KENR6245

May 2007

Specifications
1104D (Mech) Industrial Engine
NK (Engine)
NL (Engine)
NK (Engine)

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 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.

This document has been printed from SPI². Not for Resale
KENR6245 3
Table of Contents

Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Injection Lines .............................................. 4
Fuel Injection Pump ............................................. 5
Fuel Injectors ....................................................... 6
Fuel Transfer Pump ............................................. 6
Lifter Group ........................................................... 7
Rocker Shaft ........................................................ 7
Valve Mechanism Cover ...................................... 8
Cylinder Head Valves ........................................... 8
Cylinder Head ...................................................... 10
Turbocharger ....................................................... 11
Exhaust Manifold ................................................. 12
Camshaft ............................................................. 12
Camshaft Bearings .............................................. 14
Engine Oil Filter ................................................... 14
Engine Oil Cooler ................................................. 15
Engine Oil Pump .................................................. 16
Engine Oil Pressure ............................................. 18
Engine Oil Bypass Valve ...................................... 18
Engine Oil Pan ..................................................... 19
Crankcase Breather ............................................. 20
Water Temperature Regulator and Housing ......... 22
Water Pump ......................................................... 22
Cylinder Block ...................................................... 22
Crankshaft ........................................................... 24
Crankshaft Seals ................................................. 26
Connecting Rod Bearing Journal ......................... 26
Main Bearing Journal ............................................ 27
Connecting Rod ................................................... 27
Piston and Rings .................................................. 29
Piston Cooling Jet ................................................. 30
Front Housing and Covers ................................... 31
Gear Group (Front) ............................................... 31
Flywheel ............................................................... 33
Flywheel Housing ................................................ 34
Crankshaft Pulley ................................................. 34
Fan Drive ............................................................. 35
Engine Lifting Bracket ........................................... 36
Alternator ............................................................. 36
Starter Motor ........................................................ 37
Glow Plugs ........................................................... 38

Index Section
Index ..................................................................... 40

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4 KENR6245
Specifications Section

Specifications Section When the camshaft is viewed from the front of

the engine, the camshaft rotates in the following
direction: ................................................... Clockwise
i02655068
The front of the engine is opposite the flywheel end.
Engine Design The left side and the right side of the engine are
viewed from the flywheel end. The No. 1 cylinder is
the front cylinder.

i02656438

Fuel Injection Lines

g01333480
Illustration 1
Cylinder and valve location
(A) Inlet valve
(B) Exhaust valve

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

Stroke ...................................... 127 mm (5.000 inch)

Displacement ...................................... 4.4 L (269 in3)

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

g01334606
Type of combustion ............................ Direct injection Illustration 2
Typical example
Compression ratio
(1) Tighten the union nuts for the fuel injector nozzles
Naturally aspirated engines ...................... 19.3:1 to the following torque. ............. 30 N·m (22 lb ft)
Turbocharged engines .............................. 18.2:1
Tighten the union nuts for the fuel injection pump (not
Number of cylinders ................................................ 4 shown) to the following torque. ....... 30 N·m (22 lb ft)
Valves per cylinder .................................................. 2

Valve lash
Inlet valve ......................... 0.20 mm (0.008 inch)
Exhaust valve ................... 0.45 mm (0.018 inch)

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

When the crankshaft is viewed from the front of

the engine, the crankshaft rotates in the following
direction: ................................................... Clockwise

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KENR6245 5
Specifications Section

i02663071 Unlocking the shaft

Fuel Injection Pump Loosen locking screw (2) and install the washer
(3) to the unlocked position. Tighten the bolt to
the following torque. ................... 12 N·m (9 lb ft)

Note: Before the fuel injection pump is removed from

the engine the fuel injection pump shaft must be
locked. Position the engine to TC compression stroke
of number one cylinder before tightening the locking
screw. The locking screw will prevent the shaft from
rotating. If the fuel injection pump was removed
prior to correctly timing the engine and locking the
shaft, the fuel injection pump will need to be timed by
trained personnel.

g01352239
Illustration 4
Typical example of a support bracket

(4) Tighten the mounting bolt to the following

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

(5) Tighten the mounting bolt and the nut to the

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

Note: The support bracket must be installed after

the coolant pump is installed. In order to stop the
distortion of the timing case, finger tighten the bolt
(4) and then tighten the nut and bolt (5). Tighten the
bolt (4).

Tighten the bolts that hold the fuel pump to the front
housing to the following torque. ...... 25 N·m (18 lb ft)
g01352237
Illustration 3
Typical example

Note: The solenoid on the fuel injection pump is

a serviceable item. The fuel injection pump is a
nonserviceable item.

(1) O-ring

(2) Locking screw

(3) Washer

Locking the shaft

Loosen locking screw (2) and move the washer
(3) to the locked position. Tighten the bolt to the
following torque. ...................... 17 N·m (12 lb ft)

This document has been printed from SPI². Not for Resale
6 KENR6245
Specifications Section

i02662510 i02661897

Fuel Injectors Fuel Transfer Pump

g00908211
Illustration 5
Fuel injector clamp

(1) Tighten the bolt in the clamp for the fuel injector
to the following torque. ............. 35 N·m (26 lb ft)

The fuel injector should be tested at the pressure in

table 1.

Leakage in 10 seconds ................................. 0 drops

Table 1

Service setting for the Fuel Injector g00986823

Illustration 6
Injection Pressure
29.4 + 0.8 MPa (4264 + 116 psi) (1) Retaining bolts

(2) Clip

(3) Spacer

(4) Fuel transfer pump

Type .......................... 12 or 24 volt electric motor

(5) Fuel filter element

(6) O ring

(7) Fuel filter bowl

Note: Tighten the fuel filter bowl by hand. Rotate the

bowl 1/8 of a turn more by hand.

This document has been printed from SPI². Not for Resale
KENR6245 7
Specifications Section

i02677369

Lifter Group

g00629433 g01345401
Illustration 7 Illustration 8
The rocker shaft
(1) Diameter of the lifter body .. 18.987 to 19.012 mm
(0.7475 to 0.7485 inch) Note: In order to install the rocker shaft assembly,
Tooling (A) is required.
Clearance of the lifter in the cylinder block
bore ....... 0.038 to 0.095 mm (0.0015 to 0.0037 inch) (1) Snap ring

i02655105
(2) Washer

Rocker Shaft (3) Rocker arm

(4) Rocker arm bore

Diameter of the rocker arm
bore .................................. 25.013 to 25.051 mm
Table 2 (0.9848 to 0.9863 inch)
Required Tools
Rocker arm
Part
Tool Number Part Description Qty Clearance between the rocker arm and the rocker
shaft ...................................... 0.026 to 0.089 mm
A 27610227 Spacing Tool 4
(0.0010 to 0.0035 inch)
Maximum permissible clearance between the
rocker arm and the rocker shaft ............ 0.17 mm
(0.007 inch)

(5) Spring

Note: Install the longest screw at the front of the

rocker shaft assembly.

(6) Tighten the screws evenly. Begin in the center

and work toward the outside. Tighten the screws
to the following torque. ............. 35 N·m (26 lb ft)

(7) Rocker shaft

Diameter of the rocker
shaft .................................. 24.962 to 24.987 mm
(0.9828 to 0.9837 inch)

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8 KENR6245
Specifications Section

(8) In order to install the rocker shaft assembly, i02662486

ensure that the machined square is to the top of
the rocker shaft. Cylinder Head Valves
(9) Locknut
Torque for the locknut ............... 27 N·m (20 lb ft)

i02551219

Valve Mechanism Cover

g01277221
Illustration 9

Tighten the bolts for the valve mechanism cover

in the sequence that is shown to the following
torque. ................................................. 9 N·m (7 lb ft) g01345407
Illustration 10
Cross section of cylinder head

(1) Valve spring

Naturally aspirated engines
The installed length of the valve
springs .......................... 35.17 mm (1.3846 inch)
The load for the installed valve springs ..... 335 N
(75 lb)
Turbocharged engines
The installed length of the inlet valve springs
(high ratings) ................. 35.17 mm (1.3846 inch)
The load for the installed inlet valve
springs ........................................... 335 N (75 lb)
The installed length of the inlet valve springs (low
ratings) .......................... 36.17 mm (1.4240 inch)
The load for the installed inlet valve
springs ........................................... 312 N (70 lb)
The installed length of the exhaust valve springs
(all ratings) .................... 36.17 mm (1.4240 inch)
The load for the installed exhaust valve
spring ............................................. 312 N (70 lb)

This document has been printed from SPI². Not for Resale
KENR6245 9
Specifications Section

Turbocharged aftercooled engines Service limit ........................... 2.06 mm (0.0811 inch)

The installed length of the valve
springs .......................... 36.17 mm (1.4240 inch) Turbocharged aftercooled engines .. 1.55 to 1.81 mm
The load for the installed valve springs ..... 312 N (0.0610 to 0.0713 inch)
(70 lb)
Service limit ........................... 2.06 mm (0.0811 inch)
(2) Valve spring recess
(5) Inlet valve
(3) The finished valve guides Diameter of the inlet valve
Inside diameter of valve stem ...................................... 8.953 to 8.975 mm
guide ..................................... 9.000 to 9.022 mm (0.3525 to 0.3533 inch)
(0.3543 to 0.3552 inch) Clearance of valve in valve
guide .. 0.025 to 0.069 mm (0.001 to 0.0027 inch)
Outside diameter of the valve
guide ................................. 13.034 to 13.047 mm Overall length of the inlet
(0.5131 to 0.5137 inch) valve ................................... 128.838 to 129.288 mm
(5.0724 to 5.0901 inch)
Interference fit of valve guide in cylinder
head ...................................... 0.007 to 0.047 mm The face of the inlet valve is recessed below the
(0.0003 to 0.0019 inch) cylinder head by the following amount.
Length of Valve guide .......... 51.00 to 51.50 mm Naturally aspirated engines ............ 0.60 to 0.85 mm
(2.018 to 2.027 inch) (0.0236 to 0.0335 inch)
Projection of the valve guide above the valve
spring recess (2) ................... 12.35 to 12.65 mm Turbocharged engines (high rating) .. 0.60 to 0.85 mm
(0.486 to 0.498 inch) (0.0236 to 0.0335 inch)

Note: When new valve guides are installed, new Service limit ............................ 1.09 mm (0.043 inch)
valves and new valve seat inserts must be installed.
The valve guides and the valve seat inserts are Turbocharged engines (low rating) .. 1.60 to 1.85 mm
supplied as partially finished parts. The unfinished (0.0630 to 0.0728 inch)
valve guides and unfinished valve seat inserts are
installed in the cylinder head. The guides and inserts Turbocharged aftercooled engines .. 1.60 to 1.85 mm
are then cut and reamed in one operation with special (0.0630 to 0.0728 inch)
tooling. This procedure ensures the concentricity of
the valve seat to the valve guide in order to create a Service limit .......................... 2.09 mm (0.0823 inch)
seal that is tight. Refer to Disassembly and Assembly
for removal and installation procedures. (6) Exhaust valve face angle from the horizontal axis
Valve face angle ............................... 30 degrees
(4) Exhaust valve Valve seat angle ............................... 30 degrees
Diameter of the exhaust valve
stem ...................................... 8.938 to 8.960 mm (7) Diameter of the exhaust
(0.3519 to 0.3528 inch) valve head ............................ 41.51 to 41.75 mm
(1.634 to 1.643 inch)
Clearance of valve in valve
guide ..... 0.040 to 0.062 mm (0.0016 to 0.0024 inch) (8) Diameter of the head of the inlet
valve ..................................... 46.28 to 46.53 mm
Overall length of the exhaust (1.8220 to 1.8319 inch)
valve ................................... 128.184 to 128.634 mm
(5.0466 to 5.0643 inch) (9) Angle of the inlet valve face from the vertical axis
Valve face angle ............................... 45 degrees
The face of the exhaust valve is recessed below the
Valve seat angle ............................... 45 degrees
cylinder head by the following amount.
The valve lash is the following value when the engine
Naturally aspirated engines ............ 0.55 to 0.81 mm
is cold:
(0.0217 to 0.0319 inch)
Inlet valves ........................ 0.20 mm (0.008 inch)
Service limit ............................ 1.06 mm (0.042 inch) Exhaust valves ................. 0.45 mm (0.018 inch)

Turbocharged engines .................... 1.55 to 1.81 mm

(0.0610 to 0.0713 inch)

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10 KENR6245
Specifications Section

i02662502

Cylinder Head

Table 3
Required Tools
Part
Tool Number Part Description Qty
A 21825607 Angle gauge 1

g00809016
Illustration 11
The maximum distortion of the cylinder head is given
Recess for the valve seat insert in table 4.

(10) Machine the recess in the head for valve seat The cylinder head bolts are two different lengths. The
inserts to the following dimensions. following information provides the proper torque for
the cylinder head bolts.
Recess for Inlet Valve Seat for Naturally Aspirated
Engines and high rated turbocharged engines
(A) ..... 9.84 to 10.04 mm (0.3874 to 0.3953 inch)
(B) ..................................... 47.820 to 47.845 mm
(1.8827 to 1.8837 inch)
(C) Maximum radius ......... 0.38 mm (0.015 inch)
Recess for Exhaust Valve Seat for Naturally
Aspirated Engines and high rated turbocharged
engines
(A) ..... 9.84 to 10.04 mm (0.3874 to 0.3953 inch)
(B) ..................................... 42.420 to 42.445 mm
(1.6701 to 1.6711 inch)
(C) Maximum radius ......... 0.38 mm (0.015 inch)
Recess for Inlet Valve Seat for low rated
turbocharged engines and turbocharged
aftercooled engines
(A) .... 10.84 to 11.04 mm (0.4268 to 0.4346 inch)
(B) ..................................... 47.820 to 47.845 mm
(1.8827 to 1.8837 inch)
(C) Maximum radius ......... 0.38 mm (0.015 inch) Illustration 12
g00987480

Recess for Exhaust Valve Seat for turbocharged The tightening sequence
engines and turbocharged aftercooled engines
Lubricate the threads and the underside of the head
(A) .... 10.84 to 11.04 mm (0.4268 to 0.4346 inch)
bolts with clean engine oil.
(B) ..................................... 42.420 to 42.445 mm
(1.6701 to 1.6711 inch) Tighten the bolts in the sequence that is shown in
(C) Maximum radius ......... 0.38 mm (0.015 inch) Illustrations to the following torque. ......... 50 N·m
(37 lb ft)
Tighten the bolts again to the following
torque. .................................... 100 N·m (74 lb ft)

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KENR6245 11
Specifications Section

i02662519

Turbocharger

g00905621
Illustration 13

The head bolts require an additional torque turn

procedure. The numbers (1, 3, 4) are three long
cylinder head bolts. All the other bolts are short bolts.
The tightening sequence is shown in the Illustrations .
Place the angle gauge on the top of each bolt
head. Tighten the short bolts to the additional
amount. ........................................... 225 degrees
Place the angle gauge on the top of each bolt
head. Tighten the long bolts for the additional
amount. ........................................... 270 degrees
g00991357
Illustration 15
Thickness of the cylinder head .. 117.95 to 118.05 mm
Typical turbocharger
(4.643 to 4.647 inch)
(1) Actuator rod
Minimum thickness of cylinder head ........ 117.20 mm
(4.614 inch)
(2) Actuator
Note: The maximum distortion of the cylinder head
(3) Turbocharger
is given in table 4.
(4) Tighten the nuts to the following torque. .. 44 N·m
(32 lb ft)

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

(80 lb in)

(6) Tighten the bolt to the following torque. ... 22 N·m

(16 lb ft)

The maximum test pressure for the

wastegate ....................................... 205 kPa (30 psi)

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

(0.0394 inch)
g01006568
Illustration 14

Table 4
Maximum Permissible
Dimension
Distortion
Width (A) 0.03 mm (0.0012 inch)
Length (B) 0.05 mm (0.0019 inch)
Diagonal Line (C) 0.05 mm (0.0019 inch)

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12 KENR6245
Specifications Section

Table 5 i02662527

The part number for

the turbocharger
The pressure for the
wastegate
Exhaust Manifold
2674A835 138 ± 3 kPa
(20.0155 ± 0.4351 psi)
2674A841 123 ± 3 kPa
(17.8399 ± 0.4351 psi)
2674A843 138 ± 3 kPa
(20.0155 ± 0.4351 psi)
2674A816 131 ± 3 kPa
(19.0002 ± 0.4351 psi)
2674A817 100 ± 3 kPa
(14.5040 ± 0.4351 psi)
2674A836 138 ± 3 kPa
(20.0155 ± 0.4351 psi)
2674A818 123 ± 3 kPa
(17.8399 ± 0.4351 psi)
2674A844 138 ± 3 kPa
(20.0155 ± 0.4351 psi)
2674A819 131 ± 3 kPa
(19.0002 ± 0.4351 psi)
2674A821 100 ± 3 kPa
(14.5040 ± 0.4351 psi)
g01337856
2674A837 138 ± 3 kPa Illustration 16
(20.0155 ± 0.4351 psi) Typical example
2674A822 123 ± 3 kPa
(17.8399 ± 0.4351 psi) Tighten the exhaust manifold bolts in the sequence
that is shown in illustration 16 to the following
2674A838 138 ± 3 kPa torque. ............................................. 40 N·m (30 lb ft)
(20.0155 ± 0.4351 psi)
2674A825 123 ± 3 kPa
i02662539
(17.8399 ± 0.4351 psi)
2674A845 138 ± 3 kPa Camshaft
(20.0155 ± 0.4351 psi)
2674A826 131 ± 3 kPa
(19.0002 ± 0.4351 psi)
2674A827 100 ± 3 kPa
(14.5040 ± 0.4351 psi)
2674A842 138 ± 3 kPa
(20.0155 ± 0.4351 psi)

g01277351
Illustration 17
Checking the end play of the camshaft

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KENR6245 13
Specifications Section

(1) End play of a new camshaft ..... 0.10 to 0.55 mm

(0.004 to 0.022 inch)

Maximum permissible end play of a worn

camshaft ................................. 0.60 mm (0.023 inch)

g01277354
Illustration 18
Typical camshaft

(2) Bolt
Tighten the bolt to the following torque. ... 95 N·m
(70 lb ft)
g01345411
(3) Camshaft thrust washer Illustration 19
Typical example
Thickness of the thrust washer .. 5.49 to 5.54 mm
(0.216 to 0.218 inch) (5) Camshaft lobe lift
Depth of the recess in the cylinder block for the
Naturally aspirated
thrust washer ............................ 5.54 to 5.64 mm
(0.218 to 0.222 inch) Inlet lobe ............................... 7.201 to 7.301 mm
(0.2835 to 0.2874 inch)
Tolerance of the thrust washer in cylinder block Exhaust lobe ......................... 7.404 to 7.504 mm
front face ........................... −0.154 to −0.003 mm (0.2914 to 0.2954 inch)
(−0.0006 to −0.0001 inch)
Turbocharged
(4) The diameters of the camshaft journals are given Inlet lobe ............................... 7.527 to 7.627 mm
in the following table. (0.2963 to 0.3003 inch)
Exhaust lobe ......................... 7.363 to 7.463 mm
Table 6
(0.2899 to 0.2938 inch)
Diameters of Camshaft Journals
Turbocharged aftercooled
Camshaft Journals Standard Diameter
Inlet lobe ............................... 7.031 to 7.131 mm
1
50.711 to 50.737 mm (0.2768 to 0.2807 inch)
(1.9965 to 1.9975 inch) Exhaust lobe ......................... 7.363 to 7.463 mm
50.457 to 50.483 mm (0.2899 to 0.2938 inch)
2
(1.9865 to 1.9875 inch)
(6) Camshaft lobe height
49.949 to 49.975 mm
3
(1.9665 to 1.9675 inch) (7) Base circle

Maximum wear on the camshaft journals ... 0.05 mm To determine the lobe lift, use the procedure that
(0.0021 inch) follows:

1. Mount the camshaft between centers.

2. By using a dial indicator in contact with the surface

of the lobe, rotate the camshaft and record the
maximum and minimum lift.

This document has been printed from SPI². Not for Resale
14 KENR6245
Specifications Section

Note: There may be two lobes on the camshaft. i02663064

Refer to illustration 19. The surface between the
lobes may not return to the radius of the base circle. Engine Oil Filter
Using a micrometer to measure the diameter of the
base circle may give a inaccurate result.

3. Subtract the smallest dimension from the largest

dimension. The difference is the actual camshaft
lobe lift.

Maximum permissible deviation between the

actual lobe lift and the specified lobe lift of a new
camshaft ................................. 0.05 mm (0.002 inch)

i02656416

Camshaft Bearings

g01338237
Illustration 21
Typical example

(1) Setscrew
Tighten the setscrews to the following
torque. ...................................... 22 N·m (16 lb ft)

(2) Engine oil filter

Tighten the engine oil filter to the following
torque. .................................... 12 N·m (106 lb in)

g01334592
Illustration 20
Typical example

(1) The diameter of the installed camshaft

bearing .............................. 50.787 to 50.848 mm
(1.9995 to 2.0019 inch)

This document has been printed from SPI². Not for Resale
KENR6245 15
Specifications Section

i02657143

Engine Oil Cooler

g00952614
Illustration 23
Typical example
(1) Joint
(2) Oil cooler
(3) Housing
(4) Setscrew
(5) Seal
g01338238 (6) Setscrew
Illustration 22
(7) Setscrew
Typical example

(3) Setscrew
Tighten the setscrews to the following
torque. ...................................... 22 N·m (16 lb ft)

(4) Engine oil filter

Tighten the engine oil filter to the following
torque. .................................... 12 N·m (106 lb in)

(5) Plug
Tighten the plug to the following torque. .. 12 N·m
(106 lb in)

g01334858
Illustration 24

Setscrews
Tighten the setscrews (7) to the following
torque. ...................................... 22 N·m (16 lb ft)

Setscrews
Tighten the setscrews (4) and (6) in the
sequence that is in illustration 24 to the following
torque. ...................................... 22 N·m (16 lb ft)

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16 KENR6245
Specifications Section

i02656269

Engine Oil Pump

Engines with Balancer Group

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

Number of lobes
Inner rotor ......................................................... 6
Outer rotor ........................................................ 7

g01334410
Illustration 26
Inner rotor

(2) Clearance of inner rotor to outer

rotor ...................................... 0.050 to 0.200 mm
(0.0020 to 0.0079 inch)

g01334408
Illustration 25
The oil pump for the balancer

(1) Clearance of the outer rotor to the

body .. 0.130 to 0.24 mm (0.0050 to 0.0094 inch)

g01334412
Illustration 27
The end play for the rotor

(3) End play of rotor assembly

Inner rotor .................................. 0.04 to 0.11 mm
(0.0016 to 0.0043 inch)
Outer rotor ................................. 0.04 to 0.11 mm
(0.0016 to 0.0043 inch)

This document has been printed from SPI². Not for Resale
KENR6245 17
Specifications Section

(6) Tighten the nut to the following torque. .... 95 N·m

(70 lb ft)

Tighten the bolts that hold the balancer to the cylinder

block to the following torque. .......... 54 N·m (40 lb ft)

Engines without Balancer Group

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

Number of lobes
Inner rotor ......................................................... 5
Outer rotor ........................................................ 6

g01334415
Illustration 28
The end cover

(4) Torque for cover bolts for oil pump .......... 26 N·m
(19 lb ft)

g00938064
Illustration 30
The oil pump

(1) Clearance of the outer rotor to the

body ...................................... 0.152 to 0.330 mm
(0.0059 to 0.0129 inch)

g01334416
Illustration 29
Idler gear and pump gear
g00938061
Illustration 31
Note: Replace the idler gear bolt (5) and the nut for Checking the clearance
the oil pump gear (6).
(2) Clearance of inner rotor to outer
(5) Tighten the idler gear bolt to the following rotor ...................................... 0.040 to 0.127 mm
torque. ...................................... 26 N·m (19 lb ft) (0.0015 to 0.0050 inch)

Note: Set the engine to the TC position. Refer to

Systems Operation, Testing and Adjusting Manual,
“Finding Top Center Position for No. 1 Piston”. Install
the balancer. Refer to Disassembly and Assembly,
“Balancer - Install”. Install the gear for the oil pump
and tighten the nut (6).

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18 KENR6245
Specifications Section

i02505676

Engine Oil Bypass Valve

Installed in the Oil Pump

g00938799
Illustration 32
Checking the end play

(3) End play of rotor assembly

Inner rotor ............................. 0.038 to 0.089 mm
(0.0014 to 0.0035 inch)
Outer rotor ............................ 0.025 to 0.076 mm
(0.0010 to 0.0029 inch)
g00919893
Illustration 33
Tighten the bolts that hold the front cover of the oil
Typical engine oil pump
pump assembly to the following torque. ........ 10 N·m
(89 lb in)

i02731019

Engine Oil Pressure

The minimum oil pressure at the maximum engine

speed and at normal operating temperature is the
following value. ............................... 280 kPa (41 psi)

g00921377
Illustration 34
Relief valve and spring

(1) Tighten the plug for the relief valve to the

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

(2) Plunger
Diameter of the plunger ..... 19.186 to 19.211 mm
(0.7554 to 0.7563 inch)
Clearance of plunger in bore .. 0.039 to 0.114 mm
(0.0015 to 0.0045 inch)

(3) Spring
Length of the spring ...... 80.94 mm (3.1866 inch)

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KENR6245 19
Specifications Section

Installed in the Balancer i02662550

Engine Oil Pan

Table 7
Required Tools
Tool Part Number Part Description Qty
POWERPART
A 21826038 1
Retainer

Illustration 35
g00919890 Front sealant
Plug

g00921379
Illustration 36
The relief valve for the balancer

(1) Tighten the plug for the relief valve to the

following torque. ....................... 35 N·m (26 lb ft)
g01254690
Illustration 37
(2) Plunger Applying sealant

Diameter of the plunger ........ 14.46 to 14.48 mm If the gasket that is between the front housing and
(0.5692 to 0.5700 inch) the cylinder block is not renewed, apply Tooling (A) to
Clearance of the plunger in the the cylinder block and to the front housing. If a new
bore .... 0.04 to 0.08 mm (0.0015 to 0.0031 inch) gasket is installed, Tooling (A) is not required.

(3) Spring Note: Apply a sealant bead of 3.5 mm (0.1378 inch)

that is shown in illustration 37.
Length of the spring ........... 67 mm (2.6378 inch)
Rear sealant
Note: Install the rear oil seal before sealant is applied
to the bridge.

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20 KENR6245
Specifications Section

Tighten the remaining bolts to the following

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

(2) Drain plug

Tighten the drain plug for the engine oil pan to
the following torque. ................. 34 N·m (25 lb ft)

i02662638

Crankcase Breather

Table 8
Required Tools
Part
Tool Number Part Description Qty

Illustration 38
g01254887 POWERPART red rubber
A 21820221 1
grease
Applying sealant

Apply Tooling (A) to the bridge. The sealant must

not protrude more than 5 mm (0.1969 inch) above
the bridge.

g00926199
Illustration 40
Breather valve

(1) Cover

(2) Cover plate

(3) Screws
Tighten the screws for the cover plate with
a composite valve mechanism cover to the
g01255016
Illustration 39 following torque. ................... 1.3 N·m (11.5 lb in)
Typical example
(4) Diaphragm
(1) Tighten the four front bolts in position (X) to the
following torque. ....................... 22 N·m (16 lb ft) (5) Cap

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KENR6245 21
Specifications Section

(6) Spring Breather Canister

g00926200
Illustration 41
Typical example

(7) O-ring

Note: Apply Tooling (A) to the O-ring before installing

the breather pipe in the valve mechanism cover. Illustration 42
g01277902

Typical example
(8) Tighten the bolts that secure the breather pipe to
(1) Connection
the cylinder head to the following torque. .. 9 N·m (2) Clamp
(80 lb in) (3) Hose
(4) Filter base
(5) Bolts
(6) Clamp
(7) Hose
(8) Canister

(2) Tighten the clamps to the following

torque. ........................................ 3 N·m (26 lb in)

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

(16 lb ft)

(6) Tighten the clamp to the following torque. .. 3 N·m

(26 lb in)

(8) Tighten the canister to the following

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

This document has been printed from SPI². Not for Resale
22 KENR6245
Specifications Section

i02504533 i02363605

Water Temperature Regulator Water Pump

and Housing

Table 9
Required Tools
Tool Part Number Part Description Qty
POWERPART Red
A 21820221 1
Rubber Grease

g01183807
Illustration 44
Tightening sequence

Tighten the setscrews in the numerical sequence

that is shown in illustration 44 to the following
torque. ............................................. 22 N·m (16 lb ft)

i02663067
g01253716
Illustration 43
Cylinder Block
Typical example

Note: Apply Tooling (A) to the O-ring (4) in order to

install the water temperature regulator housing (2).

(1) Tighten the bolts that fasten the housing to the Table 10
following torque. ....................... 44 N·m (32 lb ft) Required Tools

(2) Water temperature regulator housing Tool Part Number Part Description Qty
POWERPART
(3) Water temperature regulator A 21826038 1
Retainer
Opening temperature ........................ 82° to 87°C
(179.6000° to 156.6000°F)
Full opening temperature .... 95 °C (203.0000 °F)
Minimum stroke at full temperature ........... 9 mm
(0.3543 inch)

This document has been printed from SPI². Not for Resale
KENR6245 23
Specifications Section

Use the following procedure in order to install the

main bearing cap bolts:

1. Apply clean engine oil to the threads of the main

bearing cap bolts.

2. Put the main bearing caps in the correct position

that is indicated by a number on the top of the
main bearing cap. Install the main bearing caps
with the locating tabs in correct alignment with the
recess in the cylinder block.

3. Evenly tighten the main bearing cap bolts.

Torque for the main bearing cap bolts. .... 245 N·m
(180 lb ft)

g00924764
Illustration 45
Typical example

(1) Cylinder block

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

(4.1338 to 4.1348 inch)

The first oversize bore

diameter .................................. 105.5 to 105.525 mm g00938203
Illustration 46
(4.1535 to 4.1545 inch)
Use the following procedure in order to install the
The second oversize bore
allen head bolts for the bridge.
diameter .............................. 106.000 to 106.025 mm
(4.1732 to 4.1742 inch)
Note: Install the rear seal before sealant is applied.
The maximum permissible wear for the cylinder bore
1. Use a straight edge in order to ensure that the
................................. 0 to 0.15 mm (0 to 0.0059 inch)
bridge is aligned with the rear face of the cylinder
block.
(3) Camshaft bearings
Diameter of the bore in the cylinder 2. Tighten the allen head bolts (6) for the bridge.
block for the number 1 camshaft
bearing .............................. 55.563 to 55.593 mm Torque for the allen head bolts ... 16 N·m (12 lb ft)
(2.1875 to 2.1887 inch)
3. When the bridge is installed on the cylinder block,
Diameter of the bore in the cylinder apply Tooling (A) into groove (7) at each end of
block for the number 2 camshaft the bridge. Apply the sealant into the groove until
journal ............................... 50.546 to 50.597 mm the sealant is forced through the bottom end of
(1.9900 to 1.9920 inch) the groove in the bridge.
Diameter of the bore in the cylinder Note: The oil pan must be installed within 10 minutes
block for the number 3 camshaft of applying the sealant.
journal ............................... 50.038 to 50.089 mm
(1.9700 to 1.9720 inch) Total height of the cylinder block between the top and
the bottom faces. ................ 441.173 to 441.274 mm
(4) Main bearings (17.3689 to 17.3729 inch)
Bore in the cylinder block for the main
bearings ............................ 80.416 to 80.442 mm
(3.1660 to 3.1670 inch)

(5) Main bearing cap bolts

This document has been printed from SPI². Not for Resale
24 KENR6245
Specifications Section

i02663072 Note: All new turbocharged engines and

turbocharged aftercooled engines have crankshafts
Crankshaft that are nitrocarburised. The crankshaft can also
be nitrided for 20 hours, if the nitrocarburised
process is not available. After a crankshaft has
been machined, the crankshaft must be rehardened.
Inspect the crankshaft for cracks before machining
and after machining. Naturally aspirated engines
have induction hardened crankshafts.

g01338264
Illustration 47
Typical example

(1) Crankshaft

The maximum end play of the crankshaft ... 0.51 mm

(0.0201 inch)

(2) Thrust washers

Standard thickness ................... 2.26 to 2.31 mm
(0.089 to 0.091 inch)
Oversize thickness ................... 2.45 to 2.50 mm
(0.097 to 0.098 inch)

(3) The crankshaft gear

Maximum permissible temperature of the gear for

installation on the crankshaft ........... 180 °C (356 °F)

Note: The timing mark is toward the outside of

the crankshaft when the gear is installed on the
crankshaft.

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KENR6245 25
Specifications Section

g01338265
Illustration 48

Note: Refer to illustration 48 in order to use table 11.

Table 11
The undersize diameter of the Crankshaft Journals
NUMBER 0.25 mm (0.010 inch) 0.51 mm (0.020 inch) 0.76 mm (0.030 inch)
75.905 to 75.926 mm 75.651 to 75.672 mm 75.397 to 75.418 mm
1
(2.9884 to 2.9892 inch) (2.9784 to 2.9792 inch) (2.9684 to 2.9692 inch)
63.216 to 63.236 mm 62.962 to 62.982 mm 62.708 to 62.728 mm
2
(2.4888 to 2.4896 inch) (2.4788 to 2.4796 inch) (2.4688 to 2.4696 inch)
39.47 mm (1.5539 inch)
3 N/A N/A
maximum
37.44 mm (1.4740 inch)
4 N/A N/A
maximum
44.68 mm (1.7591 inch)
5 N/A N/A
maximum
40.55 mm (1.5965 inch)
6 N/A N/A
maximum
7 Do not machine this diameter. N/A N/A
3.68 mm (0.1449 inch) to
8 N/A N/A
3.96 mm (0.1559 inch)
4.36 to 4.60 mm
9 N/A N/A
(0.1717 to 0.1811 inch)

Refer to table 12 for the maximum run out of the

crankshaft journals.

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26 KENR6245
Specifications Section

Table 12
Journal Excessive run out
(1) Mounting
(2) 0.08 mm (0.0031 inch)
(3) 0.15 mm (0.0059 inch)
(4) 0.08 mm (0.0031 inch)
(5) Mounting

Refer to Specifications, “Connecting Rod Bearing

Journal” for more information on the connecting rod
bearing journals and connecting rod bearings.

Refer to Specifications, “Main Bearing Journal” for

information on the main bearing journals and for
information on the main bearings.

i02658811
g00915076
Crankshaft Seals Illustration 50

(5) Tighten bolts 1, 2, 3, 4, 5, 6, 7, and 10 in the

sequence that is shown in Illustration 50 to the
following torque. ....................... 22 N·m (16 lb ft)

Remove the alignment tool.

Tighten bolts 8 and 9 in the sequence that is shown

in Illustration 50 to the following torque. ........ 22 N·m
(16 lb ft)

i02504771

Connecting Rod Bearing

Journal

Refer to Specifications, “Crankshaft” for information

on the undersize crankshaft journals.

The original size of the connecting rod bearing

journal ... 63.47 to 63.49 mm (2.4988 to 2.4996 inch)
g01335894
Illustration 49
Typical example Maximum permissible wear of a bearing journal on a
new connecting rod .............. 0.04 mm (0.0016 inch)
(1) Crankshaft
Width of the connecting rod bearing
(2) Crankshaft seal journals ................................... 40.348 to 40.424 mm
(1.5885 to 1.5915 inch)
(3) Plastic sleeve
Radius of the fillet of the connecting rod bearing
(4) Alignment tool journals ......... 3.68 to 3.96 mm (0.145 to 0.156 inch)

Surface finish of connecting rod bearing

journals ............................................. Ra 0.4 microns

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KENR6245 27
Specifications Section

Surface finish of radii ........................ Ra 1.3 microns i02662161

Connecting Rod
i02656267

Main Bearing Journal

Refer to Specifications, “Crankshaft” for information

on the undersize main bearing journals, and
information on the width of main bearing journals.

The original size of the main bearing

journal ..................................... 76.159 to 76.180 mm
(2.9984 to 2.9992 inch)

Maximum permissible wear of the main bearing

journals ............................... 0.040 mm (0.0016 inch)

Radius of the fillet of the main bearing

journals ..... 3.68 to 3.69 mm (0.1448 to 0.1452 inch)

Surface finish of bearing journals, crank pins and

radii ................................... 0.4 microns (16 µ inches)

The shell for the main bearings Illustration 51

g00907738

The shells for the main bearings are available The mating surfaces of the connecting rod are
for remachined journals which have the following produced by hydraulically fracturing the forged
undersize dimensions. connecting rod.
Undersize bearing shell .... 0.25 mm (0.010 inch)
(1) Tighten the torx screws for the connecting rod to
Undersize bearing shell .... 0.51 mm (0.020 inch)
the following torque. ................. 18 N·m (13 lb ft)
Undersize bearing shell .... 0.75 mm (0.030 inch)
Tighten the torx screws for the connecting rod again
Thickness at center of the shells .. 2.083 to 2.089 mm
to the following torque. .................... 70 N·m (52 lb ft)
(0.0820 to 0.0823 inch)
Tighten the torx screws for the connecting rod for
Width of the main bearing shells .. 31.62 to 31.88 mm
an additional 120 degrees. The torx screws for
(1.244 to 1.255 inch)
the connecting rod (1) must be replaced after this
procedure.
Clearance between the bearing shell and the main
bearing journals ........................... 0.057 to 0.117 mm
Note: Always tighten the connecting rod cap to the
(0.0022 to 0.0046 inch)
connecting rod, when the assembly is out of the
engine. Tighten the assembly to the following torque
20 N·m (14 lb ft).

(2) The bearing shell for the connecting rod

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28 KENR6245
Specifications Section

g00995584
Illustration 52
Alignment of the bearing shell

Note: The bearing shell for the connecting rod must

be aligned equally from both ends of the connecting
rod. Refer to (A) in figure 52. Refer to Disassembly
and Assembly for information on the alignment tool.

Table 13

Bearing Width for the 31.62 to 31.88 mm

Connecting Rod (1.245 to 1.255 inch)
Bearing Width for the 31.62 to 31.88 mm
Connecting Rod Cap (1.2449 to 1.2551 inch) g00907744
Illustration 53
Thickness of Connecting
1.835 to 1.842 mm
Rod Bearing at the (3) Inside diameter of the small
(0.0723 to 0.0725 inch)
Center bush .................................. 39.723 to 39.738 mm
Thickness of Connecting
(1.5639 to 1.5645 inch)
1.835 to 1.842 mm
Rod Bearing for the Cap
(0.0722 to 0.0725 inch) (4) Distance between the parent
at the Center
bores ................................. 219.05 to 219.10 mm
0.034 to 0.081 mm (8.624 to 8.626 inch)
Bearing Clearance
(0.0013 to 0.0032 inch)
(5) Diameter for the parent bore for the connecting
Table 14 rod bearing ........................... 67.21 to 67.22 mm
(2.6460 to 2.6465 inch)
Undersized Connecting Rod Bearing

0.25 mm (0.010 inch)

0.51 mm (0.020 inch)
0.76 mm (0.030 inch)

g00915056
Illustration 54

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KENR6245 29
Specifications Section

Connecting rods are color coded. The color code Ring gap ................................... 0.30 to 0.55 mm
is a reference for the length (Y) of the connecting (0.0118 to 0.0217 inch)
rod. Refer to table 15 for the different lengths of
connecting rods. Turbocharged
The shape of the top compression
Table 15 ring ........................... Keystone with a barrel face
Length Grades for Connecting Rods
Width of the top compression ring .......... tapered
Grade Letter Color Code Length (Y)
Ring gap ................................... 0.30 to 0.45 mm
165.728 to 165.761 mm (0.0118 to 0.0177 inch)
F Red
(6.5247 to 6.5260 inch)
165.682 to 165.715 mm Note: When you install a new top compression ring,
G Orange
(6.5229 to 6.5242 inch) make sure that the word “TOP” is facing the top of the
piston. New top piston rings for naturally aspirated
165.637 to 165.670 mm
H White
(6.5211 to 6.5224 inch)
engines have a red identification mark which must
be on the left of the ring end gap when the top
J Green
165.591 to 165.624 mm piston ring is installed on an upright piston. New top
(6.5193 to 6.5206 inch) piston rings for turbocharged engines have a yellow
165.545 to 165.578 mm identification mark which must be on the left of the
K Purple ring end gap when the top piston ring is installed on
(6.5175 to 6.5188 inch)
an upright piston.
165.499 to 165.532 mm
L Blue
(6.5157 to 6.4961 inch) (2) Intermediate compression ring
The shape of the intermediate compression
i02662142 ring .................................. Internal chamfer in the
bottom edge with a tapered face
Piston and Rings
Width of intermediate compression ring for
naturally aspirated engines ....... 2.47 to 2.49 mm
(0.097 to 0.098 inch)
Width of intermediate compression ring for
turbocharged engines ........... 2.470 to 2.495 mm
(0.0972 to 0.0982 inch)
Clearance between the intermediate compression
ring and the piston groove for naturally aspirated
engines ... 0.05 to 0.09 mm (0.002 to 0.003 inch)
Clearance between the intermediate compression
ring and the piston groove for turbocharged
engines .................................. 0.065 to 0.110 mm
(0.0026 to 0.0043 inch)
Ring gap for naturally aspirated
engines ..................................... 0.70 to 0.95 mm
g01363510 (0.0275 to 0.0374 inch)
Illustration 55
Typical example Ring gap for turbocharged
engines ..................................... 0.65 to 0.85 mm
(1) Top compression ring (0.0256 to 0.0335 inch)
Naturally Aspirated Note: When you install a new intermediate
The shape of the top compression compression ring, make sure that the word “TOP”
ring ...................... Rectangular with a barrel face is facing the top of the piston. New intermediate
rings for naturally aspirated engines have a green
Width of the top compression identification mark which must be on the left of the
ring ...... 2.47 to 2.49 mm (0.0972 to 0.0980 inch) ring end gap when the top piston ring is installed
on an upright piston. New intermediate rings for
Clearance between the top compression ring and turbocharged engines have a blue identification mark
the piston groove ...................... 0.09 to 0.13 mm which must be on the left of the ring end gap when
(0.0035 to 0.0051 inch) the top piston ring is installed on an upright piston.

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30 KENR6245
Specifications Section

(3) Oil control ring Piston pin

Shape of oil control Diameter of a new piston
ring ............ a two-piece coil that is spring loaded pin ..................................... 39.694 to 39.700 mm
(1.5628 to 1.5630 inch)
Width of oil control ring for naturally aspirated
engines ..................................... 3.47 to 3.49 mm Diameter of the bore for the piston
(0.1366 to 0.1374 inch) pin ..................................... 39.703 to 39.709 mm
Width of oil control ring for turbocharged (1.5631 to 1.5633 inch)
engines ..................................... 2.97 to 2.99 mm
(0.1169 to 0.1177 inch)
i02665602
Clearance between the oil control ring and
the groove in the piston for naturally aspirated Piston Cooling Jet
engines ..................................... 0.03 to 0.07 mm
(0.0011 to 0.0027 inch)
Ring gap ................................... 0.30 to 0.55 mm
(0.0118 to 0.0216 inch)

Note: A pin is used in order to hold both ends of the

spring of the oil control ring in position. The ends of
the spring of the oil control ring must be installed
opposite the end gap of the oil control ring.

Note: Ensure that the ring end gaps of the piston

rings are spaced 120 degrees from each other.

Piston
Note: An arrow which is marked on the piston crown
must be toward the front of the engine.
g00942652
The combustion bowl re-entrant angle for the Illustration 56
turbocharged engine ............................... 72 degrees (1) Installed piston cooling jets

The combustion bowl re-entrant angle for the The valve must move freely. Tighten the bolt to the
naturally aspirated engine ....................... 70 degrees following torque. .................................. 9 N·m (7 lb ft)

Piston height above cylinder block .. 0.21 to 0.35 mm Piston Cooling Jet Alignment
(0.008 to 0.014 inch)

Width of top groove in piston for the naturally

aspirated engine ............................. 2.58 to 2.60 mm
(0.1016 to 0.1024 inch)

Width of top groove in piston for the turbocharged

engine .......................................................... Tapered

Width of second groove in piston for naturally

aspirated engines ........................... 2.54 to 2.56 mm
(0.1000 to 0.1008 inch)

Width of second groove in piston for turbocharged

engines ..... 2.56 to 2.58 mm (0.1008 to 0.1016 inch)
g01006929
Illustration 57
Width of third groove in piston for naturally aspirated
(2) Piston cooling jet
engines ..... 3.52 to 3.54 mm (0.1386 to 0.1394 inch) (3) Rod
(4) Cylinder block
Width of third groove in piston for turbocharged
engines ...... 3.02 to 3.04 mm (0.1189 to 0.1197 inch) Use the following procedure in order to check the
alignment of the piston cooling jet.

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KENR6245 31
Specifications Section

1. Insert rod (3) into the end of the piston cooling

jet (2). Rod (3) has a diameter of 1.70 mm
(0.067 inch). Rod (3) must protrude out of the top
of the cylinder block.

2. Dimension (A) is 50.75 mm (1.9980 inch)

and dimension (B) is 9.35 mm (0.3681 inch).
Dimension (A) and dimension (B) are tangential
to the cylinder bore (4).

3. The position of the rod (3) must be within

dimension (C). Dimension (C) is 10 mm
(0.3937 inch).

Note: Ensure that the rod (3) can not damage the
piston cooling jet when the alignment is checked. The
piston cooling jets can not be adjusted. If a piston
cooling jet is not in alignment the piston cooling jet
must be replaced.

i02662168 g00918672
Illustration 59
Front Housing and Covers Front cover

(2) Tighten the bolts that fasten the water pump to the
front housing to the following torque. ....... 22 N·m
(16 lb ft)
The front housing must be aligned to the cylinder Note: Refer to Specifications, “Water Pump” for the
block face. .......................... + 0.05 to minus 0.05 mm correct bolt tightening sequence for the water pump.
(+ 0.0020 to minus 0.0020 inch)

i02662183

Gear Group (Front)

g01337594
Illustration 58
Alignment

(1) Tighten the bolts that fasten the front cover to the
front housing to the following torque. ....... 22 N·m
(16 lb ft)
g00995886
Illustration 60
Gear train

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32 KENR6245
Specifications Section

(1) Fuel injection pump drive gear Maximum permissible end play ............ 0.38 mm
(0.015 inch)
Tighten the nut to the following torque. ... 24 N·m
(18 lb ft) Number of teeth .............................................. 73
Release the lock on the fuel injection pump shaft.
Torque the nut to the following torque. .... 90 N·m
(66 lb ft)
Number of teeth .............................................. 68

Note: Refer to Specifications, “Fuel Injection Pump”

for the locking torque for the fuel injection pump shaft.

(2) Camshaft gear

Tighten the bolt for the camshaft gear to the
following torque. ....................... 95 N·m (70 lb ft)
Bore diameter of the camshaft
gear ...................................... 34.93 to 34.95 mm g00996214
Illustration 61
(1.3750 to 1.3760 inch)
The gear train for the oil pump
Outside diameter of the camshaft
hub .. 34.90 to 34.92 mm (1.3741 to 1.3747 inch) (4) Crankshaft gear
Clearance between the camshaft gear and the Bore diameter of crankshaft gear
camshaft hub ........................ 0.003 to 0.048 mm .... 47.625 to 47.650 mm (1.8750 to 1.8760 inch)
(0.0001 to 0.0019 inch)
Outside diameter of crankshaft
Number of teeth .............................................. 68 hub .................................... 47.625 to 47.645 mm
(1.8750 to 1.8758 inch)
(3) Idler gear and hub
Clearance of gear on
Tighten the bolts for the idler gear to the following crankshaft ......................... −0.020 to +0.020 mm
torque. ...................................... 44 N·m (33 lb ft) (−0.0008 to +0.0008 inch)
Bore diameter of the idler gear Number of teeth .............................................. 34
........ 57.14 to 57.18 mm (2.2495 to 2.2512 inch)
Bore diameter of the idler gear with roller (5) Oil pump idler gear
bearings ................................ 72.35 to 72.36 mm
(2.8484 to 2.8488 inch) Inside diameter of oil pump idler gear
bearing .............................. 16.012 to 16.038 mm
Width of idler gear and split bearing (0.6304 to 0.6314 inch)
assembly .............................. 30.14 to 30.16 mm
(1.186 to 1.187 inch) Outside diameter of oil pump idler gear
shaft .................................. 15.966 to 15.984 mm
Inside diameter of idler gear bearings with (0.6286 to 0.6293 inch)
flanges .................................. 50.78 to 50.80 mm
(1.999 to 2.000 inch) Clearance of oil pump idler gear bearing on
shaft ...................................... 0.028 to 0.072 mm
Outside diameter of idler gear (0.0011 to 0.0028 inch)
hub .. 50.70 to 50.74 mm (1.9961 to 1.9976 inch)
Outside diameter of idler gear hub with roller End play of the oil pump idler
bearings ............................ 49.975 to 49.988 mm gear ...................................... 0.050 to 0.275 mm
(1.9675 to 1.9680 inch) (0.0019 to 0.0108 inch)

Clearance of idler gear bearing on (6) Oil pump gear

hub ...... 0.04 to 0.10 mm (0.0016 to 0.0039 inch)
The number of teeth on the oil pump gear ..... 17
Idler gear end play .................... 0.10 to 0.20 mm
(0.004 to 0.008 inch) Backlash values
Idler gear end play with roller Backlash between the idler gear (5) and the oil
bearings .................................... 0.10 to 0.75 mm pump drive gear (6) .............. 0.046 to 0.106 mm
(0.0039 to 0.0295 inch) (0.0018 to 0.0041 inch)

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KENR6245 33
Specifications Section

Backlash between the oil pump idler gear (5) and i02503254
the crankshaft gear (4) ......... 0.095 to 0.160 mm
(0.0037 to 0.0063 inch) Flywheel
Backlash between the idler gear (3) and the
crankshaft gear (4) ............... 0.064 to 0.124 mm
(0.0025 to 0.0049 inch)
Backlash between the camshaft gear (2) and the
idler gear (3) ......................... 0.052 to 0.107 mm
(0.0020 to 0.0042 inch)
Backlash between the fuel injection pump gear
(1) and the idler gear (3) ....... 0.054 to 0.109 mm
(0.0021 to 0.0043 inch)
Backlash between the water pump gear (not
shown) and the fuel injection pump gear
(1) ... 0.073 to 0.133 mm (0.0028 to 0.0052 inch)
Backlash between the power take-off
drive (if equipped) and the idler gear
(3) .... 0.112 to 0.172 mm (0.0044 to 0.0068 inch)

Engines that have a Balancer

g00584712
Illustration 63
Typical example

(1) Flywheel ring gear

Heat the flywheel ring gear to the following
temperature. .............................. 250 °C (480 °F)

Note: Do not use an oxyacetylene torch to heat the

flywheel ring gear.
g00996003
Illustration 62 (2) Flywheel
Balancer gears
(3) Bolt
(7) Idler gear for the oil pump that has a balancer
Tighten the flywheel bolts to the following
The number of teeth on the gear .................... 44 torque. ..................................... 115 N·m (85 lb ft)
The bore diameter of the idler
gear .................................. 37.197 to 37.212 mm
(1.4644 to 1.4650 inch)
The hub diameter for the idler
gear .................................. 37.152 to 37.162 mm
(1.4627 to 1.4631 inch)
The end play for the idler gear .. 0.12 to 0.27 mm
(0.0047 to 0.0106 inch)

(8) Gear for the oil pump that has a balancer

The number of teeth on the gear .................... 17

Backlash between the oil pump gear (8) and the idler
gear (7) ... 0.097 to 0.17 mm (0.0038 to 0.0067 inch)

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34 KENR6245
Specifications Section

i02663068 i02662798

Flywheel Housing Crankshaft Pulley

g00915497
Illustration 65
A standard pulley

(1) Tighten the three bolts for the crankshaft pulley

to the following torque. ............ 115 N·m (85 lb ft)

Note: Recheck the torque of the bolts (1) once.

(2) Thrust block

Note: The chamfers on the bolt holes must face

toward the front of the engine.
g01338247
Illustration 64 (3) Crankshaft pulley
Typical example

(1) Bolt
Tighten the bolts for the cast iron flywheel
housing to the following torque:
M10 “8.8” .................................. 44 N·m (33 lb ft)
M10 “10.9” ................................ 63 N·m (47 lb ft)
M12 “8.8” .................................. 75 N·m (55 lb ft)
M12 “10.9” ............................... 115 N·m (85 lb ft)

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KENR6245 35
Specifications Section

Crankshaft Pulley for the Poly Note: The marks (1 and 2) on the pulley must be
vertical when the pulley is installed on the engine.
V-Belt Number one piston of the engine must be at top dead
center.

i02663070

Fan Drive

g01337951
Illustration 66
Typical example
(1) Bolt
(2) Thrust block
(3) Crankshaft adapter
(4) Crankshaft pulley
(5) Bolt

(1) Tighten the three bolts for the thrust block to the
following torque. ...................... 115 N·m (85 lb ft)

Note: Recheck the torque of the bolts (1) once.

Note: The chamfers on the bolt holes must face

toward the front of the engine.

(5) Tighten the three bolts for the crankshaft pulley g01338248
Illustration 68
to the following torque. ............. 78 N·m (58 lb ft)
Typical example

Non - Standard Pulley (1) Tighten the bolts to the following torque. .. 22 N·m
(16 lb ft)

Fan drive housing

Tighten the bolts (2) that secure the fan drive
housing (3) to the cylinder head to the following
torque. ............................................. 44 N·m (32 lb ft)

Maximum permissible end play of the shaft .. 0.20 mm

(0.0079 inch)

g01337945
Illustration 67
(1) T Mark
(2) Alignment mark

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36 KENR6245
Specifications Section

i01721280 (2) Terminal “D+”

Engine Lifting Bracket Tighten the terminal nut to the following
torque. ..................................... 3.7 N·m (33 lb in)

(3) Terminal “B+”

Tighten the terminal nut to the following
All engines are equipped with two engine lifting torque. ........................................ 7 N·m (62 lb in)
brackets.
Tighten the two bolts on each engine lifting The 12 Volt and 24 Volt Iskra
bracket to the following torque. .. 44 N·m (32 lb ft) Alternator
12 volt output
i02656398

Alternator Two alternators are

available. ....................... 150 Amp and 175 Amp

24 volt output
The 24 volt alternator ............................ 100 Amp

The 12 Volt and 24 Volt Denso

Alternators
Three types of alternator are available.

Output
Two 12 volt alternators are
available. ....................... 100 Amp and 120 Amp
One 24 volt alternator ............................. 80 Amp

g01332519
Illustration 70
Typical example

(1) Terminal “B+”

Tighten the terminal nut to the following
torque. ...................................... 11 N·m (97 lb in)

(2) Terminal “D+”

Tighten the terminal nut to the following
g01332517 torque. ........................................ 3 N·m (26 lb in)
Illustration 69
Typical example (3) The terminal “W” is spade-type.
(1) Terminal “W”
Tighten the terminal nut to the following
torque. ..................................... 3.7 N·m (33 lb in)

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KENR6245 37
Specifications Section

i02656404

Starter Motor

24 Volt Starting Motor

g00974968
Illustration 71
The 24 volt starting motor which shows the electrical connections

(1) Tighten the negative terminal nut to the following

torque. ...................................... 16 N·m (12 lb ft)

(2) Tighten the positive terminal nut to the following

torque. ...................................... 21 N·m (15 lb ft)

(3) Tighten the solenoid terminal to the following

torque. ..................................... 3.6 N·m (32 lb in)

Rated voltage ................................................ 24 volts

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38 KENR6245
Specifications Section

12 Volt Starting Motor

g00977365
Illustration 72
The 12 volt starting motor which shows the electrical connections

(1) Tighten the solenoid terminal to the following i02656374

torque. ....................................... 8 N·m ( 70 lb in)
Glow Plugs
(2) Tighten the positive terminal nut to the following
torque. ....................................... 6 N·m ( 53 lb in)

(3) Tighten the negative terminal nut to the following

torque. ....................................... 8 N·m (70 lb in)

Rated voltage ................................................ 12 volts

g01334536
Illustration 73
Typical example

(1) Tighten the glow plugs (3) in the cylinder head to

the following torque. .................. 15 N·m (11 lb ft)

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KENR6245 39
Specifications Section

Tighten the nuts (2) for the bus bar (1) that is
installed on top of the glow plugs to the following
torque. ............................................... 2 N·m (18 lb in)

Voltage ................................................. 12 or 24 volts

Note: Glow plugs are not installed on all engines.

Engines that do not have glow plugs are installed
with threaded plugs.

This document has been printed from SPI². Not for Resale
40 KENR6245
Index Section

Index
A G

Alternator ............................................................... 36 Gear Group (Front)................................................ 31

The 12 Volt and 24 Volt Denso Alternators ........ 36 Engines that have a Balancer ............................ 33
The 12 Volt and 24 Volt Iskra Alternator ............ 36 Glow Plugs ............................................................ 38

C I

Camshaft ............................................................... 12 Important Safety Information ................................. 2

Camshaft Bearings ................................................ 14
Connecting Rod..................................................... 27
Connecting Rod Bearing Journal........................... 26 L
Crankcase Breather............................................... 20
Breather Canister............................................... 21 Lifter Group............................................................ 7
Crankshaft ............................................................ 24
Crankshaft Pulley .................................................. 34
Crankshaft Pulley for the Poly V-Belt................. 35 M
Non - Standard Pulley........................................ 35
Crankshaft Seals ................................................... 26 Main Bearing Journal............................................. 27
Cylinder Block........................................................ 22 The shell for the main bearings.......................... 27
Cylinder Head........................................................ 10
Cylinder Head Valves ............................................ 8
P

E Piston and Rings ................................................... 29

Piston ................................................................. 30
Engine Design ....................................................... 4 Piston Cooling Jet.................................................. 30
Engine Lifting Bracket............................................ 36 Piston Cooling Jet Alignment ............................. 30
Engine Oil Bypass Valve ....................................... 18
Installed in the Balancer..................................... 19
Installed in the Oil Pump .................................... 18 R
Engine Oil Cooler .................................................. 15
Engine Oil Filter ..................................................... 14 Rocker Shaft.......................................................... 7
Engine Oil Pan....................................................... 19
Front sealant ...................................................... 19
Rear sealant....................................................... 19 S
Engine Oil Pressure............................................... 18
Engine Oil Pump.................................................... 16 Specifications Section ........................................... 4
Engines with Balancer Group ............................ 16 Starter Motor.......................................................... 37
Engines without Balancer Group ....................... 17 12 Volt Starting Motor ........................................ 38
Exhaust Manifold ................................................... 12 24 Volt Starting Motor ........................................ 37

F T

Fan Drive ............................................................... 35 Table of Contents................................................... 3

Fan drive housing .............................................. 35 Turbocharger ......................................................... 11
Flywheel ................................................................ 33
Flywheel Housing .................................................. 34
Front Housing and Covers..................................... 31 V
Fuel Injection Lines................................................ 4
Fuel Injection Pump............................................... 5 Valve Mechanism Cover........................................ 8
Fuel Injectors ......................................................... 6
Fuel Transfer Pump ............................................... 6
W

Water Pump........................................................... 22

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KENR6245 41
Index Section

Water Temperature Regulator and Housing .......... 22

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42 KENR6245
Index Section

This document has been printed from SPI². Not for Resale
KENR6245 43
Index Section

This document has been printed from SPI². Not for Resale
Copyright © 2007 Perkins Engine Company Limited
All Rights Reserved Printed in U. K.
This document has been printed from SPI². Not for Resale