SENR9979

October 2005

Specifications
1106D Industrial Engine
PJ (Engine)
 i01658146

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 have the most current information available.

When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SENR9979 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
Fuel Filter Base .................................................... 6
Fuel Priming Pump .............................................. 7
Lifter Group ........................................................... 7
Rocker Shaft ........................................................ 8
Valve Mechanism Cover ...................................... 9
Cylinder Head Valves ........................................... 9
Cylinder Head ...................................................... 10
Turbocharger ....................................................... 11
Inlet Manifold ....................................................... 12
Exhaust Manifold ................................................. 13
Camshaft ............................................................. 14
Camshaft Bearings .............................................. 14
Engine Oil Filter Base .......................................... 15
Engine Oil Cooler ................................................. 15
Engine Oil Pump .................................................. 16
Engine Oil Pressure ............................................. 16
Engine Oil Pan ..................................................... 17
Engine Oil Bypass Valve ...................................... 20
Crankcase Breather ............................................. 20
Water Temperature Regulator and Housing ......... 21
Water Pump ......................................................... 21
Cylinder Block ...................................................... 22
Crankshaft ........................................................... 23
Crankshaft Seals ................................................. 25
Vibration Damper and Pulley ............................... 26
Connecting Rod Bearing Journal ......................... 26
Main Bearing Journal ............................................ 27
Connecting Rod ................................................... 27
Piston and Rings .................................................. 28
Piston Cooling Jet ................................................. 29
Front Housing and Covers ................................... 30
Gear Group (Front) ............................................... 31
Flywheel ............................................................... 32
Flywheel Housing ................................................ 33
Engine Lifting Bracket ........................................... 33
Alternator ............................................................. 34
Starter Motor ........................................................ 36
Coolant Temperature Sensor ............................... 38
Fuel Pressure Sensor .......................................... 38
Engine Oil Pressure Sensor ................................. 39
Boost Pressure Sensor ......................................... 39
Inlet Manifold Temperature Sensor ....................... 40
Crankshaft Position Sensor .................................. 40
Electronic Control Module ..................................... 41
Glow Plugs ........................................................... 41

Index Section
Index ..................................................................... 42
4 SENR9979
Specifications Section

Specifications Section 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
i02331264 the front cylinder.
Engine Design
i02369446

Fuel Injection Lines

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.

g01127295 Refer to the Operation and Maintenance manual,

Illustration 1
“General Hazard Information and High Pressure Fuel
Cylinder and valve location Lines” before adjustments and repairs are performed.
(A) Exhaust valve
(B) Inlet valve Note: Refer to Testing and Adjusting Manual
, “Cleanliness of Fuel System Components”
Bore ......................................... 105 mm (4.133 inch) for detailed information on the standards of
cleanliness that must be observed during ALL
Stroke ...................................... 127 mm (5.000 inch) work on the fuel system.
Displacement ...................................... 6.6 L (403 in3) Ensure that all adjustments and repairs are performed
by authorized personnel that have had the correct
Cylinder arrangement ..................................... In-line training.
Type of combustion ............................ Direct injection
Manifold to Injector
Compression ratio
Turbocharged aftercooled ........................ 16.2:1

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

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

Valve lash
Inlet valve ....................... 0.35 mm (0.0138 inch)
Exhaust valve ................. 0.35 mm (0.0138 inch)

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

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
g01182192
Illustration 2
Typical example
SENR9979 5
Specifications Section

(1) Tighten the union nuts for the high pressure fuel
lines (1) to the following torque. ............... 30 N·m
(22 lb ft)

Pump to Manifold

g01164018
Illustration 4
Typical example

(1) Support bracket

g01192274 (2) Setscrew

Illustration 3
Typical example (3) Setscrews
(1) Tighten the union nuts for the high pressure fuel (4) Washer
line (2) to the following torque. .. 30 N·m (22 lb ft)
(5) Locking screw
i02331900
Locking the shaft
Fuel Injection Pump Loosen locking screw (5) and move the washer
(4) to the locked position. Tighten the locking
screw to the following torque. .... 9 N·m (79 lb in)
Note: Before the pump is removed from the engine
the fuel injection pump shaft must be locked. Position Unlocking the shaft
the engine to TC compression stroke of number one Loosen locking screw (5) and move the washer
cylinder before tightening the locking screw. The (4) to the unlocked position. Tighten the locking
locking screw will prevent the shaft from rotating. screw to the following torque. ..... 9 N·m (79 lb in)
If the fuel injection pump was removed prior to
correctly timing the engine and locking the shaft, the (2) Tighten the mounting setscrews to the following
fuel injection pump will need to be timed by trained torque. ...................................... 44 N·m (32 lb ft)
personnel. In order to time the fuel injection pump,
refer to Disassembly and Assembly , “Fuel Injection (3) Tighten the mounting setscrews and the nut to
Pump - Install”. the following torque. ................. 22 N·m (16 lb ft)
Note: Refer to Testing and Adjusting Manual Note: The support bracket must be installed after
, “Cleanliness of Fuel System Components” the coolant pump is installed. In order to stop the
for detailed information on the standards of distortion of the timing case, finger tighten the
cleanliness that must be observed during ALL setscrew (2) and then tighten the setscrews (3).
work on the fuel system.
Tighten the bolts that hold the fuel pump to the front
housing to the following torque. ...... 25 N·m (18 lb ft)
6 SENR9979
Specifications Section

i02367111 i02369445

Fuel Injectors Fuel Transfer Pump

Note: Refer to Testing and Adjusting Manual Note: Refer to Testing and Adjusting Manual
, “Cleanliness of Fuel System Components” , “Cleanliness of Fuel System Components”
for detailed information on the standards of for detailed information on the standards of
cleanliness that must be observed during ALL cleanliness that must be observed during ALL
work on the fuel system. work on the fuel system.

g01179017 g01208144
Illustration 5 Illustration 6
(1) Fuel outlet
(1) Tighten the nuts to the following torque 2.4 N·m (2) Retaining setscrew
(21 lb in). (3) Fuel supply
(4) Fuel return from cylinder head
(2) Tighten the bolt in the clamp for the fuel injection
nozzle to the following torque. .. 27 N·m (19 lb ft) (2) Retaining setscrew ................... 30 N·m (22 lb ft)

(3) Clamp The outlet pressure for the fuel ......... 400 to 500 kPa
(58.0160 to 72.5200 psi)
(4) O ring seal
i02368444
(5) trim code
Fuel Filter Base
Note: Refer to the Troubleshooting guide, “Injector
Trim File” for more information.

Note: Refer to Testing and Adjusting Manual

, “Cleanliness of Fuel System Components”
for detailed information on the standards of
cleanliness that must be observed during ALL
work on the fuel system.
SENR9979 7
Specifications Section

Hand Fuel Priming Pump

g01181928
Illustration 7
Typical example g01154164
Illustration 8
Typical example
(1) Retaining setscrew ................... 44 N·m (32 lb ft)
(1) The plunger that is hand operated.
(2) The canister for the fuel filter
Electric fuel Priming Pump
i02369447
The electric fuel priming pump operates on 12 volts
Fuel Priming Pump or 24 volts.

i02392326

Lifter Group
Note: Refer to Testing and Adjusting Manual
, “Cleanliness of Fuel System Components”
for detailed information on the standards of
cleanliness that must be observed during ALL
work on the fuel system.

g00629433
Illustration 9

(1) Diameter of the lifter body .. 18.987 to 19.012 mm

(0.7475 to 0.7485 inch)

Bore diameter in the cylinder block

............. 19.05 to 19.082 mm (0.7500 to 0.7513 inch)
8 SENR9979
Specifications Section

Clearance Diameter of the rocker arm bore

.... 25.031 to 25.051 mm (0.9855 to 0.9863 inch)
Clearance of the lifter .......... 0.038 to 0.095 mm
(0.0015 to 0.0037 inch) Clearance
Maximum clearance of both the rocker arm
i02386647
bores. ............................ 0.089 mm (0.0035 inch)
Rocker Shaft The service limit for both rocker arm
bores ............................... 0.17 mm (0.0067 inch)

(8) Rocker shaft

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

(9) Locator

(10) Pedestal

g01191744 g01190818
Illustration 10 Illustration 11
Typical example Tightening sequence

(1) Locknut Tighten the fasteners in the sequence that is in

illustration 11. Tighten the fasteners to the following
Torque for the locknut ............... 27 N·m (20 lb ft)
torque. ............................................. 35 N·m (25 lb ft)
(2) Snap ring

(3) Spring

(4) Adjuster

(5) Spring

(6) Inlet rocker arm

Diameter of the rocker arm bore
.... 25.031 to 25.051 mm (0.9855 to 0.9863 inch)

(7) Exhaust rocker arm

SENR9979 9
Specifications Section

i02331322 Table 1

Valve Mechanism Cover The load for the valve

spring
The length of the valve
spring
147.3 to 162.8 N 31.5 mm (1.2402 inch)
(33.1145 to 36.5991 lb)
296.4 ± 327.6 N 22.2 mm (0.8740 inch)
(66.6337 ± 73.6478 lb)

g01192804
Illustration 12
Cover

Tighten the bolts for the valve mechanism cover in g01193821

the sequence that is shown in illustration 12 to the Illustration 14
following torque. .................................. 9 N·m (7 lb ft)
(2) Valve face angle

i02333727 Inlet ................................................... 30 degrees

Exhaust ............................................. 45 degrees
Cylinder Head Valves
(3) Valve stem diameter
Inlet .. 5.942 to 5.957 mm (0.2339 to 0.2345 inch)
Exhaust ................................. 5.927 to 5.942 mm
(0.2333 to 0.2339 inch)

Clearance
Maximum clearance of the inlet valve
stem ................................ 0.05 mm (0.0020 inch)
The service limit for the inlet valve
stem ................................ 0.08 mm (0.0031 inch)

Clearance
Maximum clearance of the exhaust valve
stem .............................. 0.065 mm (0.0026 inch)
The service limit for the inlet valve
stem ................................ 0.09 mm (0.0035 inch)

(4) Length of valve

Inlet valve ..................... 107.925 to 108.375 mm
(4.2490 to 4.2667 inch)
Illustration 13
g01164859 Exhaust valve ............... 107.703 to 108.153 mm
(4.2403 to 4.2580 inch)
Typical example

(5) Valve head

The valve spring (1) may be used on the inlet valve
or the exhaust valve. When the valve springs are Diameter of inlet valve head .................... 35 mm
replaced the valve springs must be replaced in pairs. (1.3780 inch)
Diameter of exhaust valve head .............. 33 mm
(1.2992 inch)
10 SENR9979
Specifications Section

i02333586

Cylinder Head

g01164742
Illustration 16
Typical example

Note: The maximum distortion of the cylinder head

g01181390 is given in table 2.
Illustration 15
Typical example Table 2
Maximum Permissible
Lubricate the threads and the underside of the head Dimension
Distortion
bolts with clean engine oil.
Width (A) 0.03 mm (0.0018 inch)
Tighten the bolts in the sequence that is shown in
Illustrations to the following torque. ......... 50 N·m Length (B) 0.05 mm (0.0019 inch)
(37 lb ft) Diagonal Line (C) 0.05 mm (0.0019 inch)
Tighten the bolts again to the following
torque. .................................... 100 N·m (74 lb ft)
Tighten the head bolts to the additional
amount. ........................................... 225 degrees

Minimum thickness of cylinder head ......... 94.80 mm

(3.7323 inch)
SENR9979 11
Specifications Section

i02363618

Turbocharger

g01185843
Illustration 17
Typical example

(1) Valve guide bores

Inlet and exhaust .................. 5.979 to 5.992 mm
(0.2354 to 0.2359 inch) g01180566
Illustration 18
(2) Valve depths Typical example

Inlet .. 0.905 to 1.163 mm (0.0356 to 0.0458 inch) (1) Turbocharger

The service limit for the depth of the inlet valve
........................................ 1.41 mm (0.0555 inch) (2) Actuator rod
Exhaust ................................. 0.876 to 1.131 mm
(0.0345 to 0.0445 inch) (3) Actuator
The service limit for the exhaust valve
depth ............................... 1.38 mm (0.0543 inch) The maximum test pressure for the
wastegate ................................ 80 kPa (11.6032 psi)

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

(0.0394 inch)

Table 3
The part number for The pressure for the
the turbocharger wastegate
2674A256 60 kPa (8.7024 psi)
2674A604 60 kPa (8.7024 psi)
2674A236 80 kPa (11.6032 psi)
2674A607 80 kPa (11.6032 psi)
12 SENR9979
Specifications Section

Table 4

The pressure for the

Engine kW
wastegate
90 to 130 kW 60 kPa (8.7024 psi)
(120.6900 to 174.3300 hp)
131 to 168 kW 80 kPa (11.6032 psi)
(175.6710 to 225.2880 hp)

i02372001

Inlet Manifold

g01183340
Illustration 19

Tighten the setscrew in the sequence in illustration

19 to the following torque. ............... 22 N·m (16 lb ft)
SENR9979 13
Specifications Section

i02369459

Exhaust Manifold

Exhaust manifold for Top Mounted

Turbocharger

g01182238
Illustration 20
Typical example

Tighten the exhaust manifold bolts in the sequence

that is shown in illustration 20 to the following
torque. ............................................. 44 N·m (32 lb ft)

Exhaust manifold for Side Mounted

Turbocharger

g01182243
Illustration 21
Typical example

Tighten the exhaust manifold bolts in the sequence

that is shown in illustration 21 to the following
torque. ............................................. 44 N·m (32 lb ft)
14 SENR9979
Specifications Section

i02366277 Table 5

Camshaft Camshaft Journals Standard Diameter

50.711 to 50.737 mm
1
(1.9965 to 1.9975 inch)
50.457 to 50.483 mm
2
(1.9865 to 1.9875 inch)
50.203 to 50.229 mm
3
(1.9765 to 1.9775 inch)
49.941 to 49.975 mm
4
(1.9662 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.

i02370626
g00987750
Illustration 22
Checking the end play of the camshaft
Camshaft Bearings
(1) End play of a camshaft ......... 0.126 to 0.558 mm
(0.0050 to 0.0220 inch)

Maximum permissible end play of a worn

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

g01195129
Illustration 23
Typical example

(2) Bolt g01183007

Illustration 24
Tighten the bolt to the following torque. ... 95 N·m Typical example
(70 lb ft)
(1) The diameter of the installed camshaft
(3) The diameters of the camshaft journals are given bearing .............................. 50.787 to 50.848 mm
in the following tables. (1.9995 to 2.0019 inch)
SENR9979 15
Specifications Section

i02375162 Tighten the setscrews to the following

torque. .......................................... 22 N·m (16 ft)
Engine Oil Filter Base
i02373168

Engine Oil Cooler

g01185329
Illustration 25
Typical example

(1) Setscrew g01183877

Illustration 27
Tighten the setscrews to the following (1) Joint
torque. .......................................... 22 N·m (16 ft) (2) Housing
(3) Joint
(4) Oil cooler
(2) Engine oil filter (5) Setscrew

Tighten the engine oil filter to the following

torque. ........................................ 12 N·m (8 lb ft)

g01179352
Illustration 28

g01185323 Setscrews
Illustration 26
Typical example Tighten the setscrews (5) in the sequence that is
in illustration 28 to the following torque. .. 22 N·m
(3) Engine oil filter (16 lb ft)
Tighten the engine oil filter to the following
torque. ........................................ 12 N·m (8 lb ft)

(4) Setscrew
16 SENR9979
Specifications Section

i02369776

Engine Oil Pump

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

Number of lobes
Inner rotor ......................................................... 4
Outer rotor ........................................................ 5

g00938799
Illustration 31
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)

Tighten the bolts that hold the front cover of the oil
pump assembly to the following torque. ........ 22 N·m
(16 lb ft)
g00938064
Illustration 29
i02379117
(1) Clearance of the outer rotor to the
body ...................................... 0.050 to 0.330 mm Engine Oil Pressure
(0.0020 to 0.0130 inch)

The minimum oil pressure at the maximum engine

speed and at normal operating temperature is the
following value. ............................... 315 kPa (45 psi)

g00938061
Illustration 30
Checking the clearance

(2) Service limit of inner rotor to outer

rotor ...................................... 0.080 to 0.250 mm
(0.0031 to 0.0098 inch)
SENR9979 17
Specifications Section

i02373535

Engine Oil Pan

g01184169
Illustration 32
(x) Guide studs (y) Short fastener

Tighten the fasteners in the sequence that is shown

in illustration 32 to the following torque. ......... 22 N·m
(16 lb ft)

g01184167
Illustration 33

Install the fastener (27 and 28). Install all the Tighten the fastener in the sequence that is shown in
remaining fasteners . illustration 33 to the following torque. ............ 22 N·m
(16 lb ft)
18 SENR9979
Specifications Section

Refer to the Disassembly and Assembly, “Engine Oil

Pan” for tooling information.

The Cast Iron Oil Pan

g01185017
Illustration 34
(x) Guide studs

Tighten the fasteners in the sequence that is shown

in illustration 34 to the following torque. ......... 22 N·m
(16 lb ft)
SENR9979 19
Specifications Section

g01184979
Illustration 35
Sequence

Tighten the remaining fasteners in the sequence

that is shown in illustration 35 to the following
torque. ............................................. 22 N·m (16 lb ft)
20 SENR9979
Specifications Section

i02387089 Clearance of plunger in bore .. 0.030 to 0.114 mm

(0.0012 to 0.0045 inch)
Engine Oil Bypass Valve
(2) Spring
Length of spring .............................. 67 to 71 mm
(2.6378 to 2.7953 inch)

i02377051

Crankcase Breather

g01191363
Illustration 36
Typical example

g01186063
Illustration 38
Typical example

(1) Breather
Tighten the breather to the following
torque. ........................................ 8 N·m (70 lb in)

g01191367
Align the outlet of the breather to the flexible pipe.
Illustration 37
Typical example

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

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

(2) Plunger
Diameter of the plunger .... 21.949 to 21.970 mm
(0.8641 to 0.8650 inch)
SENR9979 21
Specifications Section

i02413903 i02363605

Water Temperature Regulator Water Pump

and Housing

g01183807
Illustration 40
g01206579 Tightening sequence
Illustration 39
Typical example
Tighten the setscrews in the numerical sequence
that is shown in illustration 40 to the following
(1) Tighten the bolts that fasten the housing to the
torque. ............................................. 22 N·m (16 lb ft)
following torque. ....................... 44 N·m (32 lb ft)

(2) Water temperature regulator housing

(3) Water temperature regulator

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)
22 SENR9979
Specifications Section

i02364493 Diameter of the bore in the cylinder

block for the number 2 camshaft
Cylinder Block 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

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.

g01180853
Illustration 41
Cylinder block Torque for the main bearing cap bolts. ...... 80 N·m
(59 lb ft)
(1) Cylinder block
4. Tighten the bolts for the main bearing cap for an
(2) Cylinder bore ................ 105.000 to 105.025 mm additional 90 degrees.
(4.1338 to 4.1348 inch)
Note: Ensure that the crankshaft can rotate freely.
The first oversize bore
diameter .................................. 105.5 to 105.525 mm
(4.1535 to 4.1545 inch)

The second oversize bore

diameter .............................. 106.000 to 106.025 mm
(4.1732 to 4.1742 inch)

The maximum permissible wear for the cylinder

bore ....................................... 0.15 mm (0.0059 inch)

(3) Camshaft bearings

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)
SENR9979 23
Specifications Section

i02370145

Crankshaft

g01182559
Illustration 42
Typical example
(1) Crankshaft gear
(2) Crankshaft
(3) Crankshaft thrust washers

Maximum permissible temperature of the gear for

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

The end play of a new crankshaft ... 0.17 to 0.41 mm

(0.0067 to 0.0161 inch)

Standard thickness of thrust

washer ...... 2.69 to 2.75 mm (0.1059 to 0.1083 inch)

Oversize thickness of thrust

washer ....... 2.89 to 2.95 mm (0.1138 to 0.1161 inch)
24 SENR9979
Specifications Section

g01182566
Illustration 43
Typical example

Table 6
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)
1 83.756 to 83.736 mm () 83.502 to 83.482 mm () 83.248 to 83.228 mm ()
71.746 to 71.726 mm 71.492 to 71.472 mm 71.238 to 71.218 mm
2
(2.8246 to 2.8239 inch) (2.8146 to 2.8139 inch) (2.8046 to 2.8039 inch)
3 38.165 mm (1.5026 inch) 38.165 mm (1.5026 inch) 38.165 mm (1.5026 inch)
35.38 mm 35.38 mm 35.38 mm
4
(1.3929 inch )maximum (1.3929 inch )maximum (1.3929 inch )maximum
35.5 to 35.7 mm 35.5 to 35.7 mm 35.5 to 35.7 mm
5
(1.3976 to 1.4055 inch) (1.3976 to 1.4055 inch) (1.3976 to 1.4055 inch)
6 Do not machine this diameter. Do not machine this diameter. Do not machine this diameter.

Item (6) in table 6 can be repaired with a crankshaft Table 7

wear sleeve. Refer to disassembly and Assembly, Minimum Width of machined Area of Crankshaft Web
“Crankshaft Wear Sleeve (Rear) Remove and Install”
for more information. Web 1 2 to 9 10 and 12
11
25.11 22.86 23.15 26.86
mm mm mm mm
(0.9886 (0.9000 (0.9114 (1.0575
inch) inch) inch) inch)

If necessary, machine the thrust face in order to

remove damage. Refer to table 7 for information.
SENR9979 25
Specifications Section

Refer to table 8 for the run out of the crankshaft Refer to the Specifications Module, “Connecting Rod
journals. Bearing Journal” topic for more information on the
connecting rod bearing journals and connecting rod
Table 8 bearings.
Journal Run out of the Journals
Refer to the Specifications Module, “Main Bearing
(1) Mounting Journal” topic for information on the main bearing
(2) 0.05 mm (0.0020 inch) journals and for information on the main bearings.
(3) 0.1 mm (0.0039 inch)
i02377362
(4) 0.15 mm (0.0059 inch)
(5) 0.1 mm (0.0039 inch)
Crankshaft Seals
(6) 0.05 mm (0.0020 inch)
(7) Mounting

The radii of all the crankshaft journals must be

machined. This machining must return the crankshaft
to the original standard. The radii must give a smooth
transition from the journal to the side machined face.

g01186392
Illustration 45

You do not need to remove the engine oil pan in

order to install the oil seal.

Illustration 44
g01210861 Note: Some engines also have an oil seal that
is installed in the flywheel housing. Refer to
Typical example
Specifications manual, “Flywheel Housing” for more
information.
The edge of the oil holes (4) must be machined to the
original standard after machining of the crankshaft.
The sequence for installation of the
Oil hole rear oil seal
The maximum radius of the edge of the oil
hole ................................... 0.5 mm (0.0197 inch) (2) Tighten the two fasteners to the following torque
15 N·m (11 lb ft).
Surface finish of all journals .............. Ra 0.2 microns
(1) Tighten the two fasteners to the following torque
Surface finish of all radii .................... Ra 0.4 microns 22 N·m (16 lb ft).

Inspect the crankshaft for structural cracking after Loosen both fasteners (2). Install all the other
machining. fasteners and tighten all the fasteners to 22 N·m
(16 lb ft).
26 SENR9979
Specifications Section

i02363571

Vibration Damper and Pulley

g01180539
Illustration 47
Vibration damper with out split lock assembly

i02370557

Connecting Rod Bearing

Journal

Illustration 46
g01180537 Refer to the Specifications Module, “Crankshaft” topic
Vibration damper with split lock assembly
for information on the undersize crankshaft journals.

The original size of the connecting rod bearing

(1) Crankshaft adapter
journal ..................................... 71.980 to 72.000 mm
(2) Pulley (2.8339 to 2.8346 inch)

(3) Vibration damper Maximum permissible wear of a bearing journal on a

new connecting rod .............. 0.04 mm (0.0016 inch)
(4) Tighten the damper setscrews to the following
torque. .................................... 115 N·m (84 lb ft) Width of the connecting rod bearing
journals ................................... 37.962 to 38.038 mm
(1.4946 to 1.4976 inch)
(5) Tighten the setscrews for the adapter to the
following torque. .................. 200 N·m (147 lb ft)
Radius of the fillet of the connecting rod bearing
journals ......... 3.68 to 3.96 mm (0.145 to 0.156 inch)
(6) split lock assembly
Surface finish of connecting rod bearing
journals ............................................ Ra 0.2 microns

Surface finish of radii ....................... Ra 0.4 microns

SENR9979 27
Specifications Section

i02370558 i02361077

Main Bearing Journal Connecting Rod

Refer to the Specifications module, “Crankshaft”

topic 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 ... 83.99 to 84.01 mm (3.3067 to 3.3075 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 and crank pins

................................................................ 0.2 microns

Surface finish of radii .............................. 0.4 microns

Width of new main bearing

journal ..................................... 35.235 to 35.165 mm Illustration 48
g01180150
(1.3872 to 1.3844 inch)
(1) The bearing shell for the connecting rod
The shell for the main bearings
Table 9
The shells for the main bearings are available Thickness of Connecting
1.994 to 2 mm
for remachined journals which have the following Rod Bearing at the
(0.0785 to 0.0787 inch)
undersize dimensions. Center

Undersize bearing shell .... 0.25 mm (0.010 inch) Thickness of Connecting

1.994 to 2 mm
Undersize bearing shell .... 0.51 mm (0.020 inch) Rod Bearing for the Cap
(0.0785 to 0.0787 inch)
at the Center
Undersize bearing shell .. 0.76 mm (0.0299 inch)
0.025 to 0.070 mm
Bearing Clearance
Thickness at center of the shells .. 2.083 to 2.089 mm (0.0010 to 0.0028 inch)
(0.0820 to 0.0823 inch)
Table 10
Width of the main bearing shells .. 31.62 to 31.88 mm
(1.244 to 1.255 inch) Undersized Connecting Rod Bearing

0.25 mm (0.010 inch)

Clearance between the bearing shell and the main
bearing journals .......................... 0.026 to 0.084 mm 0.51 mm (0.020 inch)
(0.0010 to 0.0033 inch)
0.76 mm (0.030 inch)

The mating surfaces of the connecting rod are

produced by hydraulically fracturing the forged
connecting rod.

(2) Tighten the setscrews for the connecting rod to

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

Tighten the setscrews for the connecting rod again to

the following torque. ........................ 70 N·m (52 lb ft)
28 SENR9979
Specifications Section

Tighten the setscrews for the connecting rod for

an additional 120 degrees. The setscrews for the
connecting rod (2) must be replaced after this
procedure.

Note: Always tighten the connecting rod cap to the

connecting rod, when the assembly is out of the
engine. Tighten the assembly to the following torque
20 N·m (14 lb ft).

g00915056
Illustration 50

Connecting rods are color coded. The color code

is a reference for the length (Y) of the connecting
rod. Refer to table 11 for the different lengths of
connecting rods.

Table 11
Length Grades for Connecting Rods
Grade Letter Color Code Length (Y)
161.259 to 161.295 mm
F Red
(6.3488 to 6.3502 inch)
161.183 to 161.216 mm
J Green
(6.3458 to 6.3471 inch)
161.107 to 161.140 mm
L Blue
(6.3428 to 6.3441 inch)

i02363087

Illustration 49
g01180149 Piston and Rings
Typical example

(3) Diameter of the finished bore for the piston

pin ..................................... 39.738 to 39.723 mm
(1.5645 to 1.5639 inch)

(4) Distance between the parent bores

...... 219.05 to 219.1 mm (8.6240 to 8.6260 inch)

(5) Diameter for the finished bore for the connecting

rod bearing ......................... 72.025 to 72.05 mm
(2.8356 to 2.8366 inch)

g01155119
Illustration 51
Typical example

(1) Top compression ring

SENR9979 29
Specifications Section

The shape of the top compression ring .. tapered Width of top groove in the piston ................. Tapered
Ring gap ................................... 0.30 to 0.45 mm Width of second groove in new
(0.0118 to 0.0177 inch) piston ........ 2.56 to 2.58 mm (0.1008 to 0.1016 inch)
Note: When you install a new top compression ring, Width of third groove in new piston .. 3.02 to 3.04 mm
make sure that the word “TOP” is facing the top (0.1189 to 0.1197 inch)
of the piston. New top piston rings have a yellow
identification mark which must be on the left of the Piston pin
ring end gap when the top piston ring is installed on
an upright piston. Diameter of a new piston
pin ..................................... 39.694 to 39.700 mm
(2) Intermediate compression ring (1.5628 to 1.5630 inch)
The shape of the intermediate compression
ring ....................................... Internal bevel in the Oversize Piston
bottom edge with a tapered face
Table 12
Width of intermediate compression Standard piston
ring .... 2.47 to 2.495 mm (0.0972 to 0.0982 inch)
1 Oversize +0.5 mm (0.0197 inch) piston
The clearance between a new intermediate
2 Oversize +1.0 mm (0.0394 inch) piston
compression ring and the piston groove in a new
piston ..................................... 0.065 to 0.011 mm
(0.0026 to 0.0004 inch)
i02367100
Ring gap ................................... 0.65 to 0.85 mm
(0.0256 to 0.0335 inch) Piston Cooling Jet
Note: When you install a new intermediate
compression ring, make sure that the word “TOP” is
facing the top of the piston. New intermediate rings
have a blue identification mark which must be on the
left of the ring end gap when the top piston ring is
installed on an upright piston.

(3) The oil control ring

Width of oil control ring ............. 2.97 to 2.99 mm
(0.1169 to 0.1177 inch)
The clearance between a new oil control ring and
the groove in a new piston ........ 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)
g00942652
Note: The oil control ring is a two-piece ring that is Illustration 52
spring loaded. A pin is used in order to hold both (1) Installed piston cooling jets
ends of the spring of the oil control ring in position.
The ends of the spring of the oil control ring must be The valve must move freely. Tighten the bolt to the
installed opposite the end gap of the oil control ring. following torque. .................................. 9 N·m (7 lb ft)

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.

Piston height above cylinder block .. 0.21 to 0.35 mm

(0.008 to 0.014 inch)
30 SENR9979
Specifications Section

Piston Cooling Jet Alignment

g01006929
Illustration 53
(2) Piston cooling jet
(3) Rod
(4) Cylinder block

Use the following procedure in order to check the Illustration 54

g00995663
alignment of the piston cooling jet.
Alignment
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 14 mm
(0.5512 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.

i02369751 g01203927
Illustration 55
Front Housing and Covers Typical example

Tighten the setscrew to the sequence that is shown

in illustration 55 to the following torque. ......... 28 N·m
(20 lb ft)

The front housing must be aligned to the cylinder (1) Tighten the bolts that fasten the front cover to the
block face. ......................... + 0.05 to minus 0.05 mm front housing to the following torque. ....... 22 N·m
(+ 0.0020 to minus 0.0020 inch ) (16 lb ft)
SENR9979 31
Specifications Section

(1) Fuel injection pump drive gear

Tighten the nut to the following torque. ... 24 N·m
(18 lb ft)
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 the Specifications Module, “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)
Number of teeth .............................................. 68

(3) Idler gear and hub

g00918672
Illustration 56
Tighten the bolts for the idler gear to the following
Typical example torque. ...................................... 44 N·m (33 lb ft)
(2) Tighten the bolts that fasten the water pump to the Width of idler gear and split bearing
front housing to the following torque. ....... 22 N·m assembly .......................... 30.164 to 30.135 mm
(16 lb ft) (1.1876 to 1.1864 inch)

Note: Refer to Specifications, “Water Pump” for the Inside diameter of idler gear bearings with
correct bolt tightening sequence for the water pump. flanges .............................. 50.797 to 50.818 mm
(1.9999 to 2.0007 inch)

i02369840 Outside diameter of idler gear

hub .................................... 50.716 to 50.737 mm
Gear Group (Front) (1.9967 to 1.9975 inch)
Clearance of idler gear bearing on
hub .... 0.06 to 0.102 mm (0.0024 to 0.0040 inch)
Idler gear end play .................. 0.10 to 0.205 mm
(0.0039 to 0.0081 inch)
Maximum permissible end play ............ 0.38 mm
(0.015 inch)
Idler gear end play with roller
bearings .................................... 0.10 to 0.75 mm
(0.0039 to 0.0295 inch)
Number of teeth .............................................. 73

g00995886
Illustration 57
Gear train
32 SENR9979
Specifications Section

Backlash between the idler gear (3) and the

crankshaft gear (4) ................. 0.05 to 0.015 mm
(0.0020 to 0.0006 inch)
Backlash between the camshaft gear (2) and the
idler gear (3) ............................. 0.05 to 0.15 mm
(0.0020 to 0.0059 inch)
Backlash between the fuel injection pump gear
(1) and the idler gear (3) ........... 0.05 to 0.15 mm
(0.0020 to 0.0059 inch)
Backlash between the water pump gear (not
shown) and the fuel injection pump gear
(1) ....... 0.05 to 0.15 mm (0.0020 to 0.0059 inch)
g00996214 Backlash between the power take-off
Illustration 58
drive ( if equipped) and the idler gear
The gear train for the oil pump (3) ..... 0.05 to 0.250 mm (0.0020 to 0.0098 inch)
(4) Crankshaft gear
i02369452
Bore diameter of crankshaft gear
........ 51.00 to 51.03 mm (2.0079 to 2.0091 inch) Flywheel
Outside diameter of crankshaft
hub ..................................... 51.021 ± 51.002 mm
(2.0087 ± 2.0079 inch)
Clearance of gear on
crankshaft ......................... í0.020 to +0.020 mm
(í0.0008 to +0.0008 inch)
Number of teeth .............................................. 34

(5) Oil pump idler gear

Inside diameter of oil pump idler gear
bearing .............................. 16.012 to 16.038 mm
(0.6304 to 0.6314 inch)
Outside diameter of oil pump idler gear
shaft .................................. 15.966 to 15.984 mm
(0.6286 to 0.6293 inch)
Clearance of oil pump idler gear bearing on
shaft ...................................... 0.028 to 0.072 mm
(0.0011 to 0.0028 inch)
End play of the oil pump idler
gear ...................................... 0.050 to 0.275 mm
g00584712
(0.0019 to 0.0108 inch) Illustration 59
Typical example
(6) Oil pump gear
(1) Flywheel ring gear
The number of teeth on the oil pump gear ..... 17
Heat the flywheel ring gear to the following
Backlash values temperature. .............................. 250 °C (480 °F)
Backlash between the idler gear (5) and the oil Note: Do not use an oxyacetylene torch to heat the
pump drive gear (6) .................. 0.05 to 0.14 mm flywheel ring gear.
(0.0020 to 0.0055 inch)
Backlash between the oil pump idler gear (5) and (2) Flywheel
the crankshaft gear (4) ............... 0.8 to 0.23 mm
(0.0315 to 0.0091 inch) (3) Bolt
SENR9979 33
Specifications Section

Tighten the flywheel bolts to the following Flywheel Housing and Oil Seal
torque. .................................... 120 N·m (88 lb ft)

i02375337

Flywheel Housing

g01185430
Illustration 61

Illustration 60
g01185448 Note: Tighten the setscrew (5) before you tighten
setscrews (4).
Note: Tighten the setscrew (2) before you tighten
setscrews (1). Setscrews
(4) Tighten the top setscrew to the following
Setscrew
torque. ............................ 190 N·m (140 lb ft)
(1) Tighten the setscrew to the following
torque. ................................ 78 N·m (57 lb ft) Setscrews
(5) Tighten the bottom setscrew to the following
Setscrew
torque. ............................... 115 N·m (84 lb ft)
(2) Tighten the setscrew to the following
torque. ................................ 63 N·m (46 lb ft) Setscrews
(6) Tighten the setscrew to the following
(3) If necessary, apply sealant 21826038 Power
torque. ................................ 63 N·m (46 lb ft)
Silicone adhesive to the flywheel housing.

i01721280

Engine Lifting Bracket

All engines are equipped with two engine lifting

brackets.
Tighten the two bolts on each engine lifting
bracket to the following torque. .. 44 N·m (32 lb ft)
34 SENR9979
Specifications Section

i02333000 The 24 volt Denso HDE Alternator

Alternator

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 Am
One 24 volt alternator ............................. 80 Amp

g01179458
Illustration 63
Typical example

(1) Terminal “G”

Tighten the nut on the terminal to the following.
.................................................... 4 N·m (35 lb in)

(2) The connector “R” has three pins.

(3) Terminal “B”

Tighten the nut on the terminal to the following
torque. ...................................... 18 N·m (13 lb ft)

Output
g01194950
Illustration 62
Typical example The output of the alternator .................... 95 Amp

(1) Terminal “W”

Tighten the terminal nut to the following
torque. ..................................... 1.5 N·m (13 lb in)

(2) Terminal “D+”

Tighten the terminal nut to the following
torque. ..................................... 1.5 N·m (13 lb in)

(3) Terminal “B+”

Tighten the terminal nut to the following
torque. ..................................... 3.3 N·m (29 lb in)
SENR9979 35
Specifications Section

The 12 Volt and 24 Volt Iskra The 12 Volt Prestolite Alternator

Alternator

g01194968
Illustration 65
g01194953 Typical example
Illustration 64
Typical example
(1) Terminal “L”
(1) Terminal “B+” Tighten the terminal nut to the following
Tighten the terminal nut to the following torque. ................................ 3.1 N·m (27.43 lb in)
torque. ...................................... 11 N·m (97 lb in)
(2) The negative terminal “-”
(2) Terminal “D+” Tighten the terminal nut to the following
torque. ............................ 8.5 N·m (75.2314 lb in)
Tighten the terminal nut to the following
torque. ........................................ 3 N·m (26 lb in)
(3) The positive terminal “+”
(3) The terminal “W” is spade-type. Tighten the terminal nut to the following
torque. ............................ 11.5 N·m (101.78 lb in)
12 volt output
Two alternators are (4) Terminal “R”
available. ....................... 150 Amp and 175 Amp In order to install a different design of
terminal, tighten that terminal to the following
24 volt output torque. ................................ 3.7 N·m (32.75 lb in)
The 24 volt alternator ............................ 100 Amp
Output
The output of the alternator .................. 160 Amp
36 SENR9979
Specifications Section

i02332916 24 Volt Starting Motor 4.5 Kw

Starter Motor

24 Volt Starting Motor 8 Kw

g01200801
Illustration 67
Typical example

(1) Tighten the negative terminal nut to the following

torque. ....................................... 15 N·m (11 lb ft)
g01164457
Illustration 66 (2) Tighten the positive terminal nut to the following
Typical example torque. ...................................... 21 N·m (15 lb ft)

(1) Tighten the positive terminal nut to the following (3) Tighten the solenoid terminal to the following
torque. ...................................... 25 N·m (18 lb ft) torque. ..................................... 3.5 N·m (31 lb in)

(2) Tighten the nut for the solenoid terminal to the Rated voltage ................................................ 24 volts
following torque. ...................... 2.5 N·m (22 lb in)

(3) Tighten the nut on the negative terminal to the

following torque. ....................... 25 N·m (18 lb ft)

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

SENR9979 37
Specifications Section

12 Volt Starting Motor 3 Kw 12 Volt Starting Motor 5 Kw

g01200844 g01164457
Illustration 68 Illustration 69
Typical example Typical example

(1) Tighten the positive terminal nut to the following (1) Tighten the positive terminal nut to the following
torque. ...................................... 6 N·m (53 lb in ) torque. ...................................... 25 N·m (18 lb ft)

(2) Tighten the solenoid terminal to the following (2) Tighten the nut for the solenoid terminal to the
torque. ....................................... 8 N·m ( 70 lb in) following torque. ...................... 2.5 N·m (22 lb in)

(3) Tighten the negative terminal nut to the following (3) Tighten the nut on the negative terminal to the
torque. ..................................... 8 N·m ( 70 lb in) following torque. ....................... 25 N·m (18 lb ft)

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

Pull in voltage ................................................. 8 volts

38 SENR9979
Specifications Section

i02371978 Note: Refer to Testing and Adjusting Manual

, “Cleanliness of Fuel System Components”
Coolant Temperature Sensor for detailed information on the standards of
cleanliness that must be observed during ALL
work on the fuel system.

Ensure that all adjustments and repairs are performed

by personnel that have had the correct training.

g01183334
Illustration 70
Typical example g01192226
Illustration 71

(1) Sensor (1) Fuel pressure sensor

(2) Washer
Tighten the sensor to the following
torque. ....................................... 15 N·m (11 lb ft) Fuel pressure sensor
Tighten the fuel pressure sensor to the following
i02388157 torque. ...................................... 34 N·m (25 lb ft)

Fuel Pressure Sensor

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 the Operation and Maintenance manual,

“General Hazard Information and High Pressure Fuel
Lines” before adjustments and repairs are performed.
SENR9979 39
Specifications Section

i02371981 i02371977

Engine Oil Pressure Sensor Boost Pressure Sensor

g01183333 g01183333
Illustration 72 Illustration 73
Typical example Typical example

(1) Sensor (1) Sensor

Tighten the sensor to the following torque. Tighten the sensor to the following
.................................................... 10 N·m (7 lb ft) torque. ........................................ 10 N·m (7 lb ft)
40 SENR9979
Specifications Section

i02371979 i02404840

Inlet Manifold Temperature Crankshaft Position Sensor

Sensor

g01201229
Illustration 75
g01183334 Typical example
Illustration 74
Typical example
(1) Tighten the bolt for the sensor to the following
torque. ...................................... 22 N·m (16 lb ft)
(1) Sensor
Tighten the sensor to the following
torque. ....................................... 15 N·m (11 lb ft)
SENR9979 41
Specifications Section

i02371980 i02360299

Electronic Control Module Glow Plugs

g01183336 g01179250
Illustration 76 Illustration 77
(1) Electronic control module (ECM) Typical example
(2) Setscrew
(3) Fuel line connectors
Tighten the glow plugs (2) in the cylinder head to the
(4) Setscrew
following torque. ............................... 15 N·m (11 lb ft)
(2) Setscrew
Tighten the nuts (1) for the bus bar (3) that is
Tighten the setscrew to the following installed on top of the glow plugs to the following
torque. ........................................ 5 N·m (44 lb in) torque. ............................................... 2 N·m (18 lb in)

(4) Setscrew Voltage ................................................. 12 or 24 volts

Tighten the setscrew to the following

torque. ...................................... 22 N·m (16 lb ft)
42 SENR9979
Index Section

Index
A Fuel Injection Lines................................................ 4
Manifold to Injector ............................................ 4
Alternator ............................................................... 34 Pump to Manifold .............................................. 5
The 12 Volt and 24 volt Denso Alternators ........ 34 Fuel Injection Pump............................................... 5
The 12 Volt and 24 Volt Iskra Alternator ............ 35 Fuel Injectors ......................................................... 6
The 12 Volt Prestolite Alternator ........................ 35 Fuel Pressure Sensor............................................ 38
Fuel Priming Pump ................................................ 7
Electric fuel Priming Pump................................. 7
B Hand Fuel Priming Pump................................... 7
Fuel Transfer Pump............................................... 6
Boost Pressure Sensor.......................................... 39

G
C
Gear Group (Front)................................................ 31
Camshaft ............................................................... 14 Glow Plugs ............................................................ 41
Camshaft Bearings ................................................ 14
Connecting Rod..................................................... 27
Connecting Rod Bearing Journal........................... 26 I
Coolant Temperature Sensor................................. 38
Crankcase Breather............................................... 20 Important Safety Information ................................. 2
Crankshaft ............................................................ 23 Inlet Manifold ......................................................... 12
Crankshaft Position Sensor ................................... 40 Inlet Manifold Temperature Sensor........................ 40
Crankshaft Seals ................................................... 25
The sequence for installation of the rear oil
seal................................................................... 25 L
Cylinder Block........................................................ 22
Cylinder Head........................................................ 10 Lifter Group............................................................ 7
Cylinder Head Valves ............................................ 9

M
E
Main Bearing Journal............................................. 27
Electronic Control Module ..................................... 41 The shell for the main bearings.......................... 27
Engine Design ....................................................... 4
Engine Lifting Bracket............................................ 33
Engine Oil Bypass Valve ....................................... 20 P
Engine Oil Cooler .................................................. 15
Engine Oil Filter Base............................................ 15 Piston and Rings ................................................... 28
Engine Oil Pan....................................................... 17 Oversize Piston.................................................. 29
The Cast Iron Oil Pan ........................................ 18 Piston ................................................................. 29
Engine Oil Pressure............................................... 16 Piston Cooling Jet.................................................. 29
Engine Oil Pressure Sensor .................................. 39 Piston Cooling Jet Alignment ............................. 30
Engine Oil Pump.................................................... 16
Exhaust Manifold ................................................... 13
Exhaust manifold for Side Mounted R
Turbocharger.................................................... 13
Exhaust manifold for Top Mounted Rocker Shaft.......................................................... 8
Turbocharger.................................................... 13

S
F
Specifications Section ........................................... 4
Flywheel ................................................................ 32 Starter Motor.......................................................... 36
Flywheel Housing .................................................. 33 12 Volt Starting Motor 3 Kw ............................... 37
Flywheel Housing and Oil Seal .......................... 33 12 Volt Starting Motor 5 Kw ............................... 37
Front Housing and Covers..................................... 30 24 Volt Starting Motor 4.5 Kw ............................ 36
Fuel Filter Base ..................................................... 6 24 Volt Starting Motor 8 Kw ............................... 36
SENR9979 43
Index Section

Table of Contents................................................... 3
Turbocharger ......................................................... 11

Valve Mechanism Cover........................................ 9

Vibration Damper and Pulley................................. 26

Water Pump........................................................... 21
Water Temperature Regulator and Housing .......... 21
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