Perkins 1103 &1104 Series

WORKSHOP MANUAL

Systems Operation /
Testing and Adjusting

3 and 4 cylinder, naturally aspirated, and turbocharged

diesel engines for agricultural and industrial use

Publication SENR9777-00
© Proprietary information of Perkins Engines Company Limited 2004, all rights reserved.
The information is correct at the time of print.
Published by Technical Publications.
Perkins Engines Company Limited, Peterborough, PE1 5NA, England
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
 3
Table of Contents

Table of Contents Electric Starting System - Test .............................. 49

Glow Plugs - Test .................................................. 51
V-Belt - Test .......................................................... 52
Systems Operation Section
Index Section
Engine Design ....................................................... 4
General Information ................................................ 5 Index ..................................................................... 53
Fuel System ........................................................... 9
Air Inlet and Exhaust System ............................... 10
Lubrication System .............................................. 13
Cooling System .................................................... 16
Basic Engine ......................................................... 17
Electrical System ................................................. 19

Testing and Adjusting Section

Fuel System
Fuel System - Inspect ........................................... 22
Air in Fuel - Test .................................................... 22
Finding Top Center Position for No. 1 Piston ........ 23
Fuel Injection Pump Timing - Check ..................... 24
Fuel Injection Pump Timing - Adjust ..................... 25
Fuel Quality - Test ................................................. 27
Fuel System - Prime ............................................. 27
Fuel System Pressure - Test ................................. 28

Air Inlet and Exhaust System

Air Inlet and Exhaust System - Inspect ................. 29
Wastegate - Test ................................................... 29
Compression - Test ............................................... 30
Engine Valve Lash - Inspect/Adjust ...................... 30
Valve Depth - Inspect ............................................ 33
Valve Guide - Inspect ............................................ 33

Lubrication System
Engine Oil Pressure - Test .................................... 35
Engine Oil Pump - Inspect .................................... 35
Excessive Bearing Wear - Inspect ........................ 36
Excessive Engine Oil Consumption - Inspect ....... 36
Increased Engine Oil Temperature - Inspect ........ 37

Cooling System
Cooling System - Check (Overheating) ................ 38
Cooling System - Inspect ...................................... 39
Cooling System - Test ........................................... 39
Engine Oil Cooler - Inspect ................................... 41
Water Temperature Regulator - Test ..................... 42

Basic Engine
Piston Ring Groove - Inspect ................................ 43
Connecting Rod - Inspect ..................................... 43
Connecting Rod Bearings - Inspect ...................... 44
Main Bearings - Inspect ........................................ 44
Cylinder Block - Inspect ........................................ 44
Cylinder Head - Inspect ........................................ 45
Piston Height - Inspect .......................................... 45
Flywheel - Inspect ................................................. 46
Gear Group - Inspect ............................................ 47

Electrical System
Alternator - Test .................................................... 48
Battery - Test ......................................................... 48
4
Systems Operation Section

Systems Operation Section

i01958113

Engine Design

g01014247
Illustration 2
1103 example of the layout of the valves
(A) Inlet valve
(B) Exhaust valve

1103 Engine Specification

g00984281
Type ......................... Three cylinder and four stroke
Illustration 1
1104 example of the layout of the valves Type of combustion .......................... Direct injection
(A) Inlet valve
(B) Exhaust valve Bore ........................................ 105 mm (4.133 inch)

1104 Engine Specification Stroke ........................................ 127 mm (5.00 inch)

Type ........................... Four cylinder and four stroke Displacement ..................................... 3.3 L (201 in3)

Type of combustion .......................... Direct injection Compression ratio

Bore ........................................ 105 mm (4.133 inch) Naturally aspirated ......................................... 19.2:1

Stroke ........................................ 127 mm (5.00 inch) Turbocharged ............................................... 18.25:1

Displacement ..................................... 4.4 L (268 in3) Number of cylinders ............................................... 3

Compression ratio Cylinder arrangement ..................................... In-line

Naturally aspirated ......................................... 19.3:1 Firing order ..................................................... 1, 2, 3

Turbocharged ................................................. 18.2:1 When the crankshaft is viewed from the front of
the engine, the crankshaft rotates in the following
Number of cylinders ............................................... 4 direction. ................................................... Clockwise

Cylinder arrangement ..................................... In-line The front of the engine is opposite the flywheel end
of the engine. The left side of the engine and the
Firing order ............................................... 1, 3, 4, 2 right side of the engine are determined from the
flywheel end. Number 1 cylinder is the front cylinder
When the crankshaft is viewed from the front of of the engine.
the engine, the crankshaft rotates in the following
direction. ................................................... Clockwise

The front of the engine is opposite the flywheel end

of the engine. The left side of the engine and the
right side of the engine are determined from the
flywheel end. Number 1 cylinder is the front cylinder
of the engine.
 5
Systems Operation Section

i01958097 Coolant from the bottom of the radiator passes

through the water pump. The water pump is driven
General Information by the idler gear.

Lifting the Engine

Engine Description
NOTICE
Note: When you are ordering new parts, refer Failure to follow recommended procedures for han-
to the engine identification number in order to dling or transporting engines can lead to engine dam-
receive the correct parts. Refer to the Operation age.
and Maintenance Manual, “Product Identification
Information” for the correct numbers for your engine. To avoid possible engine damage, use the following
procedure.
The engine cylinders are arranged in-line. The
engines are controlled by a mechanically governed When you are lifting or moving the engine, use the
fuel injection pump. following procedures in order to prevent engine
damage.
The cylinder head assembly has one inlet valve
and one exhaust valve for each cylinder. Each 1. Do not tilt the engine to an extreme angle unless
valve has one valve spring. The pistons have two the lubricating oil is first drained from the oil pan.
compression rings and an oil control ring.
2. Do not turn the engine onto a side or an end
It is important to ensure the correct piston height so surface unless the lubricating oil is first drained
that the piston does not contact the cylinder head. from the oil pan.
The correct piston height also ensures the efficient
combustion of fuel. 3. If the oil is not drained prior to tilting the engine
or turning the engine onto a side or an end
The 1104 engine crankshaft has five main journals. surface, the lubricating oil from the oil pan can
End play is controlled by thrust washers that are flow into the intake manifold and the cylinder
located on both sides of the center main bearing. bores. This situation could cause a hydraulic
lock in the engine. Hydraulic lock can severely
The 1103 engine crankshaft has four main journals. damage the engine.
End play is controlled by thrust washers that are
located on both sides of the number three main 4. The engine oil should be refilled to the correct
bearing. level before the engine is started.
The timing case has a hole that corresponds with
a hole in the crankshaft. Use an alignment pin to
find TC. The camshaft gear has a timing hole that
corresponds with a timing hole in the timing case.
The timing holes ensure that the camshaft and the
crankshaft are in time with each other.

The crankshaft gear rotates the idler gear. The idler

gear rotates the camshaft gear and the fuel injection
pump gear. The idler gear for the engine oil pump
is rotated by the crankshaft gear. This idler rotates
the engine oil pump.

The fuel injection pump is a gear-driven pump that

is mounted to the back of the front housing. The
fuel transfer pump is electrically operated. The fuel
transfer pump has an integral fuel filter. The fuel
transfer pump is usually located on the left hand
side of the cylinder block. Some applications may
have the fuel transfer pump and the water separator
(if equipped) relocated off the engine.

The oil pump is driven by an idler gear. The engine

oil pump sends lubricating oil to the main oil gallery.
The oil relief valve is internal to the oil pump.
6
Systems Operation Section

1104 Engine Model Views

g00993373
Illustration 3
(1) Water temperature regulator housing (4) Engine oil cooler (7) Crankshaft pulley
(2) Valve mechanism cover (5) Fan drive (8) Oil pan
(3) Fuel transfer pump and fuel filter (6) Water pump (9) Engine oil filter
 7
Systems Operation Section

g00928546
Illustration 4
(10) Engine oil filler cap (13) Alternator (16) Starter motor
(11) Exhaust manifold (14) Flywheel housing
(12) Turbocharger (15) Flywheel
8
Systems Operation Section

1103 Engine Model Views

g01011348
Illustration 5
(1) Alternator (3) Turbocharger oil supply (5) Turbocharger
(2) Fan pulley (4) Turbocharger oil drain (6) Exhaust manifold
 9
Systems Operation Section

g01011349
Illustration 6
(1) Fuel transfer pump (6) Oil filter
(2) Oil filler cap (7) Oil pan
(3) Fuel filter (8) Crankshaft pulley
(4) Starter motor (9) Water pump
(5) Dipstick (10) Water temperature regulator housing

i01912946 The fuel transfer pump draws fuel from the fuel
tank and through the water separator. When the
Fuel System fuel goes through the water separator, any water
in the fuel will go to the bottom of the bowl. The
fuel transfer pump sends the fuel at a low pressure
to the fuel filter. From the fuel filter, the fuel goes
The Delphi DP210 fuel injection pump is installed on through the supply line to the fuel injection pump.
the 1104 engine and the 1103 engine. The Bosch
EPVE fuel injection pump is installed on the 1104 The fuel injection pump sends fuel through the high
engine only. pressure fuel line to each of the fuel injectors. The
fuel injector sprays the fuel into the cylinder. Fuel
that is not injected flows through the fuel return line
to the top of the fuel filter, back to the fuel tank.
10
Systems Operation Section

The engine must not be started until the fuel Cold Start Advance Unit
injection pump is full of fuel that is free of air. The
fuel injection pump requires fuel for lubrication. The The cold start advance unit holds the timing of the
precision parts of the pump are easily damaged fuel injection pump in an advance position when
without lubrication. the engine is cold.

The fuel system must be primed when any of the The coolant switch for the cold start advance unit
following conditions occur: is on the rear of the timing case on the left side of
the engine.
• The fuel filter is changed.
When the engine is cold, the sender unit is
• The fuel line is removed. energized in order to advance the fuel injection
pump timing for the cold start operation. When the
• The fuel injection pump is removed. correct temperature is achieved the sender unit is
de-energized and the fuel injection pump timing is
returned to the normal operating position.
Fuel System Components
If the switch fails in the closed position, the engine
Fuel Injection Pump will run with advanced fuel injection timing. The
engine will have higher cylinder pressure and
General Operation engine damage may result.
The fuel injection pump is a pressurized system If the switch fails in the open position the engine
that is totally enclosed. The pump sends the correct will run with the fuel injection timing in the normal
amount of fuel under high pressure at the correct operating position. The engine will be more difficult
time through the fuel injectors to the individual to start. When the engine is cold the engine might
cylinders. The fuel injection pump regulates the emit white smoke.
amount of fuel that is delivered to the fuel injectors.
This action controls the engine rpm by the governor
setting or the position of the throttle control. i01912948

The fuel lines to the fuel injectors are equal lengths. Air Inlet and Exhaust System
This ensures even pressure and correct injection
timing at each fuel injector.

During operation, extra fuel is used as coolant and

lubricant for moving parts of the pump. The extra
fuel is circulated through the pump housing. The
extra fuel is then returned to the fuel tank.

The Delphi DP210 fuel injection pump must be

serviced by an authorized Delphi technician. For
repair information, contact your Perkins dealer or
contact your Perkins distributor.

High idle and low idle of the fuel injection pump are
factory set. Idle adjustments can not be made to
the fuel pump. The fuel injection pump has a boost
control and an engine stop solenoid. The Delphi Illustration 7 g00281646
DP210 fuel injection pump has a feature that vents
Air inlet and exhaust system (typical example)
air from the pump.
(1) Exhaust manifold
(2) Intake manifold
The fuel injection pump has a cold starting aid. The (3) Engine cylinders
cold starting aid advances the timing of the pump (4) Air intake
when the engine is cold. The cold starting aid is (5) Turbocharger compressor wheel
electrically operated. (6) Turbocharger turbine wheel
(7) Exhaust outlet
 11
Systems Operation Section

Engines which are naturally aspirated pull outside • Power output is increased.
air through an air cleaner directly into the inlet
manifold (2). The air flows from the intake manifold • Fuel efficiency is increased.
to the engine cylinders (3). The fuel is mixed with the
air in the engine cylinders. After the fuel combustion • Engine torque is increased.
occurs in the engine cylinder, the exhaust gases
flow directly to the outside air through the exhaust • Durability of the engine is increased.
manifold (1).
• Emissions of the engine are increased.
Turbocharged engines pull outside air through an
air cleaner into the air intake (4) of the turbocharger.
The suction is caused by the turbocharger
compressor wheel (5). Then, the turbocharger
compressor wheel compresses the air. The air flows
through the intake manifold (2) which directs an
even distribution of the air to each engine cylinder
(3). Air is pulled into the engine cylinder (3) during
the intake stroke of the piston. Then, the air is mixed
with fuel from the fuel injectors.

Each piston makes four strokes:

1. Intake

2. Compression

3. Power

4. Exhaust

The sequence of the strokes by all of pistons in all g00302786

Illustration 8
of the engine cylinders provide constant air flow to
the inlet system during the engine operation. Components of a turbocharger (typical example)
(1) Air intake
The exhaust stroke and the timing of the valve (2) Compressor housing
(3) Compressor wheel
mechanism pushes combustion gases out of the (4) Bearing
open exhaust valve through the exhaust manifold (5) Oil inlet port
(1). The exhaust gases flow through the blades of (6) Bearing
the turbocharger turbine wheel (6) which causes (7) Turbine housing
(8) Turbine wheel
the turbine wheel and the compressor wheel to turn. (9) Exhaust outlet
Then, the exhaust gases flow through the exhaust (10) Oil outlet port
outlet (7) of the turbocharger to the outside. (11) Exhaust inlet

The air inlet system is also equipped with a A turbocharger is installed between the exhaust
crankcase ventilation system. The intake strokes of and intake manifolds. The turbocharger is driven by
the pistons pull in atmospheric air to the crankcase. exhaust gases which flow through the exhaust inlet
(11). The energy of the exhaust gas turns the turbine
Turbocharger wheel (8). Then, the exhaust gas flows out of the
turbine housing (7) through the exhaust outlet (9).
Note: The turbocharger is not serviceable.
The turbine wheel and the compressor wheel (3) are
A turbocharger increases the temperature and the installed on the same shaft. Therefore, the turbine
density of the air that is sent to the engine cylinder. wheel and the compressor wheel rotate at the same
This condition causes a lower temperature of rpm. The compressor wheel is enclosed by the
ignition to develop earlier in the compression stroke. compressor housing (2). The compressor wheel
The compression stroke is also timed in a more compresses the intake air (1). The intake air flows
accurate way with the fuel injection. Surplus air into the engine cylinders through the inlet valves of
lowers the temperature of combustion. This surplus the cylinders.
air also provides internal cooling.

A turbocharger improves the following aspects of

engine performance:
12
Systems Operation Section

The oil from the main gallery of the cylinder block The camshaft gear is driven by the crankshaft gear.
flows through the oil inlet port (5) in order to The camshaft and the crankshaft are timed together.
lubricate the turbocharger bearings (4) and (6). The When the camshaft turns, the valve lifters are moved
pressurized oil passes through the bearing housing up and down. The pushrods move the rocker arms.
of the turbocharger. The oil is returned through the The movement of the rocker arms open the valves.
oil outlet port (10) to the oil pan. The opening and closing of the valves is timed with
the firing sequence of the engine. The valve springs
Some turbochargers have a wastegate. The push the valves back to the closed position.
wastegate is controlled by the boost pressure.
This allows some of the exhaust to bypass the
turbocharger at higher engine speeds. The
wastegate is a type of valve that automatically
opens at a preset level of boost pressure in order to
allow exhaust gas to flow around the turbine. The
wastegate allows the design of the turbocharger to
be more effective at lower engine speeds.

The wastegate is controlled by a diaphragm. One

side of this diaphragm is open to the atmosphere.
The other side of this diaphragm is open to the
manifold pressure.

Cylinder Head And Valves

The valves and the valve mechanism control
the flow of the air and the exhaust gases in the
cylinder during engine operation. The cylinder head
assembly has two valves for each cylinder. Each
valve has one valve spring. The ports for the inlet
valves are on the left side of the cylinder head. The
ports for the exhaust valves are on the right side
of the cylinder head. Steel valve seat inserts are
installed in the cylinder head for both the inlet and
the exhaust valves. The valve seat inserts can be
replaced.

The valves move along valve guides. The valve

guides can be replaced. The exhaust valve guide
has a counterbore in order to prevent the seizure
of the valve stem. The seizure of the valve stem is
caused by a buildup of carbon under the head of
the valve.

The inlet and the exhaust valves are opened

and closed by the rotation and movement of the
following components:

• Crankshaft
• Camshaft
• Valve lifters
• Pushrods
• Rocker arms
• Valve springs
 13
Systems Operation Section

i01958103

Lubrication System

g01009682
Illustration 9
Flow diagram of the lubrication system for the 1104 engine
14
Systems Operation Section

g01016473
Illustration 10
Flow diagram of the lubrication system for the 1103 engine

Pressure for the lubrication system is supplied by Lubricating oil from the oil pan flows through a
the oil pump (10). The crankshaft gear (13) drives strainer and a pipe (9) to the suction side of the
a lower idler gear (12). The lower idler gear drives engine oil pump. The lubricating oil flows from the
the oil pump gear (11). The pump has an inner outlet side of the pump through a passage to the oil
rotor and an outer rotor. The axis of rotation of the filter head (7). The oil then flows from the filter head
rotors are off-center relative to each other. There is through a passage to a plate type oil cooler for the
an interference fit between the inner rotor and the 1104 engine, or a modine oil cooler (3) for the 1103
drive shaft. engine. The integral oil cooler is located on the left
side of the cylinder block. The modine oil cooler is
The inner rotor has five lobes which mesh with the located on the left side of the cylinder block.
six lobes of the outer rotor. When the pump rotates,
the distance increases between the lobes of the From the oil cooler, the oil returns through a passage
outer rotor and the lobes of the inner rotor in order to the oil filter head. The oil then flows from the filter
to create suction. When the distance decreases head to the bypass valve and from the bypass
between the lobes, pressure is created. valve to the oil filter (8).
 15
Systems Operation Section

The oil flows from the oil filter through a passage

that is drilled across the cylinder block to the oil
gallery (4). The oil gallery is drilled through the total
length of the left side of the cylinder block. If the oil
filter is on the right side of the engine, the oil flows
through a passage that is drilled across the cylinder
block to the pressure gallery.

Lubricating oil from the oil gallery flows through

high pressure passages to the main bearings of
the crankshaft (5). Then, the oil flows through the
passages in the crankshaft to the connecting rod
bearing journals (6). The pistons and the cylinder
bores are lubricated by the splash of oil and the
oil mist.

Lubricating oil from the main bearings flows through

passages in the cylinder block to the journals of the
camshaft. Then, the oil flows from the second journal
of the camshaft (2) at a reduced pressure to the
cylinder head. The oil then flows through the center
of the rocker shaft (1) to the rocker arm levers. The
valve stems, the valve springs and the valve lifters
are lubricated by the splash and the oil mist.

The hub of the idler gear is lubricated by oil from

the oil gallery. The timing gears are lubricated by
the splash from the oil.

Turbochargers are lubricated by oil from a

connection on the side of the cylinder block. An
external line from the cylinder block supplies oil to
the turbocharger. The oil then flows through a line
to the oil pan.

Engines have piston cooling jets that are supplied

with oil from the oil gallery. The piston cooling jets
spray lubricating oil on the underside of the pistons
in order to cool the pistons.
16
Systems Operation Section

i01958111

Cooling System

g00985481
Illustration 11
Flow diagram of the cooling system for the 1104 engine
 17
Systems Operation Section

g01016432
Illustration 12
Flow diagram of the cooling system for the 1103 engine

The coolant flows from the bottom of the radiator to The coolant flows forward through the cylinder head
the centrifugal water pump. The water pump assists and into the water temperature regulator housing.
in the flow of the coolant through the system. The If the water temperature regulator is closed, the
water pump is installed on the front of the timing coolant goes directly through a bypass to the inlet
case. The water pump is gear-driven by the fuel side of the water pump. If the water temperature
injection pump gear. regulator is open, the bypass is closed and the
coolant flows to the top of the radiator.
The water pump forces the coolant through a
passage in the front of the timing case to the water
i01958135
jacket in the top left side of the cylinder block. The
coolant continues to the rear of the cylinder block
and some of the coolant passes into the oil cooler
Basic Engine
for the 1104 or into the modine oil cooler for the
1103. The oil cooler is located on the left side of the
cylinder block with no external lines. The modine
oil cooler is located on the left side of the cylinder Cylinder Block and Cylinder Head
block.
The cylinder block for the 1104 engine has four
The coolant flows around the element of the oil cylinders which are arranged in-line.
cooler to the rear of the cylinder block. The coolant
then passes from the rear of the cylinder block and The cylinder block for the 1103 engine has three
into the rear of the cylinder head. cylinders which are arranged in-line.
18
Systems Operation Section

The cylinder block for the 1104 engine has five The connecting rod is matched to each cylinder.
main bearings which support the crankshaft. Thrust The piston height is controlled by the length of the
washers on both sides of the center main bearing connecting rod. Six different lengths of connecting
control the end play of the crankshaft. rods are available in order to attain the correct
piston height. The different lengths of connecting
The cylinder block for the 1103 engine has four rods are made by machining the small end bearing
main bearings which support the crankshaft. Thrust off-center in order to form an eccentric bearing. The
washers on both sides of the number three main amount of the eccentricity of the bearing creates
bearing control the end play of the crankshaft. the different lengths of the connecting rods.

A cylinder head gasket is used between the engine Each cylinder has a piston cooling jet that is
block and the cylinder head in order to seal installed in the cylinder block. The piston cooling
combustion gases, water, and oil. jet sprays engine oil onto the inner surface of the
piston in order to cool the piston.
The engine has a cast iron cylinder head. The Inlet
manifold is integral within the cylinder head. An inlet
valve and an exhaust valve for each cylinder are
Crankshaft
controlled by a pushrod valve system. The ports for
The crankshaft changes the combustion forces in
the inlet valves are on the left side of the cylinder
the cylinder into usable rotating torque in order to
head. The ports for the exhaust valves are on the power the engine. Vibration is caused by impacts
right side of the cylinder head.
from combustion along the crankshaft.

Pistons, Rings, and Connecting A gear at the front of the crankshaft drives the
Rods timing gears. The crankshaft gear turns the idler
gear which then turns the following gears:
The pistons have a combustion chamber in the top
of the piston in order to provide an efficient mix of • Camshaft gear
fuel and air. The piston pin is off-center in order to
reduce the noise level. • Fuel injection pump

The pistons have two compression rings and an oil • Lower idler gear which turns the gear of the
lubricating oil pump
control ring. The groove for the top ring has a hard
metal insert in order to reduce wear of the groove.
The skirt has a layer of graphite in order to reduce Lip type seals are used on both the front of the
crankshaft and the rear of the crankshaft.
wear.

The correct piston height is important in order to Camshaft

ensure that the piston does not contact the cylinder
head. The correct piston height also ensures the The engine has a single camshaft. The camshaft is
efficient combustion of fuel which is necessary in driven by an idler gear in the front housing. The
order to conform to requirements for emissions. camshaft uses only one bearing on the front journal.
The other journals rotate in the bore of the cylinder
Engines are equipped with connecting rods that are block. The front bearing and the camshaft bores
fracture split. The fracture split connecting rods are in the cylinder block support the camshaft. As the
retained with torx screws. Connecting rods that are camshaft turns, the camshaft lobes move the valve
fracture split have the following characteristics: system components. The valve system components
move the cylinder valves. The camshaft gear must
• Higher integrity for the rod be timed to the crankshaft gear. The relationship
between the lobes and the camshaft gear causes
• The splitting produces an accurately matched the valves in each cylinder to open at the correct
surface on each side for improved strength. time. The relationship between the lobes and the
camshaft gear also causes the valves in each
• Modern design cylinder to close at the correct time.
 19
Systems Operation Section

i01958096

Electrical System

The electrical system is a negative ground system.

The charging circuit operates when the engine

is running. The alternator in the charging circuit
produces direct current for the electrical system.

Starting Motor

g00954820
Illustration 13
12 Volt Starting Motor
(1) Terminal for connection of the battery cable
(2) Terminal for connection of the ignition switch
20
Systems Operation Section

g00956095
Illustration 14
24 Volt Starting Motor
(1) Terminal for connection of the ignition (2) Terminal for connection of the battery
switch cable

The starting motor turns the engine flywheel. The Alternator

rpm must be high enough in order to initiate a
sustained operation of the fuel ignition in the
cylinders.

The starting motor has a solenoid. When the ignition

switch is activated, voltage from the electrical
system will cause the solenoid to move the pinion
toward the flywheel ring gear of the engine. The
electrical contacts in the solenoid close the circuit
between the battery and the starting motor barely
before the pinion engages the ring gear. This
causes the starting motor to rotate. This type of
activation is called a positive shift.

When the engine begins to run, the overrunning

clutch of the pinion drive prevents damage to the
armature. Damage to the armature is caused by
excessive speeds. The clutch prevents damage
by stopping the mechanical connection. However,
the pinion will stay meshed with the ring gear until
the ignition switch is released. A spring in the
overrunning clutch returns the clutch to the rest Illustration 15 g00303424
position.
(1) Shaft for mounting the pulley

The alternator produces the following electrical

output:

• Three-phase
• Full-wave
• Rectified
 21
Systems Operation Section

The alternator is an electro-mechanical component.

The alternator is driven by a belt from the crankshaft
pulley. The alternator charges the storage battery
during the engine operation.

The alternator converts the mechanical energy

and the magnetic energy into alternating current
and voltage. This conversion is done by rotating a
direct current electromagnetic field on the inside of
a three-phase stator. The electromagnetic field is
generated by electrical current flowing through a
rotor. The stator generates alternating current and
voltage.

The alternating current is changed to direct current

by a three-phase, full-wave rectifier. Direct current
flows to the output terminal of the alternator. The
rectifier has three exciter diodes. The direct current
is used for the charging process.

A regulator is installed on the rear end of the

alternator. Two brushes conduct current through two
slip rings. The current then flows to the rotor field. A
capacitor protects the rectifier from high voltages.

The alternator is connected to the battery through

the ignition switch. Therefore, alternator excitation
occurs when the switch is in the ON position.
22
Testing and Adjusting Section

Testing and Adjusting 2. Install a suitable fuel flow tube with a visual sight
gauge in the fuel return line. When possible,
Section install the sight gauge in a straight section of the
fuel line that is at least 304.8 mm (12 inches)
long. Do not install the sight gauge near the
following devices that create turbulence:
Fuel System
• Elbows
i01804057
• Relief valves
Fuel System - Inspect • Check valves
Observe the fuel flow during engine cranking.
A problem with the components that send fuel to Look for air bubbles in the fuel. If there is no
the engine can cause low fuel pressure. This can fuel that is present in the sight gauge, prime
decrease engine performance. the fuel system. Refer to Testing and Adjusting,
“Fuel System - Prime” for more information. If the
1. Check the fuel level in the fuel tank. Ensure that engine starts, check for air in the fuel at varying
the vent in the fuel cap is not filled with dirt. engine speeds. When possible, operate the
engine under the conditions which have been
2. Check all fuel lines for fuel leakage. The fuel lines suspect.
must be free from restrictions and faulty bends.
Verify that the fuel return line is not collapsed.

3. Inspect the fuel filter for excess contamination. If

necessary, install a new fuel filter. Determine the
source of the contamination. Make the necessary
repairs.

4. Service the primary fuel filter (if equipped).

5. Remove any air that may be in the fuel system.

Refer to Testing and Adjusting, “Fuel System -
Prime”.

i01854200

Air in Fuel - Test

This procedure checks for air in the fuel system. g00578151

This procedure also assists in finding the source Illustration 16
of the air. (1) A steady stream of small bubbles with a diameter of
approximately 1.60 mm (0.063 inch) is an acceptable amount
of air in the fuel.
1. Examine the fuel system for leaks. Ensure that (2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch)
the fuel line fittings are properly tightened. Check are also acceptable if there is two seconds to three seconds
the fuel level in the fuel tank. Air can enter the intervals between bubbles.
fuel system on the suction side between the fuel (3) Excessive air bubbles in the fuel are not acceptable.
transfer pump and the fuel tank.

Work carefully around an engine that is running.

Engine parts that are hot, or parts that are moving,
can cause personal injury.
 23
Testing and Adjusting Section

3. If excessive air is seen in the sight gauge in the i01893344

fuel return line, install a second sight gauge at
the inlet to the fuel transfer pump. If a second Finding Top Center Position
sight gauge is not available, move the sight for No. 1 Piston
gauge from the fuel return line and install the
sight gauge at the inlet to the fuel transfer pump.
Observe the fuel flow during engine cranking.
Look for air bubbles in the fuel. If the engine Table 1
starts, check for air in the fuel at varying engine
Required Tools
speeds.
Part
Part Description Qty
If excessive air is not seen at the inlet to the fuel Number
transfer pump, the air is entering the system after 27610211 Crankshaft timing pin 1
the fuel transfer pump. Refer to the Testing and
Adjusting, “Fuel System - Prime”. 27610212 Camshaft timing pin 1

If excessive air is seen at the inlet to the fuel

transfer pump, air is entering through the suction
side of the fuel system.

To avoid personal injury, always wear eye and face

protection when using pressurized air.

NOTICE
To avoid damage, do not use more than 55 kPa (8 psi)
to pressurize the fuel tank.

4. Pressurize the fuel tank to 35 kPa (5 psi). Do not

use more than 55 kPa (8 psi) in order to avoid
damage to the fuel tank. Check for leaks in the
fuel lines between the fuel tank and the fuel
transfer pump. Repair any leaks that are found.
Check the fuel pressure in order to ensure that g00923080
the fuel transfer pump is operating properly. For Illustration 17
information about checking the fuel pressure, see (1) Hole for crankshaft pin
Testing and Adjusting, “Fuel System Pressure (2) Hole for camshaft pin
- Test”.
1. Remove the valve mechanism cover, the glow
5. If the source of the air is not found, disconnect plugs, and the cover for the front housing.
the supply line from the fuel tank and connect an
external fuel supply to the inlet of the fuel transfer Note: The crankshaft timing pin can be inserted with
pump. If this corrects the problem, repair the fuel the crankshaft pulley still on the engine.
tank or the stand pipe in the fuel tank.
2. Rotate the crankshaft in the normal direction
of the engine until the inlet valve of the No. 4
cylinder has just opened and the exhaust valve
of the No. 4 cylinder has not completely closed.

3. Carefully rotate the crankshaft in the normal

direction of the engine in order to align the hole
in the crankshaft with the hole in the cylinder
block and the timing case. Insert the 27610211
Crankshaft Timing Pin fully into the hole in the
crankshaft web.

4. Insert the 27610212 Camshaft Timing Pin

through the hole in the camshaft gear and into
the body of the timing case. The engine is set at
the top center position for No. 1 piston.
24
Testing and Adjusting Section

Note: The camshaft gear can rotate a small amount

when the pin is installed.

5. Remove the timing pins from the camshaft gear

and the crankshaft web.

i01900283

Fuel Injection Pump Timing -

Check

Delphi DP210 Series Fuel Injection

Pump
Note: The Delphi DP210 Series fuel injection pump
timing cannot be checked. If you suspect that the
fuel injection pump timing is incorrect, contact your
Perkins dealer or your Perkins distributor for further Illustration 18 g00988405
information.
(1) Plug
The Delphi DP210 Series fuel injection pump must
be serviced by an authorized Delphi technician. For
repair information, contact your Perkins dealer or
your Perkins distributor. The internal adjustment for
the pump timing is tamper proof. High idle and low
idle are factory set. Idle adjustments can not be
made to the fuel pump.

Bosch EPVE Fuel Injection Pump

Note: The Bosch EPVE fuel injection pump is only
installed on the 1104 engine.
Table 2
Required Tools
Part
Part Description Qty
Number
Bosch EPVE fuel injection pump
27610248 1
timing adapter
g00988406
Illustration 19
1. Set the number one piston at the top center (2) Bosch EPVE fuel injection pump timing adapter
piston on the compression stroke. Refer to (3) Dial indicator
Testing and Adjusting, “Finding Top Center
Position for the No. 1 Pistion” for the procedure. 3. Remove the plug (1) and the washer from
the rear of the fuel injection pump and install
2. Remove the high pressure fuel lines from the fuel 27610248 fuel injection pump timing adapter (2).
injection pump. Install a suitable dial indicator (3) into 27610248
fuel injection pump timing adapter. Set the dial
indicator to approximately 3 mm (0.1181 inch).

4. Rotate the crankshaft counterclockwise until the

dial indicator (3) indicates that the plunger of the
fuel injection pump is at the bottom of the stroke.
Set the dial indicator (3) to zero.
 25
Testing and Adjusting Section

5. Rotate the crankshaft clockwise, until the Note: This procedure must only be carried out by a
crankshaft timing pin can be pushed into the person with the correct training.
hole in the crankshaft web.
Note: Do not rotate the fuel injection pump if the
6. With the engine set at the Top Center Position fuel injection pump shaft is locked.
for the No. 1 piston, check the reading on the
dial indicator (3). Refer to Specifications, “Fuel 1. Set the number one piston at the top center on
Injection Pump” for the correct reading for the the compression stroke. Refer to Testing and
plunger. Adjusting, “Finding Top Center Position for the
No. 1 Pistion” for the procedure.
7. If the fuel injection pump timing is correct remove
the dial indicator (3). Remove 27610248 fuel 2. Remove the rocker shaft. Refer to Disassembly
injection pump timing adapter from the fuel and Assembly, “Rocker Shaft and Pushrods”.
injection pump. Install a new washer to the
plug and install the plug in the back of the fuel 3. Remove the high pressure fuel lines from the fuel
injection pump. Refer to Specifications, “Fuel injection pump.
Injection Pump” for the correct torque.

8. Install the high pressure fuel lines on the fuel

injection pump. Eliminate all air from the fuel
system. Refer to Testing and Adjusting, “Fuel
System - Prime”.

9. If the fuel injection pump timing is incorrect, refer

to Testing and Adjusting, “Fuel Injection Pump
Timing - Adjust”.

i01912949

Fuel Injection Pump Timing -

Adjust

Delphi DP210 Series Fuel Injection

Pump g00996226
Illustration 20
The Delphi DP210 Series fuel injection pump must (1) Plug
be serviced by an authorized Delphi technician. For
repair information, contact your Perkins dealer or
your Perkins distributor. The internal adjustment for
the pump timing is tamper proof. High idle and low
idle of the fuel injection pump are factory set. Idle
adjustments can not be made to the fuel pump.

Bosch EPVE Fuel Injection Pump

Note: The Bosch EPVE fuel injection pump is only
installed on the 1104 engine.
Table 3
Required Tools
g00996227
Illustration 21
Part
Part Description Qty (2) Bosch EPVE fuel injection timing adapter
Number
(3) Dial indicator

Bosch EPVE fuel injection pump

27610248 1
timing adapter
26
Testing and Adjusting Section

4. Remove the plug (1) and the washer from 11. Remove the fuel injection pump gear. Refer
the rear of the fuel injection pump and install to Disassembly and Assembly, “Fuel Injection
27610248 fuel injection pump timing adapter (2). pump - Remove”.
Install a suitable dial indicator (3) into 27610248
fuel injection pump timing adapter. Set the dial
indicator to approximately 3 mm (0.1181 inch).

5. Ensure that the timing pins have been removed

from the engine.

6. Rotate the crankshaft counterclockwise when

the crankshaft is viewed from the front of the
engine. Carefully rotate the crankshaft until the
dial indicator (3) indicates that the plunger of
the fuel injection pump is at the bottom. Set the
dial indicator (3) to zero.

7. Rotate the crankshaft clockwise, until the

g00996242
required lift on the plunger is achieved. Refer Illustration 23
to Specifications, “Fuel Injection Pump” for the (6) Keyway
correct reading.

g00996245
Illustration 24
g00996240
Illustration 22 (7) Outlet
(4) Washer
(5) Locking screw Note: A key should not be installed in the keyway
(6).
8. Lock the fuel injection pump shaft.
In order to lock the shaft of the Bosch EPVE fuel Note: If the fuel injection pump is on the correct
injection pump, loosen the locking screw (5) and stroke, the keyway (6) is toward the outlet (7).
remove the washer (4). Tighten the locking screw
to 31 N·m (23 lb ft). Ensure that the needle of the 12. Set the number one piston at the top center
dial indicator has not moved. piston on the compression stroke. Refer to
Testing and Adjusting, “Finding Top Center
9. Remove the water pump. Refer to Disassembly Position for the No. 1 Pistion” for the procedure.
and Assembly, “Water Pump - Remove and
Install”. 13. Install the fuel injection pump gear. Refer to
Disassembly and Assembly, “Fuel Injection
10. Remove the front cover. Refer to Disassembly pump - Install”.
and Assembly, “Front Cover - Remove and
Install”.
 27
Testing and Adjusting Section

14. Install the front cover. Refer to Disassembly and • Cetane number of the fuel
Assembly, “Front Cover - Remove and Install”.
• Air in the fuel
15. Install the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove and • Other fuel characteristics
Install”.
i01958110
16. Install a new washer to the plug and install the
plug in the back of the fuel injection pump. Refer
to Specifications, “Fuel Injection Pump” for the
Fuel System - Prime
correct torque.

17. Install the rocker shaft. Refer to Disassembly If air enters the fuel system, the air must be purged
and Assembly, “Rocker Shaft and Pushrods”. before the engine can be started. Air can enter the
fuel system when the following events occur:
18. Install the high pressure fuel lines on the fuel
injection pump. Eliminate all air from the fuel
system. Refer to Testing and Adjusting, “Fuel
• The fuel tank is empty or the tank has been
partially drained during normal operation.
System - Prime”.
• The low pressure fuel lines are disconnected.
i01944302
• A leak exists in the low pressure fuel system
Fuel Quality - Test during engine operation.

• The fuel filter or the fuel pump is replaced.

Use the following procedure to test for problems • The high pressure fuel lines are disconnected.
regarding fuel quality:

1. Determine if water and/or contaminants are

Delphi DP210
present in the fuel. Check the water separator (if The Delphi fuel pump will eliminate the air from
equipped). If a water separator is not present, the fuel system automatically. Position the starting
proceed to Step 2. Drain the water separator, if
switch to the RUN position for three minutes. Air in
necessary. A full fuel tank minimizes the potential the fuel and the fuel lines will be purged from the
for overnight condensation. system.
Note: A water separator can appear to be full of fuel
when the water separator is actually full of water. Bosch EVPE
2. Determine if contaminants are present in the The Bosch EPVE fuel pump will not eliminate air
fuel. Remove a sample of fuel from the bottom automatically from the fuel system. the following
of the fuel tank. Visually inspect the fuel sample procedure must be used.
for contaminants. The color of the fuel is not
necessarily an indication of fuel quality. However, • Remove the valve mechanism cover.
fuel that is black, brown, and/or similar to sludge
can be an indication of the growth of bacteria or • Turn the start switch to the RUN position for
oil contamination. In cold temperatures, cloudy three minutes. Then return the start switch to the
fuel indicates that the fuel may not be suitable for OFF position.
the operating conditions. Refer to Operation and
Maintenance Manual, “Fuel Recommendations” • Loosen the high pressure lines at the fuel
for more information. injectors.

3. If fuel quality is still suspected as a possible • Operate the starting motor until fuel free from air
cause of problems regarding engine comes from the connections.
performance, disconnect the fuel inlet line, and
temporarily operate the engine from a separate • Tighten the connections for the fuel injectors.
source of fuel that is known to be good. This Refer to Specifications, “Fuel injection Lines”.
will determine if the problem is caused by fuel
quality. If fuel quality is determined to be the • Operate the engine and check for leaks.
problem, drain the fuel system and replace the
fuel filters. Engine performance can be affected • Fit the valve mechanism cover.
by the following characteristics:
28
Testing and Adjusting Section

i01944991 Check the Function of the Pressure

Fuel System Pressure - Test Regulator
1. Remove the fuel line from the outlet for the
supply for the fuel injection pump (B).

2. Install a pipe with a tap for a pressure gauge.

Connect a 0 to 80 kPa (0 to 12 psi) pressure
gauge.

3. Start the engine and run the engine at idle for

two minutes in order to remove any trapped air.

4. Record the pressure reading at idle and at rated

speed. The pressure reading should be the
following values:

Bosch EPVE

Illustration 25 g00928705 Idle ..................................... 31 kPa (4.49 psi)

(A and B) Fuel outlet Rated speed ...................... 31 kPa (4.49 psi)
(1) Fuel transfer pump
(2) Fuel filter
Delphi DP210
The pressure test measures the output pressure Idle .................................. 27.5 kPa (3.99 psi)
of the fuel transfer pump. Low fuel pressure and
starting difficulty may be indications of problems Rated speed ...................... 28 kPa (4.06 psi)
with the fuel priming pump.
Note: Maximum pressure for the fuel injection pump
Check the Function of the Fuel is 80 kPa (12 psi).

Transfer Pump 5. Reconnect the fuel line. Run the engine at idle for
two minutes in order to remove any trapped air.
1. Make a note of the location of the fuel lines from
the fuel transfer pump. Remove the two lines Check for the following issues if the pressures are
from the outlets (A) and (B). outside of the above specifications.

2. Connect two lengths of 5/16 inch rubber hose • All electrical connections are installed correctly.
to outlets (A) and (B). Place the hoses into a
suitable container that is capable of holding 3 L • There are no leaks in the fuel lines or connections.
(3.17 qt) of fuel.
• The O-ring on the fuel filter housing (2) does not
3. Energize the fuel transfer pump until a constant leak.
flow of fuel is running from the outlet for the
supply for the fuel injection pump.

Note: The flow from the outlet for the return for the
fuel tank will have a slower flow rate.

4. Measure the combined flow of both outlets with

a stopwatch. Fuel flow should be a minimum of
2 L/min (0.53 US gpm).

5. If the combined flow is less than 2 L/min

(0.53 US gpm), repair the pump or replace the
pump.

6. Reconnect the outlet lines in the correct positions.

7. Start the engine and check for any leakage of

fuel or air from the fuel lines.
 29
Testing and Adjusting Section

Air Inlet and Exhaust i01935833

System Wastegate - Test

i01822825

Air Inlet and Exhaust System

- Inspect Hot engine components can cause injury from
burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
A general visual inspection should be made to the
air inlet and exhaust system. Make sure that there
are no signs of leaks in the system. NOTICE
Keep all parts clean from contaminants.
There will be a reduction in the performance of the
engine if there is a restriction in the air inlet system Contaminants may cause rapid wear and shortened
or the exhaust system. component life.

Hot engine components can cause injury from

burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.

Making contact with a running engine can cause

burns from hot parts and can cause injury from
rotating parts.
g01009681
When working on an engine that is running, avoid Illustration 26
contact with hot parts and rotating parts.
Note: The turbocharger is a nonserviceable item.
The pressure for the wastegate can be checked,
1. Inspect the engine air cleaner inlet and ducting but not adjusted.
in order to ensure that the passageway is not
blocked or collapsed. 1. Use a suitable magnetic base dial indicator (1).
Align the dial gauge to the actuator rod (2).
2. Inspect the engine air cleaner element. Replace
a dirty element with a clean element. 2. Remove the air hose to the actuator (3). Install
an air line that can be adjusted in order to give
3. Check for dirt tracks on the clean side of the the correct pressure.
engine air cleaner element. If dirt tracks are
observed, contaminants are flowing past the Note: Do not exceed 205 kPa (30 psi) in order
element. to check the actuator. Refer to the Specification,
“Turbocharger” topic for information on the correct
pressure setting for your actuator.

3. Carefully apply the air pressure until the air

pressure has moved the rod 1 mm (0.0394 inch).
Check that the air pressure is correct for your
turbocharger.

4. For more information on installing a new

turbocharger, contact your Perkins dealer or your
Perkins distributor.
30
Testing and Adjusting Section

i01888954 Refer to Systems Operation, “Engine Design” for

the location of the cylinder valves.
Compression - Test
If the valve lash requires adjustment several times
in a short period of time, excessive wear exists in a
different part of the engine. Find the problem and
The cylinder compression test should only be used make necessary repairs in order to prevent more
in order to compare the cylinders of an engine. If damage to the engine.
one or more cylinders vary by more than 350 kPa
(51 psi), the cylinder and related components may Not enough valve lash can be the cause of rapid
need to be repaired. wear of the camshaft and valve lifters. Not enough
valve lash can indicate that the seats for the valves
A compression test should not be the only method are worn.
which is used to determine the condition of an
engine. Other tests should also be conducted Valves become worn due to the following causes:
in order to determine if the adjustment or the
replacement of components is required. • Fuel injectors that operate incorrectly
Before the performance of the compression test, • Excessive dirt and oil are present on the filters
make sure that the following conditions exist: for the inlet air.

• The battery is in good condition. • Incorrect fuel settings on the fuel injection pump.
• The battery is fully charged. • The load capacity of the engine is frequently
exceeded.
• The starting motor operates correctly.
Too much valve lash can cause broken valve stems,
• The valve lash is set correctly. springs, and spring retainers. Too much valve lash
can be an indication of the following problems:
• All fuel injectors are removed.
• Worn camshaft and valve lifters
• The fuel supply is disconnected.
• Worn rocker arms
1. Install a gauge for measuring the cylinder
compression in the hole for a fuel injector. • Bent pushrods
2. Operate the starting motor in order to turn the • Broken socket on the upper end of a pushrod
engine. Record the maximum pressure which is
indicated on the compression gauge. • Loose adjustment screw for the valve lash
3. Repeat Steps 1 and 2 for all cylinders. If the camshaft and the valve lifters show rapid
wear, look for fuel in the lubrication oil or dirty
i01958109
lubrication oil as a possible cause.

Engine Valve Lash - Inspect Valve Lash

Inspect/Adjust
An adjustment is NOT NECESSARY if the
measurement of the valve lash is in the acceptable
range. Inspect the valve lash while the engine is
stopped. The temperature of the engine does not
change the valve lash setting.
To prevent possible injury, do not use the starter Engine valve lash for the 1104 engine
to turn the flywheel.

Hot engine components can cause burns. Allow

additional time for the engine to cool before mea-
suring valve clearance.
 31
Testing and Adjusting Section

Table 4
Inlet Valves Exhaust Valves
1104 1104 Accidental engine starting can cause injury or
Valve Lash death to personnel.
0.20 mm 0.45 mm
(Stopped
(0.008 inch) (0.018 inch) To prevent accidental engine starting, turn the ig-
Engine)
nition switch to the OFF position, place a do not
TC operate tag at the ignition switch location and dis-
Compression 1,2 1,3
connect and tape the electrical connection to the
Stroke
stop solenoid that is located on the fuel injection
TC Exhaust pump.
3,4 2,4
Stroke(1)
Firing Order 1,3,4,2(2) Remove the valve mechanism cover and perform
(1) 
360 from TC compression stroke the following procedure in order to adjust the valve
(2) The No. 1 cylinder is at the front of the engine. lash:

Engine valve lash for the 1103 engine 1. Put the No. 1 piston at the top center position
on the compression stroke. Refer to Testing and
Table 5 Adjusting, “Finding Top Center Position for No.
Valves Inlet Valves Exhaust Valves
1 Piston”.

0.20 mm 0.45 mm Table 6

Valve Lash
(0.008 inch) (0.018 inch)
TC
Valves 1, 3, 5 2, 4, 6 Compression Inlet Valves Exhaust Valves
Stroke
Firing order 1, 2, 3
0.20 mm 0.45 mm
Valve Lash
(0.008 inch) (0.018 inch)
If the measurement is not within the acceptable
clearance, adjustment is necessary. Refer to “Valve Cylinders 1,2 1,3
Lash Adjustment”.
2. Adjust the valves according to Table 5.
Valve Lash Adjustment for the 1104
a. Lightly tap the rocker arm at the top of the
engine adjustment screw with a soft mallet. This
will ensure that the lifter seats against the
Note: The No. 1 cylinder is at the front of the engine. camshaft.

b. Loosen the adjustment locknut.

c. Place the correct feeler gauge between the

rocker arm and the valve stem. Then, turn the
adjustment screw in a clockwise direction.
Slide the feeler gauge between the rocker
arm and the valve stem. Continue turning the
adjustment screw until a slight drag is felt on
the feeler gauge. Remove the feeler gauge.

d. Tighten the adjustment locknut to a torque of

27 N·m (20 lb ft). Do not allow the adjustment
screw to turn while you are tightening the
adjustment locknut. Recheck the valve lash
after tightening the adjustment locknut.

3. Rotate the engine by 360 degrees. The engine

will be on TC compression stroke for cylinder 4.

g01016764
Illustration 27
Setting the valve lash
(1) Adjustment screw
(2) Feeler gauge
32
Testing and Adjusting Section

Table 7
TC Exhaust
Inlet Valves Exhaust Valve
Stroke(3)
0.20 mm 0.45 mm
Valve Lash
(0.008 inch) (0.018 inch)
Cylinders 3,4 2,4
(3) Position for No. 1 cylinder

4. Adjust the valves according to Table 7.

a. Lightly tap the rocker arm at the top of the

adjustment screw with a soft mallet. This
will ensure that the lifter seats against the
camshaft.

b. Loosen the adjustment locknut.

c. Place the correct feeler gauge between the

rocker arm and the valve stem. Then, turn the
adjustment screw in a clockwise direction. g01016764
Illustration 28
Slide the feeler gauge between the rocker
arm and the valve stem. Continue turning the Setting the valve lash
adjustment screw until a slight drag is felt on (1) Adjustment screw
the feeler gauge. Remove the feeler gauge. (2) Feeler gauge

d. Tighten the adjustment locknut to a torque of Remove the valve mechanism cover and perform
27 N·m (20 lb ft). Do not allow the adjustment the following procedure in order to adjust the valve
screw to turn while you are tightening the lash:
adjustment locknut. Recheck the valve lash
after tightening the adjustment locknut. 1. Put the No. 1 piston at the top center position
on the compression stroke. Refer to Testing and
Install the valve mechanism cover. Refer to Adjusting, “Finding Top Center Position for No.
Disassembly and Assembly, “Valve Mechanism 1 Piston”.
Cover - Remove and Install”.
Table 8
Valves Inlet Valves Exhaust Valves
Valve Lash Adjustment for the 1103
engine 0.20 mm 0.45 mm
Valve Lash
(0.008 inch) (0.018 inch)
Note: The No. 1 cylinder is at the front of the engine. Valves 1, 3, 5 2, 4, 6

2. Rotate the crankshaft until the inlet valve for

the cylinder 1 has just opened and the exhaust
valve for the cylinder 1 is not completely closed.
Then adjust the number 3 valve and the number
6 valve.

a. Adjust the valves according to Table 8.

b. Lightly tap the rocker arm at the top of the

adjustment screw with a soft mallet. This
will ensure that the lifter seats against the
camshaft.

c. Loosen the adjustment locknut.

 33
Testing and Adjusting Section

d. Place the correct feeler gauge between the

rocker arm and the valve stem. Then, turn the
adjustment screw in a clockwise direction.
Slide the feeler gauge between the rocker
arm and the valve stem. Continue turning the
adjustment screw until a slight drag is felt on
the feeler gauge. Remove the feeler gauge.

e. Tighten the adjustment locknut to a torque of

27 N·m (20 lb ft). Do not allow the adjustment
screw to turn while you are tightening the
adjustment locknut. Recheck the valve lash
after tightening the adjustment locknut.

3. Rotate the engine by 360 degrees. Then adjust g00983531

the number 1 valve and the number 5 valve. Illustration 29
Then adjust the number 2 valve and the number Measurement of the valve depth
4 valve. (1) 21825617 Dial gauge
(2) 21825496 Dial gauge holder
a. Adjust the valves according to Table 8.
1. Use the dial gauge (1) with the dial gauge holder
b. Lightly tap the rocker arm at the top of the (2) to check the depths of the inlet valves and
adjustment screw with a soft mallet. This the exhaust valves below the face of the cylinder
will ensure that the lifter seats against the head. Use the cylinder head face (3) to zero the
camshaft. dial gauge (1).

c. Loosen the adjustment locknut. 2. Position the dial gauge holder (2) and the dial
gauge (1) in order to measure the valve depth.
d. Place the correct feeler gauge between the Measure the depth of the inlet valve and the
rocker arm and the valve stem. Then, turn the exhaust valve before the valve springs are
adjustment screw in a clockwise direction. removed.
Slide the feeler gauge between the rocker
arm and the valve stem. Continue turning the Refer to Specifications, “Cylinder Head Valves”
adjustment screw until a slight drag is felt on for the minimum, the maximum, and the service
the feeler gauge. Remove the feeler gauge. wear limits for the valve depth below the cylinder
head face.
e. Tighten the adjustment locknut to a torque of
27 N·m (20 lb ft). Do not allow the adjustment If the valve depth below the cylinder head
screw to turn while you are tightening the face exceeds the service limit, use a new
adjustment locknut. Recheck the valve lash valve to check the valve depth. If the valve
after tightening the adjustment locknut. depth still exceeds the service limit, renew the
cylinder head or renew the valve seat inserts (if
Install the valve mechanism cover. Refer to equipped). If the valve depth is within the service
Disassembly and Assembly, “Valve Mechanism limit with a new valve, renew the valves.
Cover - Remove and Install”.
3. Inspect the valves for cracks and other damage.
Check the valve stems for wear. Check that
i01889422 the valve springs are the correct length under
the test force. Refer to Specifications, “Cylinder
Valve Depth - Inspect Head Valves” for the dimensions and tolerances
of the valves and the valve springs.

Table 9 i01938952

Required Tools Valve Guide - Inspect

Part Part Description Qty
Number
Perform this inspection in order to determine if a
21825617 Dial gauge 1 valve guide should be replaced.
21825496 Dial gauge holder 1
34
Testing and Adjusting Section

Refer to Specifications, “Cylinder Head Valves”

for the maximum clearance of the valve in the
valve guide.

g00986821
Illustration 30
(1) Valve guide
(2) Radial movement of the valve in the valve guide
(3) Valve stem
(4) Dial indicator
(5) Valve head

1. Place a new valve in the valve guide.

2. Place a suitable dial indicator with the magnetic

base on the face of the cylinder head.

3. Lift the edge of the valve head to a distance of

15.0 mm (0.60 inch).

4. Move the valve in a radial direction away from

the dial indicator. Make sure that the valve moves
away from the dial indicator as far as possible.
Position the contact point of the dial indicator on
the edge of the valve head. Set the position of
the needle of the dial indicator to zero.

5. Move the valve in a radial direction toward

the dial indicator as far as possible. Note the
distance of movement which is indicated on the
dial indicator. If the distance is greater than the
maximum clearance of the valve in the valve
guide, replace the valve guide.

When new valve guides are installed, new valves

and new valve seat inserts must be installed.
Valve guides and valve seat inserts are supplied
as an unfinished part. The unfinished valve
guides and unfinished valve seat inserts are
installed in the cylinder head. Then, the valve
guides and valve inserts are cut and reamed in
one operation with special tooling.
 35
Testing and Adjusting Section

Lubrication System i01893791

Engine Oil Pump - Inspect

i01854908

Engine Oil Pressure - Test

If any part of the oil pump is worn enough in order
to affect the performance of the oil pump, the oil
pump must be replaced.
Low Oil Pressure Perform the following procedures in order to inspect
the oil pump for clearances and torques.
The following conditions will cause low oil pressure.
Refer to the Specifications Module, “Engine Oil
• The oil level is low in the crankcase. Pump”.
• A restriction exists on the oil suction screen. 1. Remove the oil pump from the engine. Refer
to the Disassembly and Assembly, “Engine Oil
• Connections in the oil lines are leaking. Pump - Remove”. Remove the cover of the oil
pump.
• The connecting rod or the main bearings are
worn. 2. Remove the outer rotor. Clean all of the parts.
Look for cracks in the metal or other damage.
• The rotors in the oil pump are worn.
• The oil pressure relief valve is operating
incorrectly.

A worn oil pressure relief valve can allow oil to leak

through the valve which lowers the oil pressure.
Refer to the Specifications Module, “Engine Oil
Relief Valve” for the correct operating pressure and
other information.

When the engine runs at the normal temperature for

operation and at high idle, the oil pressure must be
a minimum of 280 kPa (40 psi). A lower pressure is
normal at low idle.

A suitable pressure gauge can be used in order to

test the pressure of the lubrication system.

High Oil Pressure

High oil pressure can be caused by the following g00985779
Illustration 31
conditions.
Clearance for the outer rotor body

• The spring for the oil pressure relief valve is (1) Measure the clearance of the outer rotor to the body.
installed incorrectly.
3. Install the outer rotor. Measure the clearance of
• The plunger for the oil pressure relief valve the outer rotor to the body (1).
becomes jammed in the closed position.

• Excessive sludge exists in the oil which makes

the viscosity of the oil too high.
36
Testing and Adjusting Section

i01126690

Excessive Bearing Wear -

Inspect

When some components of the engine show

bearing wear in a short time, the cause can be a
restriction in an oil passage.

An engine oil pressure indicator may show that there

is enough oil pressure, but a component is worn
due to a lack of lubrication. In such a case, look at
the passage for the oil supply to the component. A
restriction in an oil supply passage will not allow
enough lubrication to reach a component. This will
result in early wear.

i01794028
g00985780
Illustration 32
Excessive Engine Oil
Clearance for the inner rotor
(2) Measure the clearance of the inner rotor to the outer rotor.
Consumption - Inspect
4. Measure the clearance of the inner rotor to the
outer rotor (2).
Engine Oil Leaks on the Outside of
the Engine
Check for leakage at the seals at each end of
the crankshaft. Look for leakage at the gasket
for the engine oil pan and all lubrication system
connections. Look for any engine oil that may be
leaking from the crankcase breather. This can
be caused by combustion gas leakage around
the pistons. A dirty crankcase breather will cause
high pressure in the crankcase. A dirty crankcase
breather will cause the gaskets and the seals to
leak.

Engine Oil Leaks into the

Combustion Area of the Cylinders
Engine oil that is leaking into the combustion area
of the cylinders can be the cause of blue smoke.
There are several possible ways for engine oil to
g00989217 leak into the combustion area of the cylinders:
Illustration 33

5. Measure the end play of the rotor with a straight • Leaks between worn valve guides and valve
edge and a feeler gauge (3). stems

6. Clean the top face of the oil pump and the • Worn components or damaged components
bottom face of the cover. Install the cover on (pistons, piston rings, or dirty return holes for the
the oil pump. Install the oil pump on the engine. engine oil)
Refer to Disassembly and Assembly, “Engine
Oil Pump - Install”. • Incorrect installation of the compression ring
and/or the intermediate ring
 37
Testing and Adjusting Section

• Leaks past the seal rings in the turbocharger shaft

• Overfilling of the crankcase
• Wrong dipstick or guide tube
• Sustained operation at light loads
Excessive consumption of engine oil can also result
if engine oil with the wrong viscosity is used. Engine
oil with a thin viscosity can be caused by fuel
leakage into the crankcase or by increased engine
temperature.

i01945015

Increased Engine Oil

Temperature - Inspect

Look for a restriction in the oil passages of the oil

cooler (if equipped). The oil temperature may be
higher than normal when the engine is operating. In
such a case, the oil cooler may have a restriction.
A restriction in the oil cooler will not cause low oil
pressure in the engine.
38
Testing and Adjusting Section

Cooling System 6. Check the filler cap. A pressure drop in the

cooling system can cause the boiling point to be
lower. This can cause the cooling system to boil.
i01892576 Refer to Testing and Adjusting, “Cooling System
- Test”.
Cooling System - Check
(Overheating) 7. Check the cooling system hoses and clamps.
Damaged hoses with leaks can normally be
seen. Hoses that have no visual leaks can soften
during operation. The soft areas of the hose can
Above normal coolant temperatures can be caused become kinked or crushed during operation.
by many conditions. Use the following procedure These areas of the hose can cause a restriction
to determine the cause of above normal coolant in the coolant flow. Hoses become soft and/or
temperatures: get cracks after a period of time. The inside of a
hose can deteriorate, and the loose particles of
1. Check the coolant level in the cooling system. If the hose can cause a restriction of the coolant
the coolant level is too low, air will get into the flow.
cooling system. Air in the cooling system will
cause a reduction in coolant flow and bubbles 8. Check for a restriction in the air inlet system.
in the coolant. Air bubbles will keep the coolant A restriction of the air that is coming into the
away from the engine parts, which will prevent engine can cause high cylinder temperatures.
the transfer of heat to the coolant. Low coolant High cylinder temperatures require higher than
level is caused by leaks or incorrectly filling the normal temperatures in the cooling system.
expansion tank.
9. Check for a restriction in the exhaust system.
2. Check the mixture of antifreeze and water. The A restriction of the air that is coming out of the
mixture should be 50 percent water and 50 engine can cause high cylinder temperatures.
percent 21825166 POWERPART antifreeze.
a. Make a visual inspection of the exhaust
3. Check for air in the cooling system. Air can enter system.
the cooling system in different ways. The most
common causes of air in the cooling system b. Check for damage to exhaust piping. Check
are not filling the cooling system correctly and for damage to the exhaust elbow. If no
combustion gas leakage into the cooling system. damage is found, check the exhaust system
Combustion gas can get into the system through for a restriction.
inside cracks, a damaged cylinder head, or a
damaged cylinder head gasket. Air in the cooling 10. Check the water temperature regulator. A water
system causes a reduction in coolant flow and temperature regulator that does not open, or
bubbles in the coolant. Air bubbles keep the a water temperature regulator that only opens
coolant away from the engine parts, which part of the way can cause overheating. Refer
prevents the transfer of heat to the coolant. to Testing and Adjusting, “Water Temperature
Regulator - Test”.
4. Check the sending unit. In some conditions, the
temperature sensor in the engine sends signals 11. Check the water pump. A water pump with
to a sending unit. The sending unit converts a damaged impeller does not pump enough
these signals to an electrical impulse which is coolant for correct engine cooling. Remove
used by a mounted gauge. If the sending unit the water pump and check for damage to the
malfunctions, the gauge can show an incorrect impeller.
reading. Also if the electric wire breaks or if the
electric wire shorts out, the gauge can show an 12. Consider high outside temperatures. When
incorrect reading. outside temperatures are too high for the rating
of the cooling system, there is not enough of
5. Check the radiator for a restriction to coolant flow. a temperature difference between the outside
Check the radiator for debris, dirt, or deposits on air and coolant temperatures. The maximum
the inside of the core. Debris, dirt, or deposits will temperature of the ambient air that enters the
restrict the flow of coolant through the radiator. engine should not exceed 50 C (120 F).
 39
Testing and Adjusting Section

13. When a load that is applied to the engine is too i01876572

large, the engine rpm does not increase with an
increase of fuel. This lower engine rpm causes Cooling System - Test
a reduction in coolant flow through the system.
This combination of less air and less coolant flow
during high input of fuel will cause above normal
heating. Remember that temperature and pressure work
together. When a diagnosis is made of a cooling
system problem, temperature and pressure must
i01889427 be checked. The cooling system pressure will have
an effect on the cooling system temperature. For
Cooling System - Inspect an example, refer to Illustration 34. This will show
the effect of pressure on the boiling point (steam)
of water. This will also show the effect of height
above sea level.
This engine has a pressure type cooling system. A
pressure type cooling system gives two advantages:

• The pressure type cooling system can operate

safely at a higher temperature than the boiling
point of water at a range of atmospheric
pressures.

• The pressure type cooling system prevents

cavitation in the water pump.

Cavitation is the sudden generation of low pressure

bubbles in liquids by mechanical forces. The
generation of an air or steam pocket is much more
difficult in a pressure type cooling system.
g00286266
Illustration 34
Regular inspections of the cooling system should be Cooling system pressure at specific altitudes and boiling points
made in order to identify problems before damage of water
can occur. Visually inspect the cooling system
before tests are made with the test equipment.

Visual Inspection Of The Cooling Personal injury can result from hot coolant, steam
System and alkali.

1. Check the coolant level in the cooling system. At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
2. Look for leaks in the system. to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
3. Inspect the radiator for bent fins and other
restriction to the flow of air through the radiator. Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
4. Inspect the drive belt for the fan. enough to touch with your bare hand.

5. Inspect the blades of the fan for damage. The coolant level must be to the correct level in
order to check the coolant system. The engine must
6. Look for air or combustion gas in the cooling be cold and the engine must not be running.
system.
After the engine is cool, loosen the pressure cap
7. Inspect the radiator cap for damage. The sealing in order to relieve the pressure out of the cooling
surface must be clean. system. Then remove the pressure cap.

8. Look for large amounts of dirt in the radiator core. The level of the coolant should not be more than
Look for large amounts of dirt on the engine. 13 mm (0.5 inch) from the bottom of the filler pipe.
If the cooling system is equipped with a sight glass,
9. Shrouds that are loose or missing cause poor the coolant should be to the correct level in the
air flow for cooling. sight glass.
40
Testing and Adjusting Section

Making the Correct Antifreeze 1. After the engine cools, carefully loosen the filler
cap. Slowly release the pressure from the cooling
Mixtures system. Then, remove the filler cap.
Do not add pure 21825166 POWERPART antifreeze
2. Inspect the pressure cap carefully. Look for
to the cooling system in order to adjust the
damage to the seal. Look for damage to the
concentration of antifreeze. The pure antifreeze
surface that seals. Remove any debris on the
increases the concentration of antifreeze in the
cap, the seal, or the sealing surface.
cooling system. The increased concentration
increases the concentration of dissolved solids
Carefully inspect the filler cap. Look for any
and undissolved chemical inhibitors in the cooling
damage to the seals and to the sealing surface.
system.
Inspect the following components for any foreign
substances:
The antifreeze mixture must consist of equal
quantities of antifreeze and clean soft water. The
corrosion inhibitor in the antifreeze will be diluted if a • Filler cap
concentration of less than 50% of antifreeze is used.
Concentrations of more than 50% of antifreeze may • Seal
have the adverse effect on the performance of the
coolant. • Surface for seal
Remove any deposits that are found on these
Checking the Filler Cap items, and remove any material that is found on
these items.
One cause for a pressure loss in the cooling system
can be a faulty seal on the radiator pressure cap. 3. Install the pressure cap onto a suitable
pressurizing Pump.

4. Observe the exact pressure that opens the filler

cap.

5. Compare the pressure to the pressure rating that

is found on the top of the filler cap.

6. If the filler cap is damaged, replace the filler cap.

Testing The Radiator And Cooling

System For Leaks
Use the following procedure to test the radiator and
g00296067
Illustration 35 the cooling system for leaks.
Typical schematic of filler cap
(1) Sealing surface between the pressure cap and the radiator

Personal injury can result from hot coolant, steam

and alkali.
Personal injury can result from hot coolant, steam
and alkali. At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
At operating temperature, engine coolant is hot to heaters or the engine contain hot coolant or
and under pressure. The radiator and all lines steam. Any contact can cause severe burns.
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
Remove filler cap slowly to relieve pressure only enough to touch with your bare hand.
when engine is stopped and radiator cap is cool
enough to touch with your bare hand. 1. When the engine has cooled, loosen the filler cap
to the first stop. Allow the pressure to release
To check for the amount of pressure that opens the from the cooling system. Then remove the filler
filler cap, use the following procedure: cap.
 41
Testing and Adjusting Section

2. Make sure that the coolant covers the top of the

radiator core.
Personal injury can result from air pressure.
3. Put a suitable pressurizing Pump onto the
radiator.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
4. Use the pressurizing pump to increase the
tective face shield and protective clothing.
pressure to an amount of 20 kPa (3 psi) more
than the operating pressure of the filler cap.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
5. Check the radiator for leakage on the outside.

6. Check all connections and hoses of the cooling 4. Inspect the cooling plates for cracks and dents.
system for leaks. Replace the cooling plates if cracks or dents
exist.
The radiator and the cooling system do not have
leakage if all of the following conditions exist: If necessary, clean the outside and clean the
inside of the cooling plates. Use a solvent
• You do NOT observe any leakage after five that is not corrosive on copper. Ensure that no
minutes. restrictions for the flow of lubricating oil exist in
the cooling plates.
• The dial indicator remains constant beyond
five minutes. Dry the cooling plate with low pressure air.
Flush the inside of the cooling plate with clean
The inside of the cooling system has leakage lubricating oil.
only if the following conditions exist:
5. Refer to Disassembly and Assembly, “Engine
• The reading on the gauge goes down. Oil Cooler - Install” for installation of the engine
oil cooler.
• You do NOT observe any outside leakage.
6. Ensure that the cooling system and the oil system
Make any repairs, as required. of the engine are filled to the correct level.
Operate the engine. Check for oil or coolant
leakage.
i01956505

Engine Oil Cooler - Inspect Modine oil cooler for the 1103
engine
Perform the following procedure in order to inspect
the modine oil cooler (if equipped):

Hot oil and hot components can cause personal 1. Place a container under the modine oil cooler
injury. Do not allow hot oil or hot components to in order to collect any engine oil or coolant that
contact the skin. drains from the modine oil cooler.

2. Refer to Disassembly and Assembly, “Engine

Engine oil cooler for the 1104 Oil Cooler - Remove” for removal of the engine
engine oil cooler.

Perform the following procedure in order to inspect 3. Thoroughly clean the outside of the cooler plates
the engine oil cooler (if equipped): with a suitable cleaning fluid.

1. Place a container under the oil cooler in order to

collect any engine oil or coolant that drains from
the oil cooler.

2. Refer to Disassembly and Assembly, “Engine

Oil Cooler - Remove” for removal of the engine
oil cooler.

3. Thoroughly clean the flange face of the cover

plate and the cylinder block.
42
Testing and Adjusting Section

4. Keep the water at the correct temperature for

ten minutes.
Personal injury can result from air pressure.
5. After ten minutes, remove the water temperature
regulator housing. Immediately measure the
Personal injury can result without following prop-
opening of the water temperature regulator.
er procedure. When using pressure air, wear a pro-
Refer to Specifications, “Water Temperature
tective face shield and protective clothing.
Regulator” for the minimum opening distance of
the water temperature regulator at the fully open
Maximum air pressure at the nozzle must be less
temperature.
than 205 kPa (30 psi) for cleaning purposes.
If the distance is less than the amount listed in the
4. Thoroughly clean the inside of the cooler plates manual, replace the water temperature regulator.
with clean water. Refer to Disassembly and Assembly, “Water
Temperature Regulator - Remove and Install”.
Dry the cooling plate with low pressure air.
Flush the inside of the cooling plate with clean Install the water temperature regulator. Refer to
lubricating oil. Disassembly and Assembly, “Water Temperature
Regulator - Remove and Install”.
5. Install the modine oil cooler. Refer to Disassembly
and Assembly, “Engine Oil Cooler - Install”.

6. Ensure that the cooling system and the oil system

of the engine are filled to the correct level.
Operate the engine. Check for oil or coolant
leakage.

i01889428

Water Temperature Regulator

- Test

Note: Do not remove the water temperature regulator

from the water temperature regulator housing in
order to perform the test.

1. Remove the water temperature regulator housing

which contains the water temperature regulator
from the engine. Refer to Disassembly and
Assembly, “Water Temperature Regulator -
Remove and Install”.

2. Heat water in a pan until the temperature of the

water is equal to the fully open temperature
of the water temperature regulator. Refer to
Specifications, “Water Temperature Regulator”
for the fully open temperature of the water
temperature regulator. Stir the water in the pan.
This will distribute the temperature throughout
the pan.

3. Hang the water temperature regulator housing in

the pan of water. The water temperature regulator
housing must be below the surface of the water.
The water temperature regulator housing must be
away from the sides and the bottom of the pan.
 43
Testing and Adjusting Section

Basic Engine Inspect the Piston Ring End Gap

i01889476

Piston Ring Groove - Inspect

Inspect the Piston and the Piston

Rings
1. Check the piston for wear and other damage.

2. Check that the piston rings are free to move in

the grooves and that the rings are not broken.

Inspect the Clearance of the Piston

Ring
1. Remove the piston rings and clean the grooves
g00983549
and the piston rings. Illustration 37
(1) Piston ring
(2) Cylinder ring ridge
(3) Feeler gauge

1. Clean all carbon from the top of the cylinder

bores.

2. Place each piston ring (1) in the cylinder bore

just below the cylinder ring ridge (2).

3. Use a suitable feeler gauge (3) to measure the

piston ring end gap. Refer to Specifications,
“Piston and Rings” for the dimensions.

Note: The coil spring must be removed from the oil

control ring before the gap of the oil control ring is
measured.

i01946425

Connecting Rod - Inspect

g00905732
Illustration 36
(1) Feeler gauge
(2) Piston ring
(3) Piston grooves This procedure determines the following
characteristics of the connecting rod:
2. Fit new piston rings (2) in the piston grooves (3).
• The distortion of the connecting rod
3. Check the clearance for the piston ring by
placing a suitable feeler gauge (1) between the • The parallel alignment of the bores of the
piston groove (3) and the top of piston ring (2). connecting rod
Refer to Specifications, “Piston and Rings” for
the dimensions.

Note: Some pistons have a tapered top groove and

the piston ring is wedged. The clearance for the
top piston ring cannot be checked by the above
method when this occurs.
44
Testing and Adjusting Section

i01748770

Connecting Rod Bearings -

Inspect

Check the connecting rod bearings and the

connecting rod bearing journal for wear or other
damage.

Connecting rod bearings are available with a

smaller inside diameter than the original size
bearings. These bearings are for crankshafts that
Illustration 38 g00927038 have been ground.
Inspection of the connecting rod parallel alignment.
(1) Measuring pins i01748792
(2) Connecting rod
(L) Measure the distance between the center of the bore for the Main Bearings - Inspect
piston pin bearing and the center of the connecting rod bearing
bore.
(K) Measure the distance 127 mm (5.0 inch) from the connecting
rod.
Check the main bearings for wear or other damage.
1. Use the appropriate tools in order to measure Replace both halves of the bearings and check the
the distances for the connecting rod (2). condition of the other bearings if a main bearing is
worn or damaged.
• Appropriate gauges for measuring distance
Main bearings are available with a smaller inside
• Measuring pins (1) diameter than the original size bearings. These
bearings are for main bearing journals that have
Note: The connecting rod bearings should be been ground.
removed before taking the measurements.
i01946424
2. Measure the connecting rod for distortion and
parallel alignment between the bores. Cylinder Block - Inspect
The measurements must be taken at distance
(K). Distance (K) has a value of 127 mm
(5.0 inch) from both sides of the connecting rod. 1. Clean all of the coolant passages and the oil
passages.
Measure length (L).
2. Check the cylinder block for cracks and damage.
The total difference in measurements of length
(L) from each side should not vary more than 3. The top deck of the cylinder block must not
± 0.25 mm (± 0.010 inch). be machined. This will affect the piston height
above the cylinder block.
If the piston pin bearing is not removed, the limits
are reduced to ± 0.06 mm (± 0.0025 inch). 4. Check the camshaft bearing for wear. If a new
bearing is needed, use a suitable adapter to
3. Inspect the piston pin bearing and the piston pin press the bearing out of the bore. Ensure that
for wear and other damage. the oil hole in the new bearing faces the front of
the block. The oil hole in the bearing must be
4. Measure the clearance of the piston pin in aligned with the oil hole in the cylinder block.
the piston pin bearing. Refer to Specifications, The bearing must be aligned with the face of
“Connecting Rod” for clearance dimensions. the recess. Refer to Disassembly and Assembly,
“Camshaft Bearings - Remove and Install”.
 45
Testing and Adjusting Section

i01905914 Refer to Specifications, “Cylinder Head” for the

requirements of flatness.
Cylinder Head - Inspect
Remachining the Cylinder Head
1. Remove the cylinder head from the engine. The bottom face of cylinder head can be resurfaced
if any of the following conditions exist:
2. Remove the water temperature regulator housing.
• The bottom face of the cylinder head is not flat
3. Inspect the cylinder head for signs of gas or within the specifications.
coolant leakage.
• The bottom face of the cylinder head is damaged
4. Remove the valve springs and valves. by pitting, corrosion, or wear.

5. Clean the bottom face of the cylinder head Note: The thickness of the cylinder head must not
thoroughly. Clean the coolant passages and be less than 117.20 mm (4.614 inch) after the
the lubricating oil passages. Make sure that the cylinder head has been machined.
contact surfaces of the cylinder head and the
cylinder block are clean, smooth and flat. If the bottom face of the cylinder head has been
remachined, the recesses in the cylinder head
6. Inspect the bottom face of the cylinder head for for the valve seat inserts must be machined. The
pitting, corrosion, and cracks. Inspect the area valve seat inserts must be ground on the side
around the valve seat inserts and the holes for which is inserted into the cylinder head. Grinding
the fuel injectors carefully. this surface will ensure that no protrusion exists
above the bottom face of the cylinder head. Refer
7. Test the cylinder head for leaks at a pressure of to Specifications, “Cylinder Head Valves” for the
200 kPa (29 psi). correct dimensions.

i01889496

Piston Height - Inspect

Table 10

Required Tools

Part Part Description Qty

Number
21825617 Dial gauge 1
g01012606
Illustration 39 21825496 Dial gauge holder 1
Flatness of the cylinder head (typical example)
(A) Side to side
(B) End to end If the height of the piston above the cylinder block
(C) Diagonal is not within the tolerance that is given in the
Specifications Module, “Piston and Rings”, the
8. Measure the cylinder head for flatness. Measure bearing for the piston pin must be checked. Refer to
the flatness of the cylinder head with a straight Testing and Adjusting, “Connecting Rod - Inspect”.
edge and with a feeler gauge. If any of the following components are replaced or
remachined, the piston height above the cylinder
• Measure the cylinder head from one side to block must be measured:
the opposite side (A).
• Crankshaft
• Measure the cylinder head from one end to
the opposite end (B). • Cylinder head
• Measure the cylinder head from one corner to • Connecting rod
the opposite corner (C).
• Bearing for the piston pin
46
Testing and Adjusting Section

The correct piston height must be maintained in i01897548

order to ensure that the engine conforms to the
standards for emissions. Flywheel - Inspect
Note: The top of the piston should not be machined.
If the original piston is installed, be sure that
the original piston is assembled to the correct Alignment of the Flywheel Face
connecting rod and installed in the original cylinder.

Six grades of length of connecting rods determine

the piston height above the cylinder block. The
grade of length of a connecting rod is identified by
a letter or a color. The letter or the color is marked
on the side of the connecting rod. Refer to Testing
and Adjusting, “Connecting Rod - Inspect” and
Specifications, “Connecting Rod” for additional
information.

g00987751
Illustration 41

1. Install the dial indicator. Refer to Illustration 41.

2. Set the pointer of the dial indicator to 0 mm

(0 inch).

3. Turn the flywheel. Read the dial indicator for

every 90 degrees.
g00983585
Illustration 40
Note: During the check, keep the crankshaft
(1) Dial gauge pressed toward the front of the engine in order to
(2) Dial gauge holder
remove any end clearance.
1. Use the dial gauge (1) and the dial gauge holder 4. Calculate the difference between the lowest
(2) in order to measure the piston height above measurement and the highest measurement of
the cylinder block. Use the cylinder block face to the four locations. This difference must not be
zero the dial gauge (1).
greater than 0.03 mm (0.001 inch) for every
25 mm (1.0 inch) of the radius of the flywheel.
2. Rotate the crankshaft until the piston is at the The radius of the flywheel is measured from the
approximate top center.
axis of the crankshaft to the contact point of the
dial indicator.
3. Position the dial gauge holder (2) and the dial
gauge (1) in order to measure the piston height
above the cylinder block. Slowly rotate the
crankshaft in order to determine when the piston
is at the highest position. Record this dimension.
Compare this dimension with the dimensions that
are given in Specifications, “Piston and Rings”.
 47
Testing and Adjusting Section

Flywheel Runout i01958093

Gear Group - Inspect

g00987752
Illustration 42

1. Install the dial indicator. Refer to Illustration 42.

g00918708
Illustration 43
2. Set the pointer of the dial indicator to 0 mm
(0 inch). (1) Fuel pump drive gear
(2) Camshaft drive gear
(3) Idler gear
3. Turn the flywheel. Read the dial indicator for
every 90 degrees. Remove the front timing cover and inspect the
gears. The timing marks on the gears indicate the
4. Calculate the difference between the lowest front side of the gears. Inspect the gears for broken
measurement and the highest measurement of teeth or worn teeth.
the four locations. This difference must not be
greater than 0.30 mm (0.012 inch).
48
Testing and Adjusting Section

Electrical System 4. Turn the ignition switch to the ON position. Check

the voltage between terminal (B) and ground. If
the voltage is more than 2 Volts the alternator
i01899123 needs to be replaced.

Alternator - Test Warning Light is On When the

Engine is Running
1. Start the engine and run the engine at fast idle.

2. Measure the voltage between terminal (A) and

ground.

3. Measure the voltage between terminal (B) and

ground.

4. The measured voltage for terminal (A) and

terminal (B) should be 13 to 15 volts for a 12
volt system. The measured voltage for terminal
(A) and terminal (B) should be 26 to 30 volts for
a 24 volt system.

5. If the voltages do not match replace the

alternator.

6. Increase the engine to high idle. Turn an

electrical load ON.

Illustration 44 g00931045 7. Measure the voltage between terminal (A) and

Typical wiring schematic for an alternator
ground.
(A) Terminal “B+”
(B) Terminal “D+”
8. Measure the voltage between terminal (B) and
(C) Terminal “W” ground.
(D) Ground
(1) Electrical switch 9. The measured voltage for terminal (A) and
(2) Dash light terminal (B) should be 13 to 15 volts for a 12
(3) Ignition switch
(4) Battery volt system. The measured voltage for terminal
(A) and terminal (B) should be 26 to 30 volts for
a 24 volt system.
Warning Lamp Does Not Illuminate
10. Replace the alternator if the voltage does not
The warning lamp for the charging system should match.
illuminate when the ignition switch is in the ON
position. Follow the steps below in order to test the
system. i01899136

1. Check the light bulb. Replace the light bulb if Battery - Test
the element is broken.

2. Use a suitable Multimeter to check the battery

voltage. Check the battery voltage with the Most of the tests of the electrical system can be
ignition switch OFF. done on the engine. The wiring insulation must be
in good condition. The wire and cable connections
3. Check the voltage between the terminal (A) and must be clean, and both components must be tight.
ground. The measured voltage should equal the
battery voltage.
 49
Testing and Adjusting Section

The starting motor solenoid has two coils. The

pull-in coil draws about 40 amperes. The hold-in
coil requires about 5 amperes.
Never disconnect any charging unit circuit or bat-
tery circuit cable from the battery when the charg-
When the magnetic force increases in both coils,
ing unit is operated. A spark can cause an explo-
the pinion gear moves toward the ring gear of the
sion from the flammable vapor mixture of hydro-
flywheel. Then, the solenoid contacts close in order
gen and oxygen that is released from the elec-
to provide power to the starting motor. When the
trolyte through the battery outlets. Injury to per-
solenoid contacts close, the ground is temporarily
sonnel can be the result.
removed from the pull-in coil. Battery voltage is
supplied on both ends of the pull-in coil while the
The battery circuit is an electrical load on the starting motor cranks. During this period, the pull-in
charging unit. The load is variable because of the coil is out of the circuit.
condition of the charge in the battery.
Cranking of the engine continues until current to the
solenoid is stopped by releasing the ignition switch.
NOTICE
The charging unit will be damaged if the connections
Power which is available during cranking varies
between the battery and the charging unit are broken
according to the temperature and condition of the
while the battery is being charged. Damage occurs
batteries. The following chart shows the voltages
because the load from the battery is lost and because
which are expected from a battery at the various
there is an increase in charging voltage. High voltage
temperature ranges.
will damage the charging unit, the regulator, and other
electrical components. Table 11
Typical Voltage Of Electrical System During Cranking
The correct procedures to test the battery can be At Various Ambient Temperatures
found in the manual that is supplied by the OEM.
Temperature 12 Volt 24 Volt
System System
i01945632
−23 to −7C 6 to 8 volts 12 to 16 volts
(−10 to 20F)
Electric Starting System - Test
−7 to 10C 7 to 9 volts 14 to 18 volts
(20 to 50F)
10 to 27C 8 to 10 volts 16 to 24 volts
General Information (50 to 80F)

All electrical starting systems have four elements:

The following table shows the maximum acceptable
loss of voltage in the battery circuit. The battery
• Ignition switch circuit supplies high current to the starting motor.
The values in the table are for engines which have
• Start relay service of 2000 hours or more.
• Starting motor solenoid Table 12

• Starting motor Maximum Acceptable Voltage Drop In The Starting

Motor Circuit During Cranking
Start switches have a capacity of 5 to 20 amperes. Circuit 12 Volt 24 Volt
The coil of a start relay draws about 1 ampere System System
between test points. The switch contacts of the start
Battery post “-” to 0.7 volts 1.4 volts
relay for the starting motor are rated between 100
the starting motor
and 300 amperes. The start relay can easily switch terminal “-”
the load of 5 to 50 amperes for the starting motor
solenoid. Drop across the 0.5 volts 1.0 volts
disconnect switch
The starting motor solenoid is a switch with a Battery post “+” 0.5 volts 1.0 volts
capacity of about 1000 amperes. The starting motor to the terminal of
solenoid supplies power to the starter drive. The the starting motor
starting motor solenoid also engages the pinion to solenoid “+”
the flywheel.
Solenoid terminal 0.4 volts 0.8 volts
“Bat” to the solenoid
terminal “Mtr”
50
Testing and Adjusting Section

Voltage drops that are greater than the amounts in Note: If the following conditions exist, do not
Table 12 are caused most often by the following perform the test in Step 2 because the starting
conditions: motor has a problem.

• Loose connections • The voltage at the battery post is within 2

volts of the lowest value in the applicable
• Corroded connections temperature range of Table 11.

• Faulty switch contacts • The large starting motor cables get hot.

Diagnosis Procedure Use a suitable ammeter in order to measure the

current. Place the jaws of the ammeter around
the cable that is connected to the “bat” terminal.
The procedures for diagnosing the starting motor
are intended to help the technician determine if a Refer to the Specifications Module, “Starting
Motor” for the maximum current that is allowed
starting motor needs to be replaced or repaired.
for no load conditions.
The procedures are not intended to cover all
possible problems and conditions. The procedures
The current and the voltages that are specified
serve only as a guide.
in the Specifications Module are measured
Note: Do not crank the engine for more than 30 at a temperature of 27C (80F). When the
temperature is below 27C (80F), the voltage
seconds. Allow the starter to cool for two minutes
will be lower through the starting motor. When
before cranking the engine again.
the temperature is below 27C (80F), the current
through the starting motor will be higher. If the
If the starting motor does not crank or cranks slow,
current is too great, a problem exists in the
perform the following procedure:
starting motor. Repair the problem or replace the
starting motor.
1. Measure the voltage of the battery.

Measure the voltage across the battery posts If the current is within the specification, proceed
with the multimeter when you are cranking the to Step 3.
engine or attempting to crank the engine. Do
not measure the voltage across the cable post 3. Measure the voltage of the starting motor.
clamps.
a. Use the multimeter in order to measure the
a. If the voltage is equal or greater than the voltage of the starting motor, when you are
voltage in Table 11, then go to Step 2. cranking or attempting to crank the engine.

b. The battery voltage is less than the voltage b. If the voltage is equal or greater than the
in Table 11. voltage that is given in Table 11, then the
battery and the starting motor cable that goes
A low charge in a battery can be caused by to the starting motor are within specifications.
several conditions. Go to Step 5.

c. The starting motor voltage is less than the

• Deterioration of the battery voltage specified in Table 11. The voltage
drop between the battery and the starting
• A shorted starting motor motor is too great. Go to Step 4.
• A faulty alternator 4. Measure the voltage.
• Loose drive belts a. Measure the voltage drops in the cranking
circuits with the multimeter. Compare the
• Current leakage in another part of the results with the voltage drops which are
electrical system
allowed in Table 12.
2. Measure the current that is sent to the starting
b. Voltage drops are equal to the voltage drops
motor solenoid from the positive post of the
battery. that are given in Table 12 or the voltage drops
are less than the voltage drops that are given
in Table 12. Go to Step 5 in order to check
the engine.
 51
Testing and Adjusting Section

c. The voltage drops are greater than the voltage 1. Disconnect the power supply and the bus bar.
drops that are given in Table 12. The faulty
component should be repaired or replaced. 2. Connect the power supply to only one glow plug.

5. Rotate the crankshaft by hand in order to ensure 3. Place a suitable ammeter on the power supply
that the crankshaft is not stuck. Check the oil wire.
viscosity and any external loads that could affect
the engine rotation. 4. Connect a suitable digital multimeter to the
terminal on the glow plug and to a suitable
a. If the crankshaft is stuck or difficult to turn, ground.
repair the engine.
5. Turn the switch to the ON position in order to
b. If the engine is not difficult to turn, go to Step activate the glow plugs.
6.
Table 13
6. Attempt to crank the starting motor. 12 Volt System

a. The starting motor cranks slowly. Amp Time (sec)

30 Initial
Remove the starting motor for repair or
replacement. 21 4
14 8
b. The starting motor does not crank.
10 20
Check for the blocked engagement of the 9 60
pinion gear and flywheel ring gear.
Table 14
Note: Blocked engagement and open solenoid
contacts will give the same electrical symptoms. 24 Volt System
Amp Time (sec)
i01911231 12 Initial
Glow Plugs - Test 8.5 8
7 20
6 60
Continuity Check of the Glow Plugs
6. Check the reading on all of the glow plugs.
The following test will check the continuity of the
glow plugs. 7. If there is no reading on the ammeter check the
electrical connections. If the readings on the
1. Disconnect the power supply and the bus bar. ammeter are low replace the glow plugs. If there
is still no reading replace the glow plugs.
2. Use a suitable digital multimeter to check
continuity (resistance). Turn the audible signal on
the digital multimeter ON.

3. Place one probe on the connection for the glow

plug and the other probe to a suitable ground.
The digital multimeter should make an audible
sound. Replace the glow plug if there is no
continuity.

4. Check the continuity on all the glow plugs.

Checking The Operation of The

Glow Plug
The following test will check the operation of the
glow plugs.
52
Testing and Adjusting Section

i01955101

V-Belt - Test

Table 15
Belt Tension Chart
Gauge Reading
Size of Belt Width of Belt
Initial Belt Tension(1) Used Belt Tension(2)
1/2 13.89 mm (0.547 Inch) 535 N (120 lb) 355 N (80 lb)
Measure the tension of the belt that is farthest from the engine.
(1) Initial Belt Tension refers to a new belt.
(2) Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.

1. Check the belts for wear and check the belts for
damage. Belts must always be changed as a
pair.

2. Fit a suitable Burroughs gauge at the center of

the longest free length of the belt and check
the tension on both belts. Check and adjust the
tension on the tightest belt. To adjust the belt
tension, see Disassembly and Assembly Manual,
“Alternator - Install”.
 53
Index Section

Index
A Engine Valve Lash - Inspect/Adjust ....................... 30
Inspect Valve Lash............................................. 30
Air in Fuel - Test..................................................... 22 Valve Lash Adjustment for the 1103 engine....... 32
Air Inlet and Exhaust System .......................... 10, 29 Valve Lash Adjustment for the 1104 engine....... 31
Cylinder Head And Valves ................................. 12 Excessive Bearing Wear - Inspect......................... 36
Turbocharger...................................................... 11 Excessive Engine Oil Consumption - Inspect........ 36
Air Inlet and Exhaust System - Inspect.................. 29 Engine Oil Leaks into the Combustion Area of the
Alternator - Test ..................................................... 48 Cylinders .......................................................... 36
Warning Lamp Does Not Illuminate ................... 48 Engine Oil Leaks on the Outside of the Engine.. 36
Warning Light is On When the Engine is
Running............................................................ 48
F

B Finding Top Center Position for No. 1 Piston ......... 23

Flywheel - Inspect.................................................. 46
Basic Engine.................................................... 17, 43 Alignment of the Flywheel Face ......................... 46
Camshaft............................................................ 18 Flywheel Runout ................................................ 47
Crankshaft.......................................................... 18 Fuel Injection Pump Timing - Adjust...................... 25
Cylinder Block and Cylinder Head ..................... 17 Bosch EPVE Fuel Injection Pump...................... 25
Pistons, Rings, and Connecting Rods ............... 18 Delphi DP210 Series Fuel Injection Pump ........ 25
Battery - Test ......................................................... 48 Fuel Injection Pump Timing - Check...................... 24
Bosch EPVE Fuel Injection Pump...................... 24
Delphi DP210 Series Fuel Injection Pump ........ 24
C Fuel Quality - Test.................................................. 27
Fuel System....................................................... 9, 22
Compression - Test................................................ 30 Fuel System Components.................................. 10
Connecting Rod - Inspect ...................................... 43 Fuel System - Inspect............................................ 22
Connecting Rod Bearings - Inspect....................... 44 Fuel System - Prime.............................................. 27
Cooling System ............................................... 16, 38 Bosch EVPE ...................................................... 27
Cooling System - Check (Overheating) ................. 38 Delphi DP210..................................................... 27
Cooling System - Inspect....................................... 39 Fuel System Pressure - Test ................................. 28
Visual Inspection Of The Cooling System.......... 39 Check the Function of the Fuel Transfer Pump.. 28
Cooling System - Test............................................ 39 Check the Function of the Pressure Regulator .. 28
Checking the Filler Cap...................................... 40
Making the Correct Antifreeze Mixtures............. 40
Testing The Radiator And Cooling System For G
Leaks................................................................ 40
Cylinder Block - Inspect......................................... 44 Gear Group - Inspect............................................. 47
Cylinder Head - Inspect ......................................... 45 General Information................................................. 5
Remachining the Cylinder Head ........................ 45 1103 Engine Model Views ................................... 8
1104 Engine Model Views ................................... 6
Engine Description............................................... 5
E Lifting the Engine ................................................. 5
Glow Plugs - Test................................................... 51
Electric Starting System - Test .............................. 49 Checking The Operation of The Glow Plug ....... 51
Diagnosis Procedure.......................................... 50 Continuity Check of the Glow Plugs................... 51
General Information ........................................... 49
Electrical System............................................. 19, 48
Alternator ........................................................... 20 I
Starting Motor .................................................... 19
Engine Design ......................................................... 4 Important Safety Information ................................... 2
Engine Oil Cooler - Inspect.................................... 41 Increased Engine Oil Temperature - Inspect ......... 37
Engine oil cooler for the 1104 engine ................ 41
Modine oil cooler for the 1103 engine................ 41
Engine Oil Pressure - Test..................................... 35 L
High Oil Pressure............................................... 35
Low Oil Pressure................................................ 35 Lubrication System.......................................... 13, 35
Engine Oil Pump - Inspect..................................... 35
54
Index Section

Main Bearings - Inspect......................................... 44

Piston Height - Inspect .......................................... 45

Piston Ring Groove - Inspect................................. 43
Inspect the Clearance of the Piston Ring........... 43
Inspect the Piston and the Piston Rings ............ 43
Inspect the Piston Ring End Gap....................... 43

Systems Operation Section ..................................... 4

Table of Contents..................................................... 3
Testing and Adjusting Section ............................... 22

V-Belt - Test ........................................................... 52

Valve Depth - Inspect ............................................ 33
Valve Guide - Inspect ............................................ 33

Wastegate - Test.................................................... 29
Water Temperature Regulator - Test...................... 42