Specifications

1206E-E70TTA Industrial Engine

BL (Engine)

This document is printed from SPI². Not for RESALE

 

Important Safety Information

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

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

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

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

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

could result in injury  or death.

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

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

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

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

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

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

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

Attention! Become Alert! Your Safety is  Involved.

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

pictorially   presente  d.

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

this  pub lication.

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

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

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

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

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

repair procedures that you choose.

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

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

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

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

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

When  replacement  parts  are  required  for  this

product Perkins recommends using Perkins

 replacement  parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

This document is printed from SPI². Not for RESALE

 

KENR8798-01

3

Table of  Contents

Table of Contents

Engine Oil Pressure Sensor .................................  47

Boost Pressure Sensor ......................................... 48

Atmospheric Pressure Sensor .............................. 48

Inlet Manifold Temperature Sensor ....................... 49

Pressure Sensor (NOx Reduction System) .......... 49

Temperature Sensor (NOx Reduction System) ....  49

Diesel Particulate Filter Temperature and Pressure

Sensor ................................................................. 50

Speed/Timing Sensor  ..........................................  51

Electronic Control Module ..................................... 51

Electronic Control Wiring Group  (Aftertreatment

Regeneration Device) .........................................  52

Glow Plugs  ........................................................... 52

Air Compressor (Twin Cylinder Compressor) ....... 53

Air Compressor (Single Cylinder) .........................  54

Specifications Section

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

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

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

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

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

Fuel Filter Base  (Single Secondary Fuel Filter

Base) ...................................................................

Fuel Filter Base  (Twin Secondary Fuel Filter

Base) ...................................................................

Fuel Filter Base (Primary Fuel Filter Base) ...........

Fuel Control Manifold (Aftertreatment Regeneration

Device) ................................................................

Fuel Manifold (Rail) ...............................................

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

4

4

5

6

6

7

7

8

Index Section

8

8

9

Index .....................................................................  55

Rocker Shaft  ........................................................ 10

Valve Mechanism Cover  ...................................... 11

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

Cylinder Head  ...................................................... 12

Turbocharger (Series Turbochargers) ..................  14

Exhaust Gas Valve (NRS) ....................................  16

Exhaust Sensor and Lines Gp (NRS) ................... 18

Exhaust Cooler (NRS) ..........................................  18

Exhaust Manifold  .................................................  21

Flexible Exhaust Pipe ...........................................  22

Diesel Particulate Filter ......................................... 22

Camshaft  .............................................................  23

Camshaft Bearings  ..............................................  24

Engine Oil Filter Base  .......................................... 24

Engine Oil Cooler  ................................................. 25

Engine Oil Pump  .................................................. 25

Engine Oil Pressure  ............................................. 26

Engine Oil Pan  ..................................................... 27

Crankcase Breather  ............................................. 29

Water Temperature Regulator and Housing .........  29

Water Pump  ......................................................... 30

Cylinder Block  ...................................................... 30

Crankshaft  ...........................................................  31

Crankshaft Seals  .................................................  32

Vibration Damper and Pulley  ............................... 33

Connecting Rod Bearing Journal  ......................... 33

Main Bearing Journal ............................................ 34

Connecting Rod  ................................................... 34

Piston and Rings  .................................................. 36

Piston Cooling Jet ................................................. 37

Accessory Drive (SAE “B”) ...................................  37

Accessory Drive  ................................................... 38

Front Housing and Covers  ................................... 38

Gear Group (Front) ............................................... 39

Flywheel  ............................................................... 40

Flywheel Housing  ................................................  41

Belt Tensioner ....................................................... 42

Refrigerant Compressor .......................................  42

Fan Drive  .............................................................  43

Engine Lifting Bracket ........................................... 43

Alternator  .............................................................  43

Starter Motor  ........................................................ 45

Coolant Temperature Sensor  ............................... 47

This document is printed from SPI². Not for RESALE

 

4

KENR8798-01

Specifications  Section

Specifications Section

i04085729

Fuel Injection Lines

i03519906

Engine Design

Contact with  high pressure fuel  may cause fluid

penetration and  burn hazards. High pressure  fu-

el spray  may cause  a fire  hazard. Failure to  fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

Refer to Operation  and Maintenance Manual,

“General Hazard Information and High Pressure Fuel

Lines” before adjustments and repairs are performed.

NOTICE

Refer to Systems  Operation, Testing and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work on

the fuel system.

g01284058

Illustration 1

Cylinder and valve location

(A) Exhaust valve

(B) Inlet valve

Ensure that all adjustments and repairs are performed

by authorized personnel that have had the correct

training.

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

Stroke ......................................  135 mm (5.315 inch)

Displacement ................... 7.01 L (427.78 cubic inch)

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

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

Compression ratio

Turbocharged charge cooled .................... 16.5:1

Number of cylinders ................................................ 6

Valves per cylinder .................................................. 4

Firing order .........................................  1, 5, 3, 6, 2, 4

When the crankshaft is viewed  from the front of

the engine, the crankshaft rotates in the following

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

When the camshaft is  viewed from the front of

the engine, the camshaft rotates  in the following

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

The front of the engine is opposite the flywheel end.

The left side and the right  side of the engine are

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

the front cylinder.

This document is printed from SPI². Not for RESALE

 

KENR8798-01

5

Specifications Section

g02293673

Illustration 2

Typical example

(1), (2)  Tighten the nuts on the high-pressure fuel

lines to the following torque. .....  40 N·m (30 lb ft)

i04085749

Fuel Injection Pump

Note: The timing of the fuel injection pump will need

to be checked by trained personnel. In order to check

the timing of the fuel injection pump, refer to Systems

Operation, Testing and Adjusting, “Fuel  Injection

Pump Timing - Check”.

NOTICE

Refer to Systems  Operation, Testing and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work  on

the fuel system.

g02293713

Illustration 3

Typical example

(1)  Tighten the studs to the following torque. .. 11 N·m

(97 lb in)

(2)  Tighten the mounting nut  to the following

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

(3)  Tighten the fuel temperature sensor  to the

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

This document is printed from SPI². Not for RESALE

 

6

KENR8798-01

Specifications  Section

(4)  Tighten the setscrews  to the following

i04083730

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

Fuel Transfer Pump

(5)  Tighten the screws for the suction control valve

to the following torque. ............... 9 N·m (80 lb in)

(6)  Tighten the  screw to  the following

torque. ......................................  14 N·m (10 lb ft)

i03631793

Fuel Injectors

NOTICE

Refer to Systems  Operation, Testing and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work  on

the fuel system.

g02291814

Illustration 5

Typical example

(1)  Tighten the connection  to the following

torque. ......................................  20 N·m (15 lb ft)

g01862457

Illustration 4

Typical example

(3) Clamp

(4) Washer

(5) O ring seal

g02291815

Illustration 6

Typical example

(2), (3)  Tighten the  bolts to  the following

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

(1)  Torque for the nuts ...................... 2 N·m (18 lb in)

(2)  Torque for the bolt in  the clamp for the fuel

injection nozzle ......................  21 N·m (15.5 lb ft)

This document is printed from SPI². Not for RESALE

 

KENR8798-01

7

Specifications Section

i04073889

i04081471

Fuel Filter Base

(Single Secondary Fuel Filter

Base)

Fuel Filter Base

(Twin Secondary Fuel Filter

Base)

NOTICE

NOTICE

Refer to Systems  Operation, Testing and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work  on

the fuel system.

Refer to Systems  Operation, Testing and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work on

the fuel system.

If necessary, install a new fuel filter (2) to canister (1).

Refer to Operation and Maintenance Manual, “Fuel

System Secondary Filter - Replace” for the correct

procedure.

If necessary, install a new fuel filter (2) to canister (1).

Refer to Operation and Maintenance Manual, “Fuel

System Secondary Filter - Replace” for the correct

procedure.

g02289913

Illustration 7

Typical example

(3)  Tighten the bolts to the following torque. .. 44 N·m

(33 lb ft)

(4)  Tighten the bolt to the following torque. ... 17 N·m

(13 lb ft)

g02289934

Illustration 8

Typical example

(5)  Tighten the differential pressure  switch (if

equipped) to the following torque. ........... 20 N·m

(15 lb ft)

(3)  Tighten the bolts to the following torque. .. 44 N·m

(33 lb ft)

(4)  Tighten the differential pressure  switch (if

equipped) to the following torque. ........... 17 N·m

(13 lb ft)

(5)  Tighten the bolt to the following torque. ... 20 N·m

(15 lb ft)

This document is printed from SPI². Not for RESALE

 

8

KENR8798-01

Specifications  Section

i04077229

i04224205

Fuel Filter Base

(Primary Fuel Filter Base)

Fuel Control Manifold

(Aftertreatment Regeneration

Device)

NOTICE

Refer to Systems  Operation, Testing and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work  on

the fuel system.

If necessary, install a  new fuel filter element to

canister (2). Refer to Operation and Maintenance

Manual, “Fuel System  Primary Filter (Water

Separator) Element -  Replace” for the correct

procedure.

g01942619

Illustration 10

Typical example

(1)  Tighten the connectors for the  fuel control

manifold to the following torque. .............. 43 N·m

(32 lb ft)

(2)  Tighten the fuel pressure sensor for the  fuel

control manifold to the following torque. .. 20 N·m

(15 lb ft)

(3)  Tighten the fuel pilot valve assembly  to the

following torque. .......................  50 N·m (37 lb ft)

g02289936

Illustration 9

Typical example

(4)  Tighten the nut for the  coil to the following

torque. ......................................  20 N·m (15 lb ft)

Tighten water in fuel sensor (1) hand tight.

(5)  Tighten the setscrews for the fuel manifold to the

following torque. .......................  55 N·m (41 lb ft)

(3)  Tighten the connection  to the following

torque. ......................................  20 N·m (15 lb ft)

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

(32 lb ft)

i04084390

Fuel Manifold (Rail)

(5)  Tighten the connection  to the following

torque. ......................................  20 N·m (15 lb ft)

(6)  Tighten the connection  to the following

torque. ......................................  20 N·m (15 lb ft)

Refer to Operation  and Maintenance Manual,

“General Hazard Information and High Pressure Fuel

Lines” before adjustments and repairs are performed.

This document is printed from SPI². Not for RESALE

 

KENR8798-01

9

Specifications Section

i03537811

NOTICE

Lifter Group

Refer to Systems  Operation, Testing and Adjust-

ing, “Cleanliness of Fuel System Components” for

detailed information  on the standards  of cleanli-

ness that must be  observed during ALL work  on

the fuel system.

g01866794

Illustration 12

g02293653

Illustration 11

Typical example

Typical example

(A)  Diameter of the lifter body .. 21.938 to 21.963 mm

(0.86370 to 0.86468 inch)

(1)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

Bore diameter  in  the cylinder  block

...... 22.000 to 22.032 mm (0.86614 to 0.86740 inch)

(2)  Tighten the bolts to the following torque. .. 10 N·m

(89 lb in)

Clearance

(3)  Tighten the fuel pressure relief valve  to the

following torque. .......................  30 N·m (22 lb ft)

Clearance of the lifter  ..........  0.037 to 0.094 mm

(0.00146 to 0.00370 inch)

Note: The fuel pressure relief valve (3) should be

tightened an additional 24 degrees.

This document is printed from SPI². Not for RESALE

 

10

KENR8798-01

Specifications  Section

i03519944

(7)  Rocker shaft

Rocker Shaft

Diameter  of  the  rocker

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

(0.98275 to 0.98374 inch)

(8)  Retaining clip

(9)  Spring

g01850497

Illustration 14

Tightening sequence

Tighten the fasteners in  the sequence that is in

illustration 14. Tighten the fasteners to the following

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

g02113434

Illustration 13

Typical example

(1)  Tighten the threaded inserts to the  following

torque. ......................................  30 N·m (22 lb ft)

(2)  Retaining clip

(3)  Spring

(4)  Inlet rocker arm

Diameter of  the  rocker arm  bore

.... 25.013 to 25.051 mm (0.9848 to 0.9863 inch)

(5)  Exhaust rocker arm

Diameter of  the  rocker arm  bore

.... 25.013 to 25.051 mm (0.9848 to 0.9863 inch)

Clearance

Maximum clearance of both  the rocker arm

bores. ............................ 0.089 mm (0.0035 inch)

The service  limit for both  rocker arm

bores ............................... 0.17 mm (0.0067 inch)

(6)  Guide

This document is printed from SPI². Not for RESALE

 

KENR8798-01

11

Specifications Section

i03532881

Valve Mechanism Cover

g01861234

i03538600

Illustration 15

Typical example

Tighten the bolts for the valve mechanism cover in

the sequence that is shown in illustration 15. Torque

for the bolts ....................................... 9 N·m (80 lb in)

Cylinder Head Valves

g01927355

Illustration 16

Typical example

(1) Exhaust valve spring

(2) Inlet valve spring

This document is printed from SPI². Not for RESALE

 

12

KENR8798-01

Specifications  Section

When the valve springs  are replaced the valve

springs must be replaced in pairs.

The service  limit for  the inlet  valve

stem ................................ 0.08 mm (0.0031 inch)

Refer to table 1 and table 2 for information  on the

length of the valve spring and the load of the valve

spring.

Clearance

Maximum clearance of  the exhaust valve

stem ............................ 0.075 mm (0.00295 inch)

The service  limit for the  exhaust valve

Table 1

stem .............................. 0.10 mm (0.00394 inch)

The load for the inlet valve    The length of the inlet valve

spring

spring

(5)   Length of valve

161.5  to 178.5  N

(36.30682 to 40.12859 lb)

31.5 mm (1.2402 inch)

Inlet valve .......................... 109.82 to 110.27 mm

(4.32361 to 4.34133 inch)

Exhaust valve ................ 109.853 to 110.303 mm

(4.32491 to 4.34263 inch)

337.9  to 373.5  N

(75.96330 to 83.96654 lb)

21.5 mm (0.84646 inch)

Note: The free length for the  inlet valve spring is

40.65 mm (1.60039 inch).

(6)  Valve head

Diameter of inlet valve head .................... 35 mm

(1.37795 inch)

Table 2

Diameter of exhaust valve head .............. 33 mm

(1.2992 inch)

The load for the exhaust

valve spring

The length of the exhaust

valve spring

285  to  315 N

31.5 mm (1.2402 inch)

(64.07085 to 70.81515 lb)

i04131371

Cylinder Head

408.5  to 451.5  N

(91.83488 to 101.50172 lb)

22.3 mm (0.87795 inch)

Note: The free length for the exhaust valve spring is

52.73 mm (2.07598 inch).

g01927357

Illustration 17

Typical example

(3)  Valve face angle

Inlet ................................................... 30 degrees

Exhaust ............................................. 45 degrees

g01852017

Illustration 18

Typical example

(4)  Valve stem diameter

Lubricate the threads and the underside of the head

bolts with clean engine oil.

Inlet .. 6.970 to 6.985 mm (0.2744 to 0.2750 inch)

Exhaust ................................. 6.945 to 6.960 mm

(0.2734 to 0.2740 inch)

Tighten the bolts in the sequence that is shown in

illustration 18. Torque for the bolts ........... 50 N·m

(37 lb ft)

Clearance

Tighten the  bolts again to  the following

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

Maximum clearance  of the inlet  valve

stem ................................ 0.05 mm (0.0020 inch)

This document is printed from SPI². Not for RESALE

 

KENR8798-01

13

Specifications Section

Tighten the  head bolts to the  additional

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

Minimum thickness of cylinder head ......... 150.8 mm

(5.93700 inch)

g01854993

Illustration 19

g02328933

Typical example

Illustration 20

Typical example

Note: The maximum distortion of the cylinder head

is given in table 3.

(D)  Valve guide height from the top of the valve guide

to the valve spring seat .......... 10.75 to 11.25 mm

(0.42323 to 0.44291 inch)

Table 3

Maximum Permissible

Dimension

Distortion

(E)  Outside diameter  of  the valve

guides ................................ 11.029 to 11.040 mm

(0.43421 to 0.43464 inch)

Width (A)

Length (B)

0.03 mm (0.0012 inch)

0.05 mm (0.0020 inch)

0.05 mm (0.020 inch)

(F)  Length of the valve guides ... 43.75 to 44.25 mm

(1.72244 to 1.74212 inch)

Diagonal Line (C)

(G)  Internal diameter  of  the valve

guides ...................................  7.007 to 7.020 mm

(0.27587 to 0.27638 inch)

(H)  Valve depths

Inlet .. 0.905 to 1.163 mm (0.0356 to 0.0458 inch)

The service limit for the depth of the inlet valve

........................................ 1.41 mm (0.0555 inch)

Exhaust ................................. 0.876 to 1.131 mm

(0.0345 to 0.0445 inch)

The service  limit for the  exhaust valve

depth ............................... 1.38 mm (0.0543 inch)

This document is printed from SPI². Not for RESALE

 

14

KENR8798-01

Specifications  Section

g02299037

Illustration 22

Typical example

(1)  Actuator

The test  pressure for  the wastegate

actuator ........................................ 100 kPa (14.5 psi)

g02329114

Illustration 21

Typical example

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

(0.0394 inch)

(J)  Diameter of the parent bore  in the cylinder

head ................................... 11.000 to 11.022 mm

(0.43307 to 0.43394 inch)

(2)  Tighten the  studs to  the following

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

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

(32 lb ft)

i04089709

Turbocharger

(Series Turbochargers)

Note: For the  correct procedure to install the

turbochargers, refer to Disassembly and Assembly,

“Turbocharger - Install”.

g02299038

Illustration 23

Typical example

This document is printed from SPI². Not for RESALE

 

KENR8798-01

15

Specifications Section

(4), (6)  Tighten the  studs to the  following

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

(5), (7)  Tighten the  nuts to  the following

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

g02297816

Illustration 24

Typical example

(8)  Tighten the bolt to the following torque. ... 15 N·m

(11 lb ft)

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

(80 lb in)

(10)  Tighten the bolt to the following torque. .. 18 N·m

(13 lb ft)

(11), (13), (14), (15) Tighten the bolts to the following

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

(12)  Tighten the bolt to the following torque. .. 33 N·m

(24 lb ft)

This document is printed from SPI². Not for RESALE

 

16

KENR8798-01

Specifications  Section

g02297313

i04087589

Illustration 25

Typical example

(16)  Tighten the band clamps for the turbochargers

to the following torque. ........... 12 N·m (106 lb in)

Exhaust Gas Valve (NRS)

(17)  Tighten the band clamps for the ducts to the

following torque. ......................... 6 N·m (53 lb in)

g01946893

Illustration 26

Typical example

This document is printed from SPI². Not for RESALE

 

KENR8798-01

17

Specifications Section

(1)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

g02295533

Illustration 27

Typical example

(2)  Tighten the bolts to the following torque. .. 18 N·m

(13 lb ft)

(3)  Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)

(4)  Tighten the  clamps to the  following

torque. ........................................ 7 N·m (62 lb in)

(5)  Tighten the bolt to the following torque. ... 18 N·m

(13 lb ft)

g02295655

Illustration 28

Typical example

(6)  Tighten the bolt to the following torque. ... 15 N·m

(11 lb ft)

(7), (8)  Tighten the fasteners  to the following

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

This document is printed from SPI². Not for RESALE

 

18

KENR8798-01

Specifications  Section

i03636414

Exhaust Sensor and Lines Gp

(NRS)

Table 4

Required Tools

Tool

Part Number

Part Description

Qty

Bostik Pure Nickel

Anti-Seize Compound

A

-

1

g01950927

Illustration 29

Typical example

Note: Apply Tooling (A) to the sensors before  the

sensors are installed.

(1)  Tighten the sensors  to the  following

torque. ......................................  45 N·m (33 lb ft)

Tighten the harness for the sensors (not shown) to

the following torque. ........................ 45 N·m (33 lb ft)

i04087771

Exhaust Cooler (NRS)

Note: When the pipes for the  exhaust cooler are

removed or installed, care must be taken so that the

pipes are not bent or damaged.

This document is printed from SPI². Not for RESALE

 

KENR8798-01

19

Specifications Section

g02295833

Illustration 30

Typical example

(1)  Tighten the setscrews  to the following

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

(2)  Tighten the setscrews  to the following

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

This document is printed from SPI². Not for RESALE

 

20

KENR8798-01

Specifications  Section

g02295755

Illustration 31

Typical example

(3), (6)  Tighten the setscrews to  the following

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

(4), (7), (9)  Tighten the setscrews to the following

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

(5), (8)  Tighten the setscrews to  the following

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

This document is printed from SPI². Not for RESALE

 

KENR8798-01

21

Specifications Section

i04133329

Exhaust Manifold

g02330776

Illustration 32

Typical example

Tighten the exhaust manifold bolts in the sequence

that is shown in  illustration 32 to the following

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

This document is printed from SPI². Not for RESALE

 

22

KENR8798-01

Specifications  Section

i03936932

Flexible Exhaust Pipe

g02155429

Illustration 33

Typical example

(1)  Tighten the  clamp to  the following

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

(2)  Tighten the  clamp to  the following

torque. ......................................  55 N·m (41 lb ft)

Refer to Disassembly and Assembly for the correct

procedure to install the flexible exhaust pipe.

i04083749

Diesel Particulate Filter

Note: To remove and install the Diesel Particulate

Filter (DPF), refer to Disassembly and Assembly

for the correct procedures.

g02291874

Illustration 34

Typical example

This document is printed from SPI². Not for RESALE

 

KENR8798-01

23

Specifications Section

(1)  Tighten the nuts on the clamps to the following

torque. ......................................  42 N·m (31 lb ft)

i04156668

Camshaft

(2)  Tighten the nuts on the clamp to the following

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

g02291875

Illustration 35

g01927854

Typical example

Illustration 37

Checking the end play of the camshaft

(3)  Tighten the nuts on the clamps to the following

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

(1)  End play of a camshaft ......... 0.106 to 0.558 mm

(0.00417 to 0.02197 inch)

Maximum permissible  end play of  a worn

camshaft ...............................  0.62 mm (0.0244 inch)

g02291876

Illustration 36

Typical example

(4)  Tighten the nuts to the following torque. .. 18 N·m

(13 lb ft)

g01859007

Illustration 38

Typical example

(2)  Bolt

Torque for the 8.8 graded bolt ..  95 N·m (70 lb ft)

This document is printed from SPI². Not for RESALE

 

24

KENR8798-01

Specifications  Section

Torque for the 10.9 graded bolt ............. 120 N·m

(89 lb ft)

i03551117

Engine Oil Filter Base

(3)  The diameters of the camshaft journals are given

in the following tables.

Table 5

Camshaft Journals

from the Front End

of the Engine

Standard Diameter

1

Front

50.711 to  50.737  mm

(1.9965 to 1.9975 inch)

50.457 to  50.483  mm

(1.9865 to 1.9875 inch)

2

3

50.203 to  50.229  mm

(1.9765 to 1.9775 inch)

4

Rear

49.949 to  49.975  mm

(1.9665 to 1.9675 inch)

Maximum wear on the camshaft journals ... 0.05 mm

(0.0021 inch)

Check the camshaft lobes for visible damage. If a

new camshaft is installed, you must install new lifters.

g01877935

i03530782

Illustration 40

Camshaft Bearings

Typical example

(1)  Dust cap

(2)  Engine oil filter

Torque for the engine oil filter .. 12 N·m (106 lb in)

(3)  Engine oil sampling valve

Torque for the engine  oil sampling valve (if

equipped) ................................ 12 N·m (106 lb in)

Torque for the plug (if equipped) ... 12 N·m (106 lb in)

(4)  Setscrew

Torque for the setscrews that retain the oil filter

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

g01859293

Illustration 39

Typical example

(1)  The diameter of  the installed camshaft

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

(1.9995 to 2.0019 inch)

This document is printed from SPI². Not for RESALE

 

KENR8798-01

25

Specifications Section

i03524541

Tighten the setscrews in the sequence that is in

illustration 42 to the following torque. ...... 22 N·m

(16 lb ft)

Engine Oil Cooler

i04085774

Engine Oil Pump

Engine Oil Cooler  with a Low

Mounted Filter Base

Type .............................  Gear-driven differential rotor

Number of lobes

Inner rotor ......................................................... 6

Outer rotor ........................................................  7

g02005253

Illustration 41

Typical example

Setscrews

Tighten the setscrews in the sequence that is in

illustration 41 to the following torque. ...... 22 N·m

(16 lb ft)

g00938064

Illustration 43

Engine Oil Cooler  with a High

Mounted Filter Base

(1)  Clearance of  the outer  rotor to the

body ...................................... 0.050 to 0.330 mm

(0.0020 to 0.0130 inch)

g00938061

Illustration 44

Checking the clearance

(2)  Service limit  of inner  rotor to outer

rotor ......................................  0.080 to 0.250 mm

(0.0031 to 0.0098 inch)

g01854213

Illustration 42

Typical example

Setscrews

This document is printed from SPI². Not for RESALE

 

26

KENR8798-01

Specifications  Section

i03540441

Engine Oil Pressure

The minimum oil pressure at a  maximum engine

speed of 2200  rpm and at normal  operating

temperature is the following value. .. 315 kPa (45 psi)

g00938799

Illustration 45

Checking the end play

(3)  End play of rotor assembly

Inner rotor ............................. 0.050 to 0.180 mm

(0.0020 to 0.0071 inch)

Outer rotor ............................  0.050 to 0.180 mm

(0.0020 to 0.0071 inch)

g02293754

Illustration 46

Typical example

(4) Suction Pipe

(6) Bracket for the Suction Pipe

(5), (7), (8), (9)  Tighten the bolts to the  following

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

(10)  Tighten the bolt to the following torque. .. 44 N·m

(32 lb ft)

This document is printed from SPI². Not for RESALE

 

KENR8798-01

27

Specifications Section

i04129089

Engine Oil Pan

g01856874

Illustration 47

(X) Guide studs

(Y) Short fastener

Tighten the fasteners in the sequence that is shown

in illustration 47. Torque for the fasteners ...... 22 N·m

(16 lb ft)

g01857014

Illustration 48

Remove the guide studs. Install the fasteners (27),

(28), (29) and (30).

Tighten the  oil drain plug  to the following

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

Tighten the fastener in the sequence that is shown in

illustration 48. Torque for the fasteners .......... 22 N·m

(16 lb ft)

Tighten the oil level  switch (if equipped) to the

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

This document is printed from SPI². Not for RESALE

 

28

KENR8798-01

Specifications  Section

Refer to the Disassembly and Assembly, “Engine Oil

Pan” for the correct procedure to install the engine

oil pan.

The Cast Iron Oil Pan

g01397669

Illustration 49

Tightening sequence

Tighten the fasteners in the sequence that is shown

in illustration 49 to the following torque. ......... 22 N·m

(16 lb ft)

Tighten the  oil drain plug  to the following

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

Tighten the oil level  switch (if equipped) to the

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

This document is printed from SPI². Not for RESALE

 

KENR8798-01

29

Specifications Section

i04085789

i03520180

Water Temperature Regulator

and Housing

Crankcase Breather

g01853873

Illustration 51

Typical example

Water temperature regulator housing

(1)  Torque for the bolts that fasten the housing to the

cylinder head ............................  22 N·m (16 lb ft)

g02295333

Illustration 50

Typical example

(2)  Torque for the vent plug ....... 22 N·m (16.22 lb ft)

(1), (2), (3)  Tighten the setscrews to the following

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

(4)  Tighten the setscrews  to the following

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

Note: If a hexagonal pillar spacer is required, install

the spacer to the engine oil cooler. Tighten the spacer

to a torque of 22 N·m (16 lb ft).

g01854133

Illustration 52

(4)  Water temperature regulator

This document is printed from SPI². Not for RESALE

 

30

KENR8798-01

Specifications  Section

Opening temperature ........................ 80° to 84°C

(151° to 176°F)

Maximum open length of 11 mm (0.43307 inch) is

achieved at the following temperature. ...... 94° C

(201° F)

i04117792

Cylinder Block

i03520301

Water Pump

g01855114

Illustration 54

Cylinder block

(1)  Cylinder block

(2)  Cylinder bore ................ 105.000 to 105.025 mm

(4.1338 to 4.1348 inch)

g01850741

Illustration 53

Tightening sequence

(3)  Camshaft bearings

Tighten the setscrews in the numerical sequence

that is shown in  illustration 53 to the following

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

Diameter of  the bushing in the  cylinder

block for  the  number 1  camshaft

bearing .............................. 55.563 to 55.593 mm

(2.1875 to 2.1887 inch)

Diameter of  the bore  in the  cylinder

block for  the  number 2  camshaft

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

(1.9900 to 1.9920 inch)

Diameter of  the bore  in the  cylinder

block for  the  number 3  camshaft

journal ............................... 50.292 to 50.343 mm

(1.9800 to 1.9820 inch)

Diameter of  the bore  in the  cylinder

block for  the  number 4  camshaft

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

(1.9700 to 1.9720 inch)

(4)  Main bearings

Bore in  the cylinder block  for the main

bearings ............................ 88.246 to 88.272 mm

(3.4742 to 3.4753 inch)

(5)  Main bearing cap bolts

This document is printed from SPI². Not for RESALE