Coolant Inlet Connection - Installation ........................................... O-103
Coolant Outlet Connection - Installation .......................................... O-102
Coolant Vent Fitting - Installation .............................................. O-102
Coolant Vent Petcock - Installation ............................................. O-102
Coolant Vent Tube - Installation ............................................... O-103
Crankcase Breather Tube - Installation ............................................ O-95
Crankshaft - Installation ...................................................... O-47
Cylinder Block - Installation onto Engine Rebuild Stand ................................ O-39
Cylinder Head - Installation ................................................... O-85
Cylinder Liner - Installation ................................................... O-40
Drive Belt - Installation ..................................................... O-l 18
Engine Liiing Bracket - Installation .............................................. O-96
Engine - Removal from the Rebuild Stand ........................................ O-105
Engine Support, Front - Installation ............................................. O-118
Exhaust Manifold - Installation ................................................. O-97
Fan Hub Assembly - Installation ............................................... O-106
Flywheel Bore Runout Measurement ............................................. O-79
Flywheel Face Runout Measurement ............................................. O-81
Flywheel Housing - Installation ................................................. O-72
Flywheel - Installation ....................................................... O-77
Fuel Drain Manifold - Installation ................................................ O-96
Fuel Filter Head - Installation ................................................. O-111
Fuel Filter - Installation ..................................................... O-111
Fuel Injection Pump - Installation .............................................. O-106
Fuel Injection Pump Supply Line - Installation ...................................... O-l10
Fuel Lines, High Pressure - Installation .......................................... O-112
Fuel Lines, Low Pressure - Installation ........................................... O-l19
Fuel Pump Solenoid - Installation .............................................. O-l19
Fuel Transfer Pump - Installation .............................................. O-l 18
Gear Cover - Installation .................................................... O-l 16
Gear Housing - Installation ................................................... O-62
Injector - Installation ........................................................ O-95
Intake Manifold Cover - Installation .............................................. O-96
Lubricating Oil Cooler - Installation .............................................. O-84
Lubricating Oil Filter - Installation ............................................... O-85
Lubricating Oil Pan - Installation ................................................ O-68
Lubricating Oil Pump - Installation .............................................. O-64
Lubricating Oil Suction Tube - Installation O-68
Main Bearing (Lower) - Installation ..... : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : ii47-02
Main Bearing (Upper) - Installation .............................................. O-46
Main Bearing Cap - Installation ................................................. o-47
Piston Assembly - Installation .................................................. O-58
Piston Cooling Nozzle - Installation .............................................. O-6
Page O-2
Piston Pin - Installation ...................................................... O-54

Piston Ring End Gap - Measurement ............................................. O-55
Piston Ring - Installation ..................................................... O-56
Push Rod - Installation ...................................................... O-89
Rocker Lever and Shaft - Assembly ............................................. O-89
Rocker Lever Assembly - Installation ............................................. O-91
Seal, Front Crankshaft - Installation ............................................. O-113
Seal, Rear Crankshaft - Installation .............................................. O-51
Starting Motor - Installation ................................................... O-82
Tachometer Drive - Installation ................................................ O-117
Thermostat and Housing - Installation ........................................... O-101
Timing Pin Assembly - Installation ............................................... O-69
Turbocharger Exhaust Outlet Connection - Installation ................................ O-101
Turbocharger - Installation .................................................... O-98
Turbocharger Oil Drain Tube - Installation ......................................... O-99
Turbocharger Oil Supply Hose - Installation ..................................... O-100-02
Valve Arrangement ......................................................... O-93
Valve Clearance - Adjustment .................................................. O-92
Valve Cover - Installation ..................................................... O-94
Valve Tappet - installation .................................................... O-44
Vibration Damper - Installation ................................................ O-117
Water Pump - Installation .................................................... O-67
Wear Sleeve, Rear Crankshaft Seal - Installation ................................... O-51-02
Engine Accessories - Installation ............................................... O-121
Engine - Disassembly ....................................................... O-9

AFC Tube - Removal ....................................................... O-12
Aftercooler - Removal ....................................................... O-17
Air Compressor - Removal .................................................... O-14
Air Crossover Tube - Removal ................................................. O-17
Alternator Brace - Removal ................................................... O-21
Alternator Mounting Bracket - Removal ........................................... O-22
Alternator - Removal ........................................................ O-22
Belt Tensioner Bracket - Removal ............................................... O-21
Belt Tensioner - Removal .................................................... O-21
Camshaft - Removal ........................................................ O-28
Coolant - Draining ......................................................... O-10
Coolant Filter - Removal ..................................................... O-10
Coolant Heater - Removal .................................................... O-26
Coolant Inlet Connection - Removal ............................................. O-24
Coolant Outlet Connection - Removal ............................................ O-22
Coolant Vent Petcock - Removal ............................................... O-23
Coolant Vent Tube Fitting - Removal ............................................. O-23
Coolant Vent Tube - Removal O-23
Crankcase Breather Tube - Removal’ : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : O-l 6
Crankshaft - Removal ....................................................... O-36
Cylinder Head - Removal .................................................... O-23
Cylinder Liner Carbon Deposits - Removal ......................................... O-32
Cylinder Liner Protrusion - Checking ............................................. O-37
Cylinder Liner - Removal ..................................................... O-37
Drive Belt - Removal ....................................................... O-21
Engine - Installation onto Engine Rebuild Stand ..................................... O-15
Engine Lifting Equipment and Brackets ........................................... O-9
Engine - Preparation for Steam Cleaning .......................................... O-9
Engine - Steam Cleaning ..................................................... O-9
Engine Support, Front - Removal ............................................... O-31
Exhaust Manifold - Removal ................................................... O-20
Expansion Plug - Removal .................................................... o-39
Expansion Plug - Replacement ................................................. O-38
Fan Hub Assembly - Removal ................................................. O-24
Flywheel Housing - Removal .................................................. O-27
Flywheel - Removal ........................................................ o-27
Fuel Drain Manifold - Removal ................................................. O-18
Fuel Filter Head - Removal ................................................... o-11
Fuel Filter - Removal ....................................................... O-II
Page O-3
Fuel Injection Pump - Removal ................................................. O-13

Fuel Injection Pump Supply Line - Removal ........................................ O-12
Fuel Lines, High Pressure - Removal ............................................. O-12
Fuel Lines, Low Pressure - Removal ............................................. O-11
Fuel Pump Solenoid - Removal ................................................ O-15
Fuel Transfer Pump - Removal ................................................. O-11
Gear Cover - Removal ...................................................... O-26
Gear Housing - Removal ..................................................... O-31
Injector - Removal ......................................................... O-18
Intake Manifold Cover - Removal ............................................... O-17
Lubricating Oil Cooler - Removal ............................................... O-24
Lubricating Oil - Draining .................................................... O-10
Lubricating Oil Filter - Removal ................................................ O-10
Lubricating Oil Pan - Removal ................................................. O-27
Lubricating Oil Pump Gear Backlash - Measurement .................................. O-30
Lubricating Oil Pump - Removal ................................................ O-31
Lubricating Oil Suction Tube - Removal ........................................... O-27
Main Bearing (Lower) - Removal ................................................ O-36
Main Bearing (Upper) - Removal ................................................ O-36
Main Bearing Cap - Removal .................................................. O-35
Piston Assembly - Removal ................................................... O-33
Piston Cooling Nozzle - Removal ............................................... O-36
Piston Pin - Removal ....................................................... O-34
Piston Ring - Removal ...................................................... O-35
Push Rod - Removal ....................................................... O-19
Rocker Lever Assembly - Removal .............................................. O-19
Seal, Front Crankshaft - Removal ............................................... O-26
Seal, Rear Crankshaft - Removal ............................................... O-28
Starting Motor - Removal .................................................... O-26
Tachometer Drive - Removal .................................................. O-13
Thermostat and Housing - Removal ............................................. O-22
Turbocharger Exhaust Outlet Connection - Removal ................................... O-16
Turbocharger Oil Drain Tube - Removal ........................................... O-20
Turbocharger Oil Supply Hose - Removal ......................................... O-20
Turbocharger - Removal ..................................................... O-20
Valve Cover - Removal ...................................................... O-18
Valve Tappet - Removal ..................................................... O-29
Vibration Damper - Removal .................................................. O-25
Wastegate Actuator Hose - Removal ............................................. O-16
Water Pump - Removal ...................................................... O-25
Cylinder Block - Removal from Engine Rebuild Stand .................................. O-39
Engine Disassembly and Assembly - Service Tools ................................... O-4
General Information ......................................................... O-8

Disassembly ............................................................. O-8
Assembly ............................................................... O-8
Engine Disassembly and Assembly - Service Tools Engine Disassembly and Assembly - Group 00
Page O-4
Engine Disassembly and Assembly - Service Tools
The following special tools are recommended to perform procedures in Group 00. The use of these tools is shown
in the appropriate procedure. These tools can be purchased from your local Distributor.
Tool No. Tool Description Tool Illustration
Used to remove drive pulleys, impellers, air compressor

counterweights, etc.
Install cylinder liner in cylinder block.
Attaches to crankshaft flange to provide measuring of flywheel

and flywheel housing runout with dial bore gauge.
Used to measure internal diameter bores from 78.5 mm [3.09

in] to 2.032 mm [8.0 in].
Universal Cylinder Liner Puller
Remove cylinder liners from cylinder block. Requires Part No.

3375629 3822786, Cylinder Liner Puller Plate.
Engine Disassembly and Assembly - Group 00 Engine Disassembly and Assembly - Service Tools
Page O-5
Tool No. Tool

--. -Descriation
---.. C-----
Tool Illustration
Used to remove and install lubricating oil filter.
Support cylinder block during engine rebuild. Used with Part

No. 3822807, Adapter Plate.
Aid in removal and installation of crankshaft, flywheel and other

heavy components.
Remove cylinder liners from the cylinder block. Requires two of

Part No. 3376649, Puller Arm Extension Feet.
Dial Indicator and Sleeve Assembly
Use with Part No. ST-1325 Dial Gauge Attachment to measure

flywheel and flywheel housing runout. Use with Magnetic Base,
Part No. 3377399, to measure gear end clearance and
Used to rotate the crankshaft.
Used with Part No. 3378050, Dial Indicator and Sleeve
Used to clamp the liner into the bore of the cylinder block.
Note: Requires two cylinder head capscrews (not included in
Engine Disassembly and Assembly - Service Tools Engine Disassembly and Assembly - Group 00
Page O-6
Used to lift the engine.
For mounting the engine to Part No. 3375194, Engine Rebuild
Used to install piston rings onto pistons without damaging or

distorting the rings.
Used to pull the injection pump gear.
Used to pull injectors.
Piston Ring Compressor
Used to compress the piston rings while installing the pistons

3823290 into the cylinder bores.
Crowfoot Wrench
Used to torque high pressure fuel line nuts on A and MW

3823425 Bosch fuel injection pumps. Size: 17mm, 3/8 in. drive.
Sealant, Three Bond (150 Gram Tube)
Used for sealing “T” joints and front gear cover.

3823494
Engine Disassembly and Assembly - Group 00 Engine Disassembly and Assembly - Service Tools
Page O-7
Tnnl Nn Tnnl
_ __.
Descrintian
-___-. p _-_--
Tad Illustration
Measure cylinder liner protrusion on the cylinder block.
Used for torquing capscrews by the “torque plus angle”
Install the front crankshaft oil seal wear sleeve.
Fuel Injection Pump Mounting
Remove and install the fuel injection pump inboard mounting
Main Bearing Rollout Tool
Used to remove and install main bearing with the crankshaft

General Information Engine Disassembly and Assembly - Group 00
Page O-8
General Information
These procedures apply to all 6D114E-1 Series engines. The differences between engine models due to the application,
the optional equipment on an engine, and the year an engine was built are included in the instructions. Omit the steps
that do not apply to the engine being rebuilt.
A Warning: A Warning statement is included for any component or assembly that weighs more than 23 kg
[50 lb]. To avoid personal injury, use a hoist or get assistance when removing or installing these parts.
A Caution: All fasteners are given in metric measurements. All fasteners have right-hand threads unless a
Caution states that a fastener has left-hand threads.
Disassembly
The instructions in this procedure are organized in a logical sequence to disassemble an engine. This is not the only
sequence to disassemble an engine. Certain parts must be removed in the sequence indicated. Use this sequence until
you become familiar with the engine.
Discard all gaskets, seals, hoses, filters, and o-rings. Keep these parts if they are needed for a failure analysis.
Label, tag, or mark the parts for location as the parts are removed. This will help identify the parts that can be involved
in a failure and will simplify the assembly procedure.
Label, tag, mark, or photograph all special equipment prior to the removal from an engine. This engine assembly
procedure does not include the installation of special optional equipment.
Use a mallet when force is required to remove certain parts. Make sure all of the fasteners are removed before using
force.
Avoid as much dirt as possible during disassembly. The accumulation of additional dirt will make it more difficult to clean
the components.
Assembly
This procedure assumes that all of the components and assemblies have been cleaned, replaced, or rebuilt and are ready
to be installed on the engine.
Torque values are listed in each step. If a torque value is not specified, use the chart listed in the Specifications Section,
Group 18, to determine the correct torque value.
Many of the gaskets and o-rings are manufactured from a material designed to absorb oil. These gaskets will enlarge and
provide a tight seal after coming in contact with oil. Use ONLY a recommended contact adhesive or a vegetable based
oil to install these parts.
When replacing capscrews, always use one of the same configuration, either Metric or U.S. Customary. To prevent
damage to the engine or component, make sure the replacement capscrew is the same dimension, length and grade as
the capscrew removed.
Engine Disassembly and Assembly - Group 00 Engine - Disassembly (O-01)
Page 6-9
Engine - Disassembly (O-01)

Engine Lifting Equipment and Brackets
A
Warning: The engine lifting equipment must be designed
to safely lift the engine as an assembly. The dry weight
of the engine with standard accessories is 666 kg 11335
lb].
Use a properly rated hoist and engine lifting fixture, such as
Part No. 3822152, attached to the engine mounted lifting RI
brackets to lift the engine.
Install the engine on two suitable engine support stands.
Engine - Preparation for Steam Cleaning

Install plastic caps or tape on all engine openings to prevent
moisture and dirt from entering the engine: Cover all
electrical components. This will prevent water damage.
Engine - Steam Cleaning

Warning: When using a steam cleaner, wear protective
clothing and safety glasses or a face shield. Hot steam
will cause serious personal injury.
Steam clean and dry with compressed air.
Engine - Disassembly (O-01) Engine Disassembly and Assembly - Group 00
Page O-10
Lubricating Oil - Draining

17 mm
NOTE: The total system lubricating oil capacity including the
lubricating oil filter is 23.8 liters [25.2 U.S. Qts.].
Remove the drain plug and discard the drain plug sealing
washer.
Drain the lubricating oil.
op9pxm.a
Coolant - Draining
Open the draincock at the bottom of the lubricating oil cooler
housing.
Coolant Filter - Removal

90-95 mm Filter Wrench
Remove and discard the coolant filter.
Lubricating Oil Filter - Removal

Part No. 3375049 Filter Wrench
Remove and discard the engine oil filter if not needed for a
failure analysis.
Page O-l 1
Fuel Filter - Removal

75-80 mm Filter Wrench, 90-95 mm Filter Wrench
Remove and discard the fuel filters and the sealing rings.
\ \I Ilk I
Fuel Filter Head - Removal
24 mm
Remove the fuel filter head and discard the o-rings.
Fuel Lines, Low Pressure - Removal

20, 19, 17, 14 and 10 mm
Disconnect the low pressure fuel lines.
NOTE: To avoid damage to the fuel transfer pump, use two
wrenches when loosening the low pressure line.
Discard all copper washers.
Fuel Transfer Pump - Removal

10 mm
Remove the fuel transfer pump.
Page O-12
Fuel Lines, High Pressure - Removal

lo mm 17 mm and 19 mm
Remove the high pressure fuel lines.
Caution: Cover the injectors and fuel pump high pressure

outlet connections to avoid damage from contamination.
Fuel Injection Pump Supply Line - Removal

17 mm and 19 mm
Remove the fuel injection pump supply line and the fuel return
line.
AFC Tube - Removal

13 mm, 17 mm
Remove the AFC tube.
Page O-13
Tachometer Drive - Removal
Remove the gear cover access cap or the tachometer drive,
if equipped.
bD900ma
Fuel Injection Pump - Removal

22 mm (PESGA Fuel Injection Pump)
27 mm (PESGMW Fuel Injection Pump)
30 mm (PESGP Fuel Injection Pump)
Remove the nut and lock washer from the fuel injection
pump shaft.
Part No. 3823259 Fuel Pump Gear Puller

Pull the fuel injection pump drive gear loose from the shaft.
10 mm, 13 mm
If the engine is equipped with a PESGP fuel injection pump,
the support brackets must be removed.
l9bkm
Page O-14
15 mm, Part No. 3823956 Fuel Pump Mounting Tool Kii

Remove the four mounting nuts.
Remove the fuel injection pump.
Air Compressor - Removal

Remove the inlet and outlet air connections from the air
compressor.
15/16 Inch
Remove the inlet and outlet coolant lines from the air
compressor.
9/16 Inch
Remove the oil supply line.
Page O-15
19 mm, 15 mm, 14 mm
Remove the air compressor support bracket and capscrews.
Remove the air compressor.
Fuel Pump Solenoid - Removal -1 I

10 mm
Disconnect the fuel shutoff solenoid wiring.
Remove the hitch pin clip, mounting capscrews and fuel
shutoff solenoid.
Engine - Installation onto Engine Rebuild Stand

Part No. 3822512 Engine Lifting Fixture
•l
NOTE: The dry weight of the engine is 623 kg [1350 lb]. Use
an engine lifting bracket, such as Part No. 3822512, to lift the
engine.
Use four (l/2 x 13 x l-l /2 inch) grade 5 capscrews to install

the Part No. 3822607, Adapter Plate, onto the Part No.
3375194, Engine Rebuild Stand.
Torque Value: 95 Nom 170 ft-lb]
Page O-16
Use four Ml0 x 1.5 x 20 mm and two M8 x 12.5 x 20 mm

capscrews to install the adapter plate to the side of the cylinder
block.
Capscrew Capscrew Size Torque Value

Location
A M8 24 Nom [18 ft-lb]
B, C Ml0 40 Nom [30 ft-lb]
Turbocharger Exhaust Outlet Connection -

Removal
7/16 inch, 15 mm
Remove the turbocharger exhaust outlet connection.
Wastegate Actuator Hose - Removal

Screwdriver
Remove the wastegate hose.
bSho
Crankcase Breather Tube - Removal

13 mm, 16 mm
Remove the crankcase breather tube support bracket
capscrews (A) and (B).
Page O-17
Air Crossover Tube - Removal

Screwdriver
Remove the air crossover tube.
Intake Manifold Cover - Removal

10 mm
Remove the air intake cover plate.
Aftercooler - Removal
8mm
E2l
Remove the coolant supply tube (1) and coolant return tube
(2).
10 mm
Remove the aftercooler housing and gasket.
Page O-18
Fuel Drain Manifold - Removal

10 mm
Remove the fuel drain manifold. Discard the sealing washers.
Injector - Removal
10 mm, Part No. 3823276 Injector Puller
Remove the injectors.
fi9OOn
Remove and discard the sealing washers.
figwarn
Valve Cover - Removal

15 mm
Remove the valve cover.
Page O-l9
Remove and discard the and capscrew

o-rings.
Rocker Lever Assembly - Removal

14 mm Screwdriver
Loosen the rocker lever adjusting screw locknuts and loosen
the adjusting screws until they stop.
10 mm
Remove the rocker lever assemblies and oil manifold.
Push Rod - Removal

Remove the push rods.
Page O-20
Turbocharger Oil Supply Hose - Removal

16 mm, 19 mm
Remove the turbocharger oil supply line.
Turbocharger Oil Drain Tube - Removal
RI 10 mm, Screwdriver
Remove the turbocharger oil drain tube.
CB
l
Turbocharger - Removal
15 mm
Remove the turbocharger.
Exhaust Manifold - Removal
Eiil 16 mm
Remove the exhaust manifold.
63
Q
Page 0-21
Drive Belt - Removal

3/8 inch Square Drive
Remove the drive belt.
Belt Tensioner - Removal

13 mm
Remove the belt tensioner.
Belt Tensioner Bracket - Removal

5 mm Hex Wrench
Remove the belt tensioner bracket.
Alternator Brace - Removal

10 and 19 mm
Remove the alternator brace capscrew (A).
Remove the tail support bracket capscrew (B).
Page O-22
Alternator - Removal
15, 18 and 19 mm
Remove the alternator mounting capscrews and nuts.
Remove the alternator.
Alternator Mounting Bracket - Removal

13 mm
Remove the alternator mounting bracket.
Coolant Outlet Connection - Removal

10 mm
Remove the coolant outlet connection.
Thermostat and Housing - Removal

10 mm
Remove the thermostat housing and thermostats.
Page O-23
Coolant Vent Tube - Removal

9/16 inch
Remove the coolant vent tube.
Coolant Vent Petcock - Removal

7/16 inch
Remove the coolant vent petcock.
Coolant Vent Tube Fitting - Removal

l/2 inch
Remove the l/8 inch brass fiiing from the cylinder head. El
c%
0
Cylinder Head - Removal

16 mm
Loosen and remove the cylinder head capscrews in the
illustrated sequence.
Q
C%
C-- Front
Page O-24
The component weighs 74 kg [163 lb]. To avoid personal

injury, use a hoist or get assistance to remove the cylinder
head.
To prevent damage to the combustion face, make sure the

head is removed in a direct upward motion.
Lubricating Oil Cooler - Removal

10 mm
NOTE: Due to the design of the present production lubricating
oil cooler cover, there is approximately 0.7 liter IO.75 U.S. Qts.]
lubricating oil that does not drain when the system is drained.
Place a container under the cooler to catch the oil when the
cover is removed.
Remove the oil cooler cover, element and gaskets.
Coolant Inlet Connection - Removal

Screwdriver
Remove the coolant inlet connection.
Fan Hub Assembly - Removal

13 and 10 mm
Remove the fan hub assembly.
Engine - Disassembly (O-01)
Page O-25
Water Pump - Removal
13 mm
Remove the water pump.
Remove and discard the o-ring.
Part No. 3377371 Engine Barring Gear

Use the engine barring tool to prevent the engine from
rotating when loosening the damper capscrews.
Vibration Damper - Removal

ia mm
Remove the vibration damper.
Page O-26
Gear Cover - Removal

10 mm
Remove the gear cover.
Seal, Front Crankshaft - Removal

Hammer, Punch
Drive or press the seal out of the gear cover.
ocesema
Starting Motor - Removal

12 mm
Remove the starting motor.
Coolant Heater - Removal

Remove the engine coolant heater.
Page O-27
Flywheel - Removal
18 mm
Remove two capscrews 180 degrees apart. Install two
M12X1.25X90 mm guide pins.
NOTE: If a clutch is used in the equipment, the threads in
the clutch pressure plate mounting capscrew holes can be
metric or standard. Be sure to use the correct capscrews.
Determine the capscrew thread design and size and install
two “T-handles” in the flywheel at points (1) and (2).
Remove the remaining six flywheel mounting capscrews.
Remove the flywheel from the guide pins.
Flywheel Housing - Removal

15 mm
Remove the flywheel housing.
Lubricating Oil Pan - Removal

10 mm
Rotate the engine on the rebuild stand and remove the oil
pan and gasket.
Lubricating Oil Suction Tube - Removal

8mm
Remove the suction tube and gasket.
Page O-28
Seal, Rear Crankshaft - Removal

8 mm
•l Remove the rear seal housing and gasket.
Support the rear seal housing and press/drive out the seal.
ks9semd
Camshaft - Removal
Gear Backlash Measurement
Position an indicator on a tooth of the camshaft gear.
Note the camshaft gear backlash (A). Mark the camshaft gear
and crankshaft gear for further analysis if backlash exceeds
limits.
Camshaft Gear Backlash Limits

mm in
0.080 MIN 0.003
0.33 MAX 0.013
NOTE: Hold the adjoining gear from moving when checking

backlash or the reading will be the total for both gears.
ks9geia
Page O-29
0a!3
Rotate the crankshaft to align the timing marks before trying
to remove the camshaft.
15 mm
Remove the camshaft thrust plate capscrews.
Remove the camshaft and thrust plate from the cylinder

block. Take care not to drop the thrust plate. 0
C%
Refer to Procedure l-22 for camshaft cleaning and
inspection.
I,_‘=-!” / “/ \ cg900m,
Valve Tappet - Removal

Electric Pencil
Remove the valve tappets and mark for location as •l
illustrated.
Caution: When reusing the camshaft and tappets, the @SQ
tappets must be matched to their companion lobe on the
A
camshaft to prevent accelerated camshaft wear. Discard
tappets that were not marked during removal.
Page O-30
Lubricating Oil Pump Gear Backlash -

Measurement
Position the indicator on a tooth of the gear.
Note the drive gear backlash. Mark the drive gear and idler
gear for additional analysis if the limits are exceeded.
backlash or the reading will be the total of both gears.
Oil Pump Drive Gear Backlash (A)

mm in
0.08 MIN 0.003
0.33 MAX 0.013
ld9geia
Position the indicator on a tooth of the pump idler gear.
Note the idler gear backlash. Mark the idler gear and
crankshaft gear for additional analysis if the limits are
exceeded.
Oil Pump Idler Gear Backlash (A)

mm in
0.08 MIN 0.003
0.33 MAX 0.013
ld9idia
Page O-31
Lubricating Oil Pump - Removal A__
13 mm
Remove the lubricating oil pump.
Refer to Procedure 7-08 for cleaning and inspection.
Engine Support, Front - Removal

15 mm
Remove the front engine support.
Gear Housing - Removal

10 mm
Remove the capscrews, gear housing and gasket.
NOTE: Do not remove the timing pin assembly unless the

gear housing is being replaced. Refer to page O-69 in this e
section for replacing the timing pin assembly.
Pin
lt9plhb
Page O-32
Cylinder Liner Carbon Deposits - Removal
A
Caution: Do not use emery cloth or sandpaper to remove
carbon from the cylinder liners and cylinder block cylinder
head mounting surface. Aluminum oxide or silicon particles
from emery cloth or sandpaper can cause serious engine
Li
B damage.
Rotate the crankshaft to expose the carbon ridge above the
ring travel area in the cylinder liner.
Warning: When performing the following procedures, wear
A eye protection. Also, if the brush is motor driven, make sure

the wire brush is rated for the RPM being used.
Use a rotary wire brush to remove the carbon ring from the top
LJ
B of the cylinder liner.
Do not use the steel wire wheel in the piston travel area.
Operate the wheel in a circular motion to remove the deposits.
Use lint-free paper to remove all the broken wire bristles and
loose carbon from the cylinders.
If a rotary wire brush is not available, use a scraper that has

IJ
B an aluminum blade.
Use a fine fibrous abrasive pad such as Scotch-Brite@ 7447,
Part No. 3823258 or equivalent, to remove the remaining
carbon.
Page O-33
Piston Assembly - Removal

Mark each connecting rod cap according to cylinder.
NOTE: Engine serial numbers beginning with 3040000 have a
number from 1 to 7 stamped on the balancing lug. This
number is used as a connecting rod weight sort code and
does not designate cylinder number.
I cx900ia
To avoid confusion when disassembling an engine beginning

with serial number 3040000, use double digits to identify the
cylinder number from which the connecting rod was
removed. Mark the connecting rod for cylinder No. 1 with 11,
cylinder No. 2 with 22 and so on.
Also, the code used on engines beginning with serial number

3040000 to mark the connecting rod and connecting rod cap
as a matched set is a two letter code, such as AA, AB, AC,
etc. Instead of an alpha-number code.
Mark each piston according to the corresponding cylinder.
A
Catuion: Do not use a stamp on anodized pistons. A
stamp will damage the anodized coating. Use a scribe to
mark the pistons.
Page O-34
19 mm, Plastic Hammer

Remove the nuts from the connecting rod capscrews.
Tap the connecting rod bolts to loosen the connecting rod cap.
Remove the lower connecting rod bearing. Mark the cylinder
number and the letter ‘I” (lower) in the flat surface of the
bearing tang.
Catch the piston with one hand while pushing the connecting
rod and piston assembly out of the cylinder bore. Care must
be taken not to damage the crankshaft journal.
Place the connecting rod and piston assemblies on a rack to

protect them from damage.
NOTE: The piston and connecting rod assemblies must be
installed in the same cylinder number they were removed from
to be sure proper fit of worn mating surfaces if parts are used
again.
Use a tag to mark the cylinder number each piston and
connecting rod assembly was removed from.
Piston Pin - Removal

Use internal snap ring pliers to remove the retaining rings from
both sides of the piston.
Remove the piston pin.
NOTE: Heating the piston is not required.
Page O-35
Piston Ring - Removal

Part No. 3823137 Piston Ring Expander
Use piston ring expander, Part No. 3323137, to remove the
piston rings.
Place a tag on the piston rings and record the cylinder
number of the piston on the tag.
pi9OOfb
Main Bearing Cap - Removal

19 mm
Rotate the engine to a horizontal position and remove the
main bearing cap capscrews.
0429
The main bearing caps should be numbered.
Use a steel stamp to mark any main bearing caps without a
number before the main bearing cap is removed.
mb90owa
Remove the main bearing caps.

Do not pry on the main bearing caps to free them from
the cylinder block.
Use two main bearing cap capscrews to “wiggle” the main
bearing cap loose, being careful not to damage the
capscrew threads.
Page O-36
Main Bearing (Lower) - Removal

Remove the lower main bearing shells from the main bearing
caps.
Mark the main bearing shells with the journal number they were
removed from in the flat surface of the main bearing tang.
Do not mark on the main bearing to crankshaft mating surface.
Damage to the engine can result if the main bearings are used
again.
Crankshaft - Removal
The component weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift the
component.
Lii the crankshaft straight up to avoid damage to the
crankshaft or cylinder block.
Install the Part No. 3375957, Nylon Lifting Sling, around the
number “3” and “4” rod bearing journals.
Attach the sling to a hoist and remove the crankshaft.
Main Bearing (Upper) - Removal

Use both thumbs to remove the upper main bearing shells.
Mark the main bearing shells with the journal number they were
removed from in the flat surface of the main bearing tang.
Do not mark on the main bearing to crankshaft mating surface.
Damage to the engine can result if the main bearings are used
again.
Piston Cooling Nozzle - Removal

3/16 Inch Pin Punch
Remove and discard the piston cooling nozzles.
Page O-37
Cylinder Liner Protrusion - Checking

Part No. 3823495 Liner Protrusion Gauge
•xl
Cylinder liner protrusion is the distance the cylinder liner
protrudes above the block face. Before removing the liners,
check the protrusion in the “unclamped” state.
Cylinder Liner Protrusion

mm in
0.025 MIN 0.001
0.122 MAX 0.0046
If the cylinder liner protrusion is out of limits, it will be

necessary to machine the counterbore and add shims to
restore to the original specifications.
Cylinder Liner - Removal
Two service tools are available to remove the cylinder liners:
l Universal liner puller, Part No. 3376015, with extension
foot, Part No. 3376649.
l Universal liner puller, Part No. 3375629 with plate, Part
No. 3376049.
Part No. 3376015 Cylinder Liner Puller

Caution: The cylinder liner puller must be installed and RI
used as described to avoid damage to the cylinder block.
The puller must not contact the block casting at points
U), (2), (3), and (4). A
Insert the cylinder liner puller in the top of the cylinder block.
NOTE: The cylinder liner puller must be centered on the top

of the cylinder block.
Turn the cylinder liner puller jackscrew clockwise to loosen
the cylinder liner from the cylinder block.
Use both hands to remove the cylinder liner.
------.I) c _ L/O ck8slma

Page O-38
Part No. 3375629 Universal Liner Puller

Caution: The cylinder liner puller must be installed and
used as described to avoid damage to the cylinder block.
The cylinder liner puller plate must be parallel to the main
bearing saddles and must not overlap the cylinder liner
outside diameter.
Insert the cylinder liner puller in the top of the cylinder block.
NOTE: The cylinder liner puller must be centered on the top

of the cylinder block.
Turn the cylinder liner puller jackscrew clockwise to loosen the
cylinder liner from the cylinder block.
Use both hands to remove the cylinder liner.
Use Dykem@ or equivalent to mark the cylinder number on

each cylinder liner.
Remove and discard the o-ring.
cklslwa
Expansion Plug - Replacement

All expansion plugs must be replaced if the component is
cleaned in a “hot tank”, spray washer or similar equipment.
This cleaning activity can interrupt the sealing capacity of the
sealant.
Engine Disassembly and Assembly - Group 00 Engine Assembly (O-02)
Page O-39
Expansion Plug - Removal

To remove expansion plugs:
l Use a hammer and center punch to mark
expansion plug for drilling.
0 Drill a 3 mm [l/8 inch] hole in the expansion plug.
l Use a dent puller to remove the expansion plug.
Refer to Group 01 for expansion plug location
identification.
Cylinder Block - Removal from Engine Rebuild

Stand
13 mm
Remove the cylinder block from the engine rebuild stand.
The component weighs 23 kg 150 lb] or more. To avoid l
personal injury, use a hoist or get assistance to lift the @
component.
Refer to Procedures l-05 and l-06 for cleaning and
inspection of the cylinder block.
Engine - Assembly (O-02)

Cylinder Block - Installation onto Engine
Rebuild Stand
NOTE: The component weighs 23 kg [50 lb] or more. To
avoid personal injury, use a hoist or get assistance to lift
the component.
Use a hoist and Part No. 3375957, Engine Liiing Sling, to lift
the cylinder block.
Use Part No. 3822607, Adapter Plate, with Part No. 3375194,
Engine Rebuild Stand.
Engine Assembly (O-02) Engine Disassembly and Assemlby - Group 00
Page O-40
Use four Ml 0X15X20 mm and two M8X1.25X20 mm capscrews

to install the adapter plate to the fuel injection pump side of the
cylinder block:
Capscrew Location Capscrew Size Torque Value

A M8 24 Nom [18 ft-lb]
B, C Ml0 40 Nom [30 ft-lb]
Cylinder Liner - Installation

Caution: Clean all deposits and debris from sealing
surfaces A, B and C. Use Scotch-Brite@7448 or equivalent
and cleaning solvent to polish the surfaces. However, due
to the critical machined tolerances, care should be taken
not to remove any additional material.
Refer to Procedure l-06 for cylinder liner counterbore
inspection.
Lubricate surfaces A and B with clean 15W-40 engine oil.
ck9brga
NOTE: When reusing liners, install them in the same cylinder

from which they were removed and rotate them 45 degrees
(l/8 turn) from their original position. When correctly installed,
any cylinder liner pitting should be positioned as illustrated so
the pitted surface is rotated away from the location where
pitting occurs.
Use clean 15W-40 engine oil to coat the cylinder liner o-ring
seals.
Install the o-ring seal on the cylinder liner.
NOTE: The cylinder liner must be installed within 15 minutes
after applying oil to the cylinder liner o-ring seal.
Make sure the cylinder liner o-ring is not twisted or damaged
during installation.
Page O-41
Part No. ST-1229 Cylinder Liner Driver

Install the cylinder liner into the cylinder block.
Use cylinder liner driver, Part No. ST-1229, and a leather
mallet to drive the cylinder liner into the bore.
NOTE: If the cylinder liner does not rest on the cylinder
block counterbore seat, remove the cylinder liner. Inspect the
counterbore seat and cylinder liner for nicks, burrs, or dirt.
Install the cylinder liner again.
0
@
Part No. 3822503 Liner Clamps

Use two cylinder head capscrews and position the two
cylinder liner clamps as illustrated.
Tighten the capscrews.
Torque Value: 68 Nom [50 ft-lb]
Remove the clamps and repeat this procedure until all
cylinder liners have been clamped and released.
Part No. 3823495 Liner Protrusion Gauge

Cylinder liner protrusion is the distance the cylinder liner
protrudes above the block face. Measure the cylinder liner
protrusion at four points, 90 degrees apart:
\_
mm in
0.025 MIN 0.001
0.122 MAX 0.0049
NOTE: If the cylinder liner protrusion varies more than 0.025

mm [O.OOlO inch] for 180 degrees:
l Install and tighten the cylinder liner clamps again.
Engine Assembly (O-02) Engine Disassembly and Assemlbv - Group 00
Page O-42
l Inspect the cylinder liner protrusion again.
NOTE: If the cylinder liner protrusion still varies more than

0.025 mm [O.OOlO inch]:
l Remove the cylinder liner.
#
69 l
fTJ-+
‘pY_~~ _::z_-_-_i
,
J
I
t
L-----_____ I
I ck9cyda
0
Inspect the cylinder liner sealing edge for burrs, dirt or
aI9 . damage.
l Replace the cylinder liner if it is damaged.
l Install the cylinder liner again.
l Inspect the cylinder liner protrusion.
bp2cysb
Service Tip: If the out-of-limit condition is minimal, tolerance

stack-up may allow the cylinder liner protrusion limits to be
obtained by installing other new cylinder liners in the out-of-limit
bore.
Page O-43
NOTE: If the cylinder liner protrusion still does not meet the
specifications, machine the cylinder block liner counterbore
and add counterbore shims to adjust the cylinder liner
protrusion to the proper specifications.
Use a feeler gauge to inspect the cylinder liner to block

clearance at the four block casting points.
Cylinder Liner to Block Clearance

mm in
0.229 MIN 0.009
NOTE: If the cylinder liner to block clearance is less than

0.229 mm to.009 inch]:
l Remove the cylinder liner.
0a3
l Inspect the cylinder liner and cylinder block for dirt or
damage.
Engine Assembly (O-02)
Page O-44
l Replace the cylinder liner if it is damaged.

l Install the cylinder liner again.
Measure the cylinder liner bore for out-of-roundness at points

“c”, “D”, “B”,
“F” and “G”. Measure each point in the
direction “AA” and “BB”. The cylinder liner bore must not be
more than 0.08 mm [0.003 inch] out-of-round.
NOTE: If the cylinder liner bore is more than 0.08 mm [0.003

inch] out-of-round:
l Remove the cylinder liner so the cylinder block liner
bore can be measured.
-I- -..&a ck2cyj

i
Valve Tappet - Installation

Caution: Observe the following guidelines for tappet
installation:
l When reusing the camshaft and tappets, the tappet
must be matched to their companion lobe on the
camshaft. If the tappets were not marked upon
removal, they must not be reused.
l Do not install used tappets with a new camshaft.
l Mixing of new and used tappets when reusing the
camshaft is permissible, providing the used tappets
are kept with their companion lobes of the camshaft.
Page O-45
Lubricate the tappet heads, stem and sockets

LubripiateTM 105.
Install the valve tappets.
Piston Cooling Nozzle - Installation

23 mm
Remove the main bearing caps. a
g
+*
0%
l/2 Inch Center Punch

Install the piston cooling nozzles even with or below the
bearing saddle surface.
NOTE: Due to the positioning and spray angle of the
nozzles, there are no bores needed for the No. 3 main
bearing saddle.
\ \ / ‘W
0@B
Be sure spray holes are clean and open.
NOTE: Be sure the piston cooling nozzle hole is not
damaged during cleaning.
Engine Assembly (O-02) Engine Disassembly and Assembly - Group 00
Page O-46
Main Bearing (Upper) - Installation

The upper bearings contain two oil holes. The lower bearings
do not. Both upper and lower main bearings are marked on the
back to indicate either standard (STD) or oversize (OS)
thickness.
NOTE: Main bearing shells are available for crankshafts which
are machined 0.1 mm [0.040-inch] undersize the original
diameter. Crankshafts which are machined undersize in the
connecting rod and main bearing journals are marked on the
front counterweight. If the crankshaft is marked, check the main
bearing and connecting rod shell part numbers to make sure
I R-OSOmm
the correct bearing size is used.
A Caution: The tang (1) on the bearing shell must be in the

slot (2) of the bearing saddle to correctly position the
bearing and prevent engine damage.
p
Of3 +I
Install the upper main bearing shells.
NOTE: If used bearing shells are to be installed, each must be
installed in its original location in the engine. The main bearing
6B
0
journal numbers should have been marked in the bearing tangs
during disassembly.
NOTE: Do not install the combination thrust/main bearing in
the center journal. Roll the combination thrust/main bearing in
after the crankshaft is installed.
/ mb9OOwb
Lubricate the main bearings with LubriplateTM 105.

cl
Da
4 Do not lubricate the back of the main bearing.
A
Caution: Prevent dirt from mixing with the lubricant. Dirty
lubricant will accelerate main bearing wear.
Page O-47
Crankshaft - Installation
Use a lint-free cloth. Clean the crankshaft bearing journals.
q\

component.
Use a hoist and Part No. 3375957, Nylon Lifting Sling.
Install the sling around the numbers “3” and “4” connecting (@A
rod bearing journals. @ii
Do not damage or move the main bearing shells when the
crankshaft is installed.
Install the crankshaft.
After the crankshaft has been installed into the cylinder block
-0
with the six upper shells in place, make sure the thrust
bearing is clean and serviceable. OK
Use clean LubriplaW 105 or its equivalent to lubricate the
upper thrust bearing.
Part No. 3823318, Main Bearing Rollout Tool

Position the new thrust bearing on the crankshaft and install
as far as possible by hand.
Use main bearing rollout tool Part No. 3823818, and engine
barring tool, Part No. 3377371, to finish pushing the bearing
in slowly, being sure it is aligned with the block.
Page O-47-02
Main bearing (Lower) - Installation

Install the lower main bearing shells with tang (1) in the slot
(2) of the main bearing cap.
Use Lubriplate@ 105, or equivalent, to coat the inside
diameter of the main bearing shells.
Main Bearing Cap - Installation

The main bearing caps are numbered for location. No. 1
starts with the front of the block and the numbers face the
camshaft side of the engine.
When correctly installed, the main bearing tangs (slots)
should both be on the same side.
Page O-48
Position the main bearings and main bearing caps onto the
0
The thrust bearing iournal does not have tangs or slots. Care
ai3 should be taken to-be sure the number stamped on the main
bearing cap is positioned to the camshaft side of the engine.
Lubricate the main bearing capscrew threads and underside of

the capscrew head with clean engine oil.
mbscswa
Small Plastic or Rubber Mallet

RI Tap the main bearing cap gently into position.
@ Make sure the main bearing is still aligned with the cap.
When seated, the main bearing capscrews can be threaded in
by hand.
04B
mb900ha
Page O-49
19 mm
Tighten the main bearing capscrews evenly following the
illustrated sequence.
Torque Value:
Step
50 N*m [ 37 ft-lb]
: 119 N*m [ 66ft-lb]
3 176 N*m [129 ft-lb]
-Front
mb9csha
J
The crankshaft must rotate freely after the main bearings

have been torqued.
Check the main bearing installations and the size of the main
bearings if the crankshaft does not rotate freely. 0423
Measure the end clearance of the crankshaft as follows:

l Install a dial indicator such as Part No. 3376050, to the
oil pan flange.
l Put the tip of the gauge against the crankshaft
counterweight.
l Push the crankshaft toward the rear of the cylinder
block.
l Set the dial indicator at zero. u

l Push the crankshaft toward the front of the cylinder
block.
l If the end clearance is less than 0.127 mm
[0.005-inch], do the following:
Page O-50
l Loosen the main bearing capscrews one turn.

l Push the crankshaft toward the front and then toward
the rear of the cylinder block.
Tighten the main bearing capscrews in the sequence shown to

the torque values listed in the installation procedure.
I - Front
mbScsha
Measure the crankshaft end clearance. The end clearance

specification for a new or machined crankshaft with new thrust
bearings is 0.127m [O.OOSnch]to 0.32 mm [0.013-inch].
NOTE: Crankshafts that have been machined on the thrust

0.25 mm[O.OlO in.]” bearing surfaces are marked for oversize thrust bearings on the
rear crankshaft counterweight. If the crankshaft counterweight
is marked, check the thrust bearing part number to make sure
the correct bearing size is used.
Example: 0.010 = 0.25 mm [O.OlO-inch]
Page O-51
If the crankshaft end clearance is more than 0.54 mm

[0.021-inch] on a used engine, the crankshaft must be
removed from the engine and repaired.
-
Seal, Rear Crankshaft - Installation

Use crocus cloth to remove any rust or other deposits from
the crankshaft flange.
Use a clean cloth to clean the rear crankshaft flange.
q
\
,
ks9seeCi
Visually inspect the seal contact area for wear. If the seal
contact area has a groove worn deep enough to feel with a
fingernail or sharp object, it will be necessary to install a
wear sleeve over the sealing surface.
Refer to the following procedure:
Page O-51-02
Wear Sleeve, Rear Crankshaft Seal - Installation

Hammer, Chisel
If the crankshaft currently has a wear sleeve, it must be
removed before installing a new one.
0
Caution: Do not nick or gouge the crankshaft with the 6%
chisel. If the crankshaft is damaged, it must be replaced.
Use a dull chisel that is only as wide as the wear sleeve.
Make one or two soft blows with a hammer to make chisel
A
marks across the wear sleeve. This will expand the wear
sleeve allowing the sleeve to be removed.
I
NOTE: The combination crankshaft oil seal (A)/wear sleeve
(B) replacement kii for service usage is installed on the
crankshaft as an assembly. The crankshaft rear seal should
not be removed from the crankshaft rear seal wear sleeve.
Install the rear cover and gasket.

NOTE: Install the rear cover capscrews. Do not tighten. If the
oil pan is installed, loosen the oil pan capscrews to allow
clearance for rear cover and gasket clearance.
NOTE: The seal installation is being used to properly align
the rear cover. Do not push or force the cover in any
direction to prevent irregular seal lip position after the seal
installation.
Page O-52
NOTE: For installation, the lubricating oil seal requires a mild

soap on the outside diameter of the seal case.
Use service tool, Part No. 3824078, to install oil seal/wear

sleeve assembly. Install two (2) threaded studs into the
crankshaft capscrew holes.
Apply a small amount of clean 15W-40 engine oil to the
crankshaft, threaded studs, and inside diameter of the
crankshaft rear seal/wear sleeve installation tool.
Position the chamfered end of the wear sleeve (A) onto the end
of the crankshaft (B). Position the counterbore end of
installation tool (C) over threaded studs and align with wear
sleeve, perpendicular to the end of the crankshaft. Install the
washers (D) and nuts (E) onto the threaded studs.
Alternately tighten the nuts until the installation tool contacts the
end of the crankshaft.
NOTE: Do not exceed l/2 revolution of each nut to prevent

wear sleeve binding and irregular stretch.
Remove the installation tool and threaded studs.
Page O-53
NOTE: For installation, the lubricating oil seal requires a mild

soap on the outside diameter of the seal case.
Hammer, Seal Installation Tool

install the seal in the rear cover.
Use the installation tool and hammer to push the seal into
the rear cover until the outside diameter of the seal
installation tool contacts the rear cover.
NOTE: Do not remove the crankshaft seal pilot tool.
NOTE: Do not use any kind of lubricant on the crankshaft to

install the seal. The lubricating oil must be installed with the
lip of the seal and crankshaft clean and dry.
Install two M6Xl.OOX50 mm guide pins 180 degrees apart
into the rear of the cylinder block.
Install the rear cover and gasket over the guide pins.
8mm
Align the rear cover to the crankshaft with the alignment tool
provided in the seal kii. Be sure the rear cover is even with
both sides of the oil pan rail on the cylinder block.
Page O-54
Remove the guide pins.

@ Install the rear cover capscrews and tighten.
V Torque Value: 9 Nom [80 in-lb]
l *
@** Remove the rear crankshaft seal pilot tool.
(K
0
rc9toma
Trim the rear cover gasket even with the oil pan mounting
surface.
Make sure the rear cover gasket trim does not fall into the
engine.
Connecting Rod Bolt - Installation
Eil Plastic Hammer
0@
Tap the connecting rod bolts in until the head is aligned and
seated on the flat machined surface of the connecting rod.
Piston Pin - Installation

Use clean 15W-40 engine oil to coat the connecting rod piston
pin bore and piston pin.
Page O-55
Caution: Be sure “Front” marking on piston and the

numbers on the connecting rod and connecting rod cap
are oriented as illustrated.
A
Snap Ring Pliers

NOTE: Pistons do not require heating to install the piston •l
pin; however, the pistons do need to be at room temperature
or above.
NOTE: The retaining ring must be seated completely in the
piston pin bore to prevent engine damage during engine
operation.
Install a new retaining ring into the piston pin bore.
Align the piston pin bore of the connecting rod with the
piston pin bore of the piston and install the piston pin. Install
the second retaining ring.
Piston Ring End Gap - Measurement r=?

Rotate the engine on the rebuild stand until the crankshaft is
vertical and the crank gear is facing upward.
NOTE: If the engine is rotated more than 90 degrees, the
valve tappets can fall out.
0a3
To check the piston ring gap, use the top end of a piston to
align the piston rings in the wear area of the cylinder liner in
which they will be used.
Jq -3
A = 89 mm [3.5 inches]
-I
4 ____
L
-9=- pi9rita
-1
Page O-56
Use a feeler gauge to measure the piston ring gap. Replace the
ring if it does not meet the following specifications:
New Piston Ring Gap

mm in
Top: 0.35 MIN 0.014
0.60 MAX 0.024
Intermediate: 0.35 MIN 0.014
0.66 MAX 0.026
Oil Control: 0.30 MIN 0.012
0.60 MAX 0.024
NOTE: Add 0.09 mm [0.004 in] for every 0.03 mm [O.OOlin] of

cylinder liner bore wear up to the maximum worn limit.
Identify the ring sets for installation in the cylinder in which the
end gap was measured.
pi9riga
Piston Ring - Installation

The top surface of the upper and intermediate rings are
identified either with the word “TOP” or a supplier identification
mark, such as a dot. Assemble with the word “TOP” or the
supplier mark facing upward.
The bottom or oil control ring can be installed with either side
up.
pi9rise
NOTE: The two-piece oil control ring must be installed with the
expander ring gap 180 degrees from the gap of the oil ring. Do
not overlap the ends of the expander ring.
pt9riha
Page O-57
Part No. 3823137 Piston Ring Expander

Install the rings on the piston. RI
Position the oil ring expander in the oil control ring groove. Q
@.j.j
pi9rigb
Install the oil control

on the expander.
ring with the end gap opposite the ends
g
09 +a
pi9rrhc
NOTE: There are two different types of intermediate rings

used:
Rectangular (A)
Reverse Twist (B)
Refer to the appropriate Parts Manual to see which type of a
rings are required.
Install the intermediate ring.
Install the top ring.
PI901 a
Page o-58
Piston Assembly - Installation

install the connecting rod bearing shells into both the
connecting rod and connecting rod cap. Make sure the tang
on the conecting rod bearing shell is in the slot of the
connecting rod cap and connecting rod.
Connecting rod bearings are marked on the back to indicate
either standard (STD) or oversize (OS) thickness.
NOTE: If used connecting rod bearing shells are to be
installed, each bearing shell must be installed in its original
location.
Caution: Do not lubricate the back of the connecting rod

bearing shells.
Caution: Prevent dirt from mixing with the lubricant. Dirty
lubricant will accelerate connecting rod bearing wear.
Lubricate the connecting rod bearings with a light film of
Lubriplatem 105.
cx9oowa
Lubricate the piston rings and piston skirts with clean 15W-40
engine oil.
Position the ring gaps 120 degrees apart.
pi9rihb
Page O-59
Part No. 3823290 Piston Ring Compressor

Compress the rings using the piston ring compressor. lsl
0a9
Use a clean lint-free cloth to clean the crankshaft bearing

journals.
Use a clean lint-free cloth to wipe the cylinder bores.

Lubricate the cylinder bore with clean 15W-40 engine oil.
Part No. 3377371 Engine Barring Tool

Rotate the crankshaft
connecting rod, which
to position the
is being installed,
journal for the
at bottom dead
RI
center (BDC).
0a-9
DC
Page O-60
A Caution: Be sure “Front” marking on the piston and the

numbers on the connecting rod and connecting rod cap are
oriented as illustrated.
Caution: Use care when installing the piston and connecting

rod so the cylinder bore is not damaged.
Position the piston and connecting rod assembly into the
cylinder bore with the word “Front” on the piston toward the
front of the cylinder block.
Hold the piston ring compressor against the cylinder liner. Push
the piston through the ring compressor and into the cylinder
liner.
NOTE: If the piston does not move freely, remove the piston
and inspect for broken or damaged rings.
Push the piston into the bore until the top of the piston is
approximately 50 mm [2 inches] below the top of the bore.
Then, pull the connecting rod onto the crankshaft journal.
Use clean 15W-40 engine oil to lubricate the threads of the

connecting rod capscrews.
Page O-61
0
NOTE: The numbers marked on the connecting rod and the
connecting rod cap must be the same. The tang slot side of @
the conecting rod cap must be on the same side as the
tang slot in the connecting rod when the connecting rod cap
is installed.
diameter of the connecting rod bearing shell.
Install the connecting rod bearing in the connecting rod cap.
Install the connecting rod cap and start the connecting rod
nuts.
Use clean 15W-40 engine oil to lubricate the connecting rod

nuts.
Alternately tighten the connecting rod nuts to pull the Ix 1

connecting rod cap into position.
19 mm Socket, Torque Wrench

Tighten the connecting rod cap to the connecting rod.
Torque Value:
Step 1 - 40 Nom [30 ft-lb]
(K
0
Page O-62
Shake the connecting rod tightening to verify side

clearance.
Measure the side clearance between the connecting rod and

the crankshaft.
Connecting Rod Side Clearance

mm in
0.10 MIN 0.004
0.33 MAX 0.013
NOTE: The crankshaft must rotate freely.

Check for freedom of rotation as the connecting rod caps are
installed. If the crankshaft does not rotate freely, check the
installation of the connecting rod bearings and the bearing size.
I er9OOda
Gear Housing - Installation

Install the two gear housing dowel pins, if removed.
NOTE: The tapered end of the dowel fiis into the cylinder
block. Drive the pin to the bottom of the hole.
Page O-63
Position the gasket onto the alignment dowels.
15 mm
If the fuel injection pump studs are damaged or being
installed in a new housing, coat the threads with Loctitem
242 and use two nuts locked together to remove and install.
ah9OOwz
Small Chisel and Hammer

If the gear housing is being replaced, remove the engine
dataplate and install on the new gear housing. Refer to
Procedure l-25.
13 mm
Caution: If a new gear housing or other than the original
gear housing is installed, the timing pin assembly must
be accurately located. Refer to page O-69 in this section.
Install the gear housing and capscrews.
Torque Value:
M8 capscrews 24 Nom [18 it-lb]
Ml2 capscrews 60 Nom [44 ft-lb]
Page O-64
Trim the gear housing gasket off even with the oil pan rail.
NOTE: Do not let the gasket trimmings fall into the engine.
gh9gkwa
I
Lubricating Oil Pump - Installation

Lubricate the lubricating oil pump with clean 15W-40 engine oil.
NOTE: Fill the lubricating oil pump with oil during installation
to aid in quicker oil suction when the engine is started.
ip900wa
Make sure the’lubricating oil pump idler gear pin is installed

into the locating bore of the cylinder block.
The back plate on the lubricating oil pump seats against the
bottom of the bore in the cylinder block. When the pump is
correctly installed, the flange on the pump will not touch the
cylinder block.
Page O-65
13 mm
Tighten the lubricating oil pump capscrews in the sequence
shown.
Torque Value:
Step 1 - 5 Nom [44 in-lb]
Use a dial indicator with a magnetic base to measure the

idler gear backlash.
Measure the gear backlash.

NOTE: Hold the adjoining gears from moving when checking
Oil Pump and Idler Gear Backlash (A & B)

mm in
0.08 MIN 0.003
0.33 MAX 0.013
1p9gena
Camshaft - Installation
Lubricate the camshaft bores with LubriplateTM 105. 4
17
Refer to Group 01 for camshaft bushing installation.
Service Tip: The crankshaft should be positioned with the e
No. 1 cylinder at approximately top dead center (TDC), so
the camshaft does not hit the crankshaft counterweights
Page O-66
Lubricatethe camshaft journals and lobes, and thrust plate with

LubriplateTM 105.
Install the camshaft and gear assembly into the cylinder block
up to the last journal.
0
Align the timing marks on the camshaft with the timing mark on
423 the crankshaft.
Caution: If the enaine is in the vertical position, be sure the

camshaft assemgy does not drop on your fingers when
A installing the thrust plate.
Page O-67
13 mm
Install the thrust plate capscrews.
Measure the camshaft end clearance.

End clearance is controlled by the thickness of the thrust
plate and the groove in the camshaft.
Camshaft End Clearance
mm in
0.12 MIN 0.0047
0.46 MAX 0.018
Be sure the camshaft backlash is correct.

Use an indicator to measure backlash.

mm in
0.08 MIN 0.003
0.33 MAX 0.013
Water Pump - Installation

13 mm
Install an o-ring into the groove on the water pump mounting
flange.
Position the water pump assembly into the pump cavity of
the cylinder block. Align mounting holes and install two
capscrews at 1l:OO o’clock and 4:00 o’clock position.
NOTE: The capscrew located in the 7:00 o’clock position is
longer and is used for the alternator support brace, it will be
installed along with the alternator.
Torque Value: 24 N*m [18 B-lb]
Engine Assembly (O-02) Engine Disassembly and Assemlby - Grow 00
Page O-68
Lubricating Oil Suction Tube - Installation

Position the new lubricating oil suction tube gasket onto the
cylinder block.
Make sure the gasket is aligned correctly with the oil suction
hole in the cylinder block.
8mm
Install the lubricating oil suction tube over the gasket and align
the mounting holes.
Use the following sequence to tighten the capscrews:
Torque Value:
Step A Suction Tube to Block 9 N*m [80 in-lb]
Step B Brace to Block 9 N*m [80 in-lb]
Step C Brace to Suction Tube 9 Nom [80 in-lb]
Lubricating Oil Pan - Installation

Apply a 2 mm [l/16 inch] bead of Three Bond Sealant, Part
No. 3823494, to joints between the lubricating oil pan rail, gear
housing and rear seal housing.
NOTE:The lubricating oil pan and gasket must be installed
within 15 minutes after applying Three Bond Sealant.

No. 3823494, to both sides of the new lubricating oil pan
gasket.
Install the gasket.
Install the lubricating oil pan.
Page O-69
10 mm
Assemble the washers and capscrews to secure the
lubricating oil pan as illustrated. 21 17 13 9 5 1 3 7 11 15 19 23
%
Tighten all capscrews in the sequence shown in the @j@
accompanying chart.
Ir
Install the drain plug and a new drain plug sealing washer. IQ1
I w9nxh
Timing Pin Assembly - Installation

Caution: The timing pin assembly is precisely located on
;t~; ~y~;d;;~~~ ?o correspond to top dead center (TDC) A Engine
. . Timing Pin
The timing pin assembly must be relocated if a gear housing

other than the original is installed.
Failure to locate the timing pin assembly to TDC for cylinder
No. 1 will result in incorrect injection timing.
.‘I\ -Gear Housing

it9pihb
13 mm, 18 mm
Rotate the engine on the engine stand to the horizontal
position.
To relocate the timing pin assembly, temporarily install the

vibration damper and a pointer fabricated from No. 16 gauge
wire. Put a flat washer between the pointer and gear housing
to prevent damage to the gear housing.
Page O-70
19 mm, Part No. 3822503 Liner Clamp

Assemble two cylinder liner clamps over the No. 1 cylinder
bore.
Tighten the cylinder liner clamps.
Position two flat washers on the piston so they will contact the
cylinder liner clamps.
Rotate the crankshaft clockwise until the washers on the piston

contact the cylinder liner clamps.
Mark the vibration damper adjacent to the pointer.
G
Rotate the crankshaft in the opposite direction until the washers

on the piston contact the cylinder liner clamps.
Mark the vibration damper adjacent to the pointer.
Page O-71
Measure the distance and mark the vibration damper at

one-half the distance between the two pointer marks. This is
the TDC mark.
19 mm
Remove the cylinder liner clamps and washers. Rotate the &5-l
crankshaft in the direction of rotation until the nointer
with the TDC mark.
Look through the back side of the gear housing for the
timing pin hole in the camshaft gear. If the hole is not
visible, rotate the crankshaft one complete revolution.
it9OOs
Lubricate the o-ring with clean 15W-40 engine oil and install
into the groove of the timing pin.
Install the timing pin assembly.
Page O-72
T-25 Torx””
Push the timing pin into the hole in the camshaft gear to align
the housing.
Hold the timing pin in while tightening the timing pin assembly
TorxTMscrews.
Torque Value: 8 Nom 171 in-lb]
Check the timing pin to be sure it did not slip out of the
camshaft gear hole when the timing pin assembly screws were
tightened.
it900v
13 mm, 18 mm
Caution: To prevent damage to the pin and gear, be sure to
disengage the timing pin before rotating the crankshaft.
Remove the vibration damper and wire pointer.
Flywheel Housing - Installation

Dry Clutch Application
Install the two dowel pins into the back of the cylinder block.
Drive the dowels in until they are against the bottom of the
bore.
Install two M12X1.75XlOO mm guide pins into the cylinder block

to help support and align the flywheel housing during
installation.
NOTE: Dry clutch applications require a sealing ring on the
rear seal housing. Install the sealing ring in the machined
surface of the rear seal housing and lubricate with Lubriplatem
105.
Page O-73
Visually inspect the rear face of the cylinder block and

flywheel housing mounting surface for cleanliness and raised
nicks or burrs.
Install the flywheel housing. Be sure the flywheel housing is

positioned onto the alignment dowels and guide pins.
0a3
NOTE: Be sure the sealing ring is not damaged during
installation.
Remove the two M12Xi .75X100 mm guide pins.
15 mm
Install and tighten the flywheel housing mounting capscrews
using the pattern shown in the chart.
Flywheel Housing Bore - Concentricity Checking

Part No. ST-1325 Dial Gauge Attachment
Attach a dial indicator to the crankshaft. The dial indicator
can be mounted by any method that holds the extension bar
of the indicator rigid so it does not sag. If the bar sags or
the indicator slips, the readings obtained will not be
accurate.
Position the indicator in the 6:00 o’clock position and zero
the gauge.
Engine Assembly (O-02) Engine Disassembly and Assemlby - Grow 00
Page O-74

Slowly rotate the crankshaft. Record the readings obtained at
the 9:00 o’clock, 12:00 o’clock, and 3:00 o’clock positions as
[a], [b], and [c] in the concentricity work sheet. Check zero at
the 6:00 o’clock position again.
The values for [a], [b], and [c] could be posltiie or negative.
Refer to the accompanying figure to determine the correct sign
when recording these values.
Rotate the crankshaft until the dial indicator is at the 12:00

o’clock position and zero the gauge.
NOTE: Do not force the crankshaft beyond the point where the
bearing clearance has been removed. Do not pry against the
flywheel housing. These actions could cause false bearing
clearance readings.
Use a pry bar to raise the rear of the crankshaft to its upper
limit. Record the value as [d] in the concentricity work sheet.
This is the vertical bearing clearance adjustment and will always
be positive.
Use the concentricity work sheet to determine the values for

Concentricity Worksheet the ‘total vertical’ and ‘total horizontal’ values.
The ‘total horizontal’ is equal to the 9:00 o’clock reading, [a],
)I minus the 3:00 o’clock reading [cl.
The ‘total vertical’ is equal to the 12:00 o’clock reading [b],
plus the bearing clearance Id].
12 o’clock
Example:
6:00 o’clock = ref = 0.000 mm [O.OOOin].
9:00 o’clock = [a] = 0.102 mm [0.004 in].
12:00 o’clock = [b] = 0.076 mm [0.003 in.]
3:00 o’clock = [c] = -0.051 mm [-0.002 in.]
Using the work sheet and the numbers from the example, the
‘total horizontal’ value = 0.152 mm [O.OOSin.] and the ‘total
vertical’ value = 0.127 mm [0.005 in.]
Mark the ‘total horizontal’ value on the horizontal side of the
chart and the ‘total vertical’ on the vertical side of the chart.
Use a straight edge to find the intersection point of the ‘total
horizontal’ and ‘total vertical’ values. The intersection point
must fall within the shaded area for the flywheel housing
NOTE
concentricity to be within specification.
Use the ‘total horizontal’ and ‘total vertical’ values from the
previous example, the intersection point falls within the shaded
area. Therefore, the flywheel housing concentricity is within
specification.
TOTAL HORIZONTAL READING oi9OOvg

Paae 0-75
If the intersection point falls outside the shaded area, the ring
dowels must be removed and the housing repositioned.
NOTE: The ring dowels are not required to maintain
concentricity of the housing. The clamping force of the
capscrews holds the flywheel housing in position.
After the ring dowels are discarded, install the flywheel
housing on the engine.
To position the housing, tighten the capscrews enough to
hold the flywheel housing in place, but loose enough to
enable small movement when struck lightly with a mallet.
Check the concentricity again by following the above
procedure.
Use the pattern shown in the chart to install and tighten the
mounting flywheel housing capscrews.
Wet Clutch Application

Perform all the steps in the procedure for dry
installation in addition to the following:
Coat the flywheel housing drain plug with pipe sealant and
install in the hole in the bottom of the flywheel housing.
Tighten the drain plug.
Refer to the pipe plug torque values in Group 18 for different
plug sizes.
Page O-76
Install the plastic plug in the tachometer drive access hole.
fh9pxha
13 mm
Install the access plate and new access plate gasket.

Install the access plate capscrews and tighten.
Torque Value: 24 N*m 118 ft-lb]
Thoroughly clean the flywheel housing and cylinder block

mating surfaces. These surfaces must be clean and free of oil
or debris.
fh9bdea
I
NOTE: The center capscrew holes on the flywheel housing

mounting pads are drilled through. Coat set screws with
LoctiteTM 277 and install into holes.
Set Screw Installation Depth

mm in
0.00 MIN 0.000
3.00 MAX 0.118
fh9pxhc
Page O-77
Apply a continuous bead of Three Bond Sealant around all

capscrew holes on the mounting surface of the flywheel
housing.
Coat the threads of the mounting capscrews with LoctiteTM

277.
Install and tighten the capscrews. Follow the same tightening
sequence used for the dry clutch application.
Flywheel - Installation
NOTE: Use a new pilot bearing when installing a new or
rebuilt clutch.
Use a mandrel and hammer to remove the pilot bearing. 0
@z
Use a Scotch-Brit@ 7446 cleaning pad, or equivalent, to
q
clean the pilot bore.
B
Use a mandrel and hammer to install the pilot bearing.

($!A
NOTE: The pilot bearing must be installed even with the pilot @ii
bore surface.
Refer to Group 16 for flywheel ring gear replacement.
Page O-78
Install two M12X1.25X90 mm guide pins into the crankshaft

flange 180 degrees apart.
NOTE: If a clutch is used in the equipment, the threads in the
clutch pressure plate mounting capscrew holes can be metric
or standard. Be sure to use the correct capscrews.
Determine the capscrew thread design and size and install two
“T-handles” into the flywheel at points (1) and (2).
Visually inspect the rear face of the crankshaft and flywheel

mounting flange for cleanliness and raised nicks or burrs.
component.
Install the flywheel on the guide pins.
Lubricate the threads of the flywheel capscrews and the surface

of the washers with clean 15W-40 engine oil.
Install the six flywheel capscrews.

Remove the “T-handles” and guide pins.
Install the remaining flywheel capscrews into the holes from
which the guide pins were removed.
Page O-79
19 mm Socket, Torque Wrench, Part No. 3377371 Engine

Barring Tool
RI
Hold the crankshaft when tightening the flywheel capscrews. ,
Tighten the flywheel capscrews in the pattern as illustrated.
Torque Value: 137 Nom [lo1 ft-lb]
fh9OOoa
Flywheel Bore Runout Measurement

Use the dial indicator gauge (1) Part No. 3373050, or its
equivalent and dial gauge attachment (2) Part No. ST-1325,
to inspect the flywheel bore (3) and the surface (4) runout.
Install the attachment to the flywheel housing.
Install the gauge on the attachment.
Install the contact tip of the indicator against the inside
diameter of the flywheel bore, and set the dial indicator at
zero.
Use the engine barring tool, Part No. 3377371, to rotate the
crankshaft one complete revolution (360 degrees).
NOTE: The total indicator reading (TIPi) must not exceed
0.20 mm [0.008-inch].
NOTE: If the TIR is greater than the specification, do the

following:
l Remove the flywheel.
ingine Assembly (O-02) Engine Disassembly and Assemlby - Group 00
‘age O-80
l Inspect the flywheel mounting surface for dirt or

damage.
hvlbdsb
l Inspect the crankshaft for dirt or damage.
l Install the flywheel, and inspect the flywheel bore

runout again.
l Replace the flywheel if the flywheel bore runout does

not meet specifications.
Page O-81
Flywheel Face Runout Measurement

Install the contact tip of the indicator against the flywheel
face, as close to the outside diameter as possible, to inspect
the face (I) runout.
NOTE: Push the flywheel forward to remove the crankshaft
end clearance. Adjust the dial on the indicator until the
needle points to zero.
Use the engine barring tool, Part No. 3377371, to rotate the
crankshaft one complete revolution. Measure the flywheel
runout at four equal points on the flywheel.
NOTE: The flywheel must be pushed toward the front of the
engine to remove the crankshaft end clearance each time a
point is measured.
The total indicator reading (TIR) must not exceed the

following specifications:
Flywheel Maximum (TIR)

Radius (A) of Flywheel Face
mm in mm in
203 8 0.203 0.008
254 10 0.254 0.010
305 12 0.305 0.012
356 14 0.356 0.014
406 16 0.406 fw9OOtd
0.016
If the flywheel face runout is not within specifications, remove

the flywheel. Check for nicks, burrs, or foreign material
between the flywheel mounting surface and the crankshaft
flange.
Page O-82
Starting Motor - Installation

Wet Housing
Apply a coat of Three Bond Sealant to the starter mounting
surface and both sides of the spacer and starting motor gasket,
if equipped.
12 mm
Coat the starting motor capscrews with LoctiteTM pipe sealant
PST.
Install the starting motor. Tighten the starting motor capscrews.
Starting motor capscrews that are precoated with Vibra-Seal
require a lower torque.
Coolant Heater - Installation

Clean the expansion plug bore thoroughly. Make sure there
are no burrs or sharp edges that could cut the o-ring during
installation.
Lubricate the new heater o-ring with clean 15W-40 engine oil.
Page O-83
The coolant heater locking channel T-Bar should be loosened
to the end of the bolt.
Hook the element and one leg of the channel T-Bar into the @@
hole as illustrated.
4v
Hook the other leg of the channel in the hole and push the @@A
heater into the hole as far as possible by hand.
4W
Plastic Hammer, 4 mm Hex Wrench

If necessary, use a plastic hammer to tap the heater into the
RI
bore until the flange contacts the block. Make sure the o-ring
is not damaged during installation.
NOTE: Do not use the screw to pull the heater into position,
this could damage the threads.
NOTE: The cable insertion socket should be oriented to the
9:OO o’clock position.
Page O-84
Tighten the retaining capscrew.
0(K Torque Value: 12 Nom [106 in-lb]
g@
o$
+s
Insert the power cord into the socket, being careful to align the
pins with the sockets of the power cord. Tighten the retaining
nut by hand.
Do not apply power until the cooling system is filled.
Lubricating Oil Cooler - Installation

Refer to Group 07 for oil cooler assembly and rebuild
instructions.
install two M8X1.25X80 guide pins into the cylinder block.
Assemble the cooler gasket, oil cooler, and oil cooler cover
gasket together over the guide pins.
If a new element is being installed, be sure to remove the
shipping plugs.
Install nine capscrews.
Ic900hS
10 mm
Remove the two guide pins and install the remaining two
capscrews.
Tighten all the oil cooler and filter head capscrews.
Page O-85
Lubricating Oil Filter - Installation

Apply a light film of clean 15W-40 engine oil to the gasket
sealing surface before installing the filter.
NOTE: The filter must be installed within 15 minutes from the
time oil was applied to the rubber seal.
Fill the oil filter with clean 15W-40 engine oil.
A
Caution: Mechanical over-tightening may distort the
threads or damage the filter element seal.
Install the filter as specified by the filter manufacturer.
Cylinder Head - Installation

The cylinder block and head must be clean and dry.
NOTE: The maximum allowable piston protrusion above the
top of the block with a standard gasket is 0.40 mm [0.016
q
B
inch]. If the piston protrusion is greater than specified, refer e

to Group 01 for information pertaining to thicker head
gaskets.
Make sure the gasket is correctly aligned with the holes
in the cylinder block.
Position the gasket onto the dowels.
k&khb
I

component.
A
Caution: Do not drop the cylinder head on the cylinder
head gasket. The gasket material will be damaged.
0@Y
Carefully install the cylinder head onto the gasket and
cylinder block. Make sure the cylinder head is installed
onto the dowels in the cylinder block.
Page O-86
Use clean 15W-40 engine oil to coat the cylinder head

capscrew threads and underneath the head flange.
Do not install the capscrews with painted head in the center
row that will be covered by the valve cover.
Allow the excess oil to drain from the capscrew threads before
installation.
Install the capscrews into the cylinder head.

NOTE: Be sure to install the six capscrews in the holes
underneath the injectors.
kn9csha
NOTE: The top of the cylinder head capscrew is identified with

an angle marking. The cylinder head capscrews must be
tightened by using the three-step “torque plus angle” method,
described as follows:
kn3csga
1. Follow the numbered sequence and tighten all capscrews:

Torque Value: (Step One) 70 Nom [52 ft-lb]
Follow the numbered sequence and check the torque on all
capscrews again.
C-- Front
kn3csob
Page O-87
0%
2. Follow the numbered sequence and tighten only the
fourteen long capscrews:
Torque Value: (Step Two) 145 Nom [105 ft-lb]
long capscrews again.
e Front
3. Torque Value: (Step Three)

Follow the numbered sequence and turn all the capscrews
90 degrees as indicated on the capscrew head.
To accurately turn the capscrew to the desired angle, a small

“dot” and a “window” are marked on the capscrew head.
Window
kn9csvb
Mark the cylinder head adjacent to the dot on the capscrew

head. This mark will serve as an indexing aid.
Page O-88
Rotate the capscrew until the mark that has been made on the
cylinder head falls into the “window” on the capscrew head.
Service Tip: Use a permanent marker to mark the socket

corresponding to one of the flats of the socket hex.
After the torque has been completed, mark the cylinder head
at the location of the dot.
Position the socket on the capscrew such that the mark on the
socket is at the same point as the window on the capscrew.
Page O-89
Turn the socket until the mark of the socket aligns with the
mark on the cylinder head.
Push Rod - Installation

Check the push rods for straightness.
Install the push rods into the sockets of the valve tappets
from which they were removed.
Lubricate the push rod sockets and valve stems with clean
15W-40 engine oil.
Rocker Lever and Shaft - Assembly

install the adjusting screw and locknut.
I rh900fc
Page O-90
Install a retaining ring, thrust washer and wavy spring washer
rh9OOaa
Lubricate the shaft with clean 15W-M engine oil.
rh9shw.a
Position the levers on the rocker shaft.
rh9OOae
Install the remaining wavy spring washer, thrust washer and

retaining ring as illustrated.
rh900ac
Page 0-91
Compress the wavy spring washers and install the bottom

half of the pedestal as illustrated.
rh900ad
Rocker Lever Assembly - Installation

Make sure the rocker
completely backed out.
lever adjusting screws are
0
@
rh900da
Install the supports and rocker lever assemblies over the @$

rocker lever oil manifold.
@
Make sure the dowels in the pedestals are installed into -
the dowel bores.
Use clean 15W-40 engine oil to lubricate the threads and

under the heads of the pedestal capscrews.
Install the retaining clamps and capscrews.
Page O-92
10 mm
RI Caution: To prevent damage to the rocker lever or push
rod, make sure the adjusting screw ball is positioned in the
socket of the push rods when tightening.
A
NOTE: For engines with excessive oil carryover, rotate the
0(K
rocker lever shaft toward the push tube side of the engine
(clockwise when facing the front of the engine). This will reduce
the amount of oil to the overhead.
Tighten the retaining clamp capscrews.
Valve Clearance - Adjustment
RI l/2 Inch Drive, Part No. 3377371 Engine Barring Tool

Locate top dead center (TDC) for cylinder No. 1 by rotating the
crankshaft slowly while pressing on the engine timing pin.
When the pin engages the hole in the camshaft gear, cylinder
No. 1 is at (TDC) on the compression stroke.
Engine
--=?h Timing
cg9gewa
Caution: To prevent damage to the timing pin, be sure to

A disengage the pin after locating top dead center.
Page O-93
Feeler Gauge
Adjust the valves with engine cold (below 60°C [14O”F]).
The clearance is correct when slight resistance is felt as the
feeler gauge is moved between the valve stem and rocker
lever.
Valve Clearance Specifications

mm in
0.30 Intake 0.012
0.61 Exhaust 0.024
Valve Arrangement
Beginning at the front of the cylinder head, the first valve is
intake, the second one is exhaust. The same orientation is
used for all cylinders.
IE IE IE IE IE IE
1 2 3 4 5 6
0 Eront
14 mm, Flat Blade Screwdriver

Locate top dead center (TDC) for cylinder
Adjust the valves indicated for Chart A.
No. 1. RI
Tighten the locknut. @ Chart A
0(K
Torque Value: 24 Nom [18 ft-lb] Cylinder 1 2 3 4 5 6
Check the valve clearance again. Intake x x X
Exhaust X X X
Mark the end of the crankshaft or flywheel. Rotate the

crankshaft 360 degrees.
Caution: Be sure the timing pin is disengaged.
A
Page O-94

Adjust the valves indicated for Chart B.
Tighten the locknut.
Chart B w Torque Value: 24 N*m [18 ft-lb]

Cylinder 1 2 3 4 5 6 Check the valve clearance again.
Intake X x x
Exhaust X X X
Valve Cover - Installation

Install the rubber seal into the groove in the valve cover. Start
the installation at the overlap area shown in the illustration. Do
not stretch the rubber seal. If the seal has more overlap than
shown in this illustration, trim the excess to provide the proper
overlap.
Install new sealing o-rings on the valve cover capscrews.

NOTE: Engines equipped with wastegate turbochargers must
have a studded capscrew installed in the third hole from the
front. This is for the wastegate actuator hose clamp.
15 mm
Install the valve cover capscrews and tighten in the sequence
shown.
Page O-95
Crankcase Breather Tube - Installation

13 mm, 18 mm
Install the breather tube and hose clamps. Tighten the
capscrews for the breather tube support brackets.
Torque Value:
A = 24 Nom [18 ft-lb]
B = 48 Nom [32 ft-lb]
Injector - Installation
Lubricate the sealing lips of the sleeve with anti-seize
0%
compound. Assemble the injector, sealing sleeve, a new
copper sealing washer and the holddown clamp.
Use only one washer.
Service Tip: A light coat of clean 15W-40 engine oil between
the washer and injector will aid in holding the washer in
place during installation.
Install the injector assembly into the injector bore. The @@A
injector leak-off connection must be toward the valve cover.
@
13 mm
Install the holddown capscrew.
Page O-96
Fuel Drain Manifold - Installation

10 mm
Install the fuel drain manifold and new copper sealing washer
as illustrated.
Torque Value: 9 Nom [80 in-lb]
NOTE: The banjo connector seal (Siamese washer) must be
installed as illustrated.
10 mm
Install new sealing washers and connect the drain manifold,to
the fuel filter head.
Torque Value:
Filter Head Banjo 15 Nom [ll ft-lb]
Injector Banjo 9 Nom [80 in-lb]
ft9seha
Engine Lifting Bracket - Installation

18 mm
Install the front bracket onto the front exhaust side of the
cylinder head.
Install the rear bracket on the rear of the cylinder head. Tighten
the capscrews.
Intake Manifold Cover - Installation

Install the manifold cover, gasket and capscrews (charge air
cooled engines). Do Not install capscrews in the holes used
to secure the high pressure fuel line support brackets.
Page O-97
Aftercooler - Installation
Install the aftercooler, gasket and capscrews, if equipped. @
Apply 3-Bond to both sides of the aftercooler gasket. Do not &
install capscrews in the holes used to secure the high
pressure fuel line support brackets.
Torque Value: 24 Nom 118 ft-lb] 0(K
8 mm
Install the coolant supply tube (1) and coolant return tube
(2). Tighten the hose clamps.
Exhaust Manifold - Installation

Assemble the exhaust manifold capscrews, new lock plates, @
and gaskets on the manifold. Apply a thin coating of nickel @
based, high temperature, anti-seize compound to the
capscrew threads.
NOTE: The exhaust manifold gasket can be installed in either
direction.
The tabs in the holes of the gasket are designed to hold the
gasket in place during installation.
16 mm
Is-l
Install the exhaust manifold and gaskets. Follow the \w 1
sequence shown and tighten the capscrews.
Torque Value: 43 N l m [32 ft-lb]
0\
After the capscrews are tightened to the correct torque value,
bend over the lockplates to prevent the capscrews from r
loosening.
\ ’I xm9OOha
Page O-98
Turbocharger - Installation
Use precoated turbocharger mounting studs or apply a thin
coating of nickel based, high temperature, anti-seize compound
to the coarse threads of the stud.
tb9OOw
Use two nuts locked together to install the studs.

/ tb900wd
/ /
15 mm
Install the turbocharger mounting gasket with the raised bead
facing the exhaust manifold.
Install the turbocharger.
13 mm
NOTE: It may be necessary to orient the turbocharger center
bearing housing and/or compressor outlet.
To orient the center bearing housing, bend the lockplates, if
equipped, and loosen the turbine housing capscrews and
position the bearing housing.
Page O-99
Turbocharger Oil Drain Tube - Installation

Apply a thin coat of LoctiteTM 277 around the flanged end of
the lower drain tube. Use a tube driver and hammer to drive
the tube into the bore until the flange contacts the cylinder
block. Make sure the end of the tube is in the 12x10 o’clock
position.
NOTE: If a tube driver is not available, a 22 mm open end
wrench can be used as illustrated.
13 mm
Install the hose and clamps on the turbocharger drain tube
loosely. Install the drain tube and gasket on the
turbocharger. Tighten the oil drain tube capscrews.
Position the turbocharger drain hose to connect the drain

tube, tighten the clamps.
13 mm, Punch, Hammer

If loosened, tighten the turbine housing capscrews. Bend the
lockplates onto the flats to prevent loosening.
Page O-100
7/16 inch, 10 mm
Orientation of the compressor outlet requires the compressor
housing V-band clamp to be loosened.
If required, loosen the compressor housing and position the
housing to align with the air crossover tube.
NOTE: When orienting the compressor outlet on turbocharger
with wastegate actuators, do not force the movement of the
housing. This will damage the actuator bracket and cause
internal damage to the turbocharger.
Snap Ring Pliers

For turbochargers with snap rings, loosen the snap ring and
align the compressor housing with the turbocharger air outlet
connection with snap ring pliers or channel locks.
7/16 inch, Plastic Hammer

Loosen the two capscrews that secure the actuator bracket
brace to the V-band clamp. After orientation, first tighten the
V-band clamp nut, tap around the V-band clamp with a plastic
hammer, then tighten the two capscrews on the brace.
Torque Value:
V-Band Clamp Nut 8 Nom [ 71 in-lb]
Actuator Bracket Brace Capscrews 13 Nom [115 in-lb]
NOTE: New or rebuilt turbocharger must be prelubricated

before start-up.
Pour 50 to 80 cc [2 to 3 oz.] of clean 15W-40 engine oil into
the oil inlet fitting on top of the turbocharger while spinning the
turbocharger impeller to distribute the oil in the bearing.
Page O-l 00-02
Turbochazer Oil Sup ly Hose - Installation

16 mm Cro oot, 19 mm 8 ocket
Apply vegetable oil to the o-rings of the adapter fittings.
Install the fittings into the oil filter head and top of the
turbocharger bearing housing.
Tighten the fittings.
Install the oil supply line.
Page O-101
Turbocharger Exhaust Outlet Connection

Installation
install the exhaust outlet connection.
NOTE: Do not tighten the two mounting capscrews until the
band clamp has been tightened.
Torque Value:
Band Clamp 8 Nom [71 in-lb]
Capscrews 43 N*m 132 ft-lb]
Air Crossover Tube - Installation

Screwdriver
Install the air crossover tube and clamps and tighten.
Be sure there is a minimum of 9.5 mm IO.375 inch] between
0(K
the compressor outlet and the crossover tube.
Thermostat and Housing - Installation

Install two thermostats into the bores as illustrated.
Refer to Group 07 for thermostat testing procedures.
Install a new gasket and the thermostat housing. Install two

capscrews and do not tighten until after the coolant outlet
connection is installed.
Page O-102
Coolant Outlet Connection - Installation

10 mm
Install a new gasket and the coolant outlet connection.
Tighten the thermostat housing and coolant connection
capscrews.
Torque Value: 24 Nom [I8 ft-lb]
Coolant Filter - Installation

Apply a light film of clean 15W-40 engine oil to the gasket
sealing surface of the coolant filter.
Caution: Mechanical over-tightening may distort the threads
or damage the filter head.
Install the coolant filter as specified by the filter manufacturer.
Coolant Vent Fitting - Installation

9/16 inch
Coat the threads with pipe sealant with Teflon and install the
l/8 inch coolant vent fitting.
Tighten and orient the fitting so the petcock bore is at the
12:00 o’clock position.
Coolant Vent Petcock - Installation

9/16 inch
Coat the threads with pipe sealant with Teflon and install the
vent petcock.
Page O-l 03
Coolant Vent Tube - Installation

7/16 inch
Coat the threads with Teflon and install the coolant vent
tube. Tighten the fitting.
Coolant Inlet Connection - Installation

Install the new coolant inlet connection and tighten the @!!!
clamp. GB /

The final positioning of the inlet connection may need to be
made after installation of the engine in the vehicle.
Alternator Mounting Bracket - Installation

13 mm
Assemble the alternator bracket to the thermostat housing.
Alternator - Installation
Position the alternator on the bracket and install the
mounting capscrews.
The capscrews should be installed with the nuts facing
toward the inside of the bracket.
Do not tighten at this time.
Page O-104
Alternator Brace - Installation

13 mm
Install the capscrew into the alternator brace and water pump.
Finger tighten the capscrew.
eh9cshc
Caution: Make sure the alternator brace is positioned

properly for correct belt alignment.
Connect the alternator brace to the alternator. Finger tighten
the capscrew.
Tighten the water pump mounting capscrew.

15 mm, 18 mm, 19 mm
Tighten the alternator mounting capscrew.
Torque Value:
A = 43 Nom [32 ft-lb]
B = 24 Nom [18 ft-lb]
C = 80 Nom [59 It-lb]
Page O-105
Belt Tensioner Bracket - Installation

5 mm Hex Wrench
Install the tensioner bracket onto the front of the thermostat
housing.
Tighten the hex head screws.
Belt Tensioner - Installation

15 mm I-S-l
Position the belt tensioner onto the bracket and secure it Iw ’
with the capscrew. Make sure the tensioner locating tab is
positioned in the unthreaded hole of the tensioner bracket.
Engine - Removal from the Rebuild Stand

Part No. 3822512 Engine Lifting Fixture
Warning: To prevent personal injury, the engine lifting
equipment must be designed to safely lift the engine as
•il
an assembly. The dry weight of the engine with standard
accessories is 612 kg [1350 lb].
Use a properly rated hoist and engine lifting fixture such as
Part No. 3822512, attached to the engine mounted lifting
brackets to lift the engine.
A
Warning: The engine can move or drop a small distance
as it is being removed from the rebuild stand. Use
extreme care to prevent personal injury.
Use the hoist and lifting fixture to apply lifting tension to the
engine.
Remove the six capscrews that hold the engine to the
adapter plate.
Use the hoist to lower the engine to suitable engine support
stands or a shipping skid.
Remove the hoist and lifting fixture from the engine.
Page O-106
Fan Hub Assembly - Installation

10 mm
Install the fan hub. Be sure the fan hub shaft assembly turns
freely. Tighten the capscrews.
Fuel Injection Pump - Installation

LoctiteTM is used to help retain the injection pump mounting
studs.
Apply Loctitem 242 to the threads of the studs.
13 mm
Use two nuts locked together as illustrated to install the studs.
fD900hl

Make sure the piston in cylinder No. 1 is at TDC.
NOTE: Rotate the crankshaft only in the direction of rotation.
Engine Assembly (O-02)
Engine Disassembly and Assembly - Group 00 Page O-107
The fuel injection pump also has a timing pin (l), located in
the governor housing, to position the pump shaft to
correspond with TDC for cylinder No. 1. After the pump is
installed, the timing pin must be reversed and stored in the
governor housing (2).
24 mm
Remove the access plug.
Remove the timing pin.
fs9Dimi
If the timing tooth is not aligned with the timing pin hole,
rotate the pump shaft until the timing tooth aligns.
Page O-108
Reverse the position of the pin so the slot of the pin will fit
over the timing tooth in the fuel injection pump.
Install and secure the timing pin with the access plug.
fs9piha
Make sure the o-ring seals for the fill orifice (A) and pilot
(B) are correctly installed and are not damaged.
Lubricate the mounting flange with clean engine oil.
(4 NOTE: The fuel pump drive gear inside diameter and the shaft
outside diameter must be clean and dry before installing the
gear.
NOTE: The oil feed orifice o-ring for the Bosch PESP.P fuel
injection pump is found in the gear housing.
fp9hssz
NOTE: The drive gear does not require a Woodruff key. If

using a new replacement pump, remove and discard the key.
Position the pump flange onto the mounting studs.
15 mm and 13 mm, Part No. 3823956 Fuel Pump Mounting

Tool Kit
Install the mounting nuts.
Torque Value:
Mounting nuts 44 N l m [32 ft-lb]
Rear support bracket:
M8 pump to bracket capscrews
Ml0 block and bracket capscrews
Upper support bracket
Page O-l 09

•l
30 mm (PESGP Fuel Injection Pump) _
Caution: To prevent damage to the timing pins, do not
exceed the torque value given. This is not the final torque A
value for the retaining nut.
Install the fuel pump drive gear, retaining nut and washer.
Initial Torque Value: 12 Nom [106 in-lb]
Disengage the engine timing pin.
24 mm
Remove the fuel pump timing pin plug. Reverse the position •l
of the pin and install the pin, plug and sealing washer.
Torque Value: 15 Nom [il ft-lb]

Tighten the fuel injection pump drive gear nut.
Pump Model Torque Value:
PESGA 92 Nom [ 68 ft-lb]
PESGMW 104 Nom [ 77 ft-lb]
PESGP 195 Nom [144 ft-lb]
Page O-l 10
Oil Fill
A Caution: The governor housing must be prelubricated
before engine operation. Failure to do so will result in
premature governor weight wear.
•l 10 mm hex drive
Add the following quantity of clean 15W-40 engine oil:
l RSV 450 ml [0.43 qt.]
l RQV 750 ml [0.71 qt.]
l RQVK 750 ml [0.71 qt.]
Install the access plug.
Position an indicator on a tooth of the injection pump drive

gear.
Note the total indicator travel as injection pump drive gear

backlash.
Hold the adjoining camshaft gear from moving when checking
backlash or the readings will be the total of both gears.
Fuel Pump Drive Gear Backlash Limit

mm in
0.08 MIN 0.013
0.33 MAX 0.03
Fuel Injection Pump Supply Line - Installation

17 mm and 19 mm
use new sealing washers and install the injection pump supply
@ zhten the banjo fittings.

Install the fuel return line.
Page O-l 11
Fuel Filter Head - Installation

If the optional dual filter is to be used, install the adapter and
o-ring.
Install the o-ring in the dual filter head. Lubricate the o-ring @A
and the center hole with clean 15W-40 engine oil. @
24 mm
Install the dual filter head.
Tighten the nut.
Fuel Filter - Installation

Temporarily install the fuel filter(s).
When the engine is ready to be put into service, fill the

filter(s) with clean No. 2 diesel fuel and tighten l/2 turn
after the lubricated gasket contacts the filter head.
ff9etha
Page O-112
Fuel Lines, High Pressure - Installation

10 and 17 mm (PESGA and PESGMW Fuel Injection Pump)
10 and 19 mm (PESGP Fuel Injection Pump)
Loosen the vibration isolator capscrews so the fuel lines can be
easily moved.
NOTE: To prevent breakage to the fuel lines, they must be
connected to the injector and fuel injection pump in a “free
state” without forcing the connecting nuts. Since the fuel lines
are properly sized for specific application, bending should not
be necessary.
Caution: If removed, install the support clamp in the original

position and make sure the lines do not contact each other
or another component.
Install the high pressure fuel lines in the reverse order of
removal.
NOTE: Thoroughly clean the high pressure fuel lines to make
sure no debris is present before installing the fuel lines onto the
injectors or fuel injection pump.
Tighten all high pressure fuel line fittings and mounting

hardware.
Torque Value:
1. Line Fittings 24 Nom [18 ft-lb]
2. Support Bracket Capscrews 24 Nom [18 ft-lb]
3. Vibration Isolator Capscrews 6 Nom [53 in-lb]
AFC Tube - Installation

17 mm, 13 mm
Install the AFC tube.
Torque Value:
Threaded Fitting 8 Nom [71 in-lb]
Page O-l 13
Seal, Front Crankshaft - Installation

3824499 installation Tool
RI
Leave the plastic pilot installation tool in the lubricating oil
seal.
position the seal on the service tool, Part No. 3824499, with
the lubricating oil seal dust lip facing outward.
NOTE: Properly support the front cover lubricating oil seal

flange to prevent damage to the lubricating oil seal and front
cover.
Press the lubricating oil seal into the front cover from the
back side of the cover toward the front side of the cover.
press the lubricating oil seal until the service tool bottoms
against the front cover.
Wear Sleeve, Front Crankshaft - Installation

NOTE: Visually inspect the seal contact area of the
crankshaft for a wear groove. If the seal has worn a groove
deep enough to be felt with a sharp object or fingernail, it
will be necessary to install a wear sleeve to prevent an oil
leak.
NOTE: The oil seal used with the wear sleeve has a larger
inside diameter than the standard seal. The two seals are not
interchangeable. Refer to the appropriate Parts Manual for
the correct part number.
Part No. 3823908 Crankshaft Front Wear Sleeve

Installation Tool
Use the driver to install the wear sleeve to the correct
position on the crankshaft. The kit consists of the following:
Ref. Description QtY.

No.
1 Driver 1
2 Spacer 2
3 Capscrew Ml 4X1.5X60mm 2
4 Hair Pin Cotter 2 ksStolb
Page O-114
Apply a thin coat of 15W-40 engine oil to the driver inside

diameter and capscrew threads.
Use crocus cloth or equivalent to remove rust and corrosion

deposits from the crankshaft flange.
Apply a thin coat of 15W-40 engine oil to the crankshaft flange.
Position the chamfered end of the wear sleeve onto the end of
the crankshaft.
Position the counterbore end of the driver onto the wear

sleeve.
Install two capscrews (without spacers or hair pin totters)

through the driver and into the crankshaft capscrew holes.
WEAR
Align the wear sleeve and driver perpendicular with the
crankshaft. Tighten the capscrews “finger tight”.
Page O-l 15
Alternately tighten the capscrews until the sleeve is installed

to a depth of approximately 16 mm [0.625 inch].
NOTE: To prevent damage to the wear sleeve, do not
exceed l/2 revolution of each capscrew.
Approximate torque value: 20 Nom [15 ft-lb]
Remove the capscrews and install a spacer on each

capscrew. Install the two capscrews again.
Continue to alternately tighten the capscrews until the bottom

of the driver contacts the end of the crankshaft.
Remove the driver. Use the hair pin totters to secure the
capscrews and spacers to the tool during storage.
ks9tove
Page O-l 16
Gear Cover - Installation
A
Caution: The seal lip and the sealing surface on the
crankshaft must be free from all oil residue to prevent seal
leaks.
q
B Thoroughly clean and dry the front seal area of the crankshaft.
Use two M8X1.25X70 mm guide pins to aid in alignment of the

gasket. Apply a coat of Three Bond Sealant to both sides of
the gasket.
Install the gasket and gear cover,with the seal pilot tool, over
the nose of the crankshaft.
NOTE: The seal pilot tool will align the cover and the nose of
the crankshaft.
Install the capscrews.
10 mm
Tighten the gear cover capscrews.
Torque Value: 24 Nom [18 k-lb]
Remove the seal tool pilot from the nose of the crankshaft.
Page O-l 17
Install the crankshaft oil seal dust shield, if used, as follows: @&
0 Push the dust shield (1) onto the crankshaft with the @
part number facing out away from the engine.
l The dust shield should contact the oil seal.
NOTE: Liquid soap will aid in installation.
Tachometer Drive - Installation

Install the tachometer drive and cable.
bp9OOha
Vibration Damper - Installation

21 mm, Part No. 3377371 Engine Barring Tool
Install the vibration damper.
Use the engine barring tool to hold the engine from turning.
0%
Install the fan hub pulley and secure with capscrews.

@!A
NOTE: It will be easier to tighten the capscrews after the belt @
is installed.
Page O-l 18
Drive Belt - Installation

3/8 inch Square Drive
Lii the tensioner and install the drive belt.
Service Tip: If difficulty is experienced installing the drive belt
(the belt seems too short), position the belt over the fan hub
pulley first and then slide the belt over the water pump pulley
while holding the tensioner up.
13 mm
Tighten the fan hub pulley capscrews.
Engine Support, Front - Installation

15 mm
Install the front engine support.
Fuel Transfer Pump - Installation

10 mm
Apply a coating of Three Bond Sealant to the gasket.
Install the fuel transfer pump and new gasket.
Page 0-l 19
Fuel Lines, Low Pressure - Installation

14 mm, 17 mm, 20 mm
Install the fuel line to the fuel transfer pump. Use two
wrenches to tighten the connection to the fuel transfer pump.
Torque Value: 24 Nom [18 k-lb]
Fuel Pump Solenoid - Installation

8mm
Install the solenoid and connect the wires.
Torque Value: 8 N*m [70 in-lb]
Refer to Group 14 for engine testing.
Air Compressor - Installation

14 mm, 15 mm, 19 mm
Caution: Make sure the oil drain notch in the gear
housing
the side
the gear
is not blocked. The gasket must be installed with
marked “This Side Toward Gear Housing” facing
housing.
A
Use a new gasket. Install the air compressor. Tighten the two @!!!!
mounting nuts. dv
NOTE: It is not necessary to time the air compressor on the cp900ha
6D114E-1 Series engine.
Install the mounting spacer to the engine block, use the 40 @j&
mm long capscrews and tighten finger tight. @
Page O-120
Install the air compressor brace (2) to the mounting spacer (1)
and adapter (3) on the air compressor using the 30 mm long
capscrews. Make sure the brace and spacer are aligned and
no parts are in a bind. Tighten evenly to the proper torque
value.
9/16 inch
15/16 inch
RI Caution: If rubber grommets are used on the coolant lines,
be sure they are installed carefully to prevent cuts or tears
to the grommets which will cause coolant leaks.
A
Install the coolant Ines.
‘@
** Torque Value: 35 Nom [26 ft-lb]
(+i
0
Install and tighten the inlet and outlet connections.

Torque Value:
0K
Inlet 5 Nom [48 in-lb]
*Outlet 24 Nom [18 ft-lb]
*l/2 NPT fitting in the compressor cylinder head.
NOTE: Torque value for the discharge line depends on the line
size and type.
Refer to the appropriate chassis Shop Manual for the correct
torque value.
Page O-121
Engine Accessories - Installation

Install the cover plate or any additional gear driven @A
;rzeories (hydraulic pump, freon compressor, etc.) as av
NOTE: When gear driven accessories are installed, be sure

to install the correct support bracket.
ah9olh;
Cylinder Block - Group 01
Page l-l

Section Contents
Page
Camshaft Bore Expansion Plug Installation ........................................ 21
Camshaft Bushing Bore - Cleaning .............................................. 23
Camshaft Bushing - Installation ................................................ 23
Camshaft Bushing - Removal ..................................................
Camshaft - Cleaning and Inspection for Reuse ......................................

Camshaft - Cleaning ........................................................
Camshaft Gear - Inspection ...................................................
Camshaft - Inspection .......................................................
Camshaft Gear - Replacement .................................................

Camshaft Gear - Cleaning ....................................................
Camshaft Gear - Inspection ...................................................
Camshaft Gear - Installation ...................................................
Camshaft Gear- Removal ....................................................
Connecting Rod Bearings - Cleaning and Inspection for Reuse ..........................

Connecting Rod Bearings - Cleaning .............................................
Connecting Rod Bearings - Inspection ............................................
Connecting Rod Bushing - Replacement ..........................................

Inspection.. .............................................................
Installation ..............................................................
Machining.. .............................................................
Removal.. ..............................................................
Connecting Rods - Bend and Twist Inspection ......................................

Connecting Rod Alignment - Inspection ...........................................
Connecting Rod Twist - Inspection ..............................................
Fixture Calibration .........................................................
Connecting Rods - Cleaning and Inspection for Reuse ................................

Connecting Rods - Cleaning ..................................................
Connecting Rods - Inspection .................................................
Crankshaft - Cleaning and Inspection for Reuse .....................................

Crankshaft - Cleaning .......................................................
Crankshaft - Inspection ......................................................
Crankshaft Gear - Replacement .................................................

Crankshaft Gear - Inspection ..................................................
Crankshaft Gear - Installation ..................................................
Crankshaft Gear - Removal
General Information ..... : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :
Cylinder Block - Cleaning in a Hot Tank ..........................................
Cylinder Block - Cleaning with Solvent ...........................................
Cylinder Block - Disassembly ..................................................
Cylinder Block - Exploded View ................................................
Cyl;Fli;:;ock - General Information .

. . . _. . . . ........... .......................
. . . . ........... ....................... i
Connecting’ Rods 111111111111111111 . . . . ........... ....................... 9
Crankshaft . . . . . . . . . . . _. . . . . . . . . . . . . . ........... .......................
Cylinder Block . . . . . . . . . . . . . _. . . . . . . . . . ........... ....................... ii
Cylinder Liner . . . . . . . _. . . . . . . . . . . . . . . . ........... ....................... 9
Page 1-2
Oil Seals ................................................................ 9

Pistons .................................................................. 9
Vibration Damper.. ......................................................... 9
Cylinder Block - Inspection For Reuse ............................................ 16
Cylinder Block - Preparation for Cleaning ......................................... 10
Cylinder Block - Service Tools .................................................. 4
Cylinder Head Capscrews - Cleaning and Inspection for Reuse ..........................

Cleaning ................................................................
Free Length - Measurement ...................................................
Inspection ...............................................................
Cylinder Liners - Cleaning and Inspection for Reuse ..................................

Cylinder Liners - Cleaning ....................................................
Cylinder Liners - Inspection ...................................................
Dowel Pins (Cylinder Head) - Removal ...........................................
Engine Dataplate - Replacement ................................................

Engine Dataplate - Installation .................................................
Engine Dataplate - Removal ...................................................
Engine Lifting Brackets - Cleaning and Inspection for Reuse ............................
Expansion Plug - Installation ...................................................

Pipe Plug - Installation ......................................................
Gear Cover - Cleaning and Inspection for Reuse ....................................

Gear Cover - Cleaning ......................................................
Gear Cover - Inspection .....................................................
Gear Housing - Cleaning and Inspection for Reuse ...................................

Gear Housing - Cleaning .....................................................
Gear Housing - Inspection ....................................................
Main Bearing Caps and Capscrews - Cleaning and Inspection for Reuse ...................
Cleaning.. ..............................................................
Inspection ...............................................................
Main Bearings - Cleaning and Inspection for Reuse ..................................

General Information ........................................................
Main Bearings - Cleaning ....................................................
Main Bearings - Inspection ...................................................
Thrust Bearings - Inspection ..................................................
Pistons - Cleaning and Inspection for Reuse .......................................

Piston Rings - Removal ......................................................
Pistons - Cleaning .........................................................
Pistons - Inspection ........................................................
Rear Cover - Cleaning and Inspection ............................................

Cleaning.. ..............................................................
Inspection ...............................................................
Vibration Damper - Cleaning and Checking for Reuse .................................

General Information ........................................................
Rubber Element Vibration Damper - Inspection ......................................
Rubber Vibration Damper - Cleaning .............................................
Viscous Vibration Damper - Cleaning .............................................
Viscous Vibration Damper - Inspection ............................................
Cylinder Block - Group 01 Cylinder Block - Service Tools
Page 1-3
Cylinder Block - Service Tools
Measure connecting rod length, twist and bore alignment. Use

with Part No. 3823286, connecting rod checking mandrel kit.
Remove dowel pins.
Used when installing pipe plugs, cup plugs, etc. on the engine

in] to 2.032 mm [8.0 in].
Inspect components for cracks.
Used to remove expansion plugs.

Cylinder Block - Service Tools Cylinder Block - Grow 01
Page 1-4
Tad No. Tool Descrbtion Tnnl

. __- Illu~tratian
----__-__-_--
Aid in removal and installation of crankshaft, flywheel and other

heavy components.
Expansion Plug Driver Handle
Used with all expansion plug drivers larger than 0.375 inch
Expansion Plug Driver
Install 1.00 inch expansion plug to specified depth. Used with

expansion plug driver handle, Part No. 3376795.
Install 0.375 inch expansion plug to specified depth.
Metric Thread Insert Kit
Repair damaged internal metric threads.
Piston Ring Expander

Used with Part No. ST-561, connecting rod checking fixture, to

check length, twist and bore alignment.
Remove and install camshaft bushings.

Cylinder Block - Group 01 Cylinder Block - Service Tools
Page l-5

install 0.8125 inch expansion plug to specified depth. Used

3823521 with expansion plug driver handle, Part No. 3376795.
Install 1.1875 inch expansion plug to specified depth. Used

3823522 with expansion plug driver handle, Part No. 3376795.

3823523 expansion plug driver handle, Part No. 3376795.
Used to install 2.250 inch expansion plug to specified depth.

3823524
Connecting Rod Pin Bushing Removal/installation Tool
Remove and install service bushing in the pin end of the con-
3823690 netting rod.
Capscrew Length Gauge
Used to measure capscrew free length.

3823921
Piston Ring Groove (Keystone Angle) Wear Gauge
Measure the wear of the intermediate piston ring groove key-

3823965 stone angle.
Piston Ring Groove (Keystone Angle) Wear Gauge
Measure the wear of the top piston ring groove keystone

3823966 angle.
Cylinder Block - Exploded View Cylinder Block - Group 01
Page 1-6
Cylinder Block - Exploded View
231
Cylinder Block - Group 01 Cylinder Block - Exploded View
Page l-7
Ref. No. Description QtY Ref. No. Description Qv

1 Block, Cylinder 1 38 Pin, Timing 1
2 Cap, Main Bearing 7 39 Ring, Retaining 1
3 Screw, Hex Head Cap (Flange) 14 40 Screw, Round Head Cap 2
4 Bushing, Camshaft 7 41 Gasket, Gear Cover 1
5 Plug, Expansion 4 42 Cover, Gear 1
6 Plug, Expansion 4 43 Seal, Front Crankshaft 1
7 Plug, Expansion 1 44 Screw, Hex Head Cap (Flange) 17
8 Plug, Expansion 1 45 Screw, Hex Head Cap (Flange) 6
9 Plug, Expansion 1 46 Cap, Front Cover 1
10 Plug, Expansion 1 47 Seal, Rectangular 1
11 Plug, Expansion 2 48 Screw, Hex Head Cap 1
12 Liner, Cylinder 6 49 Crankshaft 1
13 Plug, Pipe 5 50 Pin, Dowel 1
14 Plug, Pipe 6 51 Gear, Crankshaft 1
15 Draincock 1 52 Bearing, Main (Upper) 6
16 Plug, Pipe 1 53 Bearing, Flange (Thrust) 1
17 Pin, Dowel 4 54 Bearing, Main (Lower) 7
18 Pin, Dowel 2 55 Damper, Vibration 1
19 Nozzle, Piston Cooling 12 56 Screw, Hex Head 4
20 Plug, Pipe 1 57 Tube, Oil Gauge 1
21 Rod, Engine Connecting 1 58 Plug Expansion 2
22 Bolt, Connecting Rod 2 59 Filler Cap 1
23 Nut, Rectangular Hexagon 2 60 Tube, Oil Fill 1
24 Bushing 1 61 Plug, Expansion 1
25 Bearing, Connecting Rod 12 62 Plug, Pipe 1
26 Piston, Engine 6 63 Sealing Ring 6
27 Pin, Piston 6 64 Camshaft 1
28 Ring, Retaining 12 65 Gear, Camshaft 1
29 Ring, Piston (Top) 6 66 Support, Camshaft Thrust 1
30 Ring, Piston (Mid) 6 67 Screw, Hex Head Cap 2
31 Ring, Piston (Oil) 6 68 Wear Sleeve, Front Crankshaft 1
32 Gasket, Gear Housing 1 69 Wear Sleeve, Rear Crankshaft 1
33 Housing, Gear 1 70 Capscrew, Hex Head (Flange) 8
34 Screw, Hex Head Cap (Flange) 4 71 Cover, Rear 1
35 Seal, Timing Housing 1 72 Gasket, Rear Cover 1
36 Housing, Timing Pin 1 73 Seal, Oil Rear Crankshaft 1
37 Seal, O-Ring 1 74 Seal, Rectangular 1
Cylinder Block - General Information Cylinder Block - Group 01
Page 1-8
Cylinder Block - General Information

Camshaft
The profile of the camshaft lobes is the same for all 6D114E-1 Series engines.
The camshaft end clearance is determined by the clearance between the camshaft and the thrust plate.
Camshafts that are damaged or worn on the fuel transfer pump or the valve lobes must be replaced. Komatsu America
International Company does not recommend grinding the camshaft lobes.
Crankshaft
The crankshaft is a balanced, forged steel, full fillet hardened unit with seven main bearing journals. The lower bearing
shells are all the same. All of the upper bearing shells are the same except for the No. 4 journal which has a flanged
upper bearing shell. The flanges on the bearing shell control the end thrust of the crankshaft.
Oversize main bearings and thrust bearings are available for service. Komatsu America International Company rec-
ommends regrinding ALL of the main or the connecting rod journals when ONE requires regrinding.
Cylinder Block
The cylinder block has provisions for the oil cooler housing, thermostat seats, coolant bypass line, water pump volute,
oil pump housing, water pump inlet and replaceable cylinder liners.
Cylinder Liner
The cylinder liner is a replaceable mid-stop design. The liner seat area is located midway of the length of the liner. Coolant
sealing between the liner and block is provided by a press fit at the top and by a sealing ring at the mid-stop of the liner.
Oil Seals
All crankshaft seals on the 6D114E-1 Series are the Teflonm lay-down lip (scroll) type. The Teflonm lay-down lip type seal
does not contain a spring on the back of the sealing lip. The sealing lip is a thin, stiff piece of Teflon”.
Teflonm seals must be dry before installation. Do not lubricate the seal lip or the shaft. After the first few revolutions of
the shaft, a thin film of Teflon TMis transferred from the seal lip to the shaft. If the shaft is not clean and dry, this transfer
will not occur and the seal will leak. There are service replacement wear sleeves available for both front and rear
crankshaft oil seals.
Pistons
The pistons have a cast aluminum body, with both high swirl and low swirl combustion bowls and three ring grooves.
The top two ring grooves have a ni-resist insert with a Keystone profile. The pistons for the different engine configurations
are similar in appearance, but are not interchangeable. Always check the part number to be sure the correct piston is
used during piston replacement.
Vibration Damper
The vibration damper controls the twisting or torsional vibration of the crankshaft. The vibration damper is engineered for
use on specific engine models, depending on the horsepower rating and engine speed.
It is not economical to repair a vibration damper in the field. Install a new or a rebuilt vibration damper if the inspection
indicates that a damper is defective.
Connecting Rods
The connecting rods have replaceable bronze bushings.
Cylinder Block - Group 01 Cylinder Block - Preparation for Cleaning (l-01)
Page l-9
Cylinder Block - Preparation for Cleaning

(l-01)
It is necessary to thoroughly clean the cylinder block if it is
going to be reused. To properly clean the block, all pipe
plugs and expansion plugs must be removed. It is also
q
\
recommended to remove the camshaft bushings.

Refer to Procedure l-09.
0
Before beginning disassembly of the block, perform a visual
inspection to see if there is any damage that would prohibit @
reuse.
Cylinder Block - Disassembly (I-02)

Remove the pipe plugs from the coolant passages.
c%
0
Remove the pipe plugs from the oil passages.
ck9pxmc
Dowel Pins (Cylinder Head) - Removal (l-03) Cylinder Block - Group 01
Page l-10
Part No. 3375784, Light Duty Dent Puller, Drill Motor, 3 mm

[l/8 inch] Drill Bit
Drill a 3 mm [l/8 inch] hole and use a slide hammer equipped
with a No. 10 sheet metal screw to remove expansion plugs.
Remove the expansion plugs from the oil passages.
Remove the expansion plugs from the coolant passages.
Dowel Pins (Cylinder Head) - Removal

(I-03)
Use a dowel pin extractor, Part No. ST-1 134, or its equivalent.
Remove the two cylinder head dowel pins.
l Put the split collet (1) over the dowel pin.
l Slide the extractor collar (2) over the split collet.
l Use the slide hammer (3) to push the extractor collar
over the split collet tightly.
l Use the slide hammer to remove the dowel pin.
Cylinder Block - Group 01 Cylinder Block - Cleaning with Solvent (l-04)
Page l-11
Cylinder Block - Cleaning with Solvent

(I-04)
Cleaning Brush RI
q
Use clean solvent and a brush to clean the main oil passage.
B
Cleaning Brush
Use clean solvent and a brush to clean the main bearing to
camshaft bore oil passage.
B
R
Cleaning Brush
Use clean solvent and a brush to clean the piston cooling E2l
nozzle passages.
B
Ll
Cleaning Brush
Use clean solvent and a brush to clean the oil passage from
q
the camshaft bore to the rocker assemblies.
B
SW2037
Cylinder Block - Cleaning with Solvent (l-04) Cylinder Block - Group 01
Page 1-12
Cleaning Brush
Use clean solvent and a brush to clean the oil cooler oil
passages.
Thoroughly clean all gasket sealing surfaces.
Clean the cylinder block head deck with a Scotch-B&9 7448

cleaning pad or equivalent and solvent.
Clean the top cylinder liner press surface (A) and the mid-stop
ledge (B) and (C) with a Scotch Britee 7448 cleaning pad or
equivalent and solvent.
ck9brga
Cylinder Block - Group 01 Cylinder Block - Cleaning with Solvent (l-04)
Page 1-13
Thoroughly clean all expansion plug bores with a Scotch

Brite@7448 cleaning pad, or equivalent, and solvent.
Inspect the coolant passages for rust or restriction. Use

bristle brushes to clean the coolant passages.
Warning: Use protective measures to prevent personal
injury. A
Build-up of deposits in the coolant passages can cause
engine overheating.
NOTE: Excessive deposits may be cleaned in an acid tank,
but the camshaft bushings and piston cooling nozzles must
first be removed to prevent damage.
A
Warning: Use protective measures to prevent personal
injury.
NOTE: The block may be cleaned in a hot tank using a soap
and water solution without removing the camshaft bushings. B
IJ
Cylinder Block - Cleaning in a Hot Tank (l-05)
Page 1-14 Cylinder Block - Group 01
Cylinder Block - Cleaning in a Hot Tank

(I-05)
component.
Use a hoist or hydraulic arm to move the cylinder block into
the cleaning tank.
Follow the instructions of the manufacturer of the cleaning tank
and the manufacturer of the cleaning solution.
NOTE: Komatsu America International Company does not
ck9bde
recommend any specific cleaning solution.
A cleaning tank that will mix and filter the cleaning solution
gives the best results.
Remove the block from the cleaning tank.
Use a nylon bristle brush to clean the oil passages.
clothing and safety glasses or a face shield. Hot steam will
cause serious personal injury.
Use steam or solvent to clean the cylinder block. Dry with
compressed air.
ck9bdeC
Caution: Do not damage the machined gasket surfaces.

Use a gasket scraper to clean the cylinder block deck surface.
Use Scotch Brite@7448, or equivalent, and solvent to remove
any residual gasket material from the cylinder block gasket
surfaces.
Caution: When using compressed air to clean capscrew
holes, always wear safety glasses or a face shield to protect
the eyes. Personal injury can result. Be sure all of the water
and debris is removed from the capscrew holes and the oil
passages.
Use compressed air to dry the block.
NOTE: If the cylinder block is not going to be used

immediately, apply a coating of preservative oil to prevent rust.
Cover the block to prevent dirt from sticking to the oil.
Cylinder Block - Group 01 Cylinder Block - Inspection For Reuse (l-06)
Page l-15
Cylinder Block - Inspection For Reuse

(I-06)
NOTE: All measurements of the cylinder block must be
made when the block is positioned on a flat surface. If the
block is mounted on the engine stand, the measurements
can be incorrect because of distortion.
0a!3
Inspect all gasket surfaces.
Visually inspect for burrs or damage.
Use a medium grit hone or crocus cloth to remove burrs.
Straight Edge and Feeler Gauge

Visually inspect the cylinder block head deck for damage. RI
Check the cylinder block head deck for flatness between
each cylinder. 04B
Cylinder Block Flatness Specification
mm in
0.075 End-to-End 0.003
0.075 Side-to-Side 0.003
Caution: Do not proceed with the repair if the cylinder

block head deck is damaged or not flat. A
NOTE: The cylinder block head deck can be resurfaced in a
machine shop and a thicker surface cylinder head gasket
installed to keep the piston-to-valve clearance the same.
The upper right corner of the rear face of the block must be
stamped with an “x” when the block is resurfaced to 0.25
mm [O.OlO inch]. A second “x” must be stamped beside the
first when the block is resurfaced to 0.50 mm [0.020 inch].
ck9bdga
Cylinder Block - Inspection For Reuse (l-06) Cylinder Block - Group 01
Page 1-16
Consult the 6D114E-1 Series parts catalog for the correct

gasket to be used with resurfaced blocks to be sure of proper
piston-to-valve clearance.
A NOTE: The gaskets are notched and color coded to aid in

identification. The standard gasket is red and does not have a
notch.
A= (Silver) Use where cylinder block head deck has been
resurfaced
B 0.25 mm [O.OlO in] (two notches)
B= (Blue) Use where cylinder block head deck has been

resurfaced
0.50 mm [0.020 in] (three notches)

Measure the upper press fit area of the cylinder liner bore.
Cylinder Liner Bore in Block (Press Fit Bore)

mm in
130.900 MIN 5.1535
130.990 MAX 5.1570
Part No. 3375432, Crack Detection Kit

Caution: Clean all deposits and debris from sealing
surfaces A, B and C. Use Scotch Brite 7448* or equivalent
and cleaning solvent to polish the surfaces. However, due
to the critical machined tolerances, care should be taken
not to remove any additional material.
Use a crack detection kit, Part No. 3375432, or its equivalent.
Check the counterbore ledge for cracks.
If surface C has signs of extreme wear, the counterbore will
require machining and the installation of shims for the correct
liner protrusion.
ck9brga
Cylinder liner shims are available as follows:
Cylinder Liner Shim Thickness

mm Part No. in
0.25 1296 603 Hl 0.010
0.38 1296 604 Hl 0.015

0.51 1296 605 Hl 0.020
0.76 1296 698 Hl 0.030
bp900gf 1.oo 1296 699 Hl 0.040

Cylinder Block - Group 01 Cylinder Block - Inspection For Reuse (l-06)
Page 1-17
Measure the liner counterbore depth.
Cylinder Block Counterbore Depth From Cylinder

mm in
122.930 MIN 4.8397
123.000 MAX 4.8425
Cylinder Block Height From Cylinder Block Head Deck

mm in
309.4 MIN 12.181
309.6 MAX 12.189
Cylinder Block Height From Cylinder Block Head Deck

mm in
361.90 MIN 14.248
362.10 MAX 14.256
ck9bdr
0a3
Inspect the main bearing bores for wear or damage.
Install new main bearing and measure the bore diameter with
0%
main bolts tightened.
Main Bearing Bore Diameter

mm in
With New Bearings 98.079 MIN 3.8614
98.125 MAX 3.8632
Without Bearings 104.982 MIN 4.1331
105.018 MAX 4.1346
NOTE:The maximum bore misalignment is 0.0127 mm
[0.0005 inch].
Expansion Plug - Installation (l-07) Cylinder Block - Group 01
Page 1-18
Inspect the camshaft bores for scoring or excessive wear.

Measure the camshaft bores. Use a bore gauge The bores
must be measured in two positions. Take a second
measurement 90 degrees from the first measurement.
Camshaft Bore Diameter (Maximum)

mm in
64.01 (Without Bushing) 2.520
60.12 (With Bushing) 2.367
Inspect the tappet bores for scoring or excessive wear.
Tappet Bore Diameter

mm in
16.000 MIN 0.630
16.055 MAX 0.632
Expansion Plug - Installation (I-07)
A
Caution: Do not install any expansion plugs or pipe plugs
in the block until the inspection and any necessary repair
procedures are completed. This will prevent dirt from being
trapped in the oil passages.
Caution: Excessive sealant can run back into the engine
and cause damage to other components. Allow the sealant
to dry for a minimum of 2 hours before operating the
engine. The plug can come out of the bore if the sealant is
not dry.
Apply a 2 mm [ l/16 inch] bead of expansion plug Lo&N Seal,
Part No. 3375068, or equivalent to the outside diameter of the
- @ii
ro;znsion plug and the inside diameter of the expansion plug
NOTE: Use an expansion plug driver to install the expansion

plug to the correct depth in the bore.
Use the following expansion plug drivers:
Tool P/N Exp. Plug P/N Exp. Plug Dimension

3822372 1240 151 Hl 0.375 inch
3823521 1240 200 Hl 0.8125 inch
3376816 6736-21-l 820 1.00 inch
3823522 1240 889 Hl 1.1875 inch
3823523 1240 979 Hl 1.375 inch
3823524 1240 154 Hl 2.250 inch
Cylinder Block - Group 01 Expansion Plug - Installation (l-07)
Page 1-19
Caution: Do not install the plug too deeply. The cross 0.5 to 1.0 mm
drillings in the cylinder block may be blocked. If the plug
is not installed straight and flat, it must be replaced with
a new expansion plug.
A
The expansion plug must be installed with the edge of the
plug 0.5 to 1 .O mm [0.020 to 0.040 inch] deeper than the
entrance chamber of the bore.
Pipe Plug - Installation

Apply a bead of pipe plug sealant, Part No. 3375066, or
equivalent to the threads.
Install and tighten the pipe plugs. Refer to the following chart
for torque values:
I ck8ppha
Tighten pipe plugs to the appropriate torque values.

Pipe Plug Torque Values
NOTE: The accompanying chart is also provided in Group 18 Size Torque Torque
“Specifications”. ACblill In Aluminum In cast IrOn or
Thread Thread O.D. Components Steel Compnnentf
1
in. mm Iin1 Nom [ft-IbS] N-m [ft-lbs]
l/16 8.1 [0.32] 5 145 in-lb] 15 LlOl
118 10.4 [0.41] 15 PO] 20 [151
l/4 13.7 [0.54] 20 P51 25 I201
316 173 LO661 25 1201 35 1251
112 21.6 [O.SS] 35 1251 55 I401
3/4 26.7 [1.05] 45 [351 75 [551
1 33.5 ]I .32) 60 1451 95 I701
t ‘/4 42.2 [1.66] 75 I551 115 P51
1‘/2 48.3 [1.90] 85 1651 135 PO01
ck6ppoa
Pipe plug and expansion plug locations in front of cylinder

block.
1. 1 inch pipe plug
2. 13/16 inch expansion plug
3. l-3/8 inch expansion plug
4. l-l /8 inch expansion plug
2
5. l/2 inch pipe plug
1, ck9PPg
Camshaft Bore Expansion Plug Installation (l-08) Cylinder Block - Group 01
Page l-20
@7 Pipe plug and expansion plug locations, right side of block.

@ 1. 2.287 inch expansion plug
2. l-3/8 inch expansion plug
3. i/2 inch pipe plug
5. 3/4 inch pipe plug
6. l/4 inch draincock
7. 3/8 inch expansion plug or dipstick tube
I ck9ppgt 8. 7/8 inch expansion plug or turbocharger drain tube
1 @ Pipe plug and expansion plug locations, rear of block.

w 1. l-3/1 6 inch expansion plug or aftercooler connections
3. Camshaft bore expansion plug
ck9PPg’
@& Pipe plug and expansion plug locations, left side of block.
@ 1. l-3/8 inch expansion plug on side oil fill
2. 3/4 inch pipe plug
3. l/8 inch pipe plug
4. 3/8 inch expansion plug or dipstick tube
ck9PPg’
Camshaft Bore Expansion Plug -

Installation (I-08)
Apply a bead of Loctite” 277 around the outside diameter of
the camshaft expansion plug.
Cylinder Block - Group 01 Camshaft Bushing - Removal (l-09)
Page 1-21
Position the plug with the convex side out.
@$?
Expand the plug with a large brass drift and a hammer
043
Expand the plug until the convex side is even with the
cylinder block.
Camshaft Bushing - Removal (I-09)

Camshaft Bushing Removal and Installation Tool, Part No.
3823509
Drive the bushings from the cylinder block bore.
0
C%
Earnshaft Bushing Bore - Cleaning (l-10) Cylinder Block - Group 01
Page 1-22
Camshaft Bushing Bore - Cleaning (I-IO)

Use fine emery cloth and solvent to remove any burrs and
sharp edges from the bores.
Camshaft Bushing - Installation (I-II)

Mark the camshaft bushings and cylinder block to align the oil
holes.
NOTE: The oil holes in the camshaft bushings should be
pointing at approximately the 7:00 o’clock position when viewed
from the front of the engine.
Universal Bushing Installation Tool

NOTE: The front camshaft bushing should be installed to a
depth of 4.5 mm [0.177 inch] below the front face of the
cylinder block. All other bushings are to be installed even with
the web of the camshaft bore.
Be sure the oil holes are aligned.

A 3.2 mm [0.128 inch] diameter rod must be able to pass
freely through the camshaft bushing oil hole.
Cylinder Block - Group 01 Cylinder Liners - Cleaning and Inspection for Reuse (1-12)
Page 1-23
Measure the installed diameter of the camshaft bushings.

m
Camshaft Bushing Bore Diameter (Installed)
mm in
60.058 MIN 2.3845
60.112 MAX 2.367
Cylinder Liners - Cleaning and Inspection

for Reuse (l-12)
Cylinder Liners - Cleaning
Caution: To prevent cylinder liner damage, do not use a
hone or any abrasives in the ring travel area of the liner.
Abrasives can damage the surface finish and the cross
hatch pattern, and can contaminate the cylinder liner.
A
Use a soft wire brush to clean the flange seating area.
Use a fine fibrous abrasive pad such as; Scotch Brite@ 7448,
Part No. 3823258, or equivalent to remove the remaining bp?cyed
scale and rust.

A
q
Use a non-metallic bristle brush, detergent soap, and warm
water to clean the inside diameter, \
Use a steam cleaner or a solvent tank to clean the liners.
Dry with compressed air.
Use clean 15W-40 oil to lubricate the inside diameter of the
liners.
Allow the oil to soak in the liner for five to ten minutes.
q
Use “lint-free” paper towels to wipe the oil from the inside of
the liners. B
Continue to lubricate the inside of the liners and wipe clean
until the paper towel shows no gray or black residue.
CylinderLiners - Cleaning and Inspection for Reuse (1-12) Cylinder Block - Group 01
Page 1-24
-
0
Cylinder Liners - Inspection
0a9
OK Visually inspect the liners for cracks on the inside and outside
diameters.
Inspect for cracks under the flange.

0
aB
ck2sISa
Visually inspect the outside diameter and seat area for

0
423 excessive corrosion or pitting.
NOTE: Pits must not be more than 1.6 mm [0.06 inch] deep.
Replace the cylinder liner if the pits are too deep or if the
corrosion cannot be removed with fine emery cloth.
0
Inspect the inside diameters for vertical scratches deep enough
0
a3 to be felt with a fingernail.
OK
NOTE: If a fingernail catches in the scratch, the cylinder liner
must be replaced.
Visually inspect the inside diameter for scuffing or scoring.
Cylinder Block - Group 01 Cylinder Liners - Cleaning and Inspection for Reuse (1-12)
Page l-25
0ai3
Visually inspect the inside diameter for liner bore polishing.
A moderate polish (A) produces a bright mirror finish in the
worn area with traces of the original hone marks or an
indication of an etch pattern.
A heavy polish (B) produces a bright mirror finish in the
worn area with no traces of hone marks or an etch pattern.
0@3
Replace the liner if:
l A heavy polish is present over 20 percent of the piston
ring travel area.
m 30 percent of the piston ring travel area has both
moderate and heavy polish and one half (15 percent)
is heavy polish.
L15% ck8slsd
Part No. 3375072, Dial Bore Gauge

Use a dial bore gauge to measure the liner inside diameter in
four places 90 degrees apart at the top and bottom of the
piston travel area.
Cylinder Liner I.D.

mm in
114.000 MIN 4.4882
114.117 MAX 4.4928
ck8slna
Measure the outside diameter of the liner top press fit area.
Cylinder Liner O.D. (Top Press Fit)

mm in
130.938 MIN 5.1550
130.958 MAX 5.1558
ck2slna
Pistons - Cleaning and Inspection for Reuse (1-13) Cylinder Block - Group 01
Page 1-26
Pistons - Cleaning and Inspection for

Reuse (l-l 3)
Piston Rings - Removal
Part No. 3823137, Piston Ring Expander
Remove the piston rings.
Place a tag on the rings and record the cylinder number of the
piston on the tag.
p1900fb
Pistons - Cleaning
Caution: Be sure the cleaning solvent is approved for
aluminum. Damage to the pistons can result.
Allow the pistons to soak for a minimum of 30 minutes in a
tank containing an approved cleaning solvent for aluminum.
NOTE: For the best results, let the pistons soak for several
hours or overnight.
Use a hot, soapy solution and a non-metallic brush to remove
carbon deposits.
Caution: Do not use a metal brush. A metal brush will

damage the piston ring grooves. Do not use glass beads to
clean the grooves.

Use steam to clean the pistons.
Cylinder Block - Group 01 Pistons - Cleaning and Inspection for Reuse (1-13)
Page l-27
Pistons - Inspection
Inspect the piston for damage and excessive wear. Check
the piston ring grooves, skirt and pin bore.
NOTE: Dimensional inspection of the piston is required only
06B
when the cause of the lack of sealing is not apparent.
Check the piston for rolled edges on the ring lands that
indicate ring beat-in. This can cause loss of sealing.
0@3
Visually inspect the piston bowl (l), pin bore (2) and skirt (3)
for cracks or damage.
NOTE: Do not use pistons with cracks.
Measure the piston pin bore when the piston temperature is

at 20” C [68” F].
Piston Pin Bore I.D.

mm in
45.006 MIN 1.7719
45.025 MAX 1.7726
NOTE: Add 0.013 mm [0.0005 inch] to the bore inside di-

ameter per 5°C [lO”F] temperature rise up to 32°C [gOoF].
Cylinder Block - Group 01 Pistons - Cleaning and Inspection for Reuse (1-13)
Page l-27-02
0423
Visually inspect the piston pin for scratches, grooves, or
other damage. e
Measure the piston pin outside diameter.
Piston Pin O.D.

mm in
44.993 MIN 1.7714
45.003 MAX 1.7718
NOTE: Discard the piston pin if it is more than 0.03 mm

[O.OOl inch] out of round
Crankshaft - Cleaning and Inspection for Reuse (l-14) Cylinder Block - Group 01
Page 1-28
Measure the piston skirt diameter as illustrated.
Piston Skirt O.D.

mm in
113.814 MIN 4.4810
113.886 MAX 4.4840
pi9bdta
Use a micrometer and Part No. 3823966, piston ring groove

gauge, to measure the wear of the top ring groove keystone
angle. Use Part No. 3823965, piston ring groove gauge, to
measure the wear of the intermediate ring groove keystone
angle.
Piston Ring Groove (Keystone Angle)

Ring mm in
Top: 113.938 MIN 4.4857
Use a new piston ring and feeler gauge to measure the side
Ezl clearance of the rectangular intermediate and oil control ring
grooves.
@ Piston Ring Clearance (Rectangular Groove)

Ring mm in
0.150 MAX 0.0090
0.130 MAX 0.0051
pi9oota
Crankshaft - Cleaning and Inspection for

Reuse (1-I 4)
Crankshaft - Cleaning
Use fine crocus cloth to polish the machined surfaces.

Use a bristle brush to clean the oil drillings.
Cylinder Block - Group 01 Crankshaft - Cleaning and Inspection for Reuse (1-14)
Page 1-29

A
Steam clean the crankshaft and dry with compressed
Make sure to blow out the threaded
air.
holes on each end of
q
B
the crankshaft and the oil drillings.
Crankshaft - Inspection
Visually inspect the threaded
Use one of the following
holes:
capscrew
methods
holes for damage.
to repair any threaded 0a3
l Chase the threads
0 Use the Part No. 3822709, Threaded Insert Kit
NOTE: If more than two threaded holes are damaged in one
end, the crankshaft must be replaced.
Measure the front and rear oil seal contact areas for a wear
groove.
Crankshaft Front and Rear Oil Seal Wear Groove

mm in
0.25 MAX 0.010
Front and rear wear sleeves are available for a crankshaft

that is worn beyond the limit.
0623
Inspect the crankshaft connecting rod and main journals for
deep scoring, overheating, etc.
Crankshaft - Cleaning and Inspection for Reuse (l-14) Cylinder Block - Grow 01
Page l-30
Use a micrometer to measure the connecting rod journal.

@ Connecting Rod Bearing Journal Diameter (Min.)
mm in
75.962 Standard 2.9906
75.712 Machined 0.25 mm 2.9808
75.462 Machined 0.50 mm 2.9709
75.212 Machined 0.75 mm 2.9611
74.962 Machined 1.00 mm 2.9513
Bearing Clearance = Connecting rod inside diameter with

bearing installed minus crankshaft journal diameter.
Maximum Bearing Clearance: 0.1 17 mm [0.0046 inch]
Connecting Rod Bearing Journal

!
Kll
mm in
Out-of-Roundness: 0.050 MAX 0.0020
Taper: 0.013 MAX 0.0005
-‘li- ks900nt
Main Bearing Journal Diameter (Minimum)

mm in
97.962 Standard 3.8568

97.712 Machined 0.25 mm 3.8469
97.462 Machined 0.50 mm 3.8371
Bearing Clearance = Main bore diameter with bearing installed

minus (-) crankshaft main journal diameter.
Maximum Bearing Clearance: 0.134 mm [0.0053 inch]
Crankshaft Main Bearing Journal

mm in
Out-of-Roundness: 0.050 MAX 0.0020
Taper: 0.013 MAX 0.0005
Cylinder Block - Group 01 Crankshaft - Cleaning and Inspection for Reuse (1-14)
Page 1-31
The following oversize service main and thrust bearings are

available for crankshafts that have been machined undersize:
Main Bearing Diameter

Oversize 0.000 0.25 mm 0.50 mm
Journal 0.000 X X X
Diameter 0.25 mm X X
0.50 mm X X
0.75 mm X
1.00 mm X
Measure the thrust face width.
Crankshaft Thrust Face Width (Standard)

mm in
42.975 MIN 1.6919
43.076 MAX 1.6959
ks200nd
Measure the rear oil seal flange outside diameter.
Crankshaft Rear Oil Seal Flange O.D.

mm in
129.975 MIN 5.1171
130.025 MAX 5.1191
ks200n
Measure the damper pilot outside diameter.
Crankshaft Damper Pilot O.D.

mm in
23.924 MIN 0.9419
24.000 MAX 0.9449
ks200nl
Crankshaft Gear - Replacement (1-15) Cylinder Block - Group 01
Page l-32
Use a light preservative oil to lubricate the crankshaft to

cl
L4 prevent rust.
If the crankshaft is not going to be used immediately, protect
the part with a plastic cover to prevent dirt from sticking to the
oil.
ks200wb
Crankshaft Gear - Replacement (l-l 5)

General Information
There are two different crankshaft gears used:
l Steel gear for engines with a Bosch PESGP fuel injection
pump.
l Austempered gear for engines without a Bosch PESGP fuel
injection pump.
ks9gega
Crankshaft Gear - Removal

Use a heavy duty bearing separator or gear puller as illustrated
to remove the gear.
NOTE: The bearing separator or gear puller must be used to
remove the steel gear; however, a gear splitter can be used to
remove the austempered gear if it is not intended to be used
again.
Refer to the following procedure:
Part No. 3823585, Crankshaft Gear Splitter

RI Caution: Safety glasses are required when using this tool.
Caution: Use care to avoid damage to the polished surfaces
of the crankshaft by driving the point of the tool into the
A crankshaft.
NOTE: This tool will not work on a steel gear.
Steel gear Part No. 3918776.
Iron gear Part No. 3918380.
bp900gk
Cylinder Block - Group 01 Crankshaft Gear - Replacement (1-15)
Page 1-33
Place the point of the chisel between two gear teeth.

Strike the splitter with a two or three pound steel hammer.
Repeat this step if necessary.
Use a dowel pin extractor to remove the gear alignment
dowel pin.
Crankshaft Gear - Inspection

Visually inspect for cracks and broken or chipped teeth.
The gear must be replaced if it is damaged. 0a!!3
0@9
Visually inspect the gear and keyway for nicks or burrs.
Use fine crocus cloth to remove nicks and burrs.
a
B
ks8gesb
0@
Visually inspect the crankshaft gear journal and the gear
alignment dowel pin hole for burrs or damage.
Use fine crocus cloth to remove burrs.
Crankshaft Gear - Replacement (l-15) Cylinder Block - Group 01
Page 1-34
Measure the crankshaft gear journal inside diameter.
Crankshaft Gear Journal I.D.

mm in
75.898 MIN 2.9661
75.923 MAX 2.9691
Measure the crankshaft gear journal outside diameter.
Crankshaft Gear Journal O.D.

mm in
75.967 MIN 2.991
76.006 MAX 2.992
ksl getb
Crankshaft Gear - Installation

Use a soft hammer to install the gear alignment dowel pin into
the crankshaft.
The pin must be 1.02 mm [0.040 inch] above the crankshaft
surface.
Caution: Do not exceed the specified heating time or

temperature. The crankshaft gear and teeth can be
damaged.
Heat the gear in an oven for a minimum of 45 minutes but not
more than six hours.
Austempered Gear - Temperature: 149°C [3OO”F]
Steel Gear - Temperature: 177” C [350” F]
ks9oewl 3
Cylinder Block - Group 01 Main Bearings - Cleaning and Inspection for Reuse (1-16)
Page 1-35
Use Lubriplatee No. 105, or equivalent to lubricate the

outside diameter of the crankshaft gear journal.
Caution: Use insulated gloves, Part No. 3823730, when

handling heated parts. Personal injury will result. A
Caution: The timing mark (1) and part number (2) on the
gear must be facing away from the crankshaft after the
gear is installed. Engine damage can result if the gear is
installed backwards.
Remove the gear from the oven.
Align the keyway of the gear with the alignment dowel pin in @A
the crankshaft and install the gear within 30 seconds. @
Caution: Do not use water or oil to reduce the cooling
time. The gear can crack. Allow air to cool the gear.
NOTE: If the gear cools and stops on the crankshaft before

it is fully installed, use a driver to complete the installation.
I I ks9geh
Main Bearings - Cleaning and Inspection

for Reuse (1-I 6)
General Information
The engine has seven main bearings. The lower bearing
shells are all the same. The upper bearings have two oil
holes, the lower bearings do not have holes. All of the upper
bearing shells are the same except for the No. 4 journal. The
No. 4 journal uses a flanged upper bearing shell. The flanges
on the bearing control the end thrust of the crankshaft.
k:s
Main Bearings - Cleaning and Inspection for Reuse (1-16) Cylinder Block - Group 01
Page l-36
Main Bearings - Cleaning

Make sure the bearings are marked for location.The bearings
must be installed in their original location if used again.
Caution: Do not use a scraper or a wire brush. The
bearings can be damaged.
Use solvent and a soft bristle brush.
Main Bearings - Inspection

Visually inspect for nicks, scratches or damage.
Replace any bearings with the following damage:
l Pitting
l Flaking
l Corrosion
l Lock tang damage
l Scratches (deep enough to be felt with a fingernail)
NOTE: For more detailed information of bearing damage, refer
to “Analysis and Prevention of Bearing Failures,” Bulletin No.
mb200sa 3810387.
Use an outside diameter ball tipped micrometer to measure the

main bearing shell thickness at the wear location.
Standard Main Bearing Shell Thickness (Used)

mm in
3.340 MIN 0.131
3.454 MAX 0.136
Discard any main bearing shell if its thickness is below the

minimum specification.
Bearing shells are identified by steel stamped characters on the

back of the bearings to indicate either standard (STD) or the
amount of oversize (OS).
mb9begt
Cylinder Block - Group 01 Main Bearing Caps and Capscrews - Cleaning and Inspection for Reuse (1-17)
Page l-37
The following oversize service main and thrust bearings are

available for crankshafts that have been machined undersize:
Main Bearing Diameter

Oversize 0.000 0.25 mm 0.50 mm
Journal 0.000 X X X
Diameter 0.25 mm X X
0.50 mm X X
0.75 mm X
1.00 mm X
\!d- ks900ad
Thrust Bearings - Inspection
0
Visually inspect the thrust bearings for wear, cracks or
damage on the front and rear face and also the crankshaft @
journal contact area.
mb9bes
Measure the thrust bearing flange thickness. Measure both

the front and rear face contact areas.
Thrust Bearing Flange Thickness

mm in
3.517 MIN 0.138
3.567 MAX 0.140
NOTE: Thrust bearings are available in 0.25 mm [O.OlO-inch]

and 0.50 mm [0.020-inch] oversize thicknesses. Refer to the e
chart above.
mb900s
Main Bearing Caps and Capscrews -

Cleaning and Inspection for Reuse (1-17)
Cleaning
q
Use solvent and a soft bristle brush to clean the main
bearing cap, capscrews and bearings. Dry with compressed B
air.
mb9caea
Connecting Rod Bearings - Cleaning and Inspection for Reuse (1-18) Cylinder Block - Group 01
Page 1-38
Inspection
0629 Visually inspect the main cap and capscrews for damage.
mb9ben, i
Connecting Rod Bearings - Cleaning and

Inspection for Reuse (l-l 8)
NOTE: For future identification, the bearings must be marked
for location as they are removed. Each bearing must be
installed in its original location if the bearing is used again.
Connecting Rod Bearings - Cleaning

Caution: Do not use a scraper or a wire brush. The
A bearings can be damaged.
cx9beea
q
\ Use solvent and a soft bristle brush. Dry with compressed air.
Connecting Rod Bearings - Inspection

Visually inspect the bearings for damage.
Replace any bearings with the following damage:
l Pitting
l Flaking
l Corrosion
l Lock tang damage
l Scratches (deep enough to be felt with a fingernail)
Refer to the Parts Reuse Guidelines, Bulletin No. 3810303, for
further information.
NOTE: Normal bearing wear produces a smooth finish which

will wear into the lining. An exposed lining does not always
indicate worn bearings. If large areas of the lining are visible in
the bearings before the engine has accumulated 240,000
kilometers [150,000 miles] or 3,750 hours, inspect the engine
for contamination from fine dirt particles and correct the
problem.
Cylinder Block - Group 01 Connecting Rods - Cleaning and inspection for Reuse (1-19)
Page 1-39
Visually inspect the bearing seating surface for nicks or

burrs. @I
If burrs can not be removed with a fine crocus cloth, the
bearings must be replaced.
For more detailed information of bearing damage, refer to e
Analysis and Prevention of Bearing Failures, Bulletin No.
3810387.
Measure the connecting rod bearing shell thickness with an

outside micrometer that has a ball tip.
Standard Connecting Rod Bearing Thickness

mm in
2.43 MIN 0.0956
2.471 MAX 0.0973
Discard a bearing shell if its thickness is below the minimum

specification.
mfflbetb
NOTE: Oversize bearing shells are available for crankshafts

which are 0.25 [O.OlO-inch], 0.50 mm [0.020-inch], 0.75 mm
[0.030-inch], or 1.OO mm [0.040-inch] undersize.
Bearing shells are identified by steel stamped characters on
the back of the bearings to indicate either standard (STD) or
the amount of oversize (OS).
Refer to the appropriate Parts Catalog.
0.25 mm (.OlO in.)
0.50 mm (.020 in.)
0.75 mm (-030 in.)
1.00 mm (.040 in.)
Connecting Rods - Cleaning and

Inspection for Reuse (1-19)
Connecting Rods - Cleaning
NOTE: The letter or number on the connecting rod cap must
be the same as the letter or number on the connecting rod.
Do not assemble a new cap to a used connecting rod or a
used cap to a new connecting rod.
Remove the connecting rod capscrew nuts and caps from
the connecting rods.
Connecting Rods - Cleaning and Inspection for Reuse (l-19) Cylinder Block - Group 01
Page l-40
A Warning: When using a steam cleaner, wear protective

q
B Use solvent or steam to clean the rods.
Use a soft bristle brush to clean the oil drilling.
Connecting Rods - Inspection

Visually inspect the connecting rod and cap for fretting damage
0
a9 on the mating surfaces.
The rod and cap must be replaced as an assembly if any
fretting damage is visible on either piece.
Replace the connecting rod if the “l-beam” is nicked or
damaged.
Visually inspect the connecting rod pin bore bushing for

0
4B damage or misalignment of the oil passage and bushing.
Measure the connecting rod piston pin bushing inside diameter.

@ Connecting Rod Pin Bore Diameter (Bushing
Installed)
mm in
45.023 MIN 1.7726
45.060 MAX 1.7740
NOTE: Service replacement rod bushings are available. Refer
to the appropriate parts catalog for part numbers.
The bushing must be precision machined after installation. If
cx9brta machining capability is available, the bushing can be replaced.
Refer to Connecting Rod Bushing - Replacement in
Procedure l-21 _
Cylinder Block - Group 01 Connecting Rods - Cleaning and Inspection for Reuse (1-19)
Page 1-41
0at3
cx9bosa
Install the bearing shells into the connecting rod and cap.
Use clean 15W-40 oil to lubricate the capscrew threads.
Install the connecting rod caps and connecting rod nuts.
NOTE: The connecting rod cap number must match the k
number on the connecting rod and be installed with the cl A
numbers aligned.
Tighten the connecting rod nuts in alternating sequence.
Torque Value: Step 1 - 40 N l m [30 ft-lb]
Measure the connecting rod crankshaft bore inside diameter

with the bearing installed.
Connecting Rod Crankshaft Bore I.D. (With Bearing)

mm in
76.046 MIN 2.9939
76.104 MAX 2.9962
Connecting Rod Crankshaft Bore I.D. (Without Bearing)

mm in
80.987 MIN 3.1885
81.013 MAX 3.1895
Caution: The connecting rod must be assembled with the

capscrew nuts tightened to specifications before stamping
the cylinder identification number on the connecting rod. A
If a new connecting rod is installed, always stamp the new
connecting rod with the cylinder number of the rod being
replaced.
Connecting Rods - Bend and Twist Inspection (l-20) Cylinder Block - Group 01
Page l-42
Connecting Rods - Bend and Twist

Inspection (I-20)
Fixture Calibration
Use a connecting rod checking fixture, Part No. ST-561, and a
connecting rod mandrel set, Part No. 3823286, to inspect the
bend and twist of the rods.
Calibrate the checking fixture with a new rod that has been
measured for correct center to center length, 215.975 mm to
216.025 mm [8.5029 inches to 8.5049 inches].
NOTE: Assemble the connecting rod cap to the rod as
described in Procedure 1-19.
Install the piston pin mandrel from the connecting rod mandrel
set, Part No. 3823286, into the piston pin bore.
NOTE: Use a mandrel, Part No. 3823283, if the piston pin
bushing has been removed or mandrel, Part No. 3823284, if the
bushing is still in place.
Install the mandrel, Part No. 3823303, into the crankshaft bore
and expand the mandrel.
NOTE: Make sure the pin on the mandrel is pointed down and
locked in position in the center of the connecting rod.
Install the connecting rod into the fixture.

Move the dial holder to position the contact points of the
indicators on the mandrel in the piston pin bore.
Tighten the bracket to hold the indicators in position.
Set the dial indicators to read zero.
Remove the connecting rod from the fixture.

Turn the rod 180 degrees horizontally, and install the rod into
the fixture again.
Cylinder Block - Group 01 Connecting Rods - Bend and Twist Inspection (l-20)
Page 1-43
0a9
Check the dial indicators for the zero position again.
If the dial indicators show any change from zero, adjust the
dials to half the indicated reading.
The fixture is now calibrated to allow the connecting rod to
be installed into the fixture in either direction, and the dials
will indicate an equal deflection on either side of zero.
Connecting Rod Alignment - Inspection

Install the mandrel and arbor into the connecting rod to be
inspected.
Install the connecting rod into the fixture.
Measure the connecting rod length and bend (alignment).
Connecting Rod Length

mm in
215.975 MIN 8.5029
216.025 MAX 8.5049
Connecting Rod Bend (Alignment)

mm in
Bushing Removed 0.20 MAX 0.008
Bushing Installed 0.15 MAX 0.006
Connecting Rod Twist - Inspection

Install a feeler gauge between the mandrel and the dial
indicator holding plate as shown.
Connecting Rod Twist

mm in
W
Bushing Removed 0.50 MAX 0.020
Bushing Installed 0.30 MAX 0.012
cx8OOnd
Connecting Rod Bushing - Replacement (1-21) Cylinder Block - Group 01
Page 1-44
Connecting Rod Bushing - Replacement

(1-21)
1
Part No. 3823690, Connecting Rod Pin Bore Bushing
Removal/installation Tool
This tool is used to remove and install the bushings to the
correct position.
Ref.
No. Part No. Description QW
1 3823691 Anvil 1
2 3823693 Cup 1
3 3823692 Mandrel 1
4 3823694 Driver Ring (thick) 1
5 3823695 Knock-out-ring (thin) 1
6 Hair Pin Cotter 1
Removal
Place the pin bore end of the connecting rod on the mandrel.
0
Place the knock-out (thin ring) on the mandrel on top of the
a3 connecting rod. Match up the angle surfaces.
cx9tohc
Cylinder Block - Group 01 Connecting Rod Bushing - Replacement (l-21)
Page l-45
Install the cup on the mandrel and secure with the hair pin
cotter.
I cx9toh
Install the mandrel in the anvil. Place the connecting rod so

the angle on the rod matches with angle on the anvil. The
connecting rod will be in the horizontal position.
cx9toh:
Press the connecting rod bushing out by applying force on

top of the cup. Press the bushing through the bore.
cx9bshc
Remove the hair pin cotter.

0
Remove the cup and slide the connecting rod from the C%
mandrel.
Page l-46
Measure the connecting rod bushing bore with the bushing

removed.
NOTE: If the connecting rod bushing bore is not within
specifications, replace the connecting rod.
Connecting Rod Pin Bore Diameter (Bushing

Removed)
mm in
46.966 MIN 1.9286
49.012 MAX 1.9296
Installation
Before installing the connecting rod bushing, submerge the
bushing and connecting rod pin end in clean 15W-40 engine
oil.
cx9oowc
Place the connecting rod bushing on the mandrel.
Place the knock-out (thin ring) inside the driver ring.
Match the angles, place the angle side down and align the
notch of the knock-out (thin ring) to the pin in the driver ring
and slide on the mandrel.
Cylinder Block - Group 01 Connecting Rod Bushing - Replacement (1-21)
Page 1-47
Install the cap and secure with the hair pin cotter.
Insert the mandrel and components into the chamfered side

of the connecting rod.
Align the angles of the bushing, connecting rod, and stop
rings.
NOTE: All connecting rods do not have a double chamfer. A
chamfer may be added to aid in the installation of the
bushing, but should not result in an unsupported bushing
area.
0eiE3
Align the oil hole in the bushing and connecting rod (use the
groove in the mandrel) and push the mandrel and
components into the pin bore of the connecting rod until
contact is made. This contact helps maintain the alignment of
the oil holes.
Bushing
Groove Rod
cx9oogl
L
Place the connecting rod and mandrel assembly on the anvil

(position so that the angle on the connecting rod matches
the angle on the anvil). The connecting rod is in the
horizontal position.
I- I cx9oowl
Page I-48
Press the bushing into the connecting rod by applying force on

the top of the cup. Use either an arbor or hydraulic press.
Push through in a continuous motion until the driver ring makes
contact with the connecting rod.
cx9bshc
Check the alignment of oil holes. A 3 mm [l/8 in] diameter rod

must move freely through the connecting rod and the bushing
oil holes (A).
Check for clearance between the connecting rod bushing and
the connecting rod.
Use a 0.025 mm [O.OOl inch] feeler gauge to make sure the
bushing is properly seated. The 0.025 mm [O.OOl inch] feeler
gauge must not enter between the bushing and the connecting
rod (B).
cx9bsnt
Machining
The inside diameter of new connecting rod bushings must be
machined with a rod boring machine such as Part No. 3823801
(Sunnen PM-300@) or Part No. 3375144 (Tobin Arp@).
When properly adjusted, a Sunnen PM-30Oe, or equivalent,
connecting rod boring machine is capable of maintaining all the
critical dimensions.
NOTE: Do not use a “floating rod” type honing machine.
Inspection
NOTE: After machining the connecting rod bushings, it will be
necessary to check all critical dimensions. Refer to Procedure
l-l 9 in this section for specifications and instructions.
Cylinder Block - Group 01 Camshaft - Cleaning and Inspection for Reuse (l-22)
Page 1-49
Camshaft - Cleaning and Inspection for

Reuse (I-22)
Camshaft - Cleaning
A
Use solvent or steam clean the camshaft. Dry with
compressed air.
Caution: After the camshaft has been steam cleaned, do

not touch the machined surfaces with bare hands, this
will cause rust to form. Lubricate the camshaft with clean
15W-40 engine oil before handling.
A
Camshaft - Inspection
Visually inspect the fuel transfer pump lobe, valve lobes and
bearing journals for wear, cracking, pitting, scratches or other
damage.
0
@
NOTE: Komatsu America International Company does not

recommend repairing camshafts by grinding the valve lobes.
If the camshaft is damaged beyond the reuse guidelines, the
camshaft must be replaced.
Tne following criteria defines the size of the pits, allowable
wear and edge deterioration of the chilled iron camshaft
lobes. I cg9shs.z
0a!3
Pitting:
A single pit must not be greater than the area of a 2 mm
[0.079 inch] diameter circle.
Camshaft - Cleaning and Inspection for Reuse (l-22) Cylinder Block - Group 01
Page l-50
0
Interconnection of pits is not allowable and is treated as one
49 pit.
cg900sd
0
The total pits, when added together, must not exceed a circle
@ of 6 mm [0.236 inch].
0
Only one pit is allowed within + or - 20 degrees of the nose of
aI9 the camshaft lobe.
Measure across the peak of the camshaft lobes.
b
Camshaft Lobe Wear Limits (Minimum)
mm in
51.774 Intake Valve 2.038
0 51.596
41.31
Exhaust Valve
Fuel Transfer Pump
2.031
1.626
t cg9oosg
Cvlinder Block - Group 01 Camshaft - Cleaning and Inspection for Reuse (l-22)
Page l-51
Measure across the camshaft journal.
Camshaft Journal Diameter

mm in
59.962 MIN 2.3607
60.013 MAX 2.3627
NOTE: Replace the camshaft if the outside diameter of any

bearing surface is less than 59.962 mm [2.3607 inch].
Edge Deterioration (Breakdown)
04B
The area of edge deterioration must not be greater than the
equivalent area of a 2 mm [0.079 inch] circle within + or -
20 degrees of the nose of the camshaft lobe.
Outside of the + or - 20 degrees of the nose of th

camshaft lobe, the areas of edge deterioration must not b
z;re$teer than the equivalent area of a 6 mm [0.236
Camshaft - Cleaning and Inspection for Reuse (l-22) Cylinder Block - Group 01
Page 1-52
0
This illustration shows normal grain pattern and a casting flaw within the nose
QB area. Both of these conditions are acceptable for reuse.
The folk use:
Camshaft Gear - Inspection

Visually inspect the camshaft gear teeth for wear and damage.
Look for cracks at the root of the camshaft gear teeth. If the
gear is damaged, it must be replaced. Refer to Procedure l-23.
Cvlinder Block - Group 01 Camshaft Gear - Replacement (l-23)
Page 1-53
Camshaft Gear - Replacement (l-23)

Camshaft Gear - Removal
Caution: Place a wooden block under the camshaft to
avoid damage as the camshaft drops free from the
camshaft gear. A
Place the camshaft and gear assembly in the hydraulic press.
6s
Q
cg9gefi
Push the camshaft from the gear.

Remove the camshaft dowel pin.
Camshaft Gear - Cleaning

Use solvent to clean the camshaft gear. Dry with compressed
air.
ca3aee
Camshaft Gear - Inspection

Visually inspect
broken teeth.
the camshaft gear for cracks,
Inspect the bore of the gear for fretting or burrs.

chipped, or
0a3
NOTE: If the fretting, burrs, or raised material cannot be
removed with Scotch-Brite@ 7448, or equivalent, replace the
gear.
Camshaft Gear - Replacement (l-23) Cylinder Block - Grouo 01
Page 1-54
Inspect the camshaft gear keyway for burrs.

Remove burrs with Scotch-B&?@ 7448, or equivalent.
NOTE: If the keyway is damaged or the burrs cannot be
removed, the camshaft gear must be replaced.
Measure the camshaft gear bore inside diameter.
Camshaft Gear Bore I.D.

mm in
41.480 MIN 1.633
41.505 MAX 1.634
Visually inspect the camshaft nose for fretting or burrs.

NOTE: If fretting or burrs cannot be removed with
Scotch-BriW 7448, or equivalent, replace the camshaft.
Measure the camshaft gear journal outside diameter.
Camshaft Gear Journal O.D.

mm in
41.56 MIN 1.636
41.58 MAX 1.637
Cylinder Block - Group 01 Camshaft Gear - Replacement (l-23)
Page 1-55
Measure the camshaft thrust plate thickness.
Camshaft Thrust Plate Thickness

mm in
9.34 MIN 0.368
9.58 MAX 0.377
Camshaft Gear - Installation

Use a leather hammer to install the camshaft gear dowel pin.
Lubricate the camshaft gear journal with Lubriplatem 105.
Steel Camshaft Gear
A
Warning: Use insulated gloves, Part No. 3823730, when
handling heated parts. Hot parts will cause serious
personal injury.
Heat the gear in an oven for a minimum of 45 minutes, but
not longer than six hours.
Temperature: 177°C [350”F]
Gear Housing - Cleaning and Inspection for Reuse (i-24) Cylinder Block - Grow 01
Page 1-56
Austempered Camshaft Gear

Heat the gear in an oven for a minimum of 45 minutes, but not
longer than six hours.
Caution: The gear will be permanently distorted if over
heated. The oven temperature should never exceed the
specification.
Temperature: 149” C [300” F]
Caution: To prevent engine damage, the timing marks and

gear part number must be facing away from the camshaft
when the gear is installed.
Caution: Keep the camshaft in a vertical position with the
gear up until the gear has cooled. Do not use water to
reduce the cooling time. Using water will crack the gear.
NOTE: The gear must be installed within 30 seconds after it is
removed from the oven.
Remove the camshaft gear from the oven. Align the keyway in
the camshaft gear with the dowel pin in the camshaft and
install the gear on the camshaft. Be sure the gear is seated
against the camshaft shoulder.
Gear Housing - Cleaning and Inspection

for Reuse (l-24)
Gear Housing - Cleaning
Use steam or solvent to clean the gear housing. Dry with
compressed air.
Gear Housing - Inspection
0+B Visually inspect the

sealing surfaces.
gear housing for cracks or damaged
Cvlinder Block - Group 01 Gear Housing - Cleaning and Inspection for Reuse (l-24)
Page 1-57
Inspect the timing pin housing and pin for damage.

Do not remove the timing pin assembly unless it is damaged
or leaking, or the gear housing is being replaced.
NOTE: The location of the timing pin assembly on the gear
housing is critical for correct engine adjustments. If the
original gear housing is being installed, it is unnecessary to
relocate the timing pin. If a new housing is being installed,
refer to Procedure O-02 for timing pin installation and
adjustment.
I I I I / it9OOvc
15 mm
Visually inspect the fuel injection pump mounting studs for
damage.
To install or remove fuel injection pump studs, use. two nuts
locked together on the stud.
15 mm
If the fuel injection pump mounting studs are damaged or
being installed in a new housing, coat the threads with
LoctiteTM 242 and use two nuts locked together to remove
and install.
I I WI fp900hz

dataplate and install on the new housing. Refer to Procedure
l-25.
Engine Dataplate - Replacement (l-25) Cylinder Block - Group 01
Page 1-58
Engine Dataplate - Replacement (I-25)

The engine dataplate shows specific information about the
engine. The engine serial number and engine part number
provide information for ordering parts and service needs.
The dataplate must remain with the engine. If the gear housing
is replaced, remove the dataplate and install it on the new
housing.
6CTAG2
Engine Dataplate - Removal

Remove the rivets that secure the dataplate to the gear
housing.
Engine Dataplate - Installation

NOTE: Be careful not to drive the rivets in too deep and
damage the dataplate.
I gh9plW
2.0 mm Drill Bit

If the dataplate is loose or has been damaged, drill new holes
and attach with new rivets. Mark the drill bit at 6.0 mm [0.236
inch] to avoid drilling too deep into the gear housing.
gh9ton
Cylinder Block - Group 01 Gear Cover - Cleaning and Inspection for Reuse (l-26)
Page 1-59
Drill the dataplate, taking care not to destroy any information
printed on the dataplate.
Drive the rivets in until they contact the dataplate.
gh9plh
Gear Cover - Cleaning and Inspection for

Reuse (I-26)
Gear Cover - Cleaning
Use a gasket scraper or Scotch-Britee 7448 to remove all
gasket material.
q
Clean the gasket sealing surfaces and the surface between
the oil seal and gear cover. B
will cause serious personal injury. A
Steam clean the gear cover. Dry with compressed air.
Gear Cover - Inspection

Visually inspect the gear cover for flatness, cracks, dents, or
other damage.
If the gear cover is bent or cracked, it must be replaced. 0a9
(yy
m -F
;
-9cvs
Vibration Damper - Cleaning and Checking for Reuse (l-27) Cylinder Block - Group 01
Page l-60
Vibration Damper - Cleaning and

Checking for Reuse (l-27)
General Information
NOTE: There are two different design vibration dampers used:
l Viscous damper (A) for certain engines rated at speeds
above 2500 RPM.
l Rubber element damper (B) for engines rated at speeds
below 2500 RPM. The rubber damper is available either
B with or without the crankshaft adapter.
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Rubber Vibration Damper - Cleaning

Use a mild detergent or solvent to clean the vibration damper.
Ld
B
da900et
Rubber Element Vibration Damper - Inspection

Check the index lines (A) on the vibration damper hub (B) and
4iB
0
the inertia member (C). If the lines are more than 1.59 mm
[l/16 inch] out of alignment, replace the vibration damper.
Inspect the vibration damper hub (B) for cracks. Replace the
vibration damper if the hub is cracked.
da900se
Inspect the rubber member for deterioration. If pieces of rubber

0
a9 are missing or if the elastic member is more than 3.18 mm
[l/8 inch] below the metal surface, replace the vibration
damper.
NOTE: Also look for forward movement of the vibration damper
ring on the hub. Replace the vibration damper if any movement
is detected.
da9OOsb
Cylinder Block - Group 01 Vibration Damper - Cleaning and Checking for Reuse (l-27)
Page 1-61
Viscous Vibration Damper - Cleaning

A
Clean the vibration damper with a solvent cleaner or steam
clean. Dry with compressed air.
Viscous Vibration Damper - Inspection

Check the mounting web for cracks. Check the housing for
dents or raised surfaces. Replace the vibration damper if any
of these defects are identified.
0423
da90Osd
The viscous vibration damper is filled with a silicone fluid.

After many hours of use, the silicone fluid can become B
thicker and expand. To determine if the vibration damper LJ
thickness is correct, remove the paint from the vibration
damper in four locations on either side of the vibration
damper. Measure and record the thickness of the vibration
damper in four places. Measure the thickness 3.18 mm
[0.125 inch] from the outside of the vibration damper.
Replace the vibration damper if its thickness varies by more
than 0.25 mm [O.OlO inch].
Spray the vibration damper with spot check developer, Type

SKD-NF or its equivalent. Heat the vibration damper in an
oven (rolled lip side down) at 93°C [2OO”F] for 2 hours.
Rear Cover - Cleaning and Inspection (l-28) Cylinder Block - Group 01
Page 1-62
A Caution: Wear protective gloves to prevent personal injury

when handling parts that have been heated.
@
Remove the vibration damper from the oven and check for fluid
l leakage. If there is leakage, replace the vibration damper.
a!3
0
da9OOsf
Rear Cover - Cleaning and Inspection

(I-28)
63
Q Use a mandrel or drift to remove the crankshaft oil seal.
Cleaning
LJ
B Remove the gasket material from the rear cover gasket sealing
surface.
Use sovent to clean the rear cover. Dry with compressed air.
LJ
B
Cylinder Block - Group 01 Cylinder Head Capscrews - Cleaning and Inspection for Reuse (l-29)
Page 1-63
Inspection
Inspect the rear cover for cracks or other damage.
Measure the rear cover crankshaft seal bore.

The rear cover must be clamped to a flat surface for
checking.
Rear Cover Crankshaft Seal Bore I.D.

mm in “@
149.99 MIN
150.04 MAX
Replace the rear cover if the crankshaft seal bore is not

within specifications.
Cylinder Head Capscrews - Cleaning and

Inspection for Reuse (l-29)
Caution: Prevent damage to the capscrews. Nicks in the
body of the capscrew can cause an area of stress that
can fail during engine operation. Damage to the threads
will cause torque values to be incorrect and will damage
the mating parts.
bpksba
Cleaning
Caution: Do not use caustic or acid solutions to clean the
cylinder head capscrews.
Use a petroleum-based solvent to clean the capscrews. Dry
A
El
with compressed air.
B
Clean the capscrews thoroughly with a wire brush, a wire
wheel (soft), or use a non-abrasive bead blast to remove
deposits from the body and threads.
Cylinder Head Capscrews - Cleaning and Inspection for Reuse (i-29) Cylinder Block - Group 01
Page 1-64
Inspection
Visually inspect the cylinder head capscrews for damaged
threads, corroded surfaces, or a reduced diameter (due to
capscrew stretching).
The capscrew must be replaced if:
l The threads are damaged
l Rust or corrosion has caused pitting in the body
l The body is nicked, galled, bent, or stretched
NOTE: The capscrew threads have been formed by a rolling
operation during manufacture. Repair of rolled threads by the
use of a thread die is not recommended. The thread die can
create a sharp corner on the minor diameter (root) of the
threads. This sharp corner can cause an area of increased
stress.
Do not reuse cylinder head capscrews under the following
conditions:
Visible corrosion or pitting exceeds 1 sq cm [0.155 sq.

inch] in area. Example:
-- Acceptable 3/8x3/8-inch
-- Unacceptable 1/2x1 /Pinch
Visible corrosion or pitting exceeds 0.12 mm [0.005-inch]
in depth.
Visible corrosion or pitting is located within 3.2 mm

[l/&inch] of the fillet.
[l/&inch] of the threads.
Stretched beyond “free length” maximum. Refer to the
measurement procedure below:
Cylinder Block - Group 01 Engine Lifting Brackets - Cleaning and Inspection for Reuse (l-30)
Page l-88
Free Length - Measurement

Part No. 3823921, Capscrew Length Gauge
NOTE: If the capscrews are not damaged, they can be
reused throughout the life of the engine unless the specified •l
“free length” is exceeded.
0@9
To check the capscrew free length, place the head of the
capscrew in the appropriate slot with the flange against the
base of the slot.
Cylinder Head Capscrew Free Length
mm in
81.5 Short 3.2
162.6 Long 6.4
0a!3
If the end of the capscrew touches the foot of the gauge, the
capscrew is too long and must be discarded.
Immediately after cleaning and inspecting, apply a film of

clean engine lubricating oil to all capscrews that are to be
used again.
Engine Lifting Brackets - Cleaning and

Inspection for Reuse (I-30)
Use solvent to clean the brackets and capscrews.
Visually inspect the engine lifting brackets for cracks, rust
and corrosion.
Cylinder Head - Group 2
Page 2-1
Cylinder Head - Group 02

Section Contents
Page
Cylinder Head Capscrew - Cleaning and Inspection ................................. 2-37

Cleaning.. ............................................................. 2-37
Inspection ...................................... . ....................... 2-38
Cylinder Head - Cleaning and Inspection for Reuse .................................. 2-9

Cleaning.. ............................................................. I-;
Handling .............................................................. -
Inspection .............................................................. 2-10
Cylinder Head - Exploded View.. ............................................... 2-6
Cylinder Head - General Information ............................................. 2-8
Cylinder Head - Pressure Testing .............................................. 2-34
Cylinder Head - Rebuild ..................................................... 2-11

Assembly .............................................................. 2-26
Cleaning.. ............................................................. 2-12
Disassembly ............................................................ 2-11
Inspection .............................................................. 2-l 3
Valve - Grinding .......................................................... 2-21
Valve Guide - Inspection .................................................... 2-17
Valve - Inspection ........................................................ 2-20
Valve Seat Insert - Grinding .................................................. 2-22
Valve Seat Insert - Inspection ................................................. 2-18
Valve Spring - Inspection ................................................... 2-19
Valve Stem Seal - Inspection ................................................. 2-19
Cylinder Head - Service Tools .................................................. 2-2
Cylinder Head - Vacuum Testing Valve Seating .................................... 2-36
Cylinder Head - Valve Guide Replacement ........................................ 2-28

Assembly .............................................................. 2-29
Disassembly ............................................................ 2-28
Inspection .............................................................. 2-29
Cylinder Head - Valve Seat Insert Replacement .................................... 231

Inspection .............................................................. 2-33
Installation ............................................................. 2-33
Removal ............................................................... 2-31
Free Length - Measurement .................................................. 2-39

Cylinder Head - Service Tools Cylinder Head - Grow 02
Page 2-2
Cylinder Head - Service Tools
The following special tools are recommended to perform procedures in Group 02. The use of these tools is
shown in the appropriate procedure. These tools can be purchased from your local Distributor.
Used to compress the valve springs to remove the valve
Grind the valve seats in the cylinder head. Used with Part No.
3823187, Valve Guide Arbor, and various valve seat grinding
stones. Refer to the appropriate grinding stone in this tool list.
Grind 15 degree exhaust seats (1.875 inch diameter).
Magnetic Crack Detector
Used to inspect the cylinder head combustion face for cracks

in the injector bore and valve seat areas. The kit includes Part
No. ST-1188-7, Powder Spray Bulb, used for spraying the
ST-1 188-8, Metal Powder.
Used with Part No. ST-12576 Vacuum Cup. Vacuum test the
cylinder head to determine if the valves are properly seated.
Valve Seat Extractor
Used to remove exhaust valve seats from the cylinder head.

Used with Part No. 3378817, Slide Hammer.
Cylinder Head - Group 02 Cylinder Head - Service Tools
Page 2-3
Measure the cylinder head valve spring tension.
Used to remove expansion plugs from the cylinder head.
Grind cylinder head valves and resurface valve stems.
Used with Part No.‘s ST-1276-1 and 3377396, Valve Seat

Extractors and Part No. 3376467, cutter, to remove valve seats
from the cylinder head.
lide Hammer Assembly
Used with Part No.‘s ST-1276-1 and 3377396, Valve Seat

Extractors, to remove valve seats from the cylinder head.
Used to install 3/4 inch expansion plug to the specified depth.
Used with Part No. 3376617, Slide Hammer Assembly, to

remove the intake valve seats from the cylinder head.
Used to ream service valve guides to proper inside diameter

after installation.
Cylinder Head - Service Tools Cylinder Head - Group 02
Page 2-4
Used to clean carbon from injector bores.
- Grind 15 degree intake seats (2.250 inch diameter)

- Grind 45 degree exhaust seats (1.875 inch diameter)
- Grind 60 degree exhaust seats (1.75 inch diameter)

Valve Seat Grinding Arbor
Used with Part No. ST-685, Valve Seat Grinding Machine, and
various grinding stones for proper alignment during the
grinding operation.
Valve Guide Driver Kit
- Used to install intake valve guides.

- Used to install exhaust valve guides.
- Used to remove intake and exhaust valve guides.
Used to measure the injector protrusion and valve recess in

the cylinder head.
Used to install 1 3/16 inch expansion plug to the specified
Used to install 2-l/4 inch expansion plug to the specified

Cylinder Head - Group 02 Cylinder Head - Service Tools
Page 2-5

Capscrew Length Gauge
Used to check cylinder head capscrew free length.

3823921
Head Holding Fixture

Hold and revolve the cylinder head repair and assembly.
ST-583
Cylinder Head - Exploded View Cylinder Head - Group 02
Page 2-6
Cylinder Head - Exploded View
24
43 -25
Cylinder Head - Group 02 Cylinder Head - Exploded View
Page 2-7
Ref. No Part Name

1 Head, Cylinder 1
2 Plug, Expansion 1
3 Plug, Expansion 5
3 Plug, Expansion 1
4 Plug, Expansion 2
5 Guide, Valve Stem 12
6 Insert, Valve Seat (Exh) 6
7 Insert, Valve Seat (lnt) 6
8 Plug, Pipe 1
9 Plug, Pipe 1
10 Plug, Pipe 1
11 Seal, Valve Stem (lnt) 6
12 Valve, Intake 6
13 Collet, Valve 24
14 Valve, Exhaust 6
15 Washer, Sealing 2
16 Plug, Pipe 2
17 Spring, Valve (lnt) 6
la Spring, Valve (Exh) 6
19 Retainer, Valve Spring 12
20 Seal, Valve Stem (Exh) 6
21 Plug, Expansion 1
22 Coupling, Elbow 1
23 Gasket, Cylinder Head 1
24 Screw, Hex Hd Cap (Flange) 12
25 Screw, Hex Hd. Cap (Flange) 14
Cylinder Head - General Information Cylinder Head - Grow 02
Page 2-8
Cylinder Head - General Information

The cylinder head group consists of the cylinder head, valves, valve guides, valve springs, valve stem seals, valve seat
inserts, cylinder head capscrews, collets and spring retainers.
The cylinder head is a one piece, crossflow design with two valves per cylinder. The valve guides and seats are
replaceable. The cylinder head has a cast intake manifold and fuel filter head. The injectors are mounted in the cylinder
head for direct injection of fuel into the cylinders.
The cylinder head gasket is a laminated design with a fire ring to seal the cylinder bores. Orifices in the gasket control
coolant flow. Thicker gaskets are available for cylinder blocks that have been resurfaced 0.25 mm [O.OlO inch] or more.
NOTE: Engines equipped with an exhaust brake that impose from 241 to 443 kPa [35 to 65 psi] exhaust back pressure
must use dual exhaust valve springs.
Mark, label, or tag the cylinder head parts such as valves and valve springs with the cylinder number and location from
which they were removed. This practice will prove to be a valuable aid in diagnosing any cylinder head or part failures
and to make sure the reuseable parts are installed in their original locations.
Cylinder Head - Group 02 Cylinder Head - Cleaning and Inspection for Reuse (2-01)
Page 2-9
Cylinder Head - Cleaning and Inspection

for Reuse (2-01)
Handling
component.
Use a hoist or hydraulic arm to lift the cylinder head.
NOTE: Place the cylinder head on wood blocks to prevent
damage to the combustion surface.
Cleaning
Remove the gasket material from the valve cover surface.
Use a gasket scraper to remove the heavy dirt and debris
from the cylinder head gasket surface and exhaust manifold
gasket surface.
A
Use steam to clean the cylinder head. Dry with compressed \
air. u
holes, always wear safety glasses or a face shield to
protect the eyes. Personal injury can result. A
Use Scotch-Brite@ 7448, Part No. 3823258 or equivalent, to

clean the cylinder head combustion surface and exhaust \
manifold gasket surface. R
Cylinder Head - Cleaning and Inspection for Reuse (2-01) Cylinder Head - Group 02
Page 2-10
Clean the cylinder head with solvent.
Inspection
Visually inspect the cylinder head for obvious damage that
would prohibit reuse. Check for cracks and damage to the
combustion surface that would result in loss of sealing.
If cracks or leaks in the cylinder head are suspected, refer to
Cylinder Head - Pressure Testing (2-05).
Visually inspect the valves and valve springs for cracks, bent or
broken valve stems, broken valve spring collets or other
damage.
Visually inspect the valves for indications of leakage or burning.
If cracked or damaged parts, or indication of leakage or
burning is found, the cylinder head must be rebuilt. Refer to
Cylinder Head - Rebuild (2-02).
Valve and Seat - Leakage Testing

NOTE: If a leaking valve is suspected, vacuum test the valves
and valve seats. The vacuum must not drop more than 25.4
mm Hg [l.O inch Hg] in 5 seconds.
Valve to Valve Seat Vacuum

mm Hg in Hg
457 used 18
635 New 25
kn900kb
Cylinder Head - Group 02 Cylinder Head - Rebuild (2-02)
Page 2-11
NOTE: If vacuum does not meet the specifications, the face

of the valves and the valve seat inserts must be resurfaced.
Refer to Procedure 2-02.
Cylinder Head - Rebuild (2-02)

Disassembly
Part No. ST-583, Cylinder Head Holding Fixture
Install the cylinder head in the Part No. ST-588 Head
Holding Fixture, as shown.
kn9toha
NOTE: Before removing the valves, use paint or Dykemm to

identify the location of the valves and retainers. If the parts
are used again, they must be installed in their original
locations.
I I kn9vawa
Part No. ST-448, Valve Spring Compressor

Place a wood block between the valves and head holding
fixture to support the valves.
Use the valve spring compressor to compress the valve
springs.
Cylinder Head - Rebuild (2-02) Cylinder Head - Group 02
Page 2-12
Use a pencil magnet to remove the valve collets. Discard the

valve collets.
Slowly release the pressure on the valve spring.
Remove the valve spring retainer.

Remove the valve spring.
Remove the valve.
Remove the valve spring seat/valve seal assembly.
Keep the valves in a labeled rack.
kn2vaaa
Cleaning
Scrape the gasket material from all gasket surfaces.
Page 2-13
Clean the cvlinder head combustion surface with a I\

Scotch-Brite@ 7448 pad, or an equivalent cleaning pad and a
solvent. u
Inspection
Use a straight edge and feeler gauge to check the cylinder
head combustion surface for flatness.
Cylinder Head Flatness Specifications

mm in
0.20 End-to-End 0.008
Use a small 51 mm [2.0 inch] straight edge and a 0.001 inch

feeler gauge to measure local cylinder head combustion
surface flatness. Check between the cylinder bores and also
between the coolant passages. If the 0.001 inch feeler gauge
fiis under the 2.0 inch straight edge or if the cylinder head is
pitted, has grooves or wear greater than the maximum
specified, the cylinder head must be replaced or resurfaced.
NOTE: A maximum of 1.00 mm IO.040 in] can be machined

from the combustion surface of the cylinder head. Maximum / I
If the cylinder head is machined, place the valve in the
respective bore and check the valve depth dimension. If the
depth is less than the minimum soecification. the valve seat
wilj require machining. Refer to Valve Seat - .Grinding in this
section.
Install an injector with an injector seal to check for proper
injector tip protrusion.
Page 2-14
Measure the cylinder head thickness.
/8 Cylinder Head Thickness (New)

mm in
115.75 MIN 4.557
116.25 MAX 4.577
Replace the cylinder head if the thickness is less than 114.75

mm [4.518 inch].
kn900na
Part No. 3822510, Injector Bore Brush

El If the cylinder head flatness and thickness
specifications, continue with the cleaning operation.
is within
q
B Clean the carbon from the cylinder head injector bore.
Expansion Plug - Removal

Clean the build-up of deposits from the coolant passages.
Excessive deposits may be cleaned in an acid tank but the
expansion plugs must first be removed.
Use a center punch to mark the expansion plugs for drilling.
Drill a l/8 inch hole in the expansion plugs.
69 l Use a dent puller to remove the expansion

Remove the pipe plugs.
plugs.
Warning: Wear protective eye covering.

A Clean carbon deposits from the valve pockets with a high
q
\ quality steel wire wheel installed in a drill or a die grinder.
NOTE: An inferior quality wire wheel will loose steel bristles
during operation, thus causing additional contamination.
Page 2-15
Place the cylinder head and parts in a tank of cleaning

solution.
NOTE: Be sure to follow the cleaning solution manufacturer’s
instructions when cleaning the parts.
d& kn900ed
Remove the cylinder head and parts from the cleaning tank.
Visually inspect all passages to make sure they are clean.
Use Scotch-Brite@ 7448, Part No. 3823258 or equivalent, to

clean the cylinder head combustion surface and the exhaust
manifold gasket surface.
kn900eb
Use the Part No. ST-1188 Magnetic Crack Detector, to find

cracks in the combustion surface and areas around the valve
ports and injector bores.
Place the magnetizing head on the combustion surface as
shown, to check for cracks that run across the cylinder
head.
Page 2-16
0
Fill the magnetic crack detector powder sprav bulb one-third
4B (l/3) full wsh metal powder. ’ . *
Spray the powder lightly onto the combustion surface.
Use compressed air to remove the excess metal powder.
Air Pressure: 276 kPa [40 psi]
NOTE: The powder will remain in the cracks, if present, and
show as a white line.
0
Check for cracks on the combustion surface. Cracks that
4iB extend from the injector bore away from the valve seats and
are not over 10 mm IO.394 inch] long are acceptable.
A = 10 mm IO.394 inch]
kn9bdsa
Any cracks that extend from the injector bore toward the valve
seats are unacceptable and the cylinder head must be
replaced.
kn9bdsd
Cracks between the valve seats are not acceptable and the
cylinder head must be replaced.
Page 2-17
0ai3
Place the magnetizing head on the combustion surface as
shown to check for cracks that run lengthwise of the cylinder
head.
Repeat the procedure as outlined above.
Remove all magnetism and use solvent to clean the cylinder

head. Dry with compressed air.
NOTE: The cylinder head must be thoroughly cleaned after
using the magnetic crack detector to remove all of the metal
powder.
Valve Guide - Inspection

Visually inspect the valve guides for scuffing or scoring.
Use a small bore gauge to measure the inside diameter of
the valve guides in locations 13 mm [l/2 inch] from each
0a3
end and at the center as shown.
Valve Guide I.D. (Installed) (Used)

mm in
9.539 MIN 0.3756
9.591 MAX 0.3776
Use a depth micrometer to measure the valve guide installed

height. Measure from the top of the valve guide to the
bottom of the recess area.
Valve Guide Height (Installed)

mm in
Intake 20.66 MIN 0.813
21.16 MAX 0.833
Exhaust 22.50 MIN 0.886
23.01 MAX 0.906
If damage is found or the valve guide(s) do not meet the e

limits specified, the valve guide(s) must be replaced. Refer to
Procedure 2-03.
Page 2-18
Valve Seat Insert - Inspection

Visually inspect the valve seat inserts for cracks or burned
spots.
no - I kn900kf
Measure the width of the valve seat area (1) of the valve seat
inserts.
Valve Seat Area (Width)

mm in
1.5 MIN 0.059
2.0 MAX 0.079
NOTE: The sealing surface of the valve should seat in the

center of the valve seat insert.
If the valve seat area is worn wider than the maximum
specified, refer to Valve Seat - Grinding or Cylinder Head -
Valve Seat Insert Replacement, in this section.
Part No. 3823495 Gauge Block

Install the valves in their respective bores and measure the
recess in the cylinder head.
Make sure the seats are clean before measuring the recess.
Valve Recess in Cylinder Head

mm in
1.62 MAX 0.064
1.12 MAX 0.044
NOTE: If the valve recess is out-of-limits, before replacing the

valve seat, try replacing the old valve (A) with a new valve (B).
If the recess is within limits with the new valve, grind the old
valve seat and use the new valve. Refer to Valve Seat -
Grinding in this section.
kn9vana
Page 2-19
Valve Spring - Inspection

Inspect the valve springs for obvious damage (breaks, etc.).
0
@
Measure the valve spring.

Valve Spring Free Height (A)
mm in
Standard Spring
Intake and Exhaust 65.66 Nominal 2.585
Dual Spring (Exhaust)
Outer Spring 77.47 Nominal 3.049
Inner Spring 72.64 Nominal 2.860
Valve Rotator Spring -
Intake and Exhaust 62.05 Nominal 2.44 kn8sptd
Use the Part No. 3375182, Valve Spring Tester, to measure

the valve spring load at the opening height.
Valve Spring Opening height (B)
mm in
Valve Rotator Springs -
Intake and 35.89 Nominal 1.413
Exhaust
All Other Springs 37.90 Nominal 1.492
Valve Spring Load for Opening Height (New)(C)

N Ibf
Standard Spring
Intake and Exhaust 960 216
1060 238
Dual Spring (Exhaust)
Outer Spring 1023 Nominal 230
Inner Spring 111 Nominal 25
Assembly 1184 MIN 266
1084 MAX 244
Valve Rotator Spring -
Intake and Exhaust 995 MIN 224
1095 MAX 246
If the valve spring load for the opening height is less than
the minimum specified, the valve spring must be replaced.
Page 2-19-02
Valve Stem Seal - Inspection

Visually inspect the valve spring retainers and valve stem
seals for damaged or worn areas. 0
@J
Remove the valve stem seals from the valve stem seal
retainers, and visually inspect for damaged or worn areas.
Discard unserviceable parts.
CylinderHead - Rebuild (2-02) Cylinder Head - Grow 02
Page 2-20
0@
Valve - Inspection
Visually inspect the valves for damage. Replace the valves if
any of the following conditions are found:
l Valve stems worn below specifications (A)
l Rust or pitting on the valve stem or sealing surface
(B)
l Worn collet grooves (C)
l Worn stem tip (D)

l Bent valve stems (E)
l Damaged valve heads (burned, cracked or broken) (F)
kn9vakc
m
w
Measure the outside diameter of the valve stem.
Valve Stem O.D.

mm in
9.46 MIN 0.372
9.50 MAX 0.374
4 2.5 ha-j
0
NOTE: It may be possible to grind and reuse valves with the
a3 following conditions:
l Minor grooves on the valve sealing surface (A)
l Fine pitting on the valve sealing surface (B)
l Carbon or varnish buildup on the valve stem (C)
Page 2-21
Valve - Grinding
Cleaning
NOTE: Any valves that are to be used again must have the
sealing surface machined.
q
Use Scotch-Britee 7448, Part No. 3823258, to clean the valve
stems. Clean the carbon deposits from the valve sealing \
surface and head.
NOTE: The valves must be clean and free of carbon
deposits before they are refaced. Valves can be cleaned by
the bead blasting method in the head area only.
knlvaec
Use a valve facing machine, Part No. 3376256, to grind the

sealing surface of the valve.
NOTE: Follow the instructions supplied with the valve
grinding machine for the correct setup before grinding the e
valves.
Grind the intake and exhaust valves to the angle shown

below:
Valve Seat Angle
Valve Angle
Intake 30 Degrees
Exhaust 45 Degrees
q
Use solvent to clean the metal particles from the valve. Dry
with compressed air. \
Put the valve on a flat surface and measure the head

thickness (1) at the outside diameter.
Valve Head Thickness (at O.D.)

mm in
NOTE: If the valve head is worn thinner than the minimum

specified, the valve(s) must be replaced.
Page 2-22
Use a lead pencil or Dykem to mark across the valve sealing

surface as shown. Install the valve in the valve guide.
Hold the valve against the valve seat, and rotate the valve
backward and forward three or four times. Correct contact
against the valve seat will break the pencil marks on the valve
sealing surface.
NOTE: Valves and valve seats that are correctly machined do
not require the use of lapping compound to make an air tight
seal. If lapping compound is required, inspect the adjustments
of the grinding machine and the condition of the grinding
stone.
Install the valves in the cylinder head. Refer to “Assembly”

under Cylinder Head - Rebuild.
Use valve vacuum tester, Part No. ST-1257, to vacuum test the
valve seating. Refer to Cylinder Head - Vacuum Testing Valve
Seating 2-06.
kn900kb
Valve Seat Insert - Grinding

NOTE: If the valve guide inside diameter exceeds the maximum
worn limit, replace the valve guide before grinding the valve
seat.
Use the Part No. ST-685 Valve Seat Grinding Machine and the
Part No. 3823187, Valve Guide Arbor Set, when grinding the
valve seat inserts.
Install the valve guide arbor (1) in the valve guide with the
arbor puller (2).
Rotate the arbor to be sure that it is installed correctly.
Install a valve seat grinding stone (3) on the grinding machine.

NOTE: The grinding stone must be the correct size and have
the correct angle (Intake: 30 Degrees, Exhaust: 45 Degrees).
Refer to the Service Tool List in the front of this section.
Install the grinding machine on the arbor.
NOTE: The grinding stone (3) must not touch the valve seat
insert when the drive unit motor is started.
Hold the drive unit in a vertical position, and use an
up-anddown movement of 12.7 mm [0.50-inch] travel and light
pressure to grind the seat.
Remove the grinding machine from the arbor.
Page 2-23
Install eccentrimeter gauge (4), Part No. ST-665-4, on the @A

valve guide arbor.
GxW
Measure the valve seat to valve guide concentricity.
Concentricity (Per 360 Degrees)

mm in
0.05 MAX 0.002
NOTE: If the valve seat concentricity does not meet the

specifications, grind the valve seat again. If the specifications e
cannot be met, replace the valve seat insert. Refer to
Cylinder Head - Valve Seat Insert Replacement (02-04).
Install reconditioned valves in their respective bores. Hold the OQn

valve firmly against the valve seat insert.
@
Part No. 3823495, Gauge Block

Measure the valve recess in the head.

mm in
1.62 MAX 0.064
1.12 MAX 0.044
If the valve recess is out of limits, replace the old valve (A)
with a new valve (B) before replacing the valve seat. If the
recess is within limits with the new valve, proceed by using
the new valve with the old seat.
Page 2-24
If the valve recess is still out of limits, even with the new valve
(B), replace valve seat (C) with a new valve seat (D). After
replacing the seat, check the valve recess again with the old
valve (A) to determine if it can be reused. If not, proceed by
using the new valve (B).
(A) = Old Valve
(B) = New Valve
(C) = Old Valve Seat Insert
(D) = New Valve Seat Insert
Check the valve seat contact area on the valve sealing surface
to see if the valve seat contacts the center of the valve sealing
surface.
Use a pencil or DykemQ to put vertical marks on the sealing
surface of the valve.
Install the valve in the valve guide. Hold the valve against the
valve seat insert.
Rotate the valve backward and forward three or four times.
Remove the valve and measure the valve seat width and the
seat contact area as indicated by the broken pencil lines.
The pencil or Dykem@ marks will be worn away where the

valve contacted the seat.
Valve Seat Width Limit

mm in
1.5 MIN 0.059
2.0 MAX 0.079
Page 2-25
Grind valve seat insert area (A) with a go-degree stone and
valve seat insert area (B) with a 15degree stone to center
the seat on the valve sealing surface and to obtain the valve
seat width limits.
I knlvaxa
The location of the broken pencil lines on the valve sealing

surface is the key to determining how much of each valve
seat insert angle to grind.
If the broken lines are at the bottom of the valve sealing
surface, the valve seat insert will require more grinding with
the 60degree stone than with the 15degree stone.
If the broken lines are at the top of the valve sealing surface,
the valve seat insert will require more grinding with the
15degree stone than with the 6Odegree stone.
After grinding the valve seat inserts, use a bristle brush to

clean the inside diameter of the valve guides.
Use solvent to clean the cylinder
air.
head. Dry with compressed
q
\
g;li;y2gHead - Rebuild (2-02) Cylinder Head - Group 02
Assembly
‘Eil
Expansion Plug Installation
Apply cup plug sealant, Part No. 3375058, to the outside
diameter of the expansion plugs.
NOTE: Use the correct expansion plug driver to make sure the
expansion plugs are installed to the correct depth in the
cylinder head. Drive the plug until the shoulder of the driver
contacts the cylinder head. Refer to the chart below:
Tool P/N Exp. Plug P/N Qty. Location
3823522 156075 1 A
3823524 3900965 2 B
3823522 3032693 5 C
3376815 3912900 1 D
NOTE: If the engine is equipped with an air compressor,

expansion plug (D) is not used. A 90degree elbow coupling is
kn9ephb
installed in this hole for the air compressor air inlet. Apply Part
No. 3375068, Cup Plug Sealant, and install the fiiing with the
beaded end pointing down to the 4:00 o’clock position.
Pipe Plug Installation

If the pipe plugs are not already precoated, apply a coat of
Part No. 3375068, Cup Plug Sealant, to the pipe plug threads.
Install the pipe plugs, refer to the following chart:
Torque Value:
Location Size Nom Ft-lb
A l/16 in. NPT 8 71 in-lb
B l/4 in. NPT 12 106 in-lb
C l/2 in. NPT 24 18 ft-lb
kn9pxh
D Hex Plug 80 59 ft-lb
NOTE: The hex plugs (D) require a copper sealing washer.
\
q
Use a bristle brush to clean the inside diameter
guide bores and blow out with compressed air.
of the valve
Page 2-27
q
Use SAE !3OW engine oil to lubricate the valve guide bores
and valve stems. \
Install the valves in the valve guides. The exhaust valves

have smaller diameter heads.
NOTE: If any valves are being used again, the valves must
be installed in the same location as they were removed.
NOTE: The valves should drop into the valve guides with
little or no resistance.
After the valves are installed, place the cylinder head on a
flat surface that will not damage the cylinder head surface.
Install the valve spring seat/valve seal assembly over the @@A
valve stem.
as9
0a3
NOTE: To prevent oil carryover, the seals are color coded
and must be installed as follows:
Exhaust Valve (A): Orange (with 64 grooves per inch)
Intake Valve (B): Black (with 40 grooves per inch)
Install the valve springs.

Install the valve spring retainers.
Use valve spring compressor, Part No. ST-448, or its

equivalent (refer to the Service Tools list) to compress the
valve springs.
Install the new valve spring retainer collets.
NOTE: Use new valve spring retainer collets when rebuilding
the cylinder head.
Cylinder Head - Valve Guide Replacement (2-03) Cylinder Head - Group 02
Page 2-28
Warning: Wear eye protection. If the collets are not correctly

installed, they can fly out when the stems are hit with a
hammer.
Use a plastic hammer to gently hit the top of the valve stems
to make sure the valve collets are correctly seated in the spring
retainer.
Use valve vacuum tester, Part No. ST-1257, to vacuum test the
valve seating. Refer to Cylinder Head - Vacuum Testing Valve
Seating (2-06).
kn900kb
Cylinder Head - Valve Guide

Replacement (2-03)
Disassembly
NOTE: It will be necessary to grind _ the valve seats after
replacing the valve guides. Refer to Procedure 2-02 in tnis
section.
Use the Part No. 3823271, Valve Guide Driver (l), to remove
the old valve guides (2).
Use a flexible brush and solvent to clean the valve guide bores
in the cylinder head. Dry with compressed air.
Cylinder Head - Group 02 Cylinder Head - Valve Guide Replacement (2-03)
Page 2-29
Inspection
Measure the inside diameter of the valve guide bore in the
cylinder head.
Valve Guide Bore I.D.

mm in
15.931 MIN 0.6272
15.971 MAX 0.6266
If the valve guide bore is worn larger than the maximum
specified, the cylinder head must be replaced.
Assembly
Measure the outside diameter of the new valve guides.
Valve Guide O.D.

mm in
15.988 MIN 0.6294
16.000 MAX 0.6299
kn2guth
The intake and exhaust valve guides are installed at

heights above the cylinder head top deck surface,
the following part numbers for the correct installation
Intake: Part No. 3823269
Exhaust: Part No. 3823270
Drive the valve guides into the cylinder head valve guide
bore until the driver contacts the cylinder head.
Use a depth micrometer to measure the new valve guide

installed height above the cylinder head top deck surface.

mm in
Intake: 20.65 MIN 0.813
21.16 MAX 0.833
23.01 MAX 0.906
Cylinder Head - Valve Guide Replacement (2-03) Cylinder Head - Group 02
Page 2-30
Part No. 3822490, Valve Guide Reamer

Ream the valve guides with no lubricant and in one direction
only. Damage to the guide can result from pulling the reamer
back through the guide.
Lubricate the reamer with clean 15W-40 engine oil and ream
the valve guide again in one direction only.
q
Clean the valve guide bore with a nylon bristle brush and
B cleaning solvent.
Cylinder Head - Group 02 Cylinder Head - Valve Seat Insert Replacement (2-04)
Page 2-31
Use a small bore gauge to measure the new valve guide

inside diameter in locations (1) 13 mm [l/2 inch] from each
end and at the center as shown.
(New) Valve Guide I.D. (Installed)

mm in
9.539 MIN 0.3756
9.559 MAX 0.3763
If the valve guide is not within the specifications given, the
valve guide must be removed and a new valve guide
installed.
L
Cylinder Head - Valve Seat Insert

Replacement (2-04)
Removal
NOTE: If it is determined that both valve seats and valve
guides need to be replaced, install and ream the valve
guides first.
Part No. 3376405, Router; Part No. 3376407, Cutter

Adjust the cutter depth to approximately 1.4 mm IO.055 inch]
from the bottom of the valve seat pocket.
Cut a groove in the valve seats. Be sure the cutter motor

base remains flat against the cylinder head while rotating the
cutter motor in a circular motion.
Cylinder Head - Valve Seat Insert Replacement (2-04) Cylinder Head - Group 02
Page 2-32
A Caution: Shavings or debris between the cutter motor base
I and the head deck can cause serious damage.
06B
Cut a groove deep enough for the expanding seat extractor
tool to engage when expanded.
hnlltoxb
0GE3
Make sure the tool cuts only the valve seat inserts and not into
the machined valve pockets of the cylinder head.
I kn9toxd
Part No. 3376617, Slide Hammer

RI Part No. 3377396, Intake Seat Extractor
Part No. ST-1276-1, Exhaust Seat Extractor
c%
0 Remove the valve seat inserts.
Cylinder Head - Group 02 Cylinder Head - Valve Seat Insert Replacement (2-04)
Page 2-33
Use a wire brush and solvent to clean the deposits from the
valve seat insert bores.
Use solvent to clean the cylinder head. Dry with compressed
air.
Inspection
Visually inspect
damage.
If cracks
the
or damage
valve seat
is found,
insert
the cylinder
bore for cracks
head must
or
be
04iD
replaced.
Measure the inside diameter of the valve seat insert bore (A)
and the valve seat insert bore depth (B) in the cylinder head.
(A) Insert Bore I.D. (Standard Insert)

mm in
Intake 53.93 MAX 2.123
Exhaust 47.03 MAX 1.852
(B) Insert Bore Depth (Standard Insert)

mm in
Intake 12.20 MAX 0.480
Exhaust 9.83 MAX 0.387
NOTE: If either dimension is out of specifications, the
Installation
For easier installation, freeze the new valve seat inserts at
18°C [O’F] for 30 minutes before attempting to install.
Remove the valve seat inserts from the freezer one at a time.
kn900hb
Cylinder Head - Pressure Testing (2-05) Cylinder Head - Group 02
Page 2-34
NOTE: The valve seat insert chamfer (1) must be installed

toward the bottom of the counterbore.
Use the Part No. 3376617, Slide Hammer, and a suitable driver,
refer to Cylinder Head - Service Tools, to drive the valve seat
insert into the counterbore.
Make sure the insert is at the bottom of the counterbore.
Use the Part No. ST-685, Valve Seat Grinding Machine, and
Part No. 3823187, Valve Guide Arbor and the appropriate
grinding stone (3), to grind the new valve seat inserts. Refer to
Valve Seat - Grinding in this section.
Cylinder Head - Pressure Testing (2-05)
A
Caution: Do not pressure test the cylinder head with the
valves and valve springs installed. Water entering the
cylinder head cannot be dried thoroughly and will damage
the valve guides and valve stems. Refer to Cylinder Head
- Disassembly (2-02).
NOTE: A cylinder head test fixture can be fabricated from a flat

piece of steel or aluminum. Refer to the following table for test
fixture dimensions:
Test Fixture Dimensions

mm in
861 Length 33.5
190 Width 7.5
16 Thickness 0.625
NOTE: Use the cylinder head gasket as a pattern for drilling
the capscrew holes.
kn9gknt
Cylinder Head - Group 02 Cylinder Head - Pressure Testing (2-05)
Page 2-35
Install the cylinder head water test fixture.

Install a new head gasket.
Install the test plate.
Install the 26 cylinder head capscrews and Ml4 X 2.0 nuts.
Tighten the nuts.
0(K
Torque Value: 45 N*m [35 ft-lb]
Connect a regulated air supply hose to the text fixture plate. q,

Apply air pressure. Q@
Use a nylon lifting strap and hoist to place the cylinder head
in a tank of heated water.
Temperature: 60”C [14O”F]
Completely submerge the cylinder head in the water.
kn900kd
0a3
Visually inspect for air bubbles rising from the water.
If air bubbles are seen, replace or rebuild the cylinder head.
Refer to Procedure (2-02).
kn900kt
Remove the test equipment.

Q
Use compressed air to dry the cylinder head. @
Assemble the cylinder head. Refer to Cylinder Head - Rebuild e
- Assembly (2-02).
kn9toma
Cylinder Head - Vacuum Testing Valve Seating (2-06) Cylinder Head - Group 02
Page 2-36
Cylinder Head - Vacuum Testing Valve

Seating (2-06)
Use the Part No. ST-1257, Valve Vacuum Tester, to inspect the
seal between the valve and the valve seat insert.
NOTE: The valve vacuum tester can be used to test all
Komatsu engine models. The Part No. ST-12576 Vacuum Cup,
is used on the 6D114E-1 Series cylinder heads.
kn900kb
Install the seal ring and vacuum cup to the vacuum line (hose).
kn2toaa
0
The valves and valve seat inserts must be clean and dry when
@ii3vacuum testing.
g+*
@on
Cover the valve with the cup and seal.
NOTE: The seal must make a tight contact on the cylinder
head around the valve.
Move the toggle switch (1) to the “ON” position.

Turn the vacuum control valve (2) to the “OPEN” position.
NOTE: The vacuum control valve is in the “OPEN” position if
the vacuum gauge needle moves clockwise.
n
Cylinder Head - Group 02 Cylinder Head Capscrew - Cleaning and Inspection (2-07)
Page 2-37
Operate the vacuum pump until the gauge indicates the

specified vacuum.

mm Hg in Hg
New 508 MIN 20
635 MAX 25
USed 457 MIN 18
Turn the toggle switch (1) to the “OFF” position.
Use a stopwatch and start timing when the needle on the

gauge indicates 457 mm Hg 118 in. Hg].
Stop timing when the needle on the gauge indicates 203 mm
Hg [8 in. Hg].
The elapsed time for the needle to move between the
specified gauge readings must be 10 seconds or more.
0ai!3
If the elapsed times is less than 10 seconds, perform the
following checks:
l Repeat the test to be sure the equipment is operating
properly.
l Use a mallet to hit the valve stem lightly to make sure
the valve is seated. Repeat the test.
l Apply a thin layer of grease on the outside diameters
of the insert and the valve head. Repeat the test. The
grease pattern will show the point of leakage.
A break in the grease seal pattern will indicate leakage e
between the valves and valve seat or the valve seat insert
kn9OOkb
and the cylinder head. Refer to Cylinder Head - Rebuild.
Cylinder Head Capscrew - Cleaning and

Inspection (2-07)
Caution: Prevent damage to the capscrews. Nicks in the
A
body of the capscrew can cause an area of stress that
can fail during engine operation. Damage to the threads
will cause torque values to be incorrect and will damage
the mating parts.
Cylinder Head Capscrew - Cleaning and Inspection (2-07) Cylinder Head - Group 02
Page 2-38
Cleaning
A Caution: Do not use caustic or acid solutions to clean the

Use a petroleum-based solvent to clean the capscrews.
q
B Clean the capscrews thoroughly with a wire brush, a soft wire
wheel, or use a non-abrasive bead blast to remove deposits
from the shank and the threads.
Inspection
a!!3 Visually
0 threads,
inspect the cylinder head capscrews for damaged
corroded surfaces, or a reduced diameter (due to
NOTE: Do not reuse a capscrew that has damaged threads or
a reduced diameter from having been stretched.
knlcssa

conditions:
a l Visible corrosion or pitting exceeds 1 sqcm’ [0.155 sq.

- Acceptable 318-x 3/8-inch
- Unacceptable 1/2-x l/2-inch
l Visible corrosion or pitting exceeds 0.12 mm
[0.005-inch] in depth.
l Visible corrosion or pitting is located within 3.2 mm

[l/&inch] of the fillet.
l Visible corrosion or pitting is located within 3.2 mm
[l/&inch] of the threads.
l Stretched beyond “free length” maximum. Refer to the
Cvlinder Head - Group 02 Cylinder Head Capscrew - Cleaning and Inspection (2-07)
Page 2-39

Part No. 3823921, Capscrew Length Gauge RI
If the capscrews are not damaged, they can be reused
throughout the life of the engine unless the specified “free
length” is exceeded.
0
capscrew in the appropriate slot with the flange against the @
base of the slot.
Capscrew Free Length

mm in
81.5 Short 3.2
162.6 Long 6.4
0a9
capscrew is too long and must be discarded.
The capscrew can be used again if there is clearance
between the end of the capscrew and the bottom base of
the tool.

used again.
used again.
Rocker Levers - Group 03
Page 3-l
Rocker Levers - Group 03

Section Contents
Crankcase Breather Tube - Cleaning and Inspection for Reuse .........................

Cleaning and Inspection .................................................... 3-8
Rocker Assembly Oil Manifold - Cleaning and Inspection for Reuse ...................... 3-7
Cleaning.. ............................................................. 3-7
Inspection ............................................................... 3-7
Rocker Lever Assembly - Cleaning and Inspection .................................. 34

Assembly .............................................................. 3-8
Cleaning.. .............................................................
Disassembly ............................................................
Inspection.. ............................................................
Rocker Lever Assembly - Exploded View ......................................... 3-2
Rocker Lever Assembly - General Information ..................................... 3-3
Valve Cover - Cleaning and Inspection for Reuse ................................... 3-8

Cleaning.. ............................................................. 3-8
Inspection.. ............................................................ 3-8
Rocker Lever Assembly - Exploded View Rocker Levers - Group 03
Page 3-2
Rocker Lever Assembly - Exploded View
Ref. No. Part Name QtY.

1 Screw, Twelve Point 12
2 Clamp, Rocker Retainer 6
3 Rod, Push 12
4 Support, Rocker Lever 6
5 Lever, Rocker 2
6 Nut 2
7 Screw, Rocker Adjusting 2
8 Washer, Curved Spring 2
9 Shaft, Rocker 1
10 Plug, Expansion
11 Washer, Thrust
12 Manifold, Oil
13 Ring, Retaining
Rocker Levers - Group 03 Rocker Lever Assembly - General Information
Page 3-3
Rocker Lever Assembly - General Information

The rocker lever group consists of the rocker lever assemblies, rocker assembly oil manifold, valve cover and crankcase
breather.
Each cylinder of the engine has a separate rocker lever assembly. The pedestal support has drillings to route the oil flow
to the shaft and levers.
The rocker levers are push rod actuated and use an adjusting screw to control the clearance between the rocker lever
and valve stem. The rocker levers do not use a bushing in the bore for the rocker lever shaft. The rocker lever must be
replaced if the bore is damaged or worn beyond the specification limit.
Rocker Lever Assembly - Cleaning and Inspection (3-01) Rocker Levers - Group 03
Page 3-4
Rocker Lever Assembly - Cleaning and

Inspection (3-01)
Disassembly
Snap Ring Pliers
Ezl Remove the retaining
washers.
rings, thrust washers and wavey spring
69
l
Remove the rocker levers.

G3
rh9OOfb
Remove the pedestal assembly.

@l
rh900ha
Remove the locknut and adjusting screw.

Rocker Levers - Group 03 Rocker Lever Assembly - Cleaning and Inspection (3-01)
Page 3-5
Cleaning
Clean all parts in strong solution of laundry detergent in hot \
water. IJ
I rh900ea
Use compressed air to dry the parts after rinsing in clean hot
water.
rh9OOeb
Inspection
Inspect for cracks and excessive wear in the bore and the
contact surface for the valve stem.
NOTE: The levers do not use a bushing in the bore for the
0
@
rocker lever shaft. The lever must be replaced if the bore is

damaged or worn beyond the specification.
rh9bdsa
Measure the rocker lever bore.
Rocker Lever Bore Diameter

mm in.
22.256 MIN 0.8762
22.301 MAX 0.878
rh9brta
Rocker Lever Assembly - Cleaning and Inspection (3-01) Rocker Levers - Group 03
Page 3-6
0
Visually inspect the rocker lever shafts for pitting, scoring or
@9 other damage.
Measure the rocker lever shaft diameter.
CD mm
Rocker Lever Shaft Diameter
in.
22.199 MIN 0.874
22.231 MAX 0.8752
bpSOOsa
Assembly
Install the adjusting screw and locknut.
rh9OOfc
Install a retaining ring, thrust washer and wavey spring washer
rh9OOaa
Lubricate the shaft with engine oil.
rh9shw.3 I
Rocker Levers - Group 03 Valve Cover - Cleaning and Inspection for Reuse (3-03)
Page 3-7
I rh900ab
Install the remaining wavey spring washer, thrust washer and @a

4W
Compress the wavey spring washers and install the bottom

rh900ad
Rocker Assembly Oil Manifold - Cleaning

. and Inspection for Reuse (3-02)
Cleaning
q
Use solvent to clean the oil manifold. Dry with compressed
air. \
Inspection
Visually inspect the oil manifold for cracks, plugged oil holes, q#
or other damage. If the oil manifold is cracked or damaged, @dW
it must be replaced.
Valve Cover - Cleaning and Inspection for Reuse (3-03) Rocker Levers - Group 03
Page 3-8
Valve Cover - Cleaning and Inspection

for Reuse (3-03)
Cleaning
‘z3
0
Inspect the valve cover seal for damage.
NOTE: The seal can be reused if it is not damaged.
A clothing and safety glasses or a face shield. Hot steam will
\
El Steam clean and dry with compressed air.
Inspection
0a
Visually inspect the valve cover for cracks or damage and
replace if necessary.
NOTE: If the seal is not damaged, it can be used again.

If the seal is damaged, install a new seal.
Install the seal into the groove in the valve cover. Start the
installation at the overlap area shown in the illustration. Do not
stretch the rubber seal.
If the seal has more overlap than shown in the illustration, trim
the length to provide the correct overlap.
Crankcase Breather Tube - Cleaning and

Cleaning and Inspection
Use solvent to clean the hose and tube. Dry with compressed
El B air.
Visually inspect the hose and tube for restrictions, cracks or
other damage. Replace the hose and tube if damaged.
0
ai!3
br9tbea
Valve Tappets and Push Rods - Group 04
Page 4-l
Valve Tappets and Push Rods - Group 04

Section Contents
Page
Push Rods - Cleaning and Inspection for Reuse ..................................... 4-4

Cleaning.. .............................................................. 4-4
Inspection.. ............................................................. 4-4
Valve Tappet Cleaning and Inspection for Reuse .................................... 4-3

Cleaning.. .............................................................. 4-3
inspection.. ............................................................. 4-3
Valve Tappets and Push Rods - Exploded View ..................................... 4-2
Valve Tappets and Push Rods - General Information .................................. 43

Valve Tappets and Push Rods - Exploded View Valve Tappets and Push Rods - Group 04
Page 4-2
Valve Tappets and Push Rods - Exploded View
Ref. No. Part Name QW

1 Tappet, Valve 12
2 Rod, Push 12
Valve Taooets and Push Rods - Group 04 Valve Tappets and Push Rods - General information
\-
Page 4-3
Valve Tappets and Push Rods - General

Information
i!!i
The camshaft has lobes to operate the intake and exhaust
valves and a special lobe to drive the fuel transfer pump. The
valve lobes contact the valve tappets which lift the push rods
subsequently opening the valves. ’
The tappets are mushroom shaped and are positioned so the

centerline of the tappet is offset to the centerline of the
camshaft lobe. The offset position causes the tappet to rotate
as it lifts the push rod.
The ball end of the push rod fiis into the ball socket in the
tappet. The other end of the push rod has a ball socket in
which the ball end of the rocker lever adjusting screw
operates.
pr900sa
Valve Tappet Cleaning and Inspection for

Reuse (4-01)
Cleaning
NOTE: Do not mix the tappets.
Clean the tappets with solvent and dry with compressed
Caution: Any time a new camshaft is installed, new
air.
q
\
tappets must also be installed to prevent damage to the

mating surface. A
Inspection
04iB
Inspect the socket, stem and face for excessive wear, cracks,
concavity and other damage.
Reuse Guidelines:
(A) - Normal wear

(B) and (C) - Abnormal wear - Do not reuse
Valve Tappet Face Concavity (Maximum)

mm in.
0.025 MAX 0.001 bp9tasa
Push Rods - Cleaning and Inspection for Reuse (4-02) Valve Tappets and Push Rods - Group 04
Page 44
Measure the valve tappet stem.
Valve Tappet Stem Diameter

mm in.
15.925 MIN 0.627
15.980 MAX 0.629
0
Pit marks on the tappet face are acceptable.
a3 The following criteria defines the size of the pits allowed:
A single pit cannot be greater than 2 mm [0.078 inch].
Interconnection of pits is not allowed.
Total pits when added together should not exceed 6 mm
IO.236 inch] diameter or a total of 4 percent of the tappet
4 face.
No pitting is allowable on the edges of the wear face of
the tappet.
Push Rods - Cleaning and Inspection for

Reuse (4-02)
Cleaning
q
B Use solvent or hot soapy water to clean the push rods. Dry
Inspection
0
Visually inspect the push rod ball and socket for signs of
@3 scoring, cracks, or other damage.
pr900sc
Valve Tappets and Push Rods - Group 04 Push Rods - Cleaning and inspection for Reuse (4-02)
Page 4-5
06B
Check the push rods for straightness.
Push Rod Straightness
mm in.
0.50 MAX 0.020
Fuel Systems - Group 05
Page 5-l
Fuel Systems - Group 05

Section Contents
Page
Direct Link Shutdown Lever - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Fuel Injection Pump Gaskets and Seals - Replacement .............................. 5-12
Fuel System - General Information ............................................. 5-2

Fuel Injection Pump ..................................................... 5-2
Fuel Injection Pump - Data Tag Location ....................................... 5-2
Fuel Injection Pump - Data Tag Information ..................................... 5-2
Governor - Data Tag Information ............................................. 5-3
Derivative Fuel Injection Pump - Data Tag Information .............................. 5-3
Fuel Shutoff Solenoid - Wiring Requirements ..................................... 5-3
Fuel Transfer Pump - Exploded View ........................................... 5-4
Fuel Transfer Pump - Rebuild ................................................ 5-5

Cleaning ............................................................. 5-5
Assembly ............................................................ 5-5
RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment ...................... 5-6
Fuel Shutoff Solenoid - Orientation ........................................... 5-5
Fuel Shutoff Solenoid - Adjustment ........................................... 5-8
RQVK Governor Fuel Shutoff Solenoid - Adjustment ... . ... .. . .. .. .. . . .. .. . .. . . .. .. . 5-9
Shutdown Lever or Spring - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Fuel System - General Information Fuel Systems - Group 05
Page S-2
Fuel System - General Information

Fuel Injection Pump
The Robert Bosch Model PESGAfuel injection pump is used on 6D114-1, S6D114-1 and SAGD114-1series engine models.
The Model PESGMWpump is used on the higher rated SAGD114-1engines. The Model PESGPfuel injection pump is used
on the 6D114E-1, S6D114E-1, SAD114E-1 and SAAGD114E-1series engine.
The fuel injection pump is calibrated for a specified performance for the different engine applications and models. The
performance of the engine is defined by the engine part number and the fuel injection pump code.
During any fuel system repair, cleanliness is of utmost importance. Thoroughly clean all affected parts with solvent and
then blow dry with compressed air.
The fuel injection pump calibration must be within published specifications. The calibration is certified by several emissions
agencies. Tampering with the injection pump is a violation of law. Tampering with the fuel injection pump will void the
engine warranty and can lower the performance of the engine.
This manual does not cover fuel injection pump rebuild or calibration. Rebuild and calibration must be performed in a
facility certified in the rebuild and calibration of the fuel injection pumps. However, there are external repairs that can be
performed on the pumps without affecting the calibration. These repairs are included in this section of the manual.
Fuel Injection Pump - Data Tag Location

Fuel injection pumps have two and sometimes three data tags
(derivative pumps). These tags contain the information needed
to properly calibrate the pump (Bosch pump shown).
(4 Fuel Injection Pump Data Tag
(B)Governor Data Tag
((3 Derivative Pump Data Tag
Fuel Injection Pump - Data Tag Information

1. Fuel Injection Pump Serial Number
2. Bosch Ten Digit Number
fD901 al
Fuel Systems - Group 05 Fuel System - General information
Page 5-3
Governor - Data Tag Information

2. Vendor Fuel Injection Pump Part Number
S/WV425 1100AOC2190-8R
CDC-NO 390 6541
fP90195
Derivative Fuel Injection Pump - Data Tag

Information
This tag is installed on the fuel injection pump when a base
fuel injection pump is converted to a derivative fuel injection
pump.
Fuel Shutoff Solenoid - Wiring Requirements DUAL COIL SOLENOID

EXISTING STARTING
USED WITH
SYSTEM
The solenoid must be wired properly. Refer to the chart

below to find the correct gauge size and length of
continuous wire for the white (pull-in) wire, which connects
the solenoid wiring. The black (ground) wire must be the
same gauge as the white (pull-in) wire regardless of its
length.
Length of Wires
O-4.5 ft O-7.0 ft O-11 ft
FUEL SOLENOID
14 12 10 WlRlNG DIAGRAM
FOR GROUNDED SYSTEM
es900af
14 gauge wire is required for the red (hold-in) wire, which

connects to the “RUN” terminal on the ignition switch.
Wire Gauge Size*

mm in
1.5 14 0.060
1.9 12 0.076
2.4 10 0.096
* Diameter of conductor only. Does not include
insulation.
Fuel Transfer Pump - Exploded View Fuel Systems - Group 05
Page S-4
Fuel Transfer Pump - Exploded View
Low Flow
SM0050
High Flow
Ref. No. Description Quantity

1 Check Valve 2
2 Check Valve Gasket 2
3 O-Ring Seal 1
4 O-Ring Seal 3
5 Outlet Fitting Check Valve 1
Fuel Systems - Group 05 Fuel Transfer Pump - Rebuild (5-01)
Page 6-5
Fuel Transfer Pump - Rebuild (5-01)

20 mm, 26 mm Wrench El
Caution: The hand-prime fitting and inlet fitting are spring
A
loaded, Sudden removal of these two fittings can cause
personal injury.
Secure the pump in a vise, taking care not to damage the
pump housing.
Remove the rubber boot from the hand-prime fitting.
Remove the three fittings as illustrated.

(A) Outlet Fitting
(B) Inlet Fitting
(C) Hand Primer Fitting
Remove all internal components of the pump.
NOTE: Make sure the check valve gaskets are removed from
the inlet fitting.
Cleaning
Thoroughly flush the
remove any debris.
pump with a cleaning solution to
q
\
I fsgooea
Assembly
20 mm, 26 mm Wrench
Assemble the pump with the new components supplied in
the rebuild kit.
1. Check valves
2. Check valve gaskets
3. O-ring seal
4. Outlet fitting/check valve
5. O-ring seal (25 mm)
6. *O-ring seal (25 mm or 30 mm)
*O-ring required is determined by the size of the inlet fitting. W
fs900aa
Discard unused o-ring.
RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment (5-02) Fuel Systems - Group 05
Page 5-6
NOTE: Extreme caution must be used to make sure the check

valves are installed to open in the direction of the fuel flow.
Improper installation of the check valves will result in low
power.
Place the pump in a vise and tighten the fittings.

Torque Value:
(A) Outlet Fitting 30 N*m 122 ft-lb]
(B) Inlet Fitting 30 Nom 122 f&lb]
(C) Hand Primer Fitting 30 N*m [22 R-lb]
fs900wb
RSV Governor Fuel Shutoff Solenoid -

Orientation and Adjustment (502)
Fuel Shutoff Solenoid - Orientation
All 6D114E-1 series engines that are equipped with a fuel
shutoff valve solenoid use either a Synchro-Start or a Trombetta
solenoid.
NOTE: To prevent moisture induced failure, all Trombetta
solenoids must be oriented in the 6:00 o’clock position
according to the following instructions:
Make sure all parts and mounting areas are free of dirt,
damage and other discrepant conditions. The plunger should
be free of rust.
Fuel Systems - Group 05 RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment (5-02)
Page 57
Insert the solenoid through the bracket with the solenoid

shaft toward the fuel pump. Make sure the rubber bellows
vent hole is in the 6:00 o’clock position.
fveoowa
Apply hand pressure to relieve the solenoid spring pressure

and align the capscrew holes. This must be done to align the
plunger on the shut down lever, which is not shown in this
illustration.
I fv900wb
Insert the capscrews through the and hand start

into the bracket.
fv9OOha
0@A
Connect the wiring harness.
RSV Governor Fuel Shutoff Solenoid - Orientation and Adjustment (502) Fuel Systems - Group 05
Page S-8
Fuel Shutoff Solenoid - Adjustment

Synchro-Start
This procedure is for adjusting and maintaining Synchro-Start
fuel shutoff solenoids used to shut down Robert Bosch A/RSV
and MW/RSV fuel injection pumps.
NOTE: The adjustment for the Trombetta is similar, refer to the

procedure on the following page. Refer to Service Bulletin
381034801 for additional fuel pump identification information.
8 mm
RI Adjust the solenoid mounting bracket so that the solenoid
plunger “targets” the center of the shutoff lever as shown in
0a3 the illustration.

0%
0 maximum
Activate the solenoid and check the plunger travel. The
a? stroke length when retracted must be so that there
is a 1 to 3 mm [0.040 to 0.118 inch] gap between the acorn
nut and the shutoff lever (full run position). The plunger length
can be adjusted by hand tightening or loosening the acorn nut.
0
Deactivate the solenoid and check the plunger travel. The
a!3 plunger must be extended so that the shutoff lever hits the shut
down stop screw. If necessary, adjust the acorn nut so the
shutoff lever will hit the stop screw.
Fuel Systems - Group 05 RQVK Governor Fuel Shutoff Solenoid - Adjustment (5-03)
Page 5-9
04B
Activate the ignition switch and check the plunger travel.
1. Synchro-Start 2. Trombetta
A = 66.6 mm [3.4 in] A = 91.4 mm [3.6 in]
B = 60.2 mm [2.4 in] B = 63.5 mm [2.5 in]
The plunger must be retracted when the fuel shutoff solenoid

is activated to the RUN position “B”. The fuel shutoff solenoid
must operate without binding.
Direct Link Solenoid, Cylinder Block Mounted

l Disconnect the solenoid linkage from the lever.
l Activate the ignition switch and check the plunger
travel.
l Measure distance ‘B’ from the center of the ball socket
to the solenoid mounting flange.
B = 117.1 mm [4.61 in]
The plunger must be retracted when the fuel shutoff
solenoid is activated to the RUN position “B”. The fuel
shutoff solenoid must operate with out binding.
RQVK Governor Fuel Shutoff Solenoid -

Adjustment (503)
Activate the ignition switch and check the fuel shutoff
solenoid plunger travel.
A = 66.9 mm [2.64 in]
NOTE: Dimension A is measured from the bottom of the
mounting bracket to the top of the pivot pin.
Shutdown Lever or Spring - Replacement (5-04) Fuel Systems - Group 05
Page 5-10
Shutdown Lever or Spring - Replacement

(5-04)
10 mm
Remove the shutdown lever retaining screw.
I fv900ln
Remove the shutdown lever (A), spring housing (8) and return
spring (C).
fv9lvm
Install the return spring as illustrated.

NOTE: The RSV governor direct link solenoid shutdown system
does not use a return spring.
Install the spring housing over the return spring and align the
outside tip of the return spring with the outside hole in the
spring housing as illustrated.
Fuel Systems - Group 05 Direct Link Shutdown Lever - ReDlacement
. (5-04)
Page S-11
Metal Awl or Pick I
Load the return spring by rotating the return spring and

spring housing counterclockwise approximately l/4 turn.
10 mm
Hold the return spring in the loaded position and install the
shutdown lever.
Install the shutdown lever retaining screw making sure the
return spring (A) is installed into the hole in the shut down
lever.
Direct Link Shutdown Lever -

Replacement
Install the cover cap without the spring.
Make sure the cover cap fits over the shutdown shaft.
I SMCO5f
10 mm
Install the new direct link shutdown lever.
Fuel Injection Pump Gaskets and Seals - Replacement (5-05) Fuel Systems - Group 05
Page 5-12
10 mm
RI Install the retaining screw.

Fuel Injection Pump Gaskets and Seals -

Replacement (5-05)
Bosch Fuel Injection Pumps
Item Type of Seal Torque Value
(4 Sealing Washer 24 Nom [18 ft-lb]
(B) Gasket
((3 Gasket
P) Sealing Washer Only 15 Nom [ll ft-lb]
03 O-ring
(F) O-ring
lniectors and Fuel Lines - Group 06
Page 6-l
Injectors and Fuel Lines - Group 06

Section Contents
Page
Fuel Drain Manifold - Inspection ................................................ 6-16
Fuel Lines, High Pressure - Cleaning and Inspection for Reuse .......................... 6-14
Fuel Lines - Cleaning and Inspection ............................................. 6-15
General Information ........................................................ 6-14
Fuel Lines, Low Pressure - Cleaning and Inspection for Reuse .......................... 6-16
Injector - Chatter Testing ..................................................... 6-14
Injector - Spray Testing ...................................................... 6-13
Injectors and Fuel Lines - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Injectors and Fuel Lines - Exploded View .......................................... 6-5
Injectors and Fuel Lines - Exploded View .......................................... 66
Injectors and Fuel Lines - General Information ...................................... 6-7
Injectors and Fuel Lines - Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Injectors - Cleaning and Inspection for Reuse ...................................... 6-6

Injector - Assembly ........................................................ 6-12
Injector - Cleaning and Inspection .............................................. 6-10
Injector - Disassembly ...................................................... 6-6
Injectors and Fuel Lines - Service Tools Injectors and Fuel Lines - Group 06
Page 6-2
Injectors and Fuel Lines - Service Tools
Used to test opening pressure, leakage, chatter and spray
Used to clean injector nozzles.

Injectors and Fuel Lines - Group 06 Injectors and Fuel Lines - Exploded View
Page S3
Injectors and Fuel Lines - Exploded View

Injectors and Fuel Lines - Exploded View Injectors and Fuel Lines - Group 06
Page 84
Ref. No. Part Name QW

1 Screw, Hex Flange Head Cap 1
3 Seal, Banjo Connector 7
4 Screw, Banjo Connector 7
6 Manifold, Fuel 1
7 Washer, Sealing 6
8 Washer, Plain 9
9 Brace, Tube 4
10 Screw, Hexagon Head Cap 9
11 Isolator, Vibration 8
12 Brace, Tube 3
13 Brace, Tube 3
14 Tube, Injector Fuel Supply 1
17 Brace, Tube 1
18 Brace, Tube 1
19 Isolator, Vibration 2
20 Brace, Tube 1
24 Tube, Fuel Supply 1

Injectors and Fuel Lines - Group 06 Injectors and Fuel Lines - Exploded View
Page 6-5

1 Screw, Hexagon Head Cap 2
3 Gasket, Cover Plate 1

4 Pump, Fuel Transfer 1
5 Washer, Sealing 2
6 Tube, Fuel Supply 1

Injectors and Fuel Lines - Exploded View Injectors and Fuel Lines - Group 06
Page 6-6
Ref. No. Part Name QtY-

1 Seal, Banjo Connector 1
2 Seal, Injector 1
3 Seal, Injector 1
4 Injector 1
6 Clamp, Injector 6
injectors and Fuel Lines - Group 06 Injectors and Fuel Lines - General Information
Page 6-7
Injectors and Fuel Lines - General Information

All 6D114E-1 Series engines use 17 mm closed-nozzle, hole-type injectors.
The injector needle valve and the nozzle tip are machined to a very precise tolerance. Never replace only the needle
valve. Never mix the needle valves and nozzle tips, they are matched sets.
This group provides instructions for disassembly, cleaning, assembly and test of the injectors. This group also provides
data for the injector, high pressure fuel lines, and fuel transfer pump.
Injectors - Cleaning and inspection for Reuse (5-01) Injectors and Fuel Lines - Group 06
Page 6-8
Injectors - Cleaning and Inspection for

Reuse (6-01)
General Information
All engines use 17 mm closed nozzles, hole-type injectors.
However, the injectors can have different part numbers for
different engine ratings. The last four digits of the Vendor part
number are used to identify the injectors.
Use only the specified injector for the engine.
Injector - Disassembly
Clean the carbon residue from the injector nozzle. Use a brass
wire brush and a piece of hardwood dipped in test oil.
Remove the injector seal and discard.
fi9waw
15 mm
Clamp an injector hold down clamp in a soft jawed vise to hold
the injector and remove the injector nozzle retaining nut.
fl9numt
Injectors and Fuel Lines - Group 06 Injectors - Cleaning and Inspection for Reuse (6-01)
Page 6-9
Remove the nozzle needle valve and intermediate plate.

NOTE: To avoid damage, place the injector nozzle and
needle valve in a suitable bath of clean test oil.
NOTE: Hold the needle valve by the stem only. Secretions

from the skin will corrode the finely lapped surfaces.
fi9OOv:
NOTE: The needle valve and nozzle tip are precisely

matched for fit. The parts must not be intermixed.
Remove the nozzle holder from the vise; then remove the
pressure spindle, pressure spring and shims.
Injectors - Cleaning and Inspection for Reuse (6-01) Injectors and Fuel Lines - Group 06
Page 810
Remove and discard the injector sealing sleeve.

l
@
fiSslmi
Injector - Cleaning and Inspection
q
Rinse the nozzle bodies and needle valves in solvent to
B thoroughly flush and completely remove all varnish and carbon
deposits.
Nozzle Cleaning Kit, Part No. 3376947

RI Dip the nozzle seat in clean test oil and use the scraper to
\
q
clean. Polish the needle seat with the piece of hardwood
dipped in test oil.
Caution: Never use emery paper or any other metal scraper
to clean the nozzle. The parts can be damaged.
A
Nozzle Cleaning Kit, Part No. 3376947

Clean the interior ring groove of the nozzle with the scraper as
shown. Rinse in solvent to remove all dirt and carbon residue
and dip in clean test oil.
Injectors and Fuel Lines - Group 06 Injectors - Cleaning and Inspection for Reuse (601)
Page 6-l 1
Clean the spray holes as shown with the appropriate size

cleaning needle.
Remove burned-on combustion deposits on all nozzles with a
commercially available cleaner. Rinse all parts in clean test
oil.
I fi900ef
Clean the needle valve tip with a brass brush. Inspect for
rough surfaces or erosion. The pressure shoulder will
normally have a rough machined appearance.
NOTE: Deteriorated needle valves must be replaced as a
matched unit with their compatible nozzle body.
fi9vas
Dip the needle valve in clean test oil and insert the needle
valve all the way into the nozzle body.
0a3
Pull the needle valve one-third of the way out of the nozzle
body. Wiih the needle valve in the vertical position, the
needle valve must slide all the way back into the nozzle
body under its own weight.
If the nozzle fails the slide test, clean and test the nozzle
again.
NOTE: Any needle valve and nozzle body assembly which

does not pass this test must be replaced.
Injectors - Cleaning and Inspection for Reuse (6-01) Injectors and Fuel Lines - Grouo 06
Page 6-12
Injector - Assembly
NOTE: Make sure all mating surfaces and pressure faces are
thoroughly cleaned and lubricated with test oil before assembly.
New nozzles must be cleaned and lubricated before assembly.
Install the shims and pressure spring.

NOTE: Install the same thickness of shims that were
removed in disassembly. Use the pressure spring to make
sure the shims are installed flat.
fi9sph:
Install the spindle.
fi9OOa;
Install the intermediate plate.

Injectors and Fuel Lines - Group 06 Injector - Spray Testing (6-02)
Page 6-13
Install the needle valve and nozzle assembly.
15 mm
Install the nozzle retaining nut.
fignut
Injector - Spray Testing (6-02)

Part No. 3376946, Injector Nozzle Tester
IQI 1 ‘I,
0
\’
Warning: Keep your body clear of test spray. Test fluid - \
can be injected into the bloodstream causing blood
poisoning and possible death. A _
.‘lOO 200’.
*
NOTE: All nozzles must be tested for opening pressure,

-.,0 300,.-
chatter and spray pattern.
fi900d
Check the injector opening pressure.

(A) Open valve
(B) Operate the lever at one stroke per second
(C) ;;;l_the pressure indicated when the injector spray
Injector - Chatter Testing (6-03) Injectors and Fuel Lines - Group 06
Page 6-14
If the opening pressure does not meet specifications:

1. Add shims to increase pressure.
2. Remove shims to decrease pressure.
fi9smva
Leakage Test:
1. Open valve (A).
2. Operate the lever (B) to maintain a pressure of 20 bar
[290 psi] below opening pressure (C).
3. No drops should fall from the tip (D) within 10 seconds.
Injector - Chatter Testing (6-03)

The chatter test indicates the ability of the needle valve to
move freely and correctly atomize the fuel. An audible sound
should be heard as the valve rapidly opens and closes. A well
optimized spray pattern should be seen.
Used nozzles should not be evaluated for chatter at lower
speeds. A used nozzle can generally be used if it passes the
leakage test.
Fuel Lines, High Pressure - Cleaning and

General Information
The high pressure fuel lines are designed and manufactured to
deliver fuel at injection pressure to the injectors. The high
pressure pulses cause the lines to expand and contract during
the injection cycle.
NOTE: The high pressure fuel lines must be clamped
securely and routed so they do not contact each other or
any other component.
Injectors and Fuel Lines - Group 06 Fuel Lines, High Pressure - Cleaning and Inspection for Reuse (6-04)
Page 615
A
Caution: Do not weld or substitute lines; use only the
specified part number for the engine.
The length, internal size and rigidity of the lines is critical for
smooth engine operation. An attached metal tag is used to
identify each line with a part number.
Fuel Lines - Cleaning and Inspection

Wash the fuel lines in clean solvent and blow dry
compressed air. Make sure all paint chips are removed.
with
q
\
04t3
Visually inspect the high pressure fuel lines for obvious
damage such as lines that have bent to facilitate injector
removal. High pressure pulses expand and contract the
injector lines which result in internal flaking at the bent areas.
Bent lines should be replaced.
Visually inspect for cracks at both ends of the fuel lines.

Fuel Drain Manifold - Inspection (6-05) Injectors and Fuel Lines - Group 06
Page 6-16
Inspect all fuel line fiiings (l), support bracket capscrews (2)
vibration isolator capscrews (3) and isolators (4) for wear and
damage. Any damaged parts must be replaced.
Fuel Drain Manifold - Inspection (6-05)

Inspect the fuel drain manifold for cracks or damage.
Inspect the fuel drain manifold banjo connections.

NOTE: The banjo connection seals must be discarded when
removed. The seals must not be used again.
Fuel Lines, Low Pressure - Cleaning and

Wash the low pressure fuel lines in clean solvent. Blow dry with
compressed air.
Injectors and Fuel Lines - Group 06 Fuel Lines, Low Pressure - Cleaning and Inspection for Reuse (6-06)
Page 6-17
Visually inspect the fuel lines and banjo connections for

obvious damage such as cracks, bends or worn areas. GB
0
NOTE: The sealing washer must be discarded when
removed. The washer must not be used again.
Lubricating Oil System - Group 07
Page 7-l
Lubricating Oil System - Group 07

Section Contents
Page
Lubricating Oil Dipstick - Calibration ............................................ 7-13
Lubricating Oil Pan - Cleaning and Inspection for Reuse .............................. 7-5
Cleaning ................................................................ 7-5
Inspection .............................................................. 7-5
Lubricating Oil Pump - Cleaning and Inspection for Reuse ............................ 7-14
Cleaning.. ............................................................. 7-15
Disassembly ............................................................ 7-14
Inspection .............................................................. 7-15
Lubricating Oil System - Exploded View .......................................... 74
Lubricating Oil System - General Information ...................................... 7-3

Dipstick ............................................................... 7-3
Lubricating Oil Cooler and Filter Head ........................................... 7-3
Lubricating Oil Pump ...................................................... 7-3
Oil Filter Head ........................................................... 7-3
Oil Pan ............................................................... 7-3
Oil Pressure Regulator ..................................................... 7-3
Oil Temperature Thermostat .................................................. 7-3
Lubricating Oil System - Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Lubricating Oil Temperature Thermostat - Cleaning and Inspection ....................... 7-12

Cleaning.. ............................................................. 7-12
Inspection .............................................................. 7-12
Oil Cooler Cover - Disassembly and Assembly ..................................... 7-10

Assembly .............................................................. 7-11
Cleaning ............................................................... 7-10
Disassembly ............................................................ 7-10
Oil Cooler Element - Cleaning and Inspection for Reuse .................. : ........... 7-6
Cleaning.. ............................................................. 7-6
Inspection .............................................................. 7-6
Pressure Test ........................................................... 7-6
Oil Filter Bypass Valve - Replacement ........................................... 7-9
Oil Pressure Regulating Valve - Cleaning and Inspection .............................. 7-7

Assembly .............................................................. 7-8
Cleaning.. ............................................................. 7-8
Disassembly ............................................................ 7-7
Inspection.. ............................................. : .............. 7-8
Lubricating Oil System - Service Tools Lubricating Oil System - Grouo 07
Page 7-2
Lubricating Oil System - Service Tools
Used to remove and install the lubricating oil filters.
Measures spring force at a given spring height.
Used to open the full-flow oil filter for filter element inspection.
Used to pressure test the lubricating oil cooler element.

Lubricating Oil System - Group 07 Lubricating Oil System - General Information
Page 7-3
Lubricating Oil System - General Information

The lubricating oil system group consists of the oil pan, oil suction tube, oil dipstick and tube, oil filter head, oil cooler
element, oil temperature thermostat, oil pressure regulator and the lubricating oil pump.
Instructions for pressure testing the lubricating oil cooler element are included in this section. The oil cooler does not have
a replaceable element and cannot be rebuilt in the field.
Lubricating Oil Cooler and Filter Head

The oil cooler cover and filter head are combined into one casting. The oil pressure regulator, oil temperature thermostat
and filter bypass valve are also located in this housing.
Oil Pressure Regulator

A pressure regulator valve is used to provide pressure relief during cold starting and to regulate oil pressure after the oil
is warm.
Oil Filter Head

The oil filter head is an integral part of the oil cooler housing cover and includes a filter bypass valve. The filter bypass
valve is designed to maintain oil flow to the engine if the oil filter becomes plugged.
Oil Temperature Thermostat

An oil temperature thermostat is located in the top of the oil cooler housing. The thermostat modulates oil flow at
temperatures between 100” and 115°C [212” and 239”F] and full flow through the oil cooler at oil temperatures above
115°C [239”F]. The thermostat also incorporates a pressure relief feature which allows oil to bypass the cooler should
it ever become plugged.
Lubricating Oil Pump

It is not practical to rebuild the gerotor type lubricating oil pump. It can be reused if it meets the inspection criteria.
Dipstick
A center-mounted dipstick location is used on either side of the cylinder block for all oil pans. Service replacement oil
dipsticks do not have the high and low oil level marks indicated on the dipstick. The dipstick must be calibrated after
the engine is installed in the chassis.
Oil Pan
There are two oil pan options available. One oil pan provides a center sump arrangement. The other oil pan can be used
to provide either a front or a rear sump with the use of the corresponding internal oil suction tube. Both oil pans have
the same capacity.
Lubricating Oil System - Exploded View Lubricating Oil System - Group 07
Page 7-4
Lubricating Oil System - Exploded View
Ref. No. Description QtY Ref. No. Description QtY

1 Gasket, Suction Tube 1 23 Plug,Pipe 1
2 Tube, Lube Oil Suction 1 24 Seal,O-Ring 1
3 Screw, Socket Head Cap 2 25 Element,Lube Oil Filter 1
4 Spacer, Mounting 2 26 Screw, Hex Flange Head Cap 11
5 Brace, Suction Tube 1 27 Gasket, Oil Cooler Element 1
6 Screw, Hex Head Cap 2 28 Element, Oil Cooler 1
7 Screw, Hex Head Cap 1 29 Gasket, Lube Oil Cooler Cvr. 1
8 Washer, Plain 1 30 Plunger, Pressure Regulator 1
9 Nut, Hex Flange 1 31 Dowel, Ring 1
10 Gasket, Oil Pan 1 32 Gasket, Filter Head 1
11 Pan, Oil 1 33 Valve, Bypass 1
12 Screw, Hex Head Cap 32 34 Screw, Hex Flange Head Cap 4
13 Washer, Spring 32 35 Head, Lube Oil Filter 1
14 Washer, Plain 32 36 Cover, Lube Oil Cooler 1
15 Washer, Sealing 1 37 Thermostat, Lube 1
16 Plug,Threaded 1 38 Plug, Threaded 1
17 Plug, Threaded 1 39 Plug, Expansion 1
18 Washer, Sealing 1 40 Dipstick 1
19 Spring, Compression 1 41 Tube, Oil Gauge 1
20 Seal, O-Ring 1 42 Pump, Lubricating Oil 1
21 Plug, Pipe 2 43 Screw, Hexagon Head Cap 4
22 Plug,Pipe 1
Lubricating Oil System - Group 07 Lubricating Oil Pan - Cleaning and Inspection for Reuse (7-01)
Page 7-5
Lubricating Oil Pan - Cleaning and

Cleaning
Remove all gasket material from the oil pan gasket sealing \
surface.
R
A
Use steam to clean the oil pan and suction tube. Dry with
compressed air.
op9tbea
0ai9
Inspection
Visually inspect the oil pan for cracks or damage.
Visually inspect the oil drain plug threads for damage.
Do not use a damaged oil drain plug or oil pan.
0ai!3
Visually inspect the oil suction tube and brace for cracks. Do
not reuse a cracked oil suction tube or brace.
Oil Cooler Element - Cleaning and Inspection for Reuse (7-02) Lubricating Oil System - Group 07
Page 7-6
-
Oil Cooler Element - Cleaning and
Cleaning
Plug the cooler element and soak it in a cleaning solution to
remove the coolant deposits.
Remove the plugs and soak the cooler element in solvent.

NOTE: The cooler element can be cleaned in a hot tank.
If the oil passages are contaminated by foreign material, the oil
cooler must be replaced.
I.
Back flush the oil passages with clean solvent and use
compressed air to dry.
I.
6
lc9eteb
Inspection
Inspect the soldered joints for corrosion or cracks.
Check the element for flatness.
Oil Cooler Element Distortion

mm in
0.8 MAX 0.031
lc9etka
Pressure Test
Part No. 3823876 Lubricating Oil Cooler Pressure Test Kit
Install the oil cooler test fixture to the cooler element.
Connect a regulated air line and apply 483 kPa [70 psi] air
pressure to the element.
IcStoha
Lubricating Oil System - Group 07 Oil Pressure Regulating Valve - Cleaning and Inspe
ction (7-03)
Page 7-7
Install the oil cooler element in a tank of water.
Temperature: 82” [18O”F]
0@3
Check for leaks.
If leaks are found in the oil cooler element. the
element must
be replaced.
Remove the oil cooler form the tank of water.

Remove the pressure test equipment. 4
%
Use compressed air to dry the oil cooler.
Cover all of the openings with tape to preven
t dirt from
entering the element when it is not in use.
Oil Pressure Regulating Valve - Cleaning

and Inspection (7-03)
Disassembly
22 mm
Remove the threaded plug and o-ring seal.
Ic9pxmb
c%
Remove the spring and pressure regulator plunger.
Q
I lc9oqma
Oil Pressure Regulating Valve - Cleaning and Inspection (7-03) Lubricating Oil System - Group 07
Page 7-8
Cleaning
Clean all parts in solvent and use compressed air to dry.
Inspection
0
inspect the plunger bore for nicks or scratches.
a3 NOTE: The plunger must move freely in the bore.
lc9pgka
Check the spring tension and free length. Replace the spring
if the measurements do not meet the specifications.
Lubricating Oil Pressure Regulator Spring Specifications

Valve Open
Height: 53.98 mm [2.125 inches]

Load: 190 N [42.8 Ibfl
Assembled
Height: 60.33 mm [2.375 inches]

Load: 153 N [34.4 Ibfl
Assembly
22 mm
Install the pressure regulating plunger and spring.
Install a new o-ring seal and plug.
Lubricating Oil System - Group 07 Oil Filter Bypass Valve - Replacement (7-04)
Page 7-9
Oil Filter Bypass Valve - Replacement

(7-04)
10 mm
Remove the oil filter head and discard the gasket.
lcehdma
Remove the oil filter bypass valve form the cooler cover.
Drive the new oil filter bypass valve in until it is fully seated @@A
against the step int the bore.
439
10 mm
lnstal the oil filter head and new gasket. Tighten the
capscrews.
Ic9hdma
Oil Cooler Cover - Disassembly and Assembly (7-05) Lubricating Oil System - GrouP 07
Page 7-10
Oil Cooler Cover - Disassembly and

Assembly (7-05)
Disassembly
10 mm
Remove the oil filter head and discard the gasket.
lcehdma
32 mm
Remove the oil temperature thermostat and discard the o-ring.
Refer to Procedure 7-06 for cleaning and inspection.
lc900ma
Remove the pipe plugs form locations (l), (2), (3) and (4).
Cleaning
1c%
Q
Remove the oil pressure
Discard the o-ring seal.
Refer to Procedure 7-03
regulator plug, spring
in this section.
Clean all parts with solvent. Dty with compressed
and plunger.
air.
lc9bdec
Lubricating Oil System - Group 07 Oil Cooler Cover - Disassembly and Assembly (7-05)
Page 7-11
Assembly
Install and tighten all pipe plugs.
Torque Value:
(1) 10 Nom [89 in-lb]
(2) 10 Nom [89 in-lb]
(3) 45 Nom [33 ft-lb]
(4) 36 Nom [27 in-lb]
32 mm
Lubricate the oil temperature thermostat o-ring with vegetable
oil. Install and tighten the thermostat.
IcSetha
10 mm
Install the oil filter head and a new gasket.
lcshdma
Install the oil pressure regulator plug, spring and plunger.

Refer to Procedure 7-03 in this section.
Lubricating Oil Temperature Thermostat - Cleaning and Inspection (7-06) Lubricating Oil System - Group 07
Page 7-12
Lubricating Oil Temperature Thermostat -

Cleaning and Inspection (7-06)
Remove the oil temperature thermostat from the oil cooler
cover. Refer to Procedure 7-05.
lc900ma
Cleaning
Clean the thermostat with solvent. Dry with compressed air.
Inspection
Visually inspect for a broken or damaged spring or other
damage.
lc9etkb
Caution: The flash point of new lubricating oil is
A approximately 221” [43O”Fj. Do not allow oil temperature in

the container to exceed 150°C [3OO”Pj. Do not allow water
droplets to enter the container of hot oil. Water droplets will
cause a violent reaction which can cause personal injury.
Lubricating Oil System - Group 07 Lubricating Oil Dipstick - Calibration (7-07)
Page 7-13
Suspend the thermostat and a 116°C [24O”F] thermometer in

a container of new lubricating oil. Do not allow the
thermostat or the thermometer to touch the side or bottom
of the container.
Heat the lubricating oil.
ICSOOSb
0@
NOTE: Wriie down the temperature at which the thermostat
is fully extended. The thermostat must be fully extended to
at least 45.9 mm [1.80 inch] when the temperature reaches
116°C [24O”F].
Replace the thermostat if it does not operate as described.
116°C [24O”F] for Part No. 1295 151 H92
45.9 mm
105°C [22O”F] for Part No. 1310 134 Hl
[1.80 in]
Lubricating Oil Dipstick - Calibration

(7-07)
Install the dipstick in the dipstick tube housing.
Use clean 15W-40 engine oil to fill the oil pan to the
specified “low” oil level. Refer to Lubricating Oil System
Specifications for engine oil capacity.
Caution: The dipstick will break if the scribe mark is too

deep.
Remove the dipstick and scribe a mark across the dipstick
A
and mark the “low” oil level with an ‘I”. 0
@z
NOTE: If a new blank dipstick is being used, cut the dipstick
off approximately 38 mm [1.5 inches] below the “low” oil
level mark.
Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08) Lubricating Oil System - Group 07
Page 7-14
Install the dipstick into the dipstick tube housing.

Fill the oil pan to the specified “high” oil level. Refer to
Lubricating Oil System Specifications for engine oil capacity.

deep.
Remove the dipstick and scribe a mark across the dipstick and
mark the “high” oil level with and “H”.
Lubricating Oil Pump - Cleaning and

Disassembly
Visually inspect the lubricating oil pump gears for chips, cracks,
or excessive wear.
NOTE: It is not practical to rebuild the pump. If any of the
internal parts are worn beyond the specifications, the pump
must be replaced.
1p9gesa I
Remove the back plate.
lpeplma
Lubricating Oil System - Group 07 Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08)
Page 7-l 5
Mark “top” on the gerotor planetary.
1p9oogtl
Remove the gerotor planetary.

Inspect for excessive wear of scoring. 69 l
4B
0
lp900ma
Cleaning
Clean all parts in solvent and use compressed air to dry.
Inspection
Inspect the pump housing
excessive wear.
and gerotor drive for damage and
0
@
Ip9hssa
Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08) Lubricating Oil System - Group 07
Page 7-18
Install the gerotor planetary.

Be sure the gerotor planetary is installed in the original
position.
Ip900he
Measure the tip clearance.
Lubricating Oil Pump Gerotor Tip Clearance

mm in
0.025 MIN 0.001
0.1778 MAX 0.007
Measure the clearance of the gerotor drive/gerotor planetary to

port plate.
Oil Pump Gerotor Drive/Gerotor Planetary to Port Plate

Clearance
mm in
0.025 MIN 0.001
0.127 MAX 0.005
Measure the clearance of the gerotor planetary to the body

bore.
Oil Pump Gerotor Planetary to Body Bore

mm in
0.127 MIN 0.005
0.381 MAX 0.015
1p900nc
Lubricating Oil System - Group 07 Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08)
Page 7-17
Measure the gear backlash.

Oil Pump Drive Gear Backlash (Used Pump)
mm in
0.08 MIN 0.003
0.45 MAX 0.018
NOTE: Hold the idler gear from moving when checking

I lP900nd
Install the back plate.
lp9plha
Cooling System - Group 08
Page 8-1
Cooling System - Group 08

Section Contents
Page
Belt Tensioner Inspection .................................................... 8-10
Coolant Filter Shutoff Valve - Cleaning and Inspection for Reuse ........................ 8-10
Assembly .............................................................. 8-11
Cleaning.. ............................................................. 8-l 1
Disassembly ............................................................ 8-l 0
Cooling System Components - Exploded View ..................................... 8-3
Cooling System - General Information ........................................... 8-4

Belt Tensioner ........................................................... 8-4
Cooling Fans ........................................................... 8-4
Fan Hub .............................................................. 8-4
Pressure Caps ........................................................... 8-4
Thermostats ............................................................ 8-4
Water Pump ............................................................ 8-4
Cooling System - Service Tools ............................................... 8-2
Fan - Cleaning and Inspection for Reuse ........................................ 8-12
Fan Hub - Cleaning and Inspection for Reuse ..................................... 8-7

Cleaning.. ............................................................. 8-7
Inspection.. ............................................................ 8-8
Fan Hub- Rebuild ......................................................... 8-8

Assembly .............................................................. 8-9
Disassembly ............................................................ 8-8
Thermostat Housing - Cleaning and Inspection for Reuse ............................. 8-6

Cleaning.. ............................................................. 8-6
Inspection .............................................................. 8-6
Thermostat - Inspection ..................................................... 8-6
Water Outlet Connection - Cleaning and Inspection for Reuse .......................... 8-7
Water Pump Assembly - Cleaning and Inspection for Reuse ........................... 85

Cleaning.. ............................................................. 86
Inspection .............................................................. 8-6
Cooling System - Service Tools Cooling System - Grouta 08
Page 8-2
Cooling System - Service Tools
Use with Magnetic Base, Part No. 3377399, to measure the fan
hub and clearance.
Used with Part No. 3378050, Dial Indicator and Sleeve

Cooling System - Group 08 Cooling System Components - Exploded View
Page 8-3
Cooling System Components - Exploded View

1 Pump, Water 1 21 Elbow, Male Adapter 2
2 Body, Water Pump 1 22 Plug, Pipe 1
3 Bearing, Water Pump 1 23 Draincock 1
4 Seal, Water Pump 1 24 Tube, Vent 1
5 Impeller 1 25 Support, Fan 1
6 Pulley, Water Pump 1 26 Bearing, Shaft 1
7 O-ring 1 27 Hub, Fan 1
8 Screw, Hex Head Cap 3 28 Retainer, Fan Hub 1
9 Thermostat, Coolant 2 29 Screw, Hex Head Cap 1
10 Gasket, Thermostat Housing 1 30 Screw, Hex Head Cap 4
11 Housing, Thermostat 1 31 Pulley, Fan 1
12 Screw, Hex Head Cap 2 32 Plate, Clamping 1
13 Connection, Water Outlet 1 33 Screw, Cap 4
14 Gasket, Connection 1 34 Screw, Cap 4
15 Screw, Hex Head Cap 2 35 Bracket, Belt Tensioner 1
16 Seal, O-ring 1 36 Screw, Flat Head Cap 2
17 Shaft, Shutoff Valve 1 37 Tensioner, Belt 1
18 Screw, Hex Head Cap 1 38 Screw, Hex Head Cap 1
19 Adapter, Filter Head 1 39 Belt, V-ribbed 1
20 Filter. Coolant 1
Cooling System - General Information Cooling System - Group 08
Page 8-4
Cooling System - General Information

Water Pump
The water pump is a belt driven, centrifugal type pump with the inlet and bypass line as an integral part of the cylinder
block.
The coolant pressure can be measured from the vent petcock. At normal operating temperature (thermostats open) and
at 2,000 RPM the minimum pressure should be: 124 kPa [18 psi] with a 103 kPa [15 psi] pressure cap or 69 kPa [lo
psi] with a 46 kPa [7 psi] pressure cap. It is not practical to replace the parts in the pump, the water pump is serviced
as an assembly. Remanufactured water pumps are available from your Komatsu Distributors and Dealers.
Thermostats
The thermostat housing contains two identical thermostats.
A Caution: Never operate the engine without the thermostats. The path of least resistance for the coolant
without thermostats is through the bypass to the water pump inlet. This will cause the engine to overheat.
Pressure Caps
The cooling system is designed to use a pressure cap to prevent boiling of the coolant. Different caps are specified for
the two recommended systems. The 104°C [22O”F] system requires a 103 kPa [15 psi] cap. The 99°C [21O”F] system
requires a 46 kPa [7 psi] cap.
Fan Hub
The fan hub is available in various drive ratios and fan center locations.
Belt Tensioner
The fan belt is tensioned by the spring loaded idler assembly and does not require adjustment.
To prevent accidents, always release the spring tension before replacing the fan belt.
Cooling Fans
Check the fan for missing balance weights at each regular maintenance interval. Do not attempt to repair broken or bent
fans, or fans with missing balance weights.
Most Komatsu powered equipment use a radiator and fan. The radiator and fan transfer heat from the coolant to the
atmosphere. The fan selection process must conclude that the fan, fan mounting arrangement, and fan drive system are
designed and matched for compatibility.
Upon request, Komatsu Application Engineering will assist in determining the proper selection. Refer any fan changes,
other than the direct replacement of a fan with precisely the same Komatsu part number, to the Komatsu Application
Engineering for prior approval.
Examples that require approval are:
1. Using an approved fan from one engine model on a different engine model.
2. Using an approved fan on an engine with a different fan mounting arrangement.
3. Using an approved fan on an engine with a different fan drive arrangement.
4. Converting an engine from on market model to another, an example is conversion of a Gdrive engine to a power
unit application.
5. Converting an engine model to a different model, an example is converting a 6D114E-1 to a S6D114E-1.
This list is not all inclusive. Always contact Application Engineering for assistance.
At times, an existing fan can yield ONLY marginal cooling when being considered for a new application.
Cooling System - Group 08 Cooling System - General Information
Page 8401
A Caution: Never repitch (bend) the blades to obtain additional air delivery. Bending the blades or spider
creates stress in the material used for the construction of the fan. Repitching (bending) will cause fan
failure. The proper diameter fan must be selected. Never modify an existing fan.
Application Engineering will provide assistance in the selection of a fan with the correct pitch and diameter for proper
cooling.
Coolina System - Group 08 Water Pump Assembly - Cleaning and Inspection for Reuse (8-01)
Page 8-5
Water Pump Assembly - Cleaning and

Cleaning
The water pump seal design requires a coolant film for
lubrication and cooling. Therefore, it is normal to observe a
0
minor chemical buildup or streaking at the weep hole. Before
cleaning the water pump: inspect the weep hole for large @
amounts of chemical buildup. Replace the pump if large
amounts of chemical buildup is observed.

A
Use solvent or steam to clean the water pump exterior. Dry \
with compressed air. IJ
Inspection
0a9
Visually inspect the water pump body for cracks or damage.
Visually inspect the impeller for cracks, erosion, or damage.
Visually inspect the pulley for damage or wear.
04B
Rotate the water pump shaft by hand to inspect the bearings
and the impeller for freedom of rotation.
NOTE: If damaged parts are found or the shaft does not
rotate freely in the water pump body, the water pump must
be replaced.
NOTE: Parts replacement is not practical: the water pump is
serviced as an assembly.
Thermostat Housing - Cleaning and Inspection for Reuse (8-02) Cooling System - Group 08
Page 8-6
Thermostat Housing - Cleaning and

Cleaning
Use a gasket scraper to remove the gasket material from the
mating surfaces of the housing.
th9hsea

\
A Use solvent or steam to clean the parts.
Inspection
049 Visually inspect the thermostat housing for cracks, corrosion,

or damage. Replace the thermostat housing if damaged.
th9hssa
0
Thermostat - Inspection (8-03)
OK
Visually inspect the thermostats for damage.
0
6B Make sure both thermostats are clean and free from corrosion.
Cooling System - Group 08 Water Outlet Connection - Cleaning and Inspection for Reuse (&CM)
Page 8-7
Suspend the thermostats and a 100°C [212” F] thermometer

in a container of well mixed water.
NOTE: Do not allow the thermostats or thermometer to
touch the container.
Heat the water slowly so the wax element in the thermostats
has sufficient time to react to the rising water temperature.
Check the thermostats as follows:
0ai3
NOTE: The nominal operating temperature is stamped on the
thermostat.
l Thermostat must begin to open within 1“C [2”F] of
l
82°C [18O”F].
Thermostat must be fully
95” C [203” F] .
open within 1°C [2”F] of CB
NOTE: The fully open clearance between the thermostat flow
valve and flange must be 41.5 mm [1.63 inches] minimum.
Water Outlet Connection - Cleaning and

Straight Edge
Use a gasket scraper to remove the gasket material from the
flange.
Clean with solvent. Dry with compressed air.
RI
Check the water outlet connection for flatness.
0ai?
Visually inspect for corrosion, cracks or damage.
Fan Hub - Cleaning and Inspection for

Reuse (8-05)
Cleaning
A
Use solvent or steam to clean the fan hub exterior.
compressed air.
Dry with
R
B
Fan Hub - Rebuild (8-06) Cooling System - Group 08
Page 8-8
Inspection
Visually inspect the fan hub for indication of oil seal leakage.
Visually inspect the fan hub for cracks or damage.
Turn the fan hub shaft by hand to check for freedom of

rotation. The fan hub must spin freely without any wobble or
excessive end clearance.
fa900sb
Measure the fan hub shaft end clearance.
Fan Hub Shaft End Clearance

mm in
0.15 MAX 0.006
If damaged parts are found, the shaft does not rotate freely or
the shaft end clearance is not within the specifications, the fan
hub must be rebuilt or replaced.
Fan Hub - Rebuild (8-06)

Disassembly
16 mm
Secure the fan hub and remove the center bolt and retainer.
Cooling System - Group 08 Fan Hub - Rebuild (8-06)
Page 8-9
Install a bearing splitter as illustrated.

NOTE: Do not over-tighten the bearing splitter as it may RI
damage the shaft when the bearing is pressed out.
0
C%
3/4 inch Drift

Support the fan hub housing/splitter and press out the shaft. RI
2 inch Pipe
Support the fan hub housing and press out the bearing.
fa9bema
Assembly
Caution: Do not press on the inside diameter of the
bearing. The bearing could be damaged.
f
Press the new bearing into the fan hub housing even with
the front of the housing.
Fan Hub Bearing Installation Force

N Ibf
9000 MIN 2023
Replace the fan hub housing if the installation force is less fa9beha
than specified.
lelt Tensioner Inspection (8-07) Cooling System - Group 08
‘age &lO
l-1/2 inch Pipe (inside diameter)

Caution: Make sure the inner race is adequately supported
to avoid damage to the bearing. Do not press on the fan
hub.
Support the bottom of the inner race and press the shaft in
until it is seated.
2lL
Check the assembled height. if the assembled height is
incorrect, disassemble and assemble with a new bearing.
Fan Hub Assembled Height

mm in.
fa9shha
124.85 MIN 4.915

125.65 MAX 4.943
18 mm
Secure the fan hub assembly and install the center bolt and
retainer.
Belt Tensioner Inspection (8-07)

Rotate the pulley to check for freedom of rotation and that
there are no rough spots on the bearing.
Check for a broken spring or damaged locating tang.
NOTE: It is not practical to rebuild the belt tensioner, if
damaged, the complete assembly must be replaced.
Coolant Filter Shutoff Valve - Cleaning

and Inspection for Reuse (8-08)
Disassembly
Remove the retaining capscrew (1) from the thermostat housing
(2) and remove the shutoff valve (3).
Remove and discard the o-ring (4).
th9boha
Cocrlina Svstem - Group 08 Coolant Fitter Shutoff Valve - Cleaning and Inspection for Reuse (8-08)
Page 8-l 1
Cleaning
Use solvent to clean the parts. Dry with compressed air.
\
La
06B
Visually inspect the water passages in the shutoff valve shaft.
Visually inspect the shaft for corrosion or pitting. Use 24.0 grii
aluminum oxide paper to remove the corrosion.
If the parts are cracked or damaged, the filter head assembly
must be replaced.
th9vasa
Assembly
Install a new o-ring in the groove of the shaft.
th9orh.s
Use clean 15W-40 engine oil to lubricate the shaft and o-ring.
Belt Tensioner Inspection (8-07) Cooling System - Group 08
Page 8-12
Install the shutoff valve shaft (3) in the thermostat housing (2).
RI Install the retaining capscrew (1) in the thermostat housing.
0%
Tighten the capscrew.
Fan - Cleaning and Inspection for Reuse

(8-09)
Cleaning
A
q B Use solvent or steam to clean the fan. Dry with compressed

air.
Inspection
Warning: A bent or damaged fan blade can fail during
A operation and cause serious personal injury or property
damage.
Visually inspect the fan for cracks, loose rivets and bent or
loose blades.
a3
0
Warning: Do not straighten a bent fan blade or continue to

A use a damaged fan. Replace the original equipment fan with
a fan of the identical part number. Komatsu must approve
any other fan changes.
Refer to page 8-4 for additional information about fan
installation and replacement.
Drive Units - Group 09
Page 9-l
Drive Units - Group 09

Section Contents
Page
Accessory Drive Adapter - Cleaning and Inspection for Reuse .......................... 46

Cleaning.. ............................................................. 4-5
Inspection .............................................................. 4-5
Accessory Drive Adapter - Exploded View ........................................ 4-3
Accessory Drive Adapter - Rebuild ............................................. 4-5

Assembly ..............................................................
Disassembly ............................................................ 1:
Accessory Drive - General Information ........................................... 4-4

Accessory Drive Adapter .................................................... 4-4
Drive Units - Service Tools ................................................... 4-2

Drive Units - Service Tools Drive Units - Group 09
Page 9-2
Drive Units - Service Tools
Tool No.
__ _ _ ___ Tool Descrbtion Tool Illustration
Standard Puller
Used to remove drive gears.

ST-647
Drive Units - Group 09 Accessory Drive Adapter - Exploded View
Page 9-3
Accessory Drive Adapter - Exploded View

1 Adapter, Accessory Drive
Bearing
Shaft, Accessory Drive
Gear, Accessory Drive
Gasket, PTO Drive Cover
Screw, Hex Head Cap
Gasket, PTO Drive Cover
Plate, PTO Drive Cover
Screw, Hex Head Cap
Accessory Drive - General Information Drive Units - Group 09
Page 9-4
Accessory Drive - General Information

Accessory Drive Adapter
The accessory drive is gear driven from the camshaft gear in the front gear train. The accessory drive is capable of driving
up to a maximum of 105 ft-lb of torque. The accessory drive is equipped with either SAE A or B flange adapters.
A cover plate is used for engines not equipped with an air compressor or hydraulic pump.
Drive Units - Group 09 Accessory Drive Adapter - Cleaning and Inspection for Reuse (9-m)
Page 9-5
Accessory Drive Adapter - Cleaning and

Cleaning
Clean the accessory drive adapter with clean solvent and
blow dry with compressed air.
ad900ea
0@3
Inspection
Visually inspect for obvious damage such as cracks, broken
teeth and damaged threads.
0a3
Rotate the gear and inspect for rough spots in the bearing
and excessive wear.
ad900Sb
Accessory Drive Adapter - Rebuild (9-02)

Disassembly
ST-647 T Bar Puller
Remove the drive gear.
ad9OOfa
Accessory Drive Adapter - Rebuild (9-02) Drive Units - Grow 09
Page 9-6
NOTE: The shaft/bearing assembly will only press out in one

direction.
Press the shaft and bearing assembly out as illustrated.
Press the shaft out of the bearing and discard the bearing.
The bearing must not be used again.
II ad900fc 1
Assembly
1 l/2 inch ID Pipe Coupling
Support the inner race of the new bearing and press the shaft
into the bearing until the shaft seats on the inner race.
ad900aa
2 inch ID Pipe
Caution: To prevent damage to the bearing, do not press
on the inner race, only press on the outer race of the
bearing assembly.
Support the housing and press the bearing and shaft assembly
in until it is seated.
Drive llnits - Group 09 Accessory Drive Adapter - Cleaning and Inspection for Reuse (9-01)
Page 9-7
Position the gear with the lip facing down. Q&

Qf@
--._- 900x
1 l/4 inch Pipe Coupling

Support the bottom of the shaft with a 1 l/4 inch pipe
coupling and press the gear on until it seats against the
inner-bearing race.
ad9OOad.
Air Intake System - Group 10
Page 10-l
Air Intake System - Group 10

Section Contents
Page
Aftercooler Assembly - Cleaning and Inspection for Reuse ............................ lo-9

Inspection ........................................................... 1O-l0
Aftercooler Assembly - Rebuild .............................................. lo-10
Air Crossover Tube - Cleaning and Inspection for Reuse ............................ lo-11
Cleaning ............................................................ 1O-l1
Inspection........................................................... lo-11
Air Intake System - Exploded View ........................................... 10-3-01
Air Intake System - General Information ......................................... 10-4

Inspection ............................................................ 1O-5
Air Intake System - Service Tools ............................................. 10-2
Air Transfer Pipe - Cleaning and Inspection for Reuse .............................. 10-l1
Cleaning.. .......................................................... lo-11
Inspection........................................................... lo-11
Charge Air Cooler (CAC) - Cleaning and Inspection for Reuse ........................ lo-12
Cleaning.. .......................................................... lo-12
Inspection........................................................... lo-12
Charge Air Cooler (CAC) - Pressure Testing ..................................... lo-13
Intake Manifold Cover - Cleaning and Inspection for Reuse ........................... lo-9
Inspection............................................................ 10-9
Turbocharger - Cleaning and Inspection for Reuse ................................. 10-5

Inspection............................................................ 10-5
Air Intake System - Service Tools Air Intake System - Group 10
Page 10-2
Air Intake System - Service Tools

Dial Depth Gauge
Measure the turbocharger axial motion.

ST-537
Pressure Test Kit
Used to test the turbocharger wastegate actuator.

3823799
Air Intake System - Exploded View Air Intake System - Group 10
Page 10-3-01
Air Intake System - Exploded View

Air Intake System - Group 10 Air Intake System - Exploded View
Page 10-3-02

1 Turbocharger 1 30 Gasket, Aftercooler 1
2 Gasket, Turbocharger 1 31 Aftercooler 1
3 Stud 4 32 Screw, Hex Head Cap 18
4 Nut, Regular Hex 4 33 Hose, Plain 1
5 Screw, Hex Head 5 34 Clamp, Hose 2
6 Connector, Adapter 1 35 Hose, Flexible 1
7 Screw, Flange Head 3 36 Connection, Female 1
8 Washer, Plain 3 37 Gasket, Turbo. Oil Drain 1
9 Clamp, V Band 1 38 Tube, Turbo. Oil Drain 1
10 Nut, Hex 1 39 Screw, Hex Head Cap 2
11 Brace, Actuator 1 40 Hose, Plain 1
12 Nut, Lock 1 41 Clamp, Hose 2
13 Actuator, Turbocharger 1 42 Tube, Turbo. Oil Drain 1
14 Bracket, Actuator 1 43 Elbow, Hose Adapter 2
15 Screw, Hex Head 3 44 Seal, O-Ring 2
16 Washer, Plain 3 45 Plate, Clamping 1
17 Nut, Hex Jam 1 46 Screw, Hex Head Cap 1
18 Ring, Retaining 1 47 Tube, Water Inlet 1
19 End, Adjusting Link 1 48 Tube, Water Outlet 1
20 Connection, Air Intake 1 49 Hose, Plain 4
21 Screw, Hex Flange Head 4 50 Clamp, Hose 8
22 Gasket, Connection 1 51 Flame and Plug, Start 2
23 Screw, Hex Head 12 52 Tube, Fuel 2
24 Cover, Intake Manifold 1 53 Tee 1
25 Gasket, Intake Mfd. Cover 1 54 Solenoid, Fuel 1
26 Lock Plate 12 55 Bracket 1
27 Manifold, Exhaust 1 56 Screw, Hex Head Cap 3
28 Gasket, Exhaust Manifold 6 57 Screw, Hex Head Cap 2.
29 Screw, Hex Head Cap 12 58 Hose, Fuel 2
Air Intake System - General Information Air Intake System - Group 10
Page 10-4
Air Intake System - General Information

The Air Intake System Group for charge air cooled engines consists of the intake manifold, charged air cooler and
associated hardware and turbocharger. On engine coolant aftercooled engines, consists of the aftercooler assembly,
aftercooler coolant tubes and the turbocharger.
The charge air cooler uses ambient air with the aid of the cooling fan to cool the intake air between the turbocharger
and the intake manifold during engine operation. Refer to the original equipment manufacturer for information on the
maintenance procedures for the charge air cooler.
On engine coolant aftercooled engines, the aftercooler utilizes engine coolant to cool the air between the turbocharger
and combustion chambers during engine operation. The aftercooler also performs as a starting aid by warming the intake
air, if the engine is equipped with an engine coolant heater.
Refer to the Hl Series Turbocharger Shop Manual, Bulletin No. 3810321 for rebuilding the turbocharger.
The turbocharger uses exhaust gas energy to turn the turbine

wheel. The turbine wheel drives the compressor impeller which
provides compressed air to the engine for combustion. The
additional air provided by the turbocharger allows for a more
complete combustion. Therefore, more fuel can be injected to
increase the power output from the engine.
NOTE: The correct turbocharger must be used. Providing too
much additional air will increase the cylinder pressures and
shorten the life of the engine.
1 The turbine and compressor wheels and the shaft are

supported by two rotating bearings in the bearing housing.
Passages in the bearing housing direct filtered, engine oil under
pressure to the shaft bearings and thrust bearings. The oil is
used to lubricate and cool the rotating components to provide
for smooth operation. The oil then drains from the bearing
housing to the engine sump through the oil drain tube.
NOTE: An adequate supply of good, filtered oil is very
important to the life of the turbocharger.
As the intake air is compressed by the turbocharger, the air is

heated. This heated air is then passed through the charge air
cooler which cools the air. Because cool air is more dense
than warm air, more air is compressed into the cylinder,
yielding a much greater combustion efficiency.
Air Intake System - Group 10 Turbocharger - Cleaning and Inspection for Reuse (10-01)
Page 10-5
Turbocharger - Cleaning and Inspection

for Reuse (10-01)
Remove all carbon deposits and gasket material from
surfaces (1) (2) and (3).
A
Caution: Tape or plug all openings to prevent solvent or
steam from damaging the oil cavities in the turbocharger. A
Use solvent or steam to clean the exterior of the
turbocharger. Dry with compressed air.
Inspection
Visually inspect the housings for damage.
Visually inspect the turbine wheel and compressor
(1) for fretting, cracked or broken vanes.
impeller 0a3
Turn the impeller in the direction shown with arrow (2) to
inspect the turbine shaft for freedom of rotation. The shaft
must rotate freely.
Replace damaged parts.
0@B
Visually inspect the mounting flange.
Cracks on the mounting flange longer than 15 mm [OX inch]
are not acceptable.
0GE@
Cracks must not reach the mounting holes.
tb900sb
Turbocharger - Cleaning and Inspection for Reuse (10-01) Air Intake System - Group 10
Page 10-6
Two cracks must be separated by a minimum of 6.4 mm [0.25

inch].
Visually inspect the wastegate actuator mounting bracket for
0ai3 cracks or bends. Replace if damaged.
Visually inspect the bracket mounting surface for cracks and

damage.
Visually inspect the wastegate valve assembly lever pin.
Replace the turbine housing if it is worn excessively.
Actuate the wastegate assembly lever by hand to be sure that

the shaft rotates freely and is not seized.
Check for excessive movement between the wastegate shaft
and bushing.
Replace the turbine housing if the wastegate shaft and the
turbine housing bushing are damaged or seized.
Air Intake System - Group 10 Turbocharger - Cleaning and inspection for Reuse (10-01)
Page 10-7
0a3
Visually inspect the actuator air supply hose for cuts, cracks
or heat damage. Replace if damaged.
Visually inspect the wastegate actuator for cracks, dents and

other damage. Replace if damaged. a9
0
0
OK
Part No. 3823799, Pressure Test Kit

Check the wastegate actuator by connecting a regulated
shop air supply line to the actuator hose connection. Apply
103 kPa [15 psi] air pressure to the wastegate actuator and
listen for leaks. If any leaks are heard, the actuator must be
replaced.
0et3
Visually inspect the wastegate actuator rod for bends, cracks,
stripped threads and wear. Replace if damaged.
I SM0075
Turbocharger - Cleaning and Inspection for Reuse (10-01) Air Intake System - Group 10
Page 10-8
Part No. ST-537, Dial Depth Gauge

Measure the turbocharger shaft end clearance.
Push the rotor assembly away from the gauge.
@ Set the gauge on zero.
Push the rotor assembly toward the gauge and record the
data.
For turbochargers with serial number before 840638:
Turbocharger Shaft End Clearance

mm in.
0.10 MIN 0.004
0.16 MAX 0.006
For turbochargers with serial number after and including

840638:
Turbocharger Shaft End Clearance

mm in.
0.03 0.001
0.08 0.003
0@3 Push the compressor

compressor housing.
impeller by hand toward the
Insert a wire feeler gauge, at the minimum clearance point,

between the impeller and the housing to measure the
clearance.
Record this clearance.
Intake Manifold Cover - Cleaning and Inspection for Reuse (10-02) Air Intake System - Group 10
Page 10-9
06B
With the feeler gauge in the same location, push the turbine
wheel by hand away from the compressor housing.
Insert a wire feeler gauge, at the same point.
Record this clearance.
Subtract the smaller from the larger clearance.
Turbine Wheel Radial Clearance
mm in.
0.21 MIN [0.008]
0.46 MAX [0.018]
lb2006
If the radial clearance does not meet the above
specifications, the turbocharger must be rebuilt. Refer to the e
Hl Series Turbocharger Shop Manual, Bulletin No. 3810321.
Intake Manifold Cover - Cleaning and

Remove the air intake connection.
Remove all gasket material. C%Q
A
Use solvent or
compressed air.
steam to clean the parts. Dry with
q
\
im9cvea
Inspection
Visually inspect the intake manifold cover and intake
connection for cracks or damage. Replace damaged parts. 0
@J
im9cvsa
Aftercooler Assembly - Cleaning and

Remove all gasket material from the mounting surfaces.
Warning: When using a steam cleaner, wear protective q
\
A
Use solvent or steam to clean the aftercooler assembly. Dry
q
B
Aftercooler Assembly - Rebuild (10-04) Air Intake System - Group 10
Page lo-10
Inspection
Visually inspect the aftercooler assembly for cracks or damage.
Replace if damaged.
Pressure Test the Aftercooler Core

Install the hose, hose clamps, and solid pipe plug (1) onto the
inlet tube.
Install the hose and hose clamps (2), and air pressure gauge
(3) onto the outlet tube.
Connect the air pressure gauge to a regulated air supply.
Submerge the aftercooler in a tank of water.
If air bubbles appear, the core is damaged and the aftercooler
must be replaced.
c%
4
Remove the aftercooler
Remove the test equipment.
Use compressed
from the water tank.
air and dry the aftercooler.
Aftercooler Assembly - Rebuild (10-04)
A
Caution: The aftercooler is a unitized assembly and cannot
be rebuilt. Any attempt to repair the aftercooler core will
reduce the coolant flow and cause future engine damage.
Refer to Aftercooler Assembly - Cleaning and Inspection for
Reuse (1O-03).
at9OOkb
Air Intake System - Group 10 Air Crossover Tube - Cleaning and Inspection for Reuse (10-06)
Page 10-l 1
Air Transfer Pipe - Cleaning and

Cleaning
A
Use solvent or steam to clean the air transfer pipe. Dry with \
compressed air. u
Inspection
Visually inspect the turbocharger compressor V-band outlet
and the air transfer pipe connection for dents or fretting.
Replace the turbocharger compressor housing or air transfer
0,
@
pipe, if damaged.
Air Crossover Tube - Cleaning and

Cleaning
A
Use solvent or steam to clean the air crossover tube. Dry
with compressed air. q
B
Inspection
Visually inspect the air crossover tube for cracks or damage.
Visually inspect the hose sealing surfaces for pitting or
damage. Replace damaged parts.
0
@
ca9tbsa
Charge Air Cooler (CAC) - Cleaning and Inspection for Reuse (10-07) Air Intake System - Group 10
Page 10-12
Charge Air Cooler (CAC) - Cleaning and

Cleaning
If the engine experiences a turbocharger failure or any other
occasion where oil or debris is put into the CAC, the CAC
must be cleaned.
Remove the CAC from the vehicle. Refer to the vehicle
manufacturer for instructions.
SMLw76
Caution: do not use caustic cleaners to clean the CAC.

Damage to the CAC will result.
NOTE: Make sure that the tubes are in the vertical direction
when flushing.
Flush the CAC internally with solvent in the opposite direction
of normal air flow. Shake the CAC and lightly tap on the end
tanks with a rubber mallet to dislodge trapped debris. Continue
flushing until all debris or oil is removed.
NOTE: If internal debris can not be removed, scrap the CAC.
Use a flashlight and mirror to visually inspect the CAC for
internal debris.
After the CAC has been thoroughly cleaned of all oil and debris
with solvent, wash the CAC internally with hot soapy water to
remove the remaining solvent. Rinse thoroughly with clean
water.
Blow compressed air into the CAC in the opposite direction of
normal air flow until the CAC is dry internally.
Caution: the CAC must be rinsed, dried, and free of solvent,
oil and debris or engine damage will result.
Inspection
Visually inspect the CAC for cracks, holes or damage.
Inspect the tubes, fins and welds for tears, breaks or other
damage. If any damage causes the CAC to fail the air leak
check mentioned in Procedure (lo-08), the CAC must be
replaced.
Install the CAC on the vehicle. Refer to the vehicle
Air Intake System - Group 10 Charge Air Cooler (CAC) - Pressure Testing (10-08)
Page lo-13
Charge Air Cooler (CAC) - Pressure

Testing (10-08) _ _ /D*
+
To check the charge air cooler for cracked tubes or header, W
remove the inlet and outlet hoses from the CAC.
Remove the charge air cooler. Refer to the vehicle e
Install a cap over the outlet side of the CAC. Install a @@A
pressure gauge, arr supply, and arr pressure regulator to the d,-
inlet side of the cooler.
A
Warning: To prevent possible injury if either plug blows
off during test, secure safety chains on the test plugs to
any convenient capscrew on the radiator assembly. This
test must be performed with securely fastened safety
chains.
0a9
Apply 207 kPa [30 psi] of air pressure to the cooler. Close
the air pressure regulator.
Monitor the pressure gauge and determine the rate of
pressure decay with a stop watch.
If the pressure decay is 49 kPa [7 psi] or less in 15 seconds,
the cooler is okey. If the pressure drop is greater than 49
kPa [7 psi] in 15 seconds, check all connections again.
Determine if pressure decay is caused by a leak in the CAC
or from a leaky connection. Use a spray bottle filled with
soapy water applied to all hose connections, and watch for
bubbles to appear at the location of the leak.
If the pressure decay is caused by a leaky connection, repair

the connection and repeat the test. If the leak is within the
CAC, repeat the test to verify the accuracy of the pressure
delay measurement. Similar pressure decay readings must
be obtained at least three consecutive tests before the
reading can be considered accurate.
Charge Air Cooler (CAC) - Pressure Testing (10-08) Air Intake System - Group 10
Page lo-14
If the pressure drop is greater than 49 kPa [7 psi] in 15

seconds, the CAC must be replaced.
Refer to the manufacturer’s repair manual for replacement
instructions.
NOTE: Charge air coolers are not designed to be 100% leak
free. If the pressure decay is less than 49 kPa [7 psi] in 15
seconds, than the CAC does not need to be replaced.
Exhaust System - Group 11
Page 11-1
Exhaust System - Group 11

Section Contents
Page
Exhaust Manifold - Cleaning and Inspection for Reuse .............................. 11-4

Cleaning . . . . . ......................................................... 11-4
Inspection . . . . ......................................................... 11-4
Exhaust Manifold - Exploded View ............................................. 11-2
Exhaust Manifold Outlet Connection - Cleaning and Inspection for Reuse ................. 11-6
Cleaning . . . . . ......................................................... 11-6
Inspection . . . . ......................................................... 11-6
Exhaust Manifold Turbocharger Mounting Stud - Replacement ......................... 11-5

Inspection . . . . ......................................................... 11-5
Installation . . . ......................................................... 11-5
Removal . . . . . ......................................................... 11-5
Exhaust System - General Information .......................................... 113

Exhaust Manifold ........................................................ 113
Exhaust Manifold - Exploded View Exhaust System - Group 11
Page 11-2
Exhaust Manifold - Exploded View
Ref. No. Part Name QtY

1 Brace, Exhaust Outlet Connection 1
2 Screw, Hex Head Cap 4
3 Connection, Exhaust Outlet 1
4 Clamp, V Band 1
5 Pipe, Plug 1
6 Gasket, Turbocharger 1
7 Stud 4
8 Nut 4
9 Manifold, Exhaust 1
10 Screw, Hex Head Cap 12
11 Gasket, Manifold 6
12 Lockplate 12
Exhaust System - Group 11 Exhaust System - General Information
Page 11-3
Exhaust System - General Information

The exhaust system group consists of the exhaust manifold, turbocharger mounting studs, and exhaust outlet connection.
Any repairs relating to the exhaust pipe or muffler should be directed to the original equipment manufacturer.
Exhaust Manifold
The engine uses a “pulse-type” exhaust manifold with a divided turbocharger entry passage (exhaust manifold outlet).
The naturally aspirated engine uses the same manifold for parts commonality.
Exhaust Manifold - Cleaning and Inspection for Reuse (11-01) Exhaust System - Group 11
‘age 11-4
Exhaust Manifold - Cleaning and

Inspection for Reuse (1 I-01)
Cleaning
Use a wire brush or 240 grit emery cloth to remove the carbon
from the gasket sealing surfaces.

LJ
B Use steam to clean the manifold. Dry with compressed air.
xm9OOeb
Inspection
0
Ia3 Visually inspect the manifold for cracks or damage.
Visually inspect the turbocharger
damaged threads.
mounting stud holes for
Replace the manifold, if damaged.
Place a straight edge across the exhaust ports.

0
6iB Inspect the mounting surfaces for flatness.
If these surfaces are not within the flatness specifications,
CB replace the manifold.
Exhaust Manifold Mounting Surface Flatness

mm in.
0.20 MAX 0.008
Turbocharger Mounting Flange Flatness
mm in.
0.13 MAX 0.005
Exhaust Svstem - Group 11 Exhaust Manifold Turbocharger Mounting Stud - Replacement (11-02)
Page 11-5
Exhaust Manifold Turbocharger Mounting

Stud - Replacement (1 I-02)
Removal
Apply penetrating oil to the base of the turbocharger
mounting stud to be removed. Follow the manufacturer’s
instructions.
xm900v
Use a standard stud extractor or two nuts locked together to

remove the turbocharger mounting stud(s) from the manifold. c%4
xm900ma
Inspection
Visually inspect for damaged
mounting stud holes.
threads in the
Visually inspect the manifold for cracks or damage.

turbocharger
0at3
xm900sb
Installation
Use precoated turbocharger mounting studs or apply a thin
coating of nickel based, high temperature, anti-seize
compound to the coarse threads of the stud.
Install the studs in the mounting flange.
Use two mounting nuts locked together to tighten the studs.
Exhaust Manifold Outlet Connection - Cleaning and Inspection for Reuse (11-03) Exhaust System - Group 11
Page 11-6
Exhaust Manifold Outlet Connection -

Cleaning and Inspection for Reuse
(1 I-03)
Cleaning
aB
Use a wire brush to remove carbon
mounting grooves.
from the v-band

clamp

A cause serious personal injury.
a\ Use steam to clean the outlet connection.

air.
Dry with compressed
Inspection
0@B Visually inspect the outlet connection for cracks or damage to

the mounting surface or clamp grooves. Replace any part that
is cracked or damaged.
Air Equipment - Group 12
614 Series Page 12-1
Air Equipment - Group 12
For air equipment service information see chassis shop manual.

Electrical Equipment - Group 13
614 Series Page 13-1
Electrical Equipment - Group 13
For electrical equipment service information see chassis shop manual.

Engine Testing - Group 14
Page 14-1

Section Contents
Page
Blowby Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Engine Dynamometer Test - Engine Run-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
Engine Dynamometer Test - installation of the Engine ................................. 14-9
Engine Dynamometer Test - Performance Checking ................................. 14-21
Engine Painting ........................................................... 14-26
Engine Run-In Procedure - “In-Chassis” ......................................... 14-24
Engine Run-In - General Procedures ............................................. 14-6
Engine Storage - Long Term .................................................. 14-29

Engine Removal from Long Term Storage ........................................ 14-32
Engine Storage - Short Term ................................................. 14-27

Engine Removal From Short Term Storage ........................................ 14-29
Engine Testing - Component Identification and Diagrams .............................. 14-3
Engine Testing - General Information ............................................. 14-5

Engine Dynamometer Run-in .................................................. 14-5
In-Chassis Run-In .......................................................... 14-5
Engine Testing - General Specifications ........................................... 14-6
Engine Testing - Service Tools ................................................. 14-2
Fuel Injection Pump - Idle Speed Adjustment ...................................... 14-25

RSV Governor ........................................................... 14-25
RQV and RQVK Governor ................................................... 14-26
General Engine Test Procedure - In Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-23

Engine Testing - Service Tools Engine Testing - Component Identification and Diagrams - Group 14
Page 142
Engine Testing - Service Tools
Tool No.
____ __-- Tool Descrhtion Tool Illustration
Check the fuel filter restriction during the engine performance

test. Hose adapter, Part No. ST-434-2 and vacuum gauge, Part
No. ST-434-12, are used to perform the test.
Used with the blowby check tool to measure engine crankcase
Used to measure the engine intake manifold pressure.
Pressure Gauge (O-160 psi)
Used to measure lubricating oil pressure.
Used to measure engine speed (RPM).
Used with manometer, Part No. ST-l 11 l-3, to measure the

engine crankcase pressure.
Engine Testing - Group 14 Engine Testing - Component Identification and Diagrams
Page 14-3
Engine Testing - Component Identification and Diagrams

The following illustrations contain information about engine components, filter locations, drain points and access locations
for instrumentation and engine controls.
The information and configuration of components shown in these illustrations are of a general nature. Some component
locations will vary depending on applications and installations.
High Pressure
X[inch]NPTF (Air)
Fuel Lines
Front Lifting M22 x 1.50 (Air)

Bracket Rear Lifting
) Bracket
Fuel
Injection -
Vi x lG[inch]UNF
Tan for Maanetic
Pick-up -
Air
Compressor I
Mounting Bracket
Fuel Pump Side View

Engine Testing - Component Identification and Diagrams Engine Testing - Group 14
Page 14-4
Wastegate Actuator
Turbocharger Water Outlet
Exhaust Outlet Connection
Lubricating Oil
Lubricating Oil
Provision for
Coolant Heater
Provision for
Pressure (before
Cab Heater
Turbocharger
Oil Drain
Temperature !%f9Sor

Engine Testing - Group 14 Engine Testing - General Information
Page 14-5
Engine Testing - General Information

This section outlines engine testing and engine run-in recommendations for 6D114E-1 Series engines. Ail engines must
be run-in after a rebuild or a repair involving the replacement of one or more piston ring sets, cylinder liners or cylinder
kiiS.
A Caution: Incorrect or insufficient break-in of the piston rings will lead to early oil consumption or high
blowby complaints. Adherence to these run-in guidelines will allow the full durability of new rings to be
realized.
The engine test is a combination of an engine run-in and a performance check. The engine run-in procedure provides
an operating period that allows the engine parts to achieve a final finish and fit. The performance check provides an
opportunity to perform final adjustments needed to optimize the engine performance.
An engine test can be performed by using either an engine dynamometer or a chassis dynamometer. If a dynamometer
is not available, an engine test must be performed in a manner that simulates a dynamometer test.
Check the dynamometer before beginning the test. The dynamometer must have the capability to test the performance
of the engine when the engine is operating at the maximum RPM and horsepower range (full power).
Before running the engine, make sure the engine is filled with the proper coolant and the lubricating oil system is filled
and primed.
The engine crankcase pressure, often referred to as engine blowby, is an important factor that indicates when the piston
rings have achieved the correct finish and fit. Rapid changes of blowby or values that exceed specification more than 50
percent indicate that something is wrong. The engine test must be discontinued until the cause has been determined and
corrected.
In-Chassis Run-In
The majority of heavy duty diesel applications will provide sufficient run-in under normal loaded operations. However, light
load/high speed operation must be avoided during the run-in period. The following in-chassis run-in guidelines are
recommended for 6D114E-1 Series engines after a repair involving replacement of one or more of the piston ring sets,
cylinder liners, or cylinder kits where engine or chassis dynamometer or load bank run-in cannot be performed.
SRT 14-704, Engine - Run-in and Test (in-Chassis), provides time for in-chassis run-in when there is no other way to
perform the run-in (chassis dynamometer, load bank or portable dynamometer) and the engine will be applied in a high
speed or low load operation immediately after the engine is returned to service.
Engine Dynamometer Run-in

This is the preferred method of run-in for engines that have been rebuilt out-of-chassis. It is not practical, nor
recommended, that an engine be removed from the application to conduct the run-in after a rebuild or cylinder repair has
been performed in-chassis. SRT 14-701, Engine - Run-In and Test (Engine Dynamometer) provides the time for this work.
There is no requirement, nor is it recommended for an engine that has been run-in and tested on an engine dynamometer
to be run-in again after it has been reinstalled in the vehicle or equipment.
Engine Testing - General Specifications Engine Testing - Group 14
Page 14-6
Engine Testing - General Specifications

NOTE: Due to variations in ratings of different engine models, refer to the specific engine data sheet for the particular
engine model being tested.
Maintain the following limits during an engine run-in on a dynamometer:
Intake Restriction: (Maximum)

l Clean Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 mm H,O [15 in. H,O]
l Dirty Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635 mm H,O [25 in. H,O]
Air Inlet Temperature (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38” C [loo” F]
Exhaust Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700” C [1290” F]
Exhaust Back Pressure: EPA Certified (Maximum) .............................. 114 mm Hg [4.5 in Hg]
Smoke:
l Bosch Smoke Meter (Maximum) ............................................... 2.5 Units
l Celesco Smoke Meter (Maximum) ............................................ 4% Opacity
Coolant Temperature (Maximum) ............................................... 100°C 1212” F]
Lubricating Oil Temperature (Maximum) ......................................... 126.6“ C 1260” F]
Lubricating Oil Pressure:

l Low Idle (Minimum Allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa [lo psi]
l Rated Speed (Minimum Allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 kPa [30 psi]
Fuel Filter Restriction - Dirty Filter (Maximum) . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . 35 kPa [5 psi]
Fuel Return Restriction (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 mm Hg [20.4 in. Hg]
*New (L/Min) *Used (L/Min)

Blowby: All engines 164 226
* Blowby checking tool, Part No. 3822566, has a special 7.67 mm [0.302 in] orifice that must be used to obtain an
accurate reading.
Refer to the blowby conversion chart on the following page to convert liters/minute into inches/water.
Engine Testing - Group 14 Blowby Measurement
Page 14-7
Blowby Measurement
Blowby is generally recorded in liters/minute.
Install the Part No. 3822566, Engine Blowby Tool, to the
crankcase breather tube in the valve cover.
Install a water manometer to the engine blowby tool.
Use the Blowby Conversion Chart to convert the manometer
reading to liters/minute.
NOTE: A pressure gauge can be used to record the engine
blowby.
Minimum Gauge Capacity: 1270 mm Ha0 [50 in H,O]
Blowby Conversion Chart (7.67 mm

[0.302in]) Orifice
Inches of
Liters/Minute
Water
1 50
2 84
3 103
4 119
5 133
6 145
7 155
8 164
9 172
10 180
11 187
12 193
13 200
14 206
15 211
16 217
17 222
18 226
19 229
20 235
21 239
22 242
23 246
24 248
Engine Run-In - General Procedures Engine Testing - Group 14
Page 148
Engine Run-In - General Procedures
A
Caution: Refer to Engine Test - General Specifications, page
14-6, before operating the engine to avoid internal
component damage.
Caution: The lubricating oil system must be pressurized
;n
before operating the engine to avoid internal component
damage.
NOTE: The amount of time specified for the following engine
run-in phases are minimums.
The engine can be operated for longer periods of time at each
operating range or phase with the exception of engine idling
which must be kept to 10 minutes or less.
0
Start the engine and idle for initial check.
a3 NOTE: Avoid long idle periods. Operate the engine at low idle
only long enough (10 minutes maximum) to check for correct
oil pressure and any fuel, oil, water, or air leaks.
NOTE: Do not operate the engine at idle speed longer than
specified during engine run-in. Excessive carbon formation will
occur and cause damage to the engine.
0
NOTE: To avoid internal component damage, do not allow the
6B engine speed to exceed 1,000 RPM before run-in.
While the engine is idling, listen for unusual noises; watch for
0
aI3 coolant, fuel, and lubricating oil leaks; and check for correct
engine operation in general.
NOTE: Repair all leaks or component problems before
continuing the engine run-in.
Engine Testing - Group 14 Engine Dynamometer Test - Installation of the Engine (14-01)
Page 14-9
Caution: Do not shut off the engine immediately after the

run-in is completed. Allow the engine to cool by
operating at low idle for a minimum of 3 minutes to avoid
internal component damage.
A
Caution: On engines equipped with a wet clutch flywheel

housing, it will be necessary to replace the rear
crankshaft oil seal after engine testing. If the engine is
operated with a dry housing, the wet clutch oil seal will
A
be destroyed.
Engine Dynamometer Test - Installation

of the Engine (14-01)
Use engine lifting fixture, Part No. 3822512, to install the e
engine to the test stand. Align and connect the
dynamometer. Refer to the manufacturer’s instructions for
aligning and testing the engine.
NOTE: Make sure the dynamometer capacity is sufficient to
permit testing at 100 percent of the engine rated horsepower.
If the capacity is not enough, the testing procedure must be
modified to match the restrictions of the dynamometer.
Install the coolant temperature sensor.

Minimum Gauge Capacity: 107°C [225”F]
Engine Dynamometer Test - Installation of the Engine (14-01) Engine Testing - Group 14
Page 1410
Connect the coolant supply to the water inlet connection (1).

Connect the coolant return to the water outlet connection (2).
Install the drain plugs, close all the water drain cocks, and
make sure all the clamps and fiiings are tight.
Connect the vent tube to the vent connection on the thermostat
housing.
Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill (or expansion) tank.
inspect the engine for coolant leaks at connections, fiiings,

plates, and plugs. Repair as necessary.
Page 14-11
The intake air piping must be plumbed through *an @@(I

aftercooler to control the temperature of the Intake air during 4~
the run-in procedure. Rig an aftercooler beside the engine,
and plumb the intake pipes from the turbocharger, through
the aftercooler and back to the intake manifold.
Use a temperature gauge (1) to measure the intake manifold
temperature.
NOTE: Maintain the intake manifold air temperature at 66°C
[150” F] or below during the dynamometer testing or run-in; if
manifold temperature exceeds this limit, terminate the test
and idle the engine to let it cool down. Do not idle more
than 10 minutes. Testing can resume when the intake air
temperature can be maintained below 66°C [15O”F]. Under
no circumstances is the intake manifold air temperature
allowed to exceed 77” C [17O”F].
Connect a water manometer to the turbocharger air inlet pipe @A
to test air restriction.
4V
NOTE: A vacuum gauge can be used in place of the water
manometer.
Minimum Gauge Capacity: 760 mm H,O [30 in. H,O]
Connect a *mercury manometer to a straight section of the @$A

exhaust prprng near the turbocharger outlet to check exhaust 4~
restriction.
NOTE: A pressure gauge can be used in place of the
mercury manometer.
Minimum Gauge Capacity: 254 mm Hg [lo in. Hg]
Remove the pipe plug from the bottom of the oil cooler and
install the lubricating oil temperature sensor.
Minimum Gauge Capacity: 150°C [3OO”F]
Engine Dynamometer Test - Installation of the Engine (1401) Engine Testing - Group 14
Page 14-12
Attach the lubricating oil pressure sensor to the main oil rifle
drilling in the cylinder block.
Minimum Gauge Capacity: 1034 kPa [150 psi]
Caution: To avoid internal component damage, the
A lubricating oil system must be pressurized before operating

the engine after any internal engine repairs or extended
engine storage (beyond 6 months).
g@
+*
OB
To pressurize the system using external pressure, connect the
supply to the lower pipe plug hole in the upper part of the oil
cooler cover as illustrated.
Use a pump capable of supplying 210 kPa [30 psi] continuous

pressure.
Use clean 15W-40 engine oil to pressurize the system until the
oil pressure registers on the gauge.
Remove the oil supply tube, and install the plug.
Make sure the lubricating oil has had time to drain to the pan
and fill the engine to the “High” mark as measured on the
dipstick.
NOTE: If the dipstick is new, it must be correctly calibrated.
Refer to Lubricating Oil Dipstick - Calibration (7-07).
op900wr
Engine Testing - Group 14 Engine Dynamometer Test - Installation of the Engine (M-01)
Page 14-13
If an external pressure pump is not available, pressurize the

lubricating system according to the following procedure:
Fill the engine with oil to the “High” level mark on the
dipstick.
Disconnect the turbocharger lubricating oil supply tube.

Pour 50 cc to 60 cc [2.0 fl. oz. to 3.0 fl. oz.] of clean
15W-40 engine oil into the turbocharger oil supply hole.
Connect the oil supply tube to the turbocharger.
Remove the lubricating oil filter and fill with clean 15W-40
engine oil.
Screw the filter onto the filter head fitting until the gasket
contacts the filter head surface.
Use oil filter wrench, Part No. 3375049, to tighten the filters
an additional 3/4 to 1 turn.
Make sure the fuel is shut off by removing the wire from the
fuel solenoid or the mechanical fuel shutoff is in the “OFF”
position. This is necessary to prevent the engine from
starting during the oil rifle pressure charging operation.
Engine Dynamometer Test - Installation of the Engine (1401) Engine Testing - Group 14
Page 14-14
Caution: Do not crank the starting motor for periods longer

than 30 seconds. Excessive heat will damage the starting
motor.
Crank the engine until the oil pressure gauge indicates system
pressure.
NOTE: Allow 2 minutes between the 30-second cranking
periods so the starting motor can cool.
NOTE: If pressure is not indicated, find and correct the
problem before continuing.
Allow the lubricating oil to drain into the oil pan, and measure
the oil level with the dipstick.
Add oil as necessary to bring the level to the “High” level
mark.
%
q
Lubricate the gasket on the fuel filter with clean 15W-40 engine
oil.
Fill the fuel filter with clean No. 2 diesel fuel.
Caution: To prevent air leaks, make sure the filter is
A installed tightly but not over-tightened. Mechanical over-

tightening can distort the threads or damage the filter
element seal.
Install the filter as specified by the filter manufacturer. If there
are no instructions, refer to the following guidelines.
Screw the fuel filter onto the filter head until the gasket
contacts the filter head surface.
Tighten the filter an additional l/2 to 3/4 turn.
+ Vi to 3/ Turn
Page 14-15
8mm
NOTE: Manual venting is required if the fuel filter is not RI
property filled prior to installation.
Open the vent screw.
Operate the plunger on the fuel transfer pump until the fuel
flowing from the Wing is free of air.
Tighten the vent screw.
Check the voltage rating on the fuel pump solenoid before

connecting the electrical wires to it. Make sure the voltage o
supply matches that of the fuel pump solenoid. @
Attach the throttle control rod onto the fuel pump throttle @&A
lever. +*
To determine the amount of turbocharger boost, remove the

l/4 inch pipe plug in the cylinder head and install the intake l
@
manifold pressure sensor or pressure gauge, Part No.
ST-1 273.
Minimum Gauge Capacity: 1905 mm Hg I75 in. Hg]
Checking Tool, Part No. 3822566

For accurate engine crankcase blowby measurement, insert RI
blowby checking tool, Part No. 3822566, in the crankcase
breather vent. W&
@@
Connect a water manometer to the blowby tool. A pressure
gauge can be used in place of the manometer.
Minimum Gauge Capacity: 1270 mm H,O [50 in. HsO]
Engine Dynamometer Test - Installation of the Engine (14-01) Engine Testing - Group 14
Page 14-16
To measure fuel filter restriction, connect vacuum gauge, Part

No. ST-434, to the fuel transfer pump inlet line.
Minimum Gauge Capacity: 760 mm Hg (30 in. Hg]
ON
To be able to unload the compressor, connect a source of

compressed air to the unloader (1). This air line must contain
a valve between the source and the unloader.
NOTE: All air compressors must be loaded during engine
run-in. All air compressors must be unloaded during the
engine performance check.
NOTE: The compressed air load in the accompanying
illustration must be attached to the air compressor outlet (2).
To provide a load on the air compressor, connect an air tank

to the compressor outlet (2), using steel tubing or a high
temperature hose (1).
Install an air regulator (3) that can maintain tank air pressure of
345 kPa to 517 kPa [50 psi to 75 psi] at both the minimum
and the maximum engine speed.
Hose Temperature (Minimum): 260”C [500”F]
Check the voltage rating on the starting motor before installing

the electrical wiring.
Attach electrical wires to the starting motor and the batteries,
if used.
NOTE: If another method of starting the engine is used, follow
the manufacturer’s instructions to make the necessary
connections.
Engine Testing - Group 14 Engine Dynamometer Test - Engine Run-In (U-02)
Page 14-17
Engine Dynamometer Test - Engine

Run-In (14-02)
The engine run-in period allows the tester to detect assembly
errors and to make final adjustments needed for performance
that meets specifications.
0
@
NOTE: The amount of time specified for the following engine

run-in phases are minimums. Additional time can be used at
each phase except engine idle periods, if so desired.
Caution: On engines equipped with a wet clutch flywheel

housing, it will be necessary to replace the rear
crankshaft oil seal after engine testing. If the engine is
operated with a dry housing, the wet clutch oil seal will
A
be destroyed.
0@
Measurements from these indicators and gauges must be
observed closely during all phases of the engine run-in
period. Refer to page 14-6 for specifications and acceptable ~
readings.
Engine Speed Torque Oil Pres.
Coolant Out Lube Oil

Temp. Temp. B’owby eg8gasd
0a9
To correctly evaluate the engine performance, this additional
measurement must be observed during engine run-in phases.
Intake Manifold
Pressure
(Turbocharger Boost)
Engine Dynamometer Test - Engine Run-In (14-02) Engine Testing - Group 14
Page 14-18
It is a good practice to observe these measurements even if

engine performance meets specifications. If engine performance
does not meet specifications, these measurements can indicate
possible reasons for under-performance.
Fuel in Restriction Exh. Back Pres. Coolant

Pressure I
Air Inlet Restriction Fuel Drain Pres. oi9OOwi
Engine performance specifications and fuel system calibration

values are listed in the Engine Diagnostic Manual.
NOTE: Fuel pump calibration changes must be performed by
an authorized ADS shop.
A Caution: Do not crank the engine for more than 30

seconds. Excessive heat will damage the starting motor.
Crank the engine and observe the oil pressure when the engine
starts. If the engine fails to start within 30 seconds, allow the
starting motor to cool for 2 minutes before cranking the engine
again.
A Caution: If the lubricating oil pressure is not within

specifications, shut off the engine immediately. Either
excessively low or excessively high oil pressure will cause
engine damage.
Engine oil pressure must be between 69 kPa and 310 kPa [lo
0
eB psi and 45 psi] at 700 RPM.
Correct the problem if the oil pressure is not within

specifications.
Engine Testing - Group 14 Engine Dynamometer Test - Engine Run-In (14-02)
Page 14-19
Caution: Do not operate the engine at idle speed longer

than specified during engine run-in. Excessive carbon
formation will cause damage to the engine.
Operate the engine at approximately 700 RPM for 3 to 5
minutes.
NOTE: If the idle speed is incorrect, refer to Procedure 14-06
for adjustment information.
Listen for unusual noises; watch for coolant, fuel, and

lubricating oil leaks; and check for correct engine operation
in general.
NOTE: Repair all leaks or component problems before
continuing the engine run-in.
Move the throttle to obtain 1,200 RPM engine speed, and set
the test load to 25 percent of the rated load.
Operate the engine at this speed and load level until the
coolant temperature is 70°C [160°F]. Check all gauges and
record the data.
NOTE: Do not proceed to the next step until a steady
blowby reading is obtained.
Test Load
1 7o”c [I 60°F]
oi802vr
Open the throttle to the speed at which peak torque occurs,

and adjust the dynamometer load to 50 percent of rated
load. Operate the engine at this speed and load level for 2
minutes.
0a!3
Torque Peak
Check all gauges and record the data.
NOTE: Do not proceed to the next step until blowby is 2x (Test Load)
stable and within specifications. (50% Rated Load)
2 Minutes
oi804vh
Engine Dynamometer Test - Engine Run-In (14-02) Engine Testing - Group 14
Page 14-20
0
With the engine speed remaining at torque peak RPM, increase
aI9 the dynamometer load to 75 percent of rated load. Operate the
engine at this speed and load level for 2 minutes. Check all
gauges and record the data.
Torque Peak
NOTE: Do not proceed to the next step until blowby is stable
and within specifications.
3x (Test Load)
(75% Rated Load)
2 Minutes
oi804vi
Move the throttle lever to its fully opened position, and increase
the dynamometer load until the engine speed is at torque peak
RPM. Operate the engine at this speed and load level for 10
minutes or until the blowby becomes stable and within
Full Throttle specifications.
Torque Peak 4B Check all gauges and record the data.
0
Maximum Load
10 Minutes
oi804vj
Reduce the dynamometer load until the engine speed increases

to the engine’s rated RPM.
Operate the engine at rated RPM for 5 minutes.
Full Throttle
Rated
Maximum Load
0
@3
Check all gauges and record the data.
at Rated Speed
5 Minutes
oi804vk
Caution: Shutting off the engine immediately after operating

at full load will damage the turbocharger and internal
A components. Always allow the engine to cool before
shutting it off.
Remove the dynamometer load completely and operate the
engine at 700 RPM for 3 to 5 minutes. This period will allow the
turbocharger and other components to cool.
NOTE: If the idle speed is incorrect, refer to Procedure 14-06
for adjustment information.
Enaine Testing - Group 14 Engine Dynamometer Test - Performance Checking (14-03)
Page 14-21
Shut off the engine.
Make sure all instrumentation is removed before removing

the engine from the engine dynamometer.
Engine Dynamometer Test - Performance

Checking (1 a-03)
0@
Make sure the air compressor will be unloaded during the
performance check.
Apply regulated air pressure of 655 kPa [95 psi] to the air
compressor unloader (1).
A
Caution: Do not crank the engine for more than 30
seconds. Excessive heat will damage the starting motor.
Crank the engine and observe the oil pressure when the
engine starts. If the engine fails to start within 30 seconds,
allow the starting motor to cool for 2 minutes before
cranking the engine again.
Engine Dynamometer Test - Performance Checking (14-03) Engine Testing - Group 14
Page 14-22
Caution: If the lubricating oil pressure is not within
A specifications, shut off the engine immediately.

excessively low or excessively high oil pressure will
engine damage. Correct the problem if oil pressure
Either
cause
is not
within specifications.
Engine oil pressure must be between 69 kPa and 310 kPa [lo
psi and 45 psi] at approximately 700 RPM.
Make sure the engine is at operating temperature.

Move the throttle lever to the “FULL OPEN” position. Adjust the
dynamometer load until the engine maintains the rated RPM.
Allow the readings to stabilize. Read the horsepower.
Check all the gauges and record the readings.
NOTE: The horsepower reading will not be accurate if the
lubricating oil temperature and fuel temperature are not within
specifications.
Lubricating Oil Temperature: MIN WC [lWF]
0
Fuel Temperature: MAX 32°C [9O”F]
aB Check all gauges and record the data.
Caution: Do not shut off the engine immediately after it has

A been loaded. It must be allowed to sufficiently cool.
Remove the dynamometer load completely and operate the
engine at idle speed for 3 to 5 minutes. This will allow the
turbocharger and other components to cool.
Idle periods longer than 5 minutes are to be avoided.
Shut off the engine after the cool-down period.
I oi802vx
Engine Testing - Group 14 General Engine Test Procedure - In Chassis (14-04)
Page 14-23
NOTE: If the horsepower is below specifications, remove the

fuel pump and have the pump checked.
NOTE: The low idle speed is an external adjustment and can
be adjusted with the pump installed. Refer to Procedure e
14-06. All other adjustments, such as; no-air setting and
governor break speed are internal which requires pump
removal for adjustment.
Remove all test instrumentation. Remove the engine from the

dynamometer.
NOTE: If the engine is to be stored temporarily and does
not have permanent-type antifreeze, it is necessary to drain
all coolant. Drain locations are identified on the engine
diagrams, pages 14-3 and 14-4.
Prepare the engine for Engine Painting (14-07) or Engine
Storage (14-08) or (14-09).
General Engine Test Procedure - In

Chassis (14-04)
A
Caution: the following procedure assumes that the
lubricating oil and fuel systems were correctly primed, the
dipstick calibrated, and the engine filled to the correct
levels with oil and coolant during installation of the
engine into the chassis. If these systems were not
serviced during installation of the engine, refer to Engine
Dynamometer Test - Installation of the Engine (14-01) for
instructions on priming the lubricating oil and the fuel
systems and calibrating the dipstick. Refer to the machine
Operation and Maintenance Manual for instructions on
filling the lubricating oil and the cooling systems.
w SMOO8
The number of instruments and gauges required to perform a

test will vary according to the type and capability of the test
equipment used.
engine performance meets specifications. If engine
performance does not meet specifications, these Fuel In Restriction Fuel Temp. Exh. Back Pre
measurements can indicate possible reasons for poor
performance.
~~
Air Inlet Restriction Fuel Drain Pres.

1Also: Coolant Pressure SM0087
General Engine Test Procedure - In-Chassis (14-04) Engine Testing - Group 14
Page U-23-01
To correctly monitor an engine’s performance, record the

following parameters:
Lubricating oil pressure (vehicle instrument panel)
Coolant temperature (vehicle instrument panel)
Coolant pressure
Intake manifold pressure
Inlet air restriction
Blowby
Engine speed (RPM) (vehicle instrument panel)
Wheel horsepower (WHP) (dynamometer controls)
Coolant Pressure
Measure the coolant pressure at the exhaust side of the
cylinder block.
Fuel Inlet Restriction

Measure the fuel inlet restriction. Install a vacuum gauge, Part
No. ST-434, to the fuel transfer pump inlet line.
Minimum Gauge Capacity: 760 mm Hg [30 in Hg]
Charge Air Cooler Restriction

Measure the intake pressure drop across the charge air cooler.
This test can be done with a mercury manometer or two
separate gauges, Part No. ST-1273. If two gauges are being
used, calibrate both gauges on a common pressure source at
206 kPa (30 psi] to ensure consistency.
Install one pressure gauge, Part No. ST-1273, in the fitting in
the turbocharger compressor outlet elbow. Install the other
pressure gauge in the fitting in the intake manifold.
Observe the reading on the gauges. Pressure drop must not
be greater than: 102 mm Hg 4.0 in Hg]
SMcml
21 kPa I3.0 PSI]
Engine Testing - Group 14 General Engine Test Procedures - In Chassis (14-04)
Page 14-23-02
NOTE: When measuring the pressure drop, operate the

dynamometer at the RPM that delivers the maximum horse- MaximumHP RPM
power of engines tested. Engine speed will be 1600 - 1700
RPM on most engines.
Lubricating Oil Pressure

Use pressure gauge, Part No. 3375275, to measure
lubricating oil pressure.
Install the pressure gauge into the main oil rifle and observe
the oil pressure.
l Low idle (minimum allowable) 69 kPa [lo psi]
l At rated speed (minimum allowable) 207 kPa [30 psi]
Intake Manifold Pressure

Measure the intake manifold pressure (turbocharger boost).
Install a pressure gauge, Part No. ST-1273, in the location
shown.
Minimum Gauge Capacity: 1905 mm Hg [75 in Hg]
Intake Air Restriction

Connect a water manometer to the turbocharger air inlet pipe
NOTE: The manometer connection must be installed at a 90
degree angle to the air flow in a straight section of pipe, one
pipe diameter before the turbocharger.
manometer.
Minimum Gauge Capacity: 760 mm H,O [30 in H,O]
General Engine Test Procedures - In Chassis (14-04) Engine Testing - Group 14
Page 14-23-03
Crankcase Gases (Blowby)

Measure the blowby by installing blowby checking tool, Part
No. 3822566, in the crankcase breather vent. Connect the
blowby tool to a water manometer. refer to page 14-7 for
blowby specifications.
NOTE: Excessive blowby indicates an engine internal
components malfunction or a turbocharger malfunction,
allowing combustion gases to enter the crankcase.
NOTE: If a sudden increase in blowby occurs, or if blowby

exceeds the maximum allowable limit during any run-in step,
return to the previous step and continue the run-in. If blowby
does not reach an acceptable level, discontinue the run-in and
determine the cause.
NOTE: Avoid long idle periods. Operate the engine at low idle
only long enough (3 to 5 minutes) to check for correct oil
pressure and any fuel, oil, water or air leaks.
Caution: Do not allow the engine speed to exceed 1000

RPM before run-in. The internal components can be
damaged.
Engine Testing - Group 14 General Engine Test Procedure - In Chassis (14-04)
Page 14-23-04

last step of the run-in is completed. Allow the engine to
cool by operating at low idle for a minimum of 3 minutes
to avoid internal component damage.
Engine Run-In Procedure - “In-Chassis” (14-05) Engine Testing - Group 14
Page 14-24
Engine Run-In Procedure - “In-Chassis”

(14-05)
A Caution: Refer to - General Engine Test Procedures - In

Chassis (14-04) before operating the engine to avoid
internal component damage.
Operate the engine as follows during the first 3 hours after
rebuild:
1. Do not idle the engine for more than 5 minutes at any

one time.
2. Operate the engine at 75 percent throttle while loaded.
Hours Hours
Hours Hours 0ilOOvy
3. Do not operate the engine at rated speed (RPM) and full

load for more than 5 minutes at any one time.
N
iours Hours
Change the lubricating oil and filter after 800 km (500 miles] or
20 hours of operation. Refer to the Operation and Maintenance
Manual.
Engine Testing - Group 14 Fuel Injection Pump - Idle Speed Adjustment (M-06)
Page 14-25
Fuel Injection Pump - Idle Speed

Adjustment (14-06)
RSV Governor
Idle adjustment for industrial engines requires the setting of
both the low idle screw (1) and the bumper spring screw (2)
on the fuel injection pump.
1
19 mm, Screwdriver, Tachometer
First, loosen the locknut and back out the bumper spring
screw on the fuel injection pump until there is no change in
engine speed.
The speed should drop 20-30 RPM as the bumper spring
screw is backed out.
fP9000~
13 mm, Screwdriver, Tachometer

Loosen the locknut and adjust the low idle screw to 2030
RPM less than the desired speed. Turn the low idle screw
counterclockwise to decrease RPM; clockwise to increase
RPM. Tighten the low idle screw locknut.
Turn the bumper spring screw clockwise until the desired

idle speed is obtained. Tighten the bumper spring screw
locknut.
Engine Painting (14-07) Engine Testing - Group 14
Page 14-26
RQV and RQVK Governor

10 mm, Screwdriver and Tachometer
Low idle adjustment on automotive fuel injection pumps
requires setting of the low idle stop screw.
Loosen the low idle screw locknut and turn the low idle screw
counterclockwise to raise the RPM; clockwise to decrease the
RPM. Tighten the low idle screw locknut.
0@h Torque Value: 8 Nom [72 in-lb]
Engine Painting (14-07)
c% 0
Remove all belts from the engine.
Cover the following
tape:
parts of the engine with plastic caps or
l Exhaust and intake openings

l Electrical components
l Fuel inlet and drain connections
l Any exposed fittings, threads, and electrical wire
terminals

q
B Use steam to clean the engine. Dry with compressed
NOTE: Make sure all engine surfaces are clean and dry before
air.
painting the engine.
Protect the following components from the paint:

. All data plates; engine, turbocharger and fuel pump
l Exhaust manifold
l Turbocharger turbine housing
l Flywheel
l Flywheel housing transmission mounting surface
Engine Testing - Group 14 Engine Storage - Short Term (1408)
Page 14-27
Paint the engine.
Engine Storage - Short Term (14-08)

NOTE: This procedure describes the correct method for
preparing an engine for short-term (1 to 6 months) storage.
Be sure the cooling system and lubricating oil system are
properly filled.
Operate the engine at high idle until the coolant temperature
reaches 70” C [ 160” F] .
Shut off the engine. High Idle
Remove the fuel tube to the engine fuel filter (1) and the
injector fuel return tube (2).
NOTE: Fuel system preservative oil must meet Federal
Specification W-L43OOC. (Example: Daubert Chemical
NoxRust No. 518).
Fill two containers, one with diesel fuel and the other with
the preservative oil. Put both fuel tubes into the container of
diesel fuel.
Start the engine and run until it is operating smoothly, then

put the fuel supply tube into the container of preservative oil.
Remove the injector return tube from the diesel fuel
container. When preservative oil flows from the tube, shut off
the engine.
Connect the fuel supply tube to the fuel filter, and put a cap
on all other fuel tubes.
Engine Storage - Short Term (14-08) Engine Testing - Grow 14
Page 14-28
Drain the lubricating oil pan, oil filters, and fuel filter.
Install the drain plug into the oil pan, and install new filters.
Tighten according to specifications.
Disconnect the electrical wires from the fuel pump solenoid.
Drain the coolant passages and jackets.

NOTE: It is not necessary to drain the coolant if it is a
permanent-type antifreeze with a rust inhibitor. Do not drain the
coolant if the engine is installed in a vehicle.
Visually check the engine and cover all openings with tape to
prevent dirt and moisture from entering.
Install a WARNING tag which alerts others of no oil in the
engine and that it must not be started.
Engine Testing - Group 14 Engine Storage - Long Term (14-09)
Page 1429
Store the engine in a dry area of even temperature.

NOVEMBER
Rotate the crankshaft two to three revolutions every 3 to 4
weeks by using the engine barring tool, Part No. 3377371, to SMTWTFS
rotate the crankshaft.
Engine Removal From Short Term Storage

Remove the
WARNING tag.
tape from all openings and remove
Refill the oil filters with clean 15W-40 engine oil, and
the
c%
0
pressurize the lubrication system. Refer to Engine
Dynamometer Test - Engine Run-in (14-02).
Use clean No. 2 diesel fuel to flush the preservative oil from
the fuel system, and fill the fuel filters again.
Connect the electrical wiring to the fuel pump solenoid. e

Prime and vent the fuel system. Refer to page 14-15.
Engine Storage - Long Term (14-09)

This procedure describes the correct method of preparing an
engine for long-term (6 to 24 months) storage.
If the engine has been stored for 24 months, the cooling
system must be flushed with a solvent. Repeat the flushing
procedure a second time.
Engine Storage - Long Term (14-09)
Page 1430
Be sure the cooling system and lubricating oil system are
properly filled.
Operate the engine at the high idle throttle position until the
coolant temperature is 70°C [16O”F].
High Idle 7o”c

[160°F]
oi803vs
Drain the lubricating oil pan. Install the drain plug, and fill the
oil pan to the “High” level mark on the dipstick with
preservative oil.
NOTE: Lubricating system preservative oil must meet Military
Specification MIL-L-21260 Type E30-1 SAE 30. (Example: Shell
66202).
Disconnect the fuel supply tube at the fuel filter (1) and the
injector fuel return tube (2).
NOTE: Fuel system preservative oil must meet Federal
Specification W-L-8OOC. (Example: Dauber-t Chemical NoxRust
No. 518).
Fill two containers, one with diesel fuel and the other with
preservative oil. Put both fuel tubes into the container of diesel
fuel.
Start the engine and run until it is operating smoothly, then put
the fuel supply tube into the container of presen/ative oil.
Remove the injector return tube from the diesel fuel container.
When the preservative oil flows from the tube, shut off the
engine.
Connect the fuel supply tube to the fuel filter, and put a cap on
the ends of all the other fuel tubes.
Engine Testing - Group 14 Engine Storage - Long Term (W-09)
Page 14-31
Drain the preservative oil from the lubricating oil pan and oil
filters. Install the drain plug. Tighten according to
specifications.
Drain and flush the cooling system, using a water-soluble
rust inhibitor.
Remove the aftercooler assembly and the exhaust manifold.

Refer to Engine Disassembly (00-01).
Spray preservative oil into the intake and exhaust ports of
the cylinder head and into the aftercooler housing and the
exhaust manifold.
Install the aftercooler assembly and exhaust manifold. Refer
to Engine Assembly (00-02).
Remove the valve cover, and spray the rocker levers, valve
springs, valve stems, valve guides, and push rods with
preservative oil. Install the valve cover.
Spray preservative oil into the intake port of the air @
compressor and on all exposed metal surfaces that are not a~@
painted.
NOTE: Use a preservative compound that meets Military
Specification MIL-C-16137C Type P-2 Grade 1 or 2.
Cover all openings with heavy paper and tape to prevent

entrance of dirt and moisture.
Put a WARNING tag on the engine which contains the
following information:
l Date the engine was prepared for storage.
l Crankshaft must not be rotated.
l Coolant has been drained.
l Engine must not be operated.
Store the engine in a dry area of even temperature.
Engine Storage - Long Term (14-09) Engine Testing - Group 14
Page 1432
Engine Removal from Long Term Storage

Remove the paper and the tape from all openings.
Remove the WARNING tag.
Flush the fuel system with clean diesel fuel to remove

preservative oil.
II In ‘-I
oi901
wk
Rotate the water pump to make sure it has not rusted in place.
Rotate the crankshaft two complete revolutions to make sure

the piston rings are free and no foreign objects are in the
engine.
Engine Testing - Group 14 Engine Storage - Long Term (14-09)
Page 14-33
Remove the intake manifold cover or aftercooler and visually

inspect the lower valve stem area for presence of rust. An Q
C%
accumulation of rust requires disassembly and rebuild of the
cylinder head.
Install all drive belts.
Remove a plug from the main oil rifle drilling and flush the
preservative oil from the engine by pumping 3.8 liters [l.O
gallon] of light mineral oil into the oil rifle. Rotate the
crankshaft three or four revolutions as the engine is being
flushed. Install the plug.
Remove the oil drain plug and allow the mineral oil to drain
from the engine. 0
C%
0pSpxma
Engine Storage - Long Term (14-09) Engine Testing - Group 14
Page 14-34
Remove the lubricating oil filter. Install a new filter according to

the manufacturer’s specifications.
Pressure fill the engine with 15W-40 lubricating oil through the
pipe plug hole on the top side of the oil cooler housing directly
below the turbocharger oil supply connection. Use 207 kPa [30
psi] to pressure fill the system with a minimum of 3.6 liters [l
U.S. gal.].
Caution: Disconnect the fuel solenoid or position the shut

down lever in the “STOP” position to make sure the engine
does not start when the crankshaft is rotated.
Use the starter to rotate the engine for a maximum of 30
seconds, with two minute intervals, until oil pressure registers
on the lubricating oil gauge.
Fill the oil pan to the “High” mark on the dipstick.

Enaine Testing - Group 14 Engine Storage - Long Term (14-09)
Page 14-35
Install a new coolant filter. Fill the cooling system with a

mixture of 50% water and 50% ethylene-glycol type
antifreeze.
Adjust the valve clearance. Refer to Engine Assembly (00-02).
Tighten all capscrews, plugs and fittings as necessary. Refer

to the Specifications section.
instruments and Controls - Group 15
Page 151
Instruments and Controls - Group 15
For instruments and controls equipment service information see chassis shop manual.
Mounting Adaptations - Group 16
Page 161
Mounting Adaptations - Group 16

Section Contents
Page
Engine Support Bracket, Front - Cleaning and Inspection for Reuse ....................... 16-9
Cleaning ................................................................ 16-9
Inspection ............................................................... 16-9
Flexplate Assembly - Cleaning and Inspection for Reuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6
Flywheel - Cleaning and Inspection for Reuse ...................................... 16-5

Cleaning................................................................16- 5
Inspection ............................................................... 16-5
Flywheel Housing - Assembly (Wet Clutch Application) ................................ 16-6
Flywheel Housing - Cleaning and Inspection for Reuse ................................ 16-7

Cleaning................................................................16- 7
Inspection ............................................................... 16-7
Flywheel Ring Gear - Replacement .............................................. 16-6

Installation .............................................................. 16-6
Removal ................................................................ 16-6
Mounting Adaptations - Exploded View ........................................... 163
Mounting Adaptations - General Information ........................................ 16-4

Flywheel and Ring Gear ..................................................... 16-4
Flywheel Housing .......................................................... 16-4
Mounting Adaptations - Service Tools ............................................ 16-2

Mounting Adaptations - Service Tools Mounting Adaptations - Group 16
Page 16-2
Mounting Adaptations - Service Tools
Tool No. Tool Descrhtion

. Tool Illustration
Crack Detection Kii
This kii provides a convenient way to detect cracks in any

3375432 engine component.
Mounting Adaptations - Group 16 Mounting Adaptations - Exploded View
Page 16-3
Mounting Adaptations - Exploded View

1 Screw, Hexagon Head Cap 12 11 Gear, Flywheel Ring 1
2 Plug, Threaded 1 12 Screw, Hexagon Head Cap a
3 Housing, Flywheel 1 13 Washer, Plain 8
4 Plug, Pipe 1 14 Adapter, Crankshaft 1
5 Gasket, Cover Plate 1 15 Flexplate 1
6 Plate, Cover 1 16 Ring, Clamping 1
7 Screw, Self Tapping Metal 2 17 Screw, Hexagon Head Cap 8
8 Seal, O-ring 1 18 Support, Engine, Front 1
9 Plug, O-ring 1 19 Screw, Hexagon Head Cap 4
10 Flywheel 1
Mounting Adaptations - General Information Mounting Adaptations - Group 16
Page 16-4
Mounting Adaptations - General Information

The mounting adaptations group consists of the flywheel housing, flywheel, flywheel ring gear, pilot bearing, and the front
engine support.
Flywheel Housing
The flywheel housings are available in different sizes and styles for the various applications. Ring dowels are used to
locate the housing within 0.20 mm [O.OOS in] total indicated runout. Service housings are drilled for the dowels and
redowelling is not required. Check the appropriate parts book and the engine parts listing for the correct part number
for the engine application being serviced.
Flywheel and Ring Gear

The flywheel is available only as an assembly. The assembly includes the flywheel and the ring gear. The ring gear is
available for service replacement.
Mounting Adaptations - Group 16 Flywheel - Cleaning and Inspection for Reuse (16-01)
Page 16-5
Flywheel - Cleaning and Inspection for

Reuse (16-01)
Cleaning
Use a wire brush to clean the crankshaft pilot bore.
A
Use steam or solvent to clean the flywheel. Dry with
compressed air.
Inspection
Visually inspect for nicks or burrs.
Use Scotch-Brite@ 7448, or equivalent, to remove small nicks
and burrs.
0@B
I\
Crack Detection Kit, Part No. 3375432

Warning: Komatsu America Inational Company does not
recommend resurfacing of the flywheel. Resurfacing of
the flywheel can cause possible personal injury, property
damage, or cause the flywheel to be too thin and result A
0BB
in breakage.
Check the face of the flywheel at the clutch engagement
point for cracks or damage.
Use the crack detection kit, Part No. 3375432, to check for e
cracks in the flywheel. Follow the instructions provided with
the kit.
04i!3
Inspect the flywheel ring gear teeth for cracks and chips.
NOTE: If the ring gear teeth are cracked or broken, the ring
gear must be replaced. Refer to Procedure (16-03).
Flexplate Assembly - Cleaning and Inspection for Reuse (1602) Mounting Adaptations - Group 16
Page 16-6
Flexplate Assembly - Cleaning and

\
El Use solvent to clean the flexplate.
Check the ring gear for damaged or worn teeth. If the ring gear
0a3
is damaged or worn, it must be replaced. Refer to Procedure,
Flywheel Ring Gear - Replacement (16-03).
0
Use dye penetrant to check the crankshaft adapter for cracks.
aB There must not be any cracks in the crankshaft adapter.
Check the pilot on the crankshaft adapter for damage or wear.
If the pilot is worn, the flexplate must be replaced.
fw9adsa
Flywheel Ring Gear - Replacement

(16-03)
Removal
Caution: Do not use a cutting torch to heat the ring gear,
the flywheel can be damaged.
Heat the outside diameter of the ring gear with a heating torch.
Warning: Wear eye protection while driving the gear from
the flywheel.
Use a blunt chisel or brass drift and hammer to remove the
gear from the flywheel.
Installation
NOTE: Do not attempt to install the ring gear without heating
the ring gear first.
Use an oven to heat the new ring gear. Heat the ring gear for
0a!3
a minimum of 30 minutes in a preheated oven. Do not heat the
ring gear for more than 6 hours.
Temperature: 177°C [350” F]
NOTE: Do not exceed the specified time or temperature. The
@ metal hardness will be changed.
Mounting Adaptations - Group 16 Flywheel Housing - Cleaning and Inspection for Reuse (16-04)
Page 167
Caution: Wear protective gloves to prevent personal injury

NOTE: The gear must be installed so the bevel on the teeth
A
is toward the crankshaft side of the flywheel.
Remove the gear from the oven, and install it on the flywheel
before it cools. Allow the air to cool the gear. Do not use
water or oil to reduce the cooling time.
NOTE: If an oven is not available, use a heating torch to
heat the inside diameter of the new ring gear to 177°C
[35O”F]. Use a TempilstW crayon or its equivalent to check
the gear temperature before installing it on the flywheel.
fwlrQha
Flywheel Housing - Cleaning and

Cleaning
A
Use steam or solvent to clean the flywheel
compressed air.
housing. Dry with
q
\
Inspection
Visually inspect all surfaces for nicks, burrs, or cracks.
Use Scotch Britee 7443, or equivalent, to remove small nicks 0a9
q
and burrs.
\
0@B
Inspect all threaded capscrew holes for damage.
Repair or replace the housing if the capscrew holes are
damaged.
fh900sb
Molrntina Adaptations - Group 16 Engine Support Bracket, Front - Cleaning and Inspection for Reuse (1606)
Page 16-9
Engine Support Bracket, Front - Cleaning

and Inspection for Reuse (16-06)
A
Cleaning
Steam clean or use solvent, and dry with compressed air.
Inspection
Visually inspect the engine support bracket for cracks or
damage. If cracks or damage are found, the support bracket
must be replaced.
0
@
Saecifications and Torque Values - Group 18
Page V-i
Section V - Specifications and Torque Values - Group 18

Section Contents
Page
Air Compressor Inspection Specifications ......................................... V-37
Air Compressor Torque Values ................................................. V-37 .
Capscrew Markings and Torque Values ........................................... V-45

Capscrew Markings and Torque Values - Metric ..................................... V-46
Capscrew Markings and Torque Values - U.S. Customary ............................... V-46
Component Specifications and Torque Values ...................................... V-3

Cylinder Block - Rebuild Specifications ........................................... V-15
Cylinder Block - Torque Values ................................................ V-21
Cylinder Head - Rebuild Specifications ........................................... V-22
Engine Assembly - Specifications ............................................... V-3
Engine Assembly - Torque Values ............................................... V-5
Cooling System Specifications ................................................. V-33

Air Intake System Specifications ................................................ V-35
Air Intake System Torque Values ............................................... V-35
Cooling System Torque Values ................................................. V-34
Drive Belt Tension .......................................................... V-41
Electrical System Specifications ................................................ V-38
Electrical System Torque Values ................................................ V-38
Engine Components - General Information ......................................... V-2
Engine Testing - Test Specifications ............................................. V-39
Exhaust System Specifications ................................................. V-37
Exhaust System Torque Values ................................................. V-37
Fuel Systems - Rebuild Specifications ............................................ V-25

Fuel Injection Pump Sealing Washer ............................................. V-27
Fuel Shutoff Solenoid Adjustment ............................................... V-27
Fuel System Specifications ................................................... V-25
Fuel System Torque Values ................................................... V-27
Lubricating Oil System Specifications .............. ............................. v-30
Lubricating Oil System Torque Values .............. ............................. v-31
Mounting Adaptations - Torque Values ............. ............................. v-40
Mounting Adaptations Specifications ............... ............................. v-39

Flywheel Housing (Wet Application) ............... ............................. v-39
Flywheel Ring Gear Installation ................... ............................. V-40
Newton-Meter to Foot-Pound Conversion Chart ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-44
Pipe Plug Torque Values ....................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v-47
Rocker Lever Assembly - Rebuild Specifications ....... ............................. V-25
Tap-Drill Chart - U.S. Customary & Metric ........... ............................. V-43
Valve Tappet - Rebuild Specifications .............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-25
Weight and Measures - Conversion Factors ........................................ V-43

Engine Components - General Information Specifications and Torque Values - Group 18
Page V-2
Engine Components - General Information

The specifications in this section are organized in the same sequence used in each group of this manual. The minimum
and maximum tolerance limit specifications are listed in both metric and U.S. Customary dimensions. The metric dimension
is given first, followed by the U.S. Customary dimension in brackets; for example: 0.50 mm [0.020 inch]. The assembly
and rebuild specifications and torque values are provided to be sure the parts are assembly correctly, fit properly, and
are secured with correct torque value.
Most of the capscrews used to assembly the 6D114E-1 Series engine are metric. Some components, such as the air
compressor and hydraulic pump, are installed using U.S. Customary capscrews. Capscrew torque value are listed in
newton-meters and foot pounds, unless otherwise specified. If a torque value is not listed, use the standard torque value
for the capscrew, refer to the Capscrew Markings and Torque Values, on page V-46.
Specifications
and Torque Values-Group 18 Component Specificationsand TorqueValues
PageV-3
Component or Assembly (Procedure) Ref.No./Steps Metric U.S.
Component Specifications and Torque Values

Engine Assembly - Specifications
Cylinder Liner Protrusion 0.025 mm MIN 0.001 in
0.122 mm MAX 0.0048 in
Note: Use Part No. 3822503, Cylinder Liner Clamp
Set to seat the liner into the bore. Check the liner
protrusion with the clamps removed.
Cylinder Liner-to-Block Clearance 0.229 mm MIN 0.009 in
Cylinder Liner Out-of-Round 0.08 mm MAX 0.003 in
130.000 MIN 5.1535

Cylinder Block Upper Liner Bore I.D.
130.990 MAX 5.1570
130.938 MIN 5.1550

Cylinder Liner Top Press Fit O.D. MAX 5.1558
130.958
Crankshaft End Clearance

New 0.127 mm MIN 0.005 in
0.330 mm MAX 0.013 in
Used 0.533 mm MAX 0.021 in
ksZOO]ah
Piston Ring Gap (New) 0.35 mm MIN 0.0138 in

Top Ring Gap 0.60 mm MAX 0.024 in
0.35 mm MIN 0.0138 in
Inteimediate Ring Gap
0.65 mm MAX 0.026 in
0.30 mm MIN 0.0118 in
Oil Control Ring Gap
0.60 mm MAX 0.0236 in
Component Specifications and Torque Values Specifications and Torque Values - Group 18
Page V-4
Connecting Rod Bearing Side Clearance 0.100 mm MIN 0.0039

0.330 mm MAX 0.0130
Oil Pump Drive Gear Backlash 0.08 mm MIN 0.003 in

0.45 mm MAX 0.018 in
Oil Pump Idler Gear Backlash

0.08 mm MIN 0.003 in
0.33 mm MAX 0.013 in
Camshaft Gear Backlash 0.08 mm MIN 0.003 in

0.33 mm MAX 0.013 in
Camshaft End Clearance 0.12 mm MIN 0.0047 in

0.46 mm MAX 0.0181 in
Flywheel Bore Runout T.I.R. 0.127 mm MAX 0.0050 in
Flywheel Face Runout T.I.R.
2:3m
Radiusit?) 0.203 mm MAX 0.008 in
254 1: 0,254 mm MAX 0.010 in
305 12 0.305 mm MAX 0.012 in
356 14 0.356 mm MAX 0.014 in
406 16 0.406 mm MAX 0.016 in
Valve Adjustment Clearance

Intake Valve 0.30 mm Nominal 0.012 in
Exhaust Valve 0.61 mm Nominal 0.024 in
Specifications and Torque Values - Group 18 Component Specifications and Torque Values
Page V-5
Vibration Damper Face Alignment

(Wobble) T.I.R. 0.28 mm MAX 0.011 in
Vibration Damper Eccentricity T.I.R. 0.28 mm MAX 0.011 in
Engine Assembly - Torque Values

Cylinder Liner Clamps 68 Nom 50 ft-lb
Main Bearing Cap Capscrews Step 1 50 N*m 37 f&lb

119 Nom 88 ft-lb
: 176 N*m 129 ft-lb
Connecting Rod Nuts Step 1 40 N*m 30 ft-lb

80 N*m 60 ft-lb
: 120 Nom 88 ft-lb
Gear Housing Mounting Capscrews

24 Nom 18 ft-lb
I!72 60 N*m 44 ft-lb
Oil Pump Mounting Capscrews 24 N*m 18 ft-lb

Page V-8
Water Pump Mounting Capscrews 24 Nom 18 ft-lb
Oil Pump Suction Tube to Block A 9 N*m 80 in-lb

Brace to Block 9 N*m 80 in-lb
Brace to Suction Tube : 9 Nom 80 in-lb
Oil Pan Mounting Capscrews 24 Nom 18 ft-lb

Note: Tighten the capscrews in the sequence
shown. Start at the center of the oil pan and
alternate toward both ends.
Oil Pan Drain Plug 80 N*m 59 ft-lb
Timing Pin Torx’” Capscrews 8 N*m 71 in-lb
Flywheel Housing Mounting Capscrews 77 Nom 57 ft-lb
Flywheel Housing Access Plate

Capscrews 24 Nom 18 f&lb
Soecifications and Torque Values - Group 18 Component Specifications and Torque Values
Page V-7
Flywheel Mounting Capscrews 140 N*m 101 ft-lb
Starting Motor Mounting Capscrews 77 Nom 57 ft-lb
Coolant Heater 12 N*m 106 in-lb
Oil Cooler Mounting Capscrews 24 Nom 18 ft-lb

Oil Filter Head Mounting Capscrews 24 Nom 18 ft-lb
Cylinder Head Mounting Capscrews Step 1 70 N*m (All Capscrews) 52 ft-lb

145 N*m (Long Only) 105 ft-lb
: Rotate 90 Degrees (Ail Capscrews)
shown. Start at the center of the cylinder head
and alternate toward both ends.
Rocker Lever Retaining Clamp Capscrews 55 Nom 41 ft-lb
Rocker Lever Adjusting Screw Locknut 24 Nom 18 ft-lb

Page V-8
Valve Cover Capscrews 24 N*m 18 ft-lb

shown. Start at the center of the valve cover
and alternate toward both ends.
Crankcase Breather Tube

Support Bracket Capscrews A 24 N*m 18 ft-lb
6 43 Nom 32 ft-lb
injection Nozzle Clamp Capscrew 24 Nom 18 ft-lb -
Fuel Drain Manifold

Banjo Connector
l Injector 9 Nom 80 in-lb
l Filter Head 15 Nom 11 ft-lb
Engine Lifting Bracket Capscrews 77 Nom 57 ft-lb
Intake Manifold Cover Capscrews 24 Nom 18 ft-lb
Aftercooler Assembly Capscrews 24 N*m 18 ft-lb

Page V-9
Aftercooler Coolant Supply Tube

Capscrews 6 Nom 53 in-lb
Exhaust Manifold Mounting Capscrews 43 N-m 32 ft-lb
Turbocharger Mounting Studs 10 Nom 89 in-lb
Turbocharger Mounting Nut 45 Nom 33 R-lb
Turbocharger Oil Drain Mounting

Capscrew 24 Nom 18 ft-lb
Turbocharger Oil Drain Line Hose Clamps 5 N*m 44 in-lb
Turbocharger Turbine Housing Capscrews 20 Nom 15 ft-lb

Page V-10
Turbocharger Compressor Housing Clamp

V-Band Clamp Nut 8 N*m 71 in-lb
Actuator Bracket Brace Capscrews 13 N*m 115 in-lb
Turbocharger Oil Supply Hose

Fittings 24 Nom 18 ft-lb
Hose Connection 35 Nom 26 ft-lb
Turbocharger Exhaust Outlet:

Band Clamp 8 Nom 71 in-lb
Capscrews 43 Nom 32 ft-lb
Turbocharger Air Crossover Hose Clamps 5 N*m 44 in-lb
Water Outlet Connection Capscrews 24 Nom 18 ft-lb
Coolant Vent Line Fitting 8 Nom 71 in-lb
Coolant Vent Petcock 5 N*m 44 in-lb

Snecifications and Torque Values - Group 18 Component Specifications and Torque Values
Page V-l 1
Coolant Vent Line Tube 8 Nom 71 in-lb
Coolant Inlet Connection Hose Clamps 5 Nom 44 in-lb
Alternator Mounting Bracket Capscrews 24 N*m 18 ft-lb
Water Pump Mounting Capscrew 24 N*m 18 ft-lb
Alternator Mounting Capscrew 43 N*m 32 ft-lb

24 N*m 18 ft-lb
80 Nom 59 ft-lb
Belt Tensioner Mounting Bracket 24 Nom 18 ft-lb
Belt Tensioner Mounting Capscrews 43 Nom 32 ft-lb

t
Page V-12
Component or Assembly (Procedure) Flef.No./Steps Metric U.S.
Fan Hub Mounting Capscrews 24 N*m 18 ft-lb
Fuel injection Pump

Mounting Nuts 44 N*m 32 ft-lb
Studs Hand Tight
Fuel Injection Pump Timing Pin Access

Plug 15 Nom 11 fi-lb
Fuel Injection Pump Drive Gear Nut

A Pump
92 N-m 68 ft-lb
MW Pump
104 N-m 77 ft-lb
P Pump
195 Nom 144 ft-lb
Fuel injection Pump Supply Banjo Fitting 32 Nern 24 ft-lb
Fuel Filter Head Adapter 11 Nom 8 ft-lb

Fuel Filter Adapter Nut 32 Nom 24 ft-lb
Fuel Filter
Install the filter as specified by the filter manufacturer.
SDecifications and Torque Values - Group 18 Component Specifications and Torque Values
Page V-13
High Pressure Fuel Line Fittings 24 Nom 18 ft-lb
High Pressure Fuel Line Support Bracket

Bracket Capscrews 24 Nom 18 ft-lb
Vibration Isolator Capscrews 6 Nom 53 in-lb
Gear Cover Capscrews 24 Nom 18 ft-lb
Vibration Damper 200 Nom 148 ft-lb

Pulley to Vibration Damper 77 N*m 57 ft-lb
Fan Hub Pulley Mounting Capscrews 45 N*m 32 ft-lb
Front Engine Support Bracket Mounting

l Without Support 60 N*m 44 ft-lb
Fuel Transfer Pump Mounting Capscrews 24 Nmrn 18 ft-lb

Page V-l 4
Component or Assembly (Procedure) Fief.No./Steps Metric U.S.
Fuel Transfer Pump Fuel Line Fittings 24 Nom 18 ft-lb
9 Nom 80 in-lb
Fuel Injection Pump Solenoid
Air Compressor Mounting Nuts 77 Nom 57 ft-lb
Air Compressor Support Brace Capscrews 43 Nom 32 ft-lb
Air Compressor Oil Supply Line Fitting 8 N*m 71 in-lb
Air Compressor Coolant Supply Line

Fitting 35 Nom 26 in-lb
Air Compressor Connections

Inlet 5 Nom 48 in-lb
Outlet 24 Nom 18 ft-lb
Suecifications and Torque Values - Group 18 Component Specifications and Torque Values
Page V-l 5
Cylinder Block - Rebuild Specifications

Cylinder Block Head Deck Flatness
End-to-End 0.075 mm 0.0030 in
Side-to-Side 0.075 mm 0.0030 in
Cylinder Block Upper Liner Bore I.D. 130.900 mm MIN 5.1535 in

130.990 mm MAX 5.1570 in
Cylinder Block Counterbore Depth From

Cylinder Block Head Deck 122.930 mm MIN 4.8397 in
123.000 mm MAX 4.8425 in
Cylinder Block Height From Head Deck

Surface to Top of Main Bearing Bore 309.40 mm MIN 12.181 in
309.60 mm MAX 12.189 in
Cylinder Block Height From Head Deck

;imfxe to Centerline of the Main Bearing
361.90 mm MIN 14.248 in
362.10 mm MAX 14.256 in
Main Bearing Bore Diameter

With New Bearings 98.079 mm MIN 3.8614 in
98.125 mm MAX 3.8632 in
Without Bearings 104.982 mm MIN 4.1331 in

105.018 mm MAX 4.1346 in
Camshaft Bore Diameter

Without Bushing 64.01 mm MAX 2.520 in
With Bushing Installed 60.12 mm MAX 2.367 in

Page V-18
Valve Tappet Bore Diameter 16.00 mm MIN 0.630 in

16.05 mm MAX 0.632 in
Cylinder Liner Inside Diameter 114.GfIOmm MIN 4.4882 in

114.140 mm MAX 4.4898 in
Cylinder Liner Taper 0.08 mm MAX 0.003 in
Cylinder Liner Seat Area Depth 123.026 mm MIN 4.8435 in

123.052 mm MAX 4.8445 in
Cylinder Liner O.D. (Top Press Fit) 130.938 mm MIN 5.1550 in

130.958 mm MAX 5.1558 in
Piston Pin Bore Inside Diameter 45.006 mm MIN 1.7719 in

45.025 mm MAX 1.7726 in
Piston Pin Outside Diameter 44.993 mm MIN 1.7714 in

45.003 mm MAX 1.7718 in
Note: Discard the piston pin if it is more than
0.03 mm [O.OOl inch] out of round.
Soecifications and Torque Values - Group 18 Component Specifications and Torque Values
Page V-17
Piston Skirt Outside Diameter 113.814 mm MIN 4.4810 in

113.886 mm MAX 4.4840 in
Top Ring Groove Keystone Angle Wear

Use micrometer and Part No. 3823966. 113.938 mm MIN 4.4857 in
Intermediate Ring Groove Keystone Angle

Wear
Use micrometer and Part No. 3823965. 114.323 mm MIN 4.5009 in
Oil Control Ring Side Clearance 0.020 mm MIN 0.0008 in

0.130 mm MAX 0.0051 in
Crankshaft Oil Seal Wear Groove, Front

and Rear 0.025 mm MAX 0.010 in
Crankshaft Connecting Rod Journal

l Outside Diameter 75.962 mm MIN 2.9906 in
76.013 mm MAX 2.9926 in
l Out-of-Round 0.050 mm MAX 0.0020 in

l Taper 0.013 mm MAX 0.0005 in

l Outside Diameter 97.962 mm MIN 3.8568 in
98.013 mm MAX 3.8588 in
l Out-of-Round 0.050 mm MAX 0.0020 in

Crankshaft Thrust Face Width (Standard) 42.975 mm MIN 1.6919 in

43.076 mm MAX 1.6959 in
Page V-18
Crankshaft Rear Oil Seal Flange O.D. 129.975 mm MIN 5.1171 in

130.025 mm MAX 5.1191 in
Crankshaft Damper Pilot O.D. 23.924 mm MIN 0.9419 in

24.000 mm MAX 0.9449 in
Crankshaft Gear Journal O.D. 75.987 in MIN 2.991 in

76.006 mm MAX 2.992 in

New 0.157 mm MIN 0.0062 in
0.334 mm MAX 0.0131 in
Used 0.535 mm MAX 0.0210 in
Crankshaft Gear Bore I.D. 75.898 mm MIN 2.9881 in

75.923 mm MAX 2.9891 in
Crankshaft Gear Installation

- Austempered Gear: 149% MAX 300°F
l Temperature 45 Min. MIN 45 Min.
l Time 6 Hrs. MAX 6 Hrs.
- Steel Gear: 177% MAX 35O’=‘F

l Time 6 Hrs. MAX 6 Hrs.
Standard Main Bearing Thickness (Used) 3.446 mm MIN 0.1357 in

3.454 mm MAX 0.1360 in
Main Bearing Clearance With Plastigauge 0.066 mm MIN 0.0026 in

0.134 mm MAX 0.0053 in
Page V-19
Thrust Bearing Flange Thickness 3.517 mm MIN 0.138 in

3.567 mm MAX 0.140 in
Connecting Rod Piston Pin I.D.

With Bushing 45.023 mm MIN 1.7726 in
45.060 mm MAX 1.7740 in
Without Bushing 48.988 mm MIN 1.9286 in

49.012 mm MAX 1.9296 in
Connecting Rod Crankshaft Bore I.D.

(With Bearings) 76.046 mm MIN 2.9939 in
76.104 mm MAX 2.9962 in
Connecting Rod Bearing Clearance (With

Plastiguage) 0.033 mm MIN 0.0013 in
0.117 mm MAX 0.0046 in
Connecting Rod Bearing Side Clearance 0.100 mm MIN 0.0039

0.330 mm MAX 0.0130
Connecting Rod Bearing Thickness

(Standard) 2.428 mm MIN 0.0956 in
2.471 mm fvlAX 0.0973 in
Connecting Rod Length 215.975 mm MIN 8.5029 in

216.025 mm MAX 8.5049 in

l Without Bushing 0.20 mm MAX 0.008 in
l With Bushing 0.15 mm MAX 0.006 in

Component Specifications and Torque Values Specifications and Torque Values - Grow 18
Page V-20


l With Bushing 60.12 mm 2.367 in
l Without Bushing 64.01 mm 2.520 in

Note: If one of the bushings exceeds the
specifications, all of the bushingsmust be
replaced.
Camshaft Journal Outside Diameter 59.962 mm MIN 2.3607 in

60.013 mm MAX 2.3627 in
Camshaft Lobe Diameter

MIN
.I’:i
Intake Lobe 51.774 mm 2.0383 in
52.251 mm MAX 2.0571 in
0 4
Exhaust Lobe 51.596
52.073
mm
mm
MIN
MAX
2.0313 in
2.0501 in
Fuel Transfer Pump Lobe 41.310 mm MIN 1.6264 in

41.829 mm MAX 1.6468 in
Camshaft Nose (Gear Mounting Surface)

Outside Diameter 41.562 mm MIN 1.6363 in
41.580 mm MAX 1.6370 in
Camshaft Thrust Plate Thickness 9.340 mm MIN 0.3677 in

0 MAX 0.3772 in
!_a
9.580 mm
0
--+I---
Camshaft Gear Bore Inside Diameter 41.480 mm MIN 1.6331 in

41.505 mm MAX 1.6341 in
Page V-21
Camshaft Gear Installation

- Austempered Gear: 149% MAX 300°F
l Heating Time 6 Hrs. MAX 6 Hrs.
- Steel Gear: 177% MAX 350°F

‘0 Temperature 45 Min. MIN 45 Min.
l Heating Time 6 Hrs. MAX 6 Hrs.
Vibration Damper Face Alignment

(Wobble ) T.I.R. 0.28 mm MAX 0.011 in
Vibration Damper Eccentricity T.I.R. 0.28 mm MAX 0.011 in
Vibration Damper Thickness

Measure the thickness at four locations 90 degrees apart approximately 3.18 mm [0.125 in] from
the outside diameter. The difference between any two of the four measurements must not exceed
0.25 mm [O.OlO in].
Rear Cover Crankshaft Seal Bore I.D. 149.96 mm MIN 5.904 in

150.04 mm MAX 5.907 in
Cylinder Block - Torque Values

Cylinder Block Pipe Plugs (Into Cast Iron) Size
Refer to chart on page V-47. 10 Nom l/l6 inch 7 ft-lb
15 Nom 118 inch 11 f&lb
25 N*m l/4 inch 20 ft-lb
35 N*m 318 inch 25 ft-lb
55 N*m 112 inch 40 ft-lb
75 Nom 314 inch 55 ft-lb
95 Nom 1 inch 70 ft-lb
Cylinder Block - Main Bearing Calf

Capscrew 1 50 Nom 37 ft-lb
119 Nom 88 ft-lb
: 176 Nom 129 ft-lb
Component Specifications and Torque Values Specifications and Torque Values - Chub 18
Page V-22
Connecting Rod Capscrew Nuts 1 40 Nom 30 ft-lb

: 120
80 Nom
N*m 88 ft-lb
60
Cylinder Head - Rebuild Specifications

fyi;;;r Head Capscrew Free Length
81.5 mm MAX 3.21 in
l Long 162.6 mm MAX 6.40 in
Cylinder Head Flatness

End-to-End 0.200 mm MAX 0.0079 in
Side-to-Side 0.076 mm MAX 0.0030 in
Local Flatness
(Within a 51 mm [2.0 inch] area) 0.0254 mm MAX 0.001 in
Fy;lifr Head Thickness

115.75 mm MIN 4.557 in
116.25 mm MAX 4.577 in
l Machined 114.75 mm MIN 4.518 in
Injector Nozzle Tip Protrusion 3.0 mm MIN 0.118 in

4.0 mm MAX 0.157 in
yk:wGuide I.D. (Installed)

9.539 mm MIN 0.3756 in
9.559 mm MAX 0.3763 in
l Used 9.591 mm MAX 0.3776 in
Krk; Guide Height (Installed)

20.65 mm MIN 0.813 in
21.16 mm MAX 0.833 in
Exhaust 22.50 mm MIN 0.886 in

23.01 mm MAX 0.906 in
Page V-23
Valve Guide Bore I.D. 15.931 mm MIN 0.6272 in

15.971 mm MAX 0.6288 in
Valve Guide (New) O.D. 15.988 mm MIN 0.6294 in
4
16.000 mm MAX 0.6299 in
Valve Seat-to-Valve Guide Concentricity

(360 Degrees) 0.05 mm MAX 0.002 in
Valve recess in Cylinder Head

1.62 mm MAX 0.064 in
Intake 0.59 mm MIN 0.023 in

1.12 mm MAX 0.044 in
Valve Insert Bore I.D. (Standard insert) A

Intake 53.930 mm MAX 2.1231 in
Exhaust 47.027 mm MAX 1.8515 in
zFk; Insert Bore Depth (Standard Insert) B

12.20 mm MAX 0.480 in
Valve Sealing Surface Angle

Intake
Exhaust
Component
Component or Assembly (Procedure) Ref.No.lSteps Metric U.S.
Valve Seat Width Limit 1.5 mm MIN 0.060 in

2.0 mm MAX 0.080 in
Valve Seat Vacuum

New 508 mm Hg MIN 20 in Hg
635 mm Hg MAX 25 in Hg
Used 457 mm Hg MIN

Acceptable leakage rate in 10 seconds. 254 mm Hg MAX
Valve Spring Free Height (New)

(7-l /2 coils)
Standard Intake and Exhaust A 65.66 mm Nominal 2.585 in
Dual Spring (Exhaust) (New)

Outer Spring A 77.47 mm Nominal 3.049 in
Inner Spring A 72.64 mm Nominal 2.860 in
Valve Rotator Spring (New) A 62.05 mm Nominal 2.440 in
Valve Spring Working Height (New)

Rotator Spring B 78.79 mm Nominal 1.92 in
All Other Springs B 50.80 mm Nominal 2.00 in
Spring Force at Assembled Height (New)

Outer Spring 689 N Nominal 154.9 Ibf
Inner Spring : 71 N Nominal 15.9 Ibf
Assembly C 710.1 N MIN 159.6 Ibf
811.1 N MAX 182.3 Ibf
All Other Springs (New) C 464.5 N MIN 104.4 Ibf
513.5 N MAX 115.4 Ibf
Standard Spring (Used)
Intake and Exhaust C 450 N MIN 101.2 Ibf
Valve Spring at Opening Height (New)
Valve Rotator Spring
Intake and Exhaust B 35.89 mm Nominal 1.413 in
All Other springs (New) B 37.99 mm Nominal 1.492 in
Spring Force at Opening Height (New)
Standard Spring
Intake and Exhaust C 959.5 N MIN 215.7 Ibf
1060.5 N MAX 238.4 Ibf
Standard Spring (Used)
Intake and Exhaust C 940.0 N MIN 211.3 Ibf
Dual Spring (Exhaust) (New)
Outer Spring C 1023 N Nominal 230 Ibf
Inner Spring C 111 N Nominal 25 Ibf
Assembly C 1084 N MIN 244 Ibf
1184 N MAX 266 Ibf
Valve Rotator Spring (New)

Intake and Exhaust C 995 N MIN 224 Ibf
1095 N MAX 246 Ibf
Page V-24-01
Valve Stem O.D. 9.46 mm MIN 0.372 in

9.50 mm MAX 0.374 in
Valve Head Thickness at O.D.

intake 3.01 mm MAX 0.119 in
Specifications and Torque Values - Group 18 Rocker Lever Assembly - Rebuild Specifications
Page V-25
Rocker Lever Assembly - Rebuild Specifications

Rocker Lever Bore I.D. 22.256 mm MIN 0.8762 in
22.301 mm MAX 0.8780 in
Rocker Lever Shaft O.D. 22.199 mm MIN 0.8740 in

22.231 mm MAX 0.8752 in
Valve Tappet - Rebuild Specifications

Valve Tappet Stem O.D. 15.925 mm MIN 0.6270 in
15.980 mm MAX 0.6291 in
Valve Tappet Visual Limits

Inspect the socket stem and face Normal Wear
for excessive wear, cracks or damage Abnormal (Do not use)
(C) Abnormal (Do not use)
Concavity (A) 0.025 mm 0.001 in
Valve Tappet Face

1. A single pit cannot be greater than 2 mm [0.078 in] in diameter.
2. Interconnection of pits is not allowed and is treated as one pit.
3. Total pits when added together should not exceed 6 mm (0.236 in]
diameter or a total of 4 percent of the tappet face.
4. No pitting is allowed on the edges of the wear face of the valve tappet.
Fuel Systems - Rebuild Specifications

Note: This manual does not cover fuel injection pump rebuild or calibration.
Rebuild and calibration should be performed in a facility certified in the
rebuild and calibration of the fuel injection pumps.
Refer to Bulletin No. 3810348 for additional service and parts information.
Fuel System Specifications

Engine Low Idle Speed
Refer to the engine dataplate.
Fuel Rebuild - System Specifications Specifications and Torque Values - Group 18
Page V-26
Fuel Transfer Pump Inlet Restriction

6D114E-1 Series Engine 100 mm Hg MAX 4 in Hg
Fuel transfer Pump Outlet Pressure

at Rated Speed
6D114E-1 Series Engine High Flow 172 kPa MIN 25 psi
Low Flow 83 kPa MAX 12 psi
Fuel Injection Pump

Fuel Inlet Pressure at Rated Speed High Flow 140 kPa MIN 20 psi
Low Flow 48 kPa MAX 7 psi
Fuel Injection Pump

Fuel Return Line Restriction 518 mm Hg MAX 20.4 in Hg
Fuel Filter Restriction

Pressure Drop Across Filter 35 kPa MAX 5 psi
Fuel Drain Line Restriction 70 kPa MAX 10 psi
Fuel Injection Pump Throttle Lever

BLeakover 3.18 mm MIN 0.125 in
6.35 mm MAX 0.250 in
Specifications and Torque Values - Group 18 Fuel Rebuild - System Specifications
Page V-27
Fuel Shutoff Solenoid Adjustment

- Synchro-Start
l Plunger Stroke Gap 0.04 mm MAX 0.118 in
l Plunger Stroke Length 25.4 mm MAX 1 .O in
- Trombetta
l Plunger Stroke Gap 0.04 mm MAX 0.118 in
l Plunger Stroke Length 33.3 mm MAX 1.3 in
Fuel Shutoff Solenoid Adjustment

RQVK Governor A 66.9 mm 2.64 in
Fuel System Torque Values
Air Fuel Control (AFC) 24 Nom 18 ft-lb

Banjo Fiiing 71 in-lb
8 Nom
Threaded Fiiing
Fuel Filter
install the filter as specified by the filter manufacturer.
Fuel Injection Pump Sealing Washer

- Bosch Pump
l Sealing Washer A 32 Nom 24 ft-lb
l Sealing Washer D 15 N*m 11 ft-lb
Fuel Filter Head Adapter 4 Nom 35 in-lb

Fuel Rebuild - System Specifications Specifications and Torque Values -‘Group 18
Page V-28
Comoonent or Assemblv (Procedure) Ref .No./Steos Metric U.S.
Fuel Filter Head Banjo Fittings 24 N*m 18 ‘h-lb
Fuel Injection Pump Solenoid Mounting 9 Nom

Capscrews 80 in-lb
Fuel Injection Pump Supply Banjo Fitting 32 Nom 24 ft-lb
Fuel Injection Pump

Mounting Nuts 44 Nom 32 ft-lb
Studs Hand Tight
Fuel Injection Pump Support

Lower Brackets
M8 Pump to Support Bracket Capscrew 24 Nom 18 ft-lb
Ml0 Support Bracket to block Capscrew 45 N*m 33 it-lb
Upper Bracket 24 N*m 18 ft-lb
Fuel Injection Pump Drive Gear ,Nut

A Pump 92 N*m 68 ft-lb
MW Pump 104 N*m 77 ft-lb
P Pump 165 N*m 122 ft-lb
Fuel Injection Pump Timing Pin Access

Plug 15 Nom 11 ft-lb
Snecifications and Torque Values - Group 18 Fuel Rebuild - System Specifications
Page V-29
Fuel Shutoff Solenoid Mounting Bracket

Capscrews 10 N*m 89 in-lb
Fuel Transfer Pump Fittings

- Outlet 30 N*m 22 ft-lb
- Inlet 30 N*m 22 ft-lb
- Hand Primer 30 N*m 22 &lb
Fuel Transfer Pump 24 N*m 18 ft-lb

Fuel Line Fittings
Fuel Transfer Pump Mounting Capscrews 24 N*m 18 ft-lb
High Pressure Fuel Line Fittings 24 Nom 18 ft-lb
High Pressure Fuel Line Support Bracket

24 Nom 18 ft-lb
Bracket Capscrews
Vibration Isolator Capscrews 6 Nom 53 in-lb
Injector Opening Pressure

a. Open valve
b. Operate spray tester lever at one stroke per second
c. Read pressure indicated when spray began
Lubricating Oil System Specifications Specifications and Torque Values - Group 18
Page V-30
Leakage Test:
a. Open valve
b. Operate spray tester lever to hold pressure 20 bar [290 psi] below opening pressure
c. No drops should fall from the tip within 20 seconds
Injector Nozzle Clamp Capscrew 24 Nom 18 ft-lb
Injector Nozzle Banjo Fitting 9 Nom 80 in-lb
Lubricating Oil System Specifications

Lubricating Oil Thermostat
l Fully Open Temperature 116% MAX 240°F
l Maximum Opening Distance 45.9 mm MAX 1.80 ‘in
Oil Capacity of Pan (All Engines):

- Low Level 15.1 liters 16.0 U.S. Qts.
- High Level 18.9 liters 20.0 U.S. Qts.
T;&J ,!9y;t;m Capacity

23.6 liters 25.0 U.S. Qts.
S6D114E-1 23.8 liters 25.2 U.S. Qts.
Oil Cooler Distortion 0.8 mm MAX 0.031 in
Oil Cooler Element Pressure Test

Pressure 483 kPa 70 psi
Temperature 82% 18OOF
Specifications and Torque Values - Group 18 Lubricating Oil System Specifications
Page V-31
Oil Pressure Regulator Spring

Spring Free Length
13-coils 86.63 mm Nominal 3.411 in
Spring Load at 53.98 mm [2.125 in]

Valve Open 190 N MIN 42.8 Ibf
Spring Load at 60.33 mm [2.375 in]
Assembled 153 N MIN 34.4 Ibf
Oil Pump Gerotor Tip Clearance 0.025 mm MIN 0.001 in

0.178 mm MAX 0.007 in
Oil Pump Port Plate Clearance 0.025 mm MIN 0.001 in

0.127 mm MAX 0.005 in
Oil Pump Body Bore Clearance 0.127 mm MIN 0.005 in

0.381 mm MAX 0.015 in

0.45 mm MAX 0.018 in
Oil Pump Idler Gear Backlash 0.08 mm MIN 0.003 in

0.45 mm MAX 0.018 in
Lubricating Oil System Torque Values

Crankcase Breather Tube Bracket
M8 (Valve Cover) 24 N*m 18 ft-lb
Ml 2 (Cylinder Head) 80 N*m 59 ft-lb
Lubricating Oil System Specifications Specifications and Torque Values - Group 18
Page V-32
Oil Cooler Cover Mounting Capscrews 24 Nom 18 ft-lb

Oil Cooler Cover Pipe Plugs

10 Nom 74 in-lb
10 N*m 74 in-lb
36 Nom 27 ft-lb
45 N*m 35 ft-lb
Oil Pressure Regulator Plug 80 N*m 59 ft-lb
Oil Drain Plug 80 N*m 59 ft-lb
Oil Pan Mounting Capscrews 24 N*m 18 ft-lb

shown. Start at the center of the oil pan and
alternate toward both ends.
Oil Pump Suction Tube Bracket

Suction Tube to Block 9 Nom 80 in-lb
Brace to Block
Brace to Suction Tube 9 N*m
Nom 80 in-lb
Oil Pump Mounting Capscrews 24 Nom 18 ft-lb

Specifications and Torque Values - Group 18 Cooling System Specifications
Page V-33
Oil Temperature Thermostat 50 Nom 37 ft-lb
Cooling System Specifications

Fan Hub Assembled Height 124.85 mm MIN 4.915 in
125.65 mm MAX 4.946 in
Fan Hub Bearing Installation Force 9000 N MIN 2023 Ibf
Fan Hub Shaft End Clearance 0.15 mm MAX 0.006 in
Radiator Cap Pressure Test

104°C [220°F] 103 kPa MIN 15 psi
99°C [210°F] 48 kPa MIN 7 psi
Thermostat Operating Temperature

Initial Opening Temperature 81 ‘=C ilN 178°F
83% MAX 182’=F
Fully Open Temperature 95% MAX 203’=‘F
Maximum Open Distance 41.5 mm MAX 1.63 in
Viscous Fan Drive Operating Temperature Viscous Fan Drive

Start Modulation 85OC 185OF Operating Temperature
Maximum Speed 93OC 200°F ~‘w~
Y.im”n
YisCD”S
FanDrive ,,.-..
Cooling System Specifications Specifications and Torque Values - Group 18
Page V-34
Cooling System Torque Values

Belt Tensioner Mounting Capscrew 43 Nom 32 ft-lb
Fan Hub Mounting Capscrew 24 Nom 18 ft-lb
Fan Hub Pulley Mounting Capscrews 45 Nom 33 ft-lb
Coolant Inlet Hose Clamps 5 N*m 44 in-lb
Thermostat Housing Mounting Capscrews 24 Nom 18 ft-lb
Water Outlet Connection 24 Nom 18 ft-lb

Specifications and Torque Values - Group 18 Cooling System Specifications
Page V-35
Air Intake System Specifications

Naturally Aspirated 50.8 cm H,O MAX 20.0 in H,O
Turbocharged 63.5 cm H,O MAX 25.0 in H,O
Turbocharger Shaft Radial Clearance (Side

to Side) 0.21 mm MIN 0.008 in
0.46 mm MAX 0.018 in
Note: Specifications and instructions for rebuilding
the turbocharger are provided in the HI Turbocharger
Shop Manual, Bulletin No. 3810321.
Turbocharger Shaft Axial Clearance (End

Clearance) 0.03 mm MIN 0.001 in
0.08 mm MAX 0.003 in
Charge Air Cooler

Differential Pressure Across Cooler 21 kPa MAX 3 psi
Wastegate Actuator Calibration

l Air Pressure 165 kPa MIN 24 psi
179 kPa MAX 26 psi
l Actuator Rod Movement 0.33 mm MIN 0.013 in

1.3 mm MAX 0.050 in
Air Intake System Torque Values

Turbocharger Mounting Nut 45 Nom 33 ft-lb
Turbocharger Oil Drain Mounting

Capscrew 24 N*m 18 ft-lb
Cooling System Specifications Specifications and Torque Values - Group 18
Page V-36
Turbocharger Air Crossover Hose Clamps 5 Nom 44 in-lb
Turbocharger Oil Drain Tube Hose Clamps 5 N*m 44 in-lb
Turbocharger Turbine Housing Capscrews 20 Nom 15 ft-lb
Turbocharger Compressor Housing Clamp

Nut 8 N*m 71 in-lb
Turbocharger Oil Supply Hose Connection 15 Nom 11 ft-lb
Turbocharger Discharge Elbow Clamp Nut 8 Nom 71 in-lb
Turbocharger Mounting Studs

Use two mounting nuts locked together 10 N*m 89 in-lb
Suecifications and Torque Values - Group 18 Exhaust System Specifications
Page V-37
Componentor Assembly (Procedure) Ref.No./Steps Metric U.S.
Exhaust System Specifications

Exhaust Restrihions -
l EPA Certified 114 mm Hg 4.5 in Hg
Exhaust Manifold Flatness 0.20 mm MAX 0.008 in
Exhaust System Torque Values

Exhaust Manifold Mounting Capscrews:
l Flan ed Head 43 Nom 32 ft-lb
l Hex 9-1ead 43 N*m 32 ft-lb
Air Compressor Inspection Specifications

l Single Cylinder Air Compressor 0.05 mm MIN 0.002 in
0.15 mm MAX 0.006 in
. Two Cylinder Air Compressor 0.05 mm MIN 0.002 in
0.19 mm MAX 0.008 in
Note: Specifications and instructions for rebuilding
the two cylinder air compressor are provided in the
Air Equipment Rebuild Manual, Bulletin Nos. 3810242 and 3810257.
Air Compressor Torque Values
Air Compressor Brace to Air Compressor
Mounting Capscrews
Holset 43 Nom 32 ft-lb
Bendix 43 N*m 32 ft-lb
Midland 32 N*m 24 ft-lb
Air Compressor Brace to Cylinder Block

Mounting Capscrew 43 Nom 32 ft-lb
Air Compressor Flange Mounting Nuts

Nut 77 Nam 57 ft-lb
Stud to Gear Housing Hand Tight
Electrical System Specifications Specifications and Torque Values - Groun 18
Page V-38
Air Compressor Oil Supply Hose

Connection 15 N*m 12 ft-lb
Air Compressor Coolant Line Connection 35 N*m 26 ft-lb
Electrical System Specifications

Drive Belt 360 N MIN 80 Ibf
Engine has an automatic belt tensioner, no 490 N MAX 100 Ibf
adjustment necessary.
Batteries Specific Gravity State of

at 27% [180°F] Charge
1.260 to 1.280 100%
1.230 to 1.250 75%
1.200 to 1.220 50%
1.170 to 1.190 25%
1.110 to 1.130 Discharged
Electrical System Torque Values

Belt Tensioner Capscrew 44 Nom 32 ft-lb
Alternator Mounting
Ml 0 Capscrew A 44 Nom 32 ft-lb
Lower Support Bracket
M8 Capscrew B 24 N*m 18 ft-lb
Ml 0 Capscrew 44 Nam 32 ft-lb
Mounting Capscrews C 77 N*m 57 ft-lb
Starting Motor Mounting Capscrew 77 N*m 57 ft-lb

Specifications and Torque Values - Group 18 Engine Testing - Test Specifications
Page V-39
Coolant Heater 12 Nom 106 in-lb
Temperature Sensor
Installation - Cast Iron 50 Nom 37 ft-lb
Installation - Aluminum 30 N*m 22 ft-lb
Oil Heater Element 120 Nom 89 ft-lb
Oil Pressure Switch

Installation - Cast Iron 16 N*m 12 ft-lb
Installation - Aluminum 10 Nom 89 in-lb
Engine Testing - Test Specifications

Note: The specifications and instructions for testing
the engine are provided in this manual. Refer to
Engine Testing - Group 14, Page 14-1.
Crankcase Gases (Blowby) Limits

Refer to Engine Testing, Page 14-6.
Mounting Adaptations Specifications

Flywheel Housing (Wet Application)
Set Screw Installation Depth 0.00 mm MIN 0.000 in
3.00 mm MAX 0.118 in
Mounting Adaptions - Torque Values Specifications and Torque Values - Group 18
Page V-40
Flywheel Ring Gear Installation
l Temperature 177% 350°F

l Time Interval 30 Min. MIN 30 Min.
6 Hours MAX 6 Hours
Mounting Adaptations - Torque Values

Flywheel Housing Access Plate
Flywheel Mounting Capscrews 140 Nom 101 ft-lb

Specifications and Torque Values - Group 18 Drive Belt Tension
Page V-41
Drive Belt Tension
Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used*
* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
FRACTION, DECIMAL, MILLIMETER CONVERSIONS Specifications and Torque Values - Group 18
Page V-42
FRACTION, DECIMAL, MILLIMETER CONVERSIONS
CONVERSION FACTOR: 1 INCH = 25.4MM

Specifications and Torque Values - Group 18 Weight and Measures - Conversion Factors
Page V-43
Weight and Measures - Conversion Factors
QUANTITY U.S. CUSTOMA IY METRIC FROM U.S. FROM METRIC

CUSTOMARY TO U.S.
TO METRIC CUSTOMARY
MULTIPLY BY MULTIPLY BY
Unit Name Abbr.
Area sq. inch mm2
cm2 \
sa. foot m2
Fuel pounds per Ib/hp-hr grams per g/kw-hr 608.277 0.001645
Consumption horsepower kilowatt hour
hour
mpg kilometers per km/l 0.4251
Fuel
Performance
miles per gallon
I liter
2.3527
gallons per mile gpm liters per I/km 2.3527 0.4251

I kilometer
Force pounds force Ibf Newton N
Length inch in millimeters mm
foot ft millimeters mm
Power horsepower hp kilowatt kw
Pressure pounds force
per sq. in
psi kilopascal kPa 6.8948
I
0.145037
inches of in Hg kilopascal kPa 3.3769 0.29613

mercury
inches of water in He0 kilopascal kPa 0.2488 4.019299
inches of in Hg millimeters of mm Hg
mercurv mercurv
inches of water in H,O millimeters of mm H,O
water
bars 100.001 0.00999
bars mm Hg 750.06 0.001333
Temoerature fahrenheit “C
Torque pound force Nom
oer foot
pound force in lb Newton-meter Nom
per inch I
Velocitv miles/hour kph
Volume: liquid gallon (U.S.) I
displacement gallon (imp*)
cubic inch I
cubic inch in3 cubic cm3
I centimeter
Weight (mass) pounds (avoir.) lb 1 kiloarams kg
uVork British Thermal i
Unit
British Thermal
Unit
horsepower hp-hr kilowatt-hour
kw-hr
kw-hr
0.000293
I
3414
0.746 1.341
hours
Newton-Meter to Foot-Pound Conversion Chart Specifications and Torque Values - Group 18
Page V-44
Newton-Meter to Foot-Pound Conversion Chart
Nom ft-lb I Nom ft-lb I Nom ft-lb

1 8.660756 in-lb 55 41 155 114
5 44.0 in-lb 60 44 160 118
6 53.0 in-lb 65 48 165 122
7 62.0 in-lb 70 52 170 125
8 71.0 in-lb 75 55 175 129
9 80.0 in-lb 80 59 180 133
10 89.0 in-lb 85 63 185 136
1 0.737562 ft-lb 90 66 190 140
12 9 95 70 195 144
14 10 100 74 200 148
15 11 105 77 205 151
16 12 110 81 210 155
18 13 115 85 215 159
20 15 120 89 220 162
25 18 125 92 225 165
30 22 130 96 230 170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184
NOTE: To convertfrom Newton-Meters to Kilogram-Meters

dive Newton-Meters by 9.803
Soecifications and Torque Values - Group 18 Capscrew Markings and Torque Values
Page V-45
Capscrew Markings and Torque Values
A Caution: When replacing capscrew, always use a capscrew of the same measurement and strength as the
capscrew being replaced. Using the wrong capscrews can result in engine damage.
Metric capscrew and nuts are identified by the grade number stamped on the head of the capscrew or on the surface
of the nuts. U.S> Customary capscrews are identified by radial lines stamped on the head of the capscrews.
The following examples indicate how capscrews are identified:
Metric - M&1.25 x 25 U.S. Customary [5/16 x 18 x l-1/2]

M8 1.25 25 5116 18 l-1/2
Major Thread Distance Length in Major Thread Number Length in
Diameter in Between Millimeters Diameter in Threads Per Inches
Millimeters threads in Inches Inch
Millimeters
NOTES:
1. Always use the torque values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other section of the manual.
3. The torque values in the table are based on the use of lubricated threads.
4. When the ft-lb value is less than 10, give consideration to converting the ft-lb value to in-lb to obtain a better torque
with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-lb.
Capscrew Markings and Torque Values Specifications and Torque Values - Group 18
Page V-48
Capscrew Markings and Torque Values - Metric
Commercial Steel Class

8.8 10.9 12.9
Capscrew Head Markings
Bodv
Size”
0 8.8
Torque
0
10.9
Torque Torque
0
12.9
Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm Nom ft-lb Nom ft-lb Nom ft-lb Nom ft-lb Nom ft-lb Nom ft-lb
6 9 5 7 4 12 9 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 25 18 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 60 45 30 25 70 50 30 25
12 80 60 55 40 105 75 55 40 125 95 55 40
14 125 90 90 65 165 122 90 65 195 145 90 65
16 180 130 140 100 240 175 140 100 290 210 140 100
18 230 170 180 135 320 240 180 135 400 290 180 135
Capscrew Markings and Torque Values - U.S. Customary

SAE Grade Number 5 8
These are allSAE Grade 5(3)line ./ \'
7 \- m
Gm@ @
@
@
Capscrew Torque- Grade 5 Capscrew Capscrew Torque - Grade 8 Capscrew
Capscrew Body Size Cast Iron Alummum Cast Iron Alumlnum
N*m ft-lb N*m ft-lb N*m ft-lb Nom ft-lb
l/4 - 20 9 7 8 6 15 11 8 6
- 28 12 9 9 7 18 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
- 24 23 17 19 14 33 24 19 14
318 - 16 40 30 25 20 55 40 25 20
- 24 40 30 35 25 60 45 35 25
7116 - 14 60 45 45 35 90 65 45 35
- 20 65 50 55 40 95 70 55 40
112 - 13 95 *70 75 55 130 95 75 55
- 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
- 18 150 110 115 85 210 155 115 85
518 - 11 180 135 150 110 255 190 150 110
- 18 210 155 160 120 290 215 160 120
314 - 10 325 240 255 190 460 340 255 190
- 16 365 270 285 210 515 380 285 210
718 - 9 490 360 380 280 745 550 380 280
- 14 530 390 420 310 825 610 420 310
l-8 720 530 570 420 1100 820 570 420
- 14 800 590 650 480 1200 890 650 480
Specifications and Torque Values - Group 18 Pipe Plug Torque Values
Page V-47
Size Torque Torque

Thread Actual Thread O.D. In Aluminum Components In Cast Iron or Steel Components
in in Nom ft-lb Nom ft-lb
l/16 0.32 5 45 in-lb 15 10
l/8 0.41 15 10 20 15
l/4 0.54 20 15 25 20
3P 0.68 25 20 35 25
l/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
l-1/4 1.66 75 55 115 85
l-1/2 1.90 85 65 135 100
index
Page X-l
About the Manual .................................. i-2 FanHub ....................................... 8-4

Accessory Drive Adapter - Cleaning and Inspection for Reuse 4-5 Pressure Caps ................................... 8-4
Cleaning ....................................... 4-5 Thermostats .................................... 8-4
Inspection ...................................... 4-5 Water Pump .................................... 8-4
Accessory Drive Adapter - Exploded view ............... 4-3 Cooling System - Service Tools ....................... 8-2
Accessory Drive Adapter - Rebuild ..................... 4-5 Cooling System Specifications ........................ V33
Assembly ...................................... 4-6 Air Intake System Specifications ...................... V-35
Disassembly .................................... 4-6 Air Intake System Torque Values ..................... V-35
Accessory Drive - General Information .................. 4-4 Cooling System Torque Values ...................... V-34
AccessoryDrive Adapter ........................... 4-4 Crankcase Breather Tube - Cleaning and Inspection
Aftercooler Assembly - Cleaning and Inspection for Reuse . . 10-7 for Reuse ........................................ 3-8
Inspection ...................................... 10-8 Cleaning and Inspection ........................... 3-8
Aftercooler Assembly - Rebuild ....................... 10-8 Crankshaft - Cleaning and Inspection for Reuse ........... 29
Air Compressor Inspection Specifications ............... V-37 Crankshaft - Cleaning .............................. 29
Air Compressor Torque Values. ....................... V-37 Crankshaft - Inspection ............................. 30
Air Crossover Tube - Cleaning and Inspection for Reuse ... 10-9 Crankshaft Gear - Replacement ........................ 33
Cleaning ....................................... 10-9 Crankshaft Gear - Inspection ......................... 34
Inspection ...................................... lO-9 Crankshaft Gear - Installation ......................... 35
Air Intake System - Exploded View ..................... 10-3 Crankshaft Gear - Removal .......................... 33
Air Intake System - General Information ................ 10-4 General Information ................................ 33
Air Intake System - Service Tools ...................... 10-2 Cylinder Block - Cleaning in a Hot Tank ................. 15
Air Transfer Pipe - Cleaning and Inspection for Reuse ..... 10-9 Cylinder Block - Cleaning with Solvent .................. 12
Cleaning ....................................... 10-9 Cylinder Block - Disassembly .......................... 10
Inspection ...................................... 1O-9 Cylinder Block - Exploded View ........................ 7
Belt Tensioner Inspection ........................... 8-l 0 Cylinder Block - General Information .................... 9
Blowby Measurement ............................... 14-7 Camshaft ....................................... 9
Camshaft Bore Expansion Plug Installation ............... 21 Connecting Rods .................................. 9
Camshaft Bushing Bore - Cleaning ..................... 23 Crankshaft.. ..................................... 9
Camshaft Bushing - Installation ........................ 23 Cylinder Block .................................... 9
Camshaft Bushing - Removal .......................... 22 Cylinder Liner .................................... 9
Camshaft - Cleaning and Inspection for Reuse ............ 50 Oil Seals ........................................ 9
Camshaft-Cleaning ............................... 50 Pistons ......................................... 9
Camshaft Gear - Inspection .......................... 53 Vibration Damper. ................................. 9
Camshaft - Inspection .............................. 50 Cylinder Block - Inspection For Reuse ................... 16
Camshaft Gear - Replacement ......................... 54 Cylinder Block - Preparation for Cleaning ................ 10
Camshaft Gear - Cleaning ........................... 54 Cylinder Block - Service Tools ......................... 4
Camshaft Gear - Inspection .......................... 54 Cylinder Head Capscrew - Cleaning and Inspection ...... 2-37
Camshaft Gear - Installation .......................... 56 Cleaning ...................................... 2-37
Camshaft Gear - Removal ........................... 54 Inspection ..................................... 2-38
Capscrew Markings and Torque Values ................. V-45 Cylinder Head Capscrews - Cleaning and Inspection
Capscrew Markings and Torque Values - Metric .......... V-46 for Reuse ......................................... 64
Capscrew Markings and Torque Values - U.S. Customary ... V-46 Cleaning ........................................ 64
Component Specifications and Torque Values ............. V-3 Free Length - Measurement .......................... 66
Cylinder Block - Rebuild Specifications ................ V-15 Inspection ....................................... 65
Cylinder Block - Torque Values ...................... V-21 Cylinder Head - Cleaning and Inspection for Reuse ....... 2-9
Cylinder Head - Rebuild Specifications. ................ V-22 Cleaning ....................................... 2-9
Engine Assembly - Specifications ...................... V3 Handling ....................................... 2-9
Engine Assembly - Torque Values ..................... V-5 Inspection ..................................... 2-10
Connecting Rod Bearings - Cleaning and Inspection Cylinder Head - Exploded View ....................... 2-6
for Reuse ......................................... 39 Cylinder Head - General Information ................... 2-8
Connecting Rod Bearings - Cleaning ................... 39 Cylinder Head - Pressure Testing ..................... 2-34
Connecting Rod Bearings - Inspection .................. 39 Cylinder Head - Rebuild ............................ 2-11
Connecting Rod Bushing - Replacement ................. 45 Assembly ..................................... 2-26
Inspection ....................................... 49 Cleaning ...................................... 2-12
Installation ....................................... 47 Disassembly ................................... 2-11
Machining ....................................... 49 Inspection ..................................... 2-13
Removal ........................................ 45 Valve - Grinding ................................. 2-21
Connecting Rods - Bend and Twist Inspection ............ 43 Valve Guide - Inspection .......................... 2-17
Connecting Rod Alignment - Inspection ................. 44 Valve - Inspection ............................... 2-20
Connecting Rod Twist - Inspection ..................... 44 Valve Seat Insert - Grinding ........................ 2-22
Fixture Calibration ................................. 43 Valve Seat Insert - Inspection ....................... 2-18
Connecting Rods - Cleaning and Inspection for Reuse ...... 40 Valve Spring - Inspection .......................... 2-19
Connecting Rods - Cleaning ......................... 40 Valve Stem Seal - Inspection ....................... 2-19
Connecting Rods - Inspection ........................ 41 Cylinder Head - Service Tools ........................ 2-2
Coolant Filter Shutoff Valve - Cleaning and Inspection Cylinder Head - Vacuum Testing Valve Seating .......... 2-36
for Reuse ....................................... 810 Cylinder Head - Valve Guide Replacement .............. 2-28
Assembly ..................................... 8-11 Assembly ..................................... 2-29
Cleaning ...................................... 8-11 Disassembly ................................... 2-28
Disassembly ................................... 810 Inspection ..................................... 2-29
Cooling System Components - Exploded View ............ 8-3 Cylinder Head - Valve Seat Insert Replacement .......... 2-31
Cooling System - General Information .................. 8-4 Inspection ..................................... 2-33
Belt Tensioner ................................... 8-4 Installation ..................................... 2-33
Cooling Fans .................................... 8-4 Removal ...................................... 2-31
Index
Page X-2
Cylinder Liners - Cleaning and Inspection for Reuse ... . . . . 24 Starting Motor - Installation ......................... O-82
Cylinder Liners - Cleaning ...................... . . . . 24 Tachometer Drive - Installation ...................... O-l 17
Cylinder Liners - Inspection ..................... . . . . 25 Thermostat and Housing - Installation ................ O-101
Dowel Pins (Cylinder Head) - Removal .............. . . . . 11 Timing Pin Assembly - Installation .................... O-69
DriveBeltTension ............................. . . . v-41 Turbocharger Exhaust Outlet Connection - Installation .... O-101
Drive Units - Service Tools ....................... . . . 4-2 Turbocharger - Installation .......................... O-98
Electrical System Specifications ................... . . . V38 Turbocharger Oil Drain Tube - Installation .............. O-99
Electrical System Torque Values .................. . * . V-38 Turbocharger Oil Supply Hose - Installation ............ 6-100
Engine - Assembly ............................. . . . o-39 Valve Arrangement ............................... O-93
AFC Tube - Installation ......................... . . o-112 Valve Clearance - Adjustment ........................ O-92
Aflercooler - Installation ........................ . . . o-97 Valve Cover - Installation ........................... O-94
Air Compressor - Installation .................... . . o-119 Valve Tappet - Installation .......................... O-44
Air Crossover Tube - Installation .................. . . O-101 Vibration Damper - Installation ...................... 6-l 17
Alternator Brace - Installation .................... .. 9-104 Water Pump - Installation ........................... O-67
Alternator - Installation ......................... .. O-103 Engine Accessories - Installation .................... O-121
Alternator Mounting Bracket - Installation ........... .. o-103 Engine Components - General Information ............... V-2
Belt Tensioner Bracket - Installation ............... .. o-105 Engine Dataplate - Replacement ....................... 59
Belt Tensioner - Installation ..................... .. O-105 Engine Dataplate - Installation ........................ 59
Camshaft - Installation ......................... ... Engine Dataplate - Removal .......................... 59
Connecting Rod Bolt - Installation ................ . . . o-54 Engine Diagrams ................................... 6
Coolant Filter - Installation ...................... . . O-102 Engine - Disassembly ................................ O-9
Coolant Heater - Installation ..................... ..9 AFC Tube - Removal .............................. O-12
Coolant Inlet Connection - Installation ............. . . O-193 Aftercooler - Removal .............................. O-17
Coolant Outlet Connection - Installation ............ . . O-102 Air Compressor - Removal .......................... O-14
Coolant Vent Fitting - Installation ................. . . O-102 Air Crossover Tube - Removal ....................... O-17
Coolant Vent Petcock - Installation ................ . . c-102 Alternator Brace - Removal .......................... O-21
Coolant Vent Tube - Installation .................. . . O-103 Alternator Mounting Bracket - Removal ................. O-22
Crankcase Breather Tube - Installation ............. . . . o-95 Alternator - Removal .............................. O-22
Crankshaft - Installation ........................ . . . o-47 Belt Tensioner Bracket - Removal ..................... O-21
Cylinder Block - Installation onto Engine Rebuild Stand . . . o-39 Belt Tensioner - Removal ........................... O-21
Cylinder Head - Installation ..................... ... Camshaft - Removal .............................. O-28
Cylinder Liner - Installation ...................... ... Coolant - Draining ................................ O-10
Drive Belt - Installation ......................... . . o-118 Coolant Filter - Removal ........................... O-10
Engine Lifting Bracket - Installation ............... . . . o-96 Coolant Heater - Removal .......................... O-26
Engine - Removal from the Rebuild Stand .......... . . O-105 Coolant Inlet Connection - Removal ................... O-24
Engine Support, Front - Installation ............... . . O-l 18 Coolant Outlet Connection - Removal ................. O-22
Exhaust Manifold - Installation ................... . o-97 Coolant Vent Petcock - Removal ..................... O-23
Fan Hub Assembly - Installation .................. * . O-106 Coolant Vent Tube Fitting - Removal .................. O-23
Flywheel Bore Runout Measurement .............. . . . o-79 Coolant Vent Tube - Removal ....................... O-23
Flywheel Face Runout Measurement .............. . . . O-81 Crankcase Breather Tube - Removal .................. O-16
Flywheel Housing - Installation ................... . . * O-72 Crankshaft - Removal ............................. O-36
Flywheel - Installation .......................... . . . o-77 Cylinder Head - Removal ........................... O-23
Fuel Drain Manifold - Installation ................. . . . o-96 Cylinder Liner Carbon Deposits - Removal .............. 6-32
Fuel Filter Head - Installation .................... . . o-111 Cylinder Liner Protrusion - Checking .................. O-37
Fuel Filter - Installation ......................... . . o-111 Cylinder Liner - Removal ........................... O-37
Fuel Injection Pump - Installation ................. . . O-106 Drive Belt - Removal .............................. O-21
Fuel Injection Pump Supply tine - Installation ....... . . O-110 Engine - Installation onto Engine Rebuild Stand .......... O-15
Fuel Lines, High Pressure - Installation ............. . . o-112 Engine Lifting Equipment and Brackets ................. O-9
Fuel Lines, .Low Pressure - Installation ............. * . o-l 19 Engine - Preparation for Steam Cleaning ................ O-9
Fuel Pump Solenoid - Installation ................. . . o-l 19 Engine - Steam Cleaning ............................ O-9
Fuel Transfer Pump - Installation ................. . . O-l 18 Engine Support, Front - Removal ..................... O-31
Gear Cover - Installation ........................ . . O-116 Exhaust Manifold - Removal ......................... O-20
Gear Housing - Installation ...................... . . . o-62 Expansion Plug - Removal .......................... O-39
Injector - Installation ........................... . . . o-95 Expansion Plug - Replacement ...................... O-38
Intake Manifold Cover - Installation ................ . . . o-96 Fan Hub Assembly - Removal ....................... 9-24
Lubricating Oil Cooler - Installation ................ .. . flywheel Housing - Removal ........................ O-27
Lubricating Oil Filter - Installation ................. .. . Flywheel - Removal ............................... O-27
Lubricating Oil Pan - Installation .................. .. . Fuel Drain Manifold - Removal ....................... O-18
Lubricating Oil Pump - Installation ................ .. . Fuel Filter Head - Removal .......................... 9-l 1
Lubricating Oil Suction Tube - Installation .......... . . Fuel Filter - Removal .............................. O-l 1
Main Bearing (Lower) - Installation ................ . . . o-47 Fuel Injection Pump - Removal ...................... O-13
Main Bearing (Upper) - Installation ................ ... Fuel Injection Pump Supply Line - Removal ............. 9-12
Main Bearing Cap - Installation .................. . . . o-47 Fuel Lines, High Pressure - Removal .................. 6-12
Piston Assembly - Installation .................... . . . O-58 Fuel Lines, Low Pressure - Removal ................... O-11
Piston Cooling Nozzle - Installation ............... . . . o-45 Fuel Pump Solenoid - Removal ...................... O-15
Piston Pin - Installation ........................ . . . o-54 Fuel Transfer Pump - Removal ....................... 6-l 1
Piston Ring End Gap - Measurement .............. . . . o-55 Gear Cover - Removal ............................. O-26
Piston Ring - Installation ....................... . . . o-56 Gear Housing - Removal ........................... O-31
Push Rod - Installation ......................... . . . o-89 Injector - Removal ................................ O-18
Rocker Lever and Shaft - Assembly ............... . . . Intake Manifold Cover - Removal ..................... O-17
Rocker Lever Assembly - Installation .............. . . . o-91 Lubricating Oil Cooler - Removal ..................... O-24
Seal, Front Crankshaft - Installation ............... .. o-113 Lubricating Oil - Draining ........................... O-10
Seal, Rear Crankshaft - Installation ................ .. . o-51 Lubricating Oil Filter - Removal ...................... O-10
Index
Page X-3
Lubricating Oil Pan - Removal ....................... O-27 Expansion Plug - Installation .......................... 19
Lubricating Oil Pump Gear Backlash - Measurement ...... O-30 Pipe Plug - Installation .............................. 20
Lubricating Oil Pump - Removal ..................... D-31 Fan Hub - Cleaning and Inspection for Reuse ............ 6-7
Lubricating Oil Suction Tube - Removal ................ O-27 Cleaning ....................................... 8-7
Main Bearing (Lower) - Removal ..................... O-36 Inspection ...................................... 8-8
Main Bearing (Upper) - Removal ..................... O-36 Fan Hub- Rebuild.. ................................ 8-8
Main Bearing Cap - Removal ........................ O-35 Assembly ...................................... 8-9
Piston Assembly - Removal ......................... O-33 Disassembly .................................... 8-8
Piston Cooling Nozzle - Removal ..................... O-36 Flexplate Assembly - Cleaning and Inspection for Reuse ... 16-6
Piston Pin - Removal .............................. D-34 Flywheel - Cleaning and Inspection for Reuse ............ 16-5
Piston Ring - Removal ............................. O-35 Cleaning ....................................... 165
Push Rod - Removal .............................. O-19 Inspection ...................................... 165
Rocker Lever Assembly - Removal .................... O-19 Flywheel Housing - Assembly (Wet Clutch Application) ..... 168
Seal, Front Crankshaft - Removal ..................... O-26 Flywheel Housing - Cleaning and Inspection for Reuse ..... 16-7
Seal, Rear Crankshaft - Removal ..................... O-28 Cleaning ....................................... 167
Starting Motor - Removal ........................... O-26 Inspection ...................................... 16-7
Tachometer Drive - Removal ........................ O-13 Flywheel Ring Gear - Replacement .................... 16-6
Thermostat and Housing - Removal ................... O-22 Installation ...................................... 16-6
Turbocharger Exhaust Outlet Connection - Removal ....... O-16 Removal ....................................... 16-6
Turbocharger Oil Drain Tube - Removal ................ O-20 Free Length - Measurement ......................... 2-39
Turbocharger Oil Supply Hose - Removal ............... O-20 Fuel Drain Manifold - Inspection ...................... 616
Turbocharger - Removal ........................... O-20 Fuel Injection Pump Gaskets and Seals - Replacement .... 511
Valve Cover - Removal ............................. O-18 Fuel Injection Pump - Idle Speed Adjustment. ........... 14-25
Valve Tappet - Removal ............................ O-29 RSV Governor .................................. 1425
Vibration Damper - Removal ........................ O-25 RQV and RQVK Governor ......................... 1426
Wastegate Actuator Hose - Removal ................... O-16 Fuel Lines, High Pressure - Cleaning and Inspection
Water Pump - Removal ............................ O-25 for Reuse ........................................ 6-14
Cylinder Block - Removal from Engine Rebuild Stand ...... O-39 Fuel tines - Cleaning and Inspection .................. 615
Engine Disassembly and Assembly - Service Tools ......... O-4 General Information ............................... 614
Engine Dynamometer Test - Engine Run-in ............. 14-17 Fuel Lines, Low Pressure - Cleaning and Inspection
Engine Dynamometer Test - Installation of the Engine ..... 14-9 for Reuse ........................................ 616
Engine Dynamometer Test - Performance Checking ...... 14-21 Fuel System - General Information ..................... 52
Engine Identification.. ............................... 2 Derivative Fuel Injection Pump - Data Tag Information ..... 5-3
Engine Dataplate .................................. 2 Fuel Injection Pump ............................... 52
Fuel Injection Pump Dataplate ........................ 3 Fuel Injection Pump - Data Tag Information ............. 52
Engine Lifting Brackets - Cleaning and Inspection Fuel Injection Pump - Data Tag Location ............... 5-2
for Reuse ......................................... 66 Fuel Shutoff Solenoid - Wiring Requirements ............ 5-3
Engine Painting .................................. 14-26 Governor - Data Tag Information ..................... 5-3
Engine Run-In Procedure - “In-Chassis” ............... 14-24 Fuel Systems - Rebuild Specifications .................. V-25
Engine Run-In - General Procedures ................... 14-6 Fuel Injection Pump Sealing Washer .................. V-27
Engine Storage - Long Term ......................... 14-29 Fuel Shutoff Solenoid Adjustment .................... V-27
Engine Removal from Long Term Storage ............. 14-32 Fuel System Specifications ......................... V-25
Engine Storage - Short Term ........................ 14-27 Fuel System Torque Values ......................... V-27
Engine Removal From Short Term Storage ............ 14-29 Fuel Transfer Pump - Exploded View ................... 5-4
Engine Support Bracket, Front - Cleaning and Inspection for Fuel Transfer Pump - Rebuild ......................... 5-5
Reuse ........................................... 16-9 Cleaning ....................................... 5-5
Cleaning ....................................... 16-9 Assembly ...................................... 5-5 .
Inspection ...................................... 16-9 Gear Cover - Cleaning and Inspection for Reuse ........... 60
Engine Testing - Component Identification and Diagrams ... 14-3 Gear Cover - Cleaning .............................. 60
Engine Testing - General Information ................... 14-5 Gear Cover - Inspection ............................. 60
Engine Dynamometer Run-in ........................ 14-5 Gear Housing - Cleaning and Inspection for Reuse ......... 57
In-Chassis Run-In ................................. 14-5 Gear Housing - Cleaning ............................ 57
Engine Testing - General Specifications ................ 14-6 Gear Housing - Inspection ........................... 57
Engine Testing - Service Tools ........................ 14-2 General Cleaning Instructions ........................ i-8
Engine Testing - Test Specifications ................... V-39 Solvent and Acid Cleaning ........................... i-8
Exhaust Manifold - Cleaning and Inspection for Reuse .... 1 l-4 Steam Cleaning .................................. i-8
Cleaning ...................................... 11-4 General Engine Specifications ......................... 4
Inspection ..................................... 11-4 Cooling System ................................... 5
Exhaust Manifold - Exploded View .................... 1 l-2 Fuel System ..................................... 5
Exhaust Manifold Outlet Connection - Cleaning and Inspection General Engine Data ............................... 4
forReuse ....................................... 11-6 Intake Air and Exhaust System ........................ 5
Cleaning ...................................... 11-6 Lubrication System ................................ 4
Inspection ..................................... 1 l-6 General Engine Test Procedure - In Chassis ............ 14-23
Exhaust Manifold Turbocharger Mounting Stud - General Information ................................. 0.8
Replacement ..................................... 1 l-5 Disassembly ..................................... 0.8
Inspection ..................................... 11-5 Assembly ....................................... .
Installation ..................................... 1 l-5 General Repair Instructions .......................... i-7
Removal ...................................... 1 l-5 General Safety Instructions .......................... i-6
Exhaust System - General Information ................. 1 l-3 Generic Symbols .................................. i-4
Exhaust Manifold ................................ 1 l-3 Glossary of Terms ................................. i-9
Exhaust System Specifications ........................ V-37 How To Use This Manual ............................ i-3
Exhaust System Torque Values ....................... V-37 Group Contents .................................. i-3
Index .......................................... i-3
Index
Page X-4
Metric Information, ................................ i-3 Inspection ...................................... 7-8

Table of Contents ................................ i-3 Pips Plug Torque Values ............................ V-47
lllustrations.. ..................................... i-5 Pistons - Cleaning and Inspection for Reuse .............. 27
Injector - Chatter Testing ............................ 6-14 Piston Rings - Removal ............................. 27
Injector - Spray Testing ............................. 6-13 Pistons - Cleaning ................................. 27
Injectors and Fuel Lfnes - Exploded View ................. 6-6 Pistons - Inspection ................................ 28
Injectors and Fuel Lines - Exploded View ................. 63 Push Rods - Cleaning and Inspection for Reuse ........... 4-4
Injectors and Fuel tines - Exploded View ................. 6-5 Cleaning ........................................ 4-4
Injectors and Fuel tines - General Information ............ 6-7 Inspection ....................................... 4-4
Injectors and Fuel tines - Service Tools ................. 6-2 Rear Cover - Cleaning and Inspection ................... 63
Injectors - Cleaning and Inspection for Reuse ............. 6-8 Cleaning ........................................ 63
General Information ................................ 6-8 Inspection ....................................... 64
Injector - Assembly ............................... 6-12 Rocker Assembly Oil Manifold - Cleaning and Inspection for
Injector - Cleaning and Inspection .................... 6-10 Reuse ........................................... 3-7
Injector - Disassembly .............................. 6-8 Cleaning ....................................... 3-7
Intake Manifold Cover - Cleaning and Inspection for Reuse . 10-7 Inspection ...................................... 3-7
Inspection ...................................... 18-7 Rocker Lever Assembly - Cleaning and Inspection ........ 3-4
Lubricating Oil Dipstick - Calibration .................. 7-13 Assembly ...................................... 3-6
Lubricating Oil Pan - Cleaning and Inspection for Reuse ... 7-5 Cleaning ....................................... 35
Cleaning ....................................... 7-5 Disassembly .................................... 3-4
Inspection ...................................... 7-5 Inspection ...................................... 3-5
Lubricating Oil Pump - Cleaning and Inspection for Reuse . 7-14 Rocker Lever Assembly - Exploded view ................ 3-2
Cleaning ...................................... 7-15 Rocker Lever Assembly - General Information ............ 33
Disassembly ................................... 7-14 Rocker Lever Assembly - Rebuild Specifications .......... V-25
Inspection ..................................... 7-15 RQVK Governor Fuel Shutoff Solenoid - Adjustment ....... 5-9
Lubricating Oil System - Exploded View ................. 7-4 RSV Governor Fuel Shutoff Solenoid - Orientation and
Lubricating Oil System - General Information ............ 7-3 Adjustment ....................................... 5-6
Dipstick ........................................ 7-3 Fuel Shutoff Solenoid - Adjustment ................... 5-8
Lubricating Oil Cooler and Filter Head ................. 7-3 Fuel Shutoff Solenoid - Orientation .................... 5-6
Lubricating Oil Pump .............................. 73 Shutdown Lever or Spring - Replacement .............. 5-10
Oil Filter Head ................................... 7-3 Tap-Drill Chart - U.S. Customary & Metric ............... V-46
Oil Pan ........................................ 73 Thermostat Housing - Cleaning and Inspection for Reuse ... 8-6
Oil Pressure Regulator ............................. 73 Cleaning ....................................... 8-6
Oil Temperature Thermostat ........................ 73 Inspection ...................................... 8-6
Lubricating Oil System - Service Tools. ................. 7-2 Thermostat - Inspection ............................. 8-6
Lubricating Oil System Specifications .................. V-30 Turbocharger - Cleaning and Inspection for Reuse ........ 16-5
Lubricating Oil System Torque Values .................. V-31 Inspection ...................................... 10-5
Lubricating Oil Temperature Thermostat - Cleaning and Valve Cover - Cleaning and Inspection for Reuse ......... 3-8
Inspection ....................................... 7-12 Cleaning ....................................... 3-8
Cleaning ...................................... 7-12 Inspection ...................................... 3-8
Inspection ..................................... 7-12 Valve Tappet Cleaning and Inspection for Reuse ........... 4-3
Main Bearing Caps and Capscrews - Cleaning and Inspection for Cleaning ...................................... ..4- 3
Reuse ............................................ 38 Inspection ....................................... 4-3
Cleaning ........................................ 38 Valve Tappet - Rebuild Specifications .................. V-25
Inspection ....................................... 39 Valve Tappets and Push Rods - Exploded View ............ 4-2
Main Bearings - Cleaning and Inspection for Reuse ........ 36 Valve Tappets and Push Rods - General Information ........ 4-3
General Information ................................ 36 Vibration Damper - Cleaning and Checking for Reuse ....... 61
Main Bearings - Cleaning ............................ 37 General Information ................................ 61
Main Bearings - Inspection ........................... 37 Rubber Element Vibration Damper - Inspection ........... 61
Thrust Bearings - Inspection .......................... 38 Rubber Vibration Damper - Cleaning ................... 61
Mounting Adaptations - Exploded View ................. 16-3 viscous Vibration Damper - Cleaning ................... 62
Mounting Adaptations - General Information ............. 16-4 Viscous Vibration Damper - Inspection .................. 62
Flywheel and Ring Gear ............................ 16-4 Water Outlet Connection - Cleaning and Inspection
FlywheelHousing ................................ 16-4 for Reuse ........................................ 8-7
Mounting Adaptations - Service Tools .................. 16-2 Water Pump Assembly - Cleaning and Inspection for Reuse 8-5
Mounting Adaptations Specifications ................... V-39 Cleaning ....................................... 8-5
Flywheel Housing (Wet Application) ................... V-39 Inspection ...................................... 8-5
Flywheel Ring Gear Installation ...................... V-40 Weight and Measures - Conversion Factors ............. V-43
Mounting Adaptations - Torque Values ................. V-40
Newton-Meter to Foot-Pound Conversion Chart .......... V-44
Oil Cooler Cover - Disassembly and Assembly .......... 7-10
Assembly ..................................... 7-l 1
Cleaning ...................................... 7-10
Disassembly ................................... 7-10
Oil Cooler Element - Cleaning and Inspection for Reuse .... 7-6
Cleaning ....................................... 7-6
Inspection ...................................... 7-6
Pressure Test. ................................... 7-6
Oil Filter Bypass Valve - Replacement .................. 7-9
Oil Pressure Regulating Valve - Cleaning and Inspection ... 7-i’
Assembly ...................................... 7-8
Cleaning ....................................... 7-8
Disassembly .................................... 7-T
Trouble Shooting and
Repair Manual
S6D114E-1
SAGDI 14E-1
SAAGDI 14E-1
Series Engine
6D114E-1 Series Engine

Foreword
This manual provides instructions for troubleshooting and repairing the 6D114E-1 Series Engine in the chassis. Component
and assembly rebuild procedures are provided in the 6D114E-1 Series Engine Shop Manual. Refer to Page i-2 in the
introduction for instructions on how to use this manual.
The manual is organized to guide a service technician through the logical steps of identifying and correcting problems
related to the engine.
This manual does not cover machine or equipment problems. Consult the appropriate machine chassis shop manual for
repair procedures.
A series of specific service manuals (Shop, Specification, Alternative Repair, and so forth) are available and can be
ordered through your distributor using the form in front of this book.
The repair procedures used in this manual are recommended by Komatsu America International Company. Some service
procedures require the use of special service tools. Use the correct tools as described.
The specifications and rebuild information in this manual is based on the information in effect at the time of printing.
Komatsu America International Company reserves the right to make any changes at any time without obligation. If
differences are found between your engine and the information in this manual, contact your Komatsu Distributor.
The latest technology and the highest quality components are used to manufacture Komatsu engines. When replacement
parts are needed, we recommend using only genuine Komatsu exchange parts.
Table of Contents
Page
Introduction .................................................. 1
Engine Identification ............................................ E
Troubleshooting ............................................... T
Cooling System Repair .......................................... 1
Lubricating Oil System Repair ...................................... 2
Air Combustion System Repair ..................................... 3
Compressed Air System Repair .................................... 4
Fuel System Repair ............................................. 5
Electrical System Repair ......................................... 6
Base Engine Components System Repair ............................. 7
Engine Testing and Run-In ........................................ a
Engine Removal and Installation .................................... 9
Specifications and Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Index . . . . . . . . . . . . . . . . . . . . . ..~............................... X
Page i-l
Section Contents
Page
About the Manual .......................................................... i-2
General Cleaning instructions .................................................. i-8

Solvent and Acid Cleaning .................................................... i-8
Steam Cleaning ........................................................... i-8
General Repair Instructions .................................................... i-7
General Safety Instructions .................................................... i-6
Generic Symbols ........................................................... i-4
Glossary of Terms .......................................................... i-9
HowTo Use This Manual ..................................................... i-3

Group Contents.. ......................................................... i-3
index.. ................................................................ i-3
Metric Information, ......................................................... i-3
Table of Contents ......................................................... i-3
illustrations ............................................................... i-5

Page i-2
About the Manual

This 6D114E-1 Series Troubleshooting and Repair Manual is intended to aid in determining the cause of engine-related
problems and to provide recommended repair procedures. The manual is divided into sections by system. Each section
provides general information, specification, diagrams, and service tools, where applicable. The specific repair procedures
are referenced in the Troubleshooting Logic Charts.
How To Use This Manual

The manual is organized to provide an easy flow from problem identification to problem correction. A list of
troubleshooting symptoms containing the most common engine problems is on Page T-2 in the Troubleshooting Section.
Complete the following steps to locate and correct the problem:
(STEP 1.) Locate the symptom on the list.
Reference is made to the procedure number where the “Troubleshooting Logic Chart” is found.
(STEP 2.) The left column of the “Troubleshooting Logic Chart” indicates a probable cause, starting at the top with
the simplest and easiest to repair, and continuing downward to the most difficult.
The right column provides a brief description of the corrective action with the reference number for the
repair.
(STEP 3.) Locate the probable cause in the left column, and then turn to the procedure number in the right column.
The repair procedures are listed by system (Cooling, Lubricating Oil, Combustion Air, Compressed Air, Fuel,
Electrical, and Base Engine Components).
(STEP 4.) The troubleshooting Logic Charts are based on the following assumptions:
1. The engine has been installed to the proper specifications.
2. The easiest repairs are done first.
3. “Generic” solutions to cover problems with the most common applications.
Table of Contents
The Table of Contents in the front of the manual contains a quick page reference for each group number.
Index
An alphabetical index is in the back of the manual to aid in locating specific information.
Metric Information,
Both metric and U.S. customary values are used in this manual. The metric value is listed first, followed by the U.S.
customary in brackets. An example is 60°C [140” F].
Section i - introduction
Page i-3
Generic Symbols
The following group of symbols have been used in this manual to help communicate the intent of the instructions.
When one of the symbols appears, it conveys the meaning defined below.
WARNING - Serious personal injury or extensive property damage can result if the warning instructions
are not followed.
CAUTION - Minor personal injury can result or a part, an assembly or the engine can be damaged if
the caution instructions are not followed,
Indicates a REMOVAL or DISASSEMBLY step.
Indicates an INSTALLATION or ASSEMBLY step,
INSPECTION is required,
CLEAN the part or assembly.
PERFORM a mechanical or time MEASUREMENT.
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE will be given.
TIGHTEN to a specific torque,
PERFORM an electrical MEASUREMENT.
Refer to another location in this manual or another publication for additional information,
The component weighs 23 kg [50 lb] or more, To avoid personal injury, use a hoist or get assistance
to lift the component.
Section i - introduction
Page i-4
Illustrations
The illustrations used in the “Repair Sections” of this manual

are intended to give an example of a problem, and to show
what to look for and where the problem can be found. Some
of the illustrations are “generic” and might not look exactly
like the engine or parts used in your application. The
illustrations can contain symbols to indicate an action
required, and an acceptable or not acceptable condition.
The illustrations are intended to show repair or replacement

procedures with the engine “in-chassis”. The illustration can
differ from your application, but the procedure given will be
the same.
Page i-5
General Safety Instructions

Important Safety Notice
A WARNING A
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the
general safety precautions that must be followed to provide personal safety. Special safety precautions are included in
the procedures when they apply.
Make sure the work area surrounding the product is safe. Be aware of hazardous conditions that can exist.
Always wear protective glasses and protective shoes when working.
Do not wear loose-fiiing or torn clothing. Remove all jewelry when working.
Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air starting
motor if equipped to prevent accidental engine starting. Put a “Do Not Operate” tag in the operator’s compartment
or on the controls.
Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the
engine by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or
damage to the fan blade(s) causing premature fan failure.
If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the filler
cap and relieve the pressure from the cooling system.
Do not work on any thing that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.
Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are removed
or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure,
Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.
To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon) lines
in a well ventilated area.
To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg 150 lb] or more.
Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity.
Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not
be side-loaded.
Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact
with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of
contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL
A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.
To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes
and compartments.
Always use tools that are in good condition, Make sure you understand how to use them before performing any
service work. Use ONLY genuine Komatsu replacement parts.
Always use the same fastener part number (or equivalent) when replacing fasteners, Do not use a fastener, of
lessor quality if replacements are necessary.
Page i-6
General Repair Instructions

This engine incorporates the latest diesel technology; yet, it is designed to be repaired using normal repair practices
performed to quality standards.
0 Komatsu America International Co. does not recommend or authorize any modifications or repairs to engines
or components except for those detailed in Komatsu Service Information. In particular, unauthorized repair
to safety-related components can cause personal Injury. Below Is a partial listing of components classified
as safety-related:
Air Compressor
Air Controls
Air Shutoff Assemblies
Balance Weights
Cooling Fan
Fan Hub Assembly
Fan Mounting Bracket(s)
Fan Mounting Capscrews
Fan Hub Spindle
Flywheel
Flywheel Crankshaft Adapter Flywheel Mounting Capscrews
Fuel Shutoff Assemblies
Fuel Supply Tubes
Lifting Brackets
Throttle Controls
Turbocharger Compressor Casing Turbocharger Oil Drain Line(s)
Turbocharger Oil Supply Line(s)
Turbocharger Turbine Casing
Vibration Damper Mounting Capscrews
Follow All Safety Instructions Noted In the Procedures.
Follow the manufacturer’s recommendations for cleaning solvents and there substances used during the repair of
the engine. Always use good safety practices with tools and equipment.
Provide A Clean Environment and Follow the Cleaning Instructions Specified in the Procedures
The engine and its components must be kept clean during any repair. Contamination of the engine and
components will cause premature wear.
Perform the Inspections Specified in the Procedures.
Use Genuine Komatsu Service Parts and Assemblies
Replace all Components or Assemblies Which are Damaged or Worn Beyond the Specifications
The assembly instructions have been written to use again as many components and assemblies as possible. When
it is necessary to replace a component or assembly, the procedure is based on the use of new Komatsu
components. All of the repair services described in this manual are available from all Komatsu Distributors.
Follow The Specified Disassembly and Assembly Procedures to Avoid Damage to the Components.
Complete rebuild instructions are available in the shop manual which can be ordered or purchased from your Komatsu
Distributor. Refer to the front of this book for ordering instructions.
Page i-7
General Cleaning Instructions

Solvent and Acid Cleaning
Several solvent and acid-type cleaners can be used to clean the engine parts. Komatsu America International
Company does not recommend any specific cleaners. Always follow the cleaner manufacturer’s instructions.
Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95”
Celsius [80 to 200” Fahrenheit]. A cleaning tank that provides a constant mixing and filtering of the cleaning
solution will give the best results.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper
before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam
clean the parts before putting them in the cleaning tank.
Warning: The use of acid can be extremely dangerous to personnel, and can damage the machinery. Always
provide a tank of strong soda water as a neutralizing agent.
Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from
all of the capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound. The
rustproofing compound must be removed from the parts before installation on the engine.
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good way
to clean the oil drillings.
Warning: Wear protective clothing to prevent personal Injury from the high pressure and extreme heat.
Do not steam clean the following parts:
1. Electrical Components
2. Wiring
3. Injectors
4. Fuel Pump
5. Belts and Hoses
6. Bearings
Glass or Plastic Bead Cleaning

Glass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning
process is controlled by the size of the plastic beads, the operating pressure and the cleaning time.
Caution: Do not use glass or plastic bead cleaning on aluminum piston skirts. Do not use glass bead
cleaning on aluminum ring groves. Small particles of glass or plastic will embed in the aluminum and result
in premature wear. Valves, turbocharger shafts, etc. can also be damaged. Follow the cleaning directions
listed in the procedures.
NOTE: Plastic bead blasting media, Part No. 3822735, can be used to clean aluminum ring grooves. Do not use
any bead blasting media on pin bores or aluminum skirts.
Page i-7-01
Follow the equipment manufacturer’s cleaning instructions. The following guidelines can be used to adapt to
manufacturer’s instructions:
1. Bead size: - Use U.S. size No. 16-20 for piston cleaning with plastic bead media, Part No. 3822735.
- Use U.S. size No. 70 for piston domes with glass media.
- Use U.S. size No. 60 for general purpose cleaning with glass media.
2. Operating Pressure: - Glass: Use 620 kPa 190 psi] for general cleaning.
- Plastic: Use 270 Kpa [40 psi] for piston cleaning.
3. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic beads after
cleaning. Rinse with hot water. Dry with compressed air.
4. Do not contaminate the wash tanks with glass or plastic beads.

Page i-8
Glossary of Terms
Definition
A. C.: Alternating Current
AFC: Air Fuel Control; a device in the fuel pump that limits the fuel delivery until there is
sufficient intake manifold pressure to allow for complete combustion.
ATDC: After Top Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is moving downward on the power stroke or intake stroke.
BDC: Bottom Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is at its lowest position in the cylinder.
BTDC: Before Top Dead Center; refers to the position of the piston or the crankshaft rod journal.
The piston is moving upward on the compression stroke or exhaust stroke.
Circumferential Direction: In the direction of a circle in respect to the centerline of a round part or a bore.
Concentricity: A measurement of the difference between the centers of either two or more parts or the
bores In one part.
Silicone Sealant: This is a one part Room Temperature Vulcanizing (RTV) silicone rubber, adhesive and
sealant material having high heat and oil resistance, and low compression set.
Some of the equivalent products are Marston Lubricants, Hylosil, Dow Corning, Silastic
732, Loctite Superflex, General Electric RTV108 and Three Bond Sealant.
DC: Direct Current
Dye Penetrant Method: A method used to check for cracks in a part by using a dye penetrant and a developer.
Use crack detection kit, Part No. 3375432, or its equivalent.
End Clearance: The clearance in an assembly determined by pushing the shaft in an axial direction one
way and then pushing the shaft the other way.
ESN Engine Serial Number
Hammer: A hand tool consisting of a hard steel head on a handle.
I. D.: Inside Diameter
Loctite 290: A single component, anaerobic, polyester resin, liquid sealant compound that hardens
between closely fitted metal surfaces producing a tough. hard bond. Equivalent products
are Komatsu 1232 273 Hl and Perma-Lok HL 126.
Page i-9
Definition
Loctite 609: A single component anaerobic, liquid adhesive that meets or exceeds the requirements
of MIL-R-46082A (MN) TYPEl.
Some of the equivalent products are Komatsu 634 018 Cl, Loctite 601 and Permabond
HL 138.
Lubriplate 105: A mineral oil base grease with calcium soap (2 percent to 6 percent), and zinc oxide (2
percent to 4 percent) additives.
Magnetic Particle Inspection: A method of checking for cracks in either steel or iron parts. This method requires a
Magnaflux or equivalent machine that imparts a magnetic field on the part being checked.
Mallet: A hand tool consisting of a soft head, either wood, plastic, lead, brass, or rawhide, on
a handle.
MAX: Maximum allowed
MIN: Minimum allowed
No.: Number
O.D.: Outside Diameter
OS: Oversize
Protrusion: The difference in the height between two parts in the assembled state.
STD: Standard
TC: Torque Converter; used when referring to the torque converter cooler.
TDC: Top Dead Center; refers to the position of the piston or the crankshaft rod journal. The
piston is at its highest position in the cylinder. The rod journal is pointing straight up
toward the piston.
T.I.R.: Total Indicator Runout; used when measuring the concentricity or the runout. The T.I.R.
refers to the total movement of the needle on a dial indicator, from the most negative
reading to the most positive reading.
Water Pump Grease: A premium high temperature grease that will lubricate antifriction bearings continually from
minus 40” C [minus 40” F] to plus 150” C [plus 350” F]. Some of the greases meeting
this requirement are Aeroshell No. 5, Chevron SRI, Amoco Rykon Premium No. 2, Texaco
Premium RB, and Shell Dolium R. Aeroshell No. 5 is not compatible with the other
greases and must not be mixed. Aeroshell No. 5 is used on new engines and
components.
Section E - Engine Identification
Page E-l
Section E - Engine and Component Identification

Section Contents
Engine Identification .......................................................... 2

Engine Dataplates .......................................................... 2
Fuel Injection Pump Dataplate .................................................. 3
General Engine Specifications ....................................................

General Engine Data ........................................................
Lubrication System.. ........................................................
Cooling System ............................................................
Intake Air and Exhaust System ..................................................
Fuel System ..............................................................
Electrical System ...........................................................
Batteries (Specific Gravity) .....................................................
Engine Diagrams ............................................................. 7

Page E-2
Engine Identification
Engine Dataplates
The engine dataplates show specific information about your
engine. The engine serial number provides information for
ordering parts and service needs.
The engine dataplates are located on the front gear cover
housing, on the fuel pump side of the engine, oriented 90
degrees from horizontal. See drawing at left.
NOTE: The engine dataplate must not be changed unless
approved by Komatsu.
6CTAG2
GCTAG1
Engine Dataplates
The. Komatsu model designation represent the

basic design and configuratron of your engrne. (1) Turbocharged
Example Engine Model Name: (2) Jacket water aftercooled (JWAC)
(2) or (3)
6D114E-1, S6D114E-1, SAGD114E-1or SAAGD114E-1
(3) Charged air cooled (CAC)
S A (AA) 6 D114 E -1 (4) Number of cylinders
(1) (2) (3) (4) (6) (6) (7) (6) (6) Diesel
(6) Cylinder Bore Dia. in mm
(7) Emissionized
(6) Engine Series
Page E-3
Fuel Injection Pump Dataplate

The injection pump dataplate is located on the side of the
injection pump. It provides information for fuel pump
calibration.
The vendor part number for the fuel pump-governor

combination is located on the governor dataplate.
Page E-4
General Engine Specifications
General Engine Data

Bore ................................................................ 114 mm [4.49 in]
Stroke ............................................................... 135 mm [5.32 in]
Displacement ........................................................ 8.27 liters [504.5 in31
Compression ratio
6D114E-1 .................................................................. 16.4:1
S6D114E-1 ................................................................. 17.3:1
SA6D114E-1 ................................................................ 16.5:1
SAAGD114E-l *
High Torque ............................................................. 17.3:1
LowTorque.. ............................................................. 18:l
Firing order ................................................................ l-5-36-2-4
Valve clearance
Intake ........................................................... 0.30 mm [0.012 in]
Exhaust .......................................................... .0.61 mm [0.024 in]
Engine rotation (viewed from front of engine) .......................................... Clockwise
Aspiration
6D114E-1 ......................................................... Naturally Aspirated
S6D114E-1 ........................................................... Turbocharged

SAGD114E-1 ......................................... Turbocharged and Jacket Water Cooled
SAA6Dll4E-1 .................................... Turbocharged and Charged Air Cooled (CAC)
Engine weight (with standard accessories)
Dryweight ............................................... 603to612kg[1330to138OIb]
Wetweight.. ............................................. 635to658kg[14OOto1450Ib]
Lubrication System
Oil pressure
At idle (minimum allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa [lo psi]
At rated speed (minimum allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 kPa [30 psi]

Differential pressure to open oil filter bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa [25 psi]
Oil flow at rated speed (less flow though pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . 106.8 Ipm [28.2 gpm]
Oil temperature at rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.9“ to 126.6”C 1210” to 26O”F]
Oil temperature thermostat
Fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116°C [241"F]
Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104%[219"F]
Oil pan capacity (all engines) (high - low) . . . . . . . . . . . . . . . . . . . . . . . . . 18.9 to 15.1 liters 120 to 16 U.S. Qts.]
Total system capacity

6D114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.6 liters 125.0 U.S. Qts.]
S6D114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.8 liters [25.2 U.S. Cts]
* All emissionized engines with Charged Air Cooling are designed as “AA”.
Page E-5
Cooling System
Thermostats
Begins to open .............................................. 81” to 83°C 1178” to 182’F]
Fully open ............................................................ 95” C [203”F]
Top tank temperature
Maximum allowable ..................................................... 100°C [212” F]
Minimum recommended ................................................... 70” C [158” F]
Pressure cap for 99°C [21O”F] system ........................................... 50 kPa [7 psi]
Pressure cap for 104°C [220” Fj system ......................................... 103 kPa [15 psi]
Water Pressure (Upper manifold) at 2090 RPM engine speed .................. 103 to 276 kPa [15 to 40 psi]
Coolant flow (thermostats fully opened, engine speed 2000 RPM) ....................... 258 Ipm [68 gpm]
Coolant capacity (engine only)
6D114E-1, S6D114E-1, SAAGD114E-1* .................................. 9.9 liters [lo.5 U.S. Cts.]
SAGD114E-1 .................................................. 10.9 liters [11.5 U.S. Cts.]
Intake Air and Exhaust System

Maximum allowable intake restriction at rated speed and load (with dirty air filter element)
6D114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.8 cm H,O [20 in H,O]
S6D114E-1, SAGD114E-1, SAAGD114E-l* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 cm H,O [25 in H,O]
Maximum turbocharger outlet restriction at rated speed and load
6D114E-1, S6D114E-1, SMGD114E-l* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.2 mm Hg [3 in Hg]
6D114E-1, SAAGD114E-l* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.6 cm H,O [40 in H,O]
SAGD114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 in H,O [6 in Hg]
Fuel System
6D114E-1, S6D114E-1, SAGD114E-1, SAAGD114E-l* . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Hg [4.0 in Hg]
Fuel transfer pump minimum output pressure at rated speed
6D114E-1, S6D114E-1, SAGD114E-1 Low Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 kPa [12 psi]
SAAGD114E-l* High Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa [25 psi]
Minimum pressure to fuel pump inlet (all in-line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Barr [18 psi]
Fuel filter restriction (maximum pressure drop across filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 kPa [5 psi]
Fuel pump gallery pressure minimum at rated speed high flow . . . . . . . . . . . . . . . . . . . . . . . . . . 140 kPa [20 psi]
Fuel pump gallery pressure minimum at rated speed low flow . . . . . . . . . . . . . . . . . . . . . . . . . 48 kPa [7 psi]
Fuel return restriction (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 mm Hg [20.4 in Hg]
* All em&ionized engines with Charged Air Cooling are designed as “AA”.
Page E-6
Electrical System
Minimum Recommended Battery Capacity
12 Volt System
-18°C [O’F] Cold cranking amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800
(Reserve capacity amperes)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (840)
0°C [32”F] Cold cranking amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1280
24 Volt System**
-18°C [O’F] Cold cranking amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .!300
O”^c [32” F] Cold cranking amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640
* The number of plates within a given battery size determining reserve capacity determines the length of time sustained
cranking can occur.
** Per battery (two 12 volt batteries in series) CCA Ratings are based on -18°C [O“F].
Batteries (Specific Gravity)
Specific Gravity
at 27°C [8O”F] State of Charge
1.280 - 1.280 100%

1.230 - 1.250 75%
1.200 - 1.220 50%
1.170 - 1.190 25%
1.110 - 1.130 Discharged
Page E-7
Engine Diagrams
The illustration which follow show the locations of the major external engine components, the filters, and other service
and maintenance points. Some external components will be at different location for different engines.
High Pressure
!b[inch]NPTF (Air)
Fuel Lines
Front Lifting M22 x 1.50 (Air)

Bracket Rear Lifting
_ Bracket
Fuel
Injection
Pump
3/4x lG[inch]UNF
Tap for Magnetic
Pick-up
Air
Compressor T
Front Engine
Mounting Bracket
FUEL PUMP SIDE VIEW

Page E-8
Turbocharger
Turbocharger
Wastegate Actuator
Exhaust Outlet Water Outlet
Lubricating Oil
Provision for Lubricating Oil

Coolant Heater
Provision for
Cab Heater
Pressure (before
Turbocharger
Oil Drain
emperature Sensor

Page E-9
Turbocharaer
Crankcase
Vent Tube
Mounting Holes
Housing
REAR VIEW
Air Outlet Engine Air
, Inlet
\ /Air ‘ldet
Coolant- _ fll
Filter Fuel Pump
Drive Cover
Fan Pulley
Drive Belt
Water Pump Y
o nn Vibration
”
Damper
FRONT VIEW
Section T - Troubleshooting Logic
Page T-l

Section Contents
Page
Section T - Troubleshooting ..................................................... 2

Procedures and Techniques .................................................... 2 ._
Troubleshooting Symptoms Charts ................................................ 2

Air Compressor Operates with Excessive Noise ....................................... 3
Air Compressor Pumping Excessive Lubricating Oil into Air System ......................... 4
Air Compressor Air Pressure Rises Slowly .......................................... 5
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously) ............. 6
Air Compressor Will Not Pump Air Pressure ......................................... 7
Air Compressor Will Not Stop Pumping Air .......................................... 8
Alternator Not Charging or Insufficient Charging ...................................... 9
Compression Knock ........................................................ 10
Coolant Contaminated ........................ 11
CoolantLoss.......:::::::::::::::::::::::::::::: ........................ 12
Coolant Temperature Above Normal - Gradual Overheat ................................ 14
Coolant Temperature Above Normal - Sudden Overheat ................................ 17
Coolant Temperature Below Normal ............................................. 18
Engine Crankcase Gases (Blowby) - Excessive ...................................... 19
Engine Cranks, But Will Not Start - No Smoke from Exhaust ............................. 20
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present ......................... 21
Engine Idle Rough, Warm Engine ............................................... 23
Engine Misfiring ........................................................... 24
Engine Power Output Low .................................................... 25
Engine Noise Excessive ..................................................... 29
Engine Starts But Will Not Keep Running .......................................... 30
Engine Surges at Idle ....................................................... 31
Engine Vibration Excessive ................................................... 32
Engine Will Not Crank or Cranks Slowly .......................................... 33
Engine Will Not Reach Rated Speed When Loaded ................................... 34
Engine Will Not Shut Off ..................................................... 35
Exhaust Black Smoke Excessive Under Load ....................................... 36
Exhaust White Smoke Excessive (Warm Engine) ..................................... 38
Fuel Consumption Excessive .................................................. 39
Fuel or Oil Leaking from Exhaust Manifold ......................................... 40
Lubricating Oil Contaminated .................................................. 41
Lubricating Oil Consumption Excessive ........................................... 42
Lubricating Oil Pressure Low .................................................. 44
Lubricating Oil Pressure High .................................................. 46
Engine Noise Diagnostic Procedures - General Information .............................. 47
Main Bearing Noise (Refer to Engine Noise Excessive - Main bearing System Chart) ............. 47
Connecting Rod Bearing Noise (Refer to Engine Noise Excessive - Connecting Rod Symptom Chart) . 47
Piston Noise (Refer to Engine Noise Excessive - Piston Symptom Chart) .................... 47
Fuel Consumption - General Information .......................................... 47
Fuel Consumption - Industrial Customer Complaint Form ............................... 48
Oil Consumption .......................................................... 49
Page T-2
Section T - Troubleshooting
Procedures and Techniques

A thorough analysis of the customer’s complaint is the key to successful troubleshooting. The more information known
about a complaint, the faster and easier the problem can be solved.
The “Troubleshooting Symptoms Charts” beginning on Page T-3 are organized so that a problem can be located and
corrected by doing the easiest and most logical things first. Complete all steps in the sequence shown from top to
bottom.
It is not possible to include all the solutions to problems that can occur; however, these charts should stimulate a thought
process that will lead to the cause and correction of the problem.
Get all the facts concerning the complaint.
Analyze the problem thoroughly.
Relate the symptoms to the basic engine systems and components.
Consider any recent maintenance or repair action that may relate to the problem.
Double-check before beginning and disassembly.
Solve the problem by using the logic charts and doing the easiest things first.
Determine the cause of the problem and make a thorough repair.
After repairs have been made, operate the engine to make sure the cause of the problem has been corrected.
Troubleshooting Symptoms Charts

Use the charts on the following pages of this section to aid diagnosing specific engine problems. Read each row of blocks
from top to bottom. Follow the arrows through the chart to identify the corrective action.
Page T-3
Air Compressor Operates with Excessive Noise
Cause Corrections
Excessive Carbon Buildup in the Air Check the air compressor for carbon buildup.
c/--------j1
OK
Air compressor
train damaged
drive gear or engine gear ________-
1 Inspect condition of gears and repair as
needed. Refer to Procedure 4-05.
1
OK
c
Replace the air compressor. Refer to

Internal Air Compressor Damage
~~~~~~~~~~~ Procedure 4-05.
I I I J
Page T-4
Air Compressor Pumping Excessive Lubricating Oil into Air System
Cause Corrections
Air Compressor Cylinder Bore or Piston Check air compressor discharge line. Refer to
gt---------{Ii
Page T-5
Air Compressor Air Pressure Rises Slowly
Cause Corrections
1 Check for air compressor gasket leaks. Refer
------_-__ to Procedure 4-02. Refer to the
Air System Leaks
manufacturer’s instructions for other air
system leaks.
OK
+
Carbon Buildup in the Air Discharge Line _________ Inspect the discharge line. Refer to
Excessive Procedure 4-01.
OK
+
Check operation of check valves, alcohol

Air System Component is Malfunctioning .____---- evaporators, air driers, etc. Refer to the
chassis Shop Manual for instructions.
I I I
OK
Air Compressor
Malfunctioning
Unloader Valve Assembly
I_________ Check unloader valve operation.

Procedure 4-03.
Refer to
OK
+
+~_________{I
Air Compressor Intake or Exhaust Valve Air Inspect the intake and exhaust valve
assemblres. Refer to Procedure 4-01.
Page T-6
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)
Cause Corrections
I I
_____-_-_ Check air system plumbing. Refer to the
Air System Leaks Excessive
Chassis Shop Manual for instructions.
t i
I I
OK
+
Air Governor is Malfunctioning or Not Set

Check air governor. Refer to Procedure 4-04
Page T-7
Air Compressor Will Not Pump Air Pressure
Cause Corrections
Check air system plumbing. Refer to the

Air System Leaks Excessive
~~~~~~~~~ chassis Shop Manual for instructions.
OK
Air Governor
Correctly
Malfunctioning or Not Set Check air governor
Procedure 4-04.
operation. Refer to
1
I
Air Compressor Unloader Valve Assembly Check the unloader valve operation. Refer to
Malfunctioning ~~~~~~~~~ Procedure 4-03.
i
Page T-8
Air Compressor Will Not Stop Pumping Air
Cause Corrections
1 Check air compressor for gasket leaks. Refer
Air System Leaks __---_----_ to Procedure 4-02. Refer to the chassis Shop
Manual for instructions for other air system
leaks.
OK
+
Air Compressor Unloader Valve is Not

Check the air governor operation. Refer to
Receiving Correct signal From the Air
Procedure 4-03.
Governor
I
OK
c
I I
Air Compressor Unloader Valve Assembly Check the unloader valve operation. Refer to
Leaks ~~~~~~~~~ Procedure 4-03.
t
I
iI
OK
+I---------{1
Air Compressor Unloader Valve Spring
Check the unloader valve spring
specifications and application. Refer to
Page T-9
Alternator Not Charging or Insufficient Charging
Cause Corrections
Load test the battery. If battery charge is low,

Battery Condition ----------- charge the battery and load test again. If the
battery fails the load test, replace the battery.
OK
+
I I I
Clean/tighten battery connections. Refer to
Battery Connections Loose or Corroded
~~~~~~~~~ Procedure 6-01.
t
I
iI I
OK
c
I I I
____----_ Check/replace belt tensioner. Refer to
Alternator Belt Slipping
Procedure l-04.
tI iI I
OK
l
Alternator Pulley Loose on Shaft
OK
*
I I
Check/replace the gauge or lamp. Refer to
Gauge or Lamp Malfunction
~~~~~~~~~ Procedure 6-01.
t
I
iI
tl_________{l
Alternator Wires Loose or Broken
Replace alternator. Refer to Procedure 6-03.

it_________]--_ Refer to the chassis Shop Manual for
Page T-10
Compression Knock
Ether Starting Aid Malfunctioning
I___--_--_ Corrections
Repair or replace ether starting aids.
Bleed fuel system and check for suction

Air in Fuel System
leaks. Refer to Procedure 5-01.
I I I I
OK
Verify by operating engine from a temporary

Fuel Quality Poor t--------- tank that contains good fuel. Refer to the
Operation and Maintenance Manual for fuel
specifications.
OK
+
Use lower gear, verify that engine load rating

Engine Overloaded
‘~~~~~~~~~ is not being exceeded.
OK
+
Check injection pump timing. Refer to

Injection Pump Timing Incorrect
~~~~~~~~~ Procedure 5-10.
I I
OK
+
I
Replace injectors. Test and repair. Refer to
Injectors Malfunctioning
~~~~~~~~~~~ procedure 5-07.
Page T-l 1
Coolant Contaminated
Cause Corrections
It---------{1
Coolant Rusty, Operation Without Correct
Mtxture of Anttfreeze, DCA4 and Water
OK
Drain and flush the cooling system, Fill with
correct mixture of antifreeze and water. Refer
Review the coolant change interval. Refer to

Operation and Maintenance Manual for
/t_________
Transmission Oil Cooler Leaking 11Check/replace oil cooler. Refer to Chassis
Shop Manual for Instructions.
OK
+/---------II
Oil Leaks From Oil Cooler, Cylinder Head
Gasket, Cylinder Head and Cylrnder Block
Refer to Troubleshooting Logic Chart for
Page T-12
Coolant Loss
Cause Corrections
Visually inspect the radiator, heater hoses and

Radiator or Cab Heater Leaking connections to locate the leak. Refer to
ci---------{I
OK
If oil is present in the coolant, check for a

transmission or lube oil cooler leak. Refer to
Procedure 2-03.
Visually inspect the engine and components

Engine External Leaks I-------- for seal, gasket, or drain cock leaks. Refer
to Procedure 2-03.
OK
+
Overheating or Leaking Compression Gases

_________ Refer to Troubleshooting Logic Chart for
Resulting in Loss Through the Radiator
“Coolant Temperature Above Normal”.
Overflow
OK
c
Check for mixing of coolant and
OK
II---------{1
Air Compressor Head or Head Gasket
OK
+
Check for coolant in the oil. Check/replace
head or gasket. Refer to the Chassis Shop
(Continued)
a ‘age T-13
Coolant Loss (Continued)
Cause Corrections
Check/replace the aftercooler. Check for

Aftercooler Leaking coolant in the intake manifold and in the oil.
UK
+
Check/replace the oil cooler. Check for

Lubricating Oil Cooler Leaking coolant in the oil. Refer to Procedure 2-03.
OK
*
Cylinder Head Cracked, Porous, or _________ Check/replace the head. Refer to Procedure
Expansion Plugs Leaking 7-09.
I I I I
OK
Remove the oil pan and check liner o-rings

for leakage. Refer to Procedure 2-13.
Page T-14
Coolant Temperature Above Normal - Gradual Overheat
Cause Corrections
Add coolant. Refer to Procedure 141. Locate
Coolant Level Low ___________ and correct the source of the leak. Refer to
Troubleshooting Logic Chart for “Coolant
Loss”.
OK
+
*t---------j1
Radiator Hose Collapsed, Restricted or Inspect hoses, replace 1 necessary. Refer to
Check and repair fan shroud fan sensor and

Air flow to the Radiator Inadequate or
-_i------------;-
equipment manufacturer’s instructions.
Water Pump or Fan Drive Belt Loose ___________ Check the belt tensioner. Refer to Procedure
l-04.
OK
+/________{I1
Lubricating Oil Level Incorrect
Add or drain engine oil. Refer to Procedure
OK
Inspect shroud, repair/replace or install.

Cooling Fan Shroud Damaged or Missing
~~~~~~~~~~~ Refer to Procedure 142.
Radiator Cap Incorrect or Malfunctioning
OK
4 (Continued)
Page T-15
Coolant Temperature Above Normal - Gradual Overheat (Continued)
Cause Corrections
I---------{
Check concentration, partially drain the
Anti-freeze Over Concentrated cooling system replace with water. Refer to
Procedure 1-ol:
OK
+
I I
Test the gauge and sensor, repair or replace
Temperature Sensor or Gauge Malfunctioning ---------
if necessary. Refer to Procedure l-02.
t
I
iI
OK
I’---------:,,..,11
Thermostat Incorrect, Missing or
OK
Check/replace thermostat Refer to
+t--------- jll
Radiator Shutters Are Not Opening
Completely or Cold Weather Radiator Cover
OK
Inspect the shutters, repair or replace if
necessary Open radiator cover. Refer to
Check and repair fan shroud, fan sensors

Air Flow to the Radiator Inadequate or
----------- and fan clutch as required. Refer to the
Restricted
Chassis Shop Manual for instructions.
Check hose clamps for leaks on the suctron

Air or Combustion Gases in Cooling System side of the pump. Make sure the fill rate is
~t---------{1
OK
If aeration continues, check for compression

leak through cylinder head gasket. Refer to
Procedure l-02.
(Continued)
Page T-16
Coolant Temperature Above Normal - Gradual Overheat (Continued)
Cause Corrections
Radiator Fins Damaged or Obstructed With
OK
Measure cylinder block coolant pressure.
OK
I I I
I
I
Check/replace water pump. Refer to
Procedures l-02 and l-07. I
I
t--------j1
Cooling Passages in Radiator, Cylinder Head,
Head Gasket or Cylrnder Block Plugged
Flush the cooling system, fill with new
Check/replace pump. Refer to Procedures
OK
+
Confirm correct fan, radiator, and other
Vehicle Cooling System Design cooling system components replace as
Page T-17
Coolant Temperature Above Normal - Sudden Overheat

Cause Corrections
OK
+
Check/clean sensor and coolant passage.

Temperature Sensor Malfunctioning Refer to Procedure l-01.
Test/replace sensor. Refer to procedure

l-02.
Test the gauge, repair or replace if

Temperature Gauge Malfunctioning
lt________-jj~ OK
Check belt and tensloner. Refer to
Radiator Cap Incorrect or Malfunctronrng. Check the radrator pressure cap. Refer to
[t---------j11
OK
Thermostat Incorrect or Malfunctioning
I_________
Check thermostat. Refer to Procedure l-02.
(Continued)
Page T-17.1
Coolant Temperature Above Normal - Sudden Overheat (Continued)
Cause Corrections
Radiator Shutters Are Not Opening Inspect the shutters. Repair or replace if
Completely or Cold Weather Radiator Cover necessary Open radiator cover. Refer to
Closed. Shutterstat Setting Incorrect Procedure l-02. Check shutterstat settrng.
It ---------II
OK
+
Air or Combustion Gasses in the Cooling Check for air or combustion gases in the
System ~~~~~~~~~ cooling system. Refer to Procedure l-02.
I I I
Vent Line From Engine and/or Radiator Check routing and operation of vent line.
Plugged or Incorrectly Routed ~~~~~~~~~ Refer to Procedure l-l 2.
I
t 1I I
OK
Check water pump operation. Replace the

Water Pump Malfunctioning
water pump. Refer to Procedure l-02.
Page T-18
Coolant Temperature Below Normal
Cause Corrections
Check/repair fan clutch, and viscous fan, as

Air flow Across Radiator Excessive required Refer to the Chassis Shop Manual
cl---------jl
OK
&
_________ Inspect the shutters, repair or replace if

Radiator Shutters Stuck in Open Position necessary. Refer to Procedure l-02.
I }
OK
+
Thermostat Broken, Damaged, Incorrect or Check thermostats and replace if necessary.

Malfunctioning Refer to Procedures l-02 and l-07.
Check fan for continuous operation. Refer to

Fan Malfunctioning
~~~~~~~~~~~Procedure l-02.
I I
Page T-l 9
Engine Crankcase Gases (Blowby) - Excessive
Cause Corrections
________ Check breather tube restriction. Refer to
1
Crankcase Breather Vent Tube Restricted
Procedures 7-03 and 8-01.
[ I I
OK
Check turbocharger seals. Refer to

Turbocharger Seals Leaking
Procedure 3-01.
OK
+
Air Compressor Malfunctioning ___________ Check air compressor. Refer to Procedure

4-02.
OK
+
Cylinder Head Valve Guides Excessively ______-__ Replace cylinder head. Refer to Procedure
Worn 7-09.
i
Check piston rings and cylinder liners. Refer

[Piston Rings Broken or Worn I---------- to Procedure 7_,3.
Page T-20
Engine Cranks, But Will Not Start - No Smoke from Exhaust
Cause Corrections
Check for loose wires and verify that the

Electrical or Manual Fuel Shutdown Not
Open
OK
‘/--------II
Loosen the bleed plug at the filter head end.
Operate the hand primer on the fuel transfer
Injection Pump Not Recervrng Fuel pump to check for fuel. Clean/replace fuel
transfer pump if necessary. Refer to
Air in the Fuel System If the Condition

Occurs During initial Start, Followrng an Bleed the fuel system. Refer to Procedure
It-----------_1
OK
+
1 I
Check fuel pump return overflow valve. Refer
Malfunctioning Fuel Return Overflow Valve
--------- to Procedure 5-09.
t 1
Fuel Filter Plugged Wiih Water or Other Drain fuel/water separator or replace fuel
Contamination _---------- filter. Refer to Procedure 5-01.
OK
+
(Continued)
Page T-20.1
Engine Cranks, But Will Not Start - No Smoke from Exhaust (Continued)
Cause Corrections

~~~~~~~~~~~Procedure 5-l 0.
Injection Pump Worn or Malfunctioning --------- delivered after bleeding the system. Refer to
OK
4
---------
Page T-21
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present
Cause Corrections
Refer to the Operation and Maintenance

Starting Procedure Incorrect Manual.
OK
+
+t --------- 11 Check engine cranking RPM. Refer to

Troubleshooting Logic Chart for “Engine Will
OK
Electrical or Manual Fuel Shut Down Binds
I_________ Check for loose wires and verify that the

solenoid is functioning. Check to be sure
manual shutoff lever is not binding at the
injection pump. Refer to Procedure 5-01.
Verify proper starting procedure. Refer to

Improper Starting Procedure I--______
Starting Instructions in the Operation and
Maintenance Manual.
I I
OK
Starting Aid Needed for Cold Weather or Not Check/repair or replace cold starting aid, if
Working Properly necessary.
OK
Bleed the fuel system and check for suction

Air in the Fuel System
~~~~~~~~~~ leaks. Refer to Procedure 5-01.
OK
+
Verify that the fuel return line is plumbed to

Fuel Drain Back ________ the bottom of the fuel tank.
t
Check/replace return overflow valve. Refer to

Malfunctioning Fuel Return Overflow Valve Procedure 5-09.
OK
+ (Continued)
Page T-22
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present (Continued)
Cause Corrections
Clean or replace pre-filters and screens and
OK
Check intake air system for restrictions Refer
OK
+
I I I
1
Verii by operating engine form a temporary
Fuel Contaminated
--------- supply tank.
t
I I I
OK
Check top dead center (TDC). Refer to

Injection Pump Timing Incorrect Procedure 7-07. Check injection pump
the fuel injection pump using the spill port

timing if equipment is available. Refer to
rocedure 5-13.
Check/replace injectors. Refer to Procedure

Injectors Worn or Malfunctioning
----------- 5-07.
I I I
OK
Perform compression check to identify

Engine Compression Low
--------- problem. Refer to Procedure 7-61.
Injection Pump Worn or Malfunctioning

calibration checked. Refer to Procedure 5-11.
rage T-23
Engine Idle Rough, Warm Engine
Cause Corrections
Idle Speed Set too Low (Below 700 RPM)
Fuel Return Overflow Valve Malfunctioning
Check/replace fuel transfer pump. Refer to

Fuel Transfer Pump Malfunctioning
]I---------{1
Clean pre-filters and screens and check fuel

--------- line for restriction. Replace fuel filter. Refer to
Injection Nozzles Plugged or Inoperative
OK
+
+/--------{I1
I/_________{1 OK
+
(Continued)
Page T-23.1
Engine Idle Rough, Warm Engine (Continued)
Cause Corrections
I________ Adjust intake and exhaust valves. Refer

Valves Incorrectly Adjusted
to Procedure 7-06.
Engine Compression Low _________

I Perform compression check repair as
required. Refer to Procedure 7-01.
OK
+
Remove the fuel injection pump, check

Injection Pump Malfunctioning ~________ calibration, check for debris in delivery valve.
i
Page T-24
Engine Misfiring
Cause Corrections
Bleed fuel system and check for suction

Cl--------- jl
OK
+
r I I I
Verify by operating from a temporary supply
, t---------- tank that contains good fuel.
OK
*
Check for loose connections. Inspect and
Fuel Injection Lines Leaking
t -I
_________ replace broken lines. Refer to Procedure
5-05.
*t---------j1
Check/replace return overflow valve. Refer to
OK

Fuel Transfer Pump Malfunctionrng
OK
_________ Clean Pre-filters and screens and check fuel
OK
+
---------
Injection Nozzles Plugged or Inoperative Replace injectors. Refer to Procedure 5-07.
OK
+ (Continued)
Page T-24.1
Engine Misfiring (Continued)
Cause Corrections
Perform compression check to identify cause

Compression Low on One or More Cylinders --------- (piston rings, head gasket or valves). Refer to
---------
OK
Camshaft, Tappets or Push Rods Damaged Check/replace parts as required. Refer to

_---------- Procedures 7-22, 7-24 and 7-08.
Page T-25
Engine Power Output Low
Cause Corrections
-----____
Check and adjust throttle linkage for full

Throttle Linkage Incorrectly Adjusted travel of the fuel control lever. Refer to
[l---------II
;t_________jjI Check/adjust solenord Irnkage. Refer to

Mechanical Shutoff Lever Partially Engaged
OK
+
High Pressure Fuel Lines or Fittings Leaking
I________- Tighten/replace fittings or lines. Refer to

Procedure 5-05.
Bleed the fuel system and check for suction
OK
Fuel Supply Restricted Clean pre-filters and screens and check fuel
----------- line for restriction. Replace fuel filter. Refer to
Procedure 5-01.
OK
+ (Continued)
Page T-26
Engine Power Output Low (Continued)
Cause Corrections
I I
Check/replace fuel return overfiow valve.
Fuel Return Overflow Valve Malfunctioning
~~~~~~~~~ Refer to Procedure 5-99.
t 1

Fuel Transfer Pump Malfunctioning
OK
Lubricating Oil Level Too High ----------- Drain oil to proper level.
I I
OK
Intake Air Temperature High - (Above 36” C Use outside air to turbocharger in warm
1166” FI) weather.
OK
Coolant passages plugged in the aftercooler
Check charge air cooler for internal

restriction. Replace restricted cooler.
Check/clean debris from front of charge air

cooler.
Check intake and exhaust system for

Intake or Exhaust System Restricted restrictions, Inspect air filter and replace as
necessary. Refer to Procedure 3-01 and
Page 3-19.
un
+ (Continued)
Page T-27
Cause Corrections
Fuel Temperature High - (Above 70” C [168”

W
OK
+
Fill tanks,
___________
weather. turn off fuel heater in warm
1
1
Check and correct leaks in the air crossover
Air Leak Between Turbocharger and Intake tube, hoses or through holes in the manifold
Manifold cover. Refer to Procedure 3-88.
OK
+
Check and correct leaks. Check for a
Exhaust Leak Between Turbocharger and
OK

Injector Nozzles Worn or Malfunctioning
--------- 5-87.
tI 1I
Turbocharger Worn or Malfunctioning specifications on Page 34. Replace turbo-

charger if low. Refer to Procedure 3-l 1.
OK
+
I I
1
Adjust valves. Inspect Push rods, springs,
Valves Incorrectly Adjusted --------- etc. Refer to Procedure 7-06.
t
I I
OK
+
I I
Injection Pump Timing Incorrect _---------- Procedure 5-l 1.
OK
+ (Continued)
Page T-28
Cause Corrections
I I
Check/replace injection pump. Refer to
Injection Pump Worn or Malfunctioning ~~~~~~~~~ Procedure 5-11.
t
I
1I
OK
+
Perform compression check to ident*@
Engine Compression Low ----------- malfunction. Repair as required. Refer to
Procedure 7-01.
Page T-29
Engine Noise Excessive
Cause Corrections
Check the tensioner and inspect the drive

Drive Belt Squeal, Insufficient Tension or
fan hub and alternator turn freely.
OK
Check the tension of accessory drive belts.

Refer to the Operation and Maintenance for
OK
Adjust valves. Make sure the push rods are

not bent or the rocker levers are not
severely worn. Refer to Procedure 7-06.
OK
c
Check turbocharger impeller and turbine

Turbocharger Noise ‘- wheel for housing contact. Refer to
Procedure 3-01.
I
OK
+
I 1 I
Check/replace vibration damper. Refer to
Gear Train Noise
~~~~~~~~~ Procedure 7-l6.
t i
I I I
OK
Visually inspect and measure gear backlash.

Replace gears as required. Refer to
Procedure 7-20.
I I
I
Check/replace connecting rod and main
Internal Engine Noise
~~-~~-~-~~~ bearings. Refer to Procedures 7-11 and 7-12.
I I I
Page T-30
Engine Starts But Will Not Keep Running
Cause Corrections
I I
Under Load _________ Disengage driven units and check for loading
from malfunctioning accessories.
tI 1I
OK
Engine Idle Speed Too Low (Below 700 --------- Adjust idle speed. Refer to Procedure 5-12.
RPM)
t 1
OK
I t
Check the flow through the filter. Bleed the
Air in the Fuel System or the Fuel Supply is _________ fuel system and check for suction leaks.
Inadequate Refer to Procedure 5-01.
t
I
iI
OK
Drain fuel-water separator or replace filter.

Fuel Filter Plugged or Fuel Waxing Due to --------- Check for fuel waxing in cold weather. Refer
Cold Weather
tI i I to Procedure 5-01.
OK
+
Clean or replace pre-filters screens and
Fuel Supply Restricted ----------- check for fuel line restrictions. Refer to
Procedure 5-01.
L 1
OK
+
I I I
1
Check and adjust injection pump timing.
~~~~~~~~~ Refer to Procedure 5-10.
tI I I
OK
Check/correct gear train timing alignment.

Camshaft Timing Incorrect ----------- Refer to Procedure 7-22.
1 1 I 1
Page T-31
Engine Surges at Idle
Cause Corrections
--------- leaks. Refer to Procedure 5-l 1.
OK
+
Clean or replace pre-filters and screens and

Fuel Supply Restricted I---------{ check fuel 5-o,
procedure lines _for restriction . Refer to
OK
+

Injectors Worn or Malfunctioning
OK
Check/replace injection pump. Refer to

Injection Pump Malfunctioning or Worn
----------- Procedure 5-l 1.
I I
Page T-32
Engine Vibration Excessive
Cause Corrections
I I
Engine Not Running Smoothly. Low Idle
--------- “Engine Misfiring”. Adjust engine low idle
Speed Set Too Low.
speed.
t i
OK
Check/replace the vibrating component

Fan Damaged or Malfunctioning Accessories _------- (refer to Chassis Shop Manual for
instructions),
OK
__________ Inspect/replace the vibration damper. Refer

Vibration Damper Malfunctioning
to Procedure 7-16.
OK
_________
+
Fan Hub Malfunctioning
OK
+
I Inspect/replace
Procedure l-06.
the fan hub. Refer to
I I
Check/replace the alternator. Refer to

Alternator Bearing Worn or Damaged
~~~~~~~~~ Procedures 6-01 and 6-03.
t
I
iI
OK
I I
Check/correct flywheel alignment. Refer to
Flywheel Misaligned
~~~~~~~~~ Procedure 7-26.
t i
J I
OK
I I I
Inspect crankshaft and rods for damage that
Loose or Broken Internal Components ----------- causes an unbalance. Refer to Procedure
7-l 4.
OK
+
Check/repair according to Chassis Shop

Drive Line Components Worn or Unbalanced ----------
Manual instructions.
I
Page T-33
Engine Will Not Crank or Cranks Slowly
Cause Corrections
Check electrolyte level and specific gravity

*t____ _____ {_
charge as requtred. Refer to Procedure 6-01.
Starting Circuit Connectrons Loose or Clean and tighten connectrons. Refer to

[t---------j-_
tit _________ 11 Check voltage to solenord. Refer to
--p-_________{I Replace startrng motor. Refer to Procedure

Solenoid or Starting Motor Malfunction
OK
+
+t_________j1
Crankshaft Rotation Restricted
Rotate the crankshaft to check for rotational
resrstance. Refer to Procedure 7-12.
OK
+
Disengage driven units and check for

Engine Driven Units Engaged ----------- loading from malfunctioning accessories.
Refer to the appropriate section.
+t---------{I
Starting Motor Operating But Not Cranking
Remove the starting motor and check for
broken tooth on the flywheel or broken
starting motor spring. Refer to Procedures
Page T-34
Engine Will Not Reach Rated Speed When Loaded
Cause Corrections
________- Check with hand or digital tachometer
Check throttle linkage adjustment for full

Throttle Linkage Worn or Incorrectly Adjusted _________ travel to the high idle stop screw. Refer to
Procedure 5-l 1.
St-_-____
Mechanical Shut off Lever Partially Engaged
Check/adjust shutoff lever. Refer to
Procedure 5-01.
I
OK
+
Vebiby by operating the engine from a
Fuel Quality Poor or Diesel Fuel Grade No. 1 _________ tempory tank No. 2 diesel fuel. Refer to the
Used Above 0°C [32” F] “Fuel Specifications” in the machine 0 & M
Manual.
OK
+
Change the fuel filter and check fuel line,

Fuel Supply Inadequate or Restricted pre-filter and screens for restrictions, Refer
to Procedure 5-91.
t--------
OK
+
Check/repair or replace fuel transfer pump.

Malfunctioning Fuel Transfer Pump
_________ Check/replace return overflow valve. Refer to

Procedure 5-09.
OK (Continued)
+
Page T-34.1
Engine Will Not Reach Rated S1teed When Loaded (Continued)
Cause Corrections
Air Fuel Control Tube Leaking and/or Check orifice, tighten fittings. Replace tube if
Restricted Orifice, Wastegate Diaphragm necessary. Refer to Procedure 5-10. Injection
Ruptured Pump Malfunction
OK
+
+/________i/
Remove the fuel injection pump, check
Fuel Injection Malfunctioning calrbratlon. Refer to Procedure 5-07.
Page T-35
Engine Will Not Shut Off
Cause Corrections
Verify the solenoid is not being energized by
a short in the wiring. Check the linkage to the
Electrical or Manual Fuel Shutoff Not Closing shutoff lever for binding. Check for the ability
of the spring in the pump to pull the lever to
the shutoff position. Refer to Procedure 5-08.
OK
+
I I I I
Engine Running On Fumes Drawn into Air Check the air intake ducts. Locate and
________-
Intake isolate the source of fumes.
t
I I I I
OK
Fuel Leaking to Intake Manifold
-
Check for porosity between the fuel filter
~~~~~~~~~ mounting to the intake manifold.
i 1
check calibration. Refer to Procedure 5-l 1.
Page T-36
Exhaust Black Smoke Excessive Under Load
Cause Corrections
_________
OK
+
Air Cleaner Plugged t__________I

Inspect air cleaner.
to Procedure 3-01.
Clean and replace. Refer
I I I
OK
Correct leaks in the air crossover tube,

Air Leak Between Turbocharger and Intake
--------- hoses or through holes in the manifold
or Exhaust Manifold
cover, Refer to Procedure 3-08.
1 I I
OK
Charge Air Cooler Malfunctioning
OK
Check/correct leaks in the manifold or

Exhaust Leak at the Manifold or _________ turbocharger gaskets. Look for a cracked
Turbocharger
exhaust manifold, Refer to Procedure 3-12.
OK
+
I I
Repair or replace wastegate. Refer to
Turbocharger Wastegate Malfunctioning
--------- Procedure 3-04.
tI 1
I
OK
+
----_-_-_ Replace
3_, ,. turbocharger. Refer to Procedure
Turbocharger Malfunctioning
More Than One Seal Washer Under Injector _________ Remove extra washers. Refer to Procedure
Nozzle 5-07.
t
I
iI
OK (Continue)
+
Page T-37
Exhaust Black Smoke Excessive Under Load (Continued)
Cause Corrections
l---------
Remove and have nozzles tested. Replace
Injector Nozzle Malfunctioning injectors if necessary. Refer to Procedure 5-
07.
OK
+
Engine Running Too Cold (Below 88” C

W” FI)
_________
1 Check thermostat and cooling system. Refer
to Procedures l-02 and l-08.
OK
+
________ Check and adjust injection pump timing.

AFC Malfunction or Injection Pump Remove and test injection pump. Refer to
Overfueled ‘~~~~~~~~~ Procedure 5-l 1.
i
OK
+
Perform a compression check, Repair as

Piston Rings Not Sealing
~~~~~~~~~~ required. Refer to Procedure 7-01.
I I I
Page T-38
Exhaust White Smoke Excessive (Warm Engine)
Cause Corrections
“Coolant Temperature Below Normal”.
OK
+
Refer to Operation and Maintenance Manual
Intake Air temperature Too Low for shutter operation. Check intake air heater
operation (ii required).
OK
+
Verify by operating engine from a temporary
Fuel Quality Poor ---______
OK
+
Check top dead center (TDC). Refer to

Procedure 7-07. Check/adjust injection
Injection Pump Timing Incorrectly Adjusted _________ pump timing. Refer to Procedure 5-11.
Check/time the fuel injection pump using the
spill port timing if equipment is available.
OK
+
;t _________ {I Replace injectors Refer to Procedure 5-07
OK
+
I I I
Coolant Leaking Into Combustion Chamber
~~~~~~~~~ “Coolant Loss”.
t
I
1I 1
(}---------{I
Injection Pump Malfunctioning
Remove fuel Injection pump. Have calrbratron
checked. Check for debris in delivery valves.
Page T-39
Fuel Consumption Excessive
Cause Corrections
Check/repair accessories and machine
Additional Loading From Malfunctioning _________ components. Refer to Chassis Shop Manual
Accessories.
for instructions.
Check for external leaks and engine oil
the fuel transfer pump and injection pump.
OK
I
Intake Air or Exhaust Restriction
OK
1 “Exhaust Smoke Excessive Under Load”.
OK
OK
+
Check/adjust valves. Refer to Procedure

Valves Not Seating I---------- 7-06.
Page T-40
Fuel or Oil Leaking from Exhaust Manifold
Cause Corrections
1 I
Operating For Extended Periods Under Light
--------- Review machine operation.
or No Load Conditions
t
I
1I
OK
+
I I
1
Check/replace filter element. Refer to
~~~~~~~~~ Procedure 5-81.
t
OK
Review operation for excessive idling.
Check/adjust fuel injection pump timing.
OK
+
Locate and replace malfunctioning injector.

Injector Needle Valve Stuck Open
----------- Refer to Procedure 5-87.
OK
+
Turbocharger Drain Line Obstructed _-______ Check/clean line. Refer to Procedure 3-11.
t I
I I I
OK
+t--------- jl
Turbocharger Seals Leaking Oil
Check/replace turbocharger. Refer to
OK
+
1 I
Check for excessive blowby. Refer to
Crankcase Gasses (Blowby) Excessive
--------- Procedure 8-81.
t 1
Page T-41
Lubricating Oil Contaminated
Cause Corrections
Coolant in the Oil, Internal Engine Refer to Troubleshooting Logic Chart for
----------- “Coo,ant Loss”*
Component Leaks
OK
+
OK
Make sure the correct oil is being used.

Refer to the Operation and Maintenance
Review the operation for excessive idling

Fuel in the Oil Engine Operating Too Cold resulting in the engine running below normal
/--------{Ii
Fuel Transfer Pump Seal Leaking
Injector Needle Valves Not Sealing
OK
+
__--_---_-- Replace
5_, ,. the fuel pump. Refer to Procedure
Fuel Pump Internal Plunger Seal Leaking
OK
Replace the fuel pump. Refer to Procedure

-t_________{~
Page T-42
Lubricating Oil Consumption Excessive
Cause Corrections
External Leaks Visually inspect for oil leaks.
OK
-t---------{l
Crankcase Being Overfilled (Dipstick
OK
Verify that the dipstick is correctly marked
+
Incorrect Oil (Specification or Viscosity)
_. r---------- Refer to the Operation and Maintenance
1 Manual for oil specifications.
I
Check for reduced viscosity form dilution

with fuel. Refer to Procedure 2-02.
I I
Review/reduce the oil change intervals. Refer
to the Operation and Maintenance Manual.
I I
I I
Check the breather tube area for signs of oil
High Blowby Forcing Oil Out the Breather _________ loss. Measure the blowby and perform the
Tube required repairs. Refer to Procedures 8-01.
1
t
I 1 4
OK
+
I I I I
________ Check for oil in the coolant. Refer to
Oil Cooler Leak Procedures 2-02 and 2-l 1.
t
I I ,
I
OK
OK
+ (Continued)
Page T-43
Lubricating Oil Consumption Excessive (Continued)
Cause Corrections
Inspect the turbocharger inlet and outlet for
Turbocharger Leaking Oil to the Air Intake or
----------- evidence of oil transfer. Refer to Procedure 3-
Exhaust 01.
I I
OK
Inspect/replace the vale seal. Refer to

Valve Seals Worn 6D114E-1 Series Engine Shop Manual.
Piston Rings Not Sealing (Oil Being ._-_____ Perform a compression check. Repair as
Consumed by the engine) required. Refer to Procedure 7-61.
Page T-44
Lubricating Oil Pressure Low
_-_-_____
Cause Corrections
Oil Level Incorrect
1 Add or drain engine oil. Refer to Procedures

2-04 and 245.
Remove and check fuel transfer pump

Oil Diluted Wiih Fuel but Engine Operation
--------- plunger seal. Replace leaking pump. Change
Normal
oil. Refer to Procedure 5-04.
t
I
iI
I
OK
Check for a stuck injector nozzle. If injectors

Oil Diluted Wiih Fuel Accompanied by Rough
OK
+
Check oil cooler, aftercooler, core plugs,

cylinder liner, head gasket, and cracked
Oil Diluted Wiih Coolant (Anti-Freeze) passages in the block and head for leaks.
Replace leaking component and change oil.
Check 01 pressure gauge and swrtch. Refer

Oil Pressure Switch of Gauge Malfunction
tit---------/i
Oil Pressure Regulating Valve Stuck Open or
OK (Continued)
+
Page T-45
Lubricating Oil Pressure Low (Continued)
Cause Corrections
OK
+
Oil Filter Plugged

I
t
_________
1
I
Change oil and replace filter. Refer to
Procedures 2-04 and 2-05.
I
I I I
OK
It ----_----
{_ Check and replace 01 cooler. Refer to
OK
+
Check oil rifle cup plugs, cup plug in front

Cup Plug Internal Leak ----------- and rear face of block. Refer to Procedure
731.
OK
+
Suction Tube Loose or Gasket Leaking

---------- I,,,,,,,.,,
Replace gasket and tighten tube Refer to
iLid-_____{-_ Check/replace 011pump. Refer to Procedure
---------
OK
+
Check/replace bearings. Also, check/replace
Connecting Rod or Main Bearing Worn piston cooling nozzles. Refer to Procedures
7-l 1 and 7-14.
Page T-46
Lubricating Oil Pressure High
Cause Corrections
Verify the pressure switch/gauge are

Pressure Switch/Gauge Malfunctioning _---------- functioning correctly. Refer to Procedure 2-03.
OK
1
Engine Running Too Cold ~~~~~~~~~ “Coolant Temperature Below Normal”.
tI I
OK

Oil Viscosity Too Thick Refer to the Operation and Maintenance
Manual.
OK
+
Check/replace valve. Refer to Procedure

___________2_,o.
Pressure Regulator Valve Stuck Closed.
Page T-47
Engine Noise Diagnostic Procedures - General Information

NOTE: When diagnosing engine noise problems, make sure that noises caused by accessories, such as the air
compressor and power takeoff, are not mistaken for engine noises. Remove the accessory drive belts to eliminate noise
caused by these units. Noise will also travel to other metal parts not related to the problem. The use of a stethoscope
can help locate engine noise.
Engine noises heard at the crankshaft speed, engine RPM, are noises related to the crankshaft, rods, pistons, and piston
pins. Noises heard at the camshaft speed, one-half of the engine RPM, are related to the valve train. A hand-held digital
tachometer can help to determine if the noise is related to components operating at the crankshaft or camshaft speed.
There is not a definite rule or test will positively determine the source of a noise complaint.
Engine driven components and accessories, such as geardriven fan clutches, hydraulic pumps, beltdriven alternators,
air-conditioning compressors, and turbochargers can contribute to engine noise. Use the following information as a guide
to diagnosing engine noise.
Main Bearing Noise (Refer to Engine Noise Excessive - Main bearing System Chart)
The noise caused by a loose main bearing is a loud dull knock heard when the engine is pulling a load. If all main
bearings are loose, a load clatter will be heard. The knock is heard regularly every other revolution. The noise is the
loudest when the engine is lugging or under a heavy load. The knock is duller than a connecting rod noise. Low oil
pressure can also accompany this condition.
If the bearing is not loose enough to produce a knock by itself, the bearing can knock if the oil is too thin, or if there
is no oil at the bearing.
An irregular noise can indicate worn crankshaft thrust bearing.
An intermittent sharp knock indicates excessive crankshaft end clearance. Repeated clutch disengagements can cause
a change in the noise.
Connecting Rod Bearing Noise (Refer to Engine Noise Excessive - Connecting Rod
Symptom Chart)
Connecting rods with excessive clearance knock at all engine speeds, and under both idle and load conditions. When
the bearings begin to become loose, the noise can be confused with slap or loose piston pins. The noise increases in
volume with engine speed. Low oil pressure can also accompany this condition.
Piston Noise (Refer to Engine Noise Excessive - Piston Symptom Chart)

It is difficult to tell the difference between piston pin, connecting rod, and piston noise. A loose piston pin causes a loud
double knock which is usually heard when the engine is idling. When the injector to this cylinder is held down, a
noticeable change will be heard in the sound of the knocking noise. However, on some engines the knock becomes more
noticeable when the machine is operated at a steady speed condition.
Fuel Consumption - General Information

The cause of excessive fuel consumption is hard to diagnose and correct because of the potential number of factors
involved. Actual fuel consumption problems can be caused by any of the following factors:
-- Engine Factors -- Driver Technique and Operating Practices

-- Vehicle Factors and Specifications -- Fuel System Factors
-- Environmental Factors -- Low Power
Before troubleshooting, it is important to determine the exact complaint and whether the problem is real or perceived,
does not meet drivers expectations. The “Fuel Consumption - Industrial Customer Complaint Form” is a valuable list of
questions that can be used to assist the service technician in determining the cause of the problem. The form should be
completed before troubleshooting the complaint. The form is on the next page. The following are some factors that may
be considered when troubleshooting.
Page T-48
Result of a Low Power Problem: An operator will change his driving style to compensate for a low power problem.
Environmental and Seasonal Weather Changes: As a general rule, there can be as much as a 1 to 1.5 mpg difference
in fuel consumption depending on the season and the weather conditions.
Excessive Idling Time: Idling the engine can use from 0.5 to 1.5 gallons per hour depending on the engine idle speed.
Fuel Consumption - Industrial Customer Complaint Form
Customer Name/Company Date
Answer the following questions. Some questions require making an X next to the appropriate answer.
1. What fuel consumption is expected? Expected gph
2. What are the expatiations based on?

Original consumption Other units in fleet Competitive engines
Previous engine owned Expectations only Engine performance curve
3. When did the problem occur?

Since New Suddenly Gradually
4. Did the problem start after a repair? Yes No

If so, what was repaired and when?
5. Is the machine also experiencing a Low Power / Poor Acceleration Response? Yes No
IF ANSWERED YES, GO TO THE ENGINE POWER OUTPUT LOW TROUBLESHOOTING SYMPTOM CHART.
6. Is the problem seasonal? Yes No
7. Weather conditions during fuel consumption check?

Rain Snow Windy Hot Temperatures Cold Temperatures
8. How is the fuel consumption measured? Tank Month Year Hourmeter
9. Do duty cycles vary between compared units? Yes No
10. Have duty cycles changed for the engine being checked? Yes No
11. What are the loads compared to a comparison unit? Heavier Lighter
12. What is the altitude that the unit is operating at? Below 10,000 feet Above 10,000 feet
13. How much of the time is the unit idling? Hours/Day
14. Is operator technique or operating practices affecting fuel economy?

Operate at rated speed or above: RPM
Incorrect shift rpm: Shift RPM Torque Peak
Believe compensating for low power
IF AFTER FILLING OUT THIS FORM IT APPEARS THAT THE PROBLEM IS NOT CAUSED BY MACHINE FACTORS,
ENVIRONMENTAL FACTORS OR OPERATOR TECHNIQUE, GO TO THE FUEL CONSUMPTlON EXCESSIVE
TROUBLESHOOTING SYMPTOM CHART.
Page T-49
HI Consumption
ACCEPTABLE OIL USAGE
ANY TIME DURING COVERAGE PERIOD
ENGINE HRS PER HRS PER HRS PER MILES PER MILES PER MILES PER KILOM PER KILOM PER KILOM
FAMILY QUART LITER IMPERIAL QUART LITER IMPERlAL QUART UTER PER
QUART QUART IMPERlAL
QUART
6D114E-1 10.0 10.6 12.0 400 425 475 650 675 775
SERIES
Engine Lubricating Oil Consumption Report
Owner’s Name Date of Delivery Engine Serial No.

Month Day Year
Address Equipment Manufacturer Engine Model & HP
City State/Province Zip Equipment Serial No. Fuel Pump Serial No.
Engine Application Oil & Filter Change Interval Complaint Originally Registered
(Describe)
Oil Filters Date Mile-Hours-Kilometers
I
Lubricating Oil Added
Date Added Oil Engine Operation Quarts - Liters Brand & viscosity of Oil Used
Miles-Hours-Kilometers Oil Added
Start Test
I I I
Last Mileage/Hours/Kilometer Minus Start Mileage/Hours/Kilometers

Equals Test Mileage/Hours/Kilometers Divided By Oil Added
Equals Usage Rate
Customer’s Signature Dealer Distributor
Page T-50
Oil Consumption Report
Customer Name Dist./Dir.

Engine Model Mi/Km/Hr
Engine Serial No. CPL No.
Machine Make/Model Date
1. Review of maintenance history.
List any previous failures that could have had a detrimental effect on cylinder component life. Failures could include
fuel, coolant, and/or foreign abrasives in the oil, second ring groove beat-out, filter plugging, etc.
“~~~~~~~~~~~~:~~~:~
ijl:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.~.:,~.:,:.:,:.:.~,:,:,:,:.:.:,:,:.:.
.,:,:,:.:.:.:.:,:.:.:.:.:.:.:.:.:.:.:.:,:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:,:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.
Brand I
viscosity
Change Interval Mi/Km/Hr
Model
II
11
Element
Change Interval
I
1 Mi/Km/Hr
II
11
Model
II Element
I
II
II Change Interval
I I
2. List any external engine leaks.
3. Visually Check for any internal leaks and list. Check turbocharger seals, valve guides, air compressor, etc.
4. Had the fuel pump been tampered with? What is maximum rail pressure readings? If Yes, the
pump must be reset to factory specifications and the customer sent out to re-evaluate his oil consumption rate and
the eligibility requirements must be met again.
5. Drain and refill oil pan to check dipstick markings and note findings.
6. Only alter above checks are completed, leaks corrected and proper documentation is completed, dis-assemble
engine to determine cause for the failure and repair as required.
7. State reason for oil consumption.
Signed:
Section 1 - Cooling System
Page l-l

Section Contents
Belt Tensioner - Replacement ................................................. l-27

Installation ............................................................. l-28
Removal ............................................................... 1-27
Removal and Installation .................................................... l-28
Cooling System - Diagnosing Malfunctions . . 1-13

BeltTension . . ......... .......... . . . . . . . . . . . . . . 1:: ::::::::: 1:: ::::: 1: . . 1-18
Coolant Hose - Inspection ................................................ . . 1-19
Coolant Pressure - Measurement ........................................... . . 1-21
Cooling System - Test for Combustion Gases ................................... . . 1-14
Fuel Pump Over-fueled .................................................. . . l-26
Radiator Cap - Pressure Test .............................................. . . 1-14
Radiator, Fan and Shutters ............................................... . . 1-21
Temperature Gauge Operation ............................................. . . l-26
Thermostat Leakage and Opening Temperature - Testing “In-Chassis” .................. . . 1-24
Thermostat Opening Temperature - Testing “Thermostat Removed” .................... . . l-25
Thermostat Operation and Testing .......................................... . . l-23
Vehicle Overloaded .................................................... . . 1-27
Water Pump - Inspection ................................................. . . 1-19
Water Pump Seal Weep Hole - Inspection ..................................... . . 1-19
Cooling System - Flow Diagrams .............................................. 1-3
Cooling System - General Information ........................................... l-2
Cooling System - Maintenance . . . . . . . . . . . . . .......... . . . . l-7

Additive Concentration - Checking . . . . . . . . . . . . . .......... . . . . l-7
Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... . . . . l-7
Antifreeze Concentration - Checking . . . . . . . . . . . . . .......... . . . . l-7
Cooling System - Cleaning . _. . . . . . . . . . . . . . . . . .......... . . . . l-8
Cooling System - Draining . . . . . . . . . . . . . . . . . . . .......... . . . . 1-7
Filling and Venting . . . . . . . . . . . . . . . . . .......... . . . . . 1-12
Cooling System - Service Tools ............................................... l-6
Cooling System - Specifications ............................................... 1-5
Drive Belt - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-27
Fan Hub - Replacement ................................................. . l-28

Removal and Installation ................................................ . l-29
Fan Pulley - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-28
Thermostat - Replacement ............................................... . . . l-32

Cleaning.. ......................................................... . . . 1-33
Installation ......................................................... . . . 1-33
Removal ........................................................... . . . 1-32
Water Pump - Replacement .............................................. . . 1-29

Cleaning.. ......................................................... . . l-30
Installation ......................................................... . . l-30
Removal ........................................................... . . l-29
Section 1 - Coolina System
Page 112
I Cooling System - General Information

The primary function of the cooling system is to remove the
heat created by the engine and its support components. The
excess heat energy that is not removed by the cooling system
is carried away by exhaust gases and radiation into the
atmosphere.
ck8hdpa 1
The accompanying charts illustrate the coolant flow through the

e engine. For more detail refer to the cooling system flow
diagrams on page 1-3.
Rabiator
Page 1-3
Cooling System - Flow Diagrams

The following illustrations identify the significant features of the cooling system:
Coolant is drawn from the radiator by the integrally mounted water pump. The output from the water pump empties into
the bottom of the oil cooler cavity in the cylinder block.
From the cooler cavity, the coolant flows into the upper water manifold. A portion of coolant flows through the coolant
filter and returns to the lower manifold. The remainder flows through six cast openings up to the cylinder head.
A portion of the coolant flowing into the cylinder head is directed to the liner cavity and, by means of a diffuser plate cast
into the cavity, is circulated around the top portion of the liners. The remainder of the coolant flows across the valve
bridges around the injector bores and down into the liner cavities through two orificed holes per cylinder. The orificed
holes control the coolant flow around the liners.
Coolant System
Cylinder Block
2 Cylinder Head
1. Coolant Inlet
1. Coolant Flow from
2. Pump Impeller
3. Coolant Flow to Cooler Upper Coolant Manifold
2. Coolant to Liner Cavity
4. Coolant Flow Past Oil Cooler
3 3. Cylinder Head Gasket
5. Upper Coolant Manifold
4. Coolant Flow Orifice
6. Coolant to Cylinder Head
Page 1-4
Cooling System - Flow Diagrams (Continued)

From the liner cavities the coolant flows through cast openings into the lower manifold and on to the thermostat cavity.
When engine is below operating temperature, the thermostats are closed. Coolant is bypassed to the water pump inlet.
As the coolant temperature increases, both thermostats begin to open allowing some of the coolant to flow to the radiator.
At normal operating temperature, both thermostats are fully open and the bypass circuit is closed.
Coolant System
Thermostat
Closed _ Intermediate Open
1. Thermostats 5. Partial Coolant 7. Coolant to

2. Coolant to Flow to Radiator Radiator
1. Coolant Flow Pump Inlet 6. Restricted 6. Bypass Closed
Past Cylinder Liners
3. Bypass Passage Coolant Flow
2. Lower Coolant Manifold
4. Coolant From to Bypass
Lower Coolant
Manifold
Page l-5
Cooling System - Specifications

Metric [U.S.]
Coolant Capacity (engine only)
S6D114E-1, SAGD114E-1 (air aftercooled) ................................ 9.9 liters [lo.5 U.S. Qts.]
SAAGD114E-1(water aftercooled) .................................... 10.9 liters [11.5 U.S. Qts.]
Thermostat
Starts to Open ................................................ 81 to 83°C [178 to 182”F]
Fully Open ........................................................... 95°C 1203”F]
Maximum Allowable Top Tank Temperature ...................................... 100” C [212” F]
Minimum Recommended Top Tank Temperature .................................... 70°C [158”F]
Minimum Allowable Pressure Cap ............................................ 50 kPa [7.0 psi]
Supplemental Coolant Additives (SCA) Concentration ............. 1.5 to 3.0 units per 3.7 liters [l U.S. Gallon]
Page l-6
Cooling System - Service Tools
The following special tools are recommended to perform procedures in Section 01. The use of these tools is shown
The Fleetguarde Refractometer is used to measure the freeze

point protection and antifreeze concentration.
Includes Part No. 3822986 Test Fluid, Part No. 3822987

Adapter, and Part No. 3877612 Instructions.
Page l-7
Cooling System - Maintenance (I-01)

Antifreeze
Caution: Never use only water for engine coolant. In
tropical climates where antifreeze availability can be
limited, use a corrosion inhibitor (Liquid DCA) to protect
the engine cooling system.
Refer to the appropriate Chassis Operation and Maintenance
Manual for antifreeze concentration recommendations.
Antifreeze Concentration - Checking

The Fleetguard@ refractometer, Part No. CC-2800, provides a
reliable and easy-to-read measurement of freeze point
protection and glycol (antifreeze) concentration.
The freeze point protection must be checked if coolant is
added to the cooling system or annually when operating in e
temperatures below 0°C [32” F]. Refer to the appropriate
Chassis Operation and Maintenance Manual for instructions.
Cooling System - Draining

Open the petcocks at the bottom of the radiator and at the
bottom of the oil cooler housing. Remove the lower radiator
hose. A 20 liter [4 U.S. gallons] drain pan will contain the
coolant in most applications.
Additive Concentration - Checking

The cooling system must contain the proper coolant additive e
Large Plastic
units to provide the best chemical protection. Refer to the
CUP
appropriate Chassis Operation and Maintenance Manual.
DCA4 Test Kit: Use only DCA4 Coolant Test Kit,

Fleetguarde Part No. CC-2626, to check the coolant additive
concentration in the cooling system.
Container
Svrinue
Cooling System - Cleaning

The following is the recommended procedure for flushing and
cleaning the engine cooling system of oil or fuel contamination.
It is assumed that the source of the contamination has been
located and corrected:
A Warning: Wait until the coolant temperature is below 50°C

[122”Fj before removing the coolant system pressure cap.
Failure to do so can cause personal injury from heated
coolant spray.
c%
0
Remove the pressure cap. Slowly overfill the top tank to flush
as much contaminated coolant as possible out the top of the
tank.
Completely drain the cooling system (block, radiator, heaters).

Do not remove the coolant filter. Use running water to quickly
flush the majority of the contamination, leaving draincocks
open. Plugged radiators can require extra treatment beyond
these procedures. Consult local regulations concerning disposal
of antifreeze and oil.
Page l-9
Connect all hoses, close all draincocks.
NOTE: The performance of RESTORE is dependent on time,

temperature, and concentration levels. An extremely flow
restricted system, for example, can require higher
concentrations of cleaners, higher temperatures, or longer
cleaning times. RESTORE can be safely used up to twice the
recommended concentration levels. Extremely fouled systems
can require more than one cleaning.
Komatsu America International Company recommends using
FleetguardQ RESTORE or an equivalent. Cooling systems
can also be cleaned using non-sudsing washing soda or
automatic dish washer soap.
The product used must be alkaline (non-acidic). Use of a
liquid cleaner will allow easier mixing and will not have the
possibility to cake or plug the cooling system.
If using a cleaner other than RESTORE, consult the label to
determine the amount of cleaner required for the cooling
system capacity. When using a powdered cleaner, thoroughly
mix the cleaner with water (an amount equal to the cooling
system capacity) in a separate container. Fill the cooling
system with the mixture.
Caution: Fleetguarde RESTORE contains no antifreeze.

Do not allow the cooling system to freeze during the
cleaning operation.
A
Immediately add 3.8 liters [l U.S. gallon] of Fleetguard@
RESTORE (or equivalent) for each 38 to 57 liters [lo to 15
gallons] of cooling system capacity, and fill the system with
plain water. Do not allow the cooling system to dry out.
RESTORE will not be as effective if the cooling system is
allowed to dry.
Page 1110
Turn the cab heater temperature switch to high to allow

maximum coolant flow through the heater core. The blower fan
does not have to be on.
I I
HEATER -W
\\
CoLD -3 HOT
Operate the engine at 2100 RPM at normal operating

temperatures (at least 85°C [185” F]) for 1 hour.
Shut off the engine, and drain the cooling system.

Use running water to flush the majority of the contaminated
mixture, leaving all draincocks open.
Connect all hoses, close all draincocks and fill the cooling
system with clean water (and neutralizer if the cleaner used
requires).
Page 1-11
Operate the engine at high idle for 5 minutes with the

coolant temperature above 85°C [185”F].
Shut off the engine and completely drain the cooling system
again. Use running water to flush the remainder of the rinse
water.
Connect all hoses, close all draincocks and leave all heater
valves open.
NOTE: If the drain water shows more than just a trace of
contamination, the cooling system must be flushed again.
Install a new coolant filter, and fill the cooling *system with a qb
fresh premixture of 50 percent low silicate antrfreeze and 50 0@,x,x
percent water. 50%
I 50%
i’VATER WATER
NOTE: Use an initial charge filter to bring the coolant to the e 50% 50%
ANTIFREEZE ANTIFREEZE
correct DCA4 concentration level of 1 unit per 3.8 liters [l
U.S. gallon] of coolant in the system. Refer to the
Page 1-12
install the pressure cap. Clean the engine compartment of any

contamination residue accumulated during the top tank overfills.
Operate the engine to check for leaks and normal operation.
Filling and Venting

The system is designed to use a specific quantity of coolant.
If the coolant level is low, the engine will run hot.
If frequent addition of coolant is necessary, the engine or
system has a leak. Find and repair the leak.
The engine coolant passages must be completely filled with

coolant.
During operation, entrapped air mixes with the coolant which
results in cavitation corrosion and poor heat transfer. Highly
aerated coolant can cause localized overheating of the cylinder
head and block which can result in a cracked head, scored
cylinder or blown head gasket.
Caution: During filling, air must be vented from the engine

coolant passages. Open the engine venting petcock and the
petcock on the aftercooler for aftercooled engines. The
system must be filled slowly to prevent air locks. Wait 2 to
3 minutes to allow air to be vented, then add mixture to
bring the level to the top.
Refer to Cooling System - Maintenance for coolant
recommendations.
Page l-13
Water will cause rust formation reducing the flow in the
smaller coolant passages.
The small holes in the head gasket are especially
susceptible to plugging.
Caution: These holes are orifices and their size is critical.
Do not enlarge the size of the orifices. To do so will
disturb the coolant flow and will not solve an overheating
problem.
A
Also, water used as a coolant for even a relatively short

period can result in the cup plugs rusting through allowing
the coolant to leak.
A
Caution: A sudden loss of coolant from a heavily loaded
engine can result in severe damage to the pistons and
cylinder bore.
NOTE: Use the correct amount of DCA4 corrosion inhibitor
to protect the cooling system. Refer to the appropriate
Chassis Operation and Maintenance Manual for DCA4
amounts.
Cooling System - Diagnosing

Malfunctions (I-02)
The function of the cooling system is to maintain a specified
operating temperature for the engine. Some of the heat
generated by the engine is absorbed by the coolant flowing
through the passages in the cylinder block and head. Then,
heat is removed from the coolant as it flows through the
radiator. When troubleshooting overheating problems,
remember that too much oil in the oil pan can cause
additional heat from friction when the rod journals are
submerged in oil.
Overfilling the oil pan raises the oil temperature which is

transferred to the coolant system at the oil cooler.
Page 1-14
Radiator Cap - Pressure Test

A
The system is designed to use a pressure cap to prevent
boiling of the coolant.
Different caps are specified for the two recommended systems:
System Cap
A - 104” C [220” F] 103 kPa [15 psi]
B - 99°C [21O”F] 48 kPa [7 psi]
Pressure test the radiator cap.

The pressure cap must seal within 14 kPa [2 psi] of the value
stated on the cap or it must be replaced.
An incorrect or malfunctioning cap can result in the loss of
coolant and the engine running hot.
Cooling System - Test for Combustion Gases

Overflow Method
Warning: Wait until the temperature is below 50°C [122”Fj
before removing the coolant system pressure cap. Failure
to do so can cause personal injury from heated coolant
spray.
Allow the engine to cool, and remove the radiator cap.
Install a radiator pressure cap which has had the spring and
the pressure relief valve removed to allow free flow from the
overflow tube.
Attach a rubber hose to the radiator overflow connection.
Put the free end of the hose below the water level in a
container of water.
The pressure cap must be tightly sealed in the top of the
radiator fill neck.
Page l-15
Operate the engine at rated RPM until it reaches a

temperature of 82°C [18O”F].
0a!?3
Check for air bubbles in the water container. A combustion
gas leak is present if a continuous flow of air bubbles is
present.
NOTE: The engine coolant temperature must be stable to
perform this test. An increasing coolant temperature will give
a false indication of air due to expansion of the coolant in
the system.
Combustion Gas Test

Use Part No. 3822985 Combustion Gas Tester or equivalent
to test for combustion gasses in the cooling system.
NOTE: It is recommended that the cooling system contain a
premixture of 50 percent antifreeze and 50 percent water
during the combustion gas leak test. The use of water only
can result in a color change in the test fluid from blue to
turquoise or light green during the test. This is not an
indication of a combustion gas leak.
04B
Drain the coolant level down approximately 50 mm [2 inch]
below the radiator cap seal ledge in the radiator fill neck.
0@Y
Pour the test fluid into the combustion gas test instrument
until it is up to the yellow fill line on the instrument.
Page 1116
Insert the rubber tip of the combustion gas leak test instrument
in the radiator fill neck. Hold the instrument down firmly and
turn back and forth to make sure that an air tight seal is
formed between the tester and radiator fill neck.
Start the engine and operate at high idle for approximately 30

minutes. Monitor the engine temperature and color of the test
fluid during engine operation. Do not allow the engine
temperature to exceed 100°C [212”F] during the test.
If the color of the test fluid changes from blue to yellow

anytime during the test, combustion gasses are leaking into the
cooling system. Discontinue the test if the color of test fluid
changes from blue to yellow.
Color Change
from Blue to
\ If a color of the test fluid does not change from blue to yellow
00
l! , during the 30 minutes test period, return the engine to low idle.
0
9
’
.
1 ’
.
3
’ 6 ’
I I 30 Minutes
----z-z- i-8 L-7

rage 1-17
043
Check the test instrument to make sure that it is firmly
sealed in the radiator fill neck.
Insert the tip of the rubber ball into the hole in the top of the @A
test Instrument. Squeeze the rubber ball 2 to 3 mrnutes to 4~
draw air from the radiator through the test fluid.
If the color of the test fluid remains blue, combustion gasses
are not entering the cooling system. If the color of the test
fluid changes from blue to yellow, combustion gasses are
0
@
entering the cooling system and further investigation is

required to determine the source of the combustion leak.
0@3
NOTE: As the cooling system warms up to operating
0
temperature, air will be expelled through the combustion gas
tester in the form of bubbles in the test fluid. This is due to OK
normal expansion of the coolant. Do not mistake the
presence of air bubbles in the tester as combustion gasses Blue
or air leaks into the cooling system. A change in the color of
the test fluid from blue to yellow is the only indication of
combustion gas in the cooling system.
0a3
A positive result from the combustion leak tester indicates
the following:
l Cracked cylinder head.
l Cylinder head or gasket leakage.
NOTE: Discard the tester fluid if it has indicated positive.
Section 1 - Coolinrr System
Page l-18
A negative result from the combustion leak tester coupled with

a continuous flow of air bubbles from the previous test
indicates the following:
l Air entrained due to faulty thermostat ball valve or
incorrect fill.
l Air in the coolant can result in loss from the overflow

when the aerated coolant is hot. The heated air expands,
increasing the pressure in the system causing the cap to
open.
l Similarly, coolant can be displaced through the overflow if
the head gasket leaks compression gasses to the coolant
system.
The operating pressure of the cooling system and the

lubricating system can result in the mixing of the fluids if
there is a leak between the systems: head gasket, oil
cooler. Refer to the Lubricating Oil System.
Transmission fluid can also leak into the coolant
through bottom tank oil coolers.
NOTE: If the cooling system is contaminated with oil, it must

be cleaned and flushed. Refer to Procedure l-01.
Belt Tension
The pump is belt driven from the crankshaft pulley. An
automatic belt tensioner is used to prevent the belt from
slipping on the pump pulley. A malfunction of the tensioner will
cause the water pump impeller to rotate at a slower speed
reducing the amount of coolant flow.
, Page 1-19
Coolant Hose - Inspection

The coolant flow can also be reduced if the inlet hose to the
water pump collapses. A hose will usually not collapse while
the engine is running at low speed. Check the hose while the
engine is running at rated speed.
Be sure the engine is warm, a minimum of 88°C [190” F], so
the thermostat is open.
Water Pump - Inspection

The water pump pulls coolant from the bottom of the radiator
and pumps it through the engine back to the top of the
radiator for cooling.
0et3
A worn or malfunctioning water pump will not produce the
flow required to prevent the engine from running hot.
However, be sure to check the other possibilities indicated in
the Troubleshooting Logic Chart before checking the flow or
replacing the pump.
Water Pump Seal Weep Hole - Inspection

The water pump seal design requires a coolant film for
lubrication and cooling. Therefore it is normal to observe a
minor chemical build up or streaking at the weep hole.
NOTE: A streak or chemical build up at the weep hole is not
justification for water pump replacement.
Use the following guidelines to determine if water pump
replacement is necessary:
06B
Make sure the weep hole is open.
A small screwdriver or a similar tool can be used to remove
any debris.
6s
0
Page 1120'
If no leakage is observed from the weep hole under operating

conditions, do not replace the water pump.
If coolant is observed to be dripping from the weep hole:

Use Fleetguard@ coolant test kit, Part No. CC-2626, to
Large Plastic check the coolant inhibitor level, and adjust the
CUP inhibitor level per the test kit chart.
NOTE: Supplemental coolant additive concentrations exceeding
2.0 units per gallon will cause water pump seal leakage.
Bottle
@$-zzzq* Small Plastic
Container
Syringe Ol.803VU
Use Fleetguard@ refractometer, Part No. CC-2800, to

check the antifreeze level of the coolant.
NOTE: Ethylene glycol type antifreeze concentration exceeding
70 percent will adversely affect freeze point protection and will
contribute to water pump seal leakage.
If the antifreeze concentration is above 60 percent, drain all the

coolant and add make up water to bring the antifreeze
concentration to a minimum of 40 percent to a maximum of 60
percent. Replace the coolant filter, add new coolant inhibitor to
the recommended levels as outlined in the Chassis Operation
and Maintenance Manual.
Page 1-21
Caution: If the coolant leakage is observed as a steady

stream upon start-up, stop the engine immediately and
replace the water pump.
A
Operate the engine at high idle for 15 minutes with the
proper inhibitor and antifreeze levels and check the water
pump for leakage again.
0
@I
0a9
If the coolant is leaking after the above checks, replace the
water pump. Refer to Procedure 147.
Coolant Pressure - Measurement

The coolant pressure can be measured from the vent
petcock to help determine the condition of the pump. At
normal operating temperature (thermostats open) and engine
operating at 2,000 RPM, the pressure should be:
Pressure Cap Minimum Pressure
103 kPa [ 15 psi] 124 kPa [18 psi]
48 kPa [ 7 psi] 69 kPa [lo psi]
Radiator, Fan and Shutters

Air forced through the fins of the radiator by a fan cools the
coolant pumped through the radiator. Environmental debris
(paper, straw, lint, dust, and bugs) can obstruct the fins and
06B
stop the flow of air which will reduce the cooling affect of the
radiator.
Caution: Wear appropriate eye and face protection when
using compressed air. Improper use can cause bodily
injury from flying debris and dirt.
Use compressed air to blow out the dirt and debris.
Section 1 - Coolina System
Page 1-2~
If the fan is belt driven, a slipping belt will result in a slower fan
speed and reduced cooling. A malfunctioning automatic belt
tensioner can be the problem.
0
Check the bearings in the fan hub and other pulleys to
a!?f slippage.
make sure they are not causing excessive belt vibration and
Interruption of the circuit to an electrically driven fan can result

in insufficient air flow and cause the engine to run hot.
04iB Make sure that the temperature sensor is functioning

correctly.
Some applications use thermatic fans. These fans operate only

as needed to keep the coolant at the correct temperature. If
the fan does not operate when the temperature of the air flow
through the radiator increases, the engine will run hot.
Make sure that the temperature sensor is functioning
0
@ correctly.
Shutters are designed to control air flow across the radiator. If

the shutters fail to open when needed, the engine can run hot.
Failure of the shutters to close can result in too much air flow
and the engine running cold.
@3
0
Make sure that the coolant temperature sensor is
functioning correctly. Check the air operated shutter
controls. Check for air leaks.
Page 1-23
0
A missing or incorrect fan shroud or obstructions can reduce
air flow and cause the engine to run hot.
043
OK
Check to be sure air is not recirculating. Check for
missing baffles.
Thermostat Operation and Testing

The engine thermostats must operate properly in order for
the engine to operate in the most efficient heat range.
Overheating or overcooling will shorten engine life.
The thermostats controls the coolant temperature. When the
coolant temperature is below operating temperature, the
thermostats are closed, and coolant is bypassed to the water
pump inlet. As the coolant temperature increases to the
intermediate range, both thermostats will start to open, and
coolant flow to the bypass will start to be restricted. At
engine operating temperature the thermostat will be open
and the bypass will be closed.
Caution: Never operate the engine without a thermostat. If

operated without a thermostat, the path of least
resistance for the coolant is through the bypass to the
pump inlet. This will cause the engine to overheat.
F@zzL-lb If%!!
0a3
Two identical thermostats are used. An incorrect, damaged,
or malfunctioning thermostat can cause the engine to run too
hot or too cold.
Section 1 - Coolinn System
Page 1-24
Thermostat Leakage and Opening Temperature

- Testing “In-Chassis”
Warning: Complete this test with the engine coolant
temperature below 49’C [12O”F], hot steam can cause
serious personal injury.
Remove the radiator hose from the thermostat housing.
Install a thermocouple or temperature gauge which is known to

be accurate in the 3/4-inch pipe plug located at the front of the
cylinder block.
Install a hose of the same size on the thermostat housing outlet

long enough to reach a remote dry container used to collect
coolant.
Install and tighten a hose clamp on the housing outlet.
Insert the end of the hose in a dry container.
Operate the engine at rated speed for 1 minute.

Shut off the engine and measure the amount of coolant
collected in the container.
The amount of coolant collected must not be more than 0.15
liter [5.1 fl. ounces].
Page l-25
If more than 0.15 liter [5.1 fl. ounces] of coolant is collected,

the thermostats are leaking and must be replaced. Refer to
Procedure l-08.
Complete the following test in-chassis to test the thermostat

opening temperature.
Start the engine and monitor the water temperature gauge
and the container. The thermostat initial opening temperature
is:
81” to 83°C [178” to 182”F]
Shut off the engine when the coolant starts to flow.
NOTE: If coolant does not start flowing into the container
during the initial opening temperature range, the thermostat
must be replaced. Refer to Procedure l-08.
Thermostat Opening Temperature - Testing

“Thermostat Removed”
Remove the thermostats and clean the gasket surfaces. Refer
to Procedure l-08.
NOTE: Do not let any debris fall into the thermostat cavity
when cleaning gasket surfaces.
Visually inspect the thermostats for damage.

Section 1 - Coolina Svstem
Page l-26.
Suspend the thermostats and a 100°C [212”F] thermometer in

a container of well stirred water.
NOTE: Do not allow the thermostats or thermometer to touch
the container.
Heat the water and check the thermostats as follows:
NOTE: The nominal operating temperature is stamped on the

thermostat.
95°C
[203”F] l Thermostat must begin to open within 1°C [2”F] of 82°C
[18O”F].
l Thermostat must be fully open within 1°C [2”F] of 95°C
[203” F].
NOTE: The fully open clearance between the thermostat flow
valve and flange must be 41.5 mm [1.63 inches] minimum.
Temperature Gauge Operation

Gauges and sensors are used in the system to measure the
coolant temperature. These can malfunction and provide an
incorrect temperature indication.
Fuel Pump Ovetfueled

Over-fueling can cause the engine to overheat. Make sure that
the fuel pump is calibrated correctly. Refer to Procedure 5-01.
Vehicle Overloaded
lo4°c
Constant overloading (lugging) can cause the engine to run
(22OOF)
hot.
Drive Belt - Replacement (I-03)

3/S or l/2 Inch Square Drive Ratchet
Lift the tensioner arm and pulley to remove and install the
belt.
Belt Tensioner - Replacement (I-04)

Preparatory Step:
Remove the drive belt.
Removal
15 mm
Remove the belt tensioner from the bracket.
Page 1-28
Installation
15 mm
Install the belt tensioner.
Fan Pulley - Replacement (I-05)

Preparatory Step:
Remove the drive belt. Refer to Procedure l-03.
e SERVICE TIP: Loosen the capscrews before removing the belt
and torque the capscrews after the belt is installed.
Removal and Installation

10 mm
Remove the four capscrews, fan and spacer.
Install the fan pulley in the reverse order of removal.
Fan Hub - Replacement (I-06)

Preparatory Steps:
e Remove the fan pulley. Refer to Procedure l-05.
Page 1-29

10 mm
Remove the four capscrews and replace the fan hub. Ezl
Water Pump - Replacement (I-07)

Preparatory Steps:
Drain the coolant. Refer to Procedure l-01.
Removal
10 mm, 19 mm
Remove the alternator link.
10 mm
Remove the water pump.
Page l-30
Cleaning
Clean the sealing surface on the cylinder block.
Installation
install a new o-ring into the groove in the water pump.
10 mm, 19 mm
Install the water pump and alternator link.
Torque Value:
(Water Pump) 24 Nom [18 ft-lb]
(Alternator Link) 43 Nom [32 ft-lb]
Lift the tensioner arm and pulley to install the drive belt.
fn9bima
Page 1-31
During filling, air must be vented from the engine coolant

passages. Open the engine vent petcock. Also, be sure to
open the petcock on the aftercooler for aftercooled engines.
The venting will permit a fill rate of 19 liters/minute [5 U.S.
gallons/minute].
Close the drain valves. Install all hoses previously removed.
Fill the cooling system with a premixture of 50 percent water 50% 50%
and 50 percent ethylene-glycol type antifreeze. Since the WATER WATER
ability of antifreeze to remove heat from the engine is not as
good as water, pouring antifreeze into the engine first could 50%
contribute to an over heated condition before the liquids are
ANTF&zE ANTIFREEZE
completely mixed. Refer to Procedure l-01 for the correct
amount of DCA corrosion inhibitor.
Refer to the Cooling System Specifications on page 1-5 for
capacities.
Install the pressure cap. Operate the engine until it reaches a

temperature of 80°C [180” F], and check for coolant leaks.
Page l-32
Thermostat - Replacement (I-08)

Preparatory Steps:
Disconnect the negative battery cable. Refer to Procedure 6-01.
Drain 2 liters (2.1 U.S. quarts) of coolant. Refer to Procedure
l-01.
Remove the radiator hose from the outlet connection.

Removal
19 mm
Loosen the alternator link capscrew.
Loosen the tail support capscrew if the alternator is so
equipped.
18 mm, 19 mm
Remove the alternator mounting bolts and nuts. Lower the
alternator.
10 mm
Remove the capscrews from the thermostat housing and water
outlet connection. Remove the water outlet connection.
Section 1 - Cooling System Page 1-33
Remove the thermostat housing and belt tensioner assembly.
Cleaning
Caution:Do not let any debris fall into the thermostat
cavity when cleaning gasket surfaces.
A
Remove the thermostats and clean the gasket surfaces. 0
C%
Installation
Install the new thermostats.
Position a new gasket over the thermostats.

Page 1-34
Position the thermostat housing and belt tensioner over the

thermostats and gasket.
Make sure the gasket is aligned with the capscrew holes. Install
the capscrews and use your fingers to tighten.
10 mm
Install the water outlet connection.
Tighten all capscrews.
18 mm, 19 mm
Position the alternator and install the mounting bolts and nuts.
Torque Value:
(Alternator Mounting) 77 Nom [57 ft-lb]
(Alternator Link) 43 Nom [32 ft-lb]
Page 1-35
Install the drive belt.
fn9blma
Install and tighten the battery electrical connectors.
Caution: During filling, air must be vented from the

engine coolant passages. Open the engine vent petcock if
equipped. Also, be sure to open the petcock on the
aftercooler for aftercooled engines. The system must be
filled slowly to prevent air locks. Wait 2 to 3 minutes to
allow air to be vented, then add coolant to bring the level
to the bottom of the radiator filler neck.
Fill the cooling system. Refer to Procedure l-01.
Operate the engine to normal operating temperature and

check for leaks.
Section 2 - Lubricating Oil System
Page 2-l

Section Contents
Page
Internal Engine Damage - Checking ............................................. 2-11

Lubricating Oil Analysis ...................................................... 2-11
Lubricating Oil Filter Inspection ................................................ 2-11
Lubricating Oil Cooler Element and Gasket - Replacement ............................. 2-28

Cleaning and Inspection ..................................................... 2-29
Installation .............................................................. 2-30
Removal ................................................................ 2-28
Lubricating Oil Dipstick - Calibration ............................................. 2-25
Lubricating Oil Dipstick Tube - Replacement ....................................... 2-26

Installation .............................................................. 2-26
Removal ................................................................ 2-26
Lubricating Oil Filter - Changing ................................................ 2-24
Lubricating Oil Leaks (External) - Checking ........................................ 2-10
Lubricating Oil Level - Checking ................................................ 2-23
Lubricating Oil Pan - Draining ................................................. 2-22
Lubricating Oil Pan - Filling ................................................... 2-22
Lubricating Oil Pan, Suction Tube and Gasket - Replacement ........................... 2-33
Cleaning.. .............................................................. 2-33
Oil Pan - Installation ........................................................ 2-34
Oil Pan - Removal ......................................................... 2-33
Suction Tube - Replacement .................................................. 2-34
Lubricating Oil Pressure Regulator, Valve and Spring - Replacement . . ................... 2-27
Cleaning and Inspection ................................. ................... 2-27
Removal ............................................ ................... 2-27
Installation .......................................... ................... 2-28
Lubricating Oil Pump - Replacement ......................... ................... 2-35

Cleaning and Inspection ................................. ................... 2-36
Installation .......................................... ................... 2-39
Removal ............................................ ................... 2-36
Lubricating Oil System - Diagnosing Malfunctions ................ ................... 2-12

Aftercooler .......................................... ................... 2-16
Bearings and Oil Pump .................................. ................... 2-15
Coolant Diluted Oil ..................................... ................... 2-15
Cracked Cylinder Block .................................. ................... 2-18
Cracked Cylinder Head .................................. ................... 2-l 7
Cracked Cylinder Liner .................................. ................... 2-18
Cylinder Head Expansion Plugs ............................ ................... 2-l 7
Cylinder Head Gasket ................................... ................... 2-17
Cylinder Liner Seals .................................... ................... 2-l 7
Fuel Diluted Oil ....................................... ................... 2-l 8
Fuel Leaking by Piston Rings .............................. ................... 2-19
Fuel Transfer Pump .................................... ................... 2-l 9
High Oil Pressure ..................................... ................... 2-12
Injection Pump ....................................... ................... 2-20
Page 2-2
Low Oil Pressure .......................................................... 2-12

Oil Cooler ............................................................... 2-16
Oil Dilution .............................................................. 2-15
Oil Filter.. .............................................................. 2-13
Oil Leaks ............................................................... 2-20
OilLevel................................................................2-1 2
Oil Pressure Gauge - Checking ................................................ 2-13
Oil Pressure Regulating Valve ................................................. 2-12
Oil Suction Tube .......................................................... 2-15
Oil Temperature Gauge - Checking .............................................. 2-14
Oil Temperature Thermostat ................................................... 2-14
Lubricating Oil System - Flow Diagram ........................................... 2-6
Lubricating Oil System - General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubricating Oil System - Service Tools ........................................... 2-3
Lubricating Oil System - Specifications ........................................... 2-5
Lubricating Oil Temperature Thermostat - Replacement ................................ 2-31

Inspection ............................................................... 2-32
Installation .............................................................. 2-33
Removal ................................................................ 2-31
Page 2-3
Lubricating Oil System - Service Tools
Tnnl Nrr
Used to remove and install the lubricating oil filters.
Measures spring force at a given spring height.
Used to open the full-flow oil filter for filter element inspection.
Used to pressure test the lubricating oil cooler element.

Lubricating Oil System - General Informa-

tion
Use 15W-40 multi-viscosity oil or equivalent which meets API
Classification CE for turbocharged engines.
NOTE: CC/CD or CD/SF engine oils can be used in areas
where CE oil is not yet available; however, the drain interval
must be reduced by 50 percent.
p1800gb
Caution: Limited use of low viscosity oils, such as low-30

'C -40-30-20-10 0 10 20 30 40 50
may be used to aid in starting the engine and providing
'F -40 -22 -4 14 32 50 66 66 104 122 sufficient oil flow at ambient temperatures below -5°C
[23”F]. However, continuous use of low viscosity oils can
All Seasons
decrease engine life due to wear. Refer to the
accompanying chart.
Winter Conditions
Arctic Conditions
'C -40 -30-20-10 0 10 20 30 40 50

OF -40 -22 -4 14 32 50 66 86 104 122
oi90Oda
Page 2-5
Lubricating Oil System - Specifications
Oil Pressure - Low Idle (Minimum Allowable) ...................................... 69 kPa [lo psi]
At Rated Speed (Minimum Allowable) ......................................... 207 kPa [30 psi]
Differential Pressure to Open Oil Filter Bypass Valve ................................. 138 kPa [20 psi]
Oil Flow at Rated Speed (Less Flow Through Pressure Regulator) ....................... 57 Ipm [16 gpm]
Oil Temperature at Rated Speed ................................... 99” to 126.6” C [210” to 260” F]
Oil Capacity of Pan (All Engines):
- Low Level .................................................... 15.1 liters [16.0 U.S. Qts.]
- High Level ................................................... 18.9 liters [20.0 U.S. Qts.]
Total System Capacity
6D114E-1 ..................................................... 23.6 liters 125.0 U.S. Qts.]
S6D114E-1 .................................................... 23.8 liters [25.2 U.S. Qts.]
Section 2 - Lubricating Oil Svstem
Page 2-6
Lubricating Oil System - Flow Diagram

The lubricating oil flow begins as the gerotor pump draws oil from the pan through the rigid, internal suction tube. The
pump then delivers the oil through an internal drilling in the cylinder block to the top of the oil cooler via the inner
channels of the cover. When the oil reaches the top of the oil cooler, it flows by the thermostat before entering the oil
cooler. If the oil is cold, the thermostat will open allowing some oil to bypass the cooler and flow to the filter. As the
temperature of the oil increases, the thermostat will close and force the oil to flow through the cooler element, thereby
regulating the oil temperature to the block. Coolant passing around the plates of the element cools the oil. From the
cooler, the oil is directed to the combination full flow/bypass oil filter and also to the pressure regulator. The regulator
valve remains closed until the oil pressure is approximately 518 kPa 175 psi]. At high pressure, the plunger moves toward
the plug and relieves the system by allowing some oil to return to the oil pan. The tapered shoulder on the plunger
creates a variable opening to regulate pressure. A combination full flow/bypass oil filter is used. The upper section of the
filter contains the full flow filter element while the lower section contains the bypass element. Oil which flows through the
full flow portion of the oil filter returns to the block. Oil that flows through the bypass returns to the oil pan. During normal
engine operation, oil circulates through the full flow section of the combination filter and into the main oil rifle. If the full
flow section of the combination filter becomes plugged to the point that a 137 kPa [20 psi] pressure difference exists
across the filter, the bypass valve opens in the oil filter head and routes unfiltered oil to the main oil rifle. This is done
to prevent oil starvation to the engine with a plugged filter.
Lubricating Oil System
Lubricating Oil Cooler;

Combination Full Flow
and Bypass Filter Bypass Filter
2. To Oil Cooler
3. From Oil Cooler
5. From Filter
6. Filter Bypass Valv
7. To Main Oil Rifle
8. To Pan
Pressure Regulating
Valve Filter Bypass Valve Trermostat
Pai; 2-7
Lubricating Oil System Flow (Continued)

At the filter head, the oil flow is divided: A portion flows to the turbocharger; the rest flows down a passage in the cylinder
block that connects to a cross drilling over the No. 3 main bearing.
Lubrication for Turbocharger
1. Filter
2. Turbocharger Supply
3. To Main Oil Rifle
4. Turbocharger Oil Drain
Page 2-8
Lubricating Oil System - Flow Diagram(Continued)

The oil has been cooled and filtered, it flows through the cross drilling over the No. 3 main bearing to the main oil rifle.
The main oil rifle is drilled through the length of the cylinder block and carries oil through individual drillings to the
overhead and lower end of the block. A transfer drilling from the main oil rifle intersects with a drilling between the main
bearing bore and the camshaft bushing bore. These drillings supply oil to the cam bushing and main bearing. The groove
in the upper main bearing shell supplies oil to the piston cooling nozzles located in the main bearing saddle. The spray
from the nozzle splash lubricates the piston pin. From the main bearings, the oil enters the crankshaft and lubricates the
connecting rod bearings through internal cross drillings.
Drillings in the cylinder block and gear housing connect to the external groove on the No. 1 camshaft bushing to supply
oil to the injection pump. An overflow hole located above the injection pump shaft allows oil to return to the oil pan.
Lubrication for the Power Components
1. From Oil Cooler

2. Main Oil Rifle
3. To Injection Pump
4. To Overhead
5. Injection Pump Drain
6. Crankshaft Main Journal
7. Rod Journal
8. To Carp Bore
9. Piston Cooling Nozzle
6
Page 2-9
Lubricating Oil System - Flow Diagram(Continued)

Oil for the overhead components is supplied by a vertical drilling through the cylinder head and block that intersects the
external groove on the No. 7 camshaft bushing. The main oil rifle supplies oil to the camshaft bushing. Oil flows from the
vertical drilling to an angle drilling in the cylinder head. From the angle drilling the oil flows through the transfer tube. The
rocker lever supports are installed over the transfer tube. From a hole in the transfer tube the oil is transferred to the
rocker lever support capscrews by the relieved area in the base of the support.
Oil flows around the capscrews up to the rocker lever shaft. Oil flows into the inside diameter of the shaft and along its
length. The ends of the shaft are sealed by cup plugs. Drillings in the shaft allow the oil to flow from the inside diameter
to the bores of the rocker levers. The rocker lever has a drilling that transfers oil from the bore to a trough on the top
of the lever. Oil flows along the trough to lubricate the push rod socket and the valve stem.
The front gear train assembly is lubricated from oil splash and carry-over. The oil pump idler gear is force lubricated. From
the gear train assembly the oil drains back to the oil pan for recirculation.
Lubrication for the Overhead
1. Main Oil Rifle

2. No. 7 Cam Bushing
3. From No. 7 Cam Bore
4. Rocker Lever Support ‘5
5. Oil Transfer Tube
6. Rocker Lever Shaft
7. Rocker Lever 4
8. Oil Trough
9. Valve Cover
Page 2-10
Lubricating Oil Leaks (External) -

Checking (2-01)
The first step in diagnosing excessive lube oil consumption is
to verify that there are no external oil leaks.
A
clothing and safety glasses or a face shield. Hot steam can
\
Li Use a steam cleaner or high pressure washer to clean the
engine. Dry with compressed air.
0
Operate the engine until the coolant temperature reaches 82°C
4B [180° F]. Inspect the exterior of the engine for leaking gaskets,
seals, o-rings, pipe plugs, or fiiings.
NOTE: Before replacing any gaskets, check the capscrews to
make sure they are tightened to the correct torque values.
Refer to Section V for capscrew torque specifications.
0
Check the engine crankcase breather tube and hose for
4B restriction.
Refer to Procedure 7-83 for removal.
Use a solvent to clean the hose and tube. Dry with
compressed air.
0
Check for a loose or missing oil dipstick tube, dipstick, or oil
a3 fill cap.
Section 2 - Lubricating Oil Svstem
Lubricating Oil System - Diagnosing

Malfunctions (2-03)
Be sure to check items related to oil pressure, such as:
gauges, high and low oil level, excessive oil contamination and
oil viscosity.
High Oil Pressure

High oil pressure usually occurs after the engine is first started
in cold weather. The lubrication system does not have a cold
start relief valve. The pressure regulating valve components are
machined to a size that will relieve the excessive pressure
created by cold engine oil.
Oil Pressure Regulating Valve
0a3 The engine will have high oil pressure if the regulator sticks in
the closed position. Check the regulator for freedom of
movement.
Low Oil Pressure
0a9 Low oil pressure can be caused by several lubrication system

related malfunctions. To begin the investigation, determine the
engine operating conditions when the low pressure was first
observed.
Oil Level
Low oil level can cause low oil pressure.
0a!? za;r
.
operate the engine with the oil level below the low (L)
Page 2-13
Oil Filter Filter Bypass Valve
A plugged filter will cause a gradual loss of oil pressure by

approximatelv 69 kPa 110 PSIl. This will cause the bvoass Valve
Closed
v&e to open, allowing unfiltered oil to flow to internal eigine
components. The oil pressure will remain low until a new
filter is installed.
Valve
Open
Oil Pressure Gauge - Checking
gage.
Check the oil gauge and sending unit to make sure they are
operating correctly by verifying the pressure with a manual 0
@
Check the following for defects:

l Electrical wiring broken
l Sending unit malfunction
l Plumbing loose or broken
If a sending unit malfunction is found:

@
l Use a master gauge of known accuracy to verify the @
0 reading of the suspect gauge.

Connect the line from the master gauge to the main oil
rifle on the fuel pump side of the engine. 0
@
l Replace the sending unit if it is defective.

Page 2-14
Oil Temperature Gauge - Checking

Remove the pipe plug from the bottom of the oil cooler and
install the oil temperature gauge sending unit.
The maximum oil temperature at rated engine speed is 126.6”C
[260” F].
Check the following for defects:

l Electrical wiring broken
l Sending unit malfunction
If a sending unit malfunction is found:

l Use a master gauge of known accuracy to verify the
reading of the suspect gauge.
l Replace the sending unit if it is defective.
Oil Temperature Thermostat

NOTE: The oil temperature thermostat cannot be checked
in-chassis, it must be removed for testing. Refer to Procedure
2-l 2.
Page 2-15
Oil Suction Tube

A loose suction tube, damaged gasket or crack in the
suction tube can cause a temporary loss of prime for the oil
pump. The engine will have low pressure or no oil pressure
at starting, followed by normal or low oil pressure.
Bearings and Oil Pump

A steady decrease in oil pressure over a long period of time
can be an indication of worn bearings or excessive oil pump
wear. Refer to Procedure 2-02 to check for internal engine
damage.
Oil Dilution
0 0
Fuel & Oil
0 0
Diluted oil can cause severe engine damage H*O & Oil
Check the condition of the oil.

l Thin, black oil is an indication of fuel in the oil.
l Milky discoloration is an indication of coolant in the oil.
Water In Oil
(Thin Black) Good Oil (Milk Color)
Coolant Diluted Oil

Coolant in the oil results from a crack or leak between the
coolant and oil circuits.
The possibility for intermixing can occur in these
components:
Oil cooler
Aftercooler
Core plugs in cylinder head
Cylinder liner seals
Head gasket
Cylinder liner (crack)
Cylinder head (cracked passage)
Cylinder block (cracked passage)
Air compressor (coolant cooled)
Page 2-16
Oil Cooler
The oil cooler design does not require gaskets or seals to
maintain the separation of oil and coolant.
If either the coolant or oil is contaminated, check for a leaking
element. Refer to the checking procedure in this section.
0
During operation the oil pressure will be higher than coolant
a3 pressure. A leak in the oil cooler will show as oil in the coolant.
However, following an engine shutdown, the residual pressure
in the coolant system can cause coolant to seep through the
leak path into the oil.
Aftercooler
043 An aftercooler
lubricating oil.
is also a source
Remove the aftercooler

for coolant
and look for evidence

to get in the
of leaking into
the intake manifold.
Plug the bottom inlet tube and pressurize the aftercooler with
348 kPa [50 psi] to check for leaks by submerging in water.
Page 2-17
Cylinder Head Expansion Plugs

The expansion plugs in the cylinder head under the valve
cover is another potential for oil dilution.
If possible, check for the leaks while the engine
remove the valve cover to look for signs of leaks.
is warm,
0
@r
It may be necessary to pressurize the coolant system to 140

kPa [20 psi].
Cylinder Liner Seals

Coolant can enter the lubricating oil through a deteriorated or
damaged liner seal.
Remove the oil pan and visually inspect the bottom
liners with the cooling system pressurized.
side of
0
@I
Cylinder Head Gasket

Coolant in the oil can also be caused by a damaged cylinder
head gasket.
Pressurize the cooling system to check for leaks. It may be
necessary to remove the oil Dan to locate internal leaks.
Refer to Procedure 2-13. ’
0
@
Cracked Cylinder Head

A crack in the head from the water jacket to an oil passage
or to the top rocker lever area will cause oil dilution.
Pressurize the cooling system to 140 kPa [20 psi] and check
0
@
for leaks.
Page 2-18
Cracked Cylinder Liner
04B A cracked cylinder liner can leak coolant into the lubricating oil.
Remove oil pan and look for coolant leaking from inside of liner
bore.
Air compressor leaks will produce the same symptoms, be sure
to perform Procedure 4-02 before concluding the leak is from
the cylinder liner.
Cracked Cylinder Block
0ai!3
A crack in the cylinder block from an oil drilling or passage to
the water jacket can cause oil dilution, and can normally be
found either as an external leak from a gasket, i.e. head gasket,
or from the oil pickup tube with the oil pan off.
The cooling system should be pressurized to 140 kPa [20 psi]
to detect leaks.
Fuel Diluted Oil

Fuel dilution is limited to three sources:
1. Fuel transfer pump
2. Fuel leaking by the rings
3. Injection pump internal wear
Page 2-19
Use the following logic to determine the source of the oil dilution with fuel:
Power Normal
I I I 1
Verify the Rings are
Check/Replace the Sealing by Performing a
Injectors Compression Check
I I I I
Fuel Transfer Pump

A worn or damaged seal around the plunger can allow fuel
to leak to the oil pan.
Fuel Leaking by Piston Rings

Incomplete combustion in the cylinders can result in
unburned fuel draining into the oil pan.
This condition can be caused by a leaking injector or
reduced compression caused by inadequate piston ring
sealing.
Page 2-20
An increase in white exhaust smoke during the first start of the

day is a symptom of an injector leaking.
An injector leak will also cause the engine to run rough and
have low power.
Remove and replace leaking injectors. Refer to Procedure 5-07.
Refer to the Shop Manual, for test and repair instructions.
Perform a compression check to verify piston rings are properly

sealing. Refer to Procedure 7-01.
Injection Pump
A worn or damaged injection pump can allow fuel to leak into
the lubricating oil as it passes through the pump.
Oil Leaks
Various gaskets, seals and plugs are used to contain the oil.
Most leaks can be identified during routine inspection of the
engine and vehicle.
Page 2-2i
A damaged rocker assembly oil manifold or blown expansion

plug can allow a large quantity of oil to escape resulting in a
sudden drop in the oil pressure.
I / I
/
0 sa
If the oil cooler element ruptures, the oil pressure will force
oil into the cooling system. Oil in the coolant should be @B
visible when the radiator cap is removed. As the oil is forced
into the cooling system, coolant will be displaced through the
radiator overflow.

Leaks can be verified by pressure testing the oil cooler
element. Apply 483 kPa [70 psi] air pressure to the element
to check for leaks.
High intake air restriction and worn or damaged seals in the

turbocharger can also allow oil to leak into the air crossover
06iB
pipe and be burned in the engine. This condition can be
verified by removing the air crossover tube and looking for
oil.
Page 2-22
inadequate sealing of the piston rings will result in combustion

gas and oil droplets being blown out the crankcase breather
tube and/or consumed by the engine. Refer to Procedure 8-01
for measuring crankcase gases (blowby).
0
Oil can also be lost through a worn or malfunctioning air
4B compressor. Look for carbon build up in the air line from the
compressor to the air tank and look for oil when draining the
tank. Refer to Compressed Air Section for additional diagnostic
procedures.
Lubricating Oil Pan - Draining (2-04)

17 mm
Warning: Hot oil can cause serious personal injury.
Warning: Avoid prolonged and repeated skin contact with
used engine oils. Such prolonged and repeated contact can
cause serious skin disorders or other bodily injury.
[14O”F]. Shut off the engine. Remove the oil drain plug. Drain
the oil immediately to make sure all the oil and suspended
contaminates are removed from the engine.
NOTE: Use a container that will hold at least 22 liters [23 U.S.
Qts.] of oil.
Lubricating Oil Pan - Filling (2-05)

17 mm
Clean and check the oil drain plug threads and sealing surface.
Install the oil pan drain plug.
Page 2-23
NOTE: Use a high quality 15W-40 multi-viscosity oil. Choose

the correct oil for your operating climate as outlined in the e
l Turbocharged engines CE/SG
l Naturally aspirated engines CC/CD/SG
Lubricating Oil Level - Checking (2-06)

Fill the engine with clean oil to the proper level.
NOTE: When filling the oil pan, use the fill tube on the side
of the engine rather than on top of the valve cover.
Refer to Lubricating Oil System Specifications, page 2-5 for e
capacities.
n
Idle the engine to inspect for leaks at the drain plug.
Shut off the engine. Waft approximately 5 minutes to let the

oil drain from the upper parts of the engine. Check the level
again.
+B
01 iI hf iii
Add oil as necessary to bring the oil level to the “H” (High)
mark on the dipstick.
Page 2-24
Lubricating Oil Filter - Changing (2-07)

Part No. 3375049 Filter Wrench
Use oil filter wrench, Part No. 3375049, to remove the filter.
Clean the area around the lubricating oil filter head. Remove
the filter. Clean the gasket surface of the filter head.
Use clean 15W-40 oil to coat the gasket surface of the filter.
Fill the filter with clean 15W-40 oil.
Part No. 3375049 Oil Filter Wrench

Install the filter on the oil filter head. Tighten the filter until the
gasket contacts the filter head surface.
Use oil filter wrench, Part No. 3375049, to tighten the filter an
additional three-fourths to one turn, or follow the instructions
supplied with the filter.
Operate the engine and check for leaks.

Section 2 - Lubricating Oil System Page 2-25
Lubricating Oil Dipstick - Calibration

(2-08) -
Install the dipstick in the dipstick tube housing.
Use clean 15W-40 oil to fill the oil pan to the specjfied “low” e
oil level. Refer to Lubricating Oil System Specificatrons, page
2-5, for engine oil capacity.

deep. A
and mark the “low” oil level with an ‘I”. 0
C%
NOTE: If a new blank dipstick is being used, cut the dipstick
off approximately 38 mm [1.5 inch] below the “low” oil level
mark.
Install the dipstick into the dipstick tube housing.

Fill the oil pan to the specified “high” oil level. Refer to
Lubricating Oil System Specifications, page 2-5, for engrne 011
capacity. .e

and mark the “high” oil level with an “H”.
Page 2-26
Lubricating Oil Dipstick Tube -

Replacement (2-09)
Removal
Clean the area around the dipstick tube before removing to
prevent debris from entering the oil system.
Remove dipstick from the dipstick tube.

Remove dipstick tube from the cylinder block.
Service Tip: Use a dent puller and a M8 X 1.25 X 21mm
self-tapping capscrew. Thread the capscrew into the dipstick
tube and remove the tube.
Installation
Apply a thin bead of LoctiteTM No. 277 around the bottom of
the knurled end of the tube.
Place knurled end of tube into the dipstick tube bore in the
cylinder block.
Use a flat washer and hex head capscrew to drive the tube into
the cylinder block.
Lightly drive the dipstick tube until it seats against the block
casting.
Page 2-27
Install dipstick into the dipstick tube.
Lubricating Oil Pressure Regulator, Valve

and Spring - Replacement (240)
Preparatory Steps:
Clean debris.
Removal
22 mm
Remove the plug and regulator valve.

Clean and
assembly.
inspect the bore and regulator valve before
q
\
0@
The valve must move freely in the bore.
Page 2-28.
Installation
22 mm
Install the regulator and spring.
Lubricating Oil Cooler Element and

Gasket - Replacement (2-11)
Preparatory Steps:
Remove the oil filter. Refer to Procedure 2-07.
Removal
Clean all debris from around the oil cooler.
18 mm
Disconnect the turbocharger oil supply line from the oil filter
head.
Page 2-29
10 mm
NOTE: Due to the design of the present production •.l
lubricating oil cooler cover, there is approximately 0.7 liter
to.75 U.S. Qts.] oil that does not drain when the system is
drained. Place a container under the cooler to catch the oil
when the cover is removed.
Remove the oil cooler cover, element and gaskets.
32 mm
Remove the oil temperature thermostat. Refer to Procedure
2-12.

Clean the sealing surfaces.
Pressure Test
Apply 483 kPa [70 PSI] air pressure to the element to check
0a!3
for leaks.
Page 2-30
Installation
10 mm
Assemble the oil cooler gasket, element, cooler cover gasket,
oil temperature thermostat and cooler cover to the cylinder
block.
Install the filter head and gasket if removed.
NOTE: Be sure to remove the shipping plugs from the new
cooler element.
Torque Value:
l Oil Cooler Cover Capscrews 24 Nom [18 ft-lb]
l Oil Filter Head Capscrews 24 Nom (18 ft-lb]
16 mm
Connect the turbocharger oil supply line.
32 mm
Install the lubricating oil temperature thermostat.
NOTE: Fill the filters with clean lubricating oil before installation.
Install a new oil filter.
Follow the manufacturer’s instructions for tightening.
Page 2-31
NOTE: Be sure to open the engine and aftercooler vents to

allow air to escape as the system is filled. Refer to Procedure
l-01.
Fill the cooling system.
Operate the engine to check for leaks.
Shut off the engine and check the oil and coolant level.
Lubricating Oil Temperature Thermostat -

Replacement (2-12)
Removal
32 mm
Remove the oil temperature thermostat.
Page 2-32
Inspection
0a3 Visually inspect for a damaged

damage.
o ring, broken spring or other
A Caution: The flash point of new lubricating oil is

approximately 221°C [43O”F]. Do not allow oil temperature
in the container to exceed 150°C [3OO”F]. Do not allow
water droplets to enter the container of hot oil. Water
droplets will cause a violent reaction which can cause
personal injury.
Suspend the valve and a 116°C [240” F] thermometer in a

container of new lubricating oil. Do not allow the valve or the
thermometer to touch the sides of the container.
Heat the lubricating oil.
0
NOTE: Write down the temperature at which the thermostat is
et9 fully extended. The thermostat must be fully extended to at
least 45.9 mm [1.80 inch] when the temperature reaches 116°C
[240” F].
Replace the thermostat if it does not operate as described.
4
45.9 mm
[1.80 in]
+
Installation
32 mm
Install the oil temperature thermostat.
Lubricating Oil Pan, Suction Tube and

Gasket - Replacement (2-13)
17 mm
Remove the oil pan drain plug to drain the oil.
Oil Pan - Removal

10 mm
Remove the oil pan.
Cleaning
Clean the sealing surface.
Page 234
Suction Tube - Replacement

8 mm
Remove the suction tube and gasket.
Position the lubricating oil suction tube gasket onto the cylinder
block.
Make sure the gasket is correctly installed and does not block
the hole for oil passage.
8 mm
Install the lubricating oil suction tube over the gasket and align
the mounting holes.
Use the following sequence to tighten the capscrews:
Torque Value:
Step A Suction tube to Block 9 Nom [80 in-lb]
Step B Brace to Block 9 Nom [80 in-lb]
Step C Brace to Suction Tube 9 Nom [80 in-lb]
Oil Pan - Installation

Be sure to fill the joints between the pan rail, gear housing and
rear cover with Three Bond RTV sealant, Part No. 3823494.
NOTE: The lubricating oil pan should be assembled and the
capscrews torqued within 15 minutes after applying the sealant.

No. 3823494, to both sides of the new lubricating pan gasket.
Install the gasket.
Install the lubricating oil pan.
10 mm
Assemble the washers and capscrews to secure the lubricatin
oil pan as illustrated. 21 17 13 9 5 1 3 7 11 15 19 23
Tighten all capscrews in the sequence shown to the right. 25 29
Torque Value: 24 Nom [18 ft-lb] 27 31
26 32
26 30
22 16 14 10 6 4 2 6 12 16 20 24
0(T
Tmoo6
The rest of this page is blank.

Page 2-35
17 mm
Install the oil pan drain plug.
06iB
Fill the oil pan with clean 15W-40 engine oil.
0623
Shut off the engine and check the oil level with the dipstick.
Lubricating Oil Pump - Replacement

(2-14)
Preparatory Step:
Page 2-36
Removal
16 mm, Part No. 3377371, Engine Barring Tool
Remove the vibration damper. Use the barring tool, Part No.
3377371, to keep the crankshaft from rotating.
Refer to Procedure 7-l 6.
10 mm
Remove gear cover cap/tachometer drive adapter assembly.
Remove the gear cover. Refer to Procedure 7-17.
bp9OOm.a
10 mm
Remove the four lubricating oil pump mounting capscrews.

Visually inspect the lubricating oil pump gears for chips, cracks,
or excessive wear.
NOTE: Parts replacement is not practical if any of the internal
parts are worn beyond the specifications, the pump should be
replaced.
Page 2-37
Remove the back plate.
Mark “TOP” on the gerotor planetary.
Remove the gerotor planetary.

inspect for excessive wear or damage.
Clean all parts in solvent and dry with compressed air.

Page 2-38
0623
inspect the pump housing and gerotor drive for damage wear.
@@# Install the gerotor planetary.

@ Be sure the gerotor planetary is installed in the original
position.
0
@3
Oil Pump Gerotor Tip Clearance

mm in
0.025 MIN 0.001
0.1778 MAX 0.007
Oil Pump Gerotor Drive/Gerotor Planetary to

Port Plate Clearance
mm in
0.025 MIN 0.001
0.127 MAX 0.005
Page 2-39
Oil Pump Gerotor Planetary to Body Bore

mm in
0.127 MIN 0.005
0.381 MAX 0.015
Oil Pump Drive Gear Backlash (Used Pump)

mm in
0.08 MIN 0.003
0.013
Install the back plate.
Installation
Lubricate the pump with clean 15W-40 engine oil.
NOTE: Fill the pump with oil during installation to aid in
quicker oil suction when the engine is started.
Page 2-40
Install the pump.

Make sure the idler gear pin is installed in the locating bore in
the cylinder block.
10mm
Tighten in the sequence shown.
Torque Value:
Step 1 5 Nom [44 in-lb]
Step 2 24 Nom [18 ft-lb]
The back plate on the pump seats against the bottom of the
bore in the cylinder block. When the pump is correctly
installed, the flange on the pump will not touch the cylinder
block.
Use a dial indicator with a magnetic base to measure the idler

gear backlash.
NOTE: Do not allow the mating gears to rotate while
measuring the backlash.
Oil Pump Idler Gear Backlash (A & B)

mm in
0.08 MIN 0.003
0.33 MAX 0.013
Page 24
Lubricate the front gear train with clean 15W-40 engine oil.
Thoroughly clean the front seal area of the crankshaft.

If the contact area has a groove worn deep enough to feel
with a fingernail or sharp object, it will be necessary to install
a wear sleeve over the sealing surface.
NOTE: The seal lip and the sealing surface on the crankshaft
must be free from all oil residue to prevent seal leaks.
Use sealant, Part No. 3823494, on both sides of the front

cover gasket
Install the front cover and gasket.
Install the capscrews.
NOTE: Torque the capscrews within 15 minutes after
applying the sealant.
Install the gear cover cap/tachometer drive adapter

assembly.
Page 2-42
Install the vibration damper. Do not tighten the capscrews to

the correct torque value at this time. Refer to Procedure 7-16.
l/2 inch or 3/8 inch Square Drive

Raise the belt tensioner to install the belt.
18 mm, Part No. 3377371 Engine Barring Tool

Use engine barring tool, Part No. 3377371, to hold the
crankshaft when tightening the capscrews.
Use a star pattern torque sequence.
Section 3 - Combustion Air System
Page 3-l

Section Contents
Page
Aftercooler and Gasket - Replacement ............................................. 3-24

Removal.. .............................................................. 3-25
Cleaning.. .............................................................. 3-25
Installation .............................................................. 3-25
Air Crossover Tube - Replacement ............................................... 3-22

Removal and installation ..................................................... 3-22
Air System Flow - Diagrams .................................................... 3-4
Charge Air Cooler ........................................................... 3-21 ,,

Cleaning and inspection ..................................................... 3-21
Charge Air Cooler (CAC) - Troubleshooting ......................................... 3-18

Pressure Drop - Checking .................................................... 3-18
Checking - Air Leak ........................................................ 3-20
Combustion Air System - Diagnosing Malfunctions .................................... 3-7

Clean Air ............................................................... 3-7
Intake Air Restriction - Checking ................................................ 3-7
Damage From Non-filtered Air ................................................. 3-8
Turbocharged Engines - Air Leaks, Pressure Side .................................... 3-8
Turbocharged Engines - Exhaust Leaks ........................................... 3-9
Turbocharger Boost Pressure - Measurement ....................................... 3-9
Malfunctioning Turbocharger .................................................. 3-l 0
Oil Consumption and Leaks ................................................... 3-10
Turbocharger Noise ........................................................ 3-l 1
Rotor Assembly Clearance - Measurement ..................................... T ... 3-12
Combustion Air System Flow - General Information .................................... 3-3
Combustion Air System - Service Tools ............................................ 3-6
Exhaust Manifold and Gaskets - Replacement ....................................... 3-30

Removal ................................................................ 3-30
Installation .............................................................. 331
Intake Air and Exhaust System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Intake Manifold Cover and Gasket - Replacement ..................................... 3-23

Removal ................................................................ 3-23
Cleaning.. .............................................................. 3-24
Installation .............................................................. 3-24
Turbocharger Boost Pressure Specifications ......................................... 3-5
Turbocharger - Replacement .................................................... 3-26

Removal.. .............................................................. 3-26
Installation .............................................................. 3-28
Turbocharger Wastegate Actuator - Calibration ....................................... 3-l 7

Exhaust Restriction - Measurement .............................................. 3-l 8
Turbocharger Wastegate Actuator - Functional Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Turbocharger Wastegate Actuator - Replacement ..................................... 3-l 5
Air regulator with pressure gauge ............................................... 3-15
Turbocharger Wastegate Actuator - Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-l 3

Page 3-3
Combustion Air System Flow - General Information

The engine was designed as a turbocharged engine, but a naturally aspirated engine is available for certain applications.
Air is pulled into the engine from an air filter. Clean air is very important to the life of the engine. Ingested dust and dirt
can very quickly damage the cylinders.
Make sure that an excellent quality air cleaner is used and that it is periodically replaced according to the
manufacturer’s recommendations.
Intake air for the naturally aspirated engine flows from the air cleaner to the intake manifold. From the intake manifold,
the air is pulled into the cylinders and used for combustion. After combustion it is forced out of the cylinders and through
the exhaust manifold.
On the turbocharged engines the intake air is drawn through the air cleaner into the compressor side of the turbocharger
and then through the crossover tube and into the intake manifold. From the intake manifold the air is forced into the
cylinders and used for combustion. Energy from the exhaust gases is utilized by flowing the exhaust through the exhaust
side of the turbocharger to drive the turbine wheel. The turbine wheel and shaft drives the compressor wheel which forces
more air into the cylinders for combustion. The additional air provided by the turbocharger allows more fuel to be injected
to increase the power output from the engine.
On turbocharged-aftercooled engines, intake air from the turbocharger flows through the cooling fins of the aftercooler
before entering the intake manifold. The cooled air becomes more dense and contains more oxygen which allows more
fuel to be injected further increasing the power output from the engine.
The 1991 and 1994 engines use a chassis-mounted charge air cooler instead of an engine mounted aftercooler to provide
cooler charge air to the engine to improve engine performance and reduce emissions. This system also uses large
diameter piping to transfer the air from the engine turbocharger to the charge air cooler, then returns the air from the
charge air cooler to the engine intake manifold.
Some turbocharger engines use a wastegated turbocharger to limit the maximum boost pressure that the turbo can
develop. Wastegate operation is controlled by an actuator that senses compressor pressure and balances it against a
preset spring load. The wastegate valve is located in the turbine inlet passage. When open, it diverts a portion of the
exhaust gas around the turbine wheel, thereby controlling the shaft speed and boost.
A
Caution: The turbocharger is a performance part and must not be tampered with. The wastegate bracket
is an integral part of the turbocharger. Tampering with the Wastegate Components can reduce durability
by increasing cylinder pressure and thermal loading due to incorrect inlet and exhaust manifold pressure.
Poor fuel economy and failure to meet regulatory emissions laws may result. Increasing the turbocharger
boost will not increase engine power.
The turbine and compressor wheels and shaft are supported by two rotating bearings in the bearing housing. Passages
within the bearing housing direct filtered, pressurized engine oil to the shaft bearings and thrust bearing. The oil is used
to lubricate and cool the rotating components to provide for smooth operation. The oil then drains from the bearing
housing to the engine sump through the oil drain line. A restricted or damaged oil drain line can cause the turbocharger
bearing housing to be pressurized causing oil to leak past the seals.
NOTE: An adequate supply of good, filtered oil is very important to the life of the turbocharger. Make sure that an
excellent quality oil is used and that it and the oil filter are changed according to the maintenance recommendations.
Page 3-4
Air System Flow - Diagrams
ir System
Exhaust System
6. Exhaust Valve
7. Exhaust Manlfold (Pulse Type)
6. Dual Entry to Turbocharger
9. Turbocharger Exhaust Outlet
Intake System
1. Intake Air Inlet to Turbocharger

2. Turbocharger Air to Charge Air Cooler
3. Charge Air Cooler
4. Intake Manifold
(Integral Part of Cylinder Head)
5. Intake Valve
Page 3-5
Intake Air and Exhaust System Specifications

Maximum allowable intake restriction (compressor inlet)
(;;;,;F, air filter element)
50.8 cm H,O [20 in HsO]
S6D114E-1; SA6Dil%l’ : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 63.5 cm H,O [25 in H,O]
Maximum turbocharger exhaust restriction (turbine outlet)

at rated speed and load
S6D114E-1, SAGD114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 mm Hg [3 in Hg]
S6D114E-1, SAGD114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 cm H,O [40 in H,O]
Wastegate calibration air pressure SA6114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . 165 to 179 Kpa [24.0 to 26.0 psi]
Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Kpa [3 psi]
Turbocharger Boost Pressure Specifications

Refer to the following table for the engine model, engine rating and corresponding rated turbocharger boost pressure.
Measurement of boost pressure is not a short cut to logical troubleshooting. Low power can be caused by the fuel used,
filter maintenance and several engine components. Follow the logic charts for “Engine Power Output Low” and measure
boost pressure as indicated. Refer to page 3-10 for measurement instructions.
A Caution: These pressures are valid only at rated conditions (rated speed and power). Any attempt to use
the values at engine speeds and loads other than those specified will result in an incorrect diagnosis.
ENGINE MODEL ENGINE RATING RATED BOOST PRESSURE

(HP @ RPM) kpa [in. Hg]
S6D114E-1 150 @ 2380 111 to 132 33 to 39
170 @ 2200 111 to 132 33 to 39
173 @ 2380 142 to 162 42 to 48
177 @ 2500 118 to 138 35 to 41
185 @ 2200 115 to 135 34 to 40
190 @ 2200 122 to 142 36 to 42
205 @ 2200 122 to 142 36 to 42
215 @ 2200 125 to 145 37 to 43
SAGD114E-1 215 @ 2000 142 to 162 42 to 48
SAAGD114E-1 230 @ 2200 115 to 135 34 to 40

Page 3-6
Combustion Air System - Service Tools
Dial Depth Gauge

‘I
Measure turbocharger axial motion.
ST-537
Pressure Gauge (O-75 in. Hg.)
Used to measure the intake manifold pressure.

ST-1273
Turbocharger Wastegate Pressure Setting Kit
Use to set wastegate pressure.

3823799
Page 3-7
Combustion Air System - Diagnosing

Malfunctions (3-01)
Clean Air
The correct amount of clean air to the cylinders is required
for good performance. As discussed earlier in Air Flow Sys-
tem, ingested dust and dirt will damage the engine cylinders.
Dust and dirt can also damage the valve stems and guides
as well as wear down the turbocharger compressor vanes
affecting efficiency. Larger debris can damage the blades of
the turbocharger.
Air flow restriction results in excessive smoke and low

power.
Restriction increases as the filter removes contaminants from
the intake air. Restricted air flow changes the air-to-fuel ratio,
reducing power and increasing smoke from the engine. Verify
that the air cleaner is being maintained correctly.
Measurement of air intake restriction is described in this
Section.
Intake Air Restriction - Checking

Replace the air cleaner element when the restriction reaches
I Naturally
Aspirated I
I
the maximum limit at rated engine power and speed.
Naturally Aspirated Turbocharged
50.8 cm Hz0 63.5 cm Hz0
[20 in. H,O] [25 in. H,O]
For turbocharged engines, measure the restriction just before

the turbocharger. Measure just before the intake manifold for
naturally aspirated engines.
Page 3-8
Damage From Non-filtered Air

Loose connections or cracks in the suction side of the intake
pipe can allow debris to be ingested by the engine causing
rapid wear in the cylinders.
Leaks at the intake manifold, unsealed bolt holes or manifold
cover gasket can also allow dust and dirt to be ingested into
naturally aspirated engines.
0@
Loose connections or cracks in the suction side of the intake
pipe on turbocharged engines can allow debris to be ingested
into the turbocharger compressor and forced into the engine.
Debris drawn into the air suction side can damage the com-
pressor blades causing an imbalance resulting in bearing
failure.
04B To verify a bearing failure or damaged compressor, remove the

intake and exhaust piping and check for contact. The rotor
assembly must rotate freely and should not be damaged.
Measurement of axial and radial clearance is described in this
Section.
Turbocharged Engines - Air Leaks, Pressure

Side
Excess smoke and low power from a turbocharged engine can
be caused by pressurized air leaking from loose connections
or cracks in the crossover tube or intake manifold. This can
also cause a noise problem.
Page 3-9
04B
In addition to the visual inspection for cracks and loose
fittings, liquid soap can be applied to the manifold cover
sealing surfaces and connections to find the leaks. The leaks
will create bubbles that are easier to detect. Measurement of e
manifold pressure is described in this Section.
Turbocharged Engines - Exhaust Leaks

Inspect for exhaust leaks at the exhaust manifold and turbo-
charger, gasket leaks, or exhaust pipe restrictions. Leaks or
restrictions will cause the turbine and impeller to operate at a
0
@
lower speed and reduce the amount of air being forced into
the cylinders. Again, the symptom will be excess smoke, low
manifold pressure and low power.
Turbocharger Boost Pressure - Measurement

Measure the boost pressure at the intake manifold by using e
one of the tapped or plugged intake access holes shown in
the illustration. Refer to the specifications in this section.
NOTE: If the engine has charge air cooling, testing must be
done to be sure that the charge air cooler system is not
leaking or restricting the turbocharger boost pressure. Refer
to Procedure 3-06 for detailed charged air cooler testing.
0a3
Exhaust leaks can usually be detected audibly or visually by
a discoloration caused by the escaping hot gases.
Don’t overlook exhaust restriction as a cause of low power. If
the exhaust gasses can not flow freely, the turbocharger will
not operate efficiently.
Page 3-10
Malfunctioning Turbocharger
Failure of the internal components of the turbocharger can
reduce its effectiveness and also cause excessive smoke and
low power. A bearing failure can produce friction which will
slow the speed of the rotor assembly. Failed bearings can also
allow the blades of the rotor assembly to rub the housings,
thus reducing the rotor assembly speed.
Malfunctioning turbocharger wastegate failure or miss-calibration
of the turbocharger wastegate can result in excessively high or
low boost pressures. Low boost pressure can cause excessive
smoke and low power. High boost pressures can cause major
engine damage.
Oil Consumption and Leaks

Engine lubricating oil is used to lubricate the bearings and
provide some cooling for the turbocharger. The oil supplied to
the turbocharger through the supply line is at engine operating
pressure. A return line connected to the bottom of the turbo-
charger routes the oil back to the engine oil pan.
Seal rings are used on each end of the rotor assembly. The
primary function of the seals is to prevent exhaust gases and
compressed air from entering the turbocharger housing. Oil
leakage from the seals is rare, but it can occur.
NOTE: Excessive crankcase pressure will not allow the oil to
drain from the turbocharger. This will load the bearing housing
and allow oil to leak past the compressor seals and into the
engine.
NOTE: If turbine seal leakage into the exhaust system occurs
on engines with catalysts, check the catalyst back pressure
during repair.
A restricted or damaged oil return line will cause the turbo-

charger housing to be pressurized causing oil to migrate past
the seals.
Page 3-I 1
Additionally, high intake or exhaust restrictions can cause a

vacuum between the compressor and the turbocharger
housing resulting in oil leaking past the seals.
To verify oil leakage past the seals, remove the exhaust pipe
and crossover tube and look for oil in the turbine casing and
the crossover tube. Locate and correct the restriction as
0
@
previously discussed.
Turbocharger Noise
It is normal for the turbocharger to emit a “whine” sound that
varies in intensity depending on engine speed and load. The
sound is caused by the very high rotational speed of the
rotor assembly. Consequently, the sound will be more audi-
ble at full speed.
If possible, operate the engine at full speed to verify the
noise level.
Leaks in the air system intake and/or exhaust components

can produce additional noises.
Pressurize the intake system and check for air intake and
crossover tube leaks. 0@
Page 3-12
Before removing the turbocharger, make sure that the noise

complaint is not caused by leaks in the air system compo
-
nents.
Look for loose turbocharger mounting, exhaust manifold gasket
leaks, and cracks in the exhaust manifold.
Lower pitch sounds or rattles at slower engine speeds

can
indicate debris in the system or the rotor assembly is touchin
g
the housings.
Rotor Assembly Clearance - Measurement
Part No. ST-537, Dial Depth Gauge

Measure the shaft end play.
End Play (A)

mm in.
* 0.10 MIN [0.004]
0.16 MAX [O.OOS]
** 0.03 MIN [O.OOl]

0.08 MAX [0.003]
* For turbochargers with a serial number before 840638.

** For turbochargers with a serial number 846638 and after.
Page 3-13
Measure radial clearance of the shaft.
Radial Clearance (6)

mm in.
0.21 MIN [0.008]
0.48 MAX [0.018]
The turbocharger must be removed for replacement or

rebuild if the clearances are beyond these limits. Refer to the
Turbocharger Shop Manual, Bulletin No. 3810321, for rebuild e
procedures.
0a3
Turbocharger Wastegate Actuator - Visual
Inspection (3-02)
Visually inspect the lever pin.
Replace the turbine housing assembly if worn excessively.
Refer to the Turbocharger Shop Manual, Bulletin No.
3810321.
0a3
W&l inspect the valve and valve seat for cracks or
X.
Replace the turbine housing assembly if worn excessively.
Refer to the turbocharger Shop manual, Bulletin No. 3810321.
04B
Actuate the lever by hand to be sure that the shaft moves
fh~.~$r
freely and is not seized.
excessive movement between the shaft and
Replace the turbine housing if the shaft and bushing are

damaged or seized.
Refer to the Turbocharger Shop Manual, Bulletin No.
3810321.
Page 3-14
Visually inspect the wastegate actuator hose for cracks or

holes. Replace the hose if damaged.
Caution: Before making any adjustments to the wastegate
A
assembly, refer to the information on page 3-2.
Visually inspect the wastegate mounting bracket, actuator rod,

and lever for damage. A bent wastegate mounting bracket,
actuator rod, or lever can cause improper operation.
If the wastegate mounting bracket, actuator rod, or lever is
bent, it must be replaced. Refer to Procedure 3-04.
Turbocharger Wastegate Actuator - Func-

tional Checking (3-03)
0a9 Connect regulated air pressure and an accurate pressure gauge

to the capsule. Apply 160 kPa [26 psi] to make sure the
wastegate is functioning properly. The actuating rod should
move approximately 5 mm [0.200 in] without sticking or air
leakage.
NOTE: A small amount of travel when air pressure is first
applied is normal, the tolerance is being removed from the
system.
0
Replace the actuator if no movement of the actuator rod and
@ lever is detected. Refer to Procedure 3-04.
If repair is not correct, refer to Procedure 3-05 for Turbocharger
e Wastegate Actuator - Calibration.
Page 3-l 5
Turbocharger Wastegate Actuator -
0ai9
Replacement (3-04)
NOTE: Prior to removal, note position length of the control
rod from the actuator housing and orientation of the actuator
hose connector in relation to the mounting bracket.
Air regulator with pressure gauge

Remove the retaining clip from the control lever.
Disconnect the actuator rod end from the turbocharger

wastegate lever. This can be accomplished by applying
regulated air pressure to the actuator in a sufficient amount
to activate control rod movement.
Disconnect the control rod from the turbocharger wastegate
lever pin.
Caution: Be careful not to bend the control lever.
NOTE: If the actuator diaphragm material is ruptured and will
not hold air pressure other than by hand, manually pull the
control rod outward in order to overcome actuator spring
tension for removal of the control rod from the turbocharger
wastegate lever pin.
Loosen the actuator mounting capscrews and disconnect the

air supply hose and remove assembly from the mounting C%Q
bracket.
Page 3-16
_ Remove the adjusting link end from the actuator.
Install the adjusting link end onto the new replacement actuator
as;o;zy into approximately the same position as originally
Fit the new actuator assembly to the actuator mounting bracket

and install the mounting capscrews.
Torque Value: 4.5 Nom [40 in-lb]
Page 3-17
Turbocharger Wastegate Actuator -

Calibration (3-05)
NOTE: The wastegate is set accurately from the factory.
Adjustment is not necessary unless the capsule is removed.
Attach a dial indicator as shown, so that its shaft is in line
with the wastegate actuator rod. Set the indicator to zero,
with no air pressure applied to the wastegate capsule.
Connect clean, regulated air pressure supply and an accurate
pressure gauge to the capsule.
For industrial rating apply 153 kPa 122.2 psi]. Measure the
rod travel and compare to the table below.
Wastegate Actuator Rod Movement

mm in.
0.33 MIN 0.013
1.3 MAX 0.050
Replace the actuator if no movement of the actuator rod and

lever is detected. Refer to Procedure 3-04.
Caution: Do not pull, push or force alignment of the

clevis pin.
While pressure is being applied, adjust linkage as follows:
A
l Pull the wastegate lever to the foremost closed
position (lever toward actuator).
l Adjust the length of the clevis end of the control rod
to where the clevis pin hole aligns to the wastegate
lever.
l Install the adjusting link and retaining clip.
l After adjustment is completed, tighten actuator rod
locknut.
Disconnect regulated air pressure line from the actuator.

Connect the turbo boost line to the actuator and secure
hose clamp.
Page 3-18
Exhaust Restriction - Measurement

Install pressure gauge, Part No. ST-1273, to the pressure tap
in the exhaust head pipe or at the inlet to the catalyst / muffler
assembly.
Operate the engine at rated speed and load. Record the
exhaust restrictions.
If restriction exceeds specification, inspect catalyst and/or

muffler and replace per vehicle manufacture’s instructions.
Industrial 76 mm Hg [3 in Hg]
91 EPA certification 114 mm Hg [4.5 in Hg]
94 EPA certification 152 mm Hg [6 in Hg]
Char e Air Cooler CAC) -

Trou 4 eshooting (31b 6)
NOTE: The long term integrity of the charge air cooling system
is the responsibility of the vehicle and component manufactur-
ers; however, the following symptoms can be checked by any
Komatsu Authorized Repair Location.
Pressure Drop - Checking

Preferred Method
Measure the CAC system pressure drop with a mercury
manometer.
Page 3-19
Install one end of the manometer into the l/8 inch pipe tap
in the turbocharger compressor outlet elbow.
Install the other end of the manometer into the l/8 inch pipe
tap in the intake manifold.
0a9
Operate the engine at the maximum advertised horse power
and correlating RPM. Record the readings on the manometer.
If differential pressure is greater than 156 mm Hg [6.0 in Hg]
or 21 kPa 13 psil, check the CAC and associated piping for
plugging. cifG or replace if necessary.
Install Fluke digital thermometer, Part No. 3822666, and

thermocouple wire kii, Part No. 3822688, into the intake
manifold at the l/8 inch NPT tap near the air horn connec-
tion with the intake manifold.
Install another thermocouple at the air cleaner inlet to mea-
sure the ambient temperature.
Page 3-20
Perform a test with the engine at peak power against a load.

Record the intake manifold temperature and the ambient air
temperature.
Calculate the differential temperature:
Intake Manifold - Ambient Air - Differential
Temperature Temperature Temperature
If the temperature differential is greater than 28°C [5O”F],

check the CAC for dirt and debris on the fins and clean as
necessary. If the problem still exists, check the CAC for debris
in fins or between the CAC and radiator. Confirm full fan
engagement.
Checking - Air Leak

To check the CAC for cracked tubes or header, remove the
inlet and outlet hoses from the cooler. The CAC does not have
to be removed from the chassis.
Install a plug or cap on the outlet side of the cooler. Install a

pressure gauge, air supply line, and air pressure regulator to
the inlet side of the cooler.
Warning: To prevent possible injury if either plug blows off
during the test, secure safety chains on the test plugs to
any convenient capscrew on the radiator assembly. This
test must be performed with securely fastened safety
chains.
Page 3-21
Apply 207 kPa [30 psi] of air pressure to the cooler. Close
the air pressure regulator.
Monitor the pressure gauge and determine the rate of pres-
sure decay with a stop watch.
0a9
If the pressure decay is 49 kPa [7 psi] or less in 15 seconds,
the cooler is okay. If the pressure drop is greater than 49
kPa [7 psi] in 15 seconds, check all connections again.
Determine if pressure decay is caused by a leak in the CAC
or from a leaky connection. Use a spray bottle filled with
soapy water applied to all hose connections, and watch for
bubbles to appear at the location of the leak.
If the pressure decay is caused by a leaky connection, repair

the connection and repeat the test. If the leak is within the
CAC, repeat the test to verify the accuracy of the pressure
delay measurement. Similar pressure decay reading must be
obtained at least three consecutive tests before the reading
can be considered accurate.
NOTE: If a CAC leaks more than 49 kPa [7psi] in 15 sec-
onds, it will appear as a major leak in a leak tank.
If the pressure drop is greater than 49 kPa [7 psi] in 15

seconds, the CAC must be replaced.
Refer to the manufacturer’s repair manual for replacement
instructions.
NOTE: Charge air coolers are not designed to be 100% leak
free. If the pressure decay is less than 49 kPa [7 psi] in 15
seconds, then the CAC does not need to be replaced.
Charge Air Cooler (3-07)

Cleaning and inspection
l
If the engine experiences a turbocharger failure or any other G9
occasion where oil or debris is put into the CAC, the CAC e
must be cleaned.
Remove the CAC from the vehicle. Refer to the vehicle
manufacturer’s instructions.
Page 3-22
Caution: Do not use caustic cleaners to clean the CAC.
A Damage to the CAC will result.
q
NOTE: Make sure that the tubes are in the vertical direction
B when flushing.
Flush the CAC internally with solvent in the opposite direction
of normal air flow. Shake the CAC and lightly tap on the end
tanks with a rubber mallet to dislodge trapped debris. Continue
flushing until all debris or oil is removed.
Use a flashlight and mirror to visually inspect the CAC for
internal debris.
NOTE: If internal debris cannot be removed, scrap the CAC.
After the CAC has been thoroughly cleaned of all oil and debris
q
\ with solvent, wash the CAC internally with hot soapy water to
remove the remaining solvent. Rinse thoroughly with clean
water.
Blow compressed air into the CAC in the opposite direction of
A normal air flow until the CAC is dry internally.
Caution: The CAC must be rinsed, dried, and free of
solvent, oil, and debris or engine damage will result.
Visually inspect the CAC for cracks, holes or damage.

a9
0
Inspect the tubes, fins and welds for tears, breaks or other
damage. If any damage causes the CAC to fail the air leak
check mentioned earlier in this Procedure, the CAC must be
replaced. Install the CAC on the vehicle. Refer to the vehicle
Air Crossover Tube - Replacement (3-08)

Removal and installation
8 mm or Screwdriver
Loosen the hose clamps and position the hose so the cross-
over tube can be removed.
Use new hose and clamps as required to install the crossover
tube.
Page 3-23
Intake Manifold Cover and Gasket -

Replacement (3-09)
Preparatory Steps:
l Disconnect the cold starting aid, if used.
l Remove the air crossover tube, if used.
l Disconnect the charged air cooler hose, if used.
Removal
10 mm
Remove the manifold cover and gasket.
Page 3-24
Cleaning
NOTE: Keep the gasket material and any other material out of
the air intake.
Installation
10 mm
Install the cover and a new gasket.
ssemble the intake piping and connect the cold starting aid
Aftercooler and Gasket - Replacement

(3-10)
Preparatory Steps:
l Disconnect the cold starting aid, if used.
l Remove the air crossover tube.
l Drain 2 liters [2.1 U.S. quarts] of coolant.
Page 3-25
Removal
8mm
•l
Remove the coolant supply tube (1) and the coolant return
tube (2).
10 mm
Remove the aftercooler housing and gasket.
Cleaning
NOTE: Keep the gasket material and any other material out
of the air intake.
Installation
10 mm
Use sealant, Part No. 3823494, on both sides of the
aftercooler housing gasket.
Install the aftercooler housing and a new gasket.
For aftercoolers with a form-in-place gasket, apply a 4 mm
bead of sealant to the cylinder head.
Page 3-26
8mm
install the coolant supply tube (1) and coolant return tube (2).
Install the air crossover tube.
A Caution: During filling, air must be vented from the engine

coolant passages. Open the engine vent petcock. Also, be
sure to open the petcock on the aftercooler for aftercooled
engines. The system must be filled slowly to prevent air
locks. Wait 2 to 3 minutes to allow air to be vented, then
add coolant to bring the level to the bottom of the radiator
filler neck.
Fill the coolant system with a pre-mixture of 50 percent water
and 50 percent ethylene-glycol type antifreeze. Use the correct
concentration of supplemental coolant additive (DCA4). Follow
the recommendations given in Section 1.
Turbocharger - Replacement (3-11)

Preparatory Steps:
l Disconnect the charge air cooler hose.
l Disconnect the wastegate actuator hose.
l Disconnect the intake and exhaust piping.
Removal
10 mm
Remove the capscrews from the oil drain tube.
Page 3-27
16 mm
Disconnect the oil supply line.
15 mm and 7/l&inch
Remove the exhaust clamp, turbocharger, and gasket.

Clean the sealing surfaces. Inspect the sealing surface and
mounting studs for damage.
NOTE: If the turbocharger is not to be immediately replaced,

cover the opening to prevent any material from falling into
the manifold.
Inspect the turbocharger wastegate linkage, valve shaft,
module, and pressure signal line.
Check to calibrate wastegate.
Refer to Turbocharger Shop Manual, Bulletin No. 3810321,
for calibration procedures.
*age 3-28
Installation
Install a new gasket and apply a high temperature anti-seize
compound to the mounting studs.
15 mm
Install the turbocharger.
10 mm and 7/1&inch
Use a new gasket and connect the oil drain tube.
Torque Value:
(Exhaust Clamp) 8 Nom 171 in-lb]
(Drain Tube) 24 Nom 118 ft-lb]
NOTE: New turbochargers must be prelubricated before

start-up.
Pour 50 to 60 cc [2 to 3 ounces] of clean engine oil into the
oil supply fiiing. Rotate the turbine wheel to allow the oil to
enter the bearing housing.
Page 3-29
16 mm
Connect the oil supply line.
Torque Value: 15 Nom [ll ft-lb]
Loosen the snap ring and align the compressor housing

with the turbocharger air outlet connection.
7116 inch
Is-l
If required, loosen the compressor housing V-band clamp lm
and position the housing to align with the turbocharger air
outlet pipe.
7/16 inch, Plastic Hammer

Tighten the band clamp. Tap around the clamp with a plastic
hammer and tighten again.
NOTE: Effective Oct. 1, 1990 all Holset Turbochargers use
silver plated nuts with the v-band clamp. The silver plated
nuts require a lower torque than the stainless steel nut to
0\
(-
provide the same v-band clamp load.

Page 3-30
Connect the wastegate actuator hose.
install the air inlet and exhaust piping.

Exhaust Manifold and Gaskets -

Replacement (3-12)
Preparatory Steps:
l Disconnect the charge air cooler hose.
l Disconnect the air intake and exhaust piping.
l Remove the turbocharger, if used.
Removal
RI 15 mm
Remove the exhaust manifold and gaskets.
Page 3-31

Clean the sealing surfaces.
0@
I
Inspect the gasket surfaces for gouges, scratches, or
burn-out.
Place a straight edge across the exhaust ports to check for

flatness.
Exhaust Manifold Flatness
mm in.
0.20 MAX 0.008
Installation
15 mm
Install the exhaust manifold and new gaskets.
Use new lockplates on the capscrews.
Follow the tightening sequence shown in the illustration.
After the capscrews are tightened to the correct torque value,
bend over the lockplates to prevent the capscrews from
loosening.
Page 3-32
I l%
**
83
Install the parts previously removed. Operate the engine and
check for leaks.
0a9
Section 4 - Compressed Air System
Page 4-l

Section Contents
Page
Air Compressor Carbon Buildup - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Air Compressor Gasket Leaks - Checking ......................................... 4-7
Air Compressor - Replacement ................................................. 4-10

Inspection ............................................................... 4-12
Installation .............................................................. 4-12
Removal................................................................4-1 1
Air Governor and Compressor Unloader Valve - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Air Governor - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Compressed Air System Flow Diagrams ........................................... 4-4
Compressed Air System General Information ....................................... 4-2
Compressed Air System Specifications ........................................... 4-3

Page 4-2
Res f- Compressed Air System General

Information
The compressed air system normally consists of a gear driven
air compressor, an air governor, air tanks and all necessary
plumbing.
(Wet Tank)
Reservoir
The Holset SS296 single cylinder air compressor is an engine-driven piston-type compressor which supplies compressed
air to operate air activated devices. The compressor runs continuously but has a loaded and unloaded operating mode.
The operating mode is controlled by a pressure-activated governor and the compressor unloading assembly.
The SS296 air compressor used on 6D114E-1 series engines uses an (E-type) unloader. The Economy (E-type) unloader
system was designed to reduce pumping losses and engine boost pressure losses through the compressor intake valve
while operating in unloaded mode.
When the air system reaches a predetermined pressure, the governor applies an air signal to the air compressor unloader
assembly causing the unloader cap to seal off incoming air at the intake valve, and compressed air stops flowing into
the air system.
NOTE: System pressure must be maintained on the outlet side of the discharge valve to keep the discharge valve closed.
As the air in the air system is used, the pressure drops. At a predetermined pressure the governor exhausts the air signal
to the compressor unloader assembly allowing the compressor to again pump compressed air into the air system.
A Caution: Machines equipped with air dryers vented to atmosphere during unloaded compressor operation,
using the Holset (E-type) air compressor, require the installation of an Econ valve to prevent excessive
oil consumption.
If the air system pressure is not maintained on the discharge valve during unloaded operation, air will be pumped out
of the compressor cylinder causing a low pressure (vacuum) condition to form in the cylinder. With the intake valve sealed
off by the unloader cap, and the exhaust valve being a one-way pressure actuated valve, no air will be allowed to enter
the cylinder. When the compressor cylinder pressure falls below crankcase pressure, oil will be drawn past the piston rings
and pumped into the air system.
Other brands of compressors may be used on 6D114E-1 series engines. Troubleshooting procedures are very similar for
these air compressors compared to the Holset SS296. Refer to the appropriate Chassis Shop Manual for specific air
compressor detailed repair information and torque specifications.
Page 4-3
Compressed Air System Specifications

Holset SS296 Single Cylinder Air Compressor
Compressor Swept Volume @ 1250 RPM ............................... 6.2 L per sec. [13.20 CFM]
Piston Displacement .................................................. 296 cc 118.06 C.I.D.]
Bore ............................................................ 92.08 mm [3.625 in.]
Stroke ................................... , ....................... 44.45 mm [1.750 in.]
Speed ............................................... 1.135 times greater than Engine Speed
Cooling .............................................................. EngineCoolant
Lubrication ....................................................... Engine Lubricating Oil
Plumbing Line Sizes
Coolant Inlet and Outlet (Pipe Fiiing) .......................................... 3/8 in NPTF
Air Inlet (Inside Diameter) ................................................ 19 mm [0.750 in]
Air Outlet (Minimum Inside Diameter) ............................... l/2” NPTF 12.7 mm [0.50 in.]
Height, Overall (Approximate) .............................................. 235 mm [9.25 in.]
Width, Overall (Approximate) ............................................... 146 cm [5.75 in.]
Length, Overall (Approximate) .............................................. 267 cm [lo.5 in]
Weight (Approximate) ..................................................... 20 kg [44.0 lb]
Holset SS336 Single Cylinder Air Compressor
Compressor Swept Volume @ 1250 RPM .......................................... [15.0 CFM]

Piston Displacement ............................................................ 338 cc
Bore ............................................................. 98.9 mm [3.875 in.]
Stroke ........................................................... 44.45 mm [1.750 in.]
Speed ............................................... 1.135 times greater than Engine Speed
Cooling .............................................................. Engine Coolant
Lubrication ....................................................... Engine Lubricating Oil
Plumbing Line Sizes
Coolant Inlet and Outlet (Pipe Fitting) .......................................... l/2 in NPTF
Air Inlet (Inside Diameter) .............................................. 22.2 mm [0.875 in]
Air Outlet (Minimum Inside Diameter) ............................... l/2” NPTF 12.7 mm [0.50 in.]
Height, Overall (Approximate) ............................................. 236.6 mm [9.31 in.]
Width, Overall (Approximate) .............................................. 133.4 cm [5.25 in.]
Weight (Approximate) ..................................................... 18 kg [40.0 lb]
Page’ 4-4
Compressed Air System Flow Diagrams

Reservoir +
Go&nor
Econ Valve
(Wet Tank)
Reservoir
Check Valve
(Normally Built into Dryer)
Air Dryer
-t
To Spitter Valve
With Air Dryer
Reservoir -
(Wet Tank)
Reservoir
Without Air Dryer

Page 4-5
Air Compressor Carbon Buildup -

Checking (401)
Open the draincock
air from the system.
on the wet tank to release compressed
0
@

can cause serious personal injury.
A
Use steam to clean the compressor.
Use compressed air to dry.
Remove the air inlet and outlet connections from the air
compressor.
Measure the total carbon deposit thickness inside the air

discharge line as shown. ID of Discharge Line
The carbon deposit thickness must not exceed 1.6 mm
[l/16 inch].
ID of Carbon Build Up cE3tbla

Page 4-6
A Warning: The air discharge line must be capable of

withstanding extreme heat and pressure to prevent personal
injury and property damage. Refer to appropriate Chassis
@
Parts Manual for replacement part number.
NOTE: If the total carbon deposit thickness exceeds
c%
0
specification:
* Remove and clean or replace the air discharge line. Refer
to appropriate Chassis Shop Manual.
* Remove the air compressor from engine, refer to
Procedure 4-03 and inspect unloader components refer to
Air Compressor Shop Manual, Bulletin No. 3810242, for
detailed instructions on servicing the unloader.
Warning: The air discharge line must be capable of

withstanding extreme heat and pressure to prevent personal
injury and property damage.Refer to appropriate Chassis
Parts Manual for replacement part number.
Continue to check for carbon buildup in the air discharge line
connections up to the first or wet tank.
Clean or replace any lines and fittings with carbon deposits
greater than 1.6 mm [0.06 (1/16) inch]. Refer to the appropriate
Chassis Shop Manual for cleaning or replacement instructions.
Install and tighten the air inlet and outlet connections.

Torque Value:
*Outlet 24 Nom [18 ft-lb]
* l/2 NPT fitting in compressor cylinder head.
NOTE: Torque value for the discharge line depends on the line
size and type. Refer to Chassis Shop Manual for the correct
torque value.
0
Close the wet tank draincock.
ez9 Operate the engine and check for air leaks.
Paie 4-7
Air Compressor Gasket Leaks - Checking

(4-02)
Open the draincock on the wet tank to release air from the
system. Close the draincock after the pressure is released.
ca800wb
Operate the engine to activate the air compressor.

With the air compressor pumping between 550 to 690 kPa
[80 to 100 psi], use a solution of soapy water to check for
air leaks in the following areas:
l Air Compressor cover gasket
l Unloader body o-ring
l Air Compressor cylinder head gasket
If air leaks are found, refer to Procedure 4-05. The
compressor will have to be removed for service.
Air Governor and Compressor Unloader

Valve - Checking (4-03)
Air Compressor Will Not Pump
Remove the air governor hose from the air compressor 0
unloader body. Gz
Caution:
machine
During this test, do not exceed maximum
air system pressure 1035 kPa [150 psi]
whichever is lower. Refer to the appropriate Chassis Shop
A
Manual for maximum air system pressure.
.!.
Page 4-8
If the air compressor does not pump, remove the air

compressor, clean and inspect the air compressor unloader
valve assembly. Refer to Air Compressor Shop Manual 3810242.
Caution: During this test, do not exceed maximum machine

air system pressure 1035 kPa [150 psi] whichever is lower.
Refer to the appropriate Chassis Shop Manual for maximum
air system pressure.
Install the air compressor. Refer to Procedure 4-05.
Operate the engine and check air compressor operation with
the air governor removed.
Install the air governor line to the unloader body and tighten.
Air Governor - Checking (MM)

Air Compressor Pumps Continuously
Remove the accessory air lines from the air governor unloader
port.
NOTE: Do not disconnect the line from the air compressor
unloader valve. Do not disconnect the reservoir air line from
the air governor.
Page 4-9
Install pipe plugs in the air governor unloader ports where

accessory air lines were removed.
If the air compressor stops pumping (air pressure stops
rising) at the governed air pressure, there is a leak in an
accessory or an accessory air line. Refer to the appropriate
Chassis Shop Manual for troubleshooting and repair.
If the air compressor does not stop pumping (air pressure

continues to rise) at the governed air pressure, connect a
regulated shop air pressure line the air compressor unloader
vale port.
NOTE: Be sure the signal line from the air governor to the
compressor unloader is not leaking.
NOTE: Be sure the air pressure gauge is accurate an the

supply line and fitting are in good condition before
performing any air pressure checks.
Use a master gauge of known accuracy to check the air
pressure gauge.
Apply 690 kpa [lo0 psi] air pressure to the unloader port.
If the air compressor stops pumping (air pressure stops
rising) the air governor is malfunctioning and must be
repaired or replaced. Refer to the appropriate Chassis Shop
Manual for instructions.
Page 4-10
If the air compressor continues to pump (air pressure continues

to rise), the unloader valve is malfunctioning and must be
repaired or replaced. Remove the air compressor for repair.
Remove the pipe plug from the governor port used for the
accessory air line.
Remove the regulated shop air.
Install and tighten the accessory air line.
Connect the line between the compressor unloader valve and
the air governor.
Operate the engine and check for air leaks.
Air Compressor - Replacement (4-05)

Preparator Steps:
l Steam clean the air compressor and dry with compressed
air.
l Drain the engine coolant.
Page 4-l 1
Removal
Remove the air connections form the air compressor.
15116 inch
Remove the coolant lines form the air compressor.
9/16 inch
Remove the oil supply line.
19 mm, 15 mm, 14 mm
Remove the air compressor support bracket and capscrews.
Remove the air compressor
Page 412
Inspection
Visually inspect the compressor housing for cracks or damage.
Visually inspect the drive gear for cracks or damage.
Be sure the gasket surfaces of the gear housing and air

compressor are clean and not damaged.
Installation
14 mm, 15 mm, 19 mm
Caution: Make sure the oil drain notch in the gear housing
is not blocked. The gasket must be installed with the side
marked “This Side Toward Gear Housing” is facing the gear
housing.
Use a new gasket. install the air compressor. Tighten the two
mounting nuts.
Torque Value: 77 N l m [57 ft-lb]
NOTE: It is not necessary to time the air compressor on the
6D114E-1 Series engine.
Install the mounting spacer to the engine block, use the 46 mm

long capscrews and tighten finger tight.
Pagd 4-lf)
Install the air compressor brace (2) to the mounting spacer

91) and adapter (3) on the air compressor using the 30 mm
long capscrews finger tight. Make sure the brace and spacer
are aligned and no parts are in a bind. Tighten evenly to the
proper torque value.
9116 inch
15/16 inch
Caution: If rubber grommets are used on the coolant
lines, be sure they are install carefully to prevent cuts or
tears to the grommets which will cause coolant leaks.
Install the coolant lines.
A
Torque Value: 35.m [26 ft-lb] @$
Install and tighten the inlet and outlet connections.

Torque Value:
*Outlet 24 Nom 118 ft-lb]
*l/2 NPT fitting in the compressor cylinder head.
NOTE: Torque value for the discharge line depends of line
size and type.
Refer to the appropriate Chassis Shop Manual for the correct
torque value.
Page 4-j4
Fill the engine cooling system.
coolant leaks and proper
Operate the engine to check for
operation.
After the system reaches governed air pressure, 690 to 862 kPa
[lo0 to 125 psi] check for air leaks.
Section 5 - Fuel System
Page 5-l

Section Contents
Page
AFCR;;Fvi Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5-31
Installatio;l’::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::5-31
Fuel Drain Manifold - Replacement ............................................... 5-26

Removal and Installation ..................................................... 5-26
Fuel Filter Head Adapter - Replacement ............................................ 5-21

Fuek;,eoTtn Pump - Replacement ............................................... 5-31

5-32
lnstallatio;l’::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::5-33
Fuel Return Overflow Valve - Replacement .......................................... 5-30
Fuel Shutoff Solenoid - Replacement .............................................. 5-28

RSV Governor Fuel Shutoff Solenoid - Removal 5-28
RSV Governor Fuel Shutoff Solenoid - Installation’ : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 5-29 _
Direct Link Solenoid, Cylinder Block Mounted ....................................... 5-29
RQVK Governor Fuel Shutoff Solenoid - Removal and Installation .......................... 5-29
Fuel System Components and Flow ............................................... 5-3
Fuel System Diagnosing - Malfunctions ............................................ 5-7

Fuel Transfer Pump ........................................................ 5-7
Air in the Fuel System ...................................................... 5-11
Fuel Water Separator/Filter Unit ................................................ 5-13
Fuel Injection Pump ........................................................ 5-14
Governor Malfunctions 5-14
Air Fuel Control (AFC) hnalfunctibns ’ : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 5-14
Fuel Control Lever Travel and Adjustment ......................................... 5-15
Fuel In’ection Pump Idle Adjustment Screws ........................................ 5-15
Manua1 Shut Down Levers .................................................... 5-15
Electrical Shut Down Devices .................................................. 5-16
Fuel Injection Pump Timing ................................................... 5-17
High Pressure Fuel Lines .................................................... 5-18
Injectors.. .............................................................. 5-19
Fuel Drain Manifold ........................................................ 5-20
Fuel System - Service Tools .................................................... 55
Fuel System Specifications ..................................................... 5-4
FuekF;;;;ar Pump - Replacement/Rebuild ... ...... . . . . . . . ...... 5-22

...... . . . . . . . ...... 5-22
Rebuild : : : : : : : : : : : : : : : : : : : : : : : : : : ...... . . . . . . . ...... 5-22
Cleaning ................................ ...... . . . . . . . 5-23
Assembly ............................... ...... . . . . . . . 5-23
Cleaning Mounting Surface ................... ...... . . . . . . . 5-24
lnstallatron ........................ ...... . . . . . . . ...... 5-24
Hig;keoyayre Fuel Lines - Replacement ........................................... 5-24

5-24
Installatio;l’::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::5-25
Idle Speed - Ad’ustment ....................................................... 5-38

Bosch RSV b overnor 5-38
Bosch RQVK Governor. : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 5-39
Inje;~;r-v;fplacement .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-26
Cleaning aid if&&tib;l' 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5-26
Page S-2
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Wine Fuel In’ection Pump Spill-Port Timing ......................................... 5-39

Governor t ever Positioning ................................................... 5-41
Low Pressure Fuel Line - Replacement ............................................ 5-21

Page 6-3
Fuel System Components and Flow

A cam-actuated fuel transfer pump provides positive fuel pressure to the fuel injection pump. Fuel flow begins as the fuel
transfer pump pulls fuel from the supply tank. The system should have a pre-filter or screen to remove larger contaminants
from the fuel before reaching the fuel transfer pump. The fuel transfer pump supplies low pressure fuel through the fuel
filter head and filter to the fuel injection pump for Bosch A, MW, P and EP9 Nippondenso pumps.
The Robert Bosch PES6A fuel injection pump is used on all engine models. The Model PESGMWand PESGAfuel injection
pumps are used on the higher rated SAGD114E-1engines. The PESGPfuel injection pump is used on the 6D114E-1 &
S6D114E-1 engines. The fuel injection pump builds the high injection pressures required for combustion and routes the
fuel through high pressure fuel lines to each injector.
All 6D114E-1 series engines use Robert Bosch 17mm closed-nozzle, hole-type injectors. When the high-pressure fuel
reaches the injector, the pressure lifts the needle valve against the spring tension to allow fuel to enter the combustion
chamber.
Any leakage past the needle valve enters the fuel drain manifold. The manifold routes leakage from the injectors to the
fuel filter head. Fuel from the injection pump vent fitting is returned to the supply tank through the fuel return line.
Fuel System
1. Fuel from Supply Tank
4
a-
0 0 2. Pm-Filter or Screen
-- _
3. Fuel Transfer Pump
0 -
4. Fuel/Water Separator
3 5. Fuel Filter
6. Low Pressure Supply Line
7. Turbo Boost Control Line
6. Robert Bosch PES.MW
lnjectlon Pump
9. Robert Bosch PES.A
Injection Pump
10. Robert Bosch PES.P
Injection Pump
11. Fuel Drain Manifold
12. High Pressure Fuel Lines
13. Robert Bosch, 17mm Closed-
Nozzle, Hole Type Injectors
14. Fuel Return to Supply Tank
Page 5-4

6D114E-1, S6D114E-1, SAGD114E-1& SAAGD114E-1 . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Hg [4 in Hg]
Fuel transfer pump output pressure (minimum) at rated speed
High flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa [25 psi]
Lowflow .. .. .. .. . .. .. .. . .. ... . .. ... .. .. ... .. .. ... . .. .. .. . . . . . . . . . 83 kPa 112 psi]
Minimum pressure to fuel pump inlet (all in-line) .................................. 1.2 Bar 118 psi]
High flow ........................................................... 138 kPa [20 psi]
Lowflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 kPa [7 psi]
Fuel filter restriction (maximum pressure drop across filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 kPa [5 psi]
Fuel return restriction (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 mm Hg [20.4 in Hg]

Page 5-5
Fuel System - Service Tools
Tnnl Nn Tnnl fbar4ntinn Tnnl llhmtratinn

.““. ‘“““..P..“.. .ww. .
..““..“..“..
Used to test injection nozzles.
Used to clean injector nozzles.
Engine Barring Tool
Used to rotate the crankshaft.
Fuel Pump Gear Puller
Used to pull the fuel pump gear.

Page 5-8
Tool No. Tool DescriDtion Tool Illustration
Injector Puller
Used to pull injectors.

3823276
Wrench, Crowfoot
Used to torque high pressure fuel lines.

3823425
Fuel System Diagnosing - Malfunctions

(5-01)
The function of the fuel system is to inject a metered
quantity of clean, atomized fuel into the engine cylinders at a
precise time near the end of the compression stroke of each
piston. The components of the system contribute to the
delivery of fuel to the cylinders.
1. Fuel injection pump
2. High pressure fuel lines
Fuel Transfer Pump

The system design requires an inlet pressure of 131 to 172
kPa [19 to 25 psi] to the fuel injection pump.
The fuel transfer pump capacity is designed to deliver
pressure in excess of 138 kPa [20 psi]. The pressure relief
valve controls the inlet to the pump by dumping excess fuel
back to the supply tank.
1. Fuel injection pump
2. Fuel supply line
3. Fuel filter
4. Fuel transfer pump
5. Fuel tank
6. Pressure relief valve
The fuel transfer pump is mechanically driven by a plunger

running against a special lobe on the camshaft. The fuel
transfer pump contains a pumping piston and check valves
to control the flow of fuel, and bleed back during engine
shutdown.
Check valves A, B, C.
1. Low pressure supply line
2. Priming pump
3. Fuel inlet line
4. Piston
Caution: Make sure the wire to the fuel solenoid is

disconnected before performing the following check.
Residual fuel in the fuel injection pump may allow the
A
engine to start.
1. Synchro-start
Trombetta
;: Direct link, cylinder block mount
Page 8-8
To determine if the fuel transfer pump is delivering the correct

amount of fuel.
l Measure the engine cranking RPM with a tachometer.
l Measure the fuel transfer pump output for a 30 second
cranking cycle.
l Use the data and the following charts to check the fuel
FUEL TRANSFER PUMPS transfer pump performance.
(HIGH FLOW)
Fuel Transfer Pump (High Flow)

FuelTransfer Pump
ml High Flow [=I Use the chart given in the illustration to find the correct flow
volume specification for the High Flow fuel transfer pump used
with the Robert Bosch PESGP (P7100) fuel injection pump.
Draw a straight vertical line above the measured
cranking RPM.
Draw a straight horizontal line from the measured flow
volume to the intersection point.
Any intersection point above the required flow line
indicates an acceptable flow.
Any intersection point below the required flow line
indicates unacceptable flow and a defective pump or
too much line restriction.
Example 1 Engine cranking speed 210 RPM

Good Pump Flow Volume 360 ml [12.9 oz]
175 zoo 225 2sa 275 Example 2 Engine cranking speed 260 RPM
Bad Pump Flow volume 370 ml [12.5 oz]
Engins Cmnklng Speed (RPM)
TRo117
Page 5-9
Fuel Transfer Pump (Low Flow)

Use the chart given in the illustration to find the correct flow
volume specification for the fuel transfer pump used with the
Robert Bosch PESGAand MW fuel injection pump.
l Draw a straight vertical line above the measured
cranking RPM.
l Draw a straight horizontal line from the measured flow
volume to the engine cranking RPM vertical line to find
the intersection point.
l Any intersection point above the required flow line
indicates an acceptable flow.
l Any intersection point below the required flow line
indicates an unacceptable flow and a defective pump
or too much restriction.
Example 1 Engine cranking speed 190 RPM
Good Pump Flow volume 320 ml [lo.8 oz]
Example 2 Engine cranking speed 260 RPM 250

Bad Pump Flow volume 290 ml [9.8 oz] 175 200 a5 250 275
Englna Cranking Speed (RPM)

TRO118
0a9
A quick check to determine if the fuel transfer pump is
delivering fuel is to measure the output pressure.
Fuel Transfer Pump Output
at Rated Speed
kPa psi
172 MIN 25
(High Flow)
83 MIN 12
(Low Flow)
0a3
If the required volume is being delivered, look for a
restriction between the fuel transfer pump and the fuel
injection pump.
1. Supply line to filter
2. Filter
3. Supply line to fuel injection pump
If the required volume is not being delivered, measure the
transfer pump inlet restriction with a vacuum gauge between
the transfer pump inlet and the supply line from the tank.
Refer to the fuel system specification for inlet restriction.
4. Inlet to transfer pump from supply tank.
Page 5-10
The pressure drop across the filter will increase as the filter
removes contamination from the fuel. Therefore, a worn fuel
transfer pump will have reduced capacity to force fuel through
a dirty filter. This can cause low engine power.
Frequent fitter replacement to get full power from the engine
can indicate a worn fuel transfer pump.
If the fuel is aerated or the volume is low, isolate the fuel

transfer pump by connecting the fuel transfer pump inlet to a
temporary supply and perform the same check as above.
If the fuel transfer pump delivers the required volume of fuel

from a temporary supply, check for restrictions or suction leaks
in the fuel circuit to the fuel transfer pump:
1. Supply line
2. Pre-filter
3. Supply line
4. Supply tank
5. Tank vent
0
Look for a plugged supply tank vent first.
a3
TRO124
Page 511
Replace or clean the pre-filter.

In cold weather look for gelled fuel blocking the pre-filter.
Look for kinks that can restrict the supply lines.

Remove and blow out supply lines.
Air in the Fuel System

The pressure relief valve arrangement in the supply side of
the fuel circuit creates a self-bleeding system on the PESGA
fuel injection pump for air introduced during replacement of
the supply side components.
Small amounts of air can be bled from the fuel injection
pump by operating the hand primer on the fuel transfer
pump or by cranking the engine.
NOTE: PESGMW fuel injection pumps without the fuel drain

arrangement on the engine side will require additional venting
prior to initial start up, fuel injection pump replacement, or if
the engine has been allowed to run out of fuel. Refer to
Procedure 5-10 for the discussion.
Page 512
The PESGMWand PESGPfuel injection pumps equipped with

engine side fuel drain arrangement creates a self-bleeding
system for air introduced during replacement of the supply side
components.
Small amounts of air can be bled from the pump by operating
the hand primer on the fuel transfer pump or by cranking the
engine.
Air from uncorrected leaks in the supply circuit will make the
engine: difficult to start, run rough, misfire, produce low power,
and can cause excessive smoke and a fuel knock.
0
A source, which is often overlooked, for air to enter the fuel
a3 system is between the inlet of the pre-filter and the suction tube
in the tank. Fuel tanks that have the outlet fiiing at the top will
have a suction tube that extends to the bottom of the tank.
Cracks or pin holes in the weld that joins the tube to the fiiing
can let air enter the fuel system.
0
Since the fuel transfer pump provides a positive pressure
689 through the fuel filter and supply line to the fuel injection pump,
loose connections or defective seals should show as a fuel
leak.
Page 5-l 3
Fuel Water Separator/Filter Unit

Filtration and separation of water from the fuel is important
for trouble-free operation and long life of the fuel system.
Some of the clearances between the fuel injection pump
parts are very close. For this reason the parts can easily be
damaged by rust formation, contaminants, or loss of the
lubricating film of fuel.
Be sure to use the correct element.
The element has a valve which must be opened daily to

drain the collected water.
A dual water separator/filter adapter provides additional

filtering capacity. The fuel flows through the adapter to a
larger combination fuel water separator filter, and back to the
fuel filter for final filtering.
Regular maintenance, including draining moisture from the

fuel water separator/filter and supply tanks, is essential to
keep water out of the fuel.
Page S-14
Fuel Injection Pump

The fuel injection pump performs the three basic functions of:
1. Producing the high fuel pressure required for injection.
2. Metering the exact amount of fuel for each injection cycle.
3. Distributing the high pressure, metered fuel to each
cylinder at the precise time.
Individual plungers are used in the fuel injection pumps to

develop and distribute the high pressure required for injection.
A worn or damaged plunger in the fuel injection pump will
affect only one cylinder.
Governor Malfunctions
Balance between the flyweight governor and the control lever
position controls the metering of the amount of fuel to be
injected.
The fuel injection pump governor performance and setting can
affect engine power. Special equipment and qualified personnel
are required to verify governor performance. If the seals are
broken on the external adjustment screw, the fuel rate may be
out of adjustment.
Air Fuel Control (AFC) Malfunctions
A
Caution: The AFC is a performance part and must not be
tampered with after adjustment at the factory. Tampering
with the AFC could cause poor fuel economy and failure to
meet regulatory emissions laws.
The RQV and RQVK governors are equipped with an air fuel
control (AFC) device to help control emissions. The AFC
regulates the fuel to air mixture by sensing manifold pressure.
A malfunction of the AFC can cause low power and excessive
exhaust smoke under load. Leaks at the fittings or a restriction
in the tube from the intake manifold to the AFC can also cause
low power and excessive smoke.
Page S-15
Fuel Control Lever Travel and Adjustment

The amount of fuel injected and subsequently the speed and
power from the engine is controlled by the fuel control lever.
Restricted travel of the fuel control lever can cause low
0
@
power. Always check for full travel of the fuel control lever
when diagnosing a low power complaint.
Fuel Injection Pump Idle Adjustment Screws

The idle speed adjustment screw provides a stop for the fuel
control lever at low speed. The idle adjustment screw can be
used to increase idle speed for accessory loading or, if
required, to lower the idle speed.
The high speed adjustment screw is set at the factory and
can only be adjusted at a certified fuel pump shop.
1. Idle Screw
2. High Idle Screw
Manual Shut Down Levers

The mechanical shut down lever (1) is located on the
governor. These levers are spring-loaded in the run position.
Not all applications will use these manual shut down controls
and there will be no cable or rod connected to the lever.
Partial actuation of the mechanical shut down lever will
affect fuel flow and engine power.
Low power or the inability to stop the engine with the

manual shut down control can be corrected by adjusting the
cable/rod length to permit stop-to-stop lever travel.
Page 6-16
Electrical Shut Down Devices

Engines using the RSV Governor are equipped with either the
Synchro-Start or Trombetta cylinder block mounted fuel shutoff
solenoid to actuate the shutoff lever. Both 12 VDC and 24 VDC
external fuel shut-off solenoids are available.
A
Warning: Solenoid surface temperature can exceed 175°C
[347“F] which can cause serious burns to the skin in event
of contact.
NOTE: Values are taken at 20°C [63”F] and rated voltage.
Minimum values are for 25 mm [l.OO inch] maximum plunger
travel. As the temperature of the solenoid increases the voltage
and resistance requirements increase, while the amperage
requirements decrease.
The solenoid specifications are as follows:

1. Synchro-Start Cylinder Block Mount
Resistance
Battery Min Voltage Min Ohms Min Amperes
0 Pull-in Hold-in Pull-in Hold-in
Voltage Pull-in Hold-in
@ii
12 7.5 3.0 0.28 19.9 44 0.61
24 15.0 6.0 1.04 79.9 23 0.30
2. Trombetta Cylinder Block Mount

Resistance
Voltage Pull-in Hold-in Pull-in Hold-in Pull-in Hold-in
12 10 4.5 0.17 13.6 58.8 0.33
24 20 9.0 0.68 50 29.4 0.18
3. Direct Link, Cylinder Block Mount

Resistance
12 5.3 2.8 0.22 11.1 55 1.1
24 10.6 5.6 0.82 41.3 29 0.5
Engines using the Robert Bosch PESGP fuel injection pump

with the RQVK governor are equipped with the Synchro-Start
fuel shutoff solenoid to actuate the shutoff lever. Both 12 VDC
and 24 VDC external fuel shut-off solenoids are available.
The solenoid specifications are as follows:
Synchro-Start Governor Mount
Min Voltage Resistance Min Amperes
Battery Min Ohms
12 6.5 4.0 0.22 11.1 55 1.10
24 13.0 8.0 0.82 41.3 29 0.60

Page 5-17
Wiring Guidelines:
Refer to the chart below to find the correct gauge size and
length of continuous wire for the white (pull-in) wire, which
connects to the solenoid wiring. The black (ground) wire
must be the same gauge as the white (pull-in) wire
regardless of its length.
Wire Length
Ft. MAX
cm Gauge 12v 24V
0 to 137 14 5 9
0 to 213 12 9 14
0 to 335 10 14 23
NOTE: 14 gauge wire is required for the red (hold-in) wire,

which connects to the “Run” terminal on the ignition switch.
Fuel Injection Pump Timing
Fuel injection pump-to-engine timing is extremely critical. Fuel
injection pump timing that is off by only a few crankshaft
degrees will cause:
1. Poor performance -- starting and power
2. Excessive smoke and emissions
3. Poor fuel economy
4. Excessive cylinder pressure
The governors have a provision for locking the fuel injection

pump shaft at a position corresponding to top dead center
(TDC) for No. 1 cylinder. New and reconditioned fuel
injection pumps should be received with the shafts locked in
this position.
The engine is equipped with an engine timing pin to locate

TDC for No. 1 cylinder.
If the timing pin is incorrectly located on the gear
housing, the timing procedure will not make sure that the
fuel injection pump is timed correctly.
The timing pin assembly is aligned to the gear housing to
correspond to a hole in the back side of the camshaft gear
when No. 1 cylinder is at TDC. If the gear housing or timing
pin assembly is removed, it will be necessary to relocate it
(refer to Procedure 7-07).
Page 518
High Pressure Fuel Lines

The high pressure fuel lines are designed and manufactured to
deliver fuel at injection pressure to the injectors. The high
pressure pulses will cause the lines to expand and contract
during the injection cycle.
The high pressure lines must be clamped securely and
routed so they do not contact each other or any other
component.
The length, internal size and rigidity of the lines is critical to

smooth engine operation. An attached metal tag is used to
identify each line with a part number.
Do not weld or substitute lines; use only the specified part
number for the engine.
Warning: The pressure of the fuel in the line is sufficient to

penetrate the skin and cause serious bodily harm.
Use cardboard to check for cracks and leaks. With the engine
running, move the cardboard over the fuel lines and look for
fuel spray on the cardboard. Fuel leaks can cause poor engine
performance.
Bleed the air from the high pressure line at the fitting that
connects the injector. Bleed one line at a time until the engine
runs smooth.
If the air cannot be removed, check the fuel injection pump
and supply line for suction leaks.
Page 5-19
Injectors
All engines use Robert Bosch, 17mm closed nozzles,
hole-type injectors. However, the injectors can have different
part numbers for different engine ratings.
Use only the specified injector for the engine, consult the e
appropriate Chassis or Engine Parts Book for injector part
numbers. Part Numbor
During the injection cycle, high pressure from the fuel

injection pump rises to the operating (pop) pressure which
causes the needle valve in the injector to lift. Fuel is then
injected into the cylinder. A shimmed spring is used to force
the needle valve closed as the injection pressure drops
below the pop pressure to seal off the nozzle after injection.
1. High pressure fuel line
2. Fuel drain manifold
Failure of the needle valve to lift and close at the correct

time or the needle valve stuck open can cause the engine to
misfire and produce low power. Fuel leaking from the open
nozzle can cause a fuel knock, poor performance, smoke,
poor fuel economy and a rough running engine.
1. High pressure fuel line
2. Fuel drain manifold
0ai9
To find which cylinder is misfiring, operate the engine and
loosen the fuel line nut at one injector and listen for a
change in engine speed.
A drop in engine speed indicates the injector was
delivering fuel to the cylinder.
Check each cylinder until the malfunctioning injector is found.
Be sure to tighten the fuel line nut before proceeding to
the next injector.
Page 5-20
Remove the malfunctioning injector to test or replace it.

Check for an extra sealing washer on the injector.
Warning: The pressure of the fuel in the line is sufficient to

penetrate the skin and cause serious bodily harm.
If the engine continues to misfire, use cardboard to check for
fuel leaks in the high pressure lines. With the engine running,
move the cardboard over the fuel lines and look for fuel spray
on the cardboard. Fuel leaks can cause poor engine
performance.
Carbon build up in the orifices in the nozzle will also cause low
power from the engine. Remove and check the spray pattern
or replace the injectors.
Fuel Drain Manifold

The fuel system is designed to use fuel to cool and lubricate
the fuel injection pump plungers and injectors. Fuel is
continually vented from the fuel injection pump and a small
amount of fuel leaks by the injector needle valve during
injection. This fuel is returned to the fuel filter head (1) by the
fuel drain manifold (2).
Page 5-21
Low Pressure Fuel Line - Replacement

(502)
Preparatory Step:
Clean debris from fittings.
NOTE: Thoroughly clean all fittings and components before
removal. Make sure that the debris, water steam or cleaning
solution does not reach the inside of the fuel system.

14 mm, 17 mm, 20 mm
Disconnect the fuel line from the fuel transfer pump and filter
head. Use two wrenches to disconnect the line from the fuel
transfer pump.
Install the fuel line to the fuel transfer pump and filter head.
Use two wrenches to tighten the connection to the fuel
transfer pump. Do not over torque, fuel leak may occur.
Fuel Filter Head Adapter - Replacement

(5-03)
Preparatory Steps:
Clean debris.

24 mm
Remove the fuel filters. •l
Remove the retaining nut, fuel filter head adapter and sealing +
washers. @
Install in the reverse order of removal.
Page 5-22
Fuel Transfer Pump - Replacement/

Rebuild (504)
Preparatory Steps:
Clean debris.
Disconnect the fuel lines.
Removal
10 mm
•l Remove the fuel transfer pump.
Rebuild
20 mm, 26 mm Wrench
•l Caution: The hand-prime fitting and inlet fitting are spring
A
loaded. Sudden removal of these two fittings can cause
personal injury.
Secure the fuel transfer pump in a vise, taking care not to
damage the pump housing.
Remove the rubber boot from the hand-prime fitting.
Remove the three illustrated fittings.
Remove all internal components of the fuel transfer pump.

NOTE: Make sure the check valve gaskets are removed from
the inlet fitting.
(A) Outlet Fitting
(B) Inlet Fitting
(C) Hand Primer Fitting
TRO167
Page 523
Cleaning
Thoroughly flush the fuel transfer pump with a cleaning
solution to remove any debris.
Assembly
20 mm, 26 mm Wrench
Assemble the fuel transfer pump with the new components
supplied in the rebuild kii.
1. Check valves
2. Check valve gaskets
3. O-ring seal
4. Outlet fitting/check valve
5. *O-ring seal (25 mm)
6. *O-ring seal (30 mm) or (25 mm)
* O-ring required is determined by the size of the inlet fitting.
Discard unused O-ring.
NOTE: Extreme caustion must be used to make sure the
check valves are installed to open in the direction of the fuel
flow.
Improper installation of the check valves will result in low
power from the engine.
Place the fuel transfer pump in a vise and torque the fittings
to the following values:
(A) Outlet Fiiing 30 Nom 122 ft-lb]
(B) Hand-Prime Fitting 30 Nom [22 ft-lb]
(C) Inlet Fiiing 30 Nom [22 ft-lb]
TR0171
Cleaning Mounting Surface

Clean the mounting surface on the cylinder block.
Installation
10 mm
Install the fuel transfer pump and a new gasket.
Connect the fuel lines.
Hi h Pressure Fuel Lines - Replacement

(535)
Removal
10 and 17 mm PESGA and PESGMW Fuel injection Pump)
10 and 19 mm I PESGP Fuel Injection Pump)
Clean debris from around the fuel lines.
NOTE: If individual lines are to be replaced, remove the
vibration isolators from the set of lines containing the line to be
replaced.
Disconnect the line(s) from the injectors.
17 mm PESGA and PESGMW Fuel injection Pump)

19 mm I PESGP Fuel Injection Pump)
Disconnect the line(s) from the fuel injection pump.
Page 525
Installation
10 and 17 mm (PES6A and PESGMW Fuel Injection

Pump)
10 and 19 mm (PESGP Fuel Injection Pump)
Loosen the vibration isolator capscrews so the fuel lines can
easily moved.
NOTE: To prevent breakage to the fuel lines, they must be
connected to the injector and fuel injection pump in a “free
state” without forcing the connecting nuts. Since the fuel
lines are properly sized for specific application, bending
should not be necessary.
A
Caution: If removed, install the support clamp in the
original position and make sure the lines do not contact
each other or another component.
Install the lines in the reverse order of removal.
Tighten all fittings and mounting hardware.

Torque Value:
1. Line Fittings 30 Nom [22 it-lb]
0\
2. Support Bracket bolts 24 Nom [18 ft-lb] r
3. Vibration Isolator Bolts 6 Nom [53 in-lb]
Page S-26
Fuel Drain Manifold - Replacement (506)

10 mm
Clean debris from around the fuel drain manifold.
Remove the banjo capscrews from the injectors and fuel filter
head.
Install the fuel drain manifold in the reverse order of removal.
Torque Value:
Filter Head Banjo 15 Nom [ll ft-lb]
Injector Banjo 9 Nom [66 in-lb]
Injector - Replacement (6-07)

Preparatory Steps:
Thoroughly clean around the injectors.
Disconnect the high pressure fuel lines. Refer to Procedure
5-05.
Disconnect the fuel drain manifold. Refer to Procedure 5-06.
Removal
10 and 13 mm, Part No. 3823276 Injector Puller
Remove the injectors.

Part No. 3822510 Injection Bore Brush
Clean the injector nozzle bore.
NOTE: If the injector sealing sleeves are melted, it is an
indication the engine has been operating in an overheated
condition. Refer to the troubleshooting Logic Chart for “Coolant
Temperature Above Normal”.
Installation
Lubricate the sealing lips of the sleeve with anti-seize &
compound. Assemble the injector, sealing sleeve, a new LJ d
copper sealing washer and the holddown clamp.
Use only one washer.
Service Tip: A light coat of clean 15W-40 engine oil between
the washer and injector can help hold the washer in place
Install the injector assemble into the injector bore. The

injector leak-off connection must be toward the valve cover.
10 and 13 mm
Install the holddown capscrew.
10 mm
Install the fuel drain manifold.
NOTE: The banjo connector seal (Siamese washer) must be
installed as shown in the illustration.
Page 8-28
17 mm (PESGA and PESGMW Fuel Injection Pump)

Install the high pressure fuel lines.
Fuel Shutoff Solenoid - Replacement

(508)
Preparatory Steps:
Label and disconnect the wiring.
RSV Governor Fuel Shutoff Solenoid - Removal

Cylinder Block Mount
10 mm
Remove the two mounting capscrews and remove the solenoid
from the bracket.
1. Synchro-Start
2. Trombetta
3. Direct link
RSV Governor Fuel Shutoff Solenoid -

Installation
Cylinder Block Mount
10 mm
NOTE: Make sure the acorn nut is tightened to be snug on
the fuel shutoff solenoid shaft (Synchro-Start only).
Install the new fuel shutoff solenoid and connect the wires. ,W&
Make sure the wiring harness on the Trombetta solenoid is as
installed in the 6:00 o’clock position. 08

1. Synchro-Start
2. Trombetta
3. Direct Link
049
Activate the ignition switch and check the plunger travel.
1. Synchro-Start 2. Trombetta
A = 66.6 mm [3.4 in] A = 91.4 mm [3.6 in]
B = 60.2 mm [2.4 in] B = 63.5 mm [2.5 in]
The plunger must be retracted when the fuel shutoff solenoid

is activated to the RUN position “B”. The fuel shutoff
solenoid must operate without binding.
Direct Link Solenoid, Cylinder Block Mounted

l Disconnect the solenoid linkage from the lever.
l Activate the ignition switch and check the plunger
travel.
l Measure distance ‘B’ from the center of the ball socket
to the solenoid mounting flange.
B = 117.1 mm [4.61 in]
The plunger must be retracted when the fuel shutoff
solenoid is activated to the RUN position “B”. The fuel
shutoff solenoid must operate without binding.
RQVK Governor Fuel Shutoff Solenoid -

10 mm RI
Remove the hitch pin clip, mounting capscrews and the fuel
shutoff solenoid. I)
@
Install the new solenoid in reverse order of removal and
connect the wires.
Page 5-30
0@B
Activate the switch and check the plunger travel.
A = 66.9 mm [2&I in]
NOTE: Dimension A is measured from the bottom of the
mounting bracket to the top of the pivot pin.
Fuel Return Overfl w Valve -

Replacement (5-097
19 mm
Remove the pressure relief valve and copper sealing washers.
Use a small screwdriver to check that the check ball is not

sticking in the high pressure relief valve assembly.
Caution: A sticky check ball will result in engine low power.
TRo194
Thoroughly flush the high pressure relief valve with cleaning

solution.
TRo195
Page S-31
10 mm, 19 mm
Install the high pressure relief valve assembly in the reverse
order of removal.
AFC Tube - Replacement (5-10)

Removal
17 mm, 13 mm
Remove the AFC tube.
Installation
17 mm, 13 mm
Use new copper washers for the banjo fitting.
Install the AFC tube.
Torque Value:
Banjo Fitting 24 Nom 118 ft-lb]
Threaded Piiing 8 Nom [71 in-lb]
Fuel Injection Pump - Replacement (5-11)

Preparatory Steps:
Clean debris.
Remove all fuel lines. Refer to Procedures 5-05 and 5-66.
Remove control linkage.
Remove fuel shutoff solenoid. Refer to Procedure 5-08.
Page 6-32
Removal
RI Part No. 3377371 Barring Tool
Locate TDC for No. 1 cylinder. Push the TDC pin into the hole
in the camshaft gear while slowly rotating the crankshaft.
NOTE: Be sure to disengage the pin after locating TDC.
22 mm PESGA Fuel Injection Pump)

27 mm PESGMW Fuel Injection Pump)
30 mm I PESGP Fuel Injection Pump)
RI Remove the gear cover access cap.
Remove the nut and washer from the fuel injection pump shaft.
Part No. 3824469 Fuel Pump Gear Puller

RI Pull the fuel injection pump drive gear loose from the shaft.
13 mm
RI Engines equipped with the PESGP fuel
support brackets must be removed.
injection pump the
Page 5-33
15 mm
Remove the four mounting nuts.

Remove the fuel injection pump.
Installation
Make sure the engine has No. 1 cylinder at TDC.
The fuel injection pump also has a timing pin (1) located in
the governor housing, to position the fuel injection pump
shaft to correspond with TDC for No. 1 cylinder. The timing
pin is to be reversed and stored in the housing (2) after the
fuel injection pump is installed.
24 mm
Page S-34
, Remove the timing pin.

@
If the timing tooth is not aligned with the timing pin hole, rotate
the fuel injection pump shaft until the timing tooth aligns.
Reverse the position of the timing pin so the slot of the timing
pin will fit over the timing tooth in the fuel injection pump.
NOTE: PES.P fuel injection pump o-ring is located in the gear
housing.
-:
Install and secure the timing pin with the access plug.
Page S-35
04B
Make sure the o-ring seals for the fill orifice and pilot are
correctly installed and are not damaged.
Lubricate the mounting flange with clean engine oil.
NOTE: The fuel pump drive gear inside diameter and the
shaft outside diameter must be clean and dry before
installing the gear.
Slide the fuel injection pump shaft through the drive gear and
position the fuel injection pump flange onto the mounting
studs.
15 mm and 13 mm
Install the mounting nuts.
Install the support bracket if so equipped.
Torque Value:
Mounting nuts 44 Nom [32 ft-lb]
Support bracket 32 Nom [24 f&lb]

30 mm PESGP Fuel Injection Pump)
Install the retaining nut and washer.
NOTE: To prevent damage to the timing pins, do not exceed
the torque value given. This is not the final torque value for
the retaining nut.
Page 6-36
Disengage the engine timing pin.
24 mm
Remove the fuel injection pump timing pin plug. Reverse the
position of the timing pin and install the timing pin, plug, and
the sealing washer.
Torque Value: 15 Nom [ll ft-lb]

30 mm PESGP Fuel Injection Pump)
Tighten the fuel injection pump drive gear nut.
Torque Value:
PESGA Fuel Injection Pump 92 Nom [ 68 ft-lb]
PESGMWFuel Injection Pump 104 Nom [ 77 ft-lb]
PESGP Fuel Injection Pump 166 Nom [122 ft-lb]
Install the gear cover access cap hand tight.
Install the fuel lines and control linkage.

Torque Value:
1. High Pressure Fuel Lines 30 Nom [22 ft-lb]
2. Pressure Relief Valve Fitting 32 Nom [24 ft-lb]
3. Low Pressure Fuel Supply Fitting 32 Nom [24 ft-lb]
Caution: The governor housing must be prelubricated

before engine operation. Failure to do so will result in
premature governor wear.
A
10 mm hex drive
RI
clean engine oil:
Install the access plug.

0(K
The PESGMW fuel injection pump not equipped with engine
side fuel return option must be vented after installation.
Loosen the vent screw located near the front on the side
nearest to the engine. Place the fuel control in the RUN
position. Crank the engine so air can bleed from the fuel
injection pump. Then, tighten the vent screw.
NOTE: Earlier PESGMW fuel injection pumps were not
equipped with a vent screw. Remove the large plug from the
location described above to vent the fuel injection pump.
PESGA fuel injection pumps are self venting. All PESGP
pumps were assembled with the engine side vent option.
17 mm (PES6A and PESGMW Fuel Injection Pump)

19 mm (PESGP Fuel Injection Pump) E2l
Warning: The pressure of the fuel in the high pressure
line is sufficient to penetrate the skin and cause serious A
bodily harm.
Vent the high pressure fuel lines. Loosen the fitting at the
No. 1 injector. Place the fuel control in the RUN position.
Crank the engine so air can bleed from the fuel lines, then
0(K
tighten the fiiing.
Torque Value: 30 Nom [22 f&lb]
Warning: The pressure of the fuel in the line is sufficient

to penetrate the skin and cause serious bodily harm. A
Vent each high pressure line separately until the engine runs
smoothly.
Page S-38
Idle Speed - Adjustment (5-12)

Bosch RSV Governor
idle speed adjustment on fuel injection pumps with the RSV
governor requires the setting of both the low idle speed screw
(1) and the bumper spring screw (2).
1- 1
l.su First, loosen the locknut and back out the bumper spring screw
until there is no change in engine speed.
-
BJ Loosen the locknut and adjust the idle speed screw to 20 to 30
RPM less than the desired speed. Turn the idle speed screw
%
0
counterclockwise to decrease RPM; clockwise to increase
RPM. Tighten the locknut.

Turn the bumper spring screw clockwise until the desired idle
speed is obtained. Tighten the locknut.
Page S-39
Bosch RQVK Governor

8 and 10 mm, Screwdriver and Tachometer
Idle speed adjustment on fuel injection pumps with the RQVK

governor require setting of the stop screw.
Loosen the locknut and turn the idle speed screw

counterclockwise to raise the RPM; clockwise to decrease
the idle speed. Tighten the locknut.
lqliqe Fuel Injection Pump Spill-Port

Tlmlng (5-I 3)
Use the No. 1 intake valve to make sure the engine is at top
dead center (TDC) on the compression stroke for cylinder
No. 1. Refer to procedure 7-07.
Fabricate a timing mark pointer for the front of the engine.

This can be done by forming a piece of wire that can be
tightened under one of the gear cover capscrews. Sharpen
the wire at the vibration damper end so that it comes to a
point for better accuracy.
Attach a degree wheel or degree tape to the front of the

vibration damper.
Line the “TDC” mark up with the pointer.
The degree wheel/tape should measure to an accuracy of at

least one degree.
Page 540
Install the fuel injection pump per the procedures for a new fuel
injection pump installation. If the fuel injection pump is already
installed, continue the procedures.
c
:_
Remove the No. 1 high pressure fuel line from the fuel injection
pump.
NOTE: Lines 2 through 6 must not be removed or loosened.
Caution: When attaching the fabricated tube, do not bend

the No. 1 high pressure fuel line. This could cause the
inside of the fuel line to flake and cause injector failure.
A short length of high pressure line that is compatible with the
fuel lines used on the engine should be bent in a “U” shape
and installed onto the delivery valve holder of the fuel injection
pump. The line is used to observe when the fuel is or is not
flowing through the delivery valve holder assembly. Place a
container under the tube to catch the fuel or drain the fuel
back into the spill port pump.
Remove the overflow valve from the fuel injection pump.

Install a 14 mm threaded plug and sealing washer into the fuel
port of the fuel injection pump.
NOTE: The fuel return port is located on the inboard front side
of the fuel injection pump for automotive inline application and
on the out board front side for most of the industrial
applications.
Page 5-41
Remove the supply line from the fuel filter head to the fuel
injection pump.
Attach the high pressure outlet hose from the spill port to the
fuel injection pump supply port.
Before continuing, make sure the fuel injection pump lock-

timing pin is disengaged.
Rotate the crankshaft counterclockwise, as viewed from the

front of the engine, to approximately 40 degrees before TDC.
Governor Lever Positioning

Caution: The governor lever must be positioned before
pressurizing the fuel injection pump.
The RQV governor throttle lever must be in the low idle lever
position.
The RQV-K governor throttle lever must be in the high idle
throttle position.
Page S-42
Both the RQV and RQV-K governor require the shut down lever
to be in the full run position.
The RSV governor throttle lever must be in the low idle position
and the shutdown lever needs to be wired or locked in a
suitable fashion to hold the shutdown lever in the l/2 travel
position.
Turn on the spill timing cart pump.

Check the fuel pressure.
The Pressure must be between 300 psi and 370 psi.
The fuel should be Rowing out of the tube attached to the No.
1 cylinder of the fuel injection pump. If the fuel is not flowing,
recheck the procedures carefully.
Page 543
0a9
Slowly rotate the crankshaft in the clockwise direction, as
viewed from the front of the engine, until the fuel flow from
the No. 1 cylinder begins.
The No. 1 plunger element is now approaching “port
closure”. Continue to rotate the crankshaft slowly until the
flow is reduced to a fast drip (more than one drip per
second). At the point where the steady stream of flow
changes from a solid flow to a fast drip, stop. This is the
static timing position of the fuel injection pump.
If the flow does not slow down to a drip, check the governor
position. Also make sure that the engine is before TDC on
the compression stroke. Turn off the spill port pump.
0@
Check the degree wheel on the vibration damper to see what

engine degree the timing pointer is indicating. This is spill
port static timing. Compare this number to be the timing
0a9
specification for your particular application.
If the fuel injection pump static timing, as measured by the

above method, does not agree with the specifications you
have been given, remove the large nut that fastens the fuel
injection pump camshaft to the fuel pump drive gear. If the
crankshaft has rotated, turn on the spill port pump and rotate
the crankshaft to find port closure.
Turn off the spill port pump.
Page S-44
Use a gear puller tool, pull the fuel injection pump drive gear
from the fuel injection pump camshaft taper.
TRo24a
Slowly rotate the crankshaft counterclockwise about 40 degrees

past the desired static timing specification. Slowly rotate the
crankshaft in the clockwise direction until the timing pointer is
indicating the desired static timing.
Tighten the fuel injection pump drive nut.

Make sure the static timing has not changed after the fuel
injection drive nut is torqued to the required specification.
Torque Value:
PESGA Fuel Injection Pump 92 Nom [66 ft-lb]
PESGMWFuel Injection Pump 104 Nom [77 ft-lb]
PESGPFuel Injection Pump 165 N*m [122 ft-lb]
Repeat this procedure as needed until the timing is found to be

in agreement with the specification.
Page S-45
04B
The fuel injection pump lock timing pin should fii over the
injection pump pointer when the engine is at TDC or on the
compression stroke for the No. 1 cylinder. If it does not, the
fuel injection pump should be adjusted by and authorized
fuel injection pump shop or the fuel injection pump was
installed incorrectly.
Section 6 - Electrical System
Page 6-l

Section Contents
Page
Alternator - Replacement ...................................................... 6-23

Installation .............................................................. 6-24
Removal.. .............................................................. 6-23
Coolant Temperature Sensor - Replacement ......................................... 6-24

Installation .............................................................. 6-25
Removal.. .............................................................. 6-25
Electrical System Description and Operation ......................................... 6-2

Bosch Kl Model Alternator (Wiring Diagram) ....................................... 6-5
Cranking Motor and Electrical Circuits ............................................ 6-2
Delco 42MT Starting Motor ................................................... 6-6
Delco Remy Mcdei 15SI 116 Alternator (Wiring Diagram) ............................... 6-5
Delco Remy Model 37MT/41MT Starting Motor ...................................... 6-3
Delco Remy Model 42MT Starting Motor .......................................... 6-3
Nippondenso F4 Starting Motor ................................................ 6-6
Nippendenso Model F2 Starting Motor ............................................ 6-4
Nippendenso Model F2 Basic Cranking Current Flow .................................. 64
Electrical System - Diagnosing Malfunctions ......................................... 6-l 1

Alternator.. ........................................................... ..6-18
Batteries - Checking ........................................................ 6-l 1
Coolant or Pan Heaters - Checking .............................................. 6-22
Engine Cranking Speed Too Slow ............................................... 6-17
Oil Pressure Switch and Temperature Sensor - Checking ............................... 6-21
Starting Circuit - Checking .................................................... 6-12
Starting Motor Solenoid and Starting Motor Checking ................................. 6-15
Electrical System - Service Tools ................................................ 6-9
Electrical System - Specifications ................................................ 6-7

Maximum Allowable Resistance of Starting Circuit .................................... 6-7
Minimum Recommended Battery Capacity ......................................... 6-7
Wiring Size Recommendationsfor Starter Solenoid and Fuel Solenoid Circuit .................. 6-6
Engine Block and Coolant Heater (750 and 500 Wats) - Replacement ....................... 6-25
Installation .............................................................. 6-26
Removal ................................................................ 6-26
Lubricating Oil Pan Heater - Replacement .......................................... 6-26

Installation .............................................................. 6-27
Removal ................................................................ 6-27
Lubricating Oil Pressure Switch Replacement ........................................ 6-27

Installation .............................................................. 6-27
Removal ................................................................ 6-27
Starting Motor - Replacement ................................................... 6-22

Page 6-2
Electrical System Description and Operation

The basic components of the electrical system are the starting motor and the alternator.
of this manual for information
If the injection pump uses an electrical fuel shut off valve, refer to the fuel system section
concerning the function of the valve.
may be wired for automatic
The engine should have temperature and oil pressure sensors connected to indicators and
shutdown. The engine may also be fitted with a cylinder block heater or oil pan heater.
Cranking Motor and Electrical Circuits
Altoytor Fuei folenoid
Crankhg Motor \
Switch
Section 6 - Electrical SyStem
Page 6-3
Basic Qanklng
Delco Remy Model 37MT/41MT Starting Motor

(Typical Starting Motor Wiring)
stutlno-
42-m Solenoid Circuit
Barlc Cranklng Circuit with gfound return
tewmhk
Delco Remy Model 42MT Starting Motor

Page 64
Nippendenso Model F2 Starting Motor

Magnmc
Switch
e.-..-
Motor
Solenoid
Keyswltcn \ 1erml
or Push Butto” -
Neg.---
T ‘Shunt
Coll
.FllEld
con
TAO255
Nippendenso Model F2 Basic Cranking Current Flow

Page 85
OPTIONAL CONNECTIONS
TO Yl TERMINAL - USE ONE
r---------~
10 OHM, 15 WATT TO
60 OHM, 3 WAlT
(10 OHM RECOMMENDED)
t6 CABLE OR LARGER
CAUTION : DO NOT EXCEED

4 AMP DRAW RECOMMENDED CH
CAPABLE l/2 GEN OUTPUT SYSTEM INDICATO
V=1/2VRMSGENOUTPUT
l IF EQUIPPED
Delco Remy Model 15SI 116 Alternator (Wiring Diagram)

(Typical Delco Alternator Wiring Diagram)
2 WA-IT
20-80 OHMS
12 v OR
3 WAIT
24 V
TR0257
Bosch Kl Model Alternator (Wiring Diagram)

Page 66
Solenoif
Sealina
Two+iece’
Housing I
O-ring
A&we
I
‘Field Coil
Shunt Coil
‘b-ring
TFio258
Nippondenso F4 Starting Motor
Seamless, One-Piece
Solenoid Case Sealfng Boot
P \
Connector Bronze ’ O-ri!/ xvy _Duty””
Bearing Bearing Drive- -
TRo259
Delco 42MT Starting Motor

Page 6-7
Electrical System - Specifications

Minimum Recommended Battery Capacity
0 12 volt system
-18°C [O’fl Cold cranking amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800
(Reserve capacity amperes)** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (540)
0°C [32”F] Clod cranking amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250
0 24 volt system
-18°C [O”F] Cold cranking amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900
0°C [32”F] Clod cranking amperes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
* Per battery (Two 12 volt batteries in series)

Ratings are based on -18°C [O’ F]
** The number of plates within a given battery size determine reserve capacity. Reserve capacity determines the length
of time sustained cranking can occur. Reserve capacity requirements will vary depending upon the electrical
accessories the vehicle or equipment may have.
Maximum Allowable Resistance of Starting Circuit

- Wih 12 V Starter - Ohms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . (0.0012)
-With 24VStarter- Ohms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..(0.0040)
BatteryCables
Total Resistance Not To Exceed 0.001 Ohms for 12V Systems,
0.002 Ohms for 24V systems.
Cable Size Nominal Resistance Maximum Total Length

In Ohms (Sum of both Cables)
(Copper Conductor) 12v 24V
Gauge Per Meter Per Foot Meter Feet Meter Feet

4 0.000984 0.000030 NR* NR* 2.03 6.7
2 0.000615 0.000186 1.63 5.3 3.26 10.6
1 0.000492 0.000150 2.03 6.7 4.06 13.4
0 0.000386 0.000118 2.59 8.5 5.18 17.0
:r 0.000232
0.000292 0.000071
0.000090 4.32
3.43 14.2
11.3 8.64
6.86 28.4
22.6
*Not recommended
Page 6-6
Wiring Size Recommendations for Starter Solenoid and Fuel Solenoid Circuit
CIRCUIT DIAGRAM
A. = MAG. SWITCH
POS = STARTER SOLENOID “S” Terminal
:. = FUEL SOLENOID Pull-in winding
TABLE OF RECOMMENDED WIRE GAUGE: (COPPER CONDUCTOR STRANDED WIRE)

Values in table are AWG. size for 12/24 volt systems.
Wire length BAT Pos to A. A. to B. ‘A. to C. C to Bat. Neg

In circuit:
up to 0.9 m [up to 3 ft.] 10114 12l14 14/16 14116
0.9 to 1.4 m (3 to 4.5 ft.] 10/l 2 10/l 4 14116 14/16
1.4 to 2.1 m [4.5 to 7 ft.] 8110 8/10 12l14 14/16
2.1 to 2.7 m [7 to 9 ft.] 618 8llO 10112 12/14
2.7 to 3.4 m (9 to 11 ft.] 4l6 618 10/12 8110 -
Wire length in circuit means total length in each individual circuit, e.g: BAT to A. = One circuit.
For example, in a 12 volt circuit:
BAT Pos to A. = 2 m; gauge required = 89.
A. to B. = 2 m; gauge required = 89.
A. to C. = 3 m; gauge required = log.
C to Bat. Neg. = 3 m; gauge required = log.
If the system is double pole wiring, (no frame ground), then the fuel &starter solenoid circuit lengths
would include the return cable run to the battery negative.
*Special requirements for 3 wire fuel solenoids.

The pull-in wiring (white lead) should conform to the above chart recommendations A to C.
The ground wiring (block lead) must be the same gauge as the pull-in wiring (white lead).
The hold-in wiring (red lead) which connects to the “Run” terminal should use a minimum of 14
gauge wire.
Note: Starter solenoids are usually internally grounded through the starting motor. No return lead
from the starting solenoid to the battery negative is required.
THoz3
Page 69
Electrical System - Service Tools
The Fleetguard@ refractometer is used to check the charge

condition of a conventional battery.
Page 6-l 1
Electrical System - Diagnosing

Malfunctions (6-01)
Batteries - Checking
If conventional batteries are used, remove the cell caps or
covers and check the electrolyte water and sulfuric acid
solution) level.
NOTE: Maintenance-free batteries are sealed and do not
require the addition of water. 0
@
Fill each battery cell with distilled water.
Part No. CC-2800, Refractometer

Use Fleetguard* refractometer, Part No. CC-2300, to check
the condition of the battery.
Refer to the battery fluid column in the refractometer to
determine the state-of-charge of each battery cell.
NOTE: If the specific gravity of any or all of the cells is
below 1.200, the battery must be charged.
0a3
Refer to the accompanying chart to determine the battery
state-of-charge based on the specific gravity readings. Battery State Specific Gravity
of Charge @ 27OC [80°F]
100% 1 I .260-l ,280

75% I I .230-I .250
I 50% I I .200-l 220

I- 25% I 1.170-1.190
I Discharged
I
1.110-1.130
T&2&3
Part No. 3377193, Analyzer

Use Part No. 3377193 Analyzer to load test the state-of- •l
charge of maintenance free batteries. If the state-of-charge is
low, use a battery charger to charge the battery. Refer to the
appropriate Chassis operator’s manual for instructions.
Replace the battery if it will not charge to specifications or
will not maintain a charge.
Page 612
Battery Terminal Connections - Checking

Visually inspect the battery terminals for loose, broken, or
corroded connections.
Repair or replace broken cables or terminals.
If the connections are corroded, remove the cables and use a

battery cable brush to clean the cable and battery terminals.
Install and tighten the battery cables.
Use grease to coat the battery terminals to prevent corrosion.
Starting Circuit - Checking

Magnetic Switch - Checking
Warning: Be sure the starting motor switch is in the “OFF”
position to prevent electrical shock and personal injury.
Remove the cable connecting the magnetic switch to the
starting motor solenoid from the magnetic switch terminal.
Connect the leads of Part No. 3376398 Digital Multimeter to the
two large switch terminals.
Set the multimeter to measure resistance (OHMS).

With the starting motor switch in the “OFF” position, the
multimeter must indicate resistance at infinity.
Turn the starting motor switch to the “START” position.
The multimeter must indicate zero or very little resistance.
Page 6-13
If the multimeter indicates resistance at infinity with the

starting motor switch in the “START” position:
l Turn the starting motor switch to the “OFF” position.
l Set the multimeter scale to read DC voltage.
l Connect one multimeter lead to the magnetic switch

terminal marked “S” and the other lead to the ground. o
@
l Turn the starting motor switch to the “START” position.
0 If the multimeter indicates no voltage, the magnetic e
switch is not the cause of the complaint. Refer to
“Starting Motor Switch - Check” in this Procedure.

0 Remove the multimeter leads and connect the
magnetic switch to the starting motor solenoid wire.
Starting Motor Switch - Checking

Warning: Be sure the starting motor switch is in the “OFF”
position to prevent electrical shock and personal injury. A
Remove the wire connecting the starting motor switch to the
magnetic switch (marked “S” or “Start”) from the starting
motor switch terminal.
Connect the positive lead of Part No. 3373898 Digital @@A
Multimeter to the starting motor switch terminal and the @
negative lead to a chassis or engine ground location.
Page 6-14
NOTE: Wiih the starting motor switch in the”OFF” position there

must not be voltage at the starting motor switch terminal. If the
meter indicates voltage, the starting motor switch is
malfunctioning and must be replaced.
Turn the starting motor switch to the “START” position.

The multimeter must indicate system voltage.
If there is not voltage:

l Connect the multimeter positive lead to the starting motor
switch terminal having a wire connecting the starting motor
switch to the starting motor solenoid “B” terminal.
If the meter indicates system voltage at the starting motor

switch input terminal, the starting motor switch is defective and
must be replaced.
Page 6-15
0@
If the meter indicates no voltage, the switch is not the cause
of the complaint.
Check the wiring from the starting switch to the starting
motor solenoid “B” terminal and from the starting motor
solenoid to the battery for broken or damaged wires.
Starting Motor Solenoid and Starting Motor

Checking
Before troubleshooting the starting motor, make sure the
battery terminals are not loose or corroded. Refer to “Battery
Terminal Connections”, in this section.
0
@
Starting Motor Solenoid
04iD
If the starting motor solenoid does not make an audible
sound, check for loose wiring connections.
0a3
Use a Digital Multimeter such as Part No. 3377161 to set the
voltage scale.
Check for system voltage at the starting motor solenoid
battery terminal.
Page 616
0
If the multimeter indicates system voltage at the starting motor
a!3 battery terminal, check the voltage at the starting motor
solenoid ‘3 terminal while the starter switch is energized.
If the multimeter indicates system voltage at ‘3’ terminal, but
0
the starter does not engage, the starting motor solenoid is
@ii malfunctioning and the starter must be replaced.
If the multimeter does not indicate system voltage at the ‘3
&ii 0 terminal, check:

l Fuses
6B
0
l Voltage to the ignition switch and magnetic switch. Refer
to “Starting Motor Switch and Magnetic Switch - Checking”
in this section.
l Application safety shutoff systems.
Starting Motor
Check for system voltage at the “M” terminal of the starting
0 motor while the starter switch is energized.
@ii
System Voltage: Starting motor is malfunctioning or not
adequately grounded and must be repaired or replaced.
No Voltage: Starting motor solenoid is malfunctioning and
must be replaced.
If the starting motor solenoid makes an audible sound, turn the

switch OFF and attempt to rotate the crankshaft in both
directions.
Page 6-17
0a3
Rotate the crankshaft as follows:
1. Direction of engine rotation.
2. Direction opposite engine rotation,
3. Direction of engine rotation.
If the crankshaft will rotate at step No. 3, attempt to start the
engine, If the starting motor cranks the engine, check the
starting motor pinion gear and flywheel ring gear for damage.
If the starting motor pinion gear or the flywheel ring gear is
damaged, the damaged component(s) must be replaced.
Refer to Procedures 6-02 and 7-26.
06B
To attain a starter motor mounting surface to ring gear face
dimension of 60.8 mm + 1.5 mm [2.0 in f 0.060 inch] a
starter spacer is used between the starter motor and flywheel
housing. If the starter to ring gear spacing dimension is not
within specification, check to make sure the correct spacer,
flywheel or flexplate, and crankshaft to flexplate mounting
adapter (ii required) is on the engine. This will help determine
which component is causing the spacing dimension to be
out of specifications.
049
Engine Cranking Speed Too Slow
Make sure the wiring connections are clean, tight and not
damaged. Refer to “Battery Terminal Connections”, Procedure
6-02.
Check the battery voltage. Refer to “Batteries - Checking”,
Procedure 6-01.
If the crankshaft was not rotated to check the starting motor,

rotate the crankshaft in the direction of engine rotation to
make sure the engine does not have an internal malfunction.
Page 616
If the engine rotates freely, check the voltage at the starting

motor during cranking. If the voltage drops more than 2.4 volts,
check that all connections are tight. The limit for 24-volt
systems is 4.8 volts.
If the cables are adequate size and good condition, but the
voltage drop exceeds the limit, replace the starting motor.
0
If the crankshaft requires more than a normal effort to rotate,
a3 check for excessive load from the driven units and accessories.
Alternator
The terminals on the alternator are shown in this illustration.
The “R ’ terminal (Delco) or “w” terminal (Bosch Kl) provides
one-half system voltage and is used to operate accessories
such as the tachometer on generator sets.
0
Trouble with the charging system may be indicated by the
a3 indicator lamp or ammeter.
Page Cl9
Abnormal Indicator Lamp Operation

Check the indicator lame for normal operation as shown
below: @I
\
Engine Switch Lamp Ammeter
stopped Off Off 0
stopped On On
Running On Off +
Switch Off, Lamp On, Engine Stopped
0a9
Disconnect the lamp lead at the ignition switch. If the lamp
stays on, there is a short to a positive wire on the ignition
side of the lamp.
If the lamp goes out, there is a short in the switch.
I I Tm296
Switch On, Lamp Off, Engine Stopped
0@B
This condition can be caused by an open in the circuit. To
determine where an open exists. Check for a blown fuse, a
burned out bulb, defective bulb socket, or an open in No. 1
or “D + ” lead circuit between alternator and ignition switch.
Page 6-20
Switch On, Lamp On, Engine Running
0a3
Check the drive belt and alternator pulley to be sure the
alternator is rotating.
0
Disconnect the lead to Terminals No. 1 and no. 2 (Delco) or
4B D + (BOSCH Kl). If the lamp stays on, there is a short to
ground on the alternator side of the lamp.
If the lamp goes out, replace the alternator.
Abnormal Charging System Operation

Check the battery and all wiring connections.
Inspect the wiring for defects. Check all connections for
tightness and cleanliness, including the slip connectors at the
alternator and firewall, and connections at the battery.
Page 6-21
1
Wiih ignition switch on and all wiring harness leads con-
nected, connect a voltmeter from: 0
A. Alternator “BAT” (Delco 15SI) “B + ” (Bosch Kl) @

terminal to ground.
B. Alternator No. 1 (Delco 1%) to ground.
C. Alternator No. 2 (Delco 15SI) to ground.
D. Alternator D+ (Bosch Kl) to ground.
0a9
A zero reading indicates an open between the alternator
connections and the battery.
Locate and repair the open circuit.
0a3
Wiih all accessories turned OFF, connect a voltmeter across
the battery. Operate engine at 1500 RPM or above.
If voltage is 15.5 or more, remove the alternator for repair.
The limit for 24 volt systems is 28 volts.
Oil Pressure Switch and Temperature Sensor -

Checking
When diagnosing problems with either the pressure switch or
the temperature sensor, check for loose or corroded 0
a
q
connections and broken wires.
\
Checking the Oil Pressure Switch

Remove the pressure switch, install a gage, start the engine l
and measure oil pressure. Minimum oil pressure:
@
Low Idle (675 to 725 RPM) . . . . . . . . . . . . 69 kPa [lo PSI]
High Idle . . . . . . . . . . . . . . . . . . . . . . . 207 kPa [30 PSI]
Pressure switch is set to actuate when oil pressure drops
to 55 kPa [6 PSI]
Page &22
Checking the Temperature Sensor

Check for continuity. The sensor will have continuity only when
coolant temperature is above 107” C 1225” F].
Coolant or Pan Heaters - Checking

When functioning properly, the engine block or oil pan heater
should make an audible sound when activated. The adjacent
parts should be warm to the touch.
Pan
Heater
Some heaters will operate continuously when plugged into the

correct voltage electrical socket. Operate them only below 0” C
[32” F] ambient temperature.
Starting Motor - Replacement (6-02)

Preparatory Steps:
l Disconnect the ground cable from the battery.
l Identify each electrical wire with a tag indicating location.
Page 6-23

19 mm
Remove the battery cable from the solenoid.
16 mm and 19 mm
Remove the starting motor and spacer.
Install the starting motor and spacer in the reverse order of
removal.
Connect the battery cable to the solenoid.
Torque Value: 77 Nom [57 ft-lb)
Alternator - Replacement (6-03)

Preparatory Steps:
Disconnect the ground cable from the battery terminal.
Identify each electrical wire with a tag indicating location.
Removal
19 mm
Remove the capscrew (A) from the alternator link.
Remove the capscrew (B) from the tail support bracket.
Page 624
16 mm, 19 mm
Remove the alternator mounting capscrews and nut
Remove the alternator.
Installation
18 mm, 19 mm
Install the alternator mounting capscrews and nuts.
19 mm
Install the alternator link and the tail support bracket
Torque Value:
(Alternator End) 43 Nom 132 ft-lb]
(Water Pump End) 24 Nom [18 ft-lb]
Connect all wires and install the drive belt.
Coolant Temperature Sensor - Re-

placement (6-04)
e Preparatory Step:
l Drain the coolant. Refer to Procedure l-01.
Page 825
Removal
3/8 inch or Screwdriver
Disconnect the temperature sensor wiring.
7/8 Inch
Remove the temperature sensor,
Installation
7/8 Inch and 3/8 Inch or screwdriver
Apply liquid teflon sealant to the threads when installing the
temperature sensor.
Connect the wiring.
Torque Value:
(Installed into Cast Iron) 50 N*m 137 ft-lb]
(Installed into Aluminum) 30 Nom [22 ft-lb]
Engine Block and Coolant Heater (750

and 500 Wats) - Replacement (6-05)
Preparatory Step:
l Drain the coolant. Refer to Procedure 141.
Page 6-26
Removal
Disconnect the block heater electrical cord.
4mm
Loosen the block heater retaining capscrew and remove the
block heater from the block.
Installation
4mm
Caution: Lose of coolant and engine damage will result If
the T-bar Is not correctly positioned In the bore.
Apply a coat of engine oil to the o-ring. Slide the heater into
the bore. Use a plastic hammer to drive the heater into the
bore. Make sure the o-ring is not damaged during installation.
Tighten the retaining capscrew.
Connect the electrical cord and refill the radiator to the proper
level.
Lubricating Oil Pan Heater - Replacement

(6-06)
Preparatory Step:
l Drain the engine oil. Refer to Procedure 2-04.
Page 827
Removal
Disconnect the oil heater electrical cord.
Installation
Ratchet, 27 mm Deep Well Socket, Torque Wrench B-l
Replace the heater element. Refill the engine to the correct L&J
oil level. A-3.x
Torque Value: 120 Nom [ES ft-lb] w
Lubricating Oil Pressure Switch -

Replacement (6-07)
Removal
c%Q
Disconnect the wire from the sending unit.
The sending units illustrated are typical and may differ
from those installed on the engine.
TR0325
1
Installation
Connect the wire to the sending unit.
Torque Value:
(Installed into Cast Iron) 16 N*m [12 ft-lb]
(installed into Aluminum) 10 Nom [69 in-lb]
Section 7 - Base Engine Components
Page 7-l

Section Contents
Page
Base Engine Components - General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Base Engine Components - Service Tools ............................................ 7-4
Camshaft - Replacement ...................................................... 7-128

General Information ....................................................... 7-l 28
Removal ............................................................... 7-130
Installation ............................................................. 7-l 37
Camshaft Gear - Replacement 7-l 40

Rernoval.............::::::::::::::::::::::::::::::::::::::::::::::::: : 7-l 40
Installation ............................................................. 7-l 42
Connecting Rod Bearings - Replacement ............................................ 7-59

Diagnosing Malfunctions ..................................................... 7-59
Removal ................................................................ 7-60
Installation .............................................................. 764
Connecting Rods - Replacement .................................................. 783

Removal.. .............................................................. 7-84
Installation .............................................................. 7-87
Crankcase Breather Tube - Replacement ............................................ 7-13

Removal ................................................................ 7-13
Installation .............................................................. 7-14
Crankshaft Gear - Replacement ................................................. 7-152

Removal ............................................................... 7-153
Cleaning and Inspection .................................................... 7-l 55
Installation ............................................................. 7-l 56
Cup Plug - Replacement ...................................................... 7-184

Removal ............................................................... 7-184
Installation ............................................................. 7-185
Cylinder Head - Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 747
Cylinder Head - Replacement .................................................... 7-30

Removal.. .............................................................. 7-33
Cylinder Block/Head Deck - Cleaning and Inspection .................................. 7-34
Cylinder Head - Cleaning and Inspection .......................................... 7-37
Installation .............................................................. 742
Cylinder Liners - Replacement 7-89

General Information ..... : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 7-89
Removal ................................................................ 7-89
Installation .............................................................. 7-96
Page 7-2
Engine Compression - Checking 7-9

Compression Gauge and Adapter : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : 7-9
Piston Ring Sealing ........................................................ 7-10
Intake and Exhaust Valve Sealing ............................................... 7-10
Cylinder Head Gasket Sealing ................................................. 7-10
Engine Dataplate - Replacement ................................................. 7-126

Removal ............................................................... 7-127
Installation ............................................................. 7-l 27
Flywheel - Replacement 7-l 59

Removal ....... ..I 1: 1:: 1: 1: 1: 1: 1: 1: 1: : 1: : : : : : 1: 1: 1: 1: 1: : : : : : : : : 1: : : : : : : 7-159
Installation ............................................................. 7-l 61
Flywheel Bore Runout Measurement ............................................ 7-163
Flywheel Face Runout Measurement ............................................ 7-164
Flywheel Housing - Replacement 7-166

Removal...............:::::::::::::::::::::::::::::::::::::: :::::::::: 7-l 66
Installation (Dry Clutch Application) ............................................. 7-l 69
Concentricity - Checking .................................................... 7-170
Installation (Wet Clutch Application) ............................................ 7-l 72
Flywheel Ring Gear - Replacement ............................................... 7-166

Removal ............................................................... 7-166
Installation ............................................................. 7-l 66
Gear Cover - Replacement 7-l 08

Removal...........::::::::::::::::::::::::::::::::::::::::::::::::::: : 7-l 08
Installation ............................................................. 7-l 10
Gear Housing - Replacement ................................................... 7-117

Removal ............................................................... 7-118
Installation ............................................................. 7-l 21
Main and Thrust Bearings - Replacement ............................................ 7-48

Removal ................................................................ 7-50
Installation .............................................................. 7-54
Pipe Plug - Replacement ..................................................... 7-183

Removal ............................................................... 7-183
Installation ............................................................. 7-184
Pistons and Rings - Replacement ................................................. 766

Piston - General Information .................................................. 766
Piston and Rings - Diagnosing Malfunctions ........................................ 766
Removal.. .............................................................. 7-66
Installation .............................................................. 7-76
Push Rod - Replacement ...................................................... 7-27

Removal ................................................................ 7-27
Installation .............................................................. 7-29
Page 7-3
Rocker Lever - Replacement .................................................... 7-15

Removal.. .............................................................. 7-15
Disassembly ........................................................... ..7-16
Assembly ............................................................. ..7-18
Installation .............................................................. 7-l 9
Rocker Lever Diagnosing - Malfunctions ............................................. 7-14

Valve Lash Specifications .................................................... 7-14
Seal, Front Crankshaft - Replacement ............................................. 7-l 12

Removal and Installation .................................................... 7-l 13
Seal, Rear Crankshaft - Replacement .............................................. 7-174

Removal ............................................................... 7-174
Installation ............................................................. 7-l 76
Timing Pin Assembly - Installation ................................................. 7-23
Valve Cover - Replacement ..................................................... 7-l 1

Removal................................................................7-1 1
Installation .............................................................. 7-12
Valve Lash - Adjustment ....................................................... 7-20

Valve Arrangement ......................................................... 7-22
Valve Tappet - Replacement ................................................... 7-143

Removal ............................................................... 7-144
Installation ............................................................. 7-l 48
Vibration Damper - Replacement .............................. 7-103

General Information ....... : : : : : : : : : : : : : : : : : : .............................. 7-103
Rubber Element Vibration Damper - Inspection (in-Chassis) ............................. 7-103
Viscous Vibration Damper - Inspection ........................................... 7-105
Removal ............................................................... 7-106
Installation ............................................................. 7-l 07
Wear Sleeve, Front Crankshaft - Replacement ........................................ 7-l 13

Removal ............................................................... 7-113
Installation ............................................................. 7-l 14
Wear Sleeve, Rear Crankshaft Seal - Replacement ..................................... 7-177

Removal ............................................................... 7-177
Installation ............................................................. 7-l 80
Page 7-4
Base Engine Components - Service Tools
Use to remove drive pulleys, impellers, air compressor

counterweights, etc.
Cylinder Liner Driver
Install cylinder liner in cylinder block.
Attaches to crankshaft flange to provide measuring of flywheel

and flywheel housing runout with dial bore gauge.
Used when installing pipe plugs, cup plugs, etc. on the engine

in] to 2.032 mm [8.0 in].
Remove cylinder liners from cylinder block. Requires Part No.

3822876 Cylinder Liner Puller Plate.
Page 7-5
Tool No. Tool Descrbtion Tool Illustration
Remove cylinder liners from the cylinder block. Requires two

Par No. 3376649 Puller Arm Extension Feet.
Use with Part No. ST-1325 Dial Gauge Attachment to measure

flywheel and flywheel housing runout.
Expansion Plug Driver Handle
Used with all expansion plug drivers larger than 0.375 inch

Engine Barring Gear
Used to engage the flywheel ring gear to rotate the crankshaft.
Install 0.375 inch expansion plug to specified depth.
Cylinder Liner Clamp Set
Used to clamp the liner into the bore of the cylinder block.
Injector Bore Brush

Page 7-6
Used to remove and install valve tappets.
Used with manometer, Part No. ST-l 11l-3, to measure the


Used to compress the piston rings while installing the pistons

into the cylinder bores.
Crowfoot Wrench
Used to torque high pressure fuel line nuts on Bosch fuel

pump. Size: 17 mm, 3/8 in. drive.
Used for sealing ‘7” joints and front gear cover.
Measure cylinder liner protrusion on the cylinder block.

with expansion plug driver handle, Part No. 3376795.
Page 7-7
Tnnl Nn. Ton1

. __. Dnacrintinn
- ___..r _._..
Tnnl lll~~etratinn

with expansion plug driver handle, Part No. 3376795.

Used to install 2.250 inch expansion plug to specified depth.
Used for machining the liner counterbore ledge.
Must be used with Part No. 3823567, cutter plate, and Part No.
Crankshaft Gear Splitter
Used to split the crankshaft gear for removal. Does not work
Used to remove and install the camshaft gear from the

camshaft with the camshaft installed.
Main Bearing Rollout Tool
Used to remove and install main bearings with the crankshaft
Used with Part No. 3823558, cylinder liner counterbore tool.

Page 7-a
Tnnl Nn Tnnl
.W”.
nararintinn
__““..P......
Used with Part No. 3823567, cutter plate, to machine the

cylinder liner counterbore ledge.
Wear Sleeve Installation Tool
Used to install the rear crankshaft lube oil seal wear sleeve.
Lube Oil Seal Installation Tool
Used to install the front lube oil seal in the front cover to a
Page 7-9
Base Engine Components - General

Information
The base engine components section consists of the
removal, cleaning, inspection, testing and assembly of all
internal and external components not previously covered in
the troubleshooting and repair of the various engine systems.
Engine Compression - Checking (7-01)

CompressionGauge and Adapter
It is very time consuming and expensive to begin removing
internal engine components to diagnose failures. A
compression gauge can be used as an aid to check for
proper functioning of the following components:
1. Piston ring sealing

2. Intake and exhaust valve sealing
3. Cylinder head gasket sealing
4. Cylinder head cracked
Refer to the appropriate procedure in this section for
replacement of failed components.
NOTE: Due to variables such as; starter and battery condi-

tions that affect engine cranking speed, it is difficult to es-
tablish an absolute value for compression pressure; however,
the following values can be used as guidelines:
l New engine (cranking speed @ 250 RPM) 2413 kPa
[350 psi] New u
l Used engine (cranking speed @ 250 RPM) 2066 kPa
[300 psi]
It is recommended that the compression pressure be
checked on all cylinders and then compared. All cylinders
should be within 690 kPa 1100 psi] of each other.
Page 7-10
Piston Ring Sealing

If the compression is low but can be increased significantly
by squirting oil into the cylinder, the cause of low
compression is inadequate sealing between the rings and the
cylinder walls. Refer to Procedure 7-13 for piston ring
replacement.
Intake and Exhaust Valve Sealing

If the compression is low on one or more non-adjacent
cylinders and the pressure cannot be increased by oiling the
rings, poor valve sealing is to be suspected.
Refer to Procedure 7-09 for cylinder head replacement.
Valve leakage is often audible from the intake and exhaust

manifold.
Cylinder Head Gasket Sealing

If the compression is low on adjacent cylinders and the
pressure cannot be increased by oiling the rings, the
cylinder head gasket is probably leaking between the
cylinders.
Refer to Procedure 7-09 for cylinder head gasket
replacement.
Page 7-l1
NOTE: Low compression on a single cylinder can be caused

by an external leak or a leak to a coolant passage. A leak to
a coolant passage of this magnitude will also result in cool-
ant in the cylinder.
06B
A compression leak to the coolant will normally be detected
by loss of coolant as the coolant is blown from the cooling
system.
Service Tip: Remove the drive belt from the water pump.
Run the engine for 1 to 2 minutes and check for coolant
being blown from the radiator by compression gasses.
Valve Cover - Replacement (7-02)

Removal
13 mm, 18 mm
Remove the crankcase breather tube and hose. Remove the
RI
air crossover tube.
15 mm
Remove the six valve cover mounting capscrews.
Discard the sealing o-rings.
Page 7-12
63 l Inspect the sealfor damage.

NOTE: The gasket can be reused if it is not damaged.
A can cause serious personal injury.
q
\ Steam clean and dry with compressed air.
Inspect the cover for cracks or damage and replace if

0
a2 necessary.
Installation
NOTE: If the seal is not damaged, it can be used again.
If the seal is damaged, install a new seal.
Install the rubber seal into the groove in the valve cover.
Start the installation at the overlap area shown in the
illustration. Do not stretch the rubber seal.
If the seal has more overlap than shown in the illustration,
trim the length to provide the correct overlap.
@@A Install new sealing o-rings on the capscrews.

@@ Install the six capscrews into the cover.
Page 7-13
15 mm
Tighten the capscrews in the sequence shown.
Torque Value: 24 Nom 118 k-lb]
13 mm, 18 mm
install the crankcase breather tube and hose. Refer to
Procedure 7-03.
Crankcase Breather Tube - Replacement

(7-03)
Removal
13 mm, 18 mm
Remove the two hose clamps from the crankcase breather.
Remove the two breather tube support bracket capscrews
(A) and (9

Use solvent to clean the hose and tube. Dry with com-
pressed air.
Visually inspect the hose and tube for restrictions, cracks or
other damage. Replace the hose and tube if damaged.
Page 7-14
Installation
13 mm, 18 mm
Install the breather tube and hose clamps. Tighten the
capscrews for the breather tube support brackets.
Torque Value:
A = 24 Nom [18 ft-lb]
B = 43 Narn [32 ft-lb]
Rocker Lever Diagnosing - Malfunctions

(7-04)
The ball end of the push rod fiis into the ball socket in the
operates.
Excessive valve lash can indicate a worn valve stem,

push rod, valve tappet or rocker lever.
Valve Lash Specifications

ml
mm in
0.30 Intake 0.012

0.61 Exhaust 0.024
Page 7-15
Loose rocker levers and the need to reset the valve clear-
ance frequently can also indicate cam lobe or tappet wear. If
an inspection of the levers, valve stems and push rods does
not show wear, then tappet and/or cam lobe wear can be
suspected. Refer to Procedures 7-22 and 7-24.
Rocker Lever - Replacement (7-05)

Removal
13 mm, 15 mm, 18 mm
Remove the crankcase breather tube and hose. Refer to
Procedure 743.
Remove the valve cover. Refer to Procedure 7-02.
14 mm, Screwdriver
Loosen the adjusting screw locknuts. Loosen the adjusting
screws until they stop.
10 mm
Remove the capscrews, retaining clamps, rocker lever
assemblies and supports.
Page 7-16
Disassembly
Snap Ring Pliers
If the rocker lever and push rods are to be inspected for
reuse, follow these steps:
Remove the retaining rings, thrust washers and wavy spring
washers.
, Remove the rocker levers.

69
Remove the pedestal assembly.
Remove the lock nut and adjusting screw.

Page 7-17
Cleaning and Inspection 1
Clean all parts in a strong solution of laundry detergent and

hot water.
Inspect for cracks and excessive wear in the bore and the
contact surface for the valve stem.
Measure the rocker lever bore.
Rocker Lever Bore Diameter

mm in
22.301 MAX 0.878
Measure the rocker lever shaft diameter.
Rocker Lever Shaft Diameter

mm in
22.199 MIN 0.874
Page T-18
I Assembly
Install the adjusting screw and locknut.
I mosw
Install a retaining ring, thrust washer and wavy spring washer

as illustrated.
Lubricate the shaft with 15W-40 engine oil.

Page 7-19
Install the remaining wavy spring washer, thrust washer and
Compress the wavy spring washers and install the bottom

I lW4ol
Installation
g;;;uzrethe rocker lever adjusting screws are completely
Install the support and rocker lever assemblies over the

rocker lever oil manifold.
Make sure the dowel rings in the pedestals are installed into
the dowel bores.
Page 7-20
Use clean 15W-40 engine oil to lubricate the threads and

under the heads of the pedestal capscrews.
Install the retaining clamps and capscrews.
._ . . IIhl 10 mm
Tighten the retaining clamp capscrews.
NOTE: To prevent damage to the rocker lever or push rod
make sure the adjusting screw ball is positioned in the
socket of the push rods when tightening.
Adjust the intake and exhaust valves. Refer to Procedure 7-
06.
Install the valve cover. Refer to Procedure 7-02.
Install the crankcase breather tube and hose. Refer to
Procedure 7-03.
Valve Lash - Adjustment (7-06)

Screwdriver, 13 mm, 18 mm
Remove the air crossover tube.
Disconnect the crankcase breather tube, support clamps, and
hose clamps. Remove the crankcase vent tube.
15 mm
Remove the valve cover.
Page 7-21
l/2 Inch Drive, 3377371 Barring Gear

Locate Top Dead Center (TDC) for cylinder No. 1 by rotating
the crankshaft slowly while pressing on the engine timing pin.
When the pin engages the hole in the camshaft gear,

cylinder No. 1 is at TDC on the compression stroke.
LGear Houdng
Caution: To prevent damage to the timing pin be sure to

disengage the pin after locating Top Dead Center.
Feeler Gauge

mm in
0.30 Intake 0.012
0.61 Exhaust 0.024
Check/adjust the valves with engine cold - below 60°C

[14O”F].
NOTE: The clearance is correct when slight resistance is felt
as the feeler gauge is moved between the valve stem and
the rocker lever.
Page 7-22
Valve Arrangement
Beginning at the front of the cylinder head, the first valve is
intake, the second one is exhaust. The same orientation is
used for all cylinders.

Locate Top Dead Center (TDC) for cylinder No. 1.
Check/adjust the valves indicated for Chart A.
Torque Value: 24 Narn [18 ft-lb]
Check the valve lash again.
Mark the vibration damper and rotate the crankshaft 360

degrees.
Be sure the timing pin is disengaged.

Check/adjust the valves indicated for Chart B.
Chart 6 Torque Value: 24 N*m [18 ft-lb]
Check the valve lash again.
[
Page 7-23
Install the valve cover. Refer to Procedure 7-02.

Install the crankcase vent tube and secure with the support
brackets and hose clamp. Refer to Procedure 743.
Timing Pin Assembly - Installation (7-07)

The timing pin assembly is precisely located on the gear
housing to correspond to Top Dead Center (TDC) for
cylinder No. 1.
Caution: If a gear housing other than the original housing

is installed, the timing pin assembly must be accurately
aligned to correspond to TDC for cylinder No. 1.
A
Failure to locate the timing pin assembly to TDC for cylinder
No. 1 will result in incorrect injection timing.
0a9
Verify that the No. 1 cylinder is at or near TDC on the
compression stroke by rotating the crankshaft until the
engine timing pin engages in the cam gear hole or the hole
is visible through the gear housing. Disengage the timing pin.
Page 7-24
13 mm, 18 mm
Fabricate and install a wire pointer for the front of the engine.
This can be done by forming a piece of wire that can be
tightened under one of the gear housing capscrews. The wire
should extend from the gear cover to a place on the crankshaft
vibration damper that is easily seen.
10 mm
Remove all injector nozzles.
This step is important to release cylinder pressure so the
crankshaft can be rotated smoothly to locate TDC for cylinder
No. 1.
Part No. 3377371, Engine Barring Gear

Rotate the crankshaft one-quarter revolution in the direction of
normal engine rotation.
Tighten the adjusting screw for the No. 1 intake valve to zero
(0) lash plus 5 turns.
NOTE: Leave the adjusting screw in this position until TDC is
established.
Page 7-25
A
Caution: Use extreme care when rotating the crankshaft.
Use of too much force could damage the valve or push
rod.
Rotate the crankshaft slowly in the opposite direction of
normal engine rotation until the piston touches the intake
valve.
Mark the vibration damper at the wire pointer.
Caution: Make sure that the piston touches the intake

valve with approximately the same amount of force as in
the previous step.
Rotate the crankshaft in the direction of normal engine
rotation until the piston touches the intake valve.
Mark the vibration damper at the wire pointer.
Measure the distance and mark the vibration damper at one-

half the distance between the two marks. This mark is the
TDC mark.
Caution: Completely loosen the intake valve adjusting

screw. Failure to do so will result in damage to the intake
valve or push rod when the crankshaft is rotated.
Page 7-26
Rotate the crankshaft in the direction of normal engine rotation

until the pointer is aligned with the TDC mark, then rotate the
crankshaft one additional revolution.
The timing pin hole in the cam gear should be visible or felt
through the back side of the gear housing. If not, the
crankshaft must be rotated one revolution in the direction of
engine rotation.
Install the o-ring into the groove of the timing pin assembly.
Lubricate the o-ring with 15W-40 engine oil.
T-25 TorxTM
Push the pin into the hole in the cam gear to align the
housing.
Hold the pin in while tightening the TorxTM screws.
Check the pin to be sure it did not slip out of the camshaft
gear hole when the screws were tightened.
Page 7-27
Caution: To prevent damage to the pin and gear, be sure

the timing pin is disengaged before rotating the
crankshaft.
13 mm, 18 mm
Remove the vibration damper and wire pointer.
Install the gear cover. Refer to Procedure 7-17.
Install the vibration damper. Refer to Procedure 7-16.
Push Rod - Replacement (7-08)

Removal
Remove crankcase breather tube and hose. Refer to Pro-
cedure 7-03.
14 mm Screwdriver
Loosen the rocker lever adjusting screw locknuts and
loosen the adjusting screws until they stop.
Page 7-28
10 mm
Remove the rocker lever assemblies. Refer to Procedure
7-05.
Mark the push rods to identify their location.

Remove the push rods.

Clean the push rods in hot soapy water.
Visually inspect the push rod ball and socket for signs of
scoring or other damage.
Page 7-29
Check the push rods for roundness and straightness.
Installation
Install the push rods into the sockets of the valve tappets
from which they were removed.
Lubricate the push rod sockets with clean 15W-40 engine oil.
Make sure the rocker lever adjusting screws are com-

pletely backed out.
To prevent damage to the rocker lever or push rod, make

sure the adjusting screw ball is positioned in the socket of
the push rods when tightening.
Install the rocker lever assemblies. Refer to Procedure 7-05.
Adjust valve lash clearance. Refer to Procedure 7-06.
Install valve cover. Refer to Procedure 7-02.
Install crankcase breather tube and hose. Refer to Procedure
7-63.
Page 7-30
Cylinder Head - Replacement (7-09)

General Information
The cylinder head is a one piece, cross flow design with two
valves per cylinder. The valve guides and seats are
replaceable.
The cylinder head has a cast intake manifold and fuel filter
head. The injectors are mounted in the head for direct
injection into the cylinders.
The cylinder head gasket is a laminated design with a fire

ring to seal the cylinder bores. The gasket also provides
orifices to control coolant flow.
Diagnosing Malfunctions
Head Gasket Sealing
External head gasket leaks can be detected visually. Liquid
soap can be used to locate external leaks.
Define the type of leak as follows:
l Lubricating oil
l Coolant
l Compression, refer to Procedure 7-01
Page 7-31
Internal head gasket leaks can be detected by performing a

compression check. Refer to Procedure 741.
If the compression was found low on adjacent cylinders and
the pressure cannot be increased by oiling the rings, the
head gasket is probably leaking between the cylinders.
0@3
Low compression on a single cylinder can be caused by an

external leak to a coolant passage. A leak to a coolant
passage of this magnitude will also result in coolant in the
cylinder.
04B
A compression leak to the coolant will normally be detected
by loss of coolant as the coolant is blown from the cooling
system.
Service Tip: Remove the drive belt from the water pump.
Run the engine for 1 to 2 minutes and check for coolant
being blown from the radiator by compression gasses.
Valve Sealing
If the compression is low on one or more non-adjacent
cylinders and the pressure cannot be increased by oiling the
rings, improper valve sealing is to be suspected.
Page 7-32
Valve leakage is often audible from the intake and exhaust

manifold.
Worn Valve Stem Seals

Worn valve stem seals are typically detected by excessive
smoke at idle or when the engine is unloaded and the
vehicle is going down hill.
Hardening of the material and wear or damage to the sealing

surfaces will cause the seal to leak.
Page 7-33
Removal
Drain the cooling system. Refer to Procedure l-01.
Remove the turbocharger. Refer to Procedure 3-l 1.
Remove the aftercooler or intake cover. Refer to
Procedure 3-l 0.
Remove the exhaust manifold. Refer to Procedure 3-12.
Remove the fuel lines and injector nozzles. Refer to
Procedure 5-05.
Remove the valve cover, rocker lever assemblies and
i
push rods. Refer to Procedure 7-08.
Remove the fuel filters. Refer to Procedure 5-03.
Remove the fan hub. Refer to Procedure l-06.
Remove the alternator. Refer to Procedure 6-03.
Remove the belt tensioner. Refer to Procedure l-04.
13 mm
NOTE: In some applications it may be easier to remove the
thermostat housing to gain access to the exhaust manifold
capscrew for No. 1 cylinder.
Remove the thermostat housing/coolant outlet assembly.
7/16 inch
Disconnect the coolant vent tube.
Page 7-34
16 mm
Remove the cylinder head capscrews in the sequence shown
in the illustration.
- Front
TM464

component.
Use a hoist or hydraulic arm to remove the cylinder head.
Make sure the head is removed in a direct upward motion.
Remove the cylinder head gasket.
NOTE: Place the cylinder head on wood blocks to prevent
damage to the combustion face.
Cylinder Block/Head Deck Cleaning and

Inspection
Place clean lint-free rags over the pistons to prevent dirt from
failing into the engine.
Plug or cover the coolant and oil passages in the cylinder
block deck.
Use a gasket scraper to clean the cylinder block deck surface.

Use Scotch-Brite@ 7448, or equivalent, and solvent to remove
any residual gasket material from the cylinder block deck
surface.
holes, always wear safety glasses or a face shield to protect
the eyes. Personal injury can result.
NOTE: Make sure the cylinder head capscrew holes are clean.
Use compressed air to clean debris from the capscrew holes.
Page 7-35
0623
Inspect the coolant passages.
Build-up of deposits in the coolant passages can cause
engine overheating.
A large build-up of rust and lime will require removal of the
cylinder block for cleaning in a hot tank.
\
El
Be sure the coolant passages are clean.
NOTE: Excessive deposits may be cleaned in an acid tank,
but the camshaft bushings must first be removed to prevent
damage.

Visually inspect the top surface for damage. •iil
0623
Check the top surface for flatness between each cylinder.
a
Cylinder Block Flatness Specification
mm in
0.075 End-to-End 0.003

Caution: Do not proceed with the repair if the cylinder

block head deck is damaged or not flat. The engine will
have to be removed for resurfacing the block.
A
NOTE: The cylinder block head deck can be resurfaced in a
machine shop and a thicker surface head gasket installed to
keep the piston-to-head clearance the same.
The cylinder block head deck can be resurfaced two times.

The first resurface should be 0.25 mm [O.OlO inch]. If
additional resurfacing is required, an additional 0.25 mm
[O.OlO inch] can be removed.
Cylindgr Block Resurface Limits

mm in
0.25 First Resurface 0.010

0.25 Second Resurface 0.010
0.50 Total Allowed 0.020
Page 7-38
The upper right corner of the rear face of the block must be
stamped with an “X” when the block is resurfaced to 0.25 mm
to.010 inch]. A second “x” must be stamped beside the first
when the block is resurfaced to 0.50 mm [0.020 inch].
Consult your machine parts catalog for the correct head

gasket to be used with resurfaced blocks to be sure of
proper piston to valve clearance.
NOTE: The gaskets are notched to aid in identification. The
standard gasket does not have a notch.
A = Use where block deck has been resurfaced
0.25 mm [O.OiO in] (two notches)
B = Use where block deck has been resurfaced
0.50 mm [0.020 in] (three notches)
Gauge Block, Part No. 3823495

Liner protrusion is the distance the liner protrudes above the
block face. Check the liner protrusion.
NOTE: The liners must be checked in the “free state”,
without clamps.
Cylinder Liner Protrusion Specifications

mm in
0.025 MIN 0.0010
0.122 MAX 0.0048
NOTE: If the cylinder liner protrusion is below specifications,

it will be necessary to machine the counterbores.
Visually inspect the cylinder liners for cracks, scuffing or

scoring.
Page 7-37
Cylinder Head - Cleaning and Inspection

Injector Bore Brush, Part No. 3822510 RI
NOTE: Omit the following five steps if a replacement head is
to be installed: B
Ll
Clean the carbon from the injector nozzle seat with an
injector bore brush, Part No. 3822510.
Caution: When using a steam cleaner, wear protective

A
Steam clean the cylinder head and dry with compressed air.
Blow out all capscrew holes.
Use Scotch-BriW 7448, or equivalent, and solvent to clean

the cylinder head combustion face. \
R
Clean the exhaust manifold gasket surface.
Clean the valve cover gasket surface.
Visuallv insoect the cvlinder head and valves for obvious LA I

damage that would piohibii reuse. Check for cracks and w
damage to the deck surface that would result in loss of
sealing.
NOTE: If a crack in the cylinder head is suspected, pressure e
test the cylinder head. Refer to Procedure 7-10.
Page 7-36
Check for cracks on the combustion face. Cracks that extend

from the injector bore away from the valve seats and are not
over 10 mm [0.394 inch] long are acceptable.
A = 10 mm IO.394 inch]
no474
Any cracks that extend from the injector bore toward the valve
seats are unacceptable and the cylinder head must be
replaced.
Cracks between the valve seats are not acceptable and the

Use a straight edge and feeler gauge to check the cylinder
head combustion surface for flatness.
Cylinder Head Flatness Specifications

mm in
0.020 End-to-End 0.008

Page 7-39
Use a small 51 mm [2.0 inch] straight edge and a 0.0254

mm 10.001 inch1 feeler aauae to measure local flatness.
Check- between ihe cylinaer”bores and also between the
coolant passages. If the 0.001 inch feeler gauge fits under
the 2.0 inch straight edge, the cylinder head must be
replaced or resurfaced.
NOTE: A maximum of 1.00 mm [0.040 inch] can be

machined from the combustion surface of the cylinder head. Maximum / I
If the cylinder head is machined, place the valve in the
respective bore and check the valve depth dimension. If the
depth is less than the minimum specification, the valve seat
will require machining. Refer to the 6D114E-1 Shop Manual.

mm in
1.62 MAX 0.064
1.12 MAX 0.0440
Visually inspect the valves for indications of leakage or

burning.
Valve and Seat - Leakage Testing

NOTE: If a leaking valve is suspected, vacuum test the
valves and valve seats. The vacuum must not drop more
than 25.4 mm Hg [l.O inch Hg] in 5 seconds.

mm Hg in Hg
457 used 18
635 New 25
Page 7-40
NOTE: If vacuum does not meet the specifications, the face of

the valves and the valve seat inserts must be resurfaced.
Refer to the 6D114E-1 Shop Manual.
Cylinder Head Capscrews

Caution: Do not use caustic or acid solutions to clean the
Use a petroleum-based solvent to clean the capscrews.
Clean the capscrews thoroughly with a wire brush, a soft wire
wheel, or use a non-abrasive bead blast to remove deposits
from the shank and the threads.
Visually inspect the cylinder head capscrews for damaged

threads, corroded surfaces, or a reduced diameter (due to
NOTE: Do not reuse a capscrew that has damaged threads or
a reduced diameter from having been stretched.

conditions:
l Visible corrosion or pitting exceeds 1 sqcm [0.155 sq.
l Acceptable 3/8- x 3/8- inch
l Unacceptable l/2- x l/2- inch
l Visible corrosion or pitting exceeds 0.12 mm [0.005
inch] in depth.
Page 7-41

[1/84nch] of the fillet.
[l/8-inch] of the threads.
Stretched beyond “free length” maximum. Refer to the

Part No. 3323921, Capscrew Length Gauge
NOTE: If the capscrews are not damaged, they can be
reused throughout the life of the engine unless the specified
‘free length” is exceeded.
04B
capscrew in the appropriate slot with the flange against the
J
base of the slot.
L Flange
Capscrew Free Length -L- agalnst

Base
mm in I
81.5 Short 3.2
162.6 Long 6.4
I
capscrew is too long and must be discarded. 0
@

used again.
Page 7-42
Installation
NOTE: Make sure the new head gasket is correctly aligned with
the holes in the cylinder block.
The cylinder block and head must be clean and dry.
Position the gasket onto the dowels.
II I i
Caution: Do not drop the cylinder head on the cylinder

head gasket. The gasket material can be damaged.
Carefully install the cylinder head onto the gasket and cylinder
block.
NOTE: Make sure the cylinder head is installed onto the dowels
in the cylinder block.
Use clean 15W-40 oil to coat the cylinder head capscrew

threads and underneath the head flange.
Allow the excess oil to drain from the capscrew threads.
Install the capscrews in the cylinder head.

NOTE: Be sure to install the six capscrews into the holes
underneath the injectors.
NOTE: The top of the cylinder head capscrew is identified

with an angle marking. The cylinder head capscrews must
be tightened by using the three-step “torque plus angle”
method, described as follows:
16 mm
1. Follow the numbered sequence and tighten all cap-
screws:
Torque Value: (Step One) 70 N*m [52 f&lb]
capscrews again.
- Front
2. Follow the numbered sequence and tighten only the 12

long capscrews:
Torque Value: (Step Two) 145 N l m [105 ft-lb]
long capscrews again.
3. Torque Value: (Step Three)

Follow the numbered sequence and turn all the capscrews
90 degrees as indicated on the capscrew head.
Page 7-44
To accurately turn the capscrew to the desired angle, a small

“dot” and a “window” are marked on the capscrew head.
window
Mark the cylinder head adjacent to the dot on the cap-screw

head. This mark will serve as an indexing aid.
Rotate the capscrew until the mark, that has been made on the
cylinder head, falls into the “window” on the capscrew head.
Service Tip:
Use a permanent marker to mark the socket corresponding to
one of the flats of the socket hex.
Page 7-45
After the torque has been completed, mark the cylinder head
at the location of the dot.
Position the socket on the capscrew such that the mark on

the socket is at the same point as the window on the
capscrew.
Turn the socket until the mark of the socket aligns with the
mark on the cylinder head.
Install the thermostat housing. Refer to Procedure l-08.

Install the belt tensioner and bracket. Refer to Procedure l-
04.
Install the exhaust manifold. Refer to Procedure 3-12.
Install the rocker lever oil manifold. Refer to Procedure 7-05.
Install the rocker assemblies. Refer to Procedure 7-05.
Page 7-46
II I - Adjust the valve clearance. Refer to Procedure 7-06.

I& install the valve cover. Refer to Procedure 7-02.
II Install the injectors. Refer to Procedure 5-07.
* Install the fuel lines. Refer to Procedure 5-05.
Install the turbocharger. Refer to Procedure 3-11.
4 Install the crankcase vent tube. Refer to Procedure 7-03.
e Fill and vent the cooling system.

Refer to Procedure 141.
e Vent the high pressure fuel lines.

0 and proper operation.

Operate the engine at idle 5 to 10 minutes to check for leaks
a?
Page 7-47
Cylinder Head - Pressure Test (7-10)

Caution: Do not pressure test the cylinder head with the
valves and valve springs installed. Water entering the
A
cylinder head cannot be dried thoroughly and will dam-
age the valve guides and valve stems. Refer to the
6D114E-1 Shop Manual for cylinder head disassembly
procedures.
NOTE: A cylinder head test fixture can be fabricated from a I

flat piece 01 steel or aluminum. Refer to the following table
for test fixture dimensions:
Test Fixture Dimensions

mm in
16 Thickness 0.625
651 Length 33.5
190 Width 7.5
NOTE: Use the cylinder head gasket as a pattern for drilling

the capscrew holes.
Install the cylinder head water test fixture.

l Install a new head gasket
0@A
l Install the test plate
l Install the 26 cylinder head capscrews and Ml4 X 2.0
nuts
Tighten the nuts.
Connect a regulated air supply hose to the text fixture plate.

Apply air pressure.
0@b
Use a nylon lifting strap and a hoist to place the cylinder
head in a tank of heated water.
Temperature: 60°C [14O”F]
Completely submerge the cylinder head in the water.
Page 7-48
Visually inspect for air bubbles rising from the water.

If air bubbles are seen, replace or rebuild the cylinder head.
Refer to the 6D114E-1 Shop Manual for rebuild procedures.
Main and Thrust Bearings - Replacement

(7-11)
General Information
The engine has seven main bearings. The lower bearing shells
are all the same. All of the upper bearing shells are the same
except for the No. 4 journal. The No. 4 journal uses a flanged
upper bearing shell. The flanges on the bearing control the end
thrust of the crankshaft.
The upper bearings are grooved and have two oval holes in
them. One hole aligns with the drilling from the main oil rifle,
the other hole supplies oil to the piston cooling nozzles.
The following oversize service main and thrust bearing

combinations are available for crankshafts that have been
machined undersized either on the main journal or thrust
bearing face:
Main Bearing Thrust Bearing

Journal Diameter Face Thickness
STD STD
-0.25 mm [-O.OlOinch] STD
-0.50 mm [-0.200 inch] STD
-0.75 mm [X1.030inch] STD
-1 mm [-0.040 inch] STD
STD +0.25 mm [+O.OlO inch]
STD +0.50 mm [ +0.020 inch]
-0.50 mm [X1.020inch] +0.50 mm [+0.020 inch]
Page 7-49
Improper maintenance of the lubrication system is the
primary cause of reduced bearing life.
Normally, worn bearings can be detected by reduced oil
pressure. If this wear goes undetected, the excessive
clearance will increase the impact between the bearing and
the crankshaft causing a distinct knocking sound.
0a3
A main bearing noise will be heard when the engine is
loaded.
A damaged or worn thrust bearing flange of the upper main

bearing shell can be detected by measuring the end thrust of
the crankshaft.
Crankshaft End Thrust (Used)

mm in
0.112 MIN 0.0044
0.330 MAX 0.013
Failures of driven units at the front or rear of the engine

which increase the end loading can damage the thrust
bearing.
Page 7-50
Removal
l Drain the lubricating oil. Refer to Procedure 2-04.
@
Remove the lubricating oil pan and suction tube. Refer to
Procedure 2-13.
0@
NOTE: The main caps should be numbered. If they are not,
be sure to mark them with the correct number.
NOTE: Do not pry on the main caps to free them from the
cylinder block.
Use two of the main bearing cap bolts to “wiggle” the main cap
loose, being careful not to damage the bolt threads.
0
Perform a visual inspection of the main bearings and crankshaft
a9 journals. Remove the No. 2 and 3 caps and the lower main
bearing shell from the crankshaft journal.
NOTE: The No. 4 main bearing cap has a thrust bearing.
Check the journals for signs of overheat, deep scratches or
other damage. If there is no damage, there is no need to pull
the other caps at this time.
Page 7-51
Mark the bearing shell with the letter “c’ (lower) and the
journal number it was removed from.
If the main bearings are to be removed, remove all bearing

caps except for cylinders No. 1 and 7.
Caution: do not damage the crankshaft when removing

the thrust bearing. A
Use a blunt tool to remove the upper thrust bearing.

Caution: Do not use a capscrew or any hard metal object
as this can damage the crankshaft and cause serious
engine failure.
To remove the upper main bearing shell, install a tool similar
to the one shown, in the oil hole of the main bearing journal.
Several varieties of small soft metal plugs are sold specifically
for this purpose.
Page 7-52
The No. 1 main does not have a hole in the journal so the
bearing rollout tool cannot be used to replace the bearing.
r Caution: Use care so the screwdriver does not damage the
pQ
crankshaft or cylinder block.
00
00
0
Oob
0I
Use a
bearing
against
bearing
flat blade screwdriver. Gently bump the end of the
to loosen it from the block. Then, use finger pressure
the bearing shell and rotate the crankshaft to roll the
out.
‘\
Part No. 3377371, Engine Barring Tool

Rotate the crankshaft so the pin pushes against the end of the
bearing opposite the tang. Remove the bearing.
Follow this procedure to remove the other bearings.

Use solvent and a soft bristle brush to clean the cap,
capscrews and bearings and dry with compressed air.
Visually inspect the main cap and capscrews for damage.

Visually inspect the bearing shells and the thrust bearings for
nicks, scratches, or damage.
NOTE: If the main bearings are damaged, refer to the
6D114E-1 Shop Manual to inspect the crankshaft main bearing
journals. If the crankshaft is damaged, the engine must be
removed for repair. Refer to Procedure 9-01.
Page 7-53
Use an outside diameter ball tipped micrometer to measure

the main bearing shell thickness.
Standard Main Bearing Shell Thickness

mm in
3.446 MIN 0.1357
3.454 MAX 0.1380
Discard any main bearing shell if it is thinner than the

minimum specification.
NOTE: For more detailed information of bearing damage, e
refer to “Analysis and Prevention of Bearing Failures,” Bulletin
No. 3810387.
0@
The upper bearings contain two oil holes. The lower bearings
do not. Both bearings are marked on the back to indicate
either standard (STD) or oversize (OS).
STD
Determine the size of the bearing removed and obtain the

same size for installation.
0@B
NOTE: Main bearing shells are available for crankshafts
which are 0.50 mm [0.020-inch] undersize. Crankshafts which
are machined undersize in the connecting rod and main
bearing journals are marked on the front counter weight. If
the crankshaft is marked, check the bearing shell part num-
ber to make sure the correct bearing size is used.
Page 7-54
Caution: The cylinder block saddle and the cap mating

surfaces must be clean and dry when the bearing shells are
installed. Used bearings must be installed in their original
location.
Use clean Lubriplateg 105 or its equivalent to lubricate the
upper main bearing shell to crankshaft journal mating surface.
Do not lubricate the side that is against the cylinder block.
Installation
Position the new upper bearing on the crankshaft and install as
far as possible by hand.
Part No. 3377371, Engine Barring Tool

Use Part No. 3823818, main bearing rollout tool, and Part No.
3377371, engine barring tool, to finish pushing the bearing in
slowly being sure it is aligned with the block. Make sure the
tang on the bearing aligns with the notch.
Caution: Make sure the pin does not slide under the
bearing and damage the crankshaft.
Page 7-55
Install the lower main bearings into the bearing caps.

Make sure the tang of the bearing shell is in the slot of the
0
cap:
Use dean Lubriplatee 105 or its equivalent to lubricate the @
bearing shells.
Use clean 15W-40 oil to lubricate the capscrew threads.

Drain the excess oil from the capscrews before installing
them.
0a9
NOTE: The main bearing caps are numbered for location.
No. 1 starts with the front of the block, and the numbers
face the camshaft side of the engine.
When correctly installed, the tangs (slots) should both be on
the same side.
Small Plastic or Rubber Mallet

Tap the main cap gently into position.
a**
NOTE: Make sure the bearing does not become dislodged ,q&
from the cap.
08
0423
When seated, the main bolts can be threaded in by hand.
Page 7-56
23 mm
Install a main bearing cap after each upper bearing is installed
to keep the bearing in place while the other uppers are
installed.
Tighten the capscrews to an initial torque.
Initial Torque Value: 50 Nom 137 ft-lb]
NOTE: Do not tighten to the final torque value at this time.
NOTE: The thrust journal does not have tangs or slots. Care
should be taken to be sure the number stamped on the main
cap is positioned to the camshaft side of the engine.
Push the crankshaft toward the center of its end thrust position
to allow clearance for the bearing.
Since the bearing rollout tool cannot be used for the No. 1
/4 bearing, use a blunt object or screwdriver to push the bearing

into position as the crankshaft is rotated.
o\i
i
-- \
b
/’
‘,
ii? /!
23 mm
Tighten the capscrews evenly following the illustrated sequence.
Torque Value:
Step
1 - 50 Narn [37 ft-lb]
2 - 119 N*m [66 ft-lb]
3 - 176 Nom [129 ft-lb]
Page 7-57
Measure the end clearance of the crankshaft as follows:

l Install a dial indicator onto the oil pan flange.
l Put the tip of the gauge against the crankshaft coun-
terweight.
l Push the crankshaft toward the rear of the cylinder
block.
l Set the dial indicator at zero.

l Push the crankshaft toward the front of the cylinder
block.
l If the end clearance is less than 0.127 mm jO.005
inch], do the following:
l Loosen the main bearing capscrews one turn.

l Push the crankshaft toward the front and then toward
the rear of the cylinder block.
Tighten the main bearing capscrews in the sequence shown

to the torque values listed in the installation procedure.
- Front
Page 7-58
Measure the crankshaft end clearance. The end clearance

specification for a new or reground crankshaft with new
thrust bearings is 0.127 mm [0.005 inch] to 0.330 mm [0.013
inch].
NOTE: Crankshafts that have been reground on the thrust

0.25 mm[O.OlO in.] 0 bearing surfaces are marked for oversize thrust bearings on
the rear crankshaft counterweight. If the crankshaft counter
weight is marked, check the thrust bearing part number to
make sure the correct bearing size is used.
Example: 0.010 = 0.25 mm [O.OlO inch]
If the crankshaft end play is more than 0.330 mm [0.013 -

inch] new or 0.533 mm IO.021 inch] used, the crankshaft
must be removed from the engine and repaired. Refer to
the 6D114E-1 Shop Manual.
Install the oil pan and suction tube (A). Refer to Procedure
2-13.
Page 7-59
Fill the engine with lubricating oil. Refer to Procedure 2-05. e
0@
Operate the engine until the coolant temperature reaches
82°C [18O”F], and check for lubricating oil leaks.
Connecting Rod Bearings - Replacement

(7-12)
The connecting rod bearings are tri-metal with steel backing.
Improper maintenance of the lubrication system is the

primary cause of reduced bearing life.
An oil analysis will aid in determining the extent of internal
engine damage. Refer to Procedure 2-02.
For additional oil analysis, refer to Komatsu’s KOWA
(Komatsu Oil & Wear Analysis) Program.
Page 7-60
Normally, worn bearings can be detected by reduced oil

pressure, but if this wear goes undetected, the excessive
clearance will increase the impact between the bearing and
the crankshaft causing a distinct knocking sound.
0
A connecting rod noise occurs when the engine is not
a3 loaded. Verify by first applying a load and then unloading
and listening for the noise.
Removal
Drain the lubricating oil. Refer to Procedure 2-04.
Remove the lubricating oil pan and oil suction tube (A).

RI Rotate the crankshaft to position two of the connecting
rods at bottom dead center (BDC).
Page 7-81

Loosen the connecting rod capscrew nuts.
NOTE: Do not remove the capscrew nuts.
Hit the connecting rod capscrew nuts with a plastic hammer
to loosen the rod caps.
Remove the capscrew nuts and rod cap.

Remove the bearing shell from the rod cap, and mark it as
the lower bearing shell from the connecting rod number from
which it was removed.
Push the rod up far enough to allow the upper bearing shell
to be removed.
Remove the bearing shell, and mark it as the upper bearing
shell from the connecting rod number from which it was
removed.

NOTE: Refer to “Patts.Reuse Guidelines”, Bulletin No.
3810303, for information on bearing inspection.
Page 7-62
0
Visually inspect the rod caps, connecting rod bearing
@3 saddles, and capscrews for nicks, cracks, burrs, scratches,
or fretting.
0
Visually inspect the bearings for damage.
aI3 NOTE: Replace any bearings with lock tang damage or
scratches (deep enough to be felt with a fingernail). Also
replace any bearings which show pitting, flaking, or corrosion
into the lining.
0
NOTE: Normal bearing wear produces a smooth finish which
a3 will wear into the lining. An exposed lining does not always
indicate worn bearings. If large areas of the lining are visible in
the bearings before the engine has accumulated 240,000
kilometers [150,000 miles] or 3,750 hours, inspect the engine
for contamination from fine dirt particles and correct the
problem.
Inspect the crankshaft rod journals for deep scoring or

0
4B overheating.
Page 7-63
Use a micrometer to measure the rod journal.
Connecting Rod Journal Dimensions (Minimum)

mm in
75.987 Standard 2.9916

75.737 Machined 0.25 mm 2.9818
75.487 Machined 0.50 mm 2.9719
75.237 Machined 0.75 mm 2.8621
74.887 Machined 1.00 mm 2.9522
Visually inspect the bearing shell seating surface for nicks or

burrs.
If nicks or burrs cannot be removed with Scotch-Britele 7448
or equivalent, the bearings must be replaced.
NOTE: For more detailed information of bearing damage,
refer to “Analysis and Prevention of Bearing Failures,” Bulletin
No. 3810387.
Measure the rod bearing shell thickness with an outside

micrometer that has a ball tip.
Standard Connecting Rod Bearing Thickness (Used)

mm in
2.43 MIN 0.0956

2.471 MAX 0.0973
Discard a bearing shell if its thickness is below the minimum

specffication.
NOTE: Connecting rod bearings are identified with a part

number and size stamped on the back side.
Determine the size of the removed rod bearing and obtain a
set of the same size.
Oversize service rod- bearings are available for use with
crankshafts that have been machined undersize. Refer to the
appropriate parts catalog.
Page 7-64
Crankshafts which are machined undersize in the connecting

rod or main bearing journals are marked on the front
counterweight. If the crankshaft is marked, check the bearing
shell part number to make sure the correct bearing size is
used.
Installation
Caution: The connecting rod and bearing shell mating
surfaces must be clean and dry when the bearing shells are
installed. Used bearings must be installed in their original
location.
Use clean Lubriplate@ 105, or its equivalent, to lubricate the
crankshaft journal mating surface of the upper bearing shell.
Install the upper bearing shell in the connecting rod with the
tang of the bearing in the slot of the rod.
Install the bearing shell in the connecting rod cap with the tang
(2) of the bearing in the slot (1) of the cap.
Use clean Lubriplate@ 105, or its equivalent, to lubricate the
bearing shell to crankshaft journal mating surface.
Use clean 15W-40 oil to lubricate the threads of the connecting
rod capscrews.
Caution: The connecting rod cap number must match the

number on the connecting rod and must be installed with
the numbers aligned to prevent damage to the connecting
rods and the crankshaft. The locking tang of the connecting
rod cap must be toward the camshaft side of the cylinder
block.
Lubricate under the connecting rod capscrew nuts with clean
15W-40 engine oil.
install the connecting rod caps and rod capscrew nuts.
Page 7-65

Tighten the connecting rod capscrew nuts in alternating
0(K
sequence.
Torque Value:
Step 2 - 30 N*m [So ft-lb]
Step 3 - 120 N-m 133 ft-lb]

crankshaft.

mm in
0.10 MIN 0.004

0.33 MAX 0.013
0a9
Check for freedom of rotation as the caps are installed. If the
crankshaft does not rotate freely, check the installation of the
rod bearings and the bearing size.
Install the oil suction tube. Refer to Procedure 2-13.

Install the lubricating oil pan. Refer to Procedure 2-13.
Fill the lubricating oil pan. Refer to Procedure 2-05.
Page 7-66

[18O”F] and check for leaks and proper operation.
Pistons and Rings - Replacement (7-13)

Piston - General Information
Design features include: Aluminum piston with dual Niresist ring
insert. The top and intermediate ring grooves are of keystone
design. The combustion bowl and piston top are hard anodized
on certain higher rated horsepower engines. Always check the
part number to be sure the correct configuration is used during
piston replacement.
Piston and Rings - Diagnosing Malfunctions

There are a number of power related problems including
excessive oil consumption, smoke, blowby and poor per-
formance that can be caused by inadequate sealing between
the piston rings and the cylinder liner walls. A blowby
measurement can aid in detecting the problem, refer to Section
8.
A loss of piston ring sealing may be detected during a

compressron check, refer to Procedure 7-01.
Page 7-67
Visual inspection of the exhaust ports after removing the

exhaust manifold can also confirm loss of sealing and
excessive oil consumption.
0@
The cause of inadequate sealing between the cylinder wall
and rings range from extreme abrasive wear “dustout” in a
short period of time because of poor maintenance of the air
intake system to wear over a long period of service.
Refer to Section 3 for troubleshooting the combustion air
system.
When troubleshooting for excessive oil consumption, re-

member oil viscosity can affect cylinder sealing.
Make sure the correct oil change intervals are being followed
and the specified grade of oil is being used, refer to the
Operation and Maintenance Manual.
A sudden increase in oil consumption can indicate damage

to the cylinder components.
Overheating of the engine from a loss of coolant will also
cause the cylinder to overheat resulting in scuffing or seizure
of the piston.
Page 7-68
Loss of piston cooling can lead to piston scuffing or seizure.
Veriiication of the damaged or worn component requires

visual and dimensional inspection of rings, pistons and
cylinder liner bores.
NOTE: If severe piston damage has occurred, check the
turbocharger and other exhaust components for damage
from debris.
Removal
Remove the lubricating oil pan. Refer to Procedure 2-13.
Remove the cylinder head. Refer to Procedure 7-09.

Page 7-69

Rotate the crankshaft so the pistons are away from top dead
center (TDC).
Caution: Do not use emery cloth or sandpaper to remove

carbon from the cylinder liners. Aluminum oxide or silicon
particles from emery cloth or sandpaper can cause
serious engine damage. Do not use any abrasives in the
ring travel area. The cylinder liner can be damaged.
Rotate the crankshaft and use a gasket scraper to remove
the carbon ridge in each cylinder.
NOTE: Only scrape or sand above the piston travel area.
Use a fine fibrous abrasive pad such as Scotch-B&@ 7446,
or equivalent, and solvent to remove the remaining carbon.

Rotate the crankshaft to position the rod caps at “BDC” for
removal.
Loosen the connecting rod capscrew nuts.
NOTE: Do not remove the capscrews from the rods.
Use a plastic hammer to hit the connecting rod capscrews to
loosen the caps.
Remove the connecting rod capscrew nuts.

Remove the rod cap.
Remove the lower rod bearing.
Mark the cylinder number and the letter “c’ (Lower) in the flat
surface of the bearing tangs.
Page 7-70
Use a “T-handle” piston pusher to push the rod away from

the crankshaft.
NOTE: Push the rod until the piston rings are outside of the
top of the cylinder liner.
-
Use both hands to remove the piston and rod assembly.
NOTE: The piston and connecting rod assemblies must be
installed in the same cylinder number they were removed from
to be sure proper fii of worn mating surfaces if parts are used
again.
Use a tag to mark the cylinder number each piston and rod
assembly was removed from.
2
(
I
-.
Place the rod and piston assemblies into a container

to protect them from damage.
NOTE: Unique serial numbers (not cylinder numbers) are

stamped on the connecting rod and matching cap.
When the rods and caps are installed in the engine, the
numbers on the rods and caps must match and be installed
on the same side of the engine.
Page 7-71
Remove the upper rod bearing.

Mark the cylinder number and the letter “U” (upper) in the flat
surface of the bearing tang.
-
Piston and Rod Disassembly
Use internal snap ring pliers to remove the retaining rings
from both sides of the piston.
Remove the piston pin.
NOTE: Heating the piston is not required.

Remove the piston rings.
Place
. . a tag on the rings and record the cylinder number of
the piston on the tag.

Caution: Be sure the cleaning solvent is approved for
aluminum. Damage to the pistons can result.
Allow the pistons to soak for a minimum of 30 minutes in a
tank containing an approved cleaning solvent for aluminum.
Use a hot, soapy solution and a non-metallic brush to
remove carbon deposits.
Page 7-72
A Caution: Do not use a metal brush. A metal brush will

damage the piston ring grooves. Do not use glass beads,
walnut shell or plastic bead blasting to clean the piston
ring grooves or pin bores. This can cause the pin bore to
crack or the rings to not seat.

A clothing and safety glasses or a face shield. Hot steam
\
q Use steam to clean the pistons.

Inspect the piston for damage and excessive wear. Check

0
6B the top ring grooves, skirt and pin bore.
NOTE: Dimensional inspection of the piston is required only
when the cause of the lack of sealing is not apparent.
Visually inspect the piston bowl (l), pin bore (2) and skirt (3)
0
4B for cracks or damage.
NOTE: Do not use pistons with cracks.
Page 7-73
Measure the piston pin bore when the piston temperature is

at 20°C [68”F].
Piston Pin Bore I.D.

mm in
45.006 MIN 1.7719

45.025 MAX 1.7726
NOTE: Add 0.013 mm [0.0005-inch] to the bore inside di-

ameter per 5°C [lo” F] temperature rise up to 32°C. [90”F].
The pin bore should be checked closer to the O.D. of the
piston since the pin bore is tapered.
Visually inspect the piston pin for scratches, grooves, or

other damage.
Measure the piston pin outside diameter
Piston Pin O.D.

mm in
44.993 MIN 1.7714
45.003 MAX 1.7718
NOTE: Discard the piston pin if it is more than 0.03 mm

[O.OOl-inch] out of round.
Measure the piston skirt diameter as illustrated.
Piston Skirt O.D.

mm in
113.808 MIN 4.4806

113.879 MAX 4.4834
I TROdlo
Use a micrometer and Part No. 3823966, piston ring groove

gauge, to measure the wear of the top ring groove keystone
angle. Use Part No. 3823965, piston ring groove gauge, to
measure the wear of the intermediate ring groove keystone
angle.
Piston Ring Groove (Keystone Angle)

Ring mm in
Top: 113.938 MIN 4.4857

Page 7-74
Use a new piston ring and feeler gauge to measure the side
clearance of the rectangular intermediate and oil control ring
grooves.
Piston Ring Clearance (Rectangular Groove)

Ring mm in
0.152 MAX 0.006
Oil Control 0.020 MIN 0.0008
0.130 MaX 0.0051
Piston Ring - Inspection
r
TOP Intermediate Check the cylinder liners for wear, for those cylinders with no
obvious damage, check the following conditions which can
cause loss of sealing:
l Rings installed incorrectly
NOTE: There are two different design intermediate rings used
(A) rectangular (B) “reverse twist.”
0
OK Refer to piston ring installation in this section.
l Worn condition
l Abrasive wear is indicated by the concentrated ver-
tical scratches (B). The chromium plate is worn

through and the face of the ring has a brighter finish
compared to the dull satin finish of a new ring (A).
l This type of wear can be caused by ingested abra-
sive material. Inadequate cleaning during a previous

repair or particles embedded in the liner can cause the
condition.
Scuffing and scoring is indicated by the heavy scratches,

metal discoloration and voids (B).
This damage indicates a break down of the oil film on the
liner wall causing transfer of material from the ring face to
the liner. The condition can be caused by:
l Engine overheating
l Oil dilution or improper maintenance of the
lubrication system
l Piston cooling nozzle malfunction
Page 7-75
Oil ring plugging is indicated by the deposits in the oil ring

grooves (B). Plugging of the ring drains restricts oil drain
back which floods the ring belt area resulting in a loss of oil
control. The condition can be caused by:
l Low engine operating temperatures - long periods
of idling or a cooling system malfunction

l Extended oil change intervals, the wrong grade of
oil or poor quality oil
06D
r
To check the piston ring gap, use the top end of a piston to
align the piston rings in the wear area of the cylinder liner in
which they will be used.
A = 89 mm [3.5 inches]
Use a feeler gauge to measure the piston ring end gap.

Replace the ring if it does not meet the following spec-
ifications:
New Piston Ring End Gap

mm in
Top: 0.40 MIN 0.016
0.70 MAX 0.028
Intermediate: MIN 0.016
i:: MAX 0.028
0.60 MAX 0.024
NOTE: Add 0.09 mm [0.004 in] for every 0.03 mm [O.OOl in]
of bore wear up to the maximum worn limit.
Identify the ring sets for installation in the cylinder in which
the end gap was measured.
Page 7-76.
Inspect the connecting rod pin bushin bore and the

crankshaft bore. Refer to Procedure 7-9 4.
-
Installation
Piston Pin Installation
L
Use clean 15W-40 oil to coat the connecting rod piston pin
bore and the piston pin.
-
NOTE: The retaining ring must be seated completely in the
piston groove to prevent engine damage during engine op-
? eration.
* Install a new retaining ring into the piston pin bore.
Align the pin bore of the rod with the pin bore of the piston
and install the piston pin.
NOTE: Be sure that the word “Front” marked on top of the
piston and the numbers on the connecting rod and cap are
properly oriented.
Piston Ring Installation

The top surface of the upper two rings are identified:
Assemble with the word “TOP” or the supplier mark
up.
The bottom or oil control ring can be installed with either
side up.
Page 7-77
NOTE: The two-piece oil control ring must be installed with

the expander ring gap 180 degrees from the gap of the oil
ring. Do not overlap the ends of the expander ring.

Install the rings on the piston. RI
Position the oil ring expander in the oil control ring groove.
Install the oil control ring with the end gap opposite the ends
on the expander.
Install the intermediate ring.

NOTE: The intermediate ring must be installed with the
cutback notch to the bottom of the piston. The word “TOP”
or the “0” stamp will be on the side opposite the cutback
notch.
Page 7-78
Install the top ring.

NOTE: The top ring must be installed with the cutback notch
to the top of the piston. The word “TOP” or the “0” stamp
will be on the same side of the ring as the cutback notch.
Install the bearing shells into both the rod and the cap. Make
rn7;z tang on the bearing shell is in the slot of the cap
Bearings are marked on the back to indicate either standard

(std.) or oversize (OS).
NOTE: If used bearing shells are to be installed, each bear-
ing shell must be installed in its original location.
Caution: Prevent dirt from mixing with the lubricant.

Dirty lubricant will accelerate bearing wear.
Lubricate the rod bearings with a light film of Lubriplate
I o!P’.
NOTE: Do not lubricate the back of the bearing.
Lubricate the rings and piston skirts with clean engine oil.
Page 7-79
Position the rings.
Part No. 3923290, Piston Ring Compressor

Compress the rings.
Use a clean lint-free cloth to clean the crankshaft bearing

journals.
q
B
Use a clean lint-free cloth to wipe the cylinder bores.

Lubricate the cylinder bore with clean engine oil. q
\
bage7-80

Rotate the crankshaft to position the journal for the con-
necting rod at bottom dead center (BDC).
DC
Caution: Be sure “Front” marking on the piston and the

numbers on the rod and cap are oriented as illustrated.
Caution: Use care when installing the piston and con-

necting rod so the cylinder bore is not damaged.
Position the piston and rod assembly into the cylinder bore
with the word “front” on the piston toward the front of the
cylinder block.
Hold the ring compressor against the cylinder liner. Push
the piston through the ring compressor and into the cylinder
liner.
NOTE: If the piston does not move freely, remove the piston
and inspect for broken or damaged rings.
Push the piston into the bore until the top of the piston is
approximately 50 mm [2 inches] below the top of the bore,
pull the connecting rod onto the crankshaft journal.
Page 7-81
Use clean engine oil to lubricate the threads of the

connecting rod capscrews.
0689
NOTE: The numbers marked on the connecting rod and the
cap must be the same. The tang slot side of the cap must
be on the same side as the tang slot in the connecting rod
when the cap is installed.
Install the bearing in the connecting rod cap.
Install the rod cap and start the connecting rod nuts.
diameter of the bearing shell.
Use clean 15W-40 oil to lubricate the connecting rod nuts.
19 mm
Alternately tighten the rod nuts to pull the rod cap into Ezl
position.
g@
O$
*s
0@A
Page 7-82

El Tighten the connecting rod cap to the connecting rod evenly.
0%
Torque Value:
Step 1 - 40 Nom 130 ft-lb]
0
Shake the connecting rod after tightening to verify side
4B clearance.

crankshaft.

mm in
0.10 MIN 0.004
0.33 MAX 0.013
0
a!!? Check for freedom of rotation as the caps are installed. If the
crankshaft does not rotate freely, check the installation of the
rod bearings and the bearing size.
Page 7-83
Install the suction tube (A) and oil pan. Refer to Procedure 2-
13.
Install the cylinder head. Refer to Procedure 7-09.
0aiD
82°C [18O”F] and check for leaks and proper operation.
Connecting Rods - Replacement (7-14)

General Information
The piston pin end of the connecting rod is angle cut to
provide additional bearing surface. The piston pin bore in the
rod is fitted with a bronze bushing.
Service replacement rod bushings are available. Refer to the e
appropriate parts catalog for part numbers.
Page 7-84
Part No. 3823890, Connecting Rod Pin Bore Bushing

•l Removal/Installation Tool
This tool is used to remove and install the bushings to the
correct position.
Ref
No Part No. Description QtY
3823691 Anvil 1
3823693 cup 1
3823692 Mandrel 1
3823694 Driver Ring 1
3823695 Knock-out-ring 1
Hitch Pin 1
Removal

Remove the lubricating oil pan and oil suction tube. Ref to
Procedure 2-13.
Remove the piston and connecting rod assemblies from the

engine. Refer to Procedure 7-13.
Remove the pistons from the connecting rods. Refer to
Procedure 7-l 4.
Page 7-85

Use a nylon bristle brush to clean the oil drillings. q
B

A
Use steam or solvent to clean the connecting rods. Dry with
compressed air.
0623
Inspect the connecting rods and caps for damage.
Replace the connecting rod if the “l-beam” is nicked or
damaged.
0@
Visually inspect the connecting rod pin bore bushing for
damage or misalignment of the oil passage and bushing.
Measure the connecting rod piston pin bushing inside

diameter.
Connecting Rod Pin Bore Specifications

mm in
46.023 MIN 1.7726

45.060 MAX 1.7740
Page 7-66
Plastic Hammer
Install the bearing shells in the connecting rod and cap.

Install the connecting rod caps and the connecting rod nuts.
NOTE: The connecting rod cap number must match the
number on the connecting rod and be installed with the
numbers aligned.
Tighten the connecting rod nuts in alternating sequence.
Torque Value: Step 1 - 40 Nom [30 ft-lb]
Step 2 - 60 Nom 160 ft-lb]
Step 3 - 120 Narn [66 ft-lb]
Measure the connecting rod crankshaft bore inside diameter

with the bearing installed.
Connecting Rod Crankshaft Bore I.D.

mm in
76.046 MIN 2.9939

76.104 MAX 2.9962
Measure and record the mean diameter of the rod journals

on the crankshaft.
Crankshaft Rod Journal Diameter

mm in
75.962 MIN 2.9906

76.013 MAX 2.9926
Out-of-Roundness: 0.050 mm [0.002 inch]

Taper: 0.013 mm [0.0005 inch]
Bearing Clearance: = Rod inside diameter minus crankshaft
journal diameter.
Page 7-87
NOTE: Bearing clearance can also be determined with Plas-

tigauge.
Connecting Rod Bearing Clearance

mm in
0.033 MIN 0.0013

0.117 MAX 0.0046
I lRo670
Installation
Install the pistons on the connecting rods. Refer to Pro-
cedure 7-l 4.
Install the piston and connecting rod assemblies. Refer to
Procedure 7-13.
Measure the connecting rod side clearance.

mm in
0.10 MIN 0.004

0.33 MAX 0.013
NOTE: If the side clearance is not within specifications:

l Remove the rod caps and inspect for dirt,
04B
damage,or correct bearings.
Page 7-88
Install the connecting rod caps.

Torque Value:
Step 1 - 40 Nern [30 ft-lb]
Step 2 - 80 Narn [60 ft-lb]
l Measure the side clearance again.
NOTE: If the side clearance is not within the specifications,
the connecting rod must be replaced.
Install the oil suction tube (A) and oil pan. Refer to
Procedure 2-l 3.

Fill the cooling system. Refer to Procedure l-01.
0
a3 82°C [18”F] and check for leaks and proper operation.
Page 7-89
Cylinder Liners - Replacement (7-15)

General Information
The cylinder block has a replaceable cylinder liner. A mid-
stop design is used to locate the liner in the block. A press
fit between the liner and the block provides coolant sealing
at the top of the liner. A rectangular ring seal (liner seal) is
used for sealing at the mid-stop portion of the liner.
NOTE: Komatsu America International Company does not e

recommend removing the cylinder liners to repair an oil
consumption problem if the inside diameters of the liners are
within the inspection limits included in this procedure.
Careful analysis of the condition of the liner bores, piston
rings and pistons can result in the restoration of cylinder
sealing with a minimum replacement of parts.
Removal
Drain the cooling system. Refer to Procedure l-01.

Remove the lubricating oil pan and oil suction tube. Refer to
Procedure 2-13.
Page 7-90
Remove the pistons and the connecting rods. Refer to

Procedure 7-13.
Preliminary Liner Inspection

NOTE: Before removing the cylinder liners, visually inspect
the condition to determine reuse.
Visually inspect the inside diameters of the liner for cracks,
scuffing or scoring.
Inspect the inside diameters for vertical scratches deep
enough to be felt with a fingernail.
NOTE: If a fingernail catches in the scratch, the liner must
be replaced.

A moderate polish produces a bright mirror finish in the worn
area with traces of the original hone marks or an indication
of an etch pattern.
A heavy polish produces a bright mirror finish in the worn
area with no traces of hone marks or an etch pattern.
Do not reuse liners exhibiting heavy polish or any indications
of particle embedded from a failure. Severely worn liners will
have a ridge near the top of the liner bore.
If the wear pattern indicates the liner bore is not straight or not
round, use a dial bore gauge to measure the liner inside
diameter in four places 90 degrees apart at the top and bottom
of the piston travel area.
Cylinder Liner Dimensions

mm in
0.04 Maximum Out Of Round 0.0016
0.04 Maximum Taper 0.0016
114.04 Maximum Bore Diameter 4.4697
Page 7-91
0@
NOTE: If a liner bore is not acceptable for reuse, it must be
replaced. Damaged liners cannot be honed or deglazed.
This would destroy the cross-hatch pattern needed for oil
contrd.
NOTE: Do not remove or disturb the liner seals for liners
which pass the inspection criteria.
Liner Protrusion Gauge Part No. 3823495

Liner protrusion is the distance the liner protrudes above the RI
block face. Before removing the liners, check the protrusion
in the “unclamped” state.

mm in
0.025 MIN 0.001

0.122 MAX 0.0048
If the liner was installed correctly and the liner protrusion is

out of limits, it will be necessary to machine the counterbore
and add shims to restore to the original specifications.
Use clean shop rags to cover the crankshaft to prevent
debris from failing into the main journal area or into the
connecting rod journal oil drilling.
Part No. 3378915 Cylinder Liner Puller

Caution: The liner puller must be installed and used as RI
described to avoid damage to the cylinder block. The
_
puller must not contact the block casting at points (l),
(2), (3) and (4).
A
Insert the liner puller into the top of the cylinder block.
Page 7-92
NOTE: The liner puller must be centered on the top of the

cylinder block.
Turn the puller jackscrew clockwise to loosen the liner from
the cylinder block.
Use both hands to remove the liner.
Part No. 3375629 Universal Liner Puller

Caution: The liner puller must be installed and used as
described to avoid damage to the cylinder block. The puller
plate must be parallel to the main bearing saddles and must
not overlap the liner outside diameter.
Insert the liner puller into the top of the cylinder block.
NOTE: The liner puller must be centered on the top of the

cylinder block.
Turn the puller jackscrew clockwise to loosen the liner from
the cylinder block.
Use both hands to remove the liner.
Use Dykems@ or equivalent to mark the cylinder number on

each liner.
Page 7-93

Caution: Do not use any abrasives in the ring travel area
A
of the liner. The liner can be damaged.
Use a soft wire brush or a fine fibrous abrasive pad such as
Scotch-B&e@ 7449 or equivalent to clean the flange seating
area.

Use solvent or steam clean the liners and dry with com-
pressed air.
Use clean 15W-40 oil to lubricate the inside diameter of the
liners.
Allow the oil to soak in the liner for 5 to 10 minutes.
NOTE: Use “lint-free” paper towels to wipe the oil from the
inside of the liners.
06B
Continue to lubricate the inside of the liners and wipe clean
until the paper towel shows no gray or back residue.
0a3
0
Visually inspect the liners for cracks on the inside and
outside diameters.
OK
L
Page 7-94
0
Inspect for cracks under the flange.
4B
Visually inspect the outside diameter and seat area for

0
429 excessive corrosion or pitting.
NOTE: Pits must not be more than 1.6 mm IO.06 inch] deep.
Replace the liner if the pits are too deep or if the corrosion
cannot be removed with fine emery cloth.
0
Inspect the inside diameters for vertical scratches deep enough
0
aB to be felt with a fingernail.
OK NOTE: If a fingernail catches in the scratch, the liner must be
replaced.
Visually inspect the inside diameter for scuffing or scoring.

0
4D A moderate polish produces a bright mirror finish in the worn
area with traces of the original hone marks or an indication of
an etch pattern.
A heavy polish produces a bright mirror finish in the worn area
with no traces of hone marks or an etch pattern.
Page 7-95
0 0aI3
Replace the liner if:
A heavy polish is present over 20 percent of
the piston ring travel area.
0 Both moderate and heavy polish over 30
percent of the piston ring travel area and one
half (15 percent) is heavy polish.
Part No. 3375072, Dial Bore Gauge

Measure the liner inside diameter in. four places 90 degrees
rt at the toottorn of the p_rstontravel area.
Cylinder Liner I.D.
mm in
114.000 MIN 4.4882

114.04 MAX 4.9897
Measure the outside diameter of the liner top press fii area.
Cylinder Liner O.D. (Top Press Fit)

mm in
130.938 MIN 5.1550
130.958 MAX 5.1558
Measure the cylinder liner bore in the block.
Cylinder Liner Bore in Block (Press Fit Bore)

mm in
130.900 MIN 5.1535
130.950 MAX 5.1570
Page 7-96
n Installation
Caution: Clean all deposits and debris from sealing sur-
faces A, B and C. Use Scotch-BriW 7446 or equivalent and
cleaning solvent to polish the surfaces. Due to the critical
machined tolerances, care should be taken not to remove
any additional material.
If surface C has cracks or signs of extreme wear, the
counterbore will require machining and the installation of shims
for the correct liner protrusion.
Cylinder liner shims are available as follows:
Cylinder Liner Shim Thickness

mm Part No. in
0.25 3924445 0.010

0.38 3924446 0.015
0.51 3924447 0.020
0.76 3924448 0.030
1.oo 3924449 0.040
Part No. 3623556, Counterbore Machining Tool

Machine the counterbore to the proper depth.
NOTE: Part No. 3823567, cutter plate, and Part No. 3823570,
cutter bit, must be used with the counterbore machining tool.
Clean the combustion deck with a gasket scraper or Scotch-

Brite@ 7448 cleaning pad or equivalent and diesel fuel or
solvent.
Page 7-97
Thoroughly flush the block with mineral spirits or cleaning

solvent.
Remove the shop rags and clean the crankshaft with a
cleaning solvent.
Blow the cylinder bores and crankshaft dry and wipe them
clean with a lint-free cloth.
Lubricate surfaces A and B with clean 15W-48 engine oil.
Use clean 15W-40 oil to coat the liner o-ring seals.

Install new o-ring seals on the liners.
I lno7i2
When reusing liners, install them in the same cylinder from

which they were removed and rotate them 45 degrees (l/8
turn) from their original position. When correctly installed, any
liner pitting should be positioned as illustrated so the pitted
surface is rotated away from the location where pitting
occurs.
Page 7-98
Part No. ST-1229, Cylinder Liner Driver, Leather Mallet

Install the liner in to the bore of the cylinder block.
NOTE: If the liner does not rest on the cylinder block count-
erbore seat, remove the liner. Inspect the counterbore seat and
liner for nicks, burrs, or dirt. Install the liner again.
Liner Clamps, Part No. 3822503

Use two cylinder head capscrews and position the two liner
clamps as illustrated.
Remove the clamps and repeat this procedure until all liners
have been clamped and released.
Liner Protrusion Gauge Part No. 3823495

Liner protrusion is the distance the liner protrudes above the
block face.
Measure the liner protrusion at four points 90 degrees apart.

mm in
0.025 MIN 0.001

0.122 MAX 0.0048
NOTE: If the liner protrusion varies more than 0.025 mm

[O.OOlOinch] for 180 degrees:
l Install and tighten the liner clamps again.
Page 7-9!
l Inspect the liner protrusion again.
NOTE: If the protrusion still varies more than 0.025 mm

[O.OOlOinch]:
l Remove the liner.
0@3
l Inspect the liner sealing edge for burrs, dirt or dam-
age.
l Replace the liner if it is damaged.
l Install the liner again.
l Inspect the liner protrusion.
Service Tip: If the out-of-limit condition is minimal, tolerance

stack-up may allow the protrusion limits to be obtained by
installing other new liners in the out-of-limit bore.
Page 7-100
NOTE: If the liner protrusion still does not meet the

specifications,machine the cylinder block liner bore for shims.
Use a feeler gauge to inspect the liner to block clearance at

the four block casting points.
Cylinder Liner to Block Clearance

mm in
NOTE: If the clearance is less than 0.229 mm to.009 inch]:

l Remove the liner.
l Inspect the liner and cylinder block for dirt or damage.

Page 7-101
l Replace the liner if it is damaged.

l Install the liner again.
Measure the liner bore for out-of-roundness at points “c”, “D”,

“E”, “F” and “G”. Measure each point in the direction “AA”
and “BB”. The bore must not be more than 0.08 mm [0.003
inch] out-of-round.
NOTE: If the liner bore is more than 0.08 mm [0.003 inch]

out-of-round:
@
l Remove the liner so the cylinder block liner bore can
be measured.
Install the pistons and connecting rods. Refer to Procedure @A

7-l 3.
@
NOTE: Do not interchange pistons from the original cylinder
location.
Page 7-102
Install the lubricating oil pan and suction tube. Refer to

Procedure 2-13.
Fill and vent the cooling system. Refer to Procedure l-01.
Fill the lubricating system with oil. Refer to Procedure 2-05.
19 mm
Start the engine and operate at idle.
Bleed the high pressure fuel lines.
Loosen the high pressure fuel line to allow entrapped air to
escape.
Tighten fuel lines.
Page 7-103
04B
82°C [180°F] and check for leaks and proper operation.
Vibration Damper - Replacement (7-I 6)

General Information
NOTE: There are two different design vibration dampers
used:
l Viscous damper (A) for certain engines rated at speeds
above 2500 RPM.
l Rubber element damper (B) for engines rated at
speeds below 2500 RPM. The rubber damper is
available either with or without the crankshaft adapter.
L ,
049
When diagnosing a vibration problem, check the damper for
obvious wobble when it is rotating.
Rubber Element Vibration Damper - Inspection

(in-Chassis)
Check the index lines (A) on the damper hub (B) and the
inertia member (C). If the lines are more than 1.59 mm [l/16
inch] out of alignment, replace the damper.
Inspect the vibration damper hub (B) for cracks. Replace the
damper if the hub is cracked.
Page 7-104
Inspect the rubber member for deterioration. If pieces of rubber

are missing or if the elastic member is more than 3.18 mm
[l/8 inch] below the metal surface, replace the damper.
NOTE: Also look for forward movement of the damper ring on
the hub. Replace the damper if any movement is detected.
Measure the vibration damper eccentricity by installing the dial

indicator on the gear cover as indicated.

Rotate the crankshaft and record the indicator movement.
Replace the vibration damper if the eccentricity exceeds 0.10
mm [0.004 inch] per 25.4 mm [l.O inch] of damper diameter.
Refer to replacement procedure in this section.
Install the dial indicator, as indicated, to measure wobble.

Push the crankshaft to the front or to the rear and zero the
indicator.
Page 7-105
Rotate the crankshaft 360 degrees, maintaining the position

of the crankshaft (either toward the front or the rear) in
relation to the cylinder block.
Record the total indicator motion.
Replace the damper if wobble exceeds 0.18 mm IO.007 inch]
per 25.4 mm [l.O inch] of radius. Refer to replacement
procedure in this section.
Viscous Vibration Damper - Inspection

Check the mounting web for cracks. Check the housing for
dents or raised surfaces. Replace the damper if any of these e
0623
defects are identified. Refer to replacement procedure in this
section.
Remove the viscous vibration damper. Refer to replacement ,

procedure in this section. @
Clean the damper with a solvent cleaner.
The viscous damper is filled with a silicone fluid. After many

hours of use, the silicone fluid may become thicker and
expand. To determine if the damper thickness is correct,
remove the paint from the damper in four locations on either
side of the damper. Measure and record the thickness of the
damper in four places. Measure the thickness 3.175 mm
El
to.125 inch] from the outside of the damper. Replace the
damper if its thickness varies by more than 0.25 mm to.010
inch].
0 00
0
00
-
Page 7-106
Spray the damper with spot check developer, Type SKD-NF or

its equivalent. Heat the damper in an oven (rolled lip side
down) at 93°C [2OO”FJfor 2 hours.

Remove the damper from the oven and check for fluid leakage.
If there is leakage, replace the damper.
Refer to replacement procedure in this section.
Removal
3/8 or l/2 inch Square Drive
Remove the fan drive belt.
15 mm
Remove the crankshaft adapter (1) and pulley (2), if equipped.
Page 7-107
18 mm, Part No. 3377371, Engine Barring Gear

Remove the vibration damper. Use the barring gear to hold RI
the crankshaft while removing the capscrews.
Installation
Lubricate the threads of the capscrews with a film of SAE
mm
-7
15W-40 engine oil.
18 mm, Part No. 3377371, Engine Barring Tool

Install the vibration damper.
Use the barring gear to hold the engine when tightening the
capscrews.
Torque Value: 200 Nom [14S ft-lb]
15 mm
Install the crankshaft adapter (1) and pulley (2), if equipped.
Page 7-108
3/S or l/2 inch Square Drive

Install the fan drive belt and driven accessories.
Gear Cover - Replacement (T-17)

Removal
Remove the tachometer drive cable.
Remove the tachometer drive.

69
l
3/S or l/2 inch Square Drive

Er Remove the fan drive belt.
Page 7-l 09

Remove the vibration damper and pulley. Hold the crankshaft RI
while removing the capscrews.
Remove the crankshaft oil seal dust shield, if used.
10 mm
Remove the gear cover RI
@ l

Clean the gasket sealing surface.
Hammer, Punch
Drive or press the seal out of the front cover.
Page 7-l 10
Clean the gasket sealing surfaces and the surface between the
oil seal and gear cover.
Inspect the gear cover for cracks, dents and other damage.
Caution: The seal lip and the sealing surface on the

crankshaft must be clean and free from all oil residue to
prevent seal leaks.
Thoroughly clean the seal contact area of the crankshaft.
Visually inspect the sealing surface of the crankshaft for wear.
If the crankshaft has a groove worn due to the oil seal, a wear
sleeve must be used to prevent seal leakage. Refer to
Procedure 7-19.
Installation
3824499 Installation Tool

Leave the plastic pilot installation tool in the lubricating oil seal.
Position the seal on the service tool, Part No. 3824499, with the
lubricating oil seal dust lip facing outward.
NOTE: Properly support the front cover lubricating oil seal

flange to prevent damage to the lubricating oil seal and front
cover.
Press the lubricating oil seal into the front cover from the back
side of the cover toward the front side of the cover.
Press the lubricating oil seal until the service tool bottoms
against the front cover.
Page 7-l 11
Apply a thin (2 mm) bead of sealant, Part No. 3823484, to

both sides of the front cover gasket.
NOTE: Do not remove the plastic seal pilot tool from the
lubricating oils seal at this time. Use the plastic seal pilot tool
to guide the seal on the crankshaft.
Install the gasket and front cover on the engine.
0%
Tighten the gear cover capscrews.
NOTE: The capscrews must be torqued within 15 minutes
after applying the sealant to the gasket.
Remove the plastic seal pilot tool from the crankshaft.
Install the crankshaft oil seal dust shield, if used, as follows:

l Push the dust shield onto the crankshaft with the part
number facing out away from the engine.
l The dust shield must contact the oil seal.
NOTE: No lubrication is required for installation.

Install the vibration damper and pulley.
Use the barring gear to hold the crankshaft while tightening @@A
the capscrews.
@
Torque Value: _
Vibration Damper: 200 N*m [148 ft-lb]
Pulley to Vibration Damper: 77 N*m [57 ft-lb]
Page 7-l 12
3/8 or l/2 inch Square Drive

Install the fan drive belt.
Install the tachometer drive and cable.

Install the driven accessories in the reverse order of removal.
Operate the engine 5 to 10 minutes to check for leaks and

proper operation.
Seal, Front Crankshaft - Replacement (7-

18)
General Information
The front crankshaft seal is mounted in the front gear cover. A
double lipped Teflon seal is used. The sealing surface on the
crankshaft must be clean and dry during assembly.
NOTE: For engines operating in extremely dusty environments,
a dust shield (1) is used to keep debris from entering the seal
and causing premature wear to the oil seal and crankshaft.
Page 7-113
Before removing the gear cover or oil seal, clean the front
area of the engine and visually inspect for leaks from the
gear cover gasket and seal area. If the seal is leaking, it will
be necessary to remove the gear cover for seal replacement.

NOTE: Since the gear cover has to be removed to replace
the crankshaft seal, the instructions are included in Proce-
dure 7-17, Gear Cover Replacement.
Wear Sleeve, Front Crankshaft -

Replacement (7-19)
Removal
Remove the fan drive belt, vibration damper, gear cover and
seal. Refer to Procedure 7-17.
Hammer and Chisel

Caution: Do not nick or gouge the crankshaft with the
Use a hammer and a chisel that is only as wide as the wear
sleeve. Make one or two chisel marks across the wear
sleeve. This will expand the wear sleeve allowing the sleeve
to be removed.
Page 7-l 14

Clean the crankshaft seal area.
Inspect the crankshaft at the oil seal area for dirt, nicks, chisel
marks, scratches, rust or corrosion, or other damage that
would prevent a proper wear sleeve installation.
Installation
Part No. 3823908, Crankshaft Front Wear Sleeve installation
Tool
Use the driver to install the wear sleeve to the correct position
on the crankshaft. The kii consists of the following:
Ref No Description QtY

Driver
Spacer
Bolt (Ml 4x1.50x60 mm)
Hair Pin Cotter
Apply a thin coat of 15W-40 engine oil to the driver inside

diameter and capscrew threads.
Page 7-l 15
Position the chamfered end of the wear sleeve onto the end
of the crankshaft.
Position the counterbore end of the driver onto the wear

sleeve.
Install two capscrews (without spacers or hair pin totters)

through the driver and into the crankshaft capscrew holes.
Align the wear sleeve and driver perpendicular with the
crankshaft. Tighten the capscrews “finger tight”.
Alternately tighten the capscrews until the sleeve is installed

to a depth of approximately 16 mm IO.625 inch].
NOTE: To prevent damage to the wear sleeve, do not
exceed l/2 revolution of each capscrew.
Approximate torque value: 20 Nern [15 ft-lb]
Page 7-l 16
Remove the capscrews and install a spacer on each

capscrew. Install the two capscrews again.
Continue to alternately tighten the capscrews unrll me Dorrom

of the driver contacts the end of the crankshaft.
Remove the driver. Use the hair pin corrers 10 secure me

capscrews and spacers to the tool during storage.
Clean the wear sleeve and crankshaft of any excess lu-

bricate.
NOTE: The wear sleeve and oil seal mating surface must be
clean and dry to be sure of proper oil sealing.
Page 7-l 17
Install the gear cover, vibration damper and fan drive belt.
Gear Housing - Replacement (7-20)

General Information
The gear housing provides a support for the injection pump,
timing pin, and the accessory drive gear, if used.
Gear Train
The gear train consists of the crankshaft gear, lubricating oil
pump drive and idler gear, camshaft gear, fuel pump drive
gear and accessory drive gear, if used.
Noise emitted from the gear housing can indicate worn or

damaged gear teeth or excessive gear back lash.
Page 7-l 18
Excessive gear backlash can affect engine timing and engine

performance.
Refer to the applicable sections in this manual to measure
the gear backlash and check gear tooth wear.
Removal
Remove the rocker assemblies and push rods. Refer to
Procedure 7-08.
Remove the fan drive belt, vibration damper and gear cover.
Remove the fuel transfer pump. Refer to Procedure 5-04.
Remove the fuel injection pump. Refer to Procedure 5-10.
Remove the camshaft and tappets. Refer to Procedure 7-24.
Remove the accessory drive or air compressor, if equipped.
15 mm
Support the front of the engine and remove the front engine
mount.
Page 7-l 19
10 mm
Loosen all the oil pan mounting capscrews four to five turns. •l
Remove the four front oil pan capscrews which secure the oil
pan to the gear housing. @
Caution: Use extreme care when releasing the oil pan
gasket from the gear housing to prevent damage to the
gasket. If the gasket is damaged, it may be necessary to
remove the oil pan and replace.the gasket. Refer to
A
Procedure 2-l3.
Insert a feeler gauge or a shim stock between the gear
housing and the oil pan gasket. Move the feeler gauge or
shim stock back and forth to release the gasket from the
gear housing.
10 mm
Remove the gear housing capscrews.
Plastic Hammer
Remove the gear housing.

Visually inspect the gear housing for cracks or damaged
sealing surfaces.
Page 7-120
Inspect the timing pin housing and pin for damage.

NOTE: Do not remove the timing pin assembly unless it is
damaged or leaking, or the gear housing is being replaced.
7/16 inch
NOTE: If the gear housing is being used again:
Remove the pipe plugs from the oil drillings.
Nylon Brush
Use solvent and a nylon bristle brush to clean the oil
drillings. Dry with compressed air.
15 mm
Visually inspect the fuel pump mounting studs for damage.
To install or remove the fuel pump studs, use two nuts
locked together on the stud.
Page 7-121
Clean the gasket surface of the cylinder block.
Installation
7/10 inch
Coat the pipe plugs with pipe sealant and install.
Do not over-tighten.
15 mm
If the fuel pump studs are damaged or bei# installed in a
new housing, coat the threads with Loctite 242 and use
two nuts locked together to remove and install.

dataplate and install on the new housing. Refer to Procedure
7-21.
Page 7-122
If removed, install the two gear housing dowel pins.

The tapered end of the dowel fiis into the cylinder block;
drive the pin to the bottom of the hole.
Inspect the oil pan gasket. If it is not torn, apply Part No.
3823494, Three Bond RTV sealant around the capscrew holes
and at the joint of the gear housing.
NOTE: The gear housing and lubricating oil pan capscrews
must be torqued within 15 minutes after applying the sealant.
If the gasket is torn, it may be repaired. Cut the torn gasket

off even with the front of the engine block.
most
m
Use the old gasket as a pattern and cut the front section of
a new gasket to the same size.
0
O)_
0
0 0
0 0
0 0 0
0
0
Page 7-l 23
q
Clean the sealing surfaces and coat the new gasket on both
sides with Part No. 3823494, Three Bond RTV sealant. B
NOTE: The gear housing and lubricating oil pan capscrews
must be torqued within 15 minutes after applying the sealant.
Use common thread or a very fine wire to hold the new

gasket splice in position as illustrated.
Mark and trim the new gear housing gasket, as illustrated.
3O/y_
1.59 mm [l/16 inch] 0
0
0 0
0 0
0 0
0
0
Position the gasket on the alignment dowels.

Page 7-124
10 mm
Carefully install the gear housing and capscrews. Make sure
both gaskets are in place.
Torque Value:
capscrews 24 Nom [18 ft-lb)
K2 capscrews 60 Nom [44 ft-lb]
Caution: If a new housing or other than the original
housing is installed, the timing pin assembly must be
accurately located. Refer to Procedure 7-07.
Start two oil pan capscrews in the holes not being used to
tie the gasket in place.
Remove the thread or wire holding the gasket in place.
10 mm
Install the remaining two capscrews and tighten all oil pan
mounting capscrews.
Page 7-l 25
Lubricate the camshaft and thrust plate with LubriplateTM

105.
Install the camshaft/thrust plate.

Make sure the timing marks on the camshaft and
camshaft gears are aligned.
Install the thrust plate capscrews.

Torque Value: 24 Narn [18 ft-lb]
Verify the camshaft has proper backlash and end play. End
play is controlled by the thickness of the thrust plate and the
groove in the camshaft.
Camshaft End Clearance (A)

mm in
0.12 MIN 0.0047
0.46 MAX 0.018
Camshaft Gear Backlash Limits (B)

mm in
0.08 MIN 0.003
0;33 MAX 0.013
Page 7-126
Timing Pin Relocating

NOTE: The location of the timing pin assembly on the gear
housing is critical for correct engine adjustments. If the original
Engine gear housing is being installed, it is unnecessary to relocate the
Timing Pin
timing pin. If a new housing is being installed, refer to
Procedure 7-07 for timing pin installation and adjustment.
LIr HowIng -___-
Complete the installation of the removed components:

l Accessory drive or air compressor, Procedure 4-05.
0 Fuel injection pump, Procedure 5-10.
l Fuel transfer pump, Procedure 544.
l Valve tappets, Procedure 7-24.
l Fan drive belt, vibration damper and gear cover,
Procedure l-03.
l Rocker assemblies and push rods, Procedure 7-05.
l Valve cover, Procedure 7-02.
Operate the engine at idle for 5 to 10 minutes to check for

leaks and proper operation.
Engine Dataplate - Replacement (7-21)

The engine dataplate shows specific information about the
engine. The engine serial number (ESN) and Control Parts List
(CPL) provide information for ordering parts and service needs.
The dataplate must remain with the engine. If the gear housing
is replaced, remove the dataplate and install it on the new
housing.
Page 7-127
Removal
Remove the rivets that secure the dataplate to the gear
housing.
Installation
Caution: If the rivets are driven in too far, they will cut
through the dataplate. A
2.0 mm Drill Bit

If the dataplate is loose or has been damaged, drill new
holes and attach with new rivets. Mark the drill bit at 6.0 mm
[0.236 inch] to avoid drilling too deep into the gear housing.
Page 7-128
Drill the dataplate, taking care not to destroy any information

printed on the dataplate.
Camshaft - Replacement (7-22)

General Information
The camshaft is gear driven from the crankshaft. A replaceable
bushing is used for each of the camshaft journals.
The camshaft has lobes to operate the intake and exhaust

valves and a special lobe to drive the fuel transfer pump. The
valve lobes contact the valve tappets which operate the valves.
The plunger of the fuel transfer pump rides directly against the
special lobe of the camshaft. The profile of the cam lobes is
the same for all S6D114e-1 Series engines.
Page 7-129
The tappets are mushroom shaped. The offset position of the I

tappet against the camshaft lobe causes the tappet to rotate
as it lifts the push rod.
&
I
0@
Loose rocker levers and the need to reset the valve clear-
ance frequently can indicate camshaft lobe or tappet wear. If
an inspection of the levers, valve stems and push rods does
not show wear, then tappet and/or camshaft lobe wear can
be suspected.
Caution: Anytime a new camshaft is installed, new tap-

pets must also be installed. A
0423
The camshaft lobes can be visually inspected after removing
the oil pan. Similarly, the face of the tappet can be
inspected after removing the push rods and lifting the tappet.
A severely damaged camshaft journal(s) can generate small

metal particles which will be found in the oil pan and filter
and will be indicated as “iron” in an oil analysis. As the
clearance in the journal(s) increases, a small decrease in oil
pressure may be detected.
Page 7-130
Removal
Remove the following components:
l Rocker assemblies, Procedure 7-05.
l Push rods, Procedure 7-08.
l Vibration damper, Procedure 7-16.
l Gear cover, Procedure 7-17.
l Fuel pump drive gear, Procedure 5-10.
l Fuel transfer pump, Procedure 5-04.
Part No. 3822513, Tappet Removal Tool Kit

Lii the tappets so the camshaft can be removed.
Ref. No. Description QtY.

1 Valve Tappet Tray 1
2 Dowel Rods 12
3 Rubber Bands 12
4 Nylon String 1
Push a wooden dowel rod into each tappet. It may be

necessary to push the dowel into the tappet with a soft face
hammer.
Pull each valve tappet up until it makes contact with the
cylinder block. Put a rubber band around two dowels to hold
the tappets off the camshaft. Refer to Procedure 7-24.
22 mm (PES.A Pump), 27 mm (PES.MW Pump), 30 mm

(PES.GP)
Remove the nut and washer from the fuel pump drive gear.
Page 7-131
Part No. 3824489, Fuel Pump Gear Puller

install the puller on the drive gear. Tighten the capscrews •l
until the gear is loose on the fuel pump drive shaft.
Remove the fuel pump drive gear.
NOTE: If the camshaft or gear are being replaced due to

gear train noise, check the gear backlash.
NOTE: Excessive gear backlash can be caused by worn
camshaft bushings.
Position an indicator on a tooth of the camshaft gear.
Note the camshaft gear backlash and end clearance. Mark

the camshaft gear and crankshaft gear for further analysis if
backlash or end clearance exceeds limits.
Camshaft End Clearance (A)

mm in
0.12 MIN 0.0047
0.46 MAX 0.018
Camshaft Gear Backlash Limits (B)

mm in
0.08 MIN 0.003

0.33 MAX 0.013
Page 7-132
0a3
Rotate the crankshaft to align the timing marks before trying to
remove the camshaft.
13 mm
Remove the camshaft thrust plate capscrews.
Remove the camshaft thrust plate.
Remove the camshaft from the cylinder block.

NOTE: Rotate the camshaft as it is being removed. Use
extreme care to be sure the camshaft bushings are not
damaged during the camshaft removal process.
Page 7-133
A
Clean the camshaft with steam or solvent. Dry with com-
pressed air.
q
\
Caution: After the camshaft has been steam cleaned, do

not touch the machined surfaces with bare hands, this
will cause rust to form. Lubricate the camshaft with clean
A
15W-40 engine oil before handling.
0a3
Visually inspect the fuel transfer pump lobe, valve lobes and
bearing journals for wear, cracking, pitting, scratches and
other damage.
The following criteria defines the size of the pits, allowable
wear and edge deterioration of the chilled iron camshaft
lobes:
I lmnsl
0a9
Pitting:
A single pit should not be greater than the area of a 2 mm
jO.079 inch] diameter circle.
Page 7-134
@A lr!terconnection of pits is not allowable and is treated as one

@ P+
0
The total pits, when added together, should not exceed a
423 circle of 6 mm [0.236 inch].
0
Only one pit is allowed within + or - 20 degrees of the nose
623 of the camshaft lobe.
Measure across the peak of the lobes.
Camshaft Lobe Wear Limits (Minimum)

mm in
51.774 Intake Valve 2.038
51.596 Exhaust Valve 2.031
41.310 Fuel Transfer Pump 1.626
Page 7-135
Camshaft Journal Diameter

mm in
59.962 MIN 2.3607

60.013 MAX 2.3627
NOTE: Replace the camshaft if the outside diameter of any

bearing surface is less than 59.962 mm [2.3607 inch].
Edge Deterioration (Breakdown)

The area of edge deterioration should not be greater than
the equivalent area of a 2 mm to.079 inch] circle within + or
0QB
- 20 degrees of the nose of the camshaft lobe.
E;TF
Outside of the + or - 20 degrees of the nose of the
camshaft lobe, the areas of edge deterioration should not be
than the equivalent area of a 6 mm [0.236 inch]
0a!3
Page 7-136
This illustration shows normal grain pattern and a casting flaw

within the nose area. Both of these conditions are acceptable
for reuse.
The following three illustrations show wear patterns that are not
acceptable for reuse:
Measure the camshaft bores. Use a bore gauge. The bores

must be measured in two positions. Take a second
measurement 90 degrees from the first measurement.
Camshaft Bore Diameter (Maximum)

mm in
64.01 (Without Bushing) 2.520
60.12 (Wiih Bushing) 2.367
Page 7-137
If the bushing diameter is more than 60.12 mm [2.367 inch],

the camshaft bushings must be replaced.
NOTE: The engine must be removed for bushing replace-
ment, refer to Procedure 9-01.
Refer to the 6D114E-1 Series Shop Manual for camshaft
bushing replacement.
0d-
Camshaft Gear Inspection
Visually inspect the gear teeth for wear and damage. Look
for cracks at the root of the teeth. If the gear is damaged, it
must be replaced. Refer to Procedure 7-23.
Installation
Lubricate the camshaft bores with LubriplateTM 105.
Service Tip: The crankshaft should be positioned so the No.
1 cylinder is at approximately TDC, so the camshaft does
not hit the crankshaft counterweight during installation.
Lubricate the cam s&ft journals and lobes, and the thrust
plate with Lubriplate 105.
Page 7-138
+q& Position the camshaft/cam gear assembly into the cylinder

* S block up to the last journal.
a
0%
0
Align the timing marks on the camshaft with the timing mark on
a9 the crankshaft.
A Caution: Make sure the camshaft assembly does not drop

on your fingers when installing the thrust plate.
Install the camshaft thrust plate.
2**
0%
13 mm
Install the camshaft thrust plate capscrews.
Page 7-139
Put a dial indicator on the camshaft gear and check the gear
backlash between the camshaft gear and the crankshaft gear.

mm in
0.08 MIN 0.003

0.33 MAX 0.013
NOTE: The gears must be replaced if the backlash is greater

than the above limit.
NOTE: Excessive gear backlash. can be caused by worn
camshaft bushings.
Measure camshaft end clearance with a dial indicator.

End clearance is controlled by the thickness of the thrust
plate and the groove in the camshaft.
Camshaft End Clearance

mm in
0.12 MIN 0.0047
0.48 MAX 0.0181
NOTE: If the camshaft end clearance is greater than the

above limit, the thrust plate must be replaced.
Remove the wooden dowel rods from the valve tappets.
Install all parts that were removed:

Page 7-140
0
Fill the engine with oil and coolant.
423 Operate the engine until the coolant temperature reaches 82°C
[18O”F] and check for leaks and proper operation.
A Camshaft Gear - Replacement

Removal
(7-23)
A camshaft gear removal/installation tool, Part No. 3823588, is

available for replacing the camshaft gear in restricted areas
where the camshaft cannot be removed from the engine.
Follow the directions included with the tool.
Caution: Place a wooden block under the camshaft to avoid
damages as the camshaft drops free from the cam gear.
Place the camshaft and gear assembly in a hydraulic press.
Press the gear off the camshaft.
Push the camshaft from the gear.

Remove the camshaft dowel pin.

Visually inspect the camshaft gear for cracks, chipped, or
broken teeth.
Inspect the bore of the gear for fretting or burrs.
NOTE: If the fretting, burrs, or raised material cannot be
removed with Scotch-Brit@ 7448 or equivalent, replace the
gear.
Page 7-141
06B
Inspect the gear keyway for burrs.
Remove burrs with Scotch-B&9 7448, or equivalent.
q
NOTE: If the keyway is damaged or the burrs cannot be
removed, the gear must be replaced. B
Measure the camshaft gear bore inside diameter.
Camshaft Gear Bore I.D.

mm in
41A80 MIN 1.633
41 so5 MAX 1.634
0a!3
Visually inspect the camshaft nose for fretting or burrs.
NOTE: If fretting or burrs cannot be removed with Scotch-
Brite@7448, or equivalent, replace the camshaft.
Measure the camshaft gear journal outside diameter.
Camshaft Gear Journal O.D.

mm in
41.56 MIN 1.636

41.58 MAX 1.637
Page 7-142
Measure the camshaft thrust plate thickness.
Camshaft Thrust Plate Thickness

mm in
9.34 MIN 0.368

9.58 MAX 0.377
Installation
Use a leather hammer to install the camshaft gear dowel pin.
NOTE: The steel camshaft, Part No. 3923388, uses a dowel
pin. The cast iron camshaft, Part No. 3924471, uses a
woodruff key.
Lubricate the camshaft gear journals with LubriplateTM 105.
Steel Camshaft Gear

Warning: Use insulated gloves, Part No. 3823730, when
handling heated parts. Hot parts can cause serious
personal injury.
Heat the gear in an oven for a minimum of 45 minutes, but
not longer than 6 hours.
Temperature: 177” C [350” F]
Page 7-143
Austempered Camshaft Gear

Heat the gear in an oven for 45 minutes.
Caution: The gear will be permanently distorted if over-
heated. The oven temperature should never exceed the
specification.
Temperature: 149”C [300”F]
Caution: To prevent engine damage, the timing marks

and gear part number must be facing away from the
camshaft when the gear is installed.
A
Caution: Keep the camshaft in a vertical position with the
gear up until the gear has cooled. Do not use water to
reduce the cooling time. Using water will crack the gear.
A
NOTE: The gear must be installed within 30 seconds after it
is removed from the oven.
Remove the gear from the oven. Align the keyway in the
gear with the dowel pin in the camshaft and install the gear
on the camshaft. Be sure the gear is seated against the
camshaft shoulder.
Valve Tappet - Replacement (7-24)

General Information
The valve tappets are mushroom shaped. The offset position
of the tappet against the camshaft lobe causes the tappet to
rotate as it lifts the push rod.
The bail end of the push rod fiis into the ball socket in the
operates.
Page 7-144
Loose rocker levers and the need to reset the valve clearance
frequently can indicate camshaft lobe or tappet wear. If an
inspection of the levers, valve stems and push rods does not
show wear, then tappet and/or camshaft lobe wear can be
suspected.
Removal
Replacement (With Oil Pan Installed)
Remove the following components:
l Camshaft, Procedure 7-22.
Part No. 3822513, Tappet Removal Tool Kit

The valve tappets can be removed with the oil pan installed by
using Part No. 3822513, tappet removal tool kit. The kii
consists of:
-
Ref No Description sty
1 Valve Tappet Tray 1
2 Dowel Rods 12
5 Rubber Bands 12
4 Nylon String 1
NOTE: It is necessary to remove the camshaft to replace the

valve tappets; therefore, the tappets will be raised and secured
with the dowel rods. Refer to Procedure 7-22 for camshaft
replacement.
NOTE: Number each tappet with the cylinder number position
as it is removed. The tappets must be installed in the same
position as removed.
Page 7-145
Insert the tray (1) to the full length of the camshaft bore.
Make sure the tray is positioned so it will catch the tappet

when the wooden dowel is removed.
NOTE: Only remove one tappet at a time.

Remove the rubber band (3) from the two companion
tappets, securing the tappet not to be removed with the
rubber band.
Pull the wooden dowel from the tappet bore allowing the
tappet to fall into the plastic tray.
Page 7-146
NOTE: The tappet must be in the horizontal position to remove

it from the camshaft bore. When the tappet is dropped into the
tray, it should fall into the horizontal position. If it does not,
gently shake the tray to allow the tappet to fall over.
Carefully pull the tray and tappet from the camshaft bore and
69
l
remove the tappet. Repeat the process until all tappets are
removed.
Valve Tappet Removal (With Oil Pan Removed)

10 mm
Remove the oil pan. Refer to Procedure 2-14.

E2l Rotate the crankshaft to access the tappets.
NOTE: Only four tappets are accessible at one time.
The crankshaft must be rotated three times to access all of
the tappets.
Page 7-147
Remove the rubber bands from the wooden dowels that are
used to hold the tappets up during camshaft removal/
installation. @@
NOTE: Only remove the rubber bands from the accessible
tappets.
Remove the accessible tappets/dowels.
Remove the tappets from the wooden dowels.
I TROW

Clean the tappets with solvent and dry with compressed air.
q
B
Caution: Any time a now camshaft is installed, new tap-
pets must also be installed. A
Page 7-148
Pit marks on the tappet face are acceptable.

The following criteria defines the size of the pits allowed:
A single pit cannot be greater than 2 mm [0.078
inch].
Interconnection of pits is not allowed.
u. Total pits when added together should not exceed 6
mm [0.236 inch] diameter or a total of 4 percent of
the tappet face.
4. No pitting is allowable on the edges of the wear
face of the tappet.
Inspect the socket, stem and face for excessive wear, cracks,
concavity and other damage.
Reuse Guidelines:
(A) - Normal wear

(B) and (C) - Abnormal wear - Do not reuse
Tappet Face Concavity (Maximum)

mm in
0.025 MAX 0.001
Measure the valve tappet stem.
Tappet Stem Diameter
A mm in
15.93 MIN 0.627
60 mm 15.98 MAX 0.629
28mm
t T+ v
moan
Installation
Valve Tappet Installation (With Oil Pan Installed)
Insert the plastic tray the full length of the camshaft bore.
Page 7-149
Insert the installation tool down through the tappet bore and
into the plastic tray.
Carefully pull the plastic tray/installation tool out through the

front of the camshaft bore.
Lubricate the tappets with Lubriplate 105.

NOTE: If the tappets to be installed have been previously
used, each tappet must be installed in the same position as
it was removed from the engine.
Insert the installation tool into the tappet bore.

NOTE: To aid in removing the installation tool after the
tappet is installed, move the tool in and out of the tappet
bore several times before installing the tappets.
Page 7-150
Pull the installation tool and tappet through the camshaft

bore and up into the tappet bore.
If difficulty is experienced in getting the tappet to make the

bend from the tray up to the tappet bore (due to the webbing
of the block), pull the tray out enough to allow the tappet to
drop down and align itself, then pull the tappet up into the
bore.
TR0m
After the tappet has been pulled up into position, turn the tray
over in the camshaft bore so that the bottom surface of the
tray is against the bottom face of the tappet. This will hold the
tappet in place.
Remove the installation tool from the tappet.

Insert a wooden dowel rod into the top of the tappet. Wrap
rubber bands around the wooden dowels to secure the
tappets.
Repeat this process until all tappets have been installed.
Remove the dowel rods and release the tappets in the tappet
bores.
Page 7-151
Valve Tappet Installation (With Oil Pan Removed)

Lubricate the tappets with LubriplateTM 105.
Insert the wooden dowel rods used for holding the tappets
up during camshaft removal/installation into the tappets.
NOTE: Only four tappets are accessible at a time which will

require rotation of the engine to install the remaining tappets.
Wrap rubber bands around the wooden dowels to secure the

tappets.
Repeat this process until all tappets have been installed.
Remove the dowel rods and release the tappets in the tappet
bores.
Page 7-152
10 mm
Install the oil pan. Refer to Procedure 2-13.
Install all components that were removed:

l Camshaft, Procedure 7-22.
Fill the engine with oil and coolant.

82°C [18O”F] and check for leaks and proper operation.
Crankshaft Gear - Replacement (7-25)

General Information
There are two different crankshaft gears used:
l Steel gear for engines with P7100 Bosch fuel
pumps.
l Austempered gear for engines without P7100 Bosch
fuel pumps.
Page 7-l 53
NOTE: The austempered gear can be replaced with the

engine in-chassis. The steel gear cannot be replaced in-
chassis. It will be necessary to remove the engine. Refer to
Procedure 9-01.
Removal
(Austempered Gear)
Remove the gear cover. Refer to Procedure 7-17.
Remove the valve cover and loosen all rocker lever adjusting
screws to remove the load on the camshaft.

Rotate the crankshaft and align the timing marks of the
camshaft and crankshaft gears.
Page 7-154
Use a felt tip marker to highlight the timing marks on the

gear train. Use the marker to make alignment marks on the
accessory drive gear and shaft.
Lock the fuel injection pump. Refer to Procedure 5-10.
Part No. 3823259, Fuel Pump Gear Puller

Remove the fuel pump drive gear and the accessory drive
gear. Refer to Procedure 5-10.
Remove the lubricating oil pump assembly. Refer to

Procedure 2-l 4.
Page 7-l 5
Part No. 3823585, Crankshaft Gear Splitter

Caution: Safety glasses are required when using this tool. RI
NOTE: Trying to accomplish this task with a cold chisel will
result in damage to the engine gear housing gasket surface. A
A
Caution: Use care to avoid damage to the polished
surfaces of the crankshaft by driving the point of the tool
into the crankshaft.
NOTE: Do not use gear splitter on steel gears.
Place the point of the chisel between two gear teeth.

Strike the splitter with a two or three pound steel hammer.
Repeat this step if necessary.
Remove the crankshaft gear.

NOTE: The camshaft gear will rotate slightly as the teeth
follow the gear helix.
c%
Q
Caution: Use great care to not disturb the position of the A

camshaft gear after the crankshaft gear has been re-
moved.
Caution: Do not damage the crankshaft when removing
the key.
Use a flat chisel and a hammer to remove the crankshaft
gear key.
04B
Visually inspect the crankshaft gear journal for burrs or
q
damage.
Remove any burrs with Scotch-Britee 7448, Part No.
\
3823258, or equivalent.
Page 7-156
l/-GA Measure the crankshaft gear bore inside diameter.

w Crankshaft Gear Bore I.D.
mm in
75.898 MIN 2.9661

75.923 MAX 2.9691
Measure the crankshaft gear fii area outside diameter.
Crankshaft Gear Fit Area O.D.

mm in
75.967 MIN 2.991
76.006 MAX 2.992
Installation
Use a leather hammer to install a new key in the crankshaft
keyway.
Caution: Do not exceed the specified time or temperature
when heating the crankshaft gear. The gear and teeth can
be damaged.
Heat the gear in an oven for a minimum of 45 minutes but
not more than 6 hours.
Temperature: 149°C [300”F]
Caution: Use insulated gloves, Part No. 3823730, when

handling heated parts. Hot parts can cause serious per-
sonal injury.
Caution: The timing mark (1) and pat-l number (2) on the
gear must be facing away from the crankshaft after the
gear is installed. Engine damage can result if the gear is
installed backwards.
Use LubriplateTM 105, or equivalent, to lubricate the outside
diameter of the crankshaft gear journal.
Remove the gear from the oven. Align the keyway of the
gear with the key in the crankshaft and install the gear within
30 seconds.
Page 7-l 57
NOTE: If the gear cools and stops on the crankshaft before

it is fully installed, use a driver to complete the installation.
NOTE: If any gears were rotated, it will be necessary to align e

the timing marks of the crankshaft and the camshaft gears.
Install the fuel pump drive gear.

Refer to procedure 5-10.
Install the accessory drive gear. Make sure to align the
marks that were made during removal.
0@A
Unlock the fuel injection pump.

Page 7-158
e Install the lubricating oil pump. Refer to Procedure 2-14.
e Install the gear cover. Refer to Procedure 7-17.
s$$S Adjust the valve clearance. Refer to Procedure 7-06.
e Install the valve cover. Refer to Procedure 7-02.

Fill the engine with oil and coolant. Refer to Procedures 2-05
and l-01.
Operate the engine at idle for 5 to 10 minutes to check for

leaks and proper operation.
Flywheel - Replacement (7-26)

Removal
Remove the vehicle drive line and transmission. Refer to the
Remove the clutch discs and the pressure plate.
NOTE: Use the barring gear, Part No. 3377371, to hold the
flywheel to prevent rotation.
Remove two capscrews 180 degrees apart. Install two

M12X1.25X90 mm guide pins.
two ‘T-handles” in the flywheel at points (1) and (2).
Remove the remaining six flywheel mounting capscrews.
Page 7-160

component.
Remove the flywheel from the guide pins.

Use a wire brush to clean the crankshaft pilot bore.
Use steam or solvent to clean the flywheel. Dry with
compressed air.
Visually inspect for nicks or burrs.

Use Scotch-BriW 7448, or equivalent, to remove small nicks
and burrs.
Warning: Do not use a cracked or resurfaced flywheel.

These can break, causing serious personal injury or prop-
erty damage.
Use the crack detection kii, Part No. 3375432, to check for
cracks in the flywheel. Follow the instructions provided with
the kit.
Page 7-161
Inspect the flywheel ring gear teeth for cracks and chips.
NOTE: If the ring gear teeth are cracked or broken, the ring
gear must be replaced. Refer to Procedure 7-27.
Installation
NOTE: Use a new pilot bearing when installing a new or
rebuilt clutch.
Use a mandrel and a hammer to remove the pilot bearing.
Use a Scotch-Brite@ 7448, or equivalent, to clean the pilot
bore.
Use a mandrel and hammer to install the pilot bearing.

NOTE: The pilot bearing must be installed even with the pilot
bore surface.
Install two M12X1.25X90 mm guide pins into the crankshaft

flange 180 degrees apart.
two ‘T-handles” into the flywheel at points (1) and (2).
Page 7-162
Visually inspect rear face of crankshaft and flywheel mounting

flange for cleanliness and raised nicks or burrs.
The component weighs 23 kg 150 Ibs] or more. To avoid
component.
Install the flywheel on the guide pins.
Lubricate the threads of the capscrews and the surface of

the washers with 15W-40 lubricating oil.
Install the six capscrews.

Remove the “T-handles” and guide pins.
Install the remaining capscrews into the holes from which the
guide pins were removed.
19 mm Socket, Torque Wrench, Part No. 3377371,

Engine Barring Gear
Hold the crankshaft when tightening the flywheel capscrews.
Tighten the capscrews in a star pattern.
Torque Value: 137 Nom [lo1 ft-lb]
Refer to the equipment manufacturer’s procedures to install
the transmission.
Page 7-163
Flywheel Bore Runout Measurement

Use the dial indicator gauge (l), Part No. 3375050, or its
equivalent and dial gauge attachment (2), Part No. ST-1325,
to inspect the flywheel bore (3) and the surface (4) runout.
Install the attachment to the flywheel housing.
Install the gauge on the attachment.
Install the contact tip of the indicator against the inside
diameter of the flywheel bore, and set the dial indicator at
“0” (zero).
Use the barring gear, Part No. 3377371, to rotate the

crankshaft one complete revolution (360 degrees).
NOTE: The total indicator reading (RR) must not exceed
0.127 mm [0.0050 inch].
NOTE: If the TIR is greater than the specification, do the

following:
l Remove the flywheel.
l Inspect the flywheel mounting surface for dirt or

damage.
Page 7-164
l Inspect the crankshaft for dirt or damage.

NOTE: Refer to the 6D114E-1 Series Shop Manual to replace
the crankshaft.
l install the flywheel, and inspect the bore runout

again.
l Replace the flywheel if the runout does not meet

specifications.
Flywheel Face Runout Measurement

Install the contact tip of the indicator against the flywheel
face, as close to the outside diameter as possible, to inspect
the face (1) runout.
NOTE: Push the flywheel forward to remove the crankshaft
end clearance. Adjust the dial on the indicator until the
needle points to “0” (zero).
Page 7-165
Use the engine barring gear, Part No. 3377371, to rotate the
crankshaft one complete revolution. Measure the flywheel
runout at four equal points on the flywheel.
NOTE: The flywheel must be pushed toward the front of the
engine to remove the crankshaft end clearance each time a
point is measured.
The total indicator reading (TIR) must not exceed the

following specifications:
Flywheel Radius (A) Maximum (TIR) of Flywheel Face
mm in mm in
203 a 0.203 0.008

254 10 0.254 0.010
305 12 0.305 0.012
356 14 0.356 0.014
406 16 0.406 0.016
If the flywheel face runout is not within specifications, remove

the flywheel. Check for nicks, burrs, or foreign material
between the flywheel mounting surface and the crankshaft
flange.
Install the clutch discs, pressure plate, transmission and drive

line (ii equipped) in reverse order of removal. Refer to the
NOTE: Align the universal joints on each end of the drive
shaft to prevent vibratipn.
Page 7-166
Flywheel Ring Gear - Replacement (7-27)

Removal
Caution: Do not use a cutting torch to heat the ring gear,
the flywheel can be damaged.
Heat the outside diameter of the ring gear with a heating
torch.
Warning: Wear eye protection while driving the gear from
the flywheel.
Use a blunt chisel or brass drift and hammer to remove the
gear from the flywheel.
Installation
NOTE: Do not attempt to install the ring gear without using
heat.
Use an oven to heat the new ring gear. Heat the ring gear
for a minimum of 30 minutes in a preheated oven. Do not
heat the ring gear for more than 6 hours.
Temperature: 177” C [350”F]
NOTE: Do not exceed the specified time or temperature. The
metal hardness will be changed.

NOTE: The gear must be installed so the bevel on the teeth
is toward the crankshaft side of the flywheel.
Remove the gear from the oven, and install it on the flywheel
before it cools. Allow the air to cool the gear. Do not use
water or oil to reduce the cooling time.
NOTE: If an oven is not available, use a heating torch to
heat the inside diameter of the new ring gear to 177’C
[35O”F]. Use a TempilskW crayon or its equivalent to check
the gear temperature before installing it on the flywheel.
Flywheel Housing - Replacement (7-28)

Removal
Remove the transmission, clutch, and all related components.
Refer to the manufacturer’s instructions.
Remove the flywheel. Refer to Procedure 7-26.
Page 7-l 67
A
16 mm
Caution: Place a wooden block the width of the oil pan
between the floor jack and oil pan to prevent damage to
the engine.
Use a floor jack or a suitable lifting fixture to support the rear
of the engine.
Disconnect the battery cables.
Remove the starting motor. Refer to Procedure 6-02.
I I TM666
Remove the capscrews and both rear engine mounts.
Remove capscrews (1) and (2) and install two M12-1.75X100

mm guide pins.
Remove the remaining capscrews.

Q
The component weighs 23 kg [50 lb] or more. To avoid C%
component.
Use a rubber hammer-to loosen the flywheel housing.
Remove the flywheel housing.
Page 7-168
c%
0
Remove the o-ring from the rear seal cover.

A can cause serious personal injury.
q
\ Use steam or solvent to clean the flywheel
compressed air.
housing. Dry with
Visually inspect all surfaces for nicks, burrs, or cracks.

Use a fine crocus cloth to remove small nicks and burrs.
Inspect all threaded capscrew holes for damage.

Repair or replace the housing if the capscrew holes are
damaged.
Page 7-l 69
Installation (Dry Clutch Application)

Install two M12X1.75XlOO mm guide pins into the cylinder
block to help support and align the housing during in-
stallation.
NOTE: Some dry clutch applications require a sealing ring
on the seal housing. Install the sealing ring in the machif)Sld
surface of the seal housing and lubricate with Lubriplate
105.
Visually inspect the rear face of the cylinder block and

flywheel housing mounting surface for cleanliness and raised
nicks or burrs.
Install the flywheel housing making sure the housing is

positioned on the alignment dowels and guide pins.
NOTE: Be sure the sealing ring is not damaged during
installation.
Remove the two M12X1.75XlOO mm guide pins.
15 mm
Install and tighten the mounting capscrews using the pattern
shown in the chart.
Page 7-170
Concentricity - Checking
Part No. ST-1325, Dial Gauge Attachment
Attach a dial indicator to the crankshaft. The dial indicator can
be mounted by any method that holds the extension bar of the
indicator rigid so it does not sag. If the bar sags or the
indicator slips, the readings obtained will not be accurate.
Position the indicator in the 6:00 o’clock position and zero the
gauge.
Part No. 3377371, Engine Barring Gear.

E2l Slowly rotate the crankshaft. Record the readings obtained at
the 9:00 o’clock, 12:00 o’clock, and 3:00 o’clock positions as
@ [a], [b], and [c] in the concentricity work sheet. Recheck zero
at the 6:00 o’clock position.
The values for [a], [b], and [c] could be positive or negative.
Refer to the accompanying figure to determine the correct sign
when recording these values.
0
Rotate the crank shaft until the dial indicator is at the 12:00
629 o’clock position and zero the gauge.
NOTE: Do not force the crankshaft beyond the point where the
bearing clearance has been removed. Do not pry against the
flywheel housing. These actions could cause false bearing
clearance readings.
Use a pry bar to raise the rear of the crankshaft to its upper
limit. Record the value as [d] in the concentricity work sheet.
This is the vertical bearing clearance adjustment and will always
be positive.
Page 7-171
Use the concentricity work sheet to determine the values for

the ‘total vertical’ and ‘total horizontal’ values. Concentricity Worksheet
The ‘total horizontal’ is equal to the 9:00 o’clock reading, [a],
minus the 3:00 o’clock reading, [cl.
The ‘total vertical’ is equal to the 12:OOo’clock reading, [b],
plus the bearing clearance, [d].
Example:
6:00 o’clock = ref = 0
9:00 o’clock = [a] = 0.004 inc
12:OOo’clock = [b] = 0.003 inch
3:00 o’clock = [c] = -0.002 inch
Using the work sheet and the numbers from the example,
the ‘total horizontal’ value = 0.006 inch and the ‘total vertical’
value = 0.005 inch.
Mark the ‘total horizontal’ value on the horizontal side of the

chart and the ‘total vertical’ on the vertical side of the chart.
Use a straight edge to find the intersection point of the ‘total
horizontal’ and ‘total vertical’ values. The intersection point
must fall within the shaded area for the flywheel housing
concentricity to be within specification.
Use the ‘total horizontal’ and ‘total vertical’ values from the
previous example, the intersection point falls within the
shaded area. Therefore, the flywheel housing concentricity is
within specification.
If the intersection point falls outside the shaded area, the ring
dowels must be removed and the housing repositioned.
NOTE: The ring dowels are not required to maintain con-
centricity of the housing/ the clamping force of the cap-
screws holds the housing in position.
After the ring dowels are discarded, install the flywheel
housing on the engine.
To position the housing, tighten the capscrews enough to
hold the flywheel housing in place, but loose enough to
enable small movement when struck lightly with a mallet.
Check the concentricity again by following the above
Page 7-172
Use the pattern shown in the chart to install and tighten the
mounting capscrews.
Install the rear engine mounts.

install the flywheel. Refer to Procedure 7-26.
Install the clutch, transmission, and all related components.
Refer to the manufacturer’s instructions.
16 mm
Install the starting motor.
Install and tighten the starting motor capscrews.
Connect the battery cables.
Installation On/et Clutch Application)

Perform all the steps in the procedure for dry clutch installation
in addition to the following:
Page 7-173
Coat the flywheel housing drain plug with pipe sealant and
install into the hole in the bottom of the flywheel housing.
Tighten the plug.
Refer to the pipe plug torque values in Section V for different
plug sizes.
Install the plastic plug into the tachometer drive access hole.
13 mm
Install the access plate and new gasket.
Install the capscrews and tighten.
Thoroughly clean the flywheel housing and cylinder block

mating surfaces. These surfaces must be clean and free of
oil or -debris.
NOTE: The capscrew holes on the mwting pads are drilled

through. Coat set screws with Loctite 277 and install into
holes.
Set Screw Installation Depth

mm in
0.00 MIN 0.000
3.00 MAX 0.118
Page 7-174
Apply a continuous bead of Three Bond Sealant around all

capscrew holes on the mounting surface of the flywheel
housing.
Coat the threads of the mounting capscrews with LoctiteTM

277.
Install and tighten the capscrews.
Install the plug into the barring gear hole.
Seal, Rear Crankshaft - Replacement

(7-29)
Removal
NOTE: It iS IlOt necessary to remove the rear cover in order
to remove the rear crankshaft seal.
Disconnect the driveline and remove the transmission, if
equipped. Refer to the manufacturer’s instructions.
TROlOW
I
Page 7-175
19 mm
Remove the clutch and flywheel, if equipped. Refer to
Procedure 7-26.
3 mm Drill Bit, Drill Motor

Drill two holes, 166 degrees apart, into the outside metal part •l
of the seal.
No. 10 Sheet Metal Screw, Slide Hammer

Remove the seal.

Use a crocus cloth to remove any rust or other deposits
from the crankshaft flange.
Use a clean cloth to clean the crankshaft flange.
NOTE: Do not use any kind of lubricant to install the seal.
The oil seal must be installed with the lip of the seal and the
crankshaft clean and dry.
Page 7-176
Visually inspect the seal contact area for wear. If the seal
contact area has a groove worn deep enough to feel with a
fingernail or sharp object, it will be necessary to install a wear
sleeve. Refer to Procedure 7-30.
Installation
NOTE: There are two rear seal configurations used; one for dry
flywheel housings (1) and one for wet housings (2). The seal
for dry housings has an aluminum case wlth urethane coated
outside diameter. The seal for wet housings has a steel case
with silicone coated outside diameter. Refer to the appropriate
6D114E-1 Series Parts Catalog for the correct part number.
install the pilot and seal from the seal replacement kll onto the
crankshaft. For wet flywheel housings, apply a coat of mild
soap to the outside diameter of the seal case. For dry
housings, nothing is required on the outside diameter of the
seal case.
Push the seal onto the pilot and into the bore of the housing.
Remove the pilot.
Do not use any sealant on the rear crankshaft seal.
Page 7-177
Hammer
Use the installation tool from the seal replacement kit to
install the seal to the correct depth. To prevent damage to
the seal, hit the installation tool alternately at the 12:00, 3:00,
6:00 and 9:00 o’clock positions.
NOTE: Make sure the seal is completely installed into the
rear housing.
Install the flywheel and clutch, if equipped. Refer to Pro-

cedure 7-26.
Install the transmission and driveline. Refer to the man-
ufacturer’s instructions.
0623
82°C [180°F], and check for leaks and proper operation.
Wear Sleeve, Rear Crankshaft Seal -

Replacement (7-30) 06B
Removal
If the crankshaft seal-has worn a groove in the crankshaft
flange, a wear sleeve must be installed to prevent oil
leakage.
Page 7-178
Disconnect the driveline and remove the transmission, if

equipped. Refer to the manufacturer’s instructions.
10 mm, 19 mm
Remove the clutch and flywheel, if equipped. Refer to
Procedure 7-26.
Remove the flywheel housing. Refer to Procedure 7-28.
Remove the four lubricating oil pan mounting capscrews which
secure the oil pan to the rear cover.
Caution: Use extreme care when releasing the oil pan

gasket from the rear cover to prevent damage to the gasket.
If the gasket is damaged, the oil pan must be removed and
the gasket replaced. Refer to Procedure 2-13.
Insert a feeler gauge or shim stock between the rear cover and
the oil pan gasket. Move the feeler gauge or the shim stock
back and forth to release the gasket from the rear cover.
Remove the capscrews from the rear cover, and remove the
cover from the crankshaft flange.
Remove the seal from the rear cover.
Page 7-179
Hammer, Chisel
If the crankshaft currently has a wear sleeve, it must be RI
removed before installing a new one.
l
Caution: Do not nick or gouge the crankshaft with the @
Use a dull chisel that is only as wide as the wear sleeve.
Make one or two soft blows with a hammer to make chisel
A
marks across the wear sleeve. This will expand the wear
sleeve allowing the sleeve to be removed.

Clean the gasket surface of the cylinder block and rear
cover.
q
B
Use a crocus cloth to remove any rust or other deposits

from the crankshaft flange.
Use a clean cloth to clean the crankshaft flange.
Inspect the crankshaft flange for dirt or nicks.
Inspect the rear cover for cracks or other damage.

Page 7-180
Installation
NOTE: Do not use any kind of lubricant to install the seal.
The oil seal must be installed with the lip of the oil seal and
the crankshaft clean and dry to ensure proper oil sealing.
NOTE: The combination crankshaft oil seal (A)/wear sleeve

(B) replacement kii for service usage is installed on the
crankshaft as an assembly. The crankshaft rear oil seal
should not be removed from the crankshaft rear seal wear
sleeve.
I TRolo36
Install the rear cover and gasket.

NOTE: Install the rear cover capscrews. Do not tighten. If the
oil pan is installed, loosen the oil pan capscrews to allow
clearance for rear cover and gasket clearance.
NOTE: The seal installation is being used to properly align
the rear cover. Do not push or force the cover in any
direction to prevent irregular seal lip position after the seal
installation.
NOTE: The oil seal for a wet flywheel housing requires soap
on the outside diameter of the seal case. Nothing is required
on the outside diameter of the seal case for dry housings.
Page 7-181
Use service tool, Part No. 3824078, to install oil seal/wear

sleeve assembly. Install two (2) threaded studs into the
crankshaft capscrew holes.
RI
Apply a small amount of clean 15W-40 engine oil to the
crankshaft, threaded studs, and inside diameter of the
crankshaft rear seal/wear sleeve installation tool.
0%
Position the chamfered end of the wear sleeve (A) onto the
end of the crankshaft (B). Position the counterbore end of
installation tool (C) over threaded studs and align with wear
sleeve, perpendicular to the end of the crankshaft. Install the
washers (D) and nuts (E) onto the threaded studs.
Alternately tighten the nuts until the installation tool contacts
the end of the crankshaft.
NOTE: Do not exceed l/2 revolution of each nut to prevent

wear sleeve binding and irregular stretch.
Remove the installation tool and threaded studs.
10 mm
Align the rear cover even with both sides of the oil pan rail
0a3
on the cylinder block.
Page 7-182
Tighten the rear cover capscrews.

Trim the gaskets even with the oil pan mounting surface.
Make sure the gasket trim does not enter the engine.
NOTE: Be sure to fill the joint between the lubricating oil pan
rail and the rear cover with Three-Bond RTV sealant, Part No.
3823494.
Install the four capscrews which hold the oil pan to the rear
cover.
NOTE: The lubricating oil pan capscrews should be torqued
within 15 minutes after applying the sealant.
Install the flywheel housing, flywheel and clutch, if equipped.

Install the transmission and the driveline. Refer to the
Page 7-183

82°C [18O”F], and check for leaks and proper operation.
Pipe Plug - Replacement (7-31)

Removal
Select the appropriate size wrench, and remove the pipe
Plug-

Use spray cleaner, Part No. 3375433, or equivalent to clean
the threads of the pipe plug and threaded bore.
Visually inspect the threads of the pipe plug for mutilation or

damage.
Visually inspect the threaded bore for damage.
Repair the bore if necessary.
Page 7-184
Installation
Apply a film of pipe plug sealant, Part No. 3375088, or
equivalent to the threads.
install and tighten the pipe plug.
Refer to the following chart for torque values:
0(K
Tighten pipe plugs to the appropriate torque values.
Pipe Plug
NOTE: The accompanying chart is also provided in Section
Sk. TOrpUO
V “Engine Component Specifications.”
A6illd Incullmnor
mud l-head O.D. it6d COlUpOllWll6
In. mm IW N-m If-4

1116 8.1 IO.321 15 IV
$18 10.4 [0.411 20 1151
114 13.7 16.W 2s WI
318 17.3 IO.661 35 1251
l/2 21.6 l0.W 55 WI
34 26.7 I1.W 7s WI
1 23.5 I’=1 95 I701
1% 42.2 IlW 115 IN
1% 45.3 11.w 135 IlW
molo62
a Cup Plug - Replacement

Removal
(7-32)
Use a center punch to mark the cup plug for drilling.

Caution: Do not allow metal shavings to fall in the engine
when drilling a hole in the cup plug. Damage to engine
components can occur.
Drill a l/8 inch hole into the cup plug.
Use a dent puller to remove the plug.

NOTE: Discard ail used cup plugs. Do not use them again.
Page 7-185

Use spray cleaner, Part No. 3375433, or equivalent to clean
the cup plug bore.
Visually inspect the cup plug bore for damage. Repair the
bore if necessary.
NOTE: Refer to Section V, “Engine Component Specifica-
tions,” for cylinder block cup plug bore dimensions and cup
plug dimensions.
Installation
Caution: Excessive sealant can run back into the engine
and cause damage to other components. Allow the
sealant to dry for a minimum of 2 hours before operating
the engine. The plug can come out of the bore if the
sealant is not dry.
Apply a 2 mm [l/l 6 inch] bead of cup plug Lock’N Seal,
Part No. 3375068, or equivalent to the outside diameter of
the cup plug and the inside diameter of cup plug installation
bore.
NOTE: Use a cup plug driver to install the cup plug to the
correct depth in the cup plug bore.
Use the following cup plug drivers:
Tool P/N Cup Plug P/n cup Plug

Dimension
3822372 3900955 0.375 inch
3823521 3902606 0.8125 inch
3376816 3900957 1.oo inch
3823522 156075 1.1875 inch
3823523 3905401 1.375 inch
3823524 3900965 2.250 inch
Page 7-186
Caution: Do not install the plug too deeply. The cross

drillings in the cylinder block may be blocked. If the plug
is not installed straight and flat, it must be replaced with
a new cup plug.
The cup plug must be installed with the edge of the plug 0.5
to 1.0 mm [0.020 to 0.040 inch] deeper than the entrance
chamber of the bore.
Section 8 - Engine Testing
Page 8-l

Section Contents
Page
Blowby Measurement .......................................................... 8-4
Engine Run-in Procedure ....................................................... 88
Engine Testing - General Information ............................................... 8-2
Engine Testing - General Specifications .............................................. 83
Engine Testing - Service Tools ................................................... 8-5
General Engine Test Procedures .................................................. 8-8

Page 8-2
Engine Testing - General Information

The engine test is a combination of an engine run-in and a performance check. The engine run-in procedure provides
an operating period that allows the engine parts to achieve a final finish and fii. The performance check provides an
opportunity to perform final adjustments needed to optimize the engine performance.
The engine test must be performed in a manner that simulates a dynamometer test.
The engine crankcase pressure, often referred to as engine blowby, is an important factor that indicates when the piston
rings have achieved the correct finish and ii. Rapid changes of blowby or values that exceed specification more than 50
percent indicate that something is wrong. The engine test must be discontinued until the cause has been determined and
corrected.
Page 8-3
Engine Testing - General Specifications

NOTE: due to variations in ratings of different engine malels, refer to the specific engine data sheet for the particular
engine model being tested.
Maintain the following limits during an engine run-in on a dynamometer:
Intake Restriction: (Maximum)

l Clean Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 mm H,O [15 in. H,O]
l Dirty Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635 mm H,O [25 in. H,O]
Air Inlet Temperature (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38°C [lOOaF]
Exhaust Temperature ........ 1 ............................................. 700°C [129O“F]
Exhaust Back Pressure: (Maximum) ........................................ 76 mm Hg 13.0 in Hg]
Smoke:
l Bosch Smoke Meter (Maximum) ............................................... 2.5 Units
l Celesco Smoke Meter (Maximum) ............................................ 4% Opacity
Coolant Temperature (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100°C [212”F]
Lubricating Oil Temperature (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126.6”C [26O”F]
Lubricating Oil Pressure:

l Low Idle (Minimum Allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa [lo psi]
l Rated Speed (Minimum Allowable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 kPa [30 psi]
Fuel Filter Restriction - Dirty Filter (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 mm Hg [3.5 in. H,O]
Fuel Return Restriction (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 kPa [5 psi]
Blowby: *New (L/Min) *Worn (L/Min)

l 6D114E-1 Rectangular intermediate ring 44 88
l S6D114E-1 Rectangular intermediate ring 113 226
l SAGD114E-1 Rectangular intermediate ring 113 226
l All engines built after ESN: CDC 44531927, DEP 21087046 164 226
* Blowby checking tool, Part No. 3822566, has a special 7.67 mm to.302 in] orifice that must be used to obtain an
accurate reading.
Refer to the blowby conversion chart on the following page to convert liters/minute into inches/water.
Page 8-4
Blowby Measurement (8-01)

Blowby is generally recorded in liters/minute.
Install the Part No. 3822566, Engine Blowby Tool, to the
crankcase breather tube in the valve cover.
Install a water manometer to the engine blowby tool.
Use the Blowby Conversion Chart to convert the manometer
reading to liters/minute.
NOTE: A pressure gauge can be used to record the engine
blowby.
Minimum Gauge Capacity: 1270 mm H,O [50 in H,O]
Blowby Conversion Chart (7.87mm [0.302 in]) Orifice
Inches of Water Liters/Minute

1 50
2 84
3 103
4 119
5 133
6 145
155
;: 164
9 172
10 180
11 187
12 193
13 200
14 206
15 211
16 217
17 222
18 226
19 229
20 232
Page 8-5
Engine Testing - Service Tools
Vacuum Gauge
Check the fuel filter restriction during the engine performance
test. Hose adapter, Part No. ST-434-2 and vacuum gauge,
ST-434 Part No. ST-434-12, are used to perform the test.
mmm
Manometer
Used with the blowby check tool to measure engine crankcase
pressure. 1
ST-1111-3
~
-
Pressure Gauge
Used to measure the engine intake manifold pressure.
ST-1 273
-
Pressure Gauge (O-180 psi)
Used to measure lubricating oil pressure. \A/
. 1Sm?16
’
3375275 -& -I-
\
Q_
Digital Optical Tachometer

Used to measure engine speed (RPM).
3377482
Blowby Check Tool

Used with manometer, Part No. ST-l 11l-3, to measure the
3822588
Page 8-8
General Engine Test Procedures (8-02)

The following procedure assumes that the lubricating oil and
fuel systems were correctly primed, the dipstick calibrated, and
the engine filled to the correct levels with oil and coolant during
installation of the engine into the chassis. If these systems were
not serviced during installation of the engine, refer to
appropriate sections in this manual or to the latest chassis
Operation and Maintenance Manual for instructions on filling the
lubricating oil and the cooling systems.
The number of instruments and gauges required to perform a

chassis dynamometer test will vary according to the type and
~~~ the capability of the test equipment used.
engine performance meets specifications. If engine performance
Fuel in Restriction Fuel Temp. Exh. Back Pres. does not meet specifications, these measurements can indicate
possible reasons for poor performance.
@ 0 Bi
Air inlet Restriction Fuel Drain PreS. fuel ~~~~

Al= Coolant Pressure
To correctly monitor an engine’s pefformance, record the

following parameters:
l Lubricating oil pressure (vehicle instrument panel)
l Coolant temperature (vehicle instrument panel)
l Coolant pressure
l Intake manifold pressure
0 Inlet air restriction
0 Blowby
l Engine speed (RPM) (vehicle instrument panel)
l Wheel horsepower (WHP) (dynamometer controls)
l Exhaust back pressure
Measure the coolant pressure at the exhaust side of the

cylinder block.
Measure the intake manifold pressure (turbocharger boost).

install a pressure gauge, Part No. ST-l 273, in the location
shown.
Minimum Gauge Capacity: 1905 mm Hg [75 in. Hg]
Connect a water manometer to the turbocharger air inlet pipe

NOTE: The manometer connection must be installed at a 90
degree angle to the air flow in a straight section of pipe, one
pipe diameter before the turbocharger.
21 kPa
manometer. 13 Psi1
Minimum Gauge Capacity: 760 mm ~~0 [30 in. ~~01
Max.
Measure the blowby by installing blowby checking tool, Part

No. 3822566, in the crankcase breather vent. Connect the
blowby tool to a water manometer. Refer to page 8-1 for
blowby specifications.
NOTE: Excessive blowby indicates an engine internal com-
ponents malfunction or a turbocharger malfunction, allowing
combustion gases to enter the crankcase.
NOTE: If a sudden increase in blowby occurs, or if blowby

exceeds the maximum allowable limit during any run-in step,
return to the previous step and continue the run-in. If blowby
does not reach an acceptable level, discontinue the run-in
and determine the cause.
Page 8-8
0
NOTE: Avoid long idle periods. Operate the engine at low idle
49 only long enough (3 to 5 minutes) to check for correct oil
pressure and any fuel, oil, water, or air leaks.
Caution: Do not allow the engine speed to exceed 1000

A RPM before run-in. The internal components can be
damaged.

A last step of the run-in is completed. Allow the engine to
cool by operating at low idle for a minimum of 3 minutes to
avoid internal component damage.
Engine Run-in Procedure (8-03)

A
Caution: Refer General Engine Test Procedures (8-02)
before operating the engine to avoid internal component
damage.
Operate the engine as follows during the first 3 hours after
rebuild:
Hours Hou -
Page 8-9
1. Do not idle the engine for more than 5 minutes at any

one time.
2. Operate the engine at 75 percent throttle while loaded.
m
m Hours Hours
HOUr8 Hours 1
3. Do not operate the engine at rated speed (RPM) and

full load for more than 5 minutes at any one time.
m
Hours Hours
Change the lubricating oil and filter after 800 km [500 miles] e
or 20 hours of operation. Refer to Procedure 2-04.
Section 9 - Engine Removal and Installation
Page 9-l

Section Contents
Page
Engine - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Throttle Control Lever Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Engine Mount - Inspection ...................................................... 9-5
Engine Removal and Installation - General Information .................................... 9-2
Engine -Removal . . .. .. .. ... .. .. .. .. .. .. .. .. ... .. ... . .. .. . .. .. . .. . .. . .. . .. .. . 9-2

Page 9-2
Engine Removal and Installation

General Information
The procedures required to replace an engine will vary with
different engine models, the type of equipment, optional
equipment, and the shop facilities. Use the following procedures
as a guide:
NOTE: All replacement steps will not apply to all types of
equipment. Complete only the steps which apply to the
equipment involved. Use the equipment manufacturer’s rec-
ommendations and precautions for removal of chassis parts to
gain access to the engine.
Engine - Removal (9-01)

Place a tag on all hoses, lines, linkage, and electrical
connections as they are removed to identify their locations.
Disconnect the battery cables.

Drain the engine coolant.
Drain the lubricating oil.

Disconnect the starter cable, engine ground straps, cab or
chassis to engine hoses, tubing, electrical wires and hydraulic
lines.
Page 9-3
Disconnect the intake and exhaust pipes.

Disconnect all chassis mounted engine driven accessories.
Disconnect the throttle linkage from the injection pump

control lever.
Disconnect the drive units from the flywheel.
Warning: If a liquid refrigerant system (air conditioning) is

used, wear eye and face protection and wrap a cloth
around the fittings before removal. Liquid refrigerant can
A
cause serious eye and skin injury.
Remove all chassis components necessary to remove the

engine from the equipment.
Page 9-4
A NOTE: On applications where the rear engine mounts are

attached to the transmission, it may be necessary to remove
the engine and transmission as an assembly.
Warning: The engine lifting equipment must be designed
to safely lift the engine and transmission as an assembly.
The dry weight of the standard engine without acces-
sories is 606 kg [1335 lb]. Refer to the equipment man-
ufacturer’s specifications for the transmission weight.
Use a properly rated hoist and engine lifting fixture, attached

to the engine mounted lifting brackets to remove the engine.
NOTE: If the transmission is not removed, place a support
under the transmission to prevent it from falling.
Cover all engine openings to prevent dirt and debris from

entering the engine.
Place the engine on suitable engine support stands.
Remove all remaining accessories and brackets to use with

the replacement engine.
Page 9!
Engine Mount - Inspection (9-02)

Inspect all rubber-cushioned mounts for cracks or damage.
Inspect all mounting brackets for cracks or damaged bolt
04B
holes.
NOTE: Damaged engine mounts and brackets can cause
engine misalignment, drive line components damage, and
result in vibration complaints.
Engine - Installation (9-03) g@

**
08
Install all accessories and brackets that were removed from
the previous engine.
NOTE: On applications where the rear engine mounts are

attached to the transmission, it may be necessary to install
the engine and transmission as an assembly.
A
Warnina: The enaine lifting eauipment must be designed e
to safeb lift the &gine ar%i ttinimission as an assembly.
The dry weight of the standard engine without
accessories is 606 kg j1335 lb]. Refer to the equipment
manufacturer’s specifications for the transmission weight.
Use a properly rated hoist and engine lifting bracket,

attached to the engine mounted lifting brackets to install the
engine.
Page Q-6
Align the engine in the chassis and tighten the engine

mounting capscrews. Refer to the equipment manufacturer’s
torque specifications.
Connect all engine and chassis mounted accessories that
were removed.
NOTE: Be sure all lines, hoses, and tubes are properly
routed and fastened to prevent damage. Be sure the air
intake and exhaust pipe connections are tight and free of
leaks.
Throttle Control Lever Connection

When connecting the cable/rod to the control lever, adjust
the length so the lever has stop-to-stop movement.
Adjust the length of the cable/rod to the mechanical shut

down lever so there is stop-to-stop movement.
Fill the engine with clean 15W-40 lubricating oil. Refer to

Procedure 2-05.
NOTE: The total oil system capacity, including full flow and
bypass filters is, 23.6 liters 125.0 U.S. Quarts] for the naturally
aspirated engines.
Page 9-7
?
Fill the cooling system with a mixture of 50 percent water, 50
50%
percent ethylene glycol base antifreeze and DCA4 corrosion WATER
protection. Refer to Procedure l-01.
50%
NOTE: The total coolant capacity (engine only) is: ANTIFREEZE
Air Aftercooled: 9.9 liters [lo.5 U.S. quarts]
Water Aftercooled: 10.9 liters [l 1.5 U.S. quarts]
Caution: Installation of the radiator cap at this point is

critical to proper purging of air trapped in the cooling
system. Improper purging of air from the cooling system
will resuit in engine damage from overheating.
Perform a final inspection to make sure that all hoses, wires,
linkages, and components have been properly installed and
tightened.
Make sure the fuel is shut off by removing the wire from the
fuel solenoid or the mechanical fuel shutoff is in the “OFF”
position. This is necessary to prevent the engine from
starting during the oil riie pressure charging operation.
Caution: Do not engage the starting motor for more than

30 seconds. Wait 2 minutes between starter engagements
to cool the starting motor.
Crank the engine until the oil pressure gauge indicates a
positive pressure. _
Page 9-8
After pressure is observed, connect the wire to the fuel

solenoid.
Prime the low pressure fuel system by opening the bleed

screw.
Operate the plunger on the fuel transfer pump until the fuel
flowing from the fitting is free of air.
Tighten the bleed screw.
A Operate the engine at low idle for 2 to 3 minutes.

Warning: Do not remove the radiator cap from a hot engine.
Hot steam can cause serious personal injury. The engine
T
a9 coolant temperature must be below 50°C [122”Fj.
0
_,‘,” ’ ‘/,,J
0
Shut off the engine and wait 5 to 7 minutes for the oil to drain
:I_..: to the oil pan and check the oil and coolant levels again.
2 - 3 Minutea 5 - 7 Minute8
Fill the engine to the correct oil and coolant levels if

necessary. Refer to the Lubricating Oil Specifications and
Cooling System Procedures 2-05 and l-01 respectively.
Page 9-9
0429
Operate the engine at 1000 to 1200 RPM for 8 to 10
minutes. Check for proper operation, unusual noises, and
coolant, fuel or lubricating oil leaks.
Repair all leaks and component problems. Refer to the
appropriate procedures.
Refer to Section 8 for the Engine Run-In and Test
Procedures.
Section V - Engine Component Specifications
Page V-l

Section Contents
Page
Capscrew Markings and Torque Values ........................................... . v-31

Capscrew Markings and Torque Values - Metric .................................... . V-32
Capscrew Markings and Torque Values - U.S. Customary .............................. . v-33
Component Specifications and Torque Values ...................................... . v-3

Base Engine Component Specifications .......................................... . v-14
Base Engine Torque Values .................................................. . v-25
Combustion Air System Specifications ........................................... . v-7
Combustion Air System Torque Values .......................................... . V-7
Compressed Air System Torque Values .......................................... . v-a
Cooling System Specifications ................................................ . v-3
Cooling System Torque Values ................................................ . v-3
Electrical System Specifications ............................................... . v-13
Electrical System Torque Values ............................................... . v-13
Fuel System Specifications .................................................. . V-9
Fuel Shutoff Solenoid Adjustment .............................................. . v-9
Fuel System Torque Values .................................................. . v-10
Lubricating Oil System Specifications ........................................... . v-4
Lubricating Oil System Torque Values ............................................ V-5
Drive Belt Tension ........................................................... V-27
Newton-Meter to Foot-Pound Conversion Chart ....................................... V-30
Pipe Plug Torque Values ...................................................... V-34
Specification - General Information ............................................... V-2
Weight and Measures - Conversion Factors ......................................... V-29

Page V-2
Specification - General Information

This section contains the engine and component specifications used in this manual, separated by systems in the same
sequence they appear in the manual. A procedure number will appear with each component description to aid in locating
illustrations that describe inspection procedures. Component capscrew installation torque values will follow the
specifications in each system procedure.
NOTE: There are some component rebuild specifications listed in this section. The procedures for Rebuilding these
components are not included in this manual. If the procedure number is not list, refer to the 6D114E-1 Series Shop
Manual for rebuild information.
Page V-3
Component Specifications and Torque Values
Cooling System Specifications

0.15 mm MAX 0.006 in
Fan Hub Shaft End Clearance
Thermostat Operating Temperature 81’C MIN 178°F

Initial Opening Temperature 83°C 182°F
Fully Open Temperature 95°C MAX 203” F
Maximun Open Distance 41.5 mm MAX 1.63 in
Viscous Fan Drive Operating Temperature
Start Modulation
I Vhcms Fm DIM
opemthg Tempmtun
Maximum Speed 85°C 185°F

93°C 200” F
Radiator Cap Pressure Test

A - 104°C [220” F] 103 kPa MIN 15 psi
B - 99°C [21O”F] 48 kPa MAX 7 psi
Cooling System Torque Values

Belt Tensioner Mounting Capscrew 43 Nom 32 ft-lb
Fan Hub Mounting Capscrew 24 Nom 18 ft-lb

Page V-4
Fan Hub Pulley Mounting Capscrews 43 Nom 32 ft-lb
Hose Clamps 5 N*m 44 in-lb
Thermostat Housing Mounting Capscrews 24 Nom 18 ft-lb
Water Outlet Connection 24 N*m 18 t-t-lb
Lubricating Oil System Specifications
Oil Cooler Distortion 0.8 mm MAX 0.031 in
Oil Cooler Element Pressure Test

Pressurize the cooler to 483 kPa [70 psi], and
check for leaks by submerging in water.
Page V-5
Oil *Pressure Regulator Spring 85.53 mm Nominal 3.411 in

Trpow&ree Length
Spring Load at 53.98 mm 12.125 in]

Valve Open 190 N MIN 42.8 Ibf
Spring Load at 88.33 mm 12.375 in]
Assembled 153 N MIN 34.4 Ibf
Oil Pump Gerotor Tip Clearance 0.025 mm MIN 0.001 in

0.178 mm MAX 0.007 in
Oil Pump Port Plate Clearance 0.025 mm MIN 0.001 in II

0.127 mm MAX 0.005 in
Oil Pump Body Bore Clearance 0.127 mm MIN 0.005 in

0.381 mm MAX 0.015 in
/ /-
0.33 mm MAX 0.013 in I
Oil Pump Idler Gear Backlash
0.08 mm
0.33 mm
MIN 0.003 in
0.013 in I&?$
, & ts
- c
_-cl_
0
Lubricating Oil System Torque Values
Crankcase Breather Tube Bracket

M8 (Rocker Cover) 24 Nom 18 ft-lb
Ml2 (Cylinder Head) 77 Nom 57 ft-lb
Page V-6
Oil Cooler Mounting Capscrews 24 Nom 18 ft-lb

Oil Pressure Regulator Plug 80 Nom 59 ft-lb
Oil Drain Plug 80 Nom 59 ft-lb
Oil Pan Mounting Capscrews 24 Nom 18 ft-lb

Note: Tighten the capscrews in the
sequence shown. Start at the center of
the oil pan and alternate toward both
ends.
Oil Pump Suction Tube Bracket

Suction Tube to Block A 9 Nom 80 in-lb
Brace to Block 9 Nom 80 in-lb
Brace to Suction Tube : 9 Nom 80 in-lb
Oil Pump Mounting Capscrews 24 Nom 18 ft-lb
Oil Temperature Thermostat 50 Nom 37 ft-lb

Page V-7
Combustion Air System Specifications

Naturally Aspirated 50.8 cm H,O 20.0 in H,O
Turbocharged 63.5 cm H,O I% 25.0 in H,O
Exhaust Restriction 76.2 mm 3.0 in Hg

152.4 mm Hg 6.0 in Hg
with catalyst
Turbocharger Radial Clearance (Side to Side) 0.21 mm MIN 0.008 in

0.46 mm MAX 0.018 in
Turbocharger Axial Clearance (End Clearance) 0.03 mm MIN 0.001 in

0.08 mm MAX 0.003 in
Charge Air Cooler

Differential Pressure Across Cooler 21 kPa MAX 3 psi
Combustion Air System Torque Values

Turbocharger Mounting Nut 45 Nom 33 ft-lb
Turbocharger Oil Drain Mounting Capscrew 24 Nom 18 ft-lb

Page v-a
Turbocharger Air Crossover Hose Clamps 5 Nom 44 in-lb
Turbocharger Oil Drain Line Hose Clamps 5 Nom 44 in-lb
--. i
Turbocharger Turbine Housing Capscrews 11 Nom 97 in-lb
Turbocharger Compressor Housing Clamp 8 Nom 71 in-lb
Turbocharger Oil Supply Line Connection 35 Nom 26 ft-lb

Note: Hold turbo supply fitting when tightening turbo
oil supply line.
Turbocharger Discharge Elbow 8 Nom 71 in-lb
Compressed Air System Torque Values

Air Compressor Brace to Air Compressor Mounting
Capscrews 2
Holset
Bendix 43 Nom 32 ft-lb
Midland 43 Nom 32 ft-lb
Air Compressor Brace to Cylinder Block 32 Nom 24 ft-lb
Mounting Capscrew 1
43 Nom 32 ft-lb
Page V-9
Air Compressor Flange mounting Nuts

Nut 77 Nom 57 ft-lb
Stud to Gear Housing Hand Tight
Air Compressor Oil Supply Line 15 Nom 12 ft-lb
Air Compressor Coolant Lines 35 Nom 26 ft-lb

Engine Low Idle Speed
Refer to the engine dataplate
Fuel Shutoff solenoid Adjustment

RQVK Governor A = 66.9 mm 2.64 in
RSV Governor
1. Synchro-start A = 86.6 mm 3.4 in
B = 60.2 mm 2.5 in
2. Trombeta A= 91.4mm 3.6 in
B = 63.5 mm 2.51 in
3. Direct Link B = 117.1 mm 4.61 in
Fuel Transfer Pump inlet Restriction

S6D114E-1 100 mm Hg MAX 4 in Hg
SAGD114E-1 153 mm Hg MAX 6 in Hg
Page V-10
Fuel Transfer Pump Outlet Pressure

at Rated Speed
6D114E-1 Series High Flow 172 kPa MIN 25 psi
Low Flow 83 kPa MIN 12 psi
Fuel Injection Pump High Flow 138 kPa MIN 20 psi

Fuel Inlet Pressure Low Flow 48 kPa MIN 7 psi
Fuel Injection Pump

Fuel Return Line Restriction 518 mm Hg MAX 20.4 in Hg
Fuel Filter Restriction

Pressure Drop Across Filter 35 kPa MAX 5 psi
Fuel Drain Line Restriction 70 kPa MAX 10 psi
Injection Pump Throttle Lever

Breakover 3.18 mm MIN 0.125 in
6.38 mm MAX 0.250 in
Fuel System Torque Values

AFC (Air Fuel Control) Fitting 24 Nom 18 ft-lb
Page V-l 1
Fuel Filter
Caution: Hand tighten only. Mechanical tightening
will damage the fuel filter
Fuel Filter Head Adapter 4 Nom 35 in-lb

Fuel Filter Banjo Fittings 24 Nom 18 ft-lb
Fuel Pump Solenoid Mounting Capscrews 10 Nom 89 in-lb
Fuel Transfer Pump

Fuel Line Fittings 24 Nom 18 ft-lb
Fuel Transfer Pump Mounting Capscrews 24 Nom 18 ft-lb
High Pressure Fuel Line Fiiings 30 Nom 22 ft-lb

Page V-12
High Pressure Fuel Line Support Bracket 24 Nom 18 f&lb

Vibration Isolator Capscrew 6 Nom 53 in-lb
Injection Pump Supply Banjo Fitting 32 Nom 24 ft-lb
Injection Pump
Mounting Nuts 44 Nom 32 ft-lb
Studs Hand Tight
Injection Pump Lower Support Bracket

Ml0 Pump to Support Bracket Capscrew 24 Nom 18 ft-lb
Ml0 Support Bracket to Block Capscrew 77 Nom 57 ft-lb
Injection Pump Drive Gear Nut

A Pump 92 Nom 68 ft-lb
MW Pump 104 Nom 77 ft-lb
P Pump 165 Nom 122 ft-lb
injection Pump Timing Pin Access Plug 15 Nom 11 ft-lb
injection Nozzle Clamp Capscrew 24 Nom 18 ft-lb

Page V-13
Injection Nozzle Banjo Fitting 10 Nom 89 in-lb
Electrical System Specifications

Alternator Belt
Belt Tensioner, no adjustment necessary.
Batteries Specific Gravity at State of

27’C [8O”F] Charge
1.260 to 1.280 100%
1.230 to 1.250 75%
1.200 to 1.220 50%
1.170 to 1.190 25%
1.110 to 1.130 Discharged
Electrical System Torque Values 44 Nom 32 ft-lb

Alternator Belt Tensioner Capscrew
Alternator Mounting Pivot A

Ml 0 Capscrew 44 Nom 32 ft-lb
Alternator Lower Support Bracket B
M8 Capscrew 24 Nom 18 ft-lb
Ml 0 Capscrew 44 Nom 32 ft-lb
Alternator Mounting Capscrews C 77N.m 57 ft-lb
Starting motor Mounting Capscrew 77 Nom 57 ft-lb
Coolant Heater _ 12 Nom 106 in-lb

Page V-14
Temperature Sensor
Installation - Cast Iron 50 N*m 37 ft-lb
Installation - Aluminum 30 N*m 22 ft-lb
Oil Heater Element 120 N*m 89 ft-lb
Oil Pressure Switch 16 Nom 12 ft-lb

Installation - Cast Iron 10 Nom 89 in-lb
Installation - Aluminum
Base Engine Component Specifications

With Bushing 60.12 mm 2.367 in
Without Bushing 64.01 mm 2.520 in
Note: If one of the bushings exceeds the
specifications, all of the bushings must be
replaced.
Camshaft Journal O.D. 59.962 mm MIN 2.3607 in

60.013 mm MAX 2.3627 in
Camshaft Lobe Diameter

Intake Lobe 51.774 mm MIN 2.0333 in
52.251 mm MAX 2.0571 in
Exhaust Lobe 51.596 mm MIN 2.0313 in

52.073 mm MAX 2.0501 in
Fuel Transfer pump Lobe 41.310 mm MIN 1.6264 in

41.829 mm MAX 1.6468 in
Camshaft Nose (Gear Mounting Surface) O.D. 41.562 mm MIN 1.6363 in

41.580 mm MAX 1.6370 in
Page V-l 5
Camshaft Thrust Plate Thickness 9.340 mm MIN 0.3677 in

9.580 mm MAX 0.3772 in
Camshaft Gear Bore I.D. 41.480 mm MIN 1.6331 in

41.505 mm MAX 1.6341 in
Camshaft End Clearance A 0.12 mm MIN 0.0047 in

0.46 mm MAX 0.018 in
Camshaft Gear Backlash Limits B 0.08 mm MIN 0.003 in
0.33 mm MAX 0.013 in
Connecting Rod Piston Pin I.D. (With 45.023 mm MIN 1.7726 in

Bushing) 45.060 mm MAX 1.7740 in
Connecting Rod Crankshaft Bore I.D. (With 76.046 mm MIN 2.9939 in

Bearings) 76.104 mm MAX 2.9962 in
Connecting Rod Bearing Clearance (With 0.033 mm MIN 0.0013 in

Plastiguage) 0.117 mm MAX 0.0046 in
I -
Connecting Rod Bebring Side Clearance 0.100 mm MIN 0.0039 in

0.330 mm MAX 0.0130 in
Page V-16
Connecting Rod Bearing Thickness

Standard 2.455 mm MIN 0.0966 in
,2.471 mm MAX 0.0973 in
Connecting Rod Length 215.975 mm MIN 8.5029 in

216.025 mm MAX 8.5049 in

Crankshaft Connecting Rod Journal 75.962 mm MIN 2.9906 in

. O.D. 76.013 mm MAX 2.9926 in
0.050 mm MAX 0.0020 in

l Out-of Round 0.013 mm MAX 0.0005 in
l Taper

l O.D. 97.962 mm MIN 3.8568 in
98.031 mm MAX 3.8595 in
l Out-of Round 0.050 mm MAX 0.0020 in

-
Crankshaft Thrust Face Width 42.975 mm MIN 1.6919 in

(Standard) 43.076 mm MAX 1.6959 in
Crankshaft Rear Oil Seal Flange O.D. 129.975 MIN 5.1171 in

130.025 MAX 5.1191 in
Page V-17
Crankshaft Damper Pilot O.D. 23.924 mm MIN 0.9419 in

24.000 mm MAX 0.9449 in
Crankshaft Gear Journal O.D. 75.987 mm MIN 2.991 in

76.006 mm MAX 2.992 in

New 0.127 mm MIN 0.005 in
0.330 mm MAX 0.013 in
used 0.533 mm MAX 0.021 in
Crankshaft Gear Bore I.D. 75.898 mm MIN 2.9881 in

75.923 mm MAX 2.9891 in
Crankshaft Rear Oil Seal Wear Groove 0.25 mm MAX 0.010 in
Cylinder Block Upper Liner Bore I.D. 130.900 mm MIN 5.1535 in

130.990 mm MAX 5.1570 in
Cylinder Block Upper Deck to Midstop Liner 122.930 mm MIN 4.8397 in

Seat Area 123.000 mm MAX 4.8425 in
Page V-18
Cylinder Block
Surface Flatness Overall 0.075 mm MAX 0.0030 in
Surface Flatness Within 50mm [2.0 in] 0.012 mm MAX 0.0005 in
Cylinder Block Main Bearing Bore I.D.

l Without Bearing 104.982 mm MIN 4.1333 in
105.018 mm MAX 4.1344 in
l With Bearing 98.079 mm MIN 3.8614 in

98.123 mm MAX 3.8632 in
Cylinder Head Cup Plug Requirements

Apply a bead of LoctiteTM 277 or Cummins 1 30.43 mm 1.198 in
sealant, Part No. 3375068, around the outside2 58.06 mm 2.286 in
diameter of all cup plugs before installation.
Cylinder Liner I.D. 114.000 mm MIN 4.4882 in

114.040 mm MAX 4.4897 in
Cylinder Liner Top Press Fit O.D. 130.938 mm MIN 5.1550 in

130.958 mm MAX 5.1558 in
Cylinder Liner Protrusion 0.025 mm MIN 0.0010 in

0.122 mm MAX 0.0048 in
Cylinder Liner-to-Block Clearance 0.229 mm MIN 0.0090 in

Page V-19
Cylinder Liner Seat Area Depth 123.026 mm

123.052 mm
MIN
MAX
4.8435 in
4.8445 in
-..
I
El_
Cylinder Liner Taper 0.08 mm MAX 0.003 in
!ylSM; Head Capscrew Free Length

81.5 mm MAX 3.21 in
l Long 162.6 mm MAX 6.40 in
Cylinder Head Flatness

End to End 0.200 mm 0.0079 in
Side to Side 0.076 mm 0.0030 in
Cylinder Head Thickness 115.75 mm MIN 4.557 in

116.25 mm MAX 4.577 in
Valve Spring Free Height 65.66 mm Nominal 2.585 in

(7 l/2 coils)
Valve Spring Workirig Height 50.80 mm Nominal 2.00 in

Spring Force at Assembled Height
New 464.5 N MIN 104.4 Ibf
513.5 N MAX 115.4 Ibf
used 450.0 N MIN 101.2 Ibf

Page V-20
Valve Spring at Opening Height 37.90 mm Nominal 1.492 in

Spring Force at Opening Height
New 959.5 N MIN 215.7 Ibf
1060.5 N MAX 238.4 Ibf
Used 940.0 N MIN 211.3 Ibf
Valve Stem O.D. 9048 mm MIN 0.373 in

9.50 mm MAX 0.374 in
Valve Head Thickness at O.D.
bL
I Exhaust 2.22 mm MAX 0.087 in
Valve Guide I.D. (Installed) 9.539 mm MIN 0.3756 in

9.559 mm MAX 0.3763 in

21.16 mm MAX 0.833 in

23.01 mm MAX 0.906 in
Valve Guide Bore I.D. 15.931 mm MIN 0.6272 in

15.971 mm MAX 0.6266 in
Valve Guide (New) O.D. 15.988 mm MIN 0.6294 in

16.000 mm MAX 0.6299 in
Page V-21
Valve Seat-to-Valve Guide Concentricity

(360 Degrees) 0.05 mm MAX 0.002 in

1.62 mm MAX 0.064 in

1.12 mm MAX 0.044 in
Valve Insert Bore I.D. (Standard Insert) A

Valve Insert Bore Depth (Standard Insert) B

Valve Face Angle

Intake 30”
Exhaust 45”
Valve Seat With Limit 1.5 mm MIN 0.060 in

Grind area (A) with a 60 degree stone, and (B) with a 2.0 mm MAX 0.080 in
15 degree stone to center the seat on the valve face
and obtain the valve seat width limits.
pe$ Seat Leakage -(Hg)

635 mm Hg MAX 25 in Hg
used 457 mm Hg MAX 18inHg

Page V-22
Injector Nozzle Tip Protrusion 3.0 mm MIN 0.118 in

4.0 mm MAX 0.157 in
Exhaust Manifold Flatness 0.20 mm MAX 0.008 in
Flywheel Face Runout T.I.R Radius (A)

mm in
203 8 0.203 mm 0.008 in
254 10 0.254 mm 0.010 in
305 12 0.305 mm 0.012 in
356 14 0.356 mm 0.014 in
406 16 0.406 mm 0.016 in
Flywheel Bore Runout T.I.R. 0.127 mm MAX 0.0050 in
Flywheel Bore Alignment T.I.R. SAE No.

1 0.20 mm 0.008 in
2 0.20 mm Ki 0.008 in
3 0.20 mm MAX 0.008 in
Main Bearing Thickness (Standard) 3.446 mm MIN 0.1357 in

3.454 mm 0.1360 in
Main Bearing Clearance with Plastiguage 0.066 mm I% 0.0026 in
0.134 mm MAX 0.0053 in
Piston Pin Bore I.D. 45.006 mm MIN 1.7719 in

45.025 mm MAX 1.7726 in
Page V-23
Piston Pin O.D. 44.993 mm MIN 1.7710 in

45.003 mm MAX 1.7718 in
Piston Ring Gap (New)

Top Ring Gap 0.35 mm MIN 0.014 in
0.60 mm MAX 0.024 in
intermediate Ring Gap 0.35 mm MIN 0.014 in

0.65 mm MAX 0.026 in
Oil Ring Gap 0.30 mm MIN 0.0118 in

0.60 mm MAX 0.0236 in
Piston Skirt O.D. (Worn Limit) 113.808 mm MIN 4.4806 in

113.879 mm MAX 4.4834 in
Top Ring Groove Keystone Angle Wear

Use Micrometer and Part No. 3823966 113.938 mm MIN 4.4857 in
Intermediate Ring Groove keystone Angle Wear

Use Micrometer and Part No. 3823965 114.323 mm MIN 4.5009 in
Intermediate Rectangular Ring Side Clearance 0.070 mm MIN 0.0028 in

0.150 mm MAX 0.0059 in
Oil Ring Side Clearance 0.020 mm MIN 0.0008 in

0.130 mm MAX 0.0051 in
Rocker Lever Bore I.D. 22.256 mm MIN 0.8762 in

22.301 mm MAX 0.8780 in
Rocker Lever Shaft O.D. 22.199 mm MIN 0.8740 in

22.231 mm MAX 0.8752 in
Page V-24
Tappet Stem O.D. 15.925 mm MIN 0.6270 in

15.980 mm MAX 0.6291 in
Tappet Visual Limits

Inspect the socket stem and face for A Normal Wear
excessive wear, cracks or damage. B Abnormal (Do not use)
C Abnormal (Do not use)
Concavity A 0.025 mm 0.001 in
Tappet Face
1. A single pit cannot be greater than 2 mm [0.078 in] in diameter.
2. Interconnection of pits is not allowed and are treated as one pit.
3. Total pits when added together should not exceed 6 mm [0.236 in] diameter or a
total of 4 percent of the tappet face.
4. No pitting is allowed on the edges of the wear face of the tappet.
Valve Adjustment Clearance

Intake valve 0.30 mm Nominal 0.012 in
Exhaust valve 0.61 mm Nominal 0.024 in
Vibration Damper Face Alignment 0.28 mm MAX 0.011 in

(Wobble) TIR
Vibration Damper Eccentricity TIR 0.28 mm MAX 0.011 in
Vibration Damper Thickness

Measure the thickness at four locations 90 degrees apart approximately 3.18 mm
IO.125 in] from the outside diameter. The difference between any two of the four
measurements must not exceed 0.25 mm [O.OlO in].
Page V-25
Base Engine Torque Values

Camshaft Thrust plate Capscrew 24 N*m 18 ft-lb
Connecting Rod Nuts Step 1 40 N*m 30 ft-lb

2 80 Nom 60 ft-lb
3 120 N*m 88 ft-lb
Cylinder Head Mounting Step 1 70 N l m (All Capscrews) 52 ft-lb

Capscrews 2 145 N*m (Long Only) 105 ft-lb
3 Rotate 90” (All Capscrews)
Exhaust Manifold Capscrews With

Lock Tabs 43 N*m 32 ft-lb
Front Engine Support Bracket

Mounting Capscrews 112 N*m 83 ft-lb
l Without Support 60 N*m 44 ft-lb
Front Gear Cover Capscrews 24 Nom 18 ft-lb
Flywheel Mounting capscrews 140 Nom 101 e-lb

Page V-26
Gear Housing Mounting Capscrews

M8 24 Nom 18 ft-lb
Ml2 , 60 Nom 44 ft-lb
Main Bearing Cap Capscrews Step 1 50 Nom 37 ft-lb

2 119 Nom 88 ft-lb
3 176 Nom 129 ft-lb
I -s I
Rear Seal Cover Capscrews 9 Nom 80 in-lb
Rocker Support Capscrews 55 Nom 41 ft-lb
Valve Cover Capscrews 24 Nom 18 ft-lb
Vibration Damper 200 Nom 148 ft-lb

pulley to Vibration Damper 77 Nom 57 ft-lb
Page V-27
Drive Belt Tension
SAE Belt Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used*
Size
Click-Type Burroughs N Ibf N Ibf
.380 in. 3822524 620 140 270 to 490 60 to 110

.440 in. 3822524 620 140 270 to 490 60 to 110
r--~l/2 in. I 3822524 I ST-l 138 620 140 270 to 490 60 to 110
11/16 in. 3822524 ST-l 138 620 140 270 to 490 60 to 110
3/4 in. 3822524 ST-1 138 620 140 270 to 490 60 to 110
718 in. 3822524 ST-1 138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-l 138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1 138 670 I 150 270 to 530 60 to 120
6 rib 3822525 ST-l 293 710 I 160 I 290 to 580 I 65 to 130
8 rib 3822525 ST-l 293 890 200 360 to 710 80 to 160

10 rib 3822525 3823138 1110 250 440 to 890 100 to 200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240
* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
Page V-20
FRACTION, DECIMAL, MILLIMETER CONVERSIONS
29 0.4531 11.509 61 0.9531 24.209
15 0.4688 11.906 31 0.9688 24.606
31 0.4844 12.303 63 0.9844 25.003
I (l/2) 0.5000 12.700 (1 INI 1 moo 25.400
CONVERSION FACTOR: 1 INCH = 25.4 MM

I
section V - Eng le Component SI lecifications
Page V-2:
Weig it and Measures - Conversion Factors
QUANTITY U.S. CUSTOMARY METRIC FROM U.S. FROM METRIC TO

CUSTOMARY TO U.S. CUSTOMARY
METRIC MULTIPLY BY
MULTIPLY BY
Unit Name
Area so. inch 645.16 O.CO1550
6.452 0.155
sq. foot f? sq. meter m2
Fuel pounds per Ib/hp-hr grams per kilowatt g/kw-hr

Consumption horsepower hour hour
Fuel Performance miles per gallon mpg kilometers per liter km/l
gallons per mile gpm liters per kilometer I/km
oounds force Ibf Newton N
Length in I millimeters I mm
foot
Power horsepower
Pressure pounds force per

so. in
inches of mercury 3.3769

I 0.29613
inches of water 0.2488 4.019299

I
‘“‘”
inches of mercury in Hg millimeters of mm Hg
mercury
inches of water in H,O millimeters of water mm H,O
bars bars kilopascals kPa
bars bars millimeters of mm Hg

mercury
Temoerature fahrenheit ‘F centiarade “C (“F-32) + 1.8 I (1.8 x ‘C) t 32

Torque pound force per ft lb Newton-meter Nom 1.35582 0.737562
foot I
pound force per in lb Newton-meter Nom 0.113 8.850756
inch
Velocity miles/hour mph kilometers/hour kph 1.6093 0.6214
Volume: liquid gallon (U.S.) aal. liter I 3.7853 0.264179

displacement gallon (imp*) gal. liter I 4.546 0.219976
cubic inch in 3 liter I 0.01639 61.02545
cubic inch in 3 cubic centimeter cm3 16.387 0.96102
Weiaht (mass) oounds (avoir.) lb kilograms kg 0.4536 1 2.204623

Work British Thermal Unit BTU joules j 1054.5 0.000948
I
British Thermal Unit ~BTU kilowatt-hour kw-hr 0.000293 I 3414
I
horseoower hours 1ho-hr kilowatt-hour kw-hr 0.746 I 1.341
Page V-30
Newton-Meter to Foot-Pound Conversion Chart
Nom ft-lb Nom ft-lb I Nom R-lb

1 8.850756 in-lb 55 41 155 114
5 44.0 in-lb 60 44 160 118
6 53.0 in-lb 65 48 165 122
7 62.0 in-lb 70 52 170 125
8 71.0 in-lb 75 55 175 129
9 80.0 in-lb 80 59 180 133
10 89.0 in-lb 85 63 185 136
1 0.737562 ft-lb 90 66 190 140
12 9 95 70 195 144
14 10 100 74 200 148
15 11 105 77 205 151
16 12 110 81 210 155
18 13 115 85 215 159
20 15 120 89 220 162
25 18 125 92 225 165
30 22 130 96 530 170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184
NOTE: To convertfrom Newton-Meters to Kilogram-Meters

dive Newton-Meters by 9.803
Page V-31
Capscrew Markings and Torque Values
A Caution: When replacing capscrew, always use a capscrew of the same measurement and strength as the
capscrew being replaced. Using the wrong capscrews can result in engine damage.
Metric capscrew and nuts are identified by the grade number stamped on the head of the capscrew or on the surface
of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrews.
The following examples indicate how capscrews are identified:
Metric - M8-1.25 x 25 U.S. Customary [5/16 x 18 x l-1/2]

M8 1.25 ’ 25 5/l 6 18 l-112
Major Thread Distance Length in Major Thread Number Length in
Diameter in Between Millimeters Diameter in Threads Per Inches
Millimeters threads in Inches Inch
Millimeters
NOTES:
1. Always use the torque values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other section of the manual.
3. The torque values in the table are based on the use of lubricated threads.
4. When the ft-lb value is less than 10, give consideration to converting the ft-lb value to in-lb to obtain a better
torque with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-lb.
Page V-32
Capscrew Markings and Torque Values - Metric
Commercial Steel Class

8.8 10.9 12.9
8.8 10.9 12.9
TRo1295 TRO1296
MY
size TOI au= Toraue I Toraue
Diam. Cast iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm Nom ft-lb N-m ft-lb N-m ft-lb Nom ft-lb N*m ft-lb N-m ft-lb
6 9 5 7 4 14 9 11 7 14 9 11 7
7 14 9 11 7 18 14 14 11 23 18 18 14
6 25 16 16 14 32 23 25 18 36 27 28 21
10 40 30 30 25 60 45 45 35 70 50 55 40
12 70 55 55 40 105 75 80 60 125 95 100 75
14 115 65 90 65 160 120 125 95 195 145 150 110
16 160 130 140 100 240 175 190 135 290 210 220 165
16 230 170 180 135 320 240 1 250 185 I400 290 310 230
Page V-33
Capscrew Markings and Torque Values - U.S. Customary
These are all SAE Grade 5

(3) line
\m
!ii? $3
-9 0 ’
I r ’
m
TRo1297
’ TRO1298 -w TRo1299
Capscrew Torque - Grade 5 Caoscrew Caoscrew Toraue - Grade 8 Caoscrew
Capscrew Body Size Cast Iron Aluminum Cast Iron
Nom ft-lb Nom ft-lb Nom ft-lb N*m ft-lb
l/4 - 20 9 7 8 6 15 11 12 9
- 28 12 9 9 7 18 13 14 10
5/16 - 18 20 15 16 12 30 22 24 18
- 24 23 17 19 14 33 24 25 19
3/8 - 16 40 30 25 20 55 40 40
- 24 30 35 25 60 45 45 :z
7/16 - 14 ii 45 45 35 90 65 65 50
- 20 65 50 55 40 95 70 75 55
l/2 - 13 95 70 75 55 130 95 100 75
- 20 100 75 80 60 150 110 120 90
9/16 - 12 135 100 110 80 190 140 150 110
- 18 150 110 115 85 210 155 170 125
518 - 11 180 135 150 110 255 190 205 150
- 18 210 155 160 120 290 215 230 170
314 - 10 325 240 255 190 340 365 270
- 16 365 270 210 ii: 380 410 300
7/8 - 9 490 360 z 280 745 550 600 440
- 14 530 390 420 310 825 610 660 490
1-8 720 530 570 420 1100 820 890 660
-14 800 590 650 480 1200 890 960 710
Page V-34

Size Torque Torque
Thread Actual Thread O.D. In Aluminum Components In Cast Iron or Steel Components
in in Nom ft-lb N*m ft-lb
l/16 0.32 5 45 in-lb 15 10
l/8 0.41 15 10 20 15
l/4 0.54 20 15 25 20
318 0.68 25 20 35 25
l/2 0.85 ’ 35 25 55 40
314 1.05 45 35 75 55
1 1.32 60 45 95 70
l-1/4 1.66 75 55 115 85
l-1/2 1.90 85 65 135 100
Index
Page X-l
About the Manual .................................. i-2 Compressed Air System Specifications .................. 4-3
AFC Tube - Replacement ............................ 5-31 Holset SS296 Single Cylinder Air Compressor ............ 43
Installation ...................................... 6-31 Holset SS338 Single Cylinder Air Compressor ............ 4-3
Removal ....................................... 6-31 Connecting Rod Bearings - Replacement. ............... 7-59
Aftercooler and Gasket - Replacement .................. 3-24 Cleaning and Inspection ........................... 761
Cleaning ....................................... 3-25 Diagnosing Malfunctions ........................... 7-59
Installation ...................................... 325 Installation ...................................... 764
Removal ....................................... 3-25 Removal ....................................... 7-60
Air Compressor Carbon Buildup - Checking .............. 4-5 Connecting Rods - Replacement ...................... 7-83
Air Compressor Gasket Leaks - Checking ................ 4-7 Cleaning and Inspection ........................... 7-85
Air Compressor - Replacement ....................... 4-10 General Information ............................... 783
Inspection ...................................... 4-12 Installation ...................................... 7-87
Installation ...................................... 4-12 Removal ....................................... 784
Removal ..................................... ..4-11 Coolant Temperature Sensor - Replacement ............. 624
Air Crossover Tube - Replacement ..................... 3-22 Installation ...................................... &25
Removal and Installation .......... , ................ 3-22 Removal ....................................... 626
Air Governor and Compressor Unloader Valve - Checking ... 4-7 Cooling System - Diagnosing Malfunctions ............. 1-13
Air Governor - Checking .............................. 4-8 Belt Tension ................................... 1-18
Air Intake Heater Description and Operation ............. 3-35 Coolant Hose - Inspection ......................... 1-19
Intake heater Controller Connection - Diagram ........... 3-38 Coolant Pressure - Measurement .................... 1-21
Air System Flow Diagrams ............................ 3-4 Cooling System - Test for Combustion Gases .......... 1-14
Alternator - Replacement ............................ 6-23 Fuel Pump Overfueled ............................ 1-26
Installation ...................................... 6-24 Radiator Cap - Pressure Test ....................... 1-14
Removal ....................................... 6-23 Radiator, Fan and Shutters ........................ 1-21
Base Engine Components - General Information ........... 7-9 Temperature Gauge Operation ...................... 1-26
Base Engine Components - Service Tools ................ 7-4 Thermostat Leakage and Opening Temperature - Testing
Belt Tensioner - Replacement ....................... l-27 “In-Chassis” ................................... 1-24
Installation ..................................... 1-28 Thermostat Opening Temperature - Testing “Thermostat
Removal ...................................... l-27 Removed” ..................................... 1-25
Removal and Installation .......................... 1-28 Thermostat Operation and Testing ................... 1-23
Blowby Measurement ................................ 8-4 Vehicle Overloaded .............................. 1-27
Camshaft Gear - Replacement ....................... 7-128 Water Pump - Inspection .......................... 1-19
Cleaning and Inspection .......................... 7-133 Water Pump Seal Weep Hole - Inspection ............. 1-19
Installation ..................................... 7-137 Cooling System - Flow Diagrams ...................... 13
Removal ...................................... 7-130 Cooling System - General Information .................. l-2
Camshaft - Replacement ........................... 7-128 Cooling System - Maintenance ........................ l-7
Cleaning and Inspection .......................... 7-133 Additive Concentration - Checking .................... l-7
General Information .............................. 7-128 Antifreeze ...................................... l-7
Installation ..................................... 7-137 Antifreeze Concentration - Checking ................... l-7
Removal ...................................... 7-130 Cooling System - Cleaning ......................... l-8
Capscrew Markings and Torque Values ................. V-31 Cooling System - Draining .......................... l-7
Capscrew Markings and Torque Values - Metric .......... V-32 Filling and Venting ............................... 1-12
Capscrew Markings and Torque Values - U.S. Customary ... V-33 Cooling System - Service Tools ....................... l-6
Combustion Air System - Diagnosing Malfunctions ......... 3-7 Cooling System - Specifications ....................... 1-5
Clean Air ........................................ 3-7 Crankcase Breather Tube - Replacement ................ 7-13
Damage From Non-filtered Air ........................ 3-8 Cleaning and Inspection ........................... 7-13
Intake Air Restriction - Checking ....................... 3-7 Installation ...................................... 7-14
Malfunctioning Turbocharger ........................ 3-10 Removal ....................................... 7-13
Oil Consumption and Leaks ......................... 3-10 Crankshaft Gear - Replacement ...................... 7-152
Rotor Assembly Clearance - Measurement .............. 3-12 Cleaning and Inspection .......................... 7-155
Turbocharged Engines - Air Leaks, Pressure Side .......... 3-8 General information .............................. 7-152
Turbocharged Engines - Exhaust Leaks ................. 3-9 Installation ..................................... 7-156
Turbocharger Boost Pressure - Measurement ............. 3-9 Removal ...................................... 7-153
Turbocharger Noise ................................ 3-4 Cup Plug - Replacement ............................ 7-184
Combustion Air System Flow - General Information ........ 3-3 Cleaning and Inspection .......................... 7-185
Combustion Air System - Service Tools .................. 3-6 Installation ..................................... 7-185
Component Specifications and Torque Values ............. V-3 Removal ...................................... 7-184
Base Engine Component Specifications ................ V-14 Cylinder Head - Pressure Test ........................ 747
Base Engine Torque Values ......................... V-25 Cylinder Head - Replacement ......................... 730
Combustion Air System Specifications .................. V-7 Cylinder Block/Head Deck Cleaning and Inspection ....... 734
Combustion Air System Torque Values .................. V-7 Cylinder Head - Cleaning and Inspection ............... 7-37
Compressed Air System Torque Values ................. V-8 Diagnosing Malfunctions ........................... i’-30
Cooling System Specifications ........................ V-3 General Information ............................... ~-XI
Cooling System Torque Values ....................... V-3 Installation ...................................... 7-42
Electrical System Specifications ...................... V-13 Removal ....................................... 733
Electrical System Torque Values ..................... V-13 Cylinder Liners - Replacement ........................ 789
Fuel Shutoff Solenoid Adjustment ..................... V-9 Cleaning and Inspection ........................... 7-93
Fuel System Specifications .......................... V-9 General Information ............................... 789
Fuel System Torque Values ......................... V-10 Installation ...................................... 7-96
Lubricating Oil System Specifications ................... V-4 Removal ....................................... 789
Lubricating Oil System Torque Values .................. V-5 Drive Belt - Replacement ........................... 1-27
Compressed Air System Flow Diagrams ................. 4-4 Drive Belt Tension ................................. V-27
Compressed Air System General Information ............. 4-2 Electrical System Description and Operation .............. 62
Index
Page X-2
Bosch Kl Model Alternator (Wiring Diagram) ............. 6-5 Installation ...................................... 529
Cranking Motor and Electrical Circuits .................. 6-2 RSV Governor Fuel Shutoff Solenoid - Installation ......... 529
Delco 42MT Starting Motor .......................... 6-6 RSV Governor Fuel Shutoff Solenoid - Removal .......... 5-28
Delco Remy Model 15SI 116 Alternator Wiring Diagram ..... 6-5 Fuel System Components and Flow ..................... 5-3
Delco Remy Model 37MT Starting Motor ................ 6-3 Fuel System Diagnosing - Malfunctions .................. 5-i’
Delco Remy Model 42MT Starting Motor ................ 6-6 Air Fuel Control (AFC) Malfunctions ................... 514
Nippendenso Model F2 Basic Cranking Current Flow ....... 6-4 AirintheFuelSystem ............................. 511
Nippendenso Model F2 Starting Motor .................. 6-4 Electrical Shut Down Devices ........................ 5-16
Electrical System - Diagnosing Malfunctions ............. 6-l 1 Fuel Control Lever Travel and Adjustment .............. 5-15
Alternator ....................................... 6-18 Fuel Drain Manifold ............................... 5-20
Batteries - Checking .............................. 6-l 1 Fuel Injection Pump ............................... 5-14
Coolant or Pan Heaters - Checking ................... 6-22 Fuel Injection Pump Idle Adjustment Screws ............ 5-15
Engine Cranking Speed Too Slow .................... 6-17 Fuel Injection Pump Timing ......................... 517
Oil Pressure Switch and Temperature Sensor - Checking ... 6-21 Fuel Transfer Pump ................................ 57
Starting Circuit - Checking .......................... 6-12 Fuel Water Separator/Filter Unit ...................... 513
Starting Motor Solenoid and Starting Motor Checking ..... 6-15 Governor Malfunctions ............................. 5-14
Electrical System - Service Tools ....................... 6-9 High Pressure Fuel Lines ........................... 5-18
Electrical System - Specifications ...................... 6-7 Injectors ..................................... ..5-19
Maximum Allowable Resistance of Starting Circuit ......... 6-7 Manual Shut Down Levers .......................... 5-15
Minimum Recommended Battery Capacity. .............. 6-7 Fuel System - Service Tools ........................... 5-5
Wiring Size Recommendations for Starter Solenoid and Fuel Fuel System Specifications ........................... 5-4
Solenoid Ciruit .................................... 6-8 Fuel Transfer Pump - Replacement .................... 5-22
Engine Block and Coolant Heater (750 and 500 Wats) - Assembly ...................................... 523
Replacement ...................................... 6-25 Cleaning ....................................... 5-23
Installation ...................................... 6-26 Cleaning Mounting Surface ......................... 524
Removal ....................................... 6-26 installation ...................................... 5-24
Engine Compression - Checking ....................... 7-9 Rebuild ...................................... ..5- 22
Compression Gauge and Adapter ..................... 7-9 Removal ....................................... 5-22
Cylinder Head Gasket Sealing ....................... 7-10 Gear Cover - Replacement .......................... 7-108
Intake and Exhaust Valve Sealing ..................... 7-10 Cleaning and Inspection .......................... 7-109
Piston Ring Sealing ............................... 7-10 Installation ..................................... 7-110
Engine Dataplate - Replacement ..................... 7-126 Removal ...................................... 7-108
Installation ..................................... 7-127 Gear Housing - Replacement ........................ 7-117
Removal ...................................... 7-127 Cleaning and Inspection .......................... 7-119
Engine Diagrams ................................. E-7 General Information .............................. 7-117
Engine Identification.. ............................. E-2 Installation ..................................... 7-121
Engine Dataplate ................................ E-2 Removal ...................................... 7-118
Fuel Injection Pump Dataplate ........................ E-3 General Cleaning Instructions ........................ i-8
Engine Run-In Procedure ............................. 8-8 Solvent and Acid Cleaning .......................... i-8
Engine Testing - General Information .................... 8-2 Steam Cleaning .................................. i-8
Engine Testing - General Specifications ................. 8-3 General Engine Specifications ....................... E-4
Engine Testing - Service Tools ......................... 8-5 Battery (Specific Gravity) ............................ E-6
Exhaust Manifold and Gaskets - Replacement ............ 3-30 Cooling System ................................. E-5
Cleaning and Inspection ........................... 3-31 Electrical System .................................. E-6
Installation ...................................... 3-31 Fuel System ................................... E-5
Removal ....................................... 3-30 General Engine Data ............................. E-4
Fan Hub - Replacement ............................ l-28 Intake Air and Exhaust System ...................... E-5
Removal and Installation .......................... l-29 Lubrication System .............................. E-4
Fan Pulley - Replacement ........................... 1-28 General Engine Test Procedures ....................... 8-6
Flywheel Housing - Replacement ..................... 7-166 General Information ................................ 8-6
Cleaning and Inspection .......................... 7-168 General Repair Instructions .......................... i-7
Concentricity - Checking .......................... 7-170 General Safety Instructions .......................... i-6
Installation (Dry Clutch Application) .................. 7-169 Generic Symbols .................................. i-4
Installation (Wet Clutch Application) .................. 7-172 Glossary of Terms ................................. i-9
Removal ...................................... 7-l 66 High Pressure Fuel tines - Replacement ................ 524
Flywheel - Replacement ............................ 7-l 59 Installation ...................................... 5-25
Cleaning and Inspection .......................... 7-160 Removal ....................................... 5-24
Flywheel Sore Runout Measurement ................. 7-163 How To Use This Manual ............................ i-3
Flywheel Face Runout Measurement ................. 7-164 Group Contents .................................. i-3
Installation ..................................... 7-161 Index.. ........................................ i-3
Removal ...................................... 7-159 Metric Information, ................................ i-3
Flywheel Ring Gear - Replacement ................... 7-166 Table of Contents ................................ i-3
Installation ................ ; .................... 7-166 Idle Speed - Adjustment ............................. 5-38
Removal ...................................... 7-166 Bosch RQVK Governor ............................. 5-39
Fuel Drain Manifold - Replacement .................... 526 Bosch RSV Governor .............................. 5-38
Removal and Installation ........................... 5-26 nlus~ations ....................................... i-5
Fuel Filter Head Adapter - Replacement. ................ 521 Injector - Replacement .............................. 5-26
Removal and Installation ........................... 5-21 Cleaning and Inspection ........................... 526
Fuel Injection Pump - Replacement .................... 5-31 Installation ...................................... 5-27
Installation ...................................... 533 Removal ....................................... 5-26
Removal ....................................... 5-32 lnline Fuel Injection Pump Spill-Port Timming ............ 539
Fuel Shutoff Solenoid - Replacement ................... 528 Governor Lever Positioning ......................... 5-41
RQVK Governor Fuel Shutoff Solenoid - Removal and Intake Air and Exhaust System Specifications ............. 3-5
Index
Page X-3
Intake Manifold Cover and Gasket - Replacement ......... 3-23 Inspection ...................................... 232
Cleaning ....................................... 3-24 Installation ...................................... 233
Installation ...................................... 3-24 Removal ....................................... 231
Removal ....................................... 3-23 Main and Thrust Bearings - Replacement ............... 7-48
Internal Engine Damage - Checking .................... 2-l 1 Cleaning and Inspection ........................... 7-62
Lubricating Oil Analysis ............................ 2-11 Diagnosing Malifunctions ........................... 7-49
Lubricating Oil Filter Inspection ...................... 2-11 General Information ............................... 748
Low Pressure Fuel Line - Replacement ................. 5-21 Installation ...................................... 7-54
Removal and Installation ........................... 5-21 Removal ....................................... 750
Lubricating Oil Cooler Element and Gasket - Replacement . . 2-28 Newton-Meter to Foot-Pound Conversion Chart .......... V-39
Cleaning and Inspection ........................... 2-29 Pipe Plug - Replacement ........................... 7-183
Installation ...................................... 2-30 Cleaning and Inspection .......................... 7-183
Removal ....................................... 2-28 Installation ..................................... 7-184
Lubricating Oil Dipstick - Calibration ................... 2-25 Removal ...................................... 7-183
Lubricating Oil Dipstick Tube - Replacement ............. 2-26 Pipe Plug Torque Values ............................ V34
Installation ....................................... 2-26 Pistons and Rings - Replacement ..................... 766
Removal ....................................... 2-26 Cleaning and Inspection ........................... 7-71
Lubricating Oil Filter - Changing ...................... 2-24 Installation ...................................... 7-76
Lubricating Oil Leaks (External) - Checking .............. 2-10 Piston and Ring - Diagnosing Malfunctions ............. 768
Lubricating Oil Level - Checking ....................... 2-23 Piston - General Information ......................... 766
Lubricating Oil Pan - Draining ........................ 2-22 Removal ....................................... 768
Lubricating Oil Pan - Filling .......................... 2-22 Push Rod - Replacement ............................ 7-27
Lubricating Oil Pan Heater - Replacement ............... 6-26 Cleaning and Inspection ........................... 7-28
Installation ...................................... 6-27 Installation ...................................... 7-29
Removal ....................................... 6-27 Removal ....................................... 7-27
Lubricating Oil Pan, Suction Tube and Gasket - Replacement 2-33 Rocker Lever Diagnosing - Malfunctions ................ 7-14
Cleaning ....................................... 2-33 Valve lash Specifications ........................... 7-14
Oil Pan - Installation ............................... 2-34 Rocker Lever - Replacement ......................... 7-15
Oil Pan - Removal ................................ 2-33 Cleaning and Inspection ........................... 7-17
Suction Tube - Replacement ........................ 2-34 Disassembly .................................... 7-16
Lubricating Oil Pressure Regulator, Valve and Spring - Installation ...................................... 7-19
Replacement ...................................... 2-27 Removal ....................................... 7-15
Cleaning and Inspection ........................... 2-27 Seal, Front Crankshaft - Replacement ................. 7-112
Removal ....................................... 2-27 General Information .............................. 7-112
Installation ...................................... 2-28 Removal and Installation .......................... 7-113
Lubricating Oil Pressure Switch Replacement ............ 6-27 Seal, Rear Crankshaft - Replacement .................. 7-174
Installation ...................................... 6-27 Cleaning and Inspection .......................... 7-175
Removal ....................................... 6-27 Installation ..................................... 7-176
Lubricatfng Oil Pump - Replacement ................... 2-35 Removal ...................................... 7-174
Cleaning and Inspection ........................... 2-36 SectionT-Troubleshooting ........................... 2
Installation ...................................... 2-39 Procedures and Techniques .......................... 2
Removal ....................................... 2-36 Specifications - General Information .................... V-2
Lubricating Oil System - Diagnosing Malfunctions ......... 2-12 Starting Motor - Replacement ........................ 622
Aftercooler ...................................... 2-16 Removal and Installation ........................... &23
Bearings and Oil Pump ............................ 2-15 Thermostat - Replacement .......................... 1-32
Coolant Diluted Oil ............................... 2-15 Cleaning ...................................... l-33
Cracked Cylinder Block ............................ 2-18 Installation ..................................... 1-33
Cracked Cylinder Head ............................ 2-17 Removal ...................................... 1-32
Cracked Cylinder Liner ............................ 2-18 Timing Pin Assembly - Installation ..................... 7-23
Cylinder Head Expansion Plugs ...................... 2-17 Troubleshooting Symptoms Charts ..................... 2
Cylinder Head Gasket ............................. 2-17 Air Compressor Air Pressure Rises Slowly. ............... 5
Cylinder Liner Seals ............................... 2-17 Air Compressor Operates with Excessive Noise ........... 3
Fuel Diluted Oil .................................. 2-18 Air Compressor Pumping Excessive Lubricating Oil into Air
Fuel Leaking by Piston Rings ........................ 2-19 System ......................................... 4
Fuel Transfer Pump ............................... 2-19 Air Compressor Will Not Maintain Adequate Air Pressure (Not
High Oil Pressure ................................ 2-12 Pumping Continuously) ............................. 6
Injection Pump .................................. 2-20 Air Compressor Will Not Pump Air Pressure .............. 7
Low Oil Pressure ................................. 2-12 Air Compressor WIII Not Stop Pumping Air ............... 8
Oil Cooler ...................................... 2-16 Alternator Not Charging or Insufficient Charging ........... 9
Oil Dilution ..................................... 2-15 Connecting Rod Bearing Noise ....................... 47
Oil Filter ....................................... 2-13 Compression Knock. ............................... 10
Oil Leaks ....................................... 2-20 Coolant Contaminated .............................. 11
Oil Level ........................................ 2-12 CoolantLoss.. ................................... 12
Oil Pressure Gauge - Checking ...................... 2-13 Coolant Temperature Above Normal - Gradual Overheat ..... 14
Oil Pressure Regulating Valve ....................... 2-12 Coolant Temperature Above Normal - Sudden Overheat ..... 17
OilSuctionTube ................................. 2-15 Coolant Temperature Below Normal .................... 18
Oil Temperature Gauge - Checking ................... 2-14 Engine Crankcase Gases (Blowby) - Excessive ............ 19
Oil Temperature Thermostat ........................ 2-14 Engine Cranks, But Will Not Start - No Smoke from Exhaust . 20
Lubricating Oil System - Flow Diagram .................. 2-6 Engine Difficult to Start or Will Not Start - Exhaust
Lubricating Oil System - General Information ............. 2-4 Smoke Present ................................... 21
Lubricating Oil System - Service Tools ................... 2-3 Engine Idle Rough, Warm Engine ..................... 23
Lubricating Oil System - Specifications .................. 2-5 Engine Misfiring ................................... 24
Lubricating Oil Temperature Thermostat - Replacement .... 2-31 Engine Noise Diagnostic Procedures - General
Index
Page X-4
Information ...................................... 47
Engine Noise Excessive ............................. 29
Engine Power Output Low ........................... 25
Engine Starts But Will Not Keep Running ................ XI
Engine Surges at Idle .............................. 31
Engine Vibration Excessive .......................... 32
Engine Will Not Crank or Cranks Slowly ................. 33
Engine Will Not Reach Rated Speed When Loaded ........ 34
Engine Will Not Shut Cff ............................ 35
Exhaust Black Smoke Excessive Under Load ............. 36
Exhaust White Smoke Excessive (Warm Engine) .......... 38
Fuel Consumption Excessive ......................... 39
Fuel Consumption - General Information ................ 47
Fuel Consumption - Industrial Customer Complaint Form .... 48
Fuel or Oil Leaking from Exhaust Manifold ............... 40
Lubricating oil Consumption Excessive ................. 42
Lubricating oil Contaminated ........................ 41
Lubricating Oil Pressure High ......................... 46
Lubricating Oil Pressure Low ......................... 44
Oil Cunsumption .................................. 49
Turbocharger Boost Pressure Specifications .............. 3-5
Turbocharger - Replacement ......................... 3-26
Cleaning and Inspection ........................... 327
Installation ...................................... 3-28
Removal ....................................... 3-26
Valve Cover - Replacement ........................... 7-11
Cleaning and Inspection ........................... 7-12
Installation ...................................... 7-12
Removal ....................................... 7-11
Valve Lash-Adjustment ............................. 7-20
Valve Arrangement ............................... 7-22
Valve Tappet - Replacement ......................... 7-143
Cleaning and Inspection .......................... 7-147
General Information .............................. 7-l 43
Installation ..................................... 7-148
Removal ...................................... 7-144
Vibration Damper - Replacement ..................... 7-103
General Information .............................. T-103
Installation ..................................... 7-107
Removal ...................................... 7-106
Rubber Element Vibration Damper - Inspection (In-Chassis) 7-103
Vrscous Vibration Damper - Inspection ................ 7-105
Water Pump - Replacement ......................... l-29
Cleaning ...................................... l-30
Installation ..................................... l-30
Removal ...................................... 1-29
Wear Sleeve, Front Crankshaft - Replacement ........... 7-113
Cleaning and Inspection .......................... 7-l 14
Installation ..................................... 7-114
Removal ...................................... 7-l 13
Wear Sleeve, Rear Crankshaft Seal - Replacement ....... 7-177
Cleaning and Inspection .......................... 7-179
Installation ..................................... 7-180
Removal ...................................... 7-177
Weight and Measures - Conversion Factors ............. V-29
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
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CEBM000601

SERIAL NUMBERS 45241940andw

May 1997 Copyright 1997 Komatsu America International Company

SHOP MANUAL ....................................... 01

TROUBLESHOOTING & REPAIR MANUAL .................... 02

DESCRIPTION FORM NUMBER

SHOP MANUAL SET: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM000601

Troubleshooting & Repair Manual

PARTS AND SERVICE PUBLICATIONS CAN ONLYBEACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS,

STREET ADDRESS ORDER DATE

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

PARTS ;FaFe; PUBLICATION

KDC91 D 022597 CURRENT PRICES WILL BE CHARGED

6D114E-I Series Engine

Engine Identification ........................................................... E

Engine Disassembly and Assembly - Group 00 .......................................... 0

Cylinder Block - Group 01 ....................................................... 1

Cylinder Head - Group 02 ..................................... . . . . . . . . . . . . . . . . . 2

Rocker Levers - Group 03 ..................................... . . . . . . . . . . . . . . . . . 3

Cam Followers - Group 04 ....................................................... 4

Fuel System - Group 05 ......................................................... 5

Injectors and Fuel Lines - Group 06 ................................................. 6

Lubricating Oil System - Group 07 ...... . . . .................. 7

Cooling System - Group 08 .......... . . . .................. 8

Drive Units - Group 09 .............. . . . .................. 9

Air Intake System - Group 10 ......... . . . ................. 10

Exhaust System - Group 11 ..................................................... 11

Air Equipment - Group 12 ...................................................... 12

Electrical Equipment - Group 13 .................................................. 13

Engine Testing - Group 14 ...................................................... 14

Instruments and Controls - Group 15 ............................................... 15

Mounting Adaptations - Group 16 ................................................. 16

Specifications and Torque Values - Group 18 .......................................... 18

Aboutthe Manual .......................................................... i-2

General Cleaning instructions .................................................. i-8

General Repair Instructions .................................................... i-7

General Safety Instructions .................................................... i-6

Generic Symbols . . . . . . . .................................................... i-4

Glossary of Terms . . . . . . .................................................... i-9

How To Use This Manual . .................................................... i-3

Illustrations . . . . . . . . . . . .................................................... i-5

About the Manual

Each group contains the following in sequence:

l An Alphabetical Table of Contents (Index).

l Exploded view(s) of all the components -in the group.

How To Use This Manual

The illustrations used in the “Repair Sections” of this manual

The illustrations are intended to show repair or replacement

General Safety Instructions

General Repair Instructions

General Cleaning Instructions

D. C.: Direct Current

E. S. N. Engine Serial Number

Hammer: A hand tool consisting of a hard steel head on a handle.

I. D.: Inside Diameter