KENR6756-10 (en-us)

June 2016

Specifications
C1.7, C1.8, and C2.4 Tier 4 Interim and
EU Stage 3A Engines for Caterpillar
Built Machines
W4T 1-UP (Machine) MX5 1-UP (Machine)
W5T 1-UP (Machine) E2W 1-UP (Machine)
W6T 1-UP (Machine) CR9 1-UP (Machine)
YKY 1-UP (Machine) AC5 1-UP (Machine)
MW4 1-UP (Machine) CR6 1-UP (Machine)
SFH 1-UP (Machine) DWD 1-UP (Machine)
JX2 1-UP (Machine)
RKY 1-UP (Machine)
SSC 1-UP (Machine)
TTN 1-UP (Machine)
WDL 1-UP (Machine)
XFA 1-UP (Machine)
YGB 1-UP (Machine)
FKY 1-UP (Machine)
RSE 1-UP (Machine)
TSR 1-UP (Machine)
XSC 1-UP (Machine)
FSC 1-UP (Machine)
DJX 1-UP (Machine)
EJX 1-UP (Machine)
BG8 1-UP (Machine)
JWY 1-UP (Machine)
CJ2 1-UP (Machine)

SAFETY.CAT.COM
 i06558969

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, including human factors
that can affect safety. 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 verify
that you are authorized to perform this work, and 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.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar 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. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
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. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
KENR6756-10 3
Table of Contents

Table of Contents
Specifications Section
Engine Design .....................................................4
Fuel Injection Lines ..............................................5
Fuel Injection Pump ..............................................7
Fuel Injection Nozzles ...........................................8
Fuel Transfer Pump ..............................................8
Lifter Group ..........................................................9
Rocker Shaft ......................................................10
Valve Mechanism ............................................... 11
Valve Mechanism Cover .....................................12
Cylinder Head Valves ..........................................13
Cylinder Head ....................................................16
Camshaft ...........................................................18
Engine Oil Pump ................................................20
Engine Oil Pressure ............................................22
Water Temperature Regulator .............................22
Cylinder Block ....................................................23
Crankshaft .........................................................24
Connecting Rod .................................................30
Piston and Rings ................................................31
Gear Group (Front)..............................................34
Flywheel ............................................................37
Crankshaft Pulley ...............................................38
Alternator and Regulator .....................................39
Electric Starting Motor ........................................40
Engine Oil Pressure Switch..................................41
Glow Plugs ........................................................41

Index Section
Index..................................................................43
4 KENR6756-10
Specifications Section

Specifications Section Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 3

Valves per cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 2

i05799171
Valve lash
Engine Design Inlet valve . . . . . . . . . . . . 0.2 mm ((0.0078 inch))
SMCS Code: 1201 Exhaust valve . . . . . . . . . 0.2 mm ((0.0078 inch))

S/N: CJ21–Up Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 2, 3

S/N: JX21–Up When the crankshaft is viewed from the front of the
engine, the crankshaft rotates in the following
S/N: MW41–Up
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
S/N: AC51–Up
When the camshaft is viewed from the front of the
S/N: MX51–Up engine, the camshaft rotates in the following
S/N: CR61–Up direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise

S/N: BG81–Up The front of the engine is opposite the flywheel end of
the engine. The left side and the right side of the
S/N: CR91–Up
engine are determined from the flywheel end.
S/N: YGB1–Up Number 1 cylinder is the front cylinder of the engine.
S/N: FSC1–Up C1.8 Engines
S/N: SSC1–Up
Bore . . . . . . . . . . . . . . . . . . . . . . . . 87 mm ((3.4 inch))
S/N: XSC1–Up
Stroke . . . . . . . . . . . . . . . . . . . 102.4 mm ((4.03 inch))
S/N: DWD1–Up
Cylinder arrangement . . . . . . . . . . . . . . . . . . . . In-line
S/N: RSE1–Up
S/N: SFH1–Up Type of combustion . . . . . . . . . . . . . . . Direct injection

S/N: WDL1–Up Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 3

S/N: TSR1–Up Valves per cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 2
S/N: W4T1–Up
Valve lash
S/N: W5T1–Up
Inlet valve . . . . . . . . . . . . 0.2 mm ((0.0078 inch))
S/N: W6T1–Up Exhaust valve . . . . . . . . . 0.2 mm ((0.0078 inch))
S/N: E2W1–Up
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 2, 3
S/N: DJX1–Up
When the crankshaft is viewed from the front of the
S/N: EJX1–Up engine, the crankshaft rotates in the following
S/N: JWY1–Up direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise

Part No.: 125-2563
S/N: RKY1–Up
S/N: YKY1–Up
C1.7 Engines
Bore . . . . . . . . . . . . . . . . . . . . . . . . 87 mm ((3.4 inch))
Stroke . . . . . . . . . . . . . . . . . . . . .92.4 mm ((3.64 inch))
Cylinder arrangement . . . . . . . . . . . . . . . . . . . . In-line
Type of combustion . . . . . . . . . . . . . . . Direct injection
When the camshaft is viewed from the front of the
engine, the camshaft rotates in the following
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
The front of the engine is opposite the flywheel end of
the engine. The left side and the right side of the
engine are determined from the flywheel end.
Number 1 cylinder is the front cylinder of the engine.
C2.4 Engines
Bore . . . . . . . . . . . . . . . . . . . . . . . . 87 mm ((3.4 inch))
KENR6756-10 5
Specifications Section

Stroke . . . . . . . . . . . . . . . . . . . 102.4 mm ((4.03 inch))

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

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

Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Valve lash

Inlet valve . . . . . . . . . . . . 0.2 mm ((0.0078 inch))

Exhaust valve . . . . . . . . . 0.2 mm ((0.0078 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

When the camshaft is viewed from the front of the

engine, the camshaft rotates in the following
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise

The front of the engine is opposite the flywheel end of

the engine. The left side and the right side of the
engine are determined from the flywheel end.
Number 1 cylinder is the front cylinder of the engine.

Tightening Torques of Screws,

Bolts, and Nuts for General Use
Note: If the tightening torque is not specified, refer to
the table below for the none specified torque values.

Table 1
Indication on top
No-grade or 4T(1) 7T(2)
of bolt
Indication on top
No-grade or 4T(1)
of nut

Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8 9.81 1.00 to 1.15 7.24 to 8.31
M8 18 to 20 1.8 to 2.1 13 to 15 24 to 27 2.4 to 2.8 18 to 20
M10 40 to 45 4.0 to 4.6 29 to 33 49 to 55 5.0 to 5.7 37 to 41
M12 63 to 72 6.4 to 7.4 47 to 53 78 to 90 7.9 to 9.2 58 to 66
(1) 4T is indicated by a “4” present on the bolt head, if no mark is present the fastener is no-grade
(2) 7T is indicated by a “7” present on the bolt head

i05419658 S/N: MW41–Up

S/N: AC51–Up
Fuel Injection Lines
S/N: MX51–Up
SMCS Code: 1252
S/N: CR61–Up
S/N: CJ21–Up
S/N: BG81–Up
S/N: JX21–Up
6 KENR6756-10
Specifications Section

S/N: CR91–Up
Part No.: 383-0148
S/N: XFA1–Up
S/N: YGB1–Up
S/N: FSC1–Up
S/N: SSC1–Up
S/N: XSC1–Up
S/N: DWD1–Up
S/N: RSE1–Up
S/N: SFH1–Up
S/N: WDL1–Up
Part No.: 383-0148
S/N: TTN1–Up
S/N: TSR1–Up
Illustration 1 g02731706
S/N: W4T1–Up
S/N: W5T1–Up (1) Torque for the nuts on the fuel injection lines
. . . . . . . . . . . . . . . . . . . . . . .19 ± 5 N·m ((14 ± 4 lb ft))
S/N: W6T1–Up
S/N: E2W1–Up Note: Use two wrenches when loosening or
tightening the fuel injection lines at the fuel injection
S/N: DJX1–Up pump. If the fuel injection pump nut turns, then the
pump timing must be reset by an authorized pump
S/N: EJX1–Up dealer.
Part No.: 383-0148
S/N: FKY1–Up
S/N: JWY1–Up
S/N: YKY1–Up
KENR6756-10 7
Specifications Section

i04703569

Fuel Injection Pump

SMCS Code: 1251; 1290

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
Part No.: 383-0160
S/N: XFA1–Up
S/N: YGB1–Up Illustration 2 g02809148
(1) Fuel Injection Pump
S/N: FSC1–Up (2) High Idling Body

S/N: SSC1–Up Table 2

S/N: XSC1–Up Torque for the high idling body 47 ± 2 N·m (35 ± 1 lb ft)

S/N: DWD1–Up
S/N: RSE1–Up
S/N: SFH1–Up
S/N: WDL1–Up
Part No.: 383-0160
S/N: TTN1–Up
S/N: TSR1–Up
S/N: W4T1–Up
S/N: W5T1–Up
S/N: W6T1–Up
S/N: E2W1–Up
S/N: DJX1–Up
S/N: EJX1–Up
Part No.: 383-0160
S/N: FKY1–Up
S/N: JWY1–Up
Part No.: 386-4650
S/N: RKY1–Up
S/N: YKY1–Up
8 KENR6756-10
Specifications Section

i05331776

Fuel Injection Nozzles

SMCS Code: 1254

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
Illustration 3 g03420839
S/N: BG81–Up (1) Overflow Pipe Assembly Bolt
(2) Fuel Injection Nozzle Holder
S/N: CR91–Up
Table 3
Part No.: 383-0155
S/N: XFA1–Up Torque for the bolt for the nozzle 27.5 ± 1.5 N·m (20 ± 1 lb ft)
holder clamp
S/N: YGB1–Up
Torque for the bolt for the over- 10 ± 1 N·m (89 ± 9 lb in)
S/N: FSC1–Up flow pipe assembly

S/N: SSC1–Up
Table 4
S/N: XSC1–Up Specifications for Injection Nozzle
S/N: DWD1–Up 18.64 MPa (2703.5 psi) to
Nozzle Pressure 20.10 MPa (2915.3 psi)
S/N: RSE1–Up
Allowable Limit 18.63 MPa (2702.1 psi)
S/N: SFH1–Up
S/N: WDL1–Up
i05413477
Part No.: 383-0155
S/N: TTN1–Up Fuel Transfer Pump
S/N: TSR1–Up SMCS Code: 1256
S/N: W4T1–Up
S/N: CJ21–Up
S/N: W5T1–Up
S/N: JX21–Up
S/N: W6T1–Up
S/N: MW41–Up
S/N: E2W1–Up
S/N: AC51–Up
S/N: DJX1–Up
S/N: MX51–Up
S/N: EJX1–Up
S/N: CR61–Up
Part No.: 383-0155 S/N: BG81–Up
S/N: FKY1–Up
S/N: CR91–Up
S/N: JWY1–Up
S/N: XFA1–Up
Part No.: 386-4644
S/N: RKY1–Up S/N: YGB1–Up
S/N: YKY1–Up Part No.: 426-0390
S/N: FSC1–Up
S/N: SSC1–Up
S/N: XSC1–Up
KENR6756-10 9
Specifications Section

S/N: DWD1–Up i05413232

S/N: RSE1–Up
Lifter Group
S/N: SFH1–Up
SMCS Code: 1209
S/N: WDL1–Up
S/N: CJ21–Up
S/N: TTN1–Up
S/N: JX21–Up
S/N: TSR1–Up
S/N: MW41–Up
S/N: W4T1–Up
S/N: AC51–Up
S/N: W5T1–Up
S/N: MX51–Up
S/N: W6T1–Up
S/N: CR61–Up
S/N: E2W1–Up
S/N: BG81–Up
S/N: DJX1–Up
S/N: CR91–Up
S/N: EJX1–Up
S/N: XFA1–Up
S/N: FKY1–Up
S/N: YGB1–Up
S/N: JWY1–Up
Part No.: 138-6095
S/N: RKY1–Up
S/N: FSC1–Up
S/N: YKY1–Up S/N: SSC1–Up
Transfer pump pressure . . . . . . . . . 34.5 kPa ((5 psi)) S/N: XSC1–Up
Transfer pump displacement S/N: DWD1–Up
. . . . . . . . . . . . . . . . . . . . . . . 0.4 L/min ((0.1 US gpm)) S/N: RSE1–Up
S/N: SFH1–Up
S/N: WDL1–Up
S/N: TTN1–Up
S/N: TSR1–Up
S/N: W4T1–Up
S/N: W5T1–Up
S/N: W6T1–Up
S/N: E2W1–Up
S/N: DJX1–Up
S/N: EJX1–Up
S/N: FKY1–Up
S/N: JWY1–Up
S/N: RKY1–Up
S/N: YKY1–Up
10 KENR6756-10
Specifications Section

i05422272

Rocker Shaft
SMCS Code: 1102

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
Illustration 4 g03417829
Oil Clearance between Tappet and Tappet Guide S/N: BG81–Up
Bore S/N: CR91–Up
Table 5
Part No.: 383-0153
Oil Clearance between Tappet and Tappet Guide Bore S/N: XFA1–Up
Allowable limit 0.07 mm (0.003 inch) S/N: YGB1–Up
0.02 mm (0.001 inch) to S/N: FSC1–Up
New Limit 0.062 mm (0.002 inch)
S/N: SSC1–Up
Table 6 S/N: XSC1–Up
Tappet and Tappet Guide Bore Specifications
S/N: DWD1–Up
23.959 mm (0.943 inch) to
Tappet outer diameter (New) S/N: RSE1–Up
23.980 mm (0.944 inch)

Tappet guide bore inner diame- 24.000 mm (0.945 inch) to S/N: SFH1–Up
ter (New) 24.021 mm (0.946 inch)
S/N: WDL1–Up
Part No.: 383-0153
S/N: TTN1–Up
S/N: TSR1–Up
S/N: W4T1–Up
S/N: W5T1–Up
S/N: W6T1–Up
S/N: E2W1–Up
S/N: DJX1–Up
S/N: EJX1–Up
Part No.: 383-0153
S/N: FKY1–Up
S/N: JWY1–Up
Part No.: 386-4643
S/N: RKY1–Up
S/N: YKY1–Up
KENR6756-10 11
Specifications Section

5. If the oil clearance stays more than the allowable

limit, replace the rocker arm shaft also.

i04761134

Valve Mechanism
SMCS Code: 1102

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
Illustration 5 g02809400
(1) External Micrometer Part No.: 383-0153
(2) Internal Micrometer S/N: XFA1–Up
S/N: YGB1–Up
1. Measure the rocker arm shaft outside diameter
with an external micrometer. S/N: FSC1–Up
2. Measure the rocker arm inside diameter with an S/N: SSC1–Up
internal micrometer.
S/N: XSC1–Up
3. Calculate the oil clearance.
S/N: DWD1–Up
4. If the oil clearance is more than the allowable limit,
S/N: RSE1–Up
replace the rocker arm and measure the oil
clearance again. S/N: SFH1–Up
Table 7
S/N: WDL1–Up
Oil clearance between rocker 0.016 mm (0.00063 inch) to
arm and rocker arm shaft (New) 0.045 mm (0.0017 inch) Part No.: 383-0153
S/N: TTN1–Up
Allowable limit 0.10 mm (0.0039 inch)
S/N: TSR1–Up
Outside diameter of rocker arm 13.973 mm (0.55012 inch) to
shaft (New) 13.984 mm (0.55055 inch) S/N: W4T1–Up
Inside diameter of rocker arm 14.000 mm (0.55119 inch) to S/N: W5T1–Up
(New) 14.018 mm (0.55188 inch)
S/N: W6T1–Up
Torque for rocker arm bracket 24 - 27 N·m (17.7 - 19.9 lb ft)
bolt S/N: E2W1–Up
NOTE: Add engine oil to the
threads and seats of the rocker S/N: DJX1–Up
arm bracket bolt
S/N: EJX1–Up
Part No.: 383-0153
S/N: FKY1–Up
S/N: JWY1–Up
Part No.: 386-4643
S/N: RKY1–Up
S/N: YKY1–Up
12 KENR6756-10
Specifications Section

The allowable limit for the bend of the pushrod i04574147

. . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm ((0.009 inch))
Valve Mechanism Cover
SMCS Code: 1107

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
Part No.: 383-0139
S/N: XFA1–Up
S/N: YGB1–Up
S/N: FSC1–Up
S/N: SSC1–Up
S/N: XSC1–Up
S/N: DWD1–Up
S/N: RSE1–Up
S/N: SFH1–Up
S/N: WDL1–Up
Part No.: 383-0139
S/N: TTN1–Up
S/N: TSR1–Up
S/N: W4T1–Up
S/N: W5T1–Up
S/N: W6T1–Up
S/N: E2W1–Up
S/N: DJX1–Up
S/N: EJX1–Up
Part No.: 383-0139
S/N: FKY1–Up
S/N: JWY1–Up
Part No.: 386-4566
S/N: RKY1–Up
S/N: YKY1–Up
KENR6756-10 13
Specifications Section

i05419810

Cylinder Head Valves

SMCS Code: 1105

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
Part No.: 383-0145
S/N: XFA1–Up
Illustration 6 g02731846 S/N: YGB1–Up
(1) Valve Mechanism Cover
(2) Bolts S/N: FSC1–Up

Table 8 S/N: SSC1–Up

Torque for bolts 9 ± 2 N·m (79 ± 18 lb in) S/N: XSC1–Up
S/N: DWD1–Up
S/N: RSE1–Up
S/N: SFH1–Up
S/N: WDL1–Up
Part No.: 383-0145
S/N: TTN1–Up
S/N: TSR1–Up
S/N: W4T1–Up
S/N: W5T1–Up
S/N: W6T1–Up
S/N: E2W1–Up
S/N: DJX1–Up
S/N: EJX1–Up
Part No.: 383-0145
S/N: FKY1–Up
S/N: JWY1–Up
Part No.: 383-0145
S/N: RKY1–Up
S/N: YKY1–Up
14 KENR6756-10
Specifications Section

Illustration 7 g02807256

Table 9
Specification for the Valve Stem

Outside diameter for the valve 7.960 mm (0.3134 inch)

stem (New) to 7.975 mm (0.3139 inch)
Illustration 9 g02807417
(3) Valve Contact Width

Table 11
Specification for Valve Contact Width

Valve contact width 2.12 mm (0.0835 inch)

Note: If the specification for the valve contact width

cannot be met, replace the valve or correct the
contact of the seat.

Illustration 8 g02807257
(2) Valve Guide

Table 10
Specifications for Valve Guide

Inside diameter of valve guide 8.015 mm (0.3156 inch) to

(New) 8.030 mm (0.3161 inch)

Clearance between valve guide 0.040 mm (0.0016 inch) to

and valve stem (New) 0.070 mm (0.0027 inch)

Allowable limit of clearance 0.10 mm (0.0039 inch) Illustration 10 g02807476

(A) Valve face angle for the intake and the exhaust
valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Degrees

Valve seat angle for the intake and exhaust . . . . . 45

Degrees

Valve Recessing
1. Clean the cylinder head surface, valve face, and
valve seat.
KENR6756-10 15
Specifications Section

2. Set the valve into the valve guide. 5. If the valve recess stays more than the allowable
limit after you replace the valve, replace the
cylinder head.

Illustration 11 g02809282
(4) Depth Gauge

3. Measure the valve recessing with a depth gauge.

Illustration 12 g02809298
(5) Cylinder Head Surface
(A) Recessing
(B) Protrusion

4. If the measurement is more than the allowable

limit, replace the valve.
Table 12
Specification for Valve Recessing

Valve recessing (New) 0.65 mm (0.026 inch) to

0.85 mm (0.033 inch)

Allowable limit for valve 1.20 mm (0.0472 inch)

recessing
16 KENR6756-10
Specifications Section

i05406929

Cylinder Head
SMCS Code: 1100

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
Illustration 13 g02732098
S/N: BG81–Up C2.4
S/N: CR91–Up
Note: Apply engine oil to the threads and seats of the
Part No.: 383-0145 cylinder head bolts before assembly.
S/N: XFA1–Up
Gradually tighten the bolts for the cylinder head, in
S/N: YGB1–Up the proper sequence from 1 to 18, to the following
S/N: FSC1–Up torque . . . . . . . . . . . . . 95.5 ± 2.5 N·m ((70.5 ± 2 lb ft))

S/N: SSC1–Up
S/N: XSC1–Up
S/N: DWD1–Up
S/N: RSE1–Up
S/N: SFH1–Up
S/N: WDL1–Up
Part No.: 383-0145
S/N: TTN1–Up
S/N: TSR1–Up
S/N: W4T1–Up Illustration 14 g02732080
C1.8
S/N: W5T1–Up
S/N: W6T1–Up Gradually tighten the bolts for the cylinder head, in
the proper sequence from 1 to 18, to the following
S/N: E2W1–Up
torque . . . . . . . . . . . . . 95.5 ± 2.5 N·m ((70.5 ± 2 lb ft))
S/N: DJX1–Up
S/N: EJX1–Up
Part No.: 383-0145
S/N: FKY1–Up
S/N: JWY1–Up
Part No.: 386-4637
S/N: RKY1–Up
S/N: YKY1–Up
KENR6756-10 17
Specifications Section

Note: Use a new cylinder head gasket and tighten

the bolts to the proper torque.

4. Turn the flywheel until the piston goes more than

the top dead center.
5. Remove the cylinder head and measure the
thickness of the fuses.
6. If the measurement is out of the factory
specifications, examine the oil clearances
between the crankpin and bearing. Also examine
that between the piston pin and bushing.

Note: After you examine the top clearance, make

sure that you assemble the cylinder head with a new
cylinder head gasket.
Table 13
Top clearance of cylinder head 0.60 to 0.70 mm
0.024 to 0.027 in.

Illustration 15 g02807179
Valve Springs
Cylinder head flatness allowable limit Table 14
. . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm ((0.002 inch))
Specifications for Valve Springs

Top Clearance Free Length (New) 41.7 to 42.2 mm

1.64 to 1.66 inch
Allowable Limit 41.2 mm
1.62 inch
Load Setting/Length Setting 118N at 35mm
(New)

Allowable Limit 100N at 35mm

Tilt 1.0 mm
0.04 inch

Illustration 16 g02839483
(1) Piston
(2) Fuse

1. Remove the cylinder head.

2. Move up the piston and attach a strip of fuse on
the piston head at three positions with grease.
3. Lower the piston and install the cylinder head.
18 KENR6756-10
Specifications Section

i05946189

Camshaft
SMCS Code: 1210

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
Part No.: 383-0137
S/N: XFA1–Up
S/N: YGB1–Up Illustration 17 g02731879
(1) Camshaft
S/N: FSC1–Up (2) Bolts

S/N: SSC1–Up Table 15

S/N: XSC1–Up Torque for camshaft bolts
24 N·m (18 lb ft) to 27 N·m
(20 lb ft)
S/N: DWD1–Up
S/N: RSE1–Up
Side Clearance of Camshaft
S/N: SFH1–Up
S/N: WDL1–Up
Part No.: 386-4564
S/N: TTN1–Up
S/N: TSR1–Up
S/N: W4T1–Up
S/N: W5T1–Up
S/N: W6T1–Up
S/N: E2W1–Up
S/N: DJX1–Up
S/N: EJX1–Up Illustration 18 g02809459
(3) Dial Indicator
Part No.: 383-0137
S/N: FKY1–Up
1. Set a dial indicator with the point on the camshaft.
S/N: JWY1–Up
2. Move the cam gear to the front and rear to
Part No.: 386-4564 measure the side clearance.
S/N: RKY1–Up Table 16
Side clearance of camshaft 0.070 mm (0.0028 inch) to
S/N: YKY1–Up
(New) 0.22 mm (0.0086 inch)

Allowable limit 0.30 mm (0.012 inch)

KENR6756-10 19
Specifications Section

3. If the measurement is more than the allowable Camshaft Height

limit, replace the camshaft stopper.

Camshaft Bend

Illustration 19 g02809462
(4) Dial Indicator
(5) V Blocks

Illustration 20 g02809857
1. Hold the two end journals of camshaft with V
(6) External Micrometer
blocks on the surface plate.
2. Set a dial indicator with the point on the middle 1. Measure the height of the cam at the highest point
journal. with an external micrometer.
3. Turn the camshaft slowly and read the variation on Table 18 contains specifications for the C1.7
the indicator. engines.
Table 17 Table 18
Allowable limit of camshaft bend 0.01 mm (0.0004 inch) Camshaft height of intake (New) 32.20 mm (1.268 inch)

Allowable limit 32.15 mm (1.27 inch)

4. If the measurement is more than the allowable Camshaft height of exhaust 31.80 mm (1.25 inch)
limit, replace the camshaft. (New)

Allowable limit 31.75 mm (1.25 inch)

Table 19 contains specifications for the C1.8 and

C2.4 engines.
Table 19
Camshaft height of intake (New) 33.90 mm (1.335 inch)

Allowable limit 33.85 mm (1.333 inch)

Camshaft height of exhaust 33.90 mm (1.335 inch)

(New)

Allowable limit 33.85 mm (1.333 inch)

Table 20 contains specifications for the 2.4

turbocharged engines.
Table 20
Camshaft height of intake (New) 33.47 mm (1.318 inch)

Allowable limit 33.42 mm (1.32 inch)

(continued)
20 KENR6756-10
Specifications Section

(Table 20, contd)

Camshaft height of exhaust 33.00 mm (1.30 inch)
(New)

Allowable limit 32.95 mm (1.30 inch)

Oil Clearance of Camshaft Journal

Illustration 22 g02811078
(8) Cylinder Gauge

2. Measure the cylinder block bore for the camshaft

with a cylinder gauge.
Table 22
Cylinder block bore for the cam- 40.000 mm (1.5748 inch) to
shaft (New) 40.025 mm (1.5757 inch)
Illustration 21 g02809998
(7) External Micrometer
3. Calculate the oil clearance.
1. Measure the camshaft journal outside diameter Table 23
with an external micrometer. Oil clearance for camshaft jour- 0.050 mm (0.0020 inch) to
Table 21 nal (New) 0.091 mm (0.0035 inch)

Outside diameter of camshaft 39.934 mm (1.5722 inch) to Allowable limit 0.15 mm (0.0059 inch)
(New) 39.950 mm (1.5728 inch)

4. If the oil clearance is more than the allowable limit,

replace the camshaft.

i05419821

Engine Oil Pump

SMCS Code: 1304

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
KENR6756-10 21
Specifications Section

Part No.: 383-0161 Table 24

S/N: XFA1–Up Clearance between inner and 0.030 mm (0.0012 inch) to
outer rotor (New) 0.14 mm (0.0055 inch)
S/N: YGB1–Up
Allowable Clearance 0.2 mm (0.008 inch)
S/N: FSC1–Up
S/N: SSC1–Up
S/N: XSC1–Up
S/N: DWD1–Up
S/N: RSE1–Up
S/N: SFH1–Up
S/N: WDL1–Up
Part No.: 383-0161
S/N: TTN1–Up
S/N: TSR1–Up
S/N: W4T1–Up
S/N: W5T1–Up Illustration 24 g03421438
(2) Pump Body
S/N: W6T1–Up
S/N: E2W1–Up 2. Measure the clearance between the outer rotor
and the pump body with a feeler gauge.
S/N: DJX1–Up
Table 25
S/N: EJX1–Up Clearance between outer rotor 0.11 mm (0.0044 inch) to
and pump body (New) 0.19 mm (0.0074 inch)
Part No.: 383-0161
S/N: FKY1–Up Allowable clearance 0.25 mm (0.0098 inch)

S/N: JWY1–Up
3. If the clearance is more than the allowable limit,
Part No.: 383-0161
S/N: RKY1–Up replace the rotor assembly of the oil pump.

S/N: YKY1–Up

Illustration 25 g02807823
(3) Plastigage
Illustration 23 g02807758
(1) Rotor 1. Put a strip of Plastigage on the rotor face with
grease.
1. Measure the clearance between the lobes of the
2. Install the cover and tighten the bolts.
inner rotor and the outer rotor with a feeler gauge.
3. Remove the cover carefully.
22 KENR6756-10
Specifications Section

4. Measure the width that Plastigage becomes flat S/N: JWY1–Up

with the scale to get the oil clearance.
S/N: RKY1–Up
Table 26
Clearance between inner rotor 0.105 mm (0.00414 inch) to S/N: YKY1–Up
and cover (New) 0.150 mm (0.00590 inch) Table 27
Allowable clearance 0.20 mm (0.008 inch) Specifications

New engine oil pressure at low

97 kPa (14 psi)
5. If the clearance is more than the allowable limit, idle
replace the rotor assembly of the oil pump. New engine oil pressure at
296 - 434 kPa (43 - 63 psi)
rated load
i05413713 Minimum oil pressure at low idle 50 kPa (7 psi)

Engine Oil Pressure Minimum oil pressure at rated

load
250 kPa (36 psi)

SMCS Code: 1924

i04715489
S/N: CJ21–Up
S/N: JX21–Up Water Temperature Regulator
S/N: MW41–Up SMCS Code: 1355
S/N: AC51–Up S/N: CJ21–Up
S/N: MX51–Up S/N: JX21–Up
S/N: CR61–Up S/N: MW41–Up
S/N: BG81–Up S/N: AC51–Up
S/N: CR91–Up S/N: MX51–Up
S/N: XFA1–Up S/N: CR61–Up
S/N: YGB1–Up S/N: BG81–Up
Part No.: 145-7990 S/N: CR91–Up
S/N: FSC1–Up
Part No.: 123-4569
S/N: SSC1–Up S/N: XFA1–Up
S/N: XSC1–Up S/N: YGB1–Up
S/N: DWD1–Up S/N: FSC1–Up
S/N: RSE1–Up S/N: SSC1–Up
S/N: SFH1–Up S/N: XSC1–Up
S/N: WDL1–Up S/N: DWD1–Up
S/N: TTN1–Up S/N: RSE1–Up
S/N: TSR1–Up S/N: SFH1–Up
S/N: W4T1–Up S/N: WDL1–Up
S/N: W5T1–Up
Part No.: 123-4569
S/N: W6T1–Up S/N: TTN1–Up
S/N: E2W1–Up S/N: TSR1–Up
S/N: DJX1–Up S/N: W4T1–Up
S/N: EJX1–Up S/N: W5T1–Up
S/N: FKY1–Up S/N: W6T1–Up
KENR6756-10 23
Specifications Section

S/N: E2W1–Up S/N: TSR1–Up

S/N: DJX1–Up S/N: W4T1–Up
S/N: EJX1–Up S/N: W5T1–Up
Part No.: 123-4569 S/N: W6T1–Up
S/N: FKY1–Up
S/N: E2W1–Up
S/N: JWY1–Up
S/N: DJX1–Up
Part No.: 392-0266
S/N: EJX1–Up
S/N: RKY1–Up
Part No.: 383-0136
S/N: YKY1–Up
S/N: FKY1–Up
Table 28
S/N: JWY1–Up
Specifications for 392-0266 Regulator
Part No.: 386-4561
Opening temperature of the reg- 80.5 to 83.5 °C
ulator when the valve starts to (176.9 to 182.3 °F)
S/N: RKY1–Up
open. S/N: YKY1–Up
Opening temperature of the reg- 95 °C (203 °F)
ulator when the valve is
opened.

i05422312

Cylinder Block
SMCS Code: 1201

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up Illustration 26 g02807876

Part No.: 383-0136 (1) Cylinder Gauge

S/N: XFA1–Up
1. Measure the inside diameter cylinder at the six
S/N: YGB1–Up positions with a cylinder gauge.
S/N: FSC1–Up 2. Find the maximum and minimum inner diameters.
S/N: SSC1–Up 3. Find the difference between the maximum and the
S/N: XSC1–Up minimum inner diameters.

S/N: DWD1–Up 4. If the maximum I.D. or the difference is more than

the allowable limit, bore and hone the cylinder to
S/N: RSE1–Up the oversize dimension.
S/N: SFH1–Up 5. Examine the cylinder wall for scratches. If you find
S/N: WDL1–Up deep scratches, bore the cylinder.

Part No.: 383-0136

S/N: TTN1–Up
24 KENR6756-10
Specifications Section

Table 29
Inside diameter of cylinder block 87.000 mm (3.4252 inch) to i05421512
bore (New) 87.022 mm (3.42606 inch)

Allowable limit 87.170 mm (3.4319 inch) Crankshaft

Allowable limit for the difference 0.15 mm (0.0059 inch) SMCS Code: 1202
between the maximum and min-
imum inside diameter S/N: CJ21–Up
S/N: JX21–Up
Cylinder Correction (Oversize) S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
Part No.: 383-0140
S/N: XFA1–Up
S/N: YGB1–Up
S/N: FSC1–Up
S/N: SSC1–Up
S/N: XSC1–Up
S/N: DWD1–Up
S/N: RSE1–Up
S/N: SFH1–Up
S/N: WDL1–Up
Part No.: 383-0140
S/N: TTN1–Up
S/N: TSR1–Up
Illustration 27 g02807996
(A) Cylinder Inside Diameter Before Correction S/N: W4T1–Up
(B) Oversized Inside Diameter
S/N: W5T1–Up
1. If the cylinder wear is more than the allowable limit, S/N: W6T1–Up
bore and hone it to the specified dimension.
S/N: E2W1–Up
Table 30
Oversized inside diameter of 87.250 mm (3.4351 inch) to S/N: DJX1–Up
bore (New) 87.272 mm (3.4359 inch)
S/N: EJX1–Up
Allowable limit 87.420 mm (3.4417 inch)
Part No.: 383-0140
Allowable limit for the difference 0.15 mm (0.0059 inch) S/N: FKY1–Up
between the maximum over-
sized inside diameter and the S/N: JWY1–Up
minimum oversized inside diam-
eter of the cylinder Part No.: 383-0140
S/N: RKY1–Up

Note: Replace the pistons and piston rings with S/N: YKY1–Up
oversized pistons.
KENR6756-10 25
Specifications Section

Illustration 28 g02848744 Illustration 30 g02848749

(1) Bolts (3) Bolts

Note: Apply engine oil to the threads and seats of the Note: Apply engine oil to the threads and seats of the
bolts for the main bearings. bolts for the main bearing case cover.
Table 31 Table 33
Torque for main bearing bolts 46 N·m (34 lb ft) to 50 N·m Torque for bolts for the main 24 N·m (18 lb ft) to 27 N·m
(37 lb ft) bearing case cover (20 lb ft)

Table 34
Maximum amount of end play of 0.2 mm (0.008 inch)
the crankshaft

Side Clearance of Crankshaft

Illustration 29 g02848747
(2) Bolts

Table 32
Torque for three bolts 69 N·m (51 lb ft) to 73 N·m
NOTE: Apply engine oil to the (54 lb ft)
threads and seats of the bolts.

Illustration 31 g02811358
(4) Dial Indicator

1. Set a dial indicator with the point on the end of the

crankshaft.
2. Move the crankshaft to the front and rear to
measure the side clearance.
26 KENR6756-10
Specifications Section

3. If the measurement is more than the allowable Crankshaft Bend

limit, replace the thrust bearings.
Table 35
Side clearance of crankshaft 0.15 to 0.31 mm to 0.0059 to
(New) 0.012 inch

Allowable limit 0.5 mm

0.02 inch

Oversized Dimensions of
Crankshaft Journals

Illustration 33 g02811379
(5) Dial Indicator
(6) V Blocks

1. Hold the two end journals of crankshaft with V

blocks on the surface plate.
2. Set a dial indicator with the point on the middle
journal.
3. Turn the crankshaft slowly and read the variation
on the indicator.
Table 37
Allowable limit for crankshaft 0.02 mm (0.0008 inch)
bend

4. If the measurement is more than the allowable

Illustration 32 g02811376 limit, replace the crankshaft.

Table 36
Oversize 0.2 mm 0.4 mm (0.02 inch)
(0.008 inch)

Dimension A 54.50 to 54.70 mm 54.60 to 54.80 mm

2.146 to 2.153 inch 2.150 to 2.157 inch

Dimension B 26.20 to 26.25 mm 26.40 to 26.45 mm

1.032 to 1.033 inch 1.040 to 1.041 inch

Dimension C 2.8 to 3.2 mm radius 2.8 to 3.2 mm radius

0.11 to 0.12 inch 0.11 to 0.12 inch
radius radius

The crankshaft journal must be fine-finished to higher than Rmax

= 0.4S
KENR6756-10 27
Specifications Section

Oil Clearance Between the 7. When you tighten the connecting rod bolts, do not
Crankshaft Pin and the Crankshaft move the crankshaft.

Pin Bearing

Illustration 35 g02840279

Illustration 34 g02840061 Table 39

Undersize Dimensions of Crankpin
1. Clean the crankshaft pin and crankshaft pin
bearing. Undersize 0.2 mm (0.008 inch) 0.4 mm (0.02 inch)

2. Put a strip of Plastigage on the center of the 3.3 mm (0.13 inch) 3.3 mm (0.13 inch)
Dimension A to 3.7 mm (0.14 to 3.7 mm (0.14
crankshaft pin. inch) inch) radius
3. Install the connecting rod cap and tighten the 1.0 mm (0.040 inch) 1.0 mm (0.040 inch)
connecting rod bolts to the specified torque, and Dimension B to 1.5 mm (0.059 to 1.5 mm (0.059
remove the cap again. inch) inch) relief

4. Measure the width that it becomes flat with the 46.759 mm (1.8409 46.559 mm (1.8331
scale to get the oil clearance. Dimension C inch) to 46.775 mm inch) to 46.575 mm
(1.8415 inch) (1.8336 inch)
5. If the oil clearance is more than the allowable limit,
The crankpin must be fine-finished to higher than Rmax = 0.4S
replace the crankshaft pin bearing.
Table 38
Oil clearance between crankpin 0.025 mm (0.0009 inch) to
and crankpin bearing (New) 0.087 mm (0.0034 inch)

Allowable Limit 0.20 mm (0.0079 inch)

Crankpin outside diameter 46.959 mm (1.8488 inch) to

(New) 46.975 mm (1.8494 inch)

Crankpin bearing inside diame- 47.000 mm (1.8504 inch) to

ter (New) 47.046 mm (1.8522 inch)

6. If the same dimension bearing is not applicable

because of the crankpin wear, replace it with an
undersize one.

Note: Do not put the Plastigage into the crankpin oil

hole.
28 KENR6756-10
Specifications Section

Oil Clearance Between Crankshaft 2. Measure the inside diameter of the crankshaft
Journal and Crankshaft Bearing bearing with an internal micrometer.
Table 41
One
Crankshaft bearing 1 inside di- 59.980 to 60.039 mm (2.3615 to
ameter (New) 2.3637) inch

3. Calculate the oil clearance.

4. If the oil clearance is more than the allowable limit,
replace the crankshaft bearing 1.
Table 42
Oil clearance between crank- 0.0400 to 0.118 mm (0.00158 to
shaft journal and crankshaft 0.00464 inch)
bearing 1 (New)

Allowable Limit 0.20 mm (0.0079 inch)

Undersize Dimensions of Crankshaft

Journal

Illustration 36 g02847958
(7) External Micrometer

1. Measure the outside diameter of the crankshaft

journal with an external micrometer.
Table 40
Crankshaft journal outside di- 59.921 to 59.940 mm (2.3591 to
ameter (New) 2.3598 inch)

Illustration 38 g02847964

Table 43
Undersize 0.2 mm (0.008 inch) 0.4 mm (0.02 inch)

2.8 to 3.2 mm radius 2.8 to 3.2 mm radius

Dimension A 0.11 to 0.12 in. 0.11 to 0.12 in.
radius radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
Dimension B 0.040 to 0.059 in. 0.040 to 0.059 in.
relief relief

(continued)
Illustration 37 g02847961
(8) Internal Micrometer
KENR6756-10 29
Specifications Section

(Table 43, contd) (Table 44, contd)

59.721 to 59.740 59.521 to 59.540 Crankshaft journal outside di- 59.921 to 59.940 mm (2.3591 to
Dimension C mm dia. 2.3513 to mm dia. 2.3434 to ameter (New) 2.3598 inch)
2.3519 in. dia. 2.3440 in. dia.
Crankshaft bearing 2 inside di- 59.980 to 60.025 mm (2.3615 to
The crankshaft journal must be fine-finished to higher than Rmax ameter (New) 2.3631 inch)
= 0.4S
Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief. 5. If the same dimension bearing is not applicable
because of the crankshaft journal wear, replace it
with an undersize one.
Oil Clearance between Crankshaft
Journal and Crankshaft Bearing 2 Undersize Dimensions of Crankshaft
Journal

Illustration 39 g02848477

Illustration 40 g02848478
1. Put a strip of Plastigage on the center of the
journal. Table 45
2. Install the bearing case and tighten the baring Undersize 0.2 mm (0.008 inch) 0.4 mm (0.02 inch)
case screws 1 to the specified torque, and remove
Dimension A 2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
the bearing case again. 0.11 to 0.12 in. 0.11 to 0.12 in.
radius radius
Note: When you tighten the bearing case screws, do
not move the crankshaft. Dimension B 1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
0.040 to 0.059 in. 0.040 to 0.059 in.
3. Measure the width that it becomes flat with the relief relief
scale to get the oil clearance. Dimension C, D 59.721 to 59.740 59.521 to 59.540
mm dia. 2.3513 to mm dia. 2.3434 to
4. If the oil clearance is more than the allowable limit, 2.3519 in. dia. 2.3440 in. dia.
replace the crankshaft bearing 2.
The crankshaft journal must be fine-finished to higher than Rmax
Table 44
= 0.4S
Oil clearance between crank- 0.0400 to 0.104 mm (0.00158 to *Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
shaft and crankshaft bearing 2 0.00409 inch) (0.040 to 0.059 in.) relief.
(New)

Allowable Limit 0.20 mm (0.0079 inch)

(continued)
30 KENR6756-10
Specifications Section

i05421537

Connecting Rod
SMCS Code: 1218

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
Part No.: 383-0374
S/N: XFA1–Up
S/N: YGB1–Up Illustration 41 g02808077
(1) Connecting Rod Bolt
S/N: FSC1–Up (2) Connecting Rod Cap

S/N: SSC1–Up Note: Apply engine oil to the threads and seats of the
S/N: XSC1–Up connecting rod bolts before assembly.

S/N: DWD1–Up Table 46

Torque for connecting rod bolts 47 ± 2 N·m (35 ± 1 lb ft)
S/N: RSE1–Up
S/N: SFH1–Up
S/N: WDL1–Up
Part No.: 383-0374
S/N: TTN1–Up
S/N: TSR1–Up
S/N: W4T1–Up
S/N: W5T1–Up
S/N: W6T1–Up
S/N: E2W1–Up
S/N: DJX1–Up
S/N: EJX1–Up
Part No.: 383-0374
S/N: FKY1–Up
S/N: JWY1–Up
Part No.: 383-0374
S/N: RKY1–Up
S/N: YKY1–Up
KENR6756-10 31
Specifications Section

Connecting Rod Alignment i05946245

Piston and Rings

SMCS Code: 1214; 1215

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
Part No.: 383-0157
S/N: XFA1–Up
S/N: YGB1–Up
S/N: FSC1–Up
S/N: SSC1–Up
S/N: XSC1–Up
S/N: DWD1–Up
Illustration 42 g02811337 S/N: RSE1–Up
(3) Connecting Rod Alignment Tool
(4) Feeler Gauge
S/N: SFH1–Up
S/N: WDL1–Up
Note: Make sure that the oil clearance of the small
end bushing is less than the allowable limit. Part No.: 383-0157
S/N: TTN1–Up
1. Install the piston pin into the connecting rod.
S/N: TSR1–Up
2. Install the connecting rod on the alignment tool of
the connecting rod. S/N: W4T1–Up

3. Put a gauge on the piston pin, and move the S/N: W5T1–Up
gauge against the face plate. S/N: W6T1–Up
4. If the gauge does not touch fully against the face S/N: E2W1–Up
plate, measure the space between the gauge pin
and face plate. S/N: DJX1–Up
Table 47 S/N: EJX1–Up
Allowable limit for connecting 0.05 mm (0.002 inch)
Part No.: 383-0157
rod alignment
S/N: FKY1–Up
S/N: JWY1–Up
5. If the measurement is more than the allowable
limit, replace the connecting rod. Part No.: 386-4646
S/N: RKY1–Up
S/N: YKY1–Up
32 KENR6756-10
Specifications Section

Illustration 43 g02803856 Illustration 45 g03415022

(1) Top Ring Clearance between piston ring and ring groove
(2) Intermediate Ring
(3) Oil Control Ring
(4) Piston Pin Snap Ring
(5) Piston
(6) Connecting Rod
(7) Piston Pin

Illustration 44 g03415019
Piston Ring Gap

Table 48
Specifications for Top Piston Ring (Naturally Aspirated Engines)

Top ring gap (New) 0.2 mm (0.008 inch) to 0.35 mm (0.014 inch)

(continued)
KENR6756-10 33
Specifications Section

(Table 48, contd)

Allowable Limit 1.25 mm (0.049 inch)

Clearance from top ring to ring groove (New) 0.50 mm (0.020 inch) to 0.90 mm (0.035 inch)

Allowable Limit 0.20 mm (0.008 inch)

Table 49
Specifications for Intermediate Piston Ring (Naturally Aspirated Engines)

Intermediate ring gap (New) 0.30 mm (0.012 inch) to 0.45 mm (0.018 inch)

Allowable Limit 1.25 mm (0.049 inch)

Clearance from the intermediate ring to the ring groove (New) 0.0930 mm (0.04 inch) to 0.128 mm (0.005 inch)

Allowable Limit 0.15 mm (0.006 inch)

Table 50
Specifications for Intermediate Piston Ring (Turbocharged
Engines)

Intermediate ring gap (New) 0.40 mm (0.016 inch) to 0.55

mm (0.021 inch)

Allowable Limit 1.25 mm (0.049 inch)

Clearance from the intermediate 0.0.0930 mm (0.004 inch) to

ring to the ring groove (New) 0.128 mm (0.005 inch)

Allowable Limit 0.20 mm (0.008 inch)

Table 51
Specifications for Oil Control Ring (Naturally Aspirated Engines)

Oil control ring gap (New) 0.20 mm (0.008 inch) to 0.40 mm (0.016 inch)

Allowable Limit 1.25 mm (0.049 inch)

Clearance between oil control ring to ring groove (New) 0.030 mm (0.0012 inch) to 0.070 mm (0.0028 inch)

Allowable Limit 0.15 mm (0.0059 inch)

Table 52
Specifications for Oil Control Ring (Turbocharged Engines)

Oil control ring gap (New) 0.25 mm (0.0099 inch) to 0.45

mm (0.021 inch)

Allowable Limit 1.25 mm (0.049 inch)

Clearance between oil control 0.20 mm (0.008 inch) to 0.40

ring to ring groove (New) mm (0.016 inch)

Allowable Limit 0.15 mm (0.0059 inch)

34 KENR6756-10
Specifications Section

Piston Pin Bore Inside Diameter i05799245

Gear Group (Front)

SMCS Code: 1206

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
Part No.: 123-4568
S/N: XFA1–Up
S/N: YGB1–Up
Illustration 46 g02811198 S/N: FSC1–Up
(8) Cylinder Gauge
S/N: SSC1–Up
1. Measure the piston pin bore I.D. in the horizontal S/N: XSC1–Up
and vertical directions with a cylinder gauge.
S/N: DWD1–Up
Table 53
Inside diameter of piston pin 25.00 (0.98441) to 25.013 S/N: RSE1–Up
bore (New) (0.98468)
S/N: SFH1–Up
Allowable Limit 25.05 mm (0.986 inch)
S/N: WDL1–Up
Part No.: 123-4569
2. Measure the small end bushing inside diameter S/N: TTN1–Up
with an internal micrometer.
Table 54 S/N: TSR1–Up
Inside diameter of small end 25.025 mm (0.98524 inch) to S/N: W4T1–Up
bushing (New) 25.040 mm (0.98582 inch)
S/N: W5T1–Up
Piston pin outside diameter 25.004 mm (0.984 inch) to
(New) 25.011 mm (0.985 inch) S/N: W6T1–Up
S/N: E2W1–Up
3. Calculate the oil clearance.
Table 55
S/N: DJX1–Up
Oil clearance between piston 0.014 mm (0.00056 inch) to S/N: EJX1–Up
pin outside diameter and small 0.036 mm (0.0014 inch)
end bushing (New) Part No.: 123-6589
S/N: FKY1–Up
Allowable limit 0.15 mm (0.0059 inch)
S/N: JWY1–Up

4. If the oil clearance is more than the allowable limit, Part No.: 123-4569
replace the bushing. S/N: RKY1–Up

5. If the oil clearance stays more than the allowable S/N: YKY1–Up
limit, replace the piston pin also.
KENR6756-10 35
Specifications Section

Table 58
Backlash between the idler gear 0.04150 mm (0.001634 inch) to
and the crankshaft gear (New) 0.1122 mm (0.004417 inch)

Allowable limit 0.15 mm (0.0059 inch)

Backlash between the idler gear 0.04150 mm (0.001634 inch) to

and the camshaft gear (New) 0.1154 mm (0.004543 inch)

Allowable limit 0.15 mm (0.0059 inch)

Backlash between the idler gear 0.04150 mm (0.001634 inch)to

and the injection pump gear 0.1154 mm (0.004543 inch)
(New)

Allowable limit 0.15 mm (0.0059 inch)

Backlash between the crank- 0.04150 mm (0.001634 inch) to

shaft gear and the oil pump gear 0.1090 mm (0.004291 inch)
(New)

Allowable limit 0.15 mm (0.0059 inch)

Illustration 47 g02807659
Side Clearance of Idler Gear
(1) Injection Pump Gear
(2) Idler Gear
(3) Camshaft Gear
(4) Crankshaft Gear
(5) Oil Pump Drive Gear

Note: Apply engine oil to the threads and seats of the

idler gear bolts before assembly.
Table 56
Torque for idler gear bolts 24 N·m (18 lb ft) to 27 N·m
(20 lb ft)

Table 57 contains specifications for the C1.7 engines.

Table 57
Backlash between the idler 0.04150 mm (0.001634 inch) to
gear and the crankshaft gear 0.1122 mm (0.004417 inch)
(New)

Allowable limit 0.15 mm (0.0059 inch)

Backlash between the idler 0.04150 mm (0.001634 inch) to

gear and the camshaft gear 0.1154 mm (0.004543 inch)
(New) Illustration 48 g02809716
(6) Dial Indicator
Allowable limit 0.15 mm (0.0059 inch)

Backlash between the idler
gear and the injection pump
gear (New)
Allowable limit
Backlash between the crank-
shaft gear and the oil pump
gear (New)
Allowable limit
0.04150 mm (0.001634 inch)to
0.1154 mm (0.004543 inch)
0.15 mm (0.0059 inch)
0.0480 mm (0.00189 inch) to
0.1154 mm (0.00454 inch)
0.30 mm (0.01181 inch)
1. Set a dial indicator with the point on the idler gear.
2. Move the idler gear to the front and rear to
measure the side clearance.
Table 59 contains specifications for the C1.7
engines.
Table 59
Side clearance of idler gear 0.15 mm (0.00591 inch) to
(New) 0.25 mm (0.00984 inch).

Allowable limit 0.9 mm (0.04 inch)

Table 58 contains specifications for the C1.8 and
C2.4 engines.
36 KENR6756-10
Specifications Section

Table 60 contains specifications for the C1.8 and 4. If the oil clearance stays more than the allowable
C2.4 engines. limit, replace the idler gear shaft also.
Table 60
Side clearance of idler gear 0.12 mm (0.0048 inch) to
(New) 0.48 mm (0.018 inch).

Allowable limit 0.9 mm (0.04 inch)

3. If the measurement is more than the allowable

limit, replace the idler gear collar.

Oil Clearance between Idle Gear

Shaft and Idle Gear Bushing

Illustration 49 g02811161
(7) External Micrometer
(8) Internal Micrometer

1. Measure the idler gear shaft outside diameter with

an external micrometer.
Table 61
Outside diameter of idler gear 37.959 mm (1.4945 inch) to
shaft (New) 37.975 mm (1.495 inch)

2. Measure the idler gear bushing inside diameter

with an internal micrometer.
Table 62
Inside diameter of idler gear 38.000 mm (1.4945 inch) to
bushing (New) 38.025 mm (1.497 inch)

3. Calculate the oil clearance.

Table 63
Oil clearance between the idler 0.025 mm (0.00099 inch) to
gear shaft and the idler gear 0.066 mm (0.0025 inch)
bushing (New)

Allowable limit 0.10 mm (0.0039 inch)

KENR6756-10 37
Specifications Section

i05421561

Flywheel
SMCS Code: 1156

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
Part No.: 183-0412
S/N: XFA1–Up
S/N: YGB1–Up Illustration 50 g02731767
(1) Flywheel
S/N: FSC1–Up (2) Bolts

S/N: SSC1–Up Note: Apply engine oil to the threads and seats of the
S/N: XSC1–Up flywheel bolts before assembly.

S/N: DWD1–Up Torque for the four bolts on the flywheel

. . . . . . . . . . . . . . . . . . 101 ± 4.5 N·m ((74 ± 3.3 lb ft))
S/N: RSE1–Up
S/N: SFH1–Up
S/N: WDL1–Up
Part No.: 183-0412
S/N: TTN1–Up
S/N: TSR1–Up
S/N: W4T1–Up
S/N: W5T1–Up
S/N: W6T1–Up
S/N: E2W1–Up
S/N: DJX1–Up
S/N: EJX1–Up
Part No.: 183-0142
S/N: FKY1–Up
S/N: JWY1–Up
Part No.: 386-4592
S/N: RKY1–Up
S/N: YKY1–Up
38 KENR6756-10
Specifications Section

i05409563

Crankshaft Pulley
SMCS Code: 1205

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
Illustration 51 g03415732
S/N: BG81–Up (1) Fan Drive Pulley
(2) Nut
S/N: CR91–Up
S/N: XFA1–Up Torque for mounting nut for the fan drive
. . . . . . . . . . . . . . . . . . . . .147 ± 9 N·m ((108 ± 7 lb ft))
S/N: YGB1–Up
S/N: FSC1–Up
S/N: SSC1–Up
S/N: XSC1–Up
S/N: DWD1–Up
S/N: RSE1–Up
S/N: SFH1–Up
S/N: WDL1–Up
S/N: TTN1–Up
S/N: TSR1–Up
Part No.: 383-0159
S/N: W4T1–Up
S/N: W5T1–Up
S/N: W6T1–Up
S/N: E2W1–Up
S/N: DJX1–Up
S/N: EJX1–Up
S/N: FKY1–Up
S/N: JWY1–Up
S/N: YKY1–Up
KENR6756-10 39
Specifications Section

i05350617

Alternator and Regulator

SMCS Code: 1405; 1410

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
Part No.: 383-0134
S/N: XFA1–Up
S/N: YGB1–Up Illustration 52 g02848742
(1) Alternator Nut
S/N: FSC1–Up
Table 64
S/N: SSC1–Up
58.4 N·m (43.1 lb ft) to
Torque for alternator nut
S/N: XSC1–Up 78.9 N·m (58.2 lb ft)

S/N: DWD1–Up Stator Resistance Less than 1.0 ohms

S/N: RSE1–Up Rotor Resistance Approximately 2.9 ohms

S/N: SFH1–Up Slip Ring Outside Diameter

14 mm (0.55118 inch)
(Allowable)
S/N: WDL1–Up
Brush Length (Allowable) 8.4 mm (0.33071 inch)
Part No.: 383-0134
S/N: TTN1–Up
S/N: TSR1–Up
S/N: W4T1–Up
S/N: W5T1–Up
S/N: W6T1–Up
S/N: E2W1–Up
S/N: DJX1–Up
S/N: EJX1–Up
Part No.: 383-0134
S/N: FKY1–Up
S/N: JWY1–Up
Part No.: 383-0134
S/N: RKY1–Up
S/N: YKY1–Up
40 KENR6756-10
Specifications Section

i05799261

Electric Starting Motor

SMCS Code: 1453

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
S/N: XFA1–Up
S/N: YGB1–Up
Illustration 53 g02848743
S/N: FSC1–Up (1) Terminal B Nut
S/N: SSC1–Up
Table 65 contains specifications for the C1.7 engines.
S/N: XSC1–Up Table 65

S/N: DWD1–Up Torque for terminal B 5.9 N·m (52.2 lb in) to 11 N·m (97 lb in)
nut
S/N: RSE1–Up
Commutator Outside 30 mm (1.2inch)
S/N: SFH1–Up Diameter (Allowable)

S/N: WDL1–Up Mica Undercut 0.2 mm (0.008 inch)

(Allowable)
S/N: TTN1–Up
Brush Length 9 mm (0.35 inch)
S/N: TSR1–Up (Allowable)

Part No.: 383-0154

S/N: W4T1–Up Table 66 contains specifications for the C1.8 and
C2.4 engines.
S/N: W5T1–Up Table 66

S/N: W6T1–Up 5.9 N·m (52.2 lb in) to 11 N·m

Torque for terminal B nut
(97 lb in)
S/N: E2W1–Up
Commutator Outside Diameter 34 mm (1.34inch)
S/N: DJX1–Up (Allowable)

S/N: EJX1–Up Mica Undercut (Allowable) 0.2 mm (0.008 inch)

S/N: FKY1–Up Brush Length (Allowable) 9 mm (0.35 inch)

S/N: JWY1–Up
S/N: RKY1–Up
S/N: YKY1–Up
KENR6756-10 41
Specifications Section

i05356016 i05404198

Engine Oil Pressure Switch Glow Plugs

SMCS Code: 1924 SMCS Code: 1412

S/N: CJ21–Up
S/N: JX21–Up
S/N: MW41–Up
S/N: AC51–Up
S/N: MX51–Up
S/N: CR61–Up
S/N: BG81–Up
S/N: CR91–Up
S/N: YGB1–Up

Illustration 54 g02848750 Part No.: 383-0538

(1) Engine Oil Pressure Switch location S/N: FSC1–Up
S/N: SSC1–Up
Table 67
Torque for engine oil pressure 15 N·m (11 lb ft) to 19 N·m S/N: XSC1–Up
switch (14 lb ft)
S/N: DWD1–Up
Table 68 S/N: RSE1–Up
Switch opens at approximate 50 kPa (7 psi) S/N: SFH1–Up
pressure
S/N: WDL1–Up
S/N: TSR1–Up
S/N: W4T1–Up
S/N: W5T1–Up
S/N: W6T1–Up
S/N: E2W1–Up
S/N: DJX1–Up
S/N: EJX1–Up
S/N: JWY1–Up
S/N: RKY1–Up
S/N: YKY1–Up
42 KENR6756-10
Specifications Section

Illustration 55 g03414216
(1) Glow Plug

(1) Tighten the glow plugs to the following torque.

. . . . . . . . . . . . . . . . . . . . 22 ± 2 N·m ((194 ± 18 lb in))

Illustration 56 g03413934
Resistance
Table 69
Specification for Glow Plug

Resistance 0.9 ohms

KENR6756-10 43
Index Section

Index
A I
Alternator and Regulator......................................39 Important Safety Information ..................................2

C L
Camshaft............................................................18 Lifter Group ..........................................................9
Camshaft Bend................................................19
Camshaft Height..............................................19
Oil Clearance of Camshaft Journal ....................20 P
Side Clearance of Camshaft .............................18 Piston and Rings .................................................31
Connecting Rod ..................................................30 Piston Pin Bore Inside Diameter........................34
Connecting Rod Alignment ...............................31
Crankshaft..........................................................24
Crankshaft Bend..............................................26 R
Oil Clearance between Crankshaft Journal and
Crankshaft Bearing 2......................................29 Rocker Shaft.......................................................10
Oil Clearance Between Crankshaft Journal and
Crankshaft Bearing One .................................28
Oil Clearance Between the Crankshaft Pin and the S
Crankshaft Pin Bearing...................................27 Specifications Section ...........................................4
Oversized Dimensions of Crankshaft Journals ...26
Side Clearance of Crankshaft ...........................25
Crankshaft Pulley................................................38 T
Cylinder Block.....................................................23
Cylinder Correction (Oversize) ..........................24 Table of Contents ..................................................3
Cylinder Head .....................................................16
Top Clearance .................................................17 V
Valve Springs ..................................................17
Cylinder Head Valves ..........................................13 Valve Mechanism ................................................ 11
Valve Recessing ..............................................14 Valve Mechanism Cover ......................................12

E W
Electric Starting Motor .........................................40 Water Temperature Regulator ..............................22
Engine Design ......................................................4
C1.7 Engines.....................................................4
C1.8 Engines.....................................................4
C2.4 Engines.....................................................4
Tightening Torques of Screws, Bolts, and Nuts for
General Use ....................................................5
Engine Oil Pressure ............................................22
Engine Oil Pressure Switch..................................41
Engine Oil Pump .................................................20

F
Flywheel.............................................................37
Fuel Injection Lines ...............................................5
Fuel Injection Nozzles ...........................................8
Fuel Injection Pump...............................................7
Fuel Transfer Pump...............................................8

G
Gear Group (Front)..............................................34
Oil Clearance between Idle Gear Shaft and Idle
Gear Bushing.................................................36
Side Clearance of Idler Gear.............................35
Glow Plugs .........................................................41
KENR6756 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2016 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.

44 June 2016