RENR9697

# November 2004

Front Gear Train

Component Inspection (Cont.)

C27 Engine 62
Oil Cooler and Filter Base
Visually inspect the base for cracks.
63 Check all threaded holes for damage.
Engine Design
64 Visually inspect the plunger, plunger seat, and spring for damage and
Bore 137 mm (5.4 inch) debris.
Stroke 152 mm (6.0 inch)
Oil Cooler Core
Number of Cylinders 12
65 Visually inspect core for cracks or damaged gasket or seal areas.
Cylinder Arrangement 65 degree V-12
66 Visually inspect core for debris (aluminum or steel particles).
Firing Order (Injection Sequence) 1, 10, 9, 6, 5, 12, 11, 4, 3, 8,
7, 2 Note: If debris is present in oil cooler core, the core must be replaced with a
Direction of Rotation (Viewed from flywheel end) Counterclockwise new or remanufactured core. The debris cannot be successfully removed from
the oil cooler core without the use of special equipment.
Oil Pan
67 Visually check the oil pan for cracks.
68 Check the oil drain plug threads for damage.
69 Check the pan rails for flatness.

Rocker Arms 1) Damper assembly for camshaft 4) Crankshaft gear

Major Overhaul Procedure Chart 70

71
Check the rocker arm bushings for damage or uneven wear.
Measure the bore in the rocker arm bearing for the rocker arm shaft.
2)
3)
Idler assembly
Camshaft drive gear
5) Oil pump idler gear
6) Oil pump gear
The maximum dimension for worn parts is 40.193 mm ( 1.5824 inch).
Replace the rocker arm assembly if the bearing bore is too large.

(Using Remanufactured Components) 72

Note: The rocker arm bearing must not extend beyond either face of
the rocker arm.
Visually check the rocker arm shaft for damage.
Disassembly (cont.) 73 Measure the diameter of the rocker arm shaft at each of the rocker arm
Tools Required locations. The diameter is 40 ± 0.01 (1.575± 0.0004 inch).
Steps Procedures
Part No. Description Part No. Description
37 Remove oil level gauge and guide assembly from cylinder block. Fuel Lines
9U-7530 Tool Kit FT-1342 Guide Bolt 92 Put front housing gasket, plate, and seal in position on cylinder block.
38 Install 111-2086 Lifting Gp – Engine (rear) and 111-2089 Lifting Gp – 74 Visually inspect the fuel lines for excessive wear, cracks or corrosion,
FT-0121 Lifting Bracket 5F-4764 Pry Bar Engine (front) on the cylinder head. Attach hoist to brackets. Remove especially where the clamps secure the fuel lines.
111-2086 Rear Lifting Gp 111-2089 Front Lifting Gp bolts that hold cylinder head in position. Remove cylinder head. Weight Note: Make sure the oil pump gear and crankshaft gear are in alignment.
of each cylinder head is approximately 235 kg (518 lb). 75 Inspect the sealing faces at both ends of the fuel lines for cracks or
1P-0510 Driver Group 138-7573 Link Bracket (2) nicks. 93 Use two 138-7573 Link Brackets and a hoist to put the front housing in
5P-1733 Seal Locator 5P-1737 Bolt (3) 76 Inspect the fuel line nuts for cracks and thread damage. position. Install bolts that hold front housing to the cylinder block.
6V-6142 Front Seal Installer 2P-8250 Wrench 77 Check the chamfer on the fuel line adapters for nicks or cracks. 94 Install the front gear group. Refer to Disassembly and Assembly, “Gear
Group (Front) – Install”.
1P-0540 Flow Checking Tool 9S-9082 Turning Tool Note: Replace any fuel line or component that is damaged.
Note: Put identification on each rocker arm assembly so it will be installed on a. Install the thrust plate for the idler gear with the oil groove
the same location. Damage to a camshaft and/or rollers may result if rocker arm side toward the idler gear assembly. Lubricate the shaft, the
Literature References assemblies are not installed in their original positions. Pulley and Damper bearing bore and the thrust faces with engine oil. Tighten the
78 Visually inspect the pulley for cracks and inspect for wear in the belt four 5/16 inch bolts to 25 ± 6 N·m (18 ± 4 lb ft).
Form No. Title 39 Remove camshaft and gear from each cylinder head as a unit. Be grooves. b. Install oil pump idler gear shaft assembly and tighten bolt to
SENR9936 Specifications for C27 Engine for Caterpillar Built Machines careful not to cause damage to camshaft during removal. 55 ± 10 N·m (41 ± 7 lb ft).
79 Check for damage or wear at the front oil seal area.
SENR9937 System Operation T&A for C27 Engine for Cat Built Machines 40 Remove sound suppression panels from cylinder block (if equipped). c. Install oil pump idler gear (5) and tighten bolt to 55 ± 10 N·m
80 Check for correct alignment of marks between damper and pulley. (41 ± 7 lb ft).
RENR9217 D&A for C27 Engine for Cat Built Machines 41 Remove the piston cooling tubes. Identify location of the tubes in the
cylinder block for installation. 81 Check all threaded holes for damage. d. Tighten bolt for oil pump gear (6) to 55 ± 10 N·m (41 ± 7 lb ft).
SEBU7764 D10T Operations and Maintenance Manual e. Tighten the camshaft bolts(7) in the following sequence: 1, 4,
42 Check & mark connecting rods, connecting rod caps & main bearing
The mechanic should have access to the current service manual for the serial Valve Mechanism Covers 2, 5, 3, 6, 1, 4. Tighten the six camshaft gear bolts to the
caps before removing. Connecting rods and main bearing caps must
number range engine being repaired. torque of 240 ± 40 N·m (177 ± 30 lb ft).
be installed into the same location and direction as removed. 82 Visually check for cracks and broken bolt holes.
95 To install the crankshaft front seal, complete the following steps;
43 Remove the connecting rod bolts and connecting rod caps. Note: All parts must be inspected again for cleanliness at time of final assembly. a. Clean the outside diameter of the crankshaft and the inside
Disassembly diameter of the wear sleeve. Note: Do not use any type of
Steps Procedures Component Inspection Assembly lubricant during installation of the crankshaft front seal and
wear sleeve. Inspect the crankshaft for scratches, distortion,
1 Remove miscellaneous attachments and brackets from the engine. Note: All parts must be cleaned before inspection. Use a suitable cleaning 83 Install sound suppression panels on cylinder block (if equipped). or any distortion that may lead to an out of round condition.
Items may include air conditioner compressor, air compressor, solution or cleaning solvent.
b. Fasten 5P-1733 Seal Locator to the crankshaft with three 5P-
alternator, fan and fan drive assembly and power steering pump. Camshaft 1737 Bolts. Install the crankshaft front seal with the arrow that
2 Remove electric starting motor. 44 Visually inspect each camshaft for damage, corrosion, pitting, or flaking shows the direction of crankshaft rotation toward the front of
3 Install FT-0121 Lifting Bracket and FT-1342 Guide Bolt on flywheel. on the bearing journals and lobes. the engine.
Remove flywheel with a hoist. Weight of the flywheel is approximately c. Position wear sleeve and crankshaft front seal on three 5P-
45 Specified camshaft lobe lifts are: Exhaust lobe is 8.515 mm (0.3352 1737 Bolts. Install 6V-6142 Front Seal Installer on the 5P-
91 kg (200 lb). inch), Injector lobe (right bank) is 10.3372 mm (0.40698 inch), Injector 1733 Seal Locator. Lubricate the face of the washer on 9S-
4 Remove sound suppression from oil pan (if equipped). lobe (left bank) is 10.3381 mm (0.40701 inch) and Inlet lobe is 9.619 8858 Nut for the Seal Installer. Install nut for the seal installer
mm (0.3787 inch). Maximum permissible difference between each on 5P-1737 Bolt.
5 Remove oil pan.
actual lobe lift measured and each specified lobe lift is 0.13 mm (0.005
6 Remove flywheel housing. inch). d. Tighten nut for the seal installer until seal installer contacts
the seal locator.
7 Remove rear crankshaft seal from flywheel housing. 46 Check each camshaft gear for broken or damaged teeth. e. Remove nut for the seal installer and the seal installer from
8 Disconnect following assemblies from fuel filter base; hose & tube. the bolt.
Install 9U-7070 Tapered Cap/Plug or 9U-7072 Tapered Cap/Plug on all Rollers for the Valve Rockers and Injector Rockers f. Remove the bolt and seal locator from the crankshaft.
openings. 47 Visually inspect the rollers for the valve rockers and the rollers for the 84 If the oil pump sleeve bearing was removed, install a new sleeve
bearing using 1P-0510 Driver Group. Orient the bearing joint (A) 30° ± 96 Install damper and pulley on the crankshaft.
9 Remove the precooler. See REHS1728 “Application Guideline for the injector rockers. Replace a roller if the wear surface is rough or shows
Bellows” for additional information on handling the bellows. signs of scuffing. 15° from center line between the two bores. Install the bearings so the
bearings are even with the outside of the oil pump body assembly.
10 Disconnect exhaust piping from turbochargers.
Oil pump 85 Install remanufactured cylinder packs. Vibration Damper and Pulley
11 Remove turbocharger air inlet elbow.
48 Visually inspect the oil pump bore and shaft assemblies for damage. 86 Install connecting rod bearings, caps and bolts. Torque the bolts.
12 Remove turbochargers. Make a note of turbocharger orientation and
clamp orientation for use when these parts are reinstalled. 49 Visually check outer rotor for wear, scratches and damaged or missing 87 Install main bearings, caps and bolts. Torque the bolts.
teeth.
13 Remove air inlet elbow. 88 Clean contact surfaces of cylinder head and cylinder block. Install new
50 Visually check the inner rotor for wear or scratches. head gasket.
14 Remove the fuel transfer pump. Install 9U-7070 Tapered Cap/Plug or
9U-7072 Tapered Cap/Plug on all openings. 51 Visually check the cover for damage. 89 Use a hoist to position each cylinder head on the cylinder block. The
52 Visually check the relief plunger for damage. weight of a cylinder head is approximately 250 kg (550 lb).
15 Remove fuel line from fuel injection pump housing & heads. Install 9U-
7070 Tapered cap/plug or 9U-7072 Tapered cap/plug on all openings. 53 Visually check the pitting and wear on the relief seat face. 90 Install cylinder head bolts. Torque the bolts.

16 Remove connector from regulator housing and water temperature 54 Visually inspect the suction bell for debris (aluminum or steel particles). 91 Lubricate camshaft bearings, journal & lobes with 50/50 mixture of
regulators (thermostats) from regulator housing. engine oil & 8T-2998 cam lubricant. Install camshaft & gears as a unit.
Note: A suction bell with debris cannot be cleaned properly. It is recommended Make sure timing marks on crankshaft gear & camshaft gear are in
17 Remove water pump from front housing if it will be inspected. If that a new suction bell be installed. alignment.
needed, recondition or replace with remanufactured water pump.
Front Housing
18 Remove two of bolts used to hold vibration damper and pulley on NOTICE
55 Visually inspect housing for cracks or damaged or stripped threads. 1) Damper bolt
crankshaft. Install two 5/8 – 18 NF by 7 inch guide bolts. Remove the
remaining bolts. Remove pulley, adapter & damper from crankshaft.
Original camshafts must be installed with original rollers for 2) Pulley
valve rocker arm group (if reusable) or with new parts. DO 3) Adapter Bolt
19 Remove front support. Crankshaft
NOT install used parts with a new or reground camshaft. 4) Damper
20 Use a strap wrench to remove oil filters. 56 Visually inspect the crankshaft front seal bore and the water pump bore 5) Adapter
21 Disconnect oil cooler hoses from front housing. for damage. 6) Crankshaft
22 Remove engine oil cooler and filter base assembly.
Flywheel Housing 97 If Adapter and damper were separated during disassembly, then use
23 Remove accessory drive. the 12 bolts (1/2 inch) to install the damper (4) to the adapter (5).
57 Visually inspect the housing for cracks and for damaged and/or
24 Remove crankshaft position sensor. Torque the bolts to 135 ± 20 N·m (99 ± 15 lb ft)
stripped threads.
25 Remove engine support. 98 Install two guide bolts (5/8 – 18 NF by 7 inch) in the crankshaft.
58 Check the starter face and bore for damage.
26 Remove bolts from block & front of oil pan. Remove front cover. 99 Install adapter/damper and pulley (2) on the guide bolts.
59 Check the crankshaft seal bore for damage.
27 Remove oil pump suction bell. 100 Install 5/8 inch bolts. Torque bolts to 215 ± 40 N·m (158 ± 30 lb ft).
60 Check the transmission face for damage.
28 Remove oil pump. 101 Remove the guide bolts and install the remaining damper bolts (1).
Inlet Elbow 102 Install front support.
29 Remove bolts & hold front housing to cylinder block. Remove front
housing. Inspect head mounting flanges & air cleaner mounting flange for cracks.
30 Remove front crankshaft seal from housing. Inspect all threaded holes for damage.
31 Remove exhaust manifolds.
Exhaust Manifold
32 Remove water separator (if equipped).
61 Check the cylinder head and exhaust pipe mounting flanges for cracks
33 Remove valve mechanism covers. near the bolt holes.
34 Remove valve rocker arm groups.
35 Use 5F-4764 Pry Bar to pry under base & free electronic unit injectors.
36 Check condition of O-ring seals. Use new parts for replacement if the
O-ring seals are worn or damaged.

©2004 Caterpillar Inc.

All Rights Reserved RENR9697 Printed in U.S.A.
Torque Procedure 125 Put the oil pan gasket in position. Install the oil pan. Procedure for Setting Valve Lash and Unit Injector
Flywheel Housing 126 Install O-ring seals on engine oil filter base. Set No. 1 cylinder to TDC on compression stroke. Use 9S-9082 Turning Tool to
Position engine oil filter base on the engine oil cooler and install bolts turn engine in direction of normal engine rotation. Turn flywheel until timing bolt
127
and bolts. Connect hose assembly. engages with threaded hole in flywheel. Insert timing bolt in flywheel.

Install new engine oil filter. Follow directions on the engine oil filter for Set inlet valves on cylinders 1, 2, 3, 7, 8, and 10.
128
correct installation procedure. Do not over tighten the engine oil filter. Set exhaust valves on cylinders 1, 2, 5, 6, 9 and 10.
129 Fill lubrication system with engine oil. Refer to Operation & Set unit injector on cylinders 4, 5, 6, 9, 11 and 12.
Maintenance Manual, "Refill Capacities" for lubrication system capacity
Turn crankshaft 360° in direction of engine rotation (No. 11 piston at TDC
of engine.
of compression stroke).
130 Apply 1U-6396 O-ring compound to O-ring seal for oil cooler bonnet.
Set inlet valves on cylinders 4, 5, 6, 9, 11 and 12.
Install oil cooler bonnet in engine oil cooler. Install filter base assembly.
Set exhaust valves on cylinders 3, 4, 7, 8, 11 and 12.
131 Install integral seal on oil cooler bonnet. Position the oil cooler bonnet
Connecting Rod Bolts Set unit injector on cylinders 1, 2, 3, 7, 8 and 10.
on the water pump and install bolts.
a. Lubricate bolts 1 through 4 with engine oil before assembly.
132 Install O-ring seals on the engine oil filter base.
b. Torque bolts (1, 3) to 70 ± 4 N·m (52 ± 3 lb ft)
133 Slide core assembly for the oil cooler toward the front of the engine. Valve Mechanism Cover Base
c. Torque bolts (2, 4) to 70 ± 4 N·m (52 ± 3 lb ft) Rotate the core assembly into position. Install bolts.
151 Install seal in valve mechanism cover base.
d. Mark the head of each bolt. 134 Install integral seal and O-ring seal on outlet bonnet. Apply 1U-6396 to
the O-ring seal. Position outlet bonnet and install bolts. 152 Put valve mechanism cover base in position on the cylinder head.
e. Tighten bolts (2, 4) an additional 60° ± 5°
135 Install new oil cooler hoses. 153 Tighten bolts (5/16 inch) to a torque of 25 ± 6 N·m (18 ± 4 lb ft).
f. Retighten bolts (1, 3) to 70 ± 4 N·m (52 ± 3 lb ft)
136 Install O-ring seal and O-ring seal on the diverter valve. Position 154 Install the harness assembly to the valve mechanism cover base.
g. Torque bolts (1, 3) an additional 60° ± 5°
Note: Bolts 1 & 2 are 3/8-16 X 6 1/4 inches. Bolts 3 through 10 are 1/2-13 X 6 diverter valve on the precooler and install bolts. 155 Position the harness assembly in position on electronic unit injector.
h. Torque the bolt for the piston cooling jet (5) to 25 ± 6 N·m (18 ± 4 lb ft). 1/2 inches. Bolts 11 through 16 are 3/8-16 X 4 inches. Bolts 17 through 30 are Orient connectors so wires are not contacting metal surfaces.
137 Connect the hose and harness assembly.
Note: Rod and piston group is to be assembled in engine with forging part 3/8-16 X 5 1/4 inches. Bolts 31 through 34 are 3/8-16 stud bolts. Bolts 35 and Tighten the cap nuts to a torque of 1.7 ± 0.25 N·m (1.3 ± 0.18 lb ft).
36 are 3/8-16 X 3 inches. 138 Fill the cooling system with coolant. Refer to Operation and
number side to thrust against the mating rod on same crank pin. Opposite side 156 Apply 4C-4030 Thread Lock Compound to 6 bolts (1/4 inch) that will
Maintenance Manual, “Cooling System Coolant – Change”.
is to be against crank pin thrust surface. 105 Thoroughly clean flywheel housing & cylinder block mating surfaces. be under valve mechanism cover and hold wiring harness clips.
Install wire harness in each clip, then install bolts & clips, torque
Piston Cooling Jets 106 Install two 138-7573 Link Brackets & a suitable lifting device on
flywheel housing. Weight of flywheel housing is about 136 kg (300 lb). Cylinder Head bolts to 12 ± 3 N·m (9 ± 2 lb ft).
157 Connect harness.
107 Install the seals in the flywheel housing.
108 Install flywheel housing. Cut the seal so it is even with the bottom of Valve Mechanism Covers
the cylinder block and flywheel housing.
158 Put seals in position on valve covers. Install valve covers.
109 In a numerical sequence, tighten bolts 1 & 2 to a torque of 55 ± 10
N·m (41 ± 7 lb ft). 159 Tighten valve cover bolts (5/16 inch) to 25 ± 6 N·m (18 ± 4 lb ft).
110 In a numerical sequence, tighten bolts 3 through 10 to a torque of 135
± 20 N·m (100 ± 15 lb ft).
Exhaust Manifolds
111 In a numerical sequence, tighten bolts 11 through 36 to a torque of 47
a. 60.63 ± 0.25 mm (2.387 ± 0.01 inch) ± 9 N·m (35 ± 7 lb ft).
b. 56.26 ± 0.25 mm (2.215 ± 0.01 inch)
112 Check flywheel housing bore runout and face runout.
c. 250 mm (9.84 inch)
d. 117.1 ± 0.25 mm (4.61 ± 0.01 inch)
e. 68.39 ± 0.25 mm (2.693 ± 0.01 inch)

Main Bearing Bolts

160 Install turbocharger air inlet elbow (if equipped).
161 Install crankcase ventilator hose(s).
162 Install fuel filter base. Use 2P-8250 Wrench to install new fuel filter.
163 Install water pump and bolts that hold water pump in position.
Maximum permissible runout (radial eccentricity) (1) of the flywheel housing 164 Install the O-ring seal on the water pump cover. Position the water
bore is 0.30 mm (0.12 inch). pump cover on water pump and install bolts.
a. Loosely install main bearing bolts (1). Note: The following bolts (3/4 inch) are 216 mm (8.5 inch) long: 11, 12, 13, 14,
Maximum permissible runout (axial eccentricity) (2) of the flywheel housing 16, 18, 20, 22, 24 and 26. The following bolts (3/8 inch) are 150 mm (5.9 inch) 165 Install O-ring seal on oil cooler bonnet. Apply 1U-6396 O-ring
b. Lubricate side bolts (2) and seal washers with engine oil. face is 0.38 mm (0.15 inch). long: 27 through 38. The rest of the bolts (3/4 inch) are 194 mm (7.6 inch) long. Compound to O-ring seal. Install oil cooler bonnet in engine oil cooler
c. Loosely install side bolts and seal washers. 166 Install integral seal on oil cooler bonnet. Position the oil cooler bonnet
a. Tighten bolts 1 through 26 (using hand torque wrench) in numerical
d. Torque tab end of main bearing cap to 258 ± 14 N·m (190 ± 10 lb ft). NOTICE sequence shown to a torque of 270 ± 15 N·m (199 ± 11 lb ft). on the water pump and install bolts.
e. Torque opposite end to 258 ± 14 N·m (190 ± 10 lb ft). If crankshaft seal & wear sleeve separate during installation, b. Tighten bolts 1 through 26 (using hand torque wrench) in numerical 167 Connect hose, install position support, and install bolts.
f. Mark each bolt and main bearing cap. do not assemble & reuse. Use new wear sleeve & seal unit. sequence shown to a torque of 450 ± 15 N·m (334 ± 11 lb ft). 168 Put water temperature regulators in position on front housing. Install
c. Retighten bolts 1 through 26 (using hand torque wrench) in numerical gasket and connector for the regulator housing.
g. Turn bolt on opposite end an additional 120° ± 5°. Note: Do not use any type of lubricant during the installation of the crankshaft
sequence shown to a torque of 450 ± 15 N·m (334 ± 11 lb ft). 169 Install gaskets, connector (shunt line elbow) & elbow on front housing.
h. Turn bolt on end of the main bearing cap with tab an additional 120° ± 5°. seal and wear sleeve.
d. Tighten bolts 27 through 39 (using hand torque wrench) to a torque of 45 ± 170 Coat female ends of exhaust manifold with oil before assembling to
i. Torque side bolt opposite end to 80 ± 10 N·m (60 ± 7 lb ft). 113 Inspect crankshaft for scratches. Inspect crankshaft for any distortion 7 N·m (33 ± 5 lb ft). male ends of exhaust manifold. Use centering tool in at least one
j. Torque side bolt tab end to 80 ± 10 N·m (60 ± 7 lb ft). on surface that may lead to an out of round condition. Use a polishing oversize hole per manifold section to align manifolds. Do not remove
cloth in order to remove any imperfections on the crankshaft. 139 Install the 9U-7255 Adjustable Idler Assembly Tool and adjust the idler assembly tools until required to tighten locknuts in sequence.
Note: Install main bearing caps with markings toward engine’s front. Main bearing
cap No. must also match cast No. on left side of each main bearing saddle. 114 Install the crankshaft rear seal and wear sleeve as follows: stub shaft bracket. Refer to Testing and Adjusting, SENR9937.
171 Tighten studs (3/8 in.) in cylinder head to a torque of 35 ± 5 N·m (26 ±
a. Clean crankshaft’s outside diameter & wear sleeve’s inside 140 Install idler gear and check backlash between the camshaft gear and 4 lb ft).
diameter. Fasten a Seal Locator (use 5P-7301 for engines with idler gear. The backlash between the two gears should be measured
Rear Gear Train rear gear train or 5P-1733 for engines without rear gear train) to with idler gear assembly held stationary.
172 Apply 5P-3931 Anti-Seize Compound on threads of locknuts that will
crankshaft with bolts (use 3 of 5P-1737 bolts for engines with rear hold exhaust manifold to cylinder head.
141 Install the camshaft gear cover and new gasket.
gear train, or for engines without rear gear train: 2 of 5P7309 and 173 Tighten locknuts holding each exhaust manifold to block in numerical
2 of 5P-7310). 142 Install the fan drive. sequence to a torque of 20 ± 3 N·m (15 ± 2 lb ft). Next, tighten nuts in
Note: Install the crankshaft rear seal with the arrow that shows the 143 Apply 4C-9507 Retaining Compound to bottom of outside surface of numerical sequence to a torque of 38 ± 5 N·m (28 ± 4 lb ft).
direction of crankshaft rotation toward the rear of the engine. the unit injector sleeves. Do not apply the compound to cylinder head. 174 Tighten the studs holding the turbochargers to the exhaust manifold to
b. Position wear sleeve & crankshaft rear seal as a unit on seal a torque of 35 ± 5 N·m (26 ± 4 lb ft).
144 Lubricate the O-ring seals with clean engine oil
locator.
145 Install a 221-9778 Puller Stud into the threads of unit injector sleeve. 175 Connect turbochargers on exhaust manifolds using locknuts & bolts,
c. Lubricate face of washer on 9S-8858 nut of the seal installer (use but do not tighten.
8T-2683 for engines with rear gear train or 6V-6143 for engines 146 Use a 9U-7258 Driver Cap and a hammer to install the unit injector
without rear gear train). Install nut for seal installer on seal locator. sleeve. Remove any excessive retaining compound. 176 Loosen V-band clamp only enough to allow turbine housing to rotate.
d. Tighten nut on seal installer until it contacts seal locator. Remove 147 Install the electronic unit injector. Lubricate the top two O-ring seals 177 Position oil lines so they are aligned without binding. Caution: Do not
the nut for the seal installer & seal installer from the seal locator. with a 50/50 mixture of clean engine oil and 8T-2998 Lubricant. tighten turbocharger mounting bolts at this time.
e. Remove the 5P-1737 bolt and the seal locator from crankshaft. 178 Tighten V-band clamp nuts to 14 ± 1 N·m (10 ± 0.7 lb ft). Tap nuts
148 Install the rocker and shaft assemblies.
f. Check crankshaft rear seal & wear sleeve for correct installation. lightly all around. Retighten to 14 ± 1 N·m (10 ± 0.7 lb ft). Do not
overtighten.
Valve Clearance 179 Tighten locknuts and bolts holding each turbocharger to an exhaust
Flywheel manifold to a torque of 55 ± 9 N·m (41 ± 7 lb ft).
180 Install electric starting motor.
181 Install miscellaneous brackets and attachments on engine.
182 Install alternator, fan, belt tightener & accessory drive belt as required.
1) Cluster idler gear
183 Prelube the engine to fill all oil passages. Use 1P-0540 Flow Check
2) Gear assembly for camshaft Tool Group as described in the following procedure.
3) Alignment marks on cam gears and rear housing
4) Camshaft bolts NOTICE
5) Idler gear assembly Remanufactured engines must be prelubricated before initial
6) Cluster idler gear Illustration: (A) Inlet valves, (B) Exhaust Valves startup. Internal engine parts may be damaged if not prelubed.
7) Alignment marks Note: The No. 1 piston at top dead center (TDC) on the compression stroke is
8) Crankshaft Gear the starting point for all timing procedures.
Procedure for Pressure Lubrication
1. Clean the tank of the 1P-0540 Flow Checking Tool
149 Install fuel lines.
115 Install one FT-1342 Guide Bolt in the crankshaft. Attach one FT-0121 150 Install gasket & crankcase ventilator on valve cover. Tighten clamps.
Lifting Bracket to the outside of the flywheel.
116 Apply clean engine oil or 5P-0960 Molybdenum Grease to bolt’s Procedure for Installation & Adjustment of Valve & Injector Mechanisms Air pressure should not be more than 345 kPa (50 psi) at any time.
threads. Valve lash settings: Intake 0.38 ± 0.08 (0.0150 ± 0.0031 inch) 2. Put engine oil in tank. Use minimum of 30% of engine oil capacity. It will be
117 Use a hoist to put the flywheel in position on the crankshaft. The Exhaust 0.76 ± 0.08 (0.299 ± 0.0031 inch) necessary with some engines to fill tank several times to get correct amount
weight of the flywheel is approximately 90 kg (200 lb). A. Adjust the valve lash setting with engine cold and stopped. of oil in engine.
103 Install rear gear group. Refer to Disassembly and Assembly, “Gear 118 Install bolts. B. Next, tighten adjusting screw locknut to 30 ± 7 N·m (22 ± 5 lb ft). 3. Connect the tooling to the main oil passage of the engine.
Group (Rear) – Install”. C. Recheck valve lash setting. 4. Add air pressure to tank, with regulator set at 240 ± 35 kPa (35 ± 5 psi). The
119 Replace FT-1342 Guide Bolt with a bolt. tank does have a hand pump, but it is difficult to get enough air pressure to
a. Related to the cluster idler gear (1), gear’s shaft, bearing bore and Unit injector adjusting instructions:
thrust surfaces with engine oil. Torque four 3/8 inch bolts to 55± 120 Tighten the flywheel’s 5/8 inch bolts (3) to a torque of 270 ± 40 N·m do job with hand pump. Therefore, use of shop air is recommended.
10 N·m (41 ± 7 lb ft). (200 ± 30 lb ft). D. Turn the unit injector rocker arm screw until unit injector height from 5. Let the engine oil flow into the oil passage under pressure.
timing seat is 78.0 ± 0.2 (3.07 ± 0.0079 inch). Use a 9U-7227 Injector
b. Related to the gear assembly for camshaft (2), lubricate gear’s 121 Check flywheel bore runout and face runout. Height Setting Gage Assembly to set the height . Fill the crankcase with the correct oil. The amount of oil used in the pressure
shaft, bearing bore and thrust surfaces with engine oil. lubrication procedures must be subtracted from the recommended refill
E. Hold adjusting screw in this position and tighten locknut to 100 ± 10 N·m capacity in the Lubrication and Maintenance Guide.
c. Related to idler gear assembly (5), lubricate gear assembly’s Maximum permissible runout (axial eccentricity) (1) of face 0.43 mm (74 ± 7 lb ft).
shaft, bearing bore and thrust faces with engine oil. Install thrust (total indicator reading) (0.017 inch) Note: If engine is not going to be used for a long time, do the above procedure
plates with side marked “OUT” away from gear face. Torque 3/8 A static torque of 100 + 50 –10 N·m (74 + 37 – 7 lb ft) is permitted. again before starting for the first time.
inch bolt to 55± 10 N·m (41 ± 7 lb ft). Maximum permissible drive hub pilot bore runout (radial 0.23 mm Note: If shop air is not available for charging the tank, the hand pump may be
eccentricity for pilot bearing) (2) off center of bore (total (0.009 inch) Note: Inlet & exhaust valves for No. 1 cylinder are fully closed if No. 1 piston is
d. Related to the cluster idler gear (6), torque the four 3/8 inch bolts used to get the minimum required pressure.
indicator reading) on compression stroke & rocker arms can be moved by hand. If rocker arms
to 55± 10 N·m (41 ± 7 lb ft). cannot be moved & valves are slightly open No. 1 piston is on exhaust stroke.
e. Lubricate the crankshaft gear’s shaft, bearing bore and thrust Note: The runout (eccentricity) of the coupling pilot diameter is not required for After actual stroke position is identified & other stroke position is needed,
faces with engine oil. this flywheel. remove timing bolt from flywheel. Flywheel is turned 360 degrees in a
f. Tighten camshaft gear bolts (4) in numerical sequence: 1, 4, 2, 5, 122 Install guide assembly for oil level gauge in cylinder block. counterclockwise direction. Timing bolt is reinstalled.
3, 6, 1, 4. Torque bolts to 240 ± 40 N·m (177 ± 30 lb ft). 123 Install oil pump suction bell.
104 Position No. 1 piston in top center position (TC). Align “V” mark on cam 124 Install underframe assembly on engine block.
gear (2) with the mark in the flywheel housing.

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