ENGINE REBUILD INSPECTION SHEET
K 38 - 50
Job No : Eng. Model :
Customer : ESN :
CPL : Pump Code :
Start Date : Finish Date :
ASSEMBLING WORK
CHECK POINT
PROCESS
1. CYLINDER BLOCK C - Clean Cylinder Block, All Oil and Coolant Passages.
I - Install Cup Plug and Dowel Pin using the correct size Cup Plug
Driver handle with loctite 648 / Sealant P/N 3375068.
C - Use Soft Hamer to Install Pin Dowel.
I - Install Seal Tamper Proof P/N 3176649 for KV Engine Using
tools AV Seal P/N 382314.
I - Install Camshaft Bushing with Specified Special Tools P/N
ST.1228 and P/N 3162248 (See tools Catalog).
C - Make sure all oil holes and passages are clean.
C - Bushing P/N
C - Calculate Liner Protrution prior to the installation.
Install Cylinder Liner
C - Use RTV Sealant P/N 3377132 at the bottom of the counter
Bore with tickness 3/64 into 1/16 inch
C - Coat O, Ring with Lubriplate P/N 1242
I - Use the liner installation tools according to the Engine Model
(See Tools Catalog)
C - Liner P/N
- Measure liner protrusion Use a gauge block, Part Number 3376220
- Press the cylinder liner into the cylinder block by tightening
the liner force plate screw Torque Value: 136 n.m [100 ft-lb]
Cylinder Liner Protrusion specification Min 0.10 mm (0.004 in)
Max 0.15 mm (0.006in )
Recorded Cylinder Liner protution
POSITION 1RB 1LB 2RB 2LB 3RB 3LB 4RB 4Lb 5RB 5LB 6LB 6RB
12 O" (clock)
3 0" (clock)
6 O" (clock)
9 O" (clock )
M - Use a dial bore gauge measure the ID of the Liner at the top -
Bottom - Middle.
M - Take 2 measurement at each location the measurement
must be go degrees apart.
C - Specification Min 139.694 mm (5.4998 in) Max 139.827 mm (5.5050 in )
Recorded Inside Diameter Liner
xx RB
yy
1# 2# 3# 4# 5# 6#
xx LB
yy
ASSEMBLING WORK
CHECK POINT
PROCESS
I - Install the upper Crankshaft Thrust Bearing Support on the rear
of the block.
I - Install the lock washers and capscrew.
T - Torque Cap Screws Thrust Bearing Support Engine
C - Install Upper Main Bearing
V - Make sure location number main bearing, the narrow bearing
V - Ensure surfaces are free from dirt or dust.
C - Do not lubricate the back of the bearing.
T - Torque all capscrew to specified torque.
C - Install Crankshaft.
C - Coat all round main journal with lubriplate P/N 1242.
I - Install Thrust Bearing with lubriplate P/N 1242.
C - Ensure the Grooves in the Thrust Bearing must point toward
the Crankshaft
C Do not rotate Crankshaft before main bearing Cap Screw
-
final Torque is done.
C - Install Lower Main Bearing on the Cap.
C - Make sure Cap number has the same number that is stamped
on the block.
C - Use Engine oil, lubricate the Cap Screw Heads, Threads and
the washers
C - Do not use Impact Wrenchs, the Main Bearing Shells can
fall out.
T - Tighten main bearing capscrew by following the step bellow.
Torque Value: Recorded
1 175 n.m [129 ft-lb]
2 285 n.m [210 ft-lb]
3 563 n.m [415 ft-lb]
4 Loosen n.m [Loosen ft-lb]
5 285 n.m [210 ft-lb]
6 600 n.m [443 ft-lb]
C - Use Engine Oil Lubricate the capscrew heads threads.
I - Install the capscrew for side of the main bearing cap.
C - Use the following steps to tighten the Capscrews in the
Sequence Shown. Torque Value: Recorded
1 102 n.m [75 ft-lb]
2 190 n.m [140 ft-lb]
C - Use a dial Indicator P/N. 3376051 with magnetic base
P/N. 3377399
M - Measure Crankshaft End Clearance.
C - Thurst Bearing
Crankshaft End Clearance Recorded
Min 0.15 mm (0.006 in ) Max 0.33 mm (0.013in)
- Install Piston Cooling Nozzle Oil Regulator
- Check to make sure all of the oil holes are in alignment
- Install the plunger, the valve spring, disc, and snap ring
in the body of the cooling regulator.
C - Use a feel or gauge measure the end Cap.
C - Ensure the chrome plating on the Ring will be damaged
and the ring will fail.
C - Ensure the Cylinder Bore I.D is correct
C - Ring Piston P/N Top Ring
Second Ring
Oil Ring
ASSEMBLING WORK
CHECK POINT
PROCESS
RECORDED CYLINDER NUMBER
POSITION CYLINDER SPECIFICATION
1 2 3 4 5 6
RB Min '0.43 mm (0.017in)
TOP
LB Max 0.68 mm (0.027in)
RB Min 0.51mm (0.020in)
SECOND
LB Max 0.76 mm (0.030in)
RB Min 0.48 mm (0.019in)
Third
LB Max 0.74 mm (0.029in)
RB Min 0.25 mm (0.010in)
Oil
LB Max 0.64 mm (0.025in)
13. PISTON C - Install piston Rings with stamped mark facing upwards and
with tools P/N. ST-1269.
C - The Gap in the oil Ring expanding (10) must be turned 180
degrees opposite the Gap on the Oil Ring (11) or the Rings and
Piston will be damaged.
C - Rotate the Rings so the Gaps are not aligned with the adjacent
Ring or a Piston Pin Bore.
C - Piston P/N
14. CONNECTING ROD
Install the rod and piston assembly until the ring compressor touches the block
T
C
C
RECORDED CONNECTING ROD BOLT STRECTH
POSITION
1 2 3 4 5 6 7 8
1
RB
2
1
LB 2
15. CONNECTING ROD
SIDE CLEARANCE M - Measure side clearance with a Feeler gauge or Dial indicator
P/N. 3376051 with Magnetic Base P/N. 33777399.
C - Make sure that machine number must be same both
Rod and Cap.
C - Make sure that Mark Number is according Cylinder specification.
CLEARENCE MM IN
MIN
MAX
RECORDED
CON ROD CONDITION
REMARKS MECH. DATE
PART NO. QTY OK REWORKED REPLACED REPAIR
RECORDED CON ROD CLEARENCE NUMBER
POSITION
1 2 3 4 5 6 7 8
RB
LB
16. PISTON COOLING I - Install Piston cooling nozzle.
NOOZLE C - Ensure the tip of each nozzle is directed at the centre of each
Piston Shacker Hole.
Do not use washers on the mounting Capscrew of the Piston
Cooling Nozzle contact between the Connecting Rod and
Capscrew head will result in engine damaged.
T - Torque Cap Screw refer to specification.
SPECIFICATIONS
N.m ft-lb
RECORDED
COOLING NOOZLE CONDITION
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
RECORDED CAP SCREW COOLING NOOZLE CYLINDER
POSITION
1 2 3 4 5 6 7 8
LB
RB
17. FRONT GEAR
HOUSING I - Install Gear housing
C - Use Sequence Shown to tighten the Cap Screw.
C - Make sure the Gasket already installed down on front of Block
with Housing Gear.
SPECIFICATION RECORDED
N.m ft-lb RESULT MECH. DATE
GEAR HOUSING CONDITION
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
18. CAMSHAFT
I - Install Camshaft
C - Use Lubriplate, Lubricate each camshaft and all of the Camshaft
Bushings completely.
C - Don't damaged the Camshaft Bushings when installing the
Camshaft, the bushing will fail.
I - Install the two Cap Screws and Lock plates.
SPECIFICATION RECORDED
N.m ft-lb RESULT MECH. DATE
CAMSHAFT CONDITION
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
GEAR CONDITION
REMARKS MECHANIC DATE
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
19. INJECTION TIMING
C - Use Injection Timing tools P/N. 3375522
Make sure Cpl and Timing code already install on engine.
CODE PUSHROD TRAVEL
MM IN
AE 2,74 0,108
AJ 3,20 0,126
AL 2,74 0,108
AM 3,00 0,118
BL 3,14 0,163
CL 3,66 0,144
CV 3,89 0,153
RECORDED
ACTUAL ACTUAL TIMING
REMARKS MECHANIC DATE
READING READING CODE
KEY CONDITION
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
20. IDLER SHAFT &
GEAR I - Install Gear Idler
C - make sure rotate the Shaft until the Oil Holes Area at 3 o'clock
and 9 o'clock positions as shown.
C - make sure sign marks between Gear is true.
T - Torque Cap Screw refer to specifications.
SPECIFICATION RECORDED
CAP SCREW N.m ft-lb RESULT MECHANIC DATE
WITH FLANGE
WITHOUT FLANGE
GEAR CONDITION
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
21. CAMSHAFT END
CLEARANCE M - Measure Camshaft End Clearance
C - Make sure when do measurement the place of Torque position
is true.
SPECIFICATION RECORDED
N.m IN RESULT MECHANIC DATE
MIN
MAX
GEAR CONDITION
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
22. IDLER GEAR
END CLEARANCE M - Measure Idler Gear End Clearance
C - Make sure when do measurement the place of Torque position
is true.
RECORDED
MM IN RESULT MECHANIC DATE
MIN
MAX
GEAR CONDITION DATE
REMARKS MECHANIC
PART NO. QTY OK REWORKED REPLACED
GEAR TRAIN AND FLOAT
CAMSHAFT RB CAMSHAFT LB CAM IDLER RB CAM IDLER LB W/P IDLER HYD. DRIVE IDLER
23. FRONT GEAR
TRAIN M - Measure the Front Gear Train Blacklash.
C - Make sure position the indicator at "O" rotate the Gear
Counter clockwise. Read the indicator.
RECORDED
MM IN RESULT MECHANIC DATE
MIN
MAX
GEAR TRAIN BACKLASH
W/P IDLER CAM IDLER RB CAM IDLER LB CAMSHAFT RB CAMSHAFT LB HYD. DRIVE IDLER
24. FLYWHEEL HOUSING
CAP SCREW C - Install the flywheel housing, push the housing over the
Dowel Pins and to the Cylinder Block follow the sequences
shown to tighten the cap screws.
T - Follow the sequence shown to tighten the Cap Screw.
RECORDED
CAPSCREW N.m ft-lb RESULT MECH. DATE
FLYWHEEL HOUSING CONDITION
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
25. FLYWHEEL HOUSING
RUNOUT C Measure the bore and the face of the housing must be in
alignment with the crankshaft measure the indicator arm
must be Rigid for and accurate reading.
RECORDED
POSITION MM IN MECHANIC DATE
12 O'CLOCK
3 O'CLOCK
6 O'CLOCK
9 O'CLOCK
EQUAL TIR
BORE
FACE
_________TIR
_________TIR
26. FLYWHEEL
ALIGNMENT
C Measure the distance from the centre of the Crankshaft to
the indicator Tip multiply (X) the distancery 0,025 mm
(0,00)
RECORDED
MM IN RESULT MECHANIC DATE
BORE FAC
E
BORE FAC
E
_________TIR
_________TIR
27. FLYWHEEL CAP
SCREW C The flywheel mounting Capscrew must be SAE grade 8
minimum with Rolled Threads.
Check tu be sure the mating surfaces of the Crankshaft and
Flywheel are clean, dry, and free of nick or burns.
RECORDED
N.m STEP ft-lb RESULT MECHANIC DATE
FLYWHEEL CONDITION
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
28. LUBRICATING PUMP
I - Install Oil Pump, make sure the condition is good.
C - Check to be sure each Mounting Leg of the Pump Contains
a Dowel Pin.
C - Bend the Lock Plate over the Heads of the Cap Screw and the
Feet of the Pump Special for KV series.
RECORDED
MM ft-lb RESULT MECHANIC DATE
LUBE PUMP CONDITION
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED REPAIR
29. LUBRICATING PUMP
GEAR BACKLASH M - Use a Dial Indicator, measure the Pump Drive Gear to Rear
Crankshaft Gear Backlash.
SPECIFICATION RECORDED
MM IN RESULT MECHANIC DATE
MIN
MAX
30. LUBRICATING OIL
TRANSFER TUBE I - Install Lubricating Oil Transfer Tube.
C - The correct Oil transfer tube must be installed of the engine will
be damaged extensively from lack of lubrication.
SPECIFICATION RECORDED
TORQUE VALUE
POSITION MECHANIC
N.m ft-lb RESULT DATE
Cap Screw
Cap Screw
Cap Screw
LUBE. OIL TRANS CONDITION
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
31. CAM FOLLOWER
CAP I - Install Cam Follower the Shaft Must Fit Correctly on both Ring
Dowels.
C - Make sure Roller condition is good and true. Coat all Roler with
Lubrication.
T - Torque Cap Screw
RECORDED
N.m ft-lb RESULT MECHANIC DATE
MIN
MAX
ROCKER HOUSING CONDITION
CONDITION REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
ROLLER INJ.
ROLLER VLV INT.
ROLLER VLV EXS.
PIN INJ.
PIN VLV.
32. CYLINDER HEAD
CAP SCREW I - Install Cylinder Head, make sure that good condition.
C - Make sure Gasket - the word "TOP" that is stamped on the
Head Gasket must be visible after the Gasket is installed.
C - Make sure the Gasket mudt slide easily over groove Pins.
Check the Pins for damaged.Use engine Oil Lubricate the Cap
Screw Heads, Thread and Washers.
T - Torque Cap Screws.
SPECIFICATION RECORDED
BLACK SILVER
STEP MECHANIC DATE
N.m ft-lb N.m ft-lb
1
2
3
4
5 * *
CONDITION RECORDED CYLINDER HEAD NUMBER
CYLINDER HEAD 1 2 3 4 5 6 7 8
RIGHT BANK
PART NO.
WITH NEW
WITH RECON
REBUILD
LEFT BANK
PART NO.
WITH NEW
WITH RECON
REBUILD
33. ROCKER HOUSING
CAP SCREW I - Install Rocker Housing, check Water Transfer Tube condition.
C - Use vegetable Oil. Lubricate the O-Ring seals.
C - Make sure that Water Transfer Tube condition is good, not
corotion.
T - Use the sequence shown to tighten the Cap Screws.
SPECIFICATIONS
N.m ft-lb RESULT
RECORDED
ROCKER HOUSING CONDITION
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED REPAIR
34. INJECTOR
I - Install injector, make sure O-Ring, Sealing Ring is installed and
true with Orifice Screen.
C Use Vegetable Oil. Lubricate the O-Ring.
-
C - Be sure the injector plunger moves freely after the Clamp is
tightened.
RECORDED
INJECTOR CONDITION
POSITION REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED REBUILD
RB
LB
35. INJECTOR CAP
SCREW
T - Torque Cap Screw refer to specification.
SPECIFICATIONS
N.m In-lb RESULT
RECORDED
CAP SCREWS CONDITION
POSITION REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
RB
LB
36. JUMPER TUBE
CONNECTOR I - Install the Jumper Tube and the Copper Sealing washer and
O-Ring.
C - Use Engine Oil Lubricate the O-Ring.
T - Torque the Connector Screw.
C - Jumper Tube specially engine K38/K50/K19 injector STC.
SPECIFICATIONS
N.m ft-lb RESULT
RECORDED
JUMPER TUBE CONDITION
POSITION REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED
RB
LB
37. ROCKER LEVER
I - Install Rocker Lever. Make sure Adjusting Screw are loose.
C - Be sure that the Ring Dowel that aligns the Rocker Lever Shaft
is installed in the Housing.
C - Make sure push Rod already true installing.
T - Torque Cap Screw refer to specification.
SPECIFICATIONS
N.m ft-lb RESULT
RECORDED
ROCKER LEVER CONDITION
REMARKS MECHANIC DATE
PART NO. QTY OK REWORKED REPLACED REPAIR
38. INJECTOR
ADJUSTMENT C - Make sure Injector Adjusment following manual instruction and
use special tolls according Injector Model.
C - Re-check rotate engine, make sure that adjusting valve Injector
is true.
Tools Part. No Descriptions Remark
3822575 Injector and adjusting kit -
3822648 STC Tapet adjusting tools -
3376592 torque Wrench 10 in-lb
3398032 Torque Wrench 600 in lb
Specifications Result MECHANIC DATE
N.m FT-LB N.m ft-lb
N.m INJECTOR in-lb RESULT MECHANIC DATE
WITH STC (HVT)
39. VALVE ADJUSTMENT
C - Make sure Valve Adjustment mark pointer position and FO
according manual instruction.
C - Use Feeler Gauge refer to Specifications.
T - Torque Lock Nut reefr to specifications.
mm POSITION INCH
EXHAUST
INTAKE
RECORDED
Specifications Result MECHANIC DATE
N.m ft-lb N.M ft-lb
Turbo Charger High Pressure P/N Low Pressure
Fulel Pump ESN Fuel Pump P/N
COMMENTS :
Q. A : FOREMAN/ SPV : DATE :
Note : I = Install C = Caution T = Torque M = Measurement V = Visual
