PERKINS DIESEL

ENGINES
704-26 (UB)
H2.00-3.20XM (H40-65XM) [D177, H177]

PART NO. 1456975 600 SRM 706

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Perkins Diesel Engines Table of Contents

TABLE OF CONTENTS

Description ......................................................................................................................................................... 1
General Safety Rules ......................................................................................................................................... 1
Engine Removal and Installation ..................................................................................................................... 2
General ........................................................................................................................................................... 2
Lifting Engine ................................................................................................................................................ 2
Engine Identification ......................................................................................................................................... 2
General ........................................................................................................................................................... 2
Engine Data ................................................................................................................................................... 3
Cylinder Head Assembly Repair ....................................................................................................................... 4
Description ..................................................................................................................................................... 4
Valve Cover .................................................................................................................................................... 4
Remove....................................................................................................................................................... 4
Breather System, Clean and Replace....................................................................................................... 4
Install ......................................................................................................................................................... 5
Rocker Assembly............................................................................................................................................ 5
Remove....................................................................................................................................................... 5
Disassemble ............................................................................................................................................... 6
Assemble .................................................................................................................................................... 6
Install ......................................................................................................................................................... 6
Valve Clearance, Adjust ............................................................................................................................ 6
Valve Spring, Replace................................................................................................................................ 7
Piston TDC ................................................................................................................................................ 8
Cylinder Head ................................................................................................................................................ 8
Remove....................................................................................................................................................... 8
Clean and Inspect...................................................................................................................................... 10
Valve, Check .............................................................................................................................................. 10
Install ......................................................................................................................................................... 10
Valves and Valve Springs .............................................................................................................................. 12
Remove....................................................................................................................................................... 12
Install ......................................................................................................................................................... 12
Valve Guides .................................................................................................................................................. 13
Inspect........................................................................................................................................................ 13
Remove....................................................................................................................................................... 13
Install ......................................................................................................................................................... 13
Valve Seats, Repair ................................................................................................................................... 14
Valve Seat Insert, Install .......................................................................................................................... 14
Piston and Connecting Rod Assembly Repair .................................................................................................. 15
Description ..................................................................................................................................................... 15
Connecting Rod Bearings, Replace ............................................................................................................... 16
Piston and Connecting Rods ......................................................................................................................... 17
Remove....................................................................................................................................................... 17
Disassemble ............................................................................................................................................... 17
Inspect........................................................................................................................................................ 18
Replace ....................................................................................................................................................... 18
Assemble .................................................................................................................................................... 18
Install ......................................................................................................................................................... 19
Piston Rings ................................................................................................................................................... 20
Remove....................................................................................................................................................... 20
Inspect........................................................................................................................................................ 20
Install ......................................................................................................................................................... 21
Crankshaft Assembly Repair ............................................................................................................................ 22

©2004 HYSTER COMPANY i

Table of Contents Perkins Diesel Engines

TABLE OF CONTENTS (Continued)

Description ..................................................................................................................................................... 22
Crankshaft Pulley.......................................................................................................................................... 22
Remove....................................................................................................................................................... 22
Install ......................................................................................................................................................... 22
Rear Oil Seal .................................................................................................................................................. 22
Remove....................................................................................................................................................... 22
Install ......................................................................................................................................................... 23
Wear Sleeve, Install .................................................................................................................................. 23
Thrust Washers.............................................................................................................................................. 24
Crankshaft Axial Movement, Check ........................................................................................................ 24
Remove....................................................................................................................................................... 24
Install ......................................................................................................................................................... 25
Main Bearings................................................................................................................................................ 25
Remove....................................................................................................................................................... 25
Install ......................................................................................................................................................... 26
Crankshaft ..................................................................................................................................................... 26
Remove....................................................................................................................................................... 26
Inspect........................................................................................................................................................ 27
Wear Sleeve, Install .................................................................................................................................. 27
Install ......................................................................................................................................................... 28
Front and Rear Bearing Cap Seals, Install.................................................................................................. 29
Timing Case and Timing Gears Repair ............................................................................................................ 30
Description ..................................................................................................................................................... 30
Timing Case ................................................................................................................................................... 31
Remove....................................................................................................................................................... 31
Replace ....................................................................................................................................................... 31
Install ......................................................................................................................................................... 32
Front Oil Seal................................................................................................................................................. 33
Remove....................................................................................................................................................... 33
Install ......................................................................................................................................................... 33
Idler Gear ....................................................................................................................................................... 34
Remove....................................................................................................................................................... 34
Install ......................................................................................................................................................... 34
Idler Gear Bushings, Replace ....................................................................................................................... 34
Idler Gear Hub............................................................................................................................................... 35
Remove....................................................................................................................................................... 35
Install ......................................................................................................................................................... 35
Camshaft Assembly, Fuel Injection Pump ................................................................................................... 36
Remove....................................................................................................................................................... 36
Install ......................................................................................................................................................... 36
Camshaft Assembly, Valves........................................................................................................................... 37
Remove....................................................................................................................................................... 37
Install ......................................................................................................................................................... 38
Crankshaft Gear ............................................................................................................................................ 38
Remove....................................................................................................................................................... 38
Install ......................................................................................................................................................... 38
Timing Case Backplate ................................................................................................................................. 38
Remove....................................................................................................................................................... 38
Install ......................................................................................................................................................... 39
Cylinder Block Assembly Repair....................................................................................................................... 39
Description ..................................................................................................................................................... 39

ii
Perkins Diesel Engines Table of Contents

TABLE OF CONTENTS (Continued)

Cylinder Block ............................................................................................................................................... 39
Disassemble ............................................................................................................................................... 39
Inspect........................................................................................................................................................ 40
Cylinder Bore, Check ................................................................................................................................ 40
Assemble .................................................................................................................................................... 40
Engine Timing.................................................................................................................................................... 41
Description ..................................................................................................................................................... 41
Set Timing of Number One Piston to Top Dead Center (TDC) ................................................................... 42
Valve Timing, Check...................................................................................................................................... 43
Fuel Pump Timing Check.............................................................................................................................. 43
Lubrication System Repair................................................................................................................................ 45
Description ..................................................................................................................................................... 45
Oil Filter, Replace .......................................................................................................................................... 45
Oil Sump ........................................................................................................................................................ 46
Remove....................................................................................................................................................... 46
Install ......................................................................................................................................................... 46
Oil Pump ........................................................................................................................................................ 47
Remove....................................................................................................................................................... 47
Inspect........................................................................................................................................................ 47
Install ......................................................................................................................................................... 48
Relief Valve .................................................................................................................................................... 48
Remove....................................................................................................................................................... 48
Disassemble ............................................................................................................................................... 48
Inspect........................................................................................................................................................ 48
Assemble .................................................................................................................................................... 48
Install ......................................................................................................................................................... 48
Fuel System Repair............................................................................................................................................ 49
Description ..................................................................................................................................................... 49
Fuel Filter, Replace ....................................................................................................................................... 49
Fuel Injectors ................................................................................................................................................. 50
Remove....................................................................................................................................................... 50
Inspect........................................................................................................................................................ 50
Install ......................................................................................................................................................... 50
Fuel Pump...................................................................................................................................................... 51
Remove....................................................................................................................................................... 51
Disassemble ............................................................................................................................................... 51
Assemble .................................................................................................................................................... 52
Install ......................................................................................................................................................... 52
Test ............................................................................................................................................................. 52
Water Separator............................................................................................................................................. 53
Remove....................................................................................................................................................... 53
Disassemble ............................................................................................................................................... 53
Assemble .................................................................................................................................................... 53
Install ......................................................................................................................................................... 53
Fuel Injection Pump ...................................................................................................................................... 54
Remove....................................................................................................................................................... 54
Install ......................................................................................................................................................... 54
Fuel System Air Removal.............................................................................................................................. 55
Governor Weight Assembly ........................................................................................................................... 56
Remove....................................................................................................................................................... 56
Install ......................................................................................................................................................... 56

iii
Table of Contents Perkins Diesel Engines

TABLE OF CONTENTS (Continued)

Engine Speed Control Assembly................................................................................................................... 56
Remove....................................................................................................................................................... 56
Replace ....................................................................................................................................................... 57
Install ......................................................................................................................................................... 57
Fuel Injection Pump Linkage........................................................................................................................ 58
Remove....................................................................................................................................................... 58
Fuel Control Lever, Replace...................................................................................................................... 58
Governor Control Lever, Replace.............................................................................................................. 59
Install ......................................................................................................................................................... 59
Record Maximum Fuel Position.................................................................................................................... 60
Record Maximum Fuel Position of Fuel Rack ......................................................................................... 60
Set Adjustment Screw for Maximum Fuel Setting ................................................................................. 62
Electrical Stop Solenoid ................................................................................................................................ 63
Remove....................................................................................................................................................... 63
Install ......................................................................................................................................................... 63
Cooling System Repair ...................................................................................................................................... 63
Description ..................................................................................................................................................... 63
Thermostat, Replace...................................................................................................................................... 63
Coolant Pump ................................................................................................................................................ 64
Remove....................................................................................................................................................... 64
Install ......................................................................................................................................................... 64
Fan.................................................................................................................................................................. 64
Remove....................................................................................................................................................... 64
Install ......................................................................................................................................................... 64
Flywheel and Housing Repair ........................................................................................................................... 65
Description ..................................................................................................................................................... 65
Flywheel ......................................................................................................................................................... 65
Remove....................................................................................................................................................... 65
Install ......................................................................................................................................................... 65
Ring Gear, Replace ........................................................................................................................................ 65
Flywheel Housing .......................................................................................................................................... 65
Remove....................................................................................................................................................... 65
Install ......................................................................................................................................................... 65
Electrical System Repair ................................................................................................................................... 66
Drive Belt ....................................................................................................................................................... 66
Alternator....................................................................................................................................................... 66
Remove....................................................................................................................................................... 66
Install ......................................................................................................................................................... 67
Starter Motor ................................................................................................................................................. 67
Remove....................................................................................................................................................... 67
Install ......................................................................................................................................................... 67
Glow Plugs ..................................................................................................................................................... 67
Remove....................................................................................................................................................... 67
Continuity Check....................................................................................................................................... 68
Operation Check........................................................................................................................................ 68
Install ......................................................................................................................................................... 68
Engine Specifications......................................................................................................................................... 69
Cylinder Head Assembly ............................................................................................................................... 69
Piston and Connecting Rods ......................................................................................................................... 71
Crankshaft Assembly .................................................................................................................................... 72
Crankshaft Heat Treatment ..................................................................................................................... 73

iv
Perkins Diesel Engines Table of Contents

TABLE OF CONTENTS (Continued)

Crankshaft Overhaul ................................................................................................................................ 73
Timing Case and Gear Assembly.................................................................................................................. 74
Engine Block Assembly ................................................................................................................................. 75
Timing Data ................................................................................................................................................... 75
Lubrication System ....................................................................................................................................... 76
Fuel System ................................................................................................................................................... 76
Cooling System .............................................................................................................................................. 77
Electrical Equipment..................................................................................................................................... 77
Torque Specifications ......................................................................................................................................... 78
Cylinder Head Assembly ............................................................................................................................... 78
Piston and Connecting Rod Assemblies ....................................................................................................... 78
Crankshaft Assembly .................................................................................................................................... 78
Timing Case and Drive Assembly................................................................................................................. 78
Lubrication System ....................................................................................................................................... 78
Fuel System ................................................................................................................................................... 78
Cooling System .............................................................................................................................................. 79
Flywheel ......................................................................................................................................................... 79
Valve Cover .................................................................................................................................................... 79
Electrical Equipment..................................................................................................................................... 79
Special Tools ....................................................................................................................................................... 79

This section is for the following models:

H2.00-3.20XM (H40-65XM) [D177, H177]

v
"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
600 SRM 706
Description
This section has the description and the repair pro-
cedures for the Perkins diesel 704-26 (Model UB) en-
gine. Disassembly, cleaning, assembly procedures,
Engine Specifications, and Torque Specifications are
included in this section. The end of the engine with
the fan is the front of the engine.
Model UB is a 2.6-liter, four-cylinder, liquid-cooled
engine. This diesel engine uses indirect fuel injec-
tion. An indirect fuel injection engine has a small
precombustion chamber in the cylinder head. This
precombustion chamber permits ignition of a normal
fuel-to-air ratio which then expands into a less than
normal fuel-to-air-air ratio of the combustion cham-
ber in the piston head. This combustion process de-
creases smoke and possible harmful emissions from
the engine exhaust.
This engine has a closed crankcase ventilation sys-
tem (breather system). Exhaust gases generated
in the crankcase and cylinder head spaces during
General Safety Rules
WARNING
Viton Seals
Some seals used in this engine are made of a
synthetic material called Viton. Viton is a safe
material when used under normal conditions
of operation.
If Viton is burned, a dangerous acid is pro-
duced as a byproduct. Never permit burned
material to come into contact with the skin or
the eyes.
If it is necessary to handle components that
have been burned, use the following proce-
dures:
• Make sure the components are cool.
• Use neoprene gloves and discard the gloves
after use.
• Wash the area with calcium hydroxide solu-
tion and then clean with water.
• Discard the components and gloves in accor-
dance with environmental regulations.
Burned Viton byproduct that touches the skin
or eyes must be immediately flushed with
General Safety Rules
engine operation are returned to the combustion
chambers through the air induction system.
The cast-iron cylinder block is made without cylin-
der liners. The crankshaft is induction hardened and
has five main bearings. The end clearance of the
crankshaft is controlled by two half thrust washers
installed on each side of the number four main bear-
ing. Each piston has two compression rings and an
oil control ring. Each piston and connecting rod is
matched to its cylinder. The correct piston height is
obtained during engine assembly by careful selection
of one of six possible lengths of connecting rods.
The cylinder head has two valves per cylinder. There
is a valve guide and a valve seat for each valve. Each
valve has a single valve spring and an oil seal in-
stalled on top of the valve guide. The face angle for
all of the valves is 45 degrees and the angle for all
of the valve seats is 45 degrees. The bottom face of
the cylinder head cannot be machined because of the
precombustion chamber.
water or a calcium hydroxide solution. Get
medical help immediately.
WARNING
Disconnect the battery cables before doing any
disassembly and repair of the engine or parts of
the electrical system. Put a DO NOT OPERATE
tag in the operator’s area and on the battery
connectors.
Long-term exposure to used engine oil can
cause skin irritation or cancer. Wash with
detergent and water.
Exhaust from internal combustion engines
contains carbon monoxide and other harmful
chemicals. Carbon monoxide is a colorless,
odorless poison and can cause unconscious-
ness or death without warning. Long-term
exposure to exhaust or chemicals in the ex-
haust can cause cancer, birth defects, and
other reproductive harm. Avoid exposure to
engine exhaust.
Do not use diesel engines indoors where soot
can accumulate.
1
Engine Identification
WARNING
If engines are operated in confined spaces,
maintain adequate ventilation or vent exhaust
to the outside. Do not exceed applicable air
contaminant limits.
Follow the inspection and maintenance sched-
ule and procedures in this manual. Do not alter
exhaust, ignition, or fuel systems.
Disposal of batteries must meet local environ-
mental regulations.
The diodes and resistors in the electrical sys-
tem can be damaged if the following cautions
are not followed:
Engine Removal and Installation
GENERAL
See Frame section for the procedure for removing
the engine and transmission. See Transmission
section for the procedure to separate the transmis-
sion from the engine.
LIFTING ENGINE
WARNING
A complete engine weighs approximately
300 kg (700 lb). Use a lifting device that has a
minimum capacity of 500 kg (1100 lb) when a
complete engine assembly must be moved.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
Engine Identification
GENERAL
The engine number is on a label that is fastened to
the right, rear side of the cylinder block. See Fig-
ure 2.
An example of an engine number is:
UB80862U123456A
2
600 SRM 706
• Do not disconnect the battery when the en-
gine is running. The voltage surge can dam-
age the diodes and resistors.
• Do not disconnect an electric wire before the
engine is stopped and the switches are OFF.
• Do not cause a short circuit by connection
of the electric wires to the wrong terminals.
Make sure a correct identification is made of
a wire before it is connected.
• Make sure a battery is the correct voltage and
polarity before it is connected.
• Do not check for current flow by mak-
ing a spark because the diodes and other
solid-state components can be damaged.
Please observe the previous warnings before working
on engine.
Before an engine is lifted:
• Make sure the lifting equipment has the correct
capacity to lift the engine. Use a vertical lift as
shown in Figure 1. Never use a single lift bracket
to lift an engine.
• Make sure the engine lift brackets are in good con-
dition and correctly fastened to the engine. The
capscrews for the engine brackets are tightened to
22 N•m (195 lbf in).
• Make sure lifting slings do not damage the valve
cover or other engine components.
• Some components of the engine assembly are
heavy. Always use a lifting device when moving
the cylinder bock, cylinder head, flywheel housing,
crankshaft, and flywheel.
The components of an engine number are as follows:
UB Type code letters
80862 Build list number
U Built in the UK
123456 Engine serial number
A Year of manufacture
600 SRM 706
1. ENGINE LIFT BRACKETS
Figure 1. Lifting Engine
Engine Identification
The complete engine number must be used if any
parts, service, or information is needed.
Figure 2. Engine Number
ENGINE DATA
Number of cylinders......... In-line 4
Firing order ...................... 1–3–4–2
Bore................................... 91.0 mm (3.58 in.)
Stroke................................ 100.0 mm (3.94 in.)
Displacement.................... 2.6 liter (159 in. 3 )
Valve clearances (all)
(cold).................................. 0.35 mm (0.014 in.)
Engine oil pressure at
maximum governed speed
and normal operating
temperature...................... 420 kPa (61 psi)
Engine oil capacity:
Initial fill .......................... 8.3 liter (8.8 qt)
Oil and filter change ........ 7.0 liter (7.4 qt)
Direction of engine
rotation ............................. clockwise
Governor speed................. See Periodic
Maintenance
section for your model
of lift truck.
3
Cylinder Head Assembly Repair 600 SRM 706

Cylinder Head Assembly Repair

DESCRIPTION 3. Remove the valve cover from the cylinder head.

The cylinder head assemblies for the UB engine con-
tain two valves for each cylinder. From the front of
the engine, the sequence for valves is first inlet and
then exhaust.
Included in the cylinder head assembly is a valve
guide and a valve seat insert for each valve. The in-
serts and guides can be replaced if necessary.
The inlet and the exhaust valves are each installed
in the cylinder head with a single valve spring and
an oil seal. The oil seal is installed over the top of
the valve guide. The valve and valve spring are held
in place with a hardened steel cap and two collets.
Breather System, Clean and Replace
The breather assembly is installed in the top of the
valve cover and has the following components: cover,
four machine screws, diaphragm and location ring
assembly, and spring. See Figure 4.
Replace the spring and the diaphragm every
2000 hours of engine operation. Clean the in-
side of the breather pipe every 1000 hours of engine
operation.

The glow plugs and the fuel injectors are both in-
stalled into the top of the cylinder head. The tip of
the glow plug and the fuel injector protrude into the
precombustion chamber.

VALVE COVER
Remove
The aluminum valve cover has a closed breather as-
sembly and a connection for the breather pipe.

1. Disconnect the breather pipe.

1. BREATHER HOSE 6. LOCATION RING
2. Remove the special nuts, washers, and seals from 2. CAPSCREW (4) ASSEMBLY WITH
the valve cover. See Figure 3. 3. BREATHER COVER DIAPHRAGM
4. BREATHER CAVITY 7. VENT HOLE
5. SPRING

Figure 4. Breather Components

CAUTION
Make sure the area around the vent hole (Fig-
ure 4) is kept clean and the vent hole is not re-
stricted.

Make sure the breather pipe (Figure 4) does not

contact other components that may cause dam-
age to the breather pipe.

Make sure the components of the breather sys-

tem are installed correctly to prevent possible
damage to the engine.
1. CAP NUT 3. RUBBER SEAL 1. Remove the four machine screws and remove the
2. STEEL WASHER breather cover.
Figure 3. Valve Cover Fasteners

4
600 SRM 706 Cylinder Head Assembly Repair

2. Remove the diaphragm and location ring assem-

bly. Remove the spring.

3. Release the clips that hold the breather pipe and

remove the breather pipe.

4. Clean the breather cavity in the valve cover, the

breather pipe, and the vent hole.

5. Install a new spring in the cavity in the valve

cover.

6. Install a new location ring and new diaphragm.

See Figure 5. Make sure the location ring is on
the spring.
1. BREATHER HOSE
2. MACHINED GROOVE OF VALVE COVER
3. STUD AND PLATE ASSEMBLY

Figure 6. Valve Cover Installation

ROCKER ASSEMBLY
Remove
1. Remove the valve cover. See Valve Cover, Re-
move.

1. DIAPHRAGM 2. LOCATION RING 2. Remove the eight capscrews (Figure 7) that

Figure 5. Location Ring and Diaphragm
7. Install the breather cover and tighten the four
machine screws.
fasten the rocker brackets to the cylinder head.
First, loosen the two outer nuts. Then, loosen
the two inner nuts. Remove the nuts.

8. Install the breather pipe and tighten the clips.

Install
1. Make sure the rubber seals are in good condition.
Make sure the breather system is clean and in
good condition.

2. Clean the seal face on the cylinder head and in-

stall the valve cover. Make the sure the seal stays
in the groove in the valve cover.

CAUTION 1. CAPSCREW (8)

If the cap nut (Figure 3) is tightened too much, 2. STUD PLATE (3)
the stud and plate assembly (Figure 6) can be 3. INNER BRACKET NUT
4. OUTER BRACKET NUT
damaged.
Figure 7. Rocker Brackets
3. Install the valve cover. Make sure the special
nuts, washers, and seals are installed correctly. NOTE: The rocker assembly has three plates which
Tighten the special nuts to 11 N•m (97 lbf in). include the studs for the valve cover. See Figure 7.
These plates must be installed in the correct posi-
tions.

5
Cylinder Head Assembly Repair 600 SRM 706

3. Remove the rocker assembly from the cylinder Assemble

head. See Figure 8.
1. Clean and inspect the components for wear and
damage. Check the clearance between the rocker
levers and the rocker shaft. If the clearance is
greater than 0.124 mm (0.0049 in.), replace the
worn parts.

2. Assemble the parts of the rocker assembly as

shown in Figure 9.

Install
1. Install the rocker assembly on the cylinder head
as shown in Figure 8.
1. ALIGNMENT PIN 4. ADJUSTMENT
2. OIL HOLE SCREW 2. Make sure the stud and plate assembly for the
3. PUSH ROD
valve cover are installed on the correct rocker
Figure 8. Rocker Assembly brackets. See Figure 7. Make sure the push rods
fit into the sockets in the tappets and the rocker
NOTE: A special steel pin is installed in the lower levers.
part of the front rocker bracket. See Figure 8. The
function of this pin is to make sure this rocker 3. Install the four nuts and eight capscrews.
bracket is correctly aligned with the oil hole in the Tighten the capscrews and nuts only with your
cylinder head. This oil passage is for the oil to lu- fingers. Make sure the parts are correctly fitted
bricate the rocker assembly. Make sure the oil holes together.
are clean.
4. Tighten the nuts evenly to 22 N•m (196 lbf in).
Disassemble 5. Tighten the capscrews evenly to 9 N•m
(80 lbf in).
1. Remove the end clips from both ends of the rocker
shaft. See Figure 9. 6. Adjust the valve clearances. See Valve Cover,
Install.

Valve Clearance, Adjust

1. Check the valve clearance with a spacer gauge
between the top of the valve stem and the rocker
lever as shown in Figure 10. The engine must be
cold. The correct valve clearance for all valves is
0.35 mm (0.014 in.).

1. SPRINGS 4. SPACER
2. ROCKER LEVER 5. CLIP
3. ROCKER 6. BRACKET
BRACKET

Figure 9. Rocker Assembly Components

2. Remove the spacer, rocker levers, rocker brack-

ets, and springs.

Figure 10. Valve Adjustment

6
600 SRM 706 Cylinder Head Assembly Repair

NOTE: The arrangement of the valves is shown in

Figure 11. The valve numbers 1 and 2 are for the CAUTION
number 1 cylinder, which is at the front of the engine. Do not rotate the crankshaft while the valve
springs are removed.

3. Remove the rocker assembly. See Rocker Assem-

bly, Remove.

4. Install a valve spring compressor on the valve

for which the valve spring must be replaced. See
Figure 12.

Figure 11. Valve Arrangement

NOTE: The engine rotation is clockwise when viewed

from the front.

2. Rotate the crankshaft clockwise until valve num-

ber 7 has just opened and valve number 8 has not
closed completely. Adjust the valve clearance on
valves 1 and 2.

3. Rotate the crankshaft clockwise until valve num-

ber 3 has just opened and valve number 4 has not
closed completely. Adjust the valve clearance on
valves 5 and 6.
4. Rotate the crankshaft clockwise until valve num-
ber 1 has just opened and valve number 2 has not
closed completely. Adjust the valve clearance on
valves 7 and 8.
5. Rotate the crankshaft clockwise until valve num-
ber 5 has just opened and valve number 6 has not
closed completely. Adjust the valve clearance on
valves 3 and 4.
1. VALVE SPRING COMPRESSOR
2. CAPSCREW ADAPTOR
Figure 12. Valve Spring Compressor
5. Compress the valve spring and remove the col-
lets. Make sure the valve spring is compressed
squarely so the valve stem is not damaged. For
a list of valve components, see Figure 13.
6. Release the valve spring compressor. Remove the
valve spring caps and the valve spring.

Valve Spring, Replace 7. Install a new valve spring.

The following procedure describes how to replace 8. Install the valve spring cap.
valve springs when the cylinder head is still installed
on the engine. This procedure is for the replacement 9. Install a valve spring compressor on the valve.
of a single valve spring. Compress the valve spring and install the collets.

1. Remove the valve cover. See Valve Cover, Re- 10. Install the rocker assembly. See Rocker Assem-
move. bly, Install.

2. Identify the cylinder for which the valve spring 11. Adjust the valve clearances. See Valve Clear-
will be replaced. Rotate the crankshaft clockwise ance, Adjust.
until the inlet valve has just opened and the ex-
12. Install the valve cover. See Valve Cover, Install.
haust valve has not fully closed. In this position,
the piston will be at approximately top dead cen-
ter (TDC).

7
Cylinder Head Assembly Repair 600 SRM 706

1. CAP 4. VALVE STEM SEAL

2. COLLET (2) 5. VALVE
3. SPRING
Figure 14. Find TDC With Valve Spring
Figure 13. Valve Components
Compressor
NOTE: The valve springs for all the cylinders can be
changed by this method one cylinder at a time. The CYLINDER HEAD
sequence of cylinders is 1 and 4, 2 and 3.
Remove
Piston TDC
CAUTION
If the rocker assembly has been removed and the
Some coolant can enter the cylinder bores
TDC of a piston must be determined, use the follow-
when the cylinder head is removed. Clean any
ing method.
coolant to prevent corrosion.
1. Install the valve spring compressor on valve of
1. Drain the cooling system.
the piston. Compress the valve spring to open
the valve. 2. Disconnect the battery.
2. Rotate the crankshaft clockwise by hand until 3. Remove the valve cover. See Valve Cover, Re-
the piston touches the valve. move.
3. Rotate the crankshaft and permit the piston to
raise the valve until the piston is at TDC. See CAUTION
Figure 14. Disposal of lubricants and fluids must meet lo-
cal environmental regulations.

8
600 SRM 706
CAUTION
Use a separate wrench to prevent movement
of the outlet connections of the fuel injection
pump when the high-pressure lines are loos-
ened or tightened.
4. Remove the high-pressure fuel lines. Install caps
on the open connections of the fuel lines and fuel
injectors to prevent dirt from entering the fuel
system.
5. Remove the exhaust manifold and gasket. See
Figure 15.
Figure 15. Exhaust Manifold and Gasket
6. Remove the air induction manifold and gasket.
See Figure 16.
Figure 16. Air Induction Manifold and Gasket
7. Remove the fuel return line that is installed be-
tween the fuel filter and the fuel injector returns.
8. Remove the fuel injectors as described in the sec-
tion for fuel injectors. See Fuel Injectors, Re-
move.
Cylinder Head Assembly Repair
9. Remove the glow plugs as described in the section
for glow plugs. See Glow Plugs, Remove.
10. Release the clips on the coolant hose that is in-
stalled between the coolant pump and the ther-
mostat housing. Remove the coolant hose.
11. Disconnect the sender for the coolant tempera-
ture.
12. Remove the valve cover. See Valve Cover, Re-
move.
13. Remove the rocker assembly. See Rocker Assem-
bly, Remove.
NOTE: Many service persons make an organizer
rack to make sure the valve train components are
installed in their original locations.
14. Make a note of the location of each push rod so
they can be installed again in their original loca-
tions. Remove the push rods.
15. Loosen the capscrews for the cylinder head
evenly and gradually. Use the sequence shown
in Figure 17.
1. CYLINDER HEAD CAPSCREWS
Figure 17. Cylinder Head Loosening Sequence
CAUTION
Do not use a pry bar to separate the cylinder
head from the cylinder block and cause dam-
age to the cylinder head.
16. Remove the cylinder head and move it to a work
space that will not cause damage to the face of
the cylinder head.
9
Cylinder Head Assembly Repair
Clean and Inspect
1. Inspect the cylinder head for indications of leaks.
2. Clean the cylinder head and internal passages.
The coolant passages can be cleaned with a spe-
cial solvent. Follow the instructions of the man-
ufacturer for the solvent.
3. Carefully check for cracks in the following areas:
valve seats, holes for the fuel injectors and glow
plugs, and the port for the precombustion cham-
bers. Cracks in these areas of the cylinder head
require replacement of the cylinder head.
4. Use a straight edge and spacer gauge to check the
cylinder head for distortion. See Figure 127. If
the distortion exceeds specifications, replace the
cylinder head. See the Engine Specifications.
NOTE: The bottom face of the cylinder head cannot
be machined because of the precombustion chamber.
5. Check the valve seats for wear and damage. A
correction for minimum wear and damage to the
valve and seat can be done by a process called
lapping. When the valve seats are lapped, keep
the valve faces and seats within the specifica-
tions. Make sure all of the lapping compound is
removed from the valve and valve seat when the
process is completed. If a valve seat must be re-
placed, see the procedure for valve seats.
Valve, Check
1. Before the valve springs are removed, check the
depth of the valves below the surface of the cylin-
der head. See Figure 18.
Figure 18. Cylinder Head Valve Depth Check
10
600 SRM 706
Make sure the heads of the valves and the bot-
tom face of the cylinder head are clean. Care-
fully measure the depth of the valve. The normal
depth and service limits are shown in the Engine
Specifications.
2. If a valve is below the depth limit, check the valve
depth with a new valve in that position. If the
valve depth is still below the limit, the valve seat
insert must be replaced. This procedure is de-
scribed in the section for valve seats. See Valve
Seat Insert, Install.
3. Check the valves for cracks. Check the stems of
the valves for wear and the correct fit in the valve
guides.
4. Check that the seat faces of the valves are not
burned or damaged. A correction for minimum
wear and damage to the valve face and seat can
be done by a process called lapping. When the
valve seats are lapped, keep the valve faces and
seats within the specifications. Make sure all of
the lapping compound is removed from the valve
and valve seat when the process is completed. If
a new valve is installed, the valve depth must be
checked as described in Step 1.
5. Check that the compression of the valve springs
is correct at their fitted length. See the Engine
Specifications.
NOTE: Install new valve springs during an engine
overhaul.
Install
1. Make sure the bottom face of the cylinder head
and the top of the cylinder block are clean. Make
sure the precombustion chambers are clean.
CAUTION
The bottom face of the cylinder head cannot be
machined because of the precombustion cham-
ber.
2. Make sure the two dowels (Figure 19) are in-
stalled in the cylinder head. These dowels make
sure the cylinder head and cylinder head gasket
stay correctly aligned during installation.
600 SRM 706
1. DOWEL PINS
2. RUBBER GROMMET
3. TOP GASKET STAMP
4. FRONT GASKET STAMP
Figure 19. Cylinder Head Bottom Face
3. Make sure the rubber grommet is installed in the
cylinder head.
4. Put the cylinder head gasket in position on the
cylinder block. The cylinder head gasket is
marked top and front. Do not use any sealant on
the cylinder head gasket.
5. Install the cylinder head on the cylinder block.
Make sure the parts are in alignment.
6. Install all of the capscrews and tighten them with
your fingers.
7. Gradually and evenly tighten the capscrews to
70 N•m (52 lbf ft) in the sequence shown in Fig-
ure 20.
8. Gradually and evenly tighten the capscrews to
100 N•m (74 lbf ft) in the sequence shown in Fig-
ure 20. Repeat the sequence to make sure all of
the capscrews are correctly tightened.
9. Install the push rods into the same sockets of the
tappets from which they were removed.
10. Install the rocker assembly. See Rocker Assem-
bly, Install.
11. Adjust the valve clearances. See Valve Clear-
ance, Adjust.
Cylinder Head Assembly Repair
1. CYLINDER HEAD CAPSCREW
Figure 20. Cylinder Head Tightening Sequence
12. Install the valve cover. See Valve Cover, Install.
13. Connect the sender for the coolant temperature.
14. Install the coolant hose between the thermostat
housing and the coolant pump.
15. Install the glow plugs as described in the section
for glow plugs. See Glow Plugs, Install.
16. Install the fuel injectors as described in the sec-
tion for fuel injectors. See Fuel Injectors, Install.
17. Install the fuel return line between the fuel filter
and the fuel injector returns.
18. Install the exhaust manifold and gasket. To hold
the exhaust manifold and gasket in alignment,
use two guide studs as shown in Figure 15.
19. Install the capscrews to fasten the exhaust man-
ifold to the cylinder head.
NOTE: The threaded part of the exhaust manifold
capscrews has a three-lobe shape.
20. Remove the two guide studs and install the
correct capscrews. Tighten the inner capscrews
first and then the outer capscrews. Tighten the
capscrews evenly to a final torque of 18 N•m
(159 lbf in).
11
Cylinder Head Assembly Repair
CAUTION
If the face of the exhaust manifold has been ma-
chined, add a shim (washer) under the heads
of the capscrews. This shim must be the same
thickness as the metal that was removed. The
shim prevents the length of the capscrews from
causing damage to the cylinder head.
21. Install two guide studs as shown in Figure 21.
Figure 21. Air Induction Manifold and Gasket
22. Install the gasket and the air induction manifold.
23. Install the capscrews and remove the two guide
studs.
24. Tighten the capscrews to 22 N•m (195 lbf in).
25. Install the high-pressure fuel lines. Tighten the
connection nuts to 22 N•m (195 lbf in).
CAUTION
Do not tighten the connection nuts more than
the torque recommendation, or the fuel flow
through the line can be restricted.
When the engine can be operated, check for
fuel leaks. A leak can be caused if the fuel line
is not correctly aligned with the fuel injector.
26. Install the breather hose between the valve cover
and the air induction manifold.
27. Add coolant to the cooling system.
28. Connect the battery terminals.
29. Connect the air filter.
30. Remove the air from the fuel injection system as
described in the procedure for removal of the air.
See Fuel System Air Removal.
12
600 SRM 706
31. Remove the valve cover. Start the engine and
operate it at low speed. Make sure that oil flows
from all of the rocker levers.
32. If the oil flow is correct, stop the engine. Install
the valve cover. If the oil flow is not correct, find
the fault.
VALVES AND VALVE SPRINGS
Remove
WARNING
Wear eye protection.
1. Remove the cylinder head. See Cylinder Head,
Remove.
2. Clean the bottom face of the cylinder head and
check the depth of the valve heads below the face
of the cylinder head. See Valve, Check.
3. If the valves will be used again, make a mark on
each valve head so they can be installed again in
the same positions.
4. Use a valve spring compressor to compress the
valve spring and remove the collets. See Fig-
ure 13. Make sure the valve spring is compressed
squarely so the valve stem is not damaged.
5. Release the valve spring compressor and remove
the valve spring cap, valve spring, valve stem
seal, and valve.
6. Repeat this procedure to remove all valves.
Install
WARNING
Wear eye protection.
1. Lubricate the valve with clean engine oil and in-
stall the valve into the valve guide.
2. Install a new valve stem seal onto the valve
guide. Install the valve spring and valve spring
cap. See Figure 13. The valve spring is the same
on either end.
3. Use the valve spring compressor to compress the
valve spring. Install the collets. Make sure the
valve spring is compressed squarely so the valve
stem is not damaged. See Figure 12.
4. Repeat this procedure to install the other valves.
600 SRM 706 Cylinder Head Assembly Repair

VALVE GUIDES Remove

Inspect Use a valve guide removal and installation tool as
shown in Figure 23 to pull the valve guide from the
1. Measure the clearance between the valve stem cylinder head.
and the guide as shown in Figure 22. The max-
imum clearance for the inlet valves is 0.107 mm
(0.0042 in.). The maximum clearance for the ex-
haust valves is 0.14 mm (0.006 in.). If the clear-
ance is more than the maximum amount when a
new valve is installed in the valve guide, a new
valve guide must be installed.

1. MAGNETIC BASE 4. VALVE GUIDE

2. DIAL INDICATOR 5. MAXIMUM
3. VALVE HEAD CLEARANCE

Figure 22. Valve Guide Check

2. Do the following procedure to check the valve

guide for wear:

a. Put a new valve in the valve guide.

Figure 23. Valve Guide Removal
b. Raise the valve 15.0 mm (0.6 in.) and move
the valve away from the dial indicator. Set Install
the dial indicator to touch the edge of the
1. Clean the bore in the cylinder head for the valve
valves shown in Figure 22. Set the dial in-
guide.
dicator to zero.
NOTE: The internal recess in the valve guide must be
c. Push the valve toward the dial indicator. If
toward the valve guide removal and installation tool.
the dial indicator shows greater clearance
than the data shown below, the valve guide 2. Lubricate the outer surface of the valve guide
must be replaced. with engine oil. Install the valve guide removal
Inlet guide: 0.24 mm (0.009 in.) and installation tool as shown in Figure 24.
Exhaust guide: 0.28 mm (0.011 in.)

13
Cylinder Head Assembly Repair 600 SRM 706

1. Install the pilot in the valve guide and tighten

the pilot. See Figure 25.

Figure 25. Valve Seat Cutter

2. Set the blades of the valve seat cutter to the di-

ameter of the valve seat to be cut.

3. Carefully rotate the cutter clockwise and remove

only the minimum metal to make a good valve
seat. Keep the valve seat as narrow as possible.

4. Remove the valve seat cutter and lightly tap the

valve into position on the valve seat.

5. Check the valve depth to see that it is within

specifications. See Engine Specifications. If the
valve depth exceeds the specifications, install a
1. 7.7 to 7.9 mm (0.30 to 0.31 in.) ABOVE SEAT OF new valve seat insert.
VALE SPRING

Figure 24. Valve Guide Installation Valve Seat Insert, Install

3. Pull the valve guide into the cylinder head. The NOTE: Install a new valve guide before installing a
valve guide must extend 7.7 to 7.9 mm (0.30 to new valve seat insert.
0.31 in.) above the spring seat in the cylinder
NOTE: Cylinder heads with new valve guides and
head.
new valve seat inserts are available from the man-
4. The valve guide’s internal diameter must be ufacturer of the engine.
reamed or machined to 7.027 to 7.052 mm
1. Use the bore of the valve guide as a pilot hole.
(0.2767 to 0.2776 in.).
Use a rotary cutter to cut out the old valve seat
insert. See Engine Specifications for the size of
Valve Seats, Repair
the valve seat insert.
NOTE: Before any work is done on the valve seats,
2. Measure the depth of the recess in the cylinder
the valve guides must be inspected and replaced as
head in two places, 90 degrees apart. The correct
necessary. The following procedure is to repair a
depth is 8.20 to 8.40 mm (0.323 to 0.331 in.).
damaged valve seat with a valve seat cutter.

14
600 SRM 706
CAUTION
Do not use a hammer or lubrication to install
the valve seat insert. To install the valve seat
insert, use a hydraulic or hand press in a con-
tinuous operation.
3. Use the valve guide as a pilot hole and press the
valve seat insert into position.
4. Make sure the valve seat insert is fully seated
in its recess. Measure the depth of the valve
Piston and Connecting Rod Assembly Repair
DESCRIPTION
The combustion chamber is in the top of the piston.
See Figure 26. This combustion chamber works with
the precombustion chamber in the cylinder head to
use fuel efficiently and to decrease possible harmful
emissions from the engine exhaust.
1. COMBUSTION CHAMBER
Figure 26. Combustion Chamber in Piston
Each piston and connecting rod is matched to the
cylinder in which it is installed. The correct piston
height is obtained during engine assembly by selec-
tion of one of six possible lengths of connecting rods.
These piston and connecting rod assemblies must al-
ways be installed in the same cylinder from which
they were removed. The cylinder number is etched
on the side of the connecting rod and its bearing cap.
Item 1 and item 2 are etched on the side of the con-
necting rod nearest the fuel injection pump. Item 1
Piston and Connecting Rod Assembly Repair
seat below the bottom face of the cylinder head.
Make the measurement in two places, 90 degrees
apart. The correct measurement is 2.4 to 2.7 mm
(0.09 to 0.11 in.).
5. Use a valve seat cutter to cut a 45-degree valve
seat. Make sure the depth of the valve in the
valve seat is within the production specifications.
New valves and valve seats are lapped to make
sure the parts make a better seal.
indicates the cylinder number. Item 2 indicates the
length grade of the connecting rod. Item 3 is etched
on the opposite side of the connecting rod and indi-
cates a manufacturing reference number. See Fig-
ure 27.
1. CYLINDER NUMBER
2. CONNECTING ROD LENGTH GRADE
3. MANUFACTURING REFERENCE NUMBER
Figure 27. Connecting Rod Number
If a piston and connecting rod assembly must be re-
placed, one length of connecting rod and three dif-
ferent piston heights are available. Larger diameter
pistons are also available if a cylinder is bored over-
size.
The connecting rod has a lead-bronze bushing in the
small end. The bearing halves for the large end of
the connecting rod are steel with an aluminum-tin
bearing surface. See Figure 28.
15
Piston and Connecting Rod Assembly Repair 600 SRM 706

Figure 28. Connecting Rod Assembly

CONNECTING ROD BEARINGS, REPLACE

CAUTION
Special bolts are used to fasten the bearing cap
to the connecting rod. These bolts must not
be removed from the connecting rod when the
bearing cap is removed. If the bolts are re-
moved, the bolts and the connecting rod will be
damaged.

1. Drain the engine oil.

CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
2. Remove the oil sump, oil strainer, and suction
pipe. See Oil Sump, Remove.
3. Rotate the crankshaft until the connecting rod is
at the lowest position in the engine.
4. Remove the nuts and remove the bearing cap.
5. Carefully push the connecting rod up the cylinder
bore just enough to permit access to the upper
bearing half.
6. Remove the bearing from the connecting rod.
7. Clean and inspect the bearing surface of the
crank pin. If the bearing surface for the con-
necting rod has damage, the crankshaft must be
repaired or replaced. See Crankshaft.
8. Install the upper half of the bearing into the con-
necting rod. Make sure the location tab of the top
bearing half is installed correctly in the connect-
ing rod. See Figure 29.
1. LOCATION TAB RECESS
2. LOCATION TAB
Figure 29. Connecting Rod Bearing
9. Lubricate the bearing surface with clean engine
oil and fit the connecting rod to the crank pin.
10. Install the lower half of the bearing into the bear-
ing cap. Make sure the location tab of the bearing
half is installed correctly in the bearing cap. See
Figure 29. Lubricate the bearing surface with
clean engine oil.
11. Install the bearing cap on the connecting rod.
Make sure that the assembly numbers are
matched on the same side of the connecting rod.
12. Install the nuts for the bearing cap.
13. Tighten each nut gradually and evenly to 54 N•m
(40 lbf ft).
14. After each connecting rod is tightened, make
sure the crankshaft rotates smoothly and cor-
rectly.
15. Install the oil strainer, suction pipe, and oil
sump. See Oil Sump, Install.

16
600 SRM 706 Piston and Connecting Rod Assembly Repair

16. Add the correct amount of engine oil when the Disassemble
engine is ready to operate.
1. Remove the piston rings. See Piston Rings, Re-
PISTON AND CONNECTING RODS move.

Remove
NOTE: If a piston must be replaced, make sure that
the piston has the same height grade. An H or an L is
stamped into the top of the piston. See Figure 30. A
production piston does not have an H or an L mark.
The piston height must be checked after installation.
See the procedure described in Install.
2. Remove the snap rings that hold the piston pin
in the piston.
3. Make a mark on the piston to indicate the same
cylinder number as shown on the connecting rod.
Put the mark on the same side of the piston as the
mark on the connecting rod so that the parts will
be assembled again correctly. See Figure 31.

1. Drain the engine oil.

Figure 30. Piston Grade Mark

2. Drain the cooling system.

3. Remove the cylinder head assembly. See Cylin-

der Head, Remove.

4. Clean the carbon from the tops of the cylinder

bores.

5. Remove the oil sump, oil strainer, and suction

pipe. See Oil Sump, Remove.

6. Remove the bearing caps from the connecting

rods as described in Connecting Rod Bearings, 1. MANUFACTURER’S REFERENCE NUMBER
Replace. Keep the bearing caps in order so they 2. ASSEMBLY NUMBER
can be installed again in their original positions. 3. PISTON MARK (ARROW)

7. Push the piston and connecting rod from the top Figure 31. Piston and Connecting Rod
of the cylinder bore. Keep the parts in order so Assembly
they can be installed again in their original posi-
4. Push the piston pin from the piston and connect-
tions.
ing rod. If the piston pin is difficult to remove,
8. Clean and inspect the bearing surfaces of the heat the assembly in an oven to 40 to 50 C (100
crank pins. If a bearing surface for the connect- to 120 F).
ing rod has damage, the crankshaft must be re-
paired or replaced.

17
Piston and Connecting Rod Assembly Repair
Inspect
1. Clean and inspect all the components for wear
and damage. Check the alignment of the con-
necting rod with a test mandrel. See Figure 130.
2. Check the clearance of the bushing in the con-
necting rod with the piston pin. If the clearance
is greater than 0.014 mm (0.0006 in.) or is dam-
aged, install a new bushing.
3. If the bushing in the connecting rod is worn, use
a press to remove the bushing.
4. Use a press to install a new bushing in the con-
necting rod. Make sure the lubrication hole in
the bushing is aligned with the lubrication hole
in the connecting rod.
5. Use a reamer in the bushing as necessary to give
the correct clearance on the piston pin. See for
correct data.
6. Machine the ends of the bushing to fit the shape
of the connecting rod.
NOTE: If the bushing is replaced in a connecting rod,
a new piston must be installed that will be the correct
height above the top face of the cylinder block.
Replace
NOTE: If a piston must be replaced, make sure the
piston has the same height grade. An H or an L is
stamped into the top of the piston. See Figure 30. A
production piston does not have an H or an L mark.
The piston height must be checked after installation.
See the procedure described in Install.
Each piston and connecting rod is matched to the
cylinder in which it is installed. The correct piston
height is obtained during engine assembly by selec-
tion of one of six possible lengths of connecting rods.
These piston and connecting rod assemblies must al-
ways be installed in the same cylinder from which
they were removed. The cylinder number is etched
on the side of the connecting rod and its bearing cap.
If a connecting rod must be replaced during repair
of an engine, a connecting rod marked with an X is
supplied as a service part. An identification letter
is etched on the production grades of the connecting
rods. See Table 1.
18
600 SRM 706
Table 1. Connecting Rod Dimensions
Grade Length mm (in.)
A 132.08 to 132.11 mm
(5.200 to 5.201 in.)
B 132.05 to 132.08 mm
(5.199 to 5.200 in.)
C 132.02 to 132.05 mm
(5.198 to 5.199 in.)
D 131.99 to 132.02 mm
(5.196 to 5.198 in.)
E 131.96 to 131.99 mm
(5.195 to 5.196 in.)
F 131.93 to 191.96 mm
(5.194 to 5.195 in.)
X 131.99 to 132.02 mm
(5.196 to 5.198 in.)
Assemble
1. Make sure all the parts are clean. Lubricate the
parts with engine oil as they are installed.
2. Install a new snap ring into one of the grooves on
the piston pin to hold the pin in place.
3. Turn the piston over and install the connecting
rod in position inside the piston.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
NOTE: If the original piston is being installed, align
the mark made on the piston with the mark on the
connecting rod. Make sure the piston and connect-
ing rod are installed in the same cylinder from which
they were removed.
If a new piston or connecting rod is being installed,
make sure that the piston mark is toward the front
of the engine and that the assembly number is on the
left side of the engine. See Figure 31.
4. Install the piston pin to fasten the connecting rod
to the piston. If the piston pin is tight, heat the
piston to 40 to 50 C (100 to 120 F) to make instal-
lation of the piston pin easier.
600 SRM 706
5. Install a second snap ring on the other end of the
piston pin to hold the piston in place.
6. Install the piston rings. See Piston Rings, In-
stall.
Install
1. Make sure all the parts are clean. Lubricate the
parts with engine oil as they are installed.
2. Turn the crankshaft until the position for the
connecting rod to be installed is at the lowest po-
sition on the crankshaft.
3. Install the upper bearing half into the connect-
ing rod. Make sure the location tab is installed
correctly into its position in the connecting rod.
See Figure 29.
4. Put the piston installation tool at the top of the
cylinder. See Figure 32. The tool has a bore with
a taper to compress the piston rings when the
piston and connecting rod assembly are installed.
Make sure the smaller end of the taper is toward
the cylinder block.
Figure 32. Piston Installation Tool
5. Put the spaces in the three piston rings so that
they are 120 degrees apart. Put the connecting
rod through the piston installation tool and per-
mit the piston to enter the tool.
Piston and Connecting Rod Assembly Repair
6. When the connecting rod has passed the cool-
ing jet during installation, the arrow or FRONT
mark on the piston must be turned toward the
end of the engine with the cooling fan. See Fig-
ure 33.
Figure 33. Piston Position in Cylinder Bore
7. Lubricate the lower half of the rod bearing and
install it into the bearing cap.
8. Install the bearing cap on the connecting rod.
Make sure the assembly number on the bearing
cap is the same as the number on the connecting
rod. Make sure the two assembly numbers are
on the same side of the connecting rod. See item
1, Figure 27.
9. Install and tighten the nuts evenly to a torque of
54 N•m (40 lbf ft). Make sure that the crankshaft
turns freely.
10. Turn the crankshaft so the piston is at TDC in
the engine block.
11. Put the dial indicator on the top of the engine
block and measure the height of the piston above
the face of the engine block. See Figure 34.
NOTE: The correct height of the piston above the en-
gine block is 0.26 to 0.52 mm (0.010 to 0.020 in.). The
tops of the pistons must not be changed or ma-
chined.
19
Piston and Connecting Rod Assembly Repair 600 SRM 706

3. Install the piston rings in the top part of the

cylinder liner and measure the clearance at the
ends of each piston ring. See Figure 35.

NOTE: The spring must be installed in the oil control

ring when its end clearance is measured. The clear-
ance measurements for the piston rings are shown in
the Engine Specifications.

Figure 34. Height Measurement of Piston Above

Engine Block

12. Loosely assemble the bracket of the suction pipe

to the main bearing cap.

13. Install a new gasket and fasten the flanges of the

suction pipe to the oil pump.
Figure 35. Piston Ring End Clearance Check
14. Make sure the suction pipe is aligned correctly
4. Install new piston rings on the piston and check
and tighten the capscrew that holds the bracket
the clearance in the grooves with a spacer gauge.
to the main bearing cap.
See Figure 36.
15. Install the oil sump. See Oil Sump, Install.

16. Install the cylinder head. See Cylinder Head,

Install.

PISTON RINGS
Remove
1. Check that the piston rings can move freely in
their grooves and are not broken.

2. Remove the piston rings with a ring expander.

3. Increase the diameter of the piston rings only

Figure 36. Piston Ring Clearance Check
enough to remove them without damaging the
piston. NOTE: If the clearance between the piston rings and
the piston is greater than the specifications, the pis-
Inspect ton must be replaced. See the Engine Specifications.
1. Check the piston for wear and damage. The clearance in the top groove of the pistons for
these engines cannot be checked because it has a ta-
2. Clean the carbon from the top of the cylinder lin- per.
ers.

20
600 SRM 706
Install
NOTE: Install the piston rings with a ring expander.
Increase the diameter of the piston rings only enough
to remove them without damaging the piston.
1. Install the spring for the oil control ring in the
bottom groove of the piston. See Figure 37.
1. TOP RING, RED IDENTIFICATION MARK
2. SECOND RING, GREEN IDENTIFICATION MARK
3. SPRING, OIL CONTROL RING
4. CHAMFER, INNER BOTTOM FACE
Figure 37. Piston Rings Installation
2. Install the latch pin inside both ends of the
spring.
3. Install the oil control ring over the spring so that
the end space in the oil control ring is 180 degrees
to the latch pin. See Figure 38.
4. Install the barrel face ring with the molybdenum
insert into the top groove of the piston. Make
sure the word TOP or the manufacturer’s symbol
is toward the top of the piston.
Piston and Connecting Rod Assembly Repair
1. OIL CONTROL RING LATCH PIN
Figure 38. Oil Control Ring Spring Installation
NOTE: New piston rings have a red identification
mark. This mark must be on the left of the clear-
ance space at the ends of the ring when the ring is
installed on the piston and the piston is upright.
5. Make sure the clearances at the ends of the pis-
ton rings are installed in an orientation 120 de-
grees apart before the piston is installed.
6. Install the cast-iron ring with the taper into the
second groove of the piston. Make sure the word
TOP, or the manufacturer’s symbol, is toward the
top of the piston.
NOTE: New piston rings have a green identification
mark. This mark must be on the left of the clearance
at the ends of the ring when the ring is installed on
the piston and the piston is upright.
21
Crankshaft Assembly Repair 600 SRM 706

Crankshaft Assembly Repair

DESCRIPTION 3. Clean the parts and check for damage. Replace
any damaged parts.
WARNING
See the WARNING in General Safety Rules
Install
about Viton seals for safety precautions re- 1. Put the pulley into position on the crankshaft.
garding these seals. Align the Woodruff key on the crankshaft with
the key slot in the pulley. See Figure 40.
The crankshaft is forged of chrome-molybdenum
steel and has five main bearing journals. The crank-
shaft rotates in five main bearings, which have a
steel back and an aluminum-tin face. The shell
bearings are held in position by tags which fit into
recesses machined in the bearing housings and the
bearing caps. The front and rear oil seals are lip
seals with an additional dust seal outside the main
lip and oil return grooves on the face of the main lip.

CRANKSHAFT PULLEY
Remove
NOTE: The crankshaft pulley is installed on the front
of the crankshaft. It is retained by a single capscrew
and washer. 1. WOODRUFF KEY
1. Remove the drive belt as described in Drive Belt. Figure 40. Crankshaft Pulley Alignment
2. Remove the capscrew and washer that hold the 2. Lightly lubricate the threads of the capscrew.
pulley to the crankshaft. See Figure 39.
3. Install the washer and capscrew.

4. Tighten the capscrew to 185 N•m (136 lbf ft).

5. Install the drive belt. See Drive Belt.

REAR OIL SEAL

Remove
1. Remove the drive components from the rear of
the engine. See the section Frame 100 SRM 505.

2. Remove the starter motor. See Starter Motor,

Remove.

3. Remove the flywheel and housing. See Flywheel,

1. WASHER 2. CAPSCREW Remove and Flywheel Housing, Remove.

Figure 39. Crankshaft Pulley Capscrew

22
600 SRM 706 Crankshaft Assembly Repair

CAUTION
When installing the screw into the oil seal face,
make sure the oil seal recess and the front of
the crankshaft are not damaged.

4. Install two small self-tapping screws with wash-

ers into the face of the oil seal approximately 180
degrees apart.

5. Use suitable levers under the installed screws to

pry the oil seal from the housing. See Figure 41.

1. OIL SEAL REPLACEMENT TOOL

2. PROTRUSION ABOVE CYLINDER HEAD

Figure 42. Oil Seal Installation

4. Remove all excess oil from the seal and crank-

shaft face.

Wear Sleeve, Install

NOTE: If the oil seal has caused a groove to be cut
into the surface of the pulley, a wear sleeve can be in-
stalled on certain types of pulleys. A wear sleeve can
1. OIL SEAL 3. SELF-TAPPING only be installed on pulleys of the type shown in Fig-
2. LEVERS SCREWS ure 43. All other damaged pulleys must be replaced.
Figure 41. Oil Seal Removal 1. With the pulley removed, carefully install the
wear sleeve over the pulley. See Figure 44.
Install Install the wear sleeve according to the manu-
1. Check that the oil seal area, the outer circumfer- facturer’s instructions supplied with the wear
ence of the crankshaft flange, and the crankshaft sleeve.
pulley are not worn or damaged.

NOTE: If the oil seal has worn a groove into the pulley
surface, a wear sleeve can be installed over the pul-
ley. This only applies to certain model pulleys. See
Wear Sleeve, Install.

2. Lubricate the oil seal with engine oil.

3. Use the oil seal replacement tool to carefully

press the oil seal into the housing until it pro-
trudes 1.5 mm (0.06 in.) above the rear face of
the cylinder block. See Figure 42.
Figure 43. Wear Sleeve-Type Pulley

23
Crankshaft Assembly Repair
1. WEAR SLEEVE
Figure 44. Pulley With Wear Sleeve Installed
2. Install the pulley into the oil sleeve.
THRUST WASHERS
Crankshaft Axial Movement, Check
The axial movement of the crankshaft is controlled
by two half-thrust washers, installed on each side of
the number four main bearing. The axial clearance
can be checked with a spacer gauge inserted between
the crankshaft and the thrust washer. See Figure 45.
1. HALF-THRUST 2. FEELER GAUGE
WASHERS
Figure 45. Thrust Washers, Feeler Gauge Check
24
600 SRM 706
A dial indicator can be used to check the axial move-
ment from the end of the crankshaft as shown in Fig-
ure 46. See Engine Specifications for normal and
maximum axial movement of the crankshaft.
Figure 46. Thrust Washers, Dial Indicator
Check
Remove
1. Remove the flywheel and housing. See Flywheel,
Remove and Flywheel Housing, Remove.
2. Drain the engine oil from the sump and remove
the sump. See Oil Sump, Remove.
3. Remove the two capscrews that hold the num-
ber four main bearing cap. Carefully remove the
bearing cap. Make sure the bearing stays in po-
sition in the bearing cap.
CAUTION
Do not rotate the crankshaft. The lower bear-
ing can be moved out of position.
4. Use a thin, flexible tool to push the upper halves
of the thrust washers from their positions next
to the main bearing housing. See Figure 47. Use
a small pry bar as necessary to move the crank-
shaft to loosen a tight thrust washer.
600 SRM 706
1. HALF-THRUST 2. REMOVAL TOOL
WASHERS
Figure 47. Thrust Washers Removal
Install
1. Lubricate the thrust washers with engine oil.
2. Slide the two thrust washers into their positions
in the engine block. Make sure the sides of the
thrust washers with the grooves are against the
crankshaft. See Figure 48.
Figure 48. Thrust Washers Installation
3. Install the bearing cap. Make sure the bearing is
secure in the correct position before installation.
4. Make sure the capscrews are in good condition.
Install the capscrews into the bearing cap.
5. Tighten the capscrews gradually and evenly.
Tighten the capscrews to a final torque of
147 N•m (108 lbf ft).
Crankshaft Assembly Repair
6. Make sure the crankshaft rotates freely. Check
the axial movement of the crankshaft to make
sure it is within the specifications.
7. Install the oil sump. See Oil Sump, Install.
8. Install the flywheel and housing. See Flywheel,
Install and Flywheel Housing, Install.
MAIN BEARINGS
Remove
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
NOTE: The following procedure is for replacement of
the main bearings without removing the crankshaft
from the engine.
If the front main bearing must be removed, remove
the timing case and backplate. See Timing Case, Re-
move.
If the rear main bearing must be replaced, remove
the flywheel and flywheel housing. See Flywheel,
Remove and Flywheel Housing, Remove. Check the
rear oil seal and replace, if necessary.
If main bearing number two or number three must
be replaced, remove the suction pipe. See Oil Sump,
Remove.
1. Drain the engine oil and remove the oil sump.
2. Remove the necessary components for access to
the bearing cap for the bearing that must be re-
placed. See NOTE.
3. Remove the capscrews and remove the bearing
cap. Remove the lower half of the bearing from
the bearing cap.
4. Use a thin, flexible tool to push on the side of
the upper bearing half that is opposite from the
location tab. See Figure 49. Push on the bearing
half so that it begins to rotate out of the engine
block. Carefully rotate crankshaft so the bearing
will rotate out of the engine block.
25
Crankshaft Assembly Repair
1. FLEXIBLE TOOL
Figure 49. Main Bearings Removal
5. Check that the bearing journal on the crankshaft
is clean and in good condition.
Install
NOTE: Only the upper half of the bearing has lubri-
cation holes, and it must be installed into the engine
block.
1. Lubricate the upper bearing half with engine oil.
Install the plain end of the bearing between the
crankshaft journal and the side of the bearing
housing that has the location slot. Carefully slide
the bearing half into the bearing housing until
the location tab fits into the location slot.
2. Lubricate the lower bearing half with engine oil
and install it into the bearing cap. Make sure the
location tab is installed correctly into the location
slot.
3. Make sure the orientation of the location slots
for the bearing halves is correct as shown in Fig-
ure 50. Install the bearing cap.
4. Make sure the capscrews are in good condi-
tion. Install the capscrews into the bearing cap.
Tighten the capscrews gradually and evenly.
5. Tighten the capscrews to a final torque of
147 N•m (108 lbf ft).
6. Make sure that the crankshaft rotates freely. If
the thrust washers have been removed and in-
stalled again, the axial movement of the crank-
shaft must be checked. See Thrust Washers.
26
600 SRM 706
1. MAIN BEARING HALF, NO OIL HOLE
2. LOCATION TAB
3. LOCATION SLOT
Figure 50. Shell Bearing Installation
7. If the front or rear main bearings were replaced,
install the main bearing seals. See Front and
Rear Bearing Cap Seals, Install.
8. Install the components that were removed for ac-
cess to the main bearing. See NOTE.
9. Install the oil sump. See Oil Sump, Install.
CRANKSHAFT
Remove
WARNING
Use lifting equipment to handle all heavy en-
gine components.
1. Remove the engine from the truck. See the sec-
tionFrame 100 SRM 505.
2. Drain the oil and cooling system.
3. Turn the engine so the crankshaft is facing up.
4. Remove the fan and fan drive pulley. See Fan,
Remove.
5. Remove the drive belt. See Drive Belt.
6. Remove the crankshaft pulley. See Crankshaft
Pulley, Remove.
7. Remove the timing case. See Timing Case, Re-
move.
8. Remove the idler gear. See Idler Gear, Remove.
600 SRM 706 Crankshaft Assembly Repair

9. Remove the starter motor. See Starter Motor,
Remove.
10. Remove the flywheel and the flywheel housing.
See Flywheel, Remove and Flywheel Housing,
Remove.
11. Remove the oil sump and oil suction pipe. See Oil
Sump, Remove.
NOTE: Mark each connecting rod bearing cap so it
can be installed in the same location from which it
was removed.
12. Remove the nuts from the connecting rods and
remove the bearing caps. Make sure the bearing
stays with the cap.
NOTE: Make note of the orientation of the bearing
caps as they are removed. When assembling the en-
gine, make sure they are installed in their original
positions. See Figure 51.
13. Remove the main bearing capscrews and remove
the main bearing caps.
17. Remove the thrust washer.
Inspect
1. Check the crankshaft for wear and other dam-
age. The maximum wear and out-of-round on the
bearing journals is 0.04 mm (0.0016 in.). See En-
gine Specifications and for undersize tolerances.
2. The bearing journals on standard crankshafts
can be ground to the following diameters smaller
than the original size:
0.25 mm (0.010 in.)
0.50 mm (0.020 in.)
0.75 mm (0.030 in.)
Special bearings are available for these sizes.
NOTE: The area on the crankshaft flange for the rear
oil seal can be machined to remove wear marks. See
Engine Specifications for the minimum diameter of
this area.
3. The crankshaft must be replaced if the surface
must be ground more than 0.75 mm (0.030 in.).

Wear Sleeve, Install

NOTE: If the face of the main journal on the crank-
shaft is worn, a wear sleeve can be installed as shown
in Figure 52.

1. REAR BEARING CAP, NO MARK

2. NUMBER 2, 3, 4 BEARING CAPS, SHOWS
NUMBER AND ARROW
3. FRONT BEARING CAP, SHOWS NUMBER ONLY

Figure 51. Main Bearing Cap Installation

Position

14. Remove the rear oil seal. Inspect for wear or

damage and replace if necessary. See Rear Oil 1. WEAR SLEEVE FLANGE
Seal. 2. WEAR SLEEVE
3. INSTALLATION DIMENSION
15. Lift the crankshaft out of the engine. 4. END OF CRANKSHAFT

16. Remove the upper half of the connecting rod Figure 52. Wear Sleeve Installation
bearings and the main bearings. Make note of
their orientation and temporarily store them 1. To install a wear sleeve, first remove the crank-
with their respective bearing cap. shaft from the engine block.

27
Crankshaft Assembly Repair 600 SRM 706

2. Install the wear sleeve according to the manu-

facturer’s instructions supplied with the sleeve.
Make sure the sleeve is installed to a depth of
12.0 mm (0.47 in.). See Figure 52.

CAUTION
Failure to remove the flange from the sleeve
after installation will damage the sleeve, the
cylinder block, and the oil seal.

3. After the wear sleeve is installed, break off the

flange from the sleeve. It is scored for easy re-
moval. Figure 53. Application of Silicon Sealant to
Cylinder Block for Rear Main Bearing Cap
Install 12. Before the front and rear bearing caps are fully
1. Make sure all oil passages are clean. tightened, use a straight edge to make sure the
front and rear main bearing is aligned with the
2. Make sure all bearings and bearing caps are face of the cylinder block. See Figure 54.
clean.

3. Install the upper bearing halves into their posi-

tions in the connecting rods and the housings for
the main bearings. Make sure the position tags
of the bearings fit into their position slots. Lubri-
cate the bearings with engine oil.

4. Install the crankshaft in position on the main

bearings.

5. Lubricate the half-thrust washers with engine

oil.

6. Slide the half-thrust washers into position in the

engine block, one on each side of the rear main
bearing. Make sure the side of the thrust washer
with the groove is toward the crankshaft web.
7. Make sure the position of the location slots for
the main bearing halves are correct as shown in
Figure 50.
8. Lubricate the bearing with engine oil.
Figure 54. Front and Rear Main Bearing
Alignment
13. Tighten the capscrews gradually and evenly.
Tighten the capscrews to a final torque of
265 N•m (195 lbf ft). Repeat this step for all five
main bearings.

9. Install the main bearing caps. Make sure the
main bearing caps are installed according to
their position numbers shown on the cap. See
Figure 51.
10. Apply a small amount of silicon adhesive to the
corners of the cylinder block for the rear main
bearing cap. See Figure 53.
NOTE: After the rear main bearing cap has been
tightened, remove all excess sealant from the inside
of the rear oil seal recess.
14. Install the connecting rod bearing caps on the
connecting rod. Make sure the assembly num-
bers are matched on the same side of the connect-
ing rod.

11. Make sure the capscrews are in good condition. 15. Install the nuts for the bearing cap. Tighten each
Install the capscrews into the main bearing cap. nut gradually and evenly to 54 N•m (40 lbf ft).

28
600 SRM 706 Crankshaft Assembly Repair

After each connecting rod is tightened, make 1. Inject a small quantity of sealant into the bearing
sure the crankshaft rotates smoothly and cor- seal holes on each side of the front and rear main
rectly. bearing caps. See Figure 55.

16. Insert front and rear main bearing seals as nec-

essary. See Front and Rear Bearing Cap Seals,
Install.

17. Install the oil suction pipe and strainer. See Oil
Sump, Install.

18. Install the rear oil seal. See Rear Oil Seal.

19. Install the flywheel housing and flywheel. See

Flywheel Housing, Install and Flywheel, Install.

20. Install the starter motor. See Starter Motor, In-

stall.

21. Install the timing case backplate. See Timing

Case Backplate, Install.
1. LONG BEARING SEAL
22. Install the timing case. See Timing Case, Install. 2. ORIENTATION OF BEARING SEAL
3. SEAL IN BEARING HOLE
23. Install the crankshaft pulley. See Crankshaft 4. APPLICATION OF SEALANT
Pulley, Install. Figure 55. Front and Rear Bearing Seal
24. Install the drive belt. See Drive Belt. Installation

25. Install the fan. See Fan, Install. 2. Insert the seals by hand and push approximately
one-third of the seal into the hole.

WARNING 3. Slide the seal replacement tool over each seal and
Use lifting equipment to handle all heavy en- press the seals fully into their holes. See Fig-
gine components. ure 56.

26. Turn the engine so the crankshaft is facing down.

27. Install the engine into the lift truck. See the sec-
tions Frame 100 SRM 505 and Single-Speed
Powershift Transmission, Troubleshooting
and Repair 1300 SRM 501 for the lift truck.

28. Fill the oil and cooling systems.

FRONT AND REAR BEARING CAP SEALS,

INSTALL

CAUTION
The front and rear main bearing seals contain
a soft metal insert. Do not bend the insert when
inserting the seal into the hole.
1. SEAL REPLACEMENT TOOL OVER SEAL
NOTE: The front and rear main bearing seals have 2. INSERTING SEAL INTO HOLE
a curve at one end which must be inserted with the
curve facing down and to the side of the engine. See Figure 56. Front and Rear Bearing Seal, Long
Figure 55. Seal

29
Timing Case and Timing Gears Repair 600 SRM 706

4. Use a small punch to push the seal below the

surface of the cap until it touches the bottom of
the hole. Remove any excess sealant from around
the holes.

5. Fit the two smaller seals to the holes in the front

main bearing cap. See Figure 57.

Figure 57. Front Bearing Seal, Short Seal

Timing Case and Timing Gears Repair

DESCRIPTION The timing case covers the gear train. The gear
train includes the crankshaft gear, the idler gear,
The aluminum timing case assembly contains the the camshaft gear for the valves, and the camshaft
lubricating oil pump assembly, the lubricating oil gear for the fuel injection pump. See Figure 59.
relief valve assembly, and the fuel injector linkage.
The timing case also has the front oil seal for the
crankshaft and the crankshaft gear bushing. See
Figure 58.

1. CAMSHAFT GEAR, FUEL INJECTION PUMP

2. IDLER GEAR
3. CAMSHAFT GEAR, VALVES
4. CRANKSHAFT GEAR
1. CAMSHAFT SUPPORT BUSHING 5. GOVERNOR WEIGHT ASSEMBLY
2. FRONT OIL SEAL
3. FUEL INJECTION PUMP LINKAGE Figure 59. Timing Gears
4. FUEL POSITION ADJUSTMENT SCREW
5. OIL PUMP ASSEMBLY The camshaft for the fuel injection pump is made of
6. OIL RELIEF VALVE ASSEMBLY steel with hardened cams.

Figure 58. Timing Case Components The camshaft for the valves is made of cast iron with
hardened cams.

30
600 SRM 706
TIMING CASE
Remove
CAUTION
The maximum fuel setting can be affected
when the timing case is removed from the
engine. Before removing the timing case,
record the maximum fuel setting, the high-idle
setting, and the low-idle setting. See Record
Maximum Fuel Position of Fuel Rack.
1. Disconnect the battery.
2. Remove the drive belt. See Drive Belt.
3. Remove the fan. See Fan, Remove.
4. Remove the alternator. See Alternator, Remove.
5. Remove the crankshaft pulley. See Crankshaft
Pulley, Remove.
CAUTION
The maximum fuel setting is affected if a
sealant is used on the gasket faces of the tim-
ing case or backplate, or if the joint gaskets
are damaged when the old joint is removed.
6. Record the maximum fuel position of the fuel con-
trol rack. See Record Maximum Fuel Position of
Fuel Rack.
7. Disconnect the governor control link. See Fig-
ure 60. Also, see Fuel Injection Pump, Remove
for the procedure for removing the link.
1. GOVERNOR CONTROL LINK
Figure 60. Governor Control Link
Timing Case and Timing Gears Repair
8. Clean all dirt and debris from the edge of the
gasket face of the timing case.
CAUTION
The capscrews for the timing case are different
lengths and thread sizes. Make note of their po-
sition so that they can be installed in the same
holes from which they were removed.
9. Remove the capscrews holding the timing case to
the cylinder block.
10. Hold the governor control link and carefully re-
move the timing case.
Replace
CAUTION
When the fuel injection pump linkage is either
removed or replaced, or a new timing case is
installed, the setting for the maximum fuel can
be affected.
1. Remove the timing case assembly. See Timing
Case, Remove.
2. Remove the oil pump assembly from the timing
case. See Oil Pump, Remove.
3. Remove the oil relief valve assembly from the
timing case. See Relief Valve, Remove.
4. Remove the engine speed control lever assembly
from the timing case. See Engine Speed Control
Assembly, Remove.
5. Remove the fuel injection pump linkage from the
timing case. See Fuel Injection Pump Linkage,
Remove.
6. Measure and record the position of the maximum
fuel setting screw, the high-idle screw, and the
low-idle screw. See Figure 61. Remove all these
screws.
7. Install all the components removed in Step 2
through Step 6 in the new timing case.
8. Install the maximum fuel setting screw, the
high-idle screw, and the low-idle screw. Set
these screws to the measurements recorded in
Step 6. See Figure 61.
9. Install the timing case assembly. See Timing
Case, Install.
31
Timing Case and Timing Gears Repair 600 SRM 706

3. Make sure the gasket between the backplate and

the cylinder block is not damaged.

4. Install a new O-ring into the front of the idler

gear hub.

5. Make sure the oil hole in the camshaft bushing

is not restricted.

6. Lubricate the bushing and the gears with clean

engine oil.

7. Turn the adjustment screw for the maximum fuel

to its original setting and then rotate in the op-
posite direction by two full turns. Install the
washer and lock nut.
1. MAXIMUM FUEL 2. HIGH-IDLE SCREW
SETTING SCREW 3. LOW-IDLE SCREW 8. Hold the governor control link and make sure
the gasket is in position on the timing case. In-
Figure 61. Adjustment Screw Measurement stall the timing case assembly in position over
the studs and the dowels.
Install
NOTE: It may be necessary to align the teeth on the
NOTE: If a new gear has been installed, check the oil pump gear with the teeth on the crankshaft gear
backlash. See for correct tolerances. as the timing case is being installed.
1. Clean the face of the timing case assembly and 9. Install the timing case capscrews and tighten
the backplate. them by fingers.
2. Install a new gasket, without sealant, to the tim- 10. Install the governor control link. See Figure 60.
ing case assembly. See Figure 62. Also, see Fuel Injection Pump, Install for the pro-
cedure for installing the link.

CAUTION
To make sure there are no side loads on the
camshaft gear, tighten the timing case cap-
screws gradually and evenly. Do not tighten
the capscrew in the center of the assembly.

11. Install the timing case capscrews. Make sure

each capscrew is installed into the hole from
which it was removed. Tighten the capscrews
gradually and evenly to 22 N•m (16 lbf ft).

12. Install the center capscrew. Tighten the cap-

screw to 22 N•m (16 lbf ft).

1. BACKPLATE 5. OIL HOLE 13. Check the backlash on the camshaft gear. See
2. GASKET 6. POSITION STUD Engine Specifications.
3. GOVERNOR 7. FRONT OF
CONTROL LINK CAMSHAFT 14. Install the crankshaft pulley. See Crankshaft
4. CAMSHAFT 8. O-RING Pulley, Install.
SUPPORT 9. DOWELS
BUSHING 10. POSITION STUD
15. Install the alternator. See Alternator, Install.
Figure 62. Timing Case Installation

32
600 SRM 706 Timing Case and Timing Gears Repair

16. Install the drive belt. See Drive Belt.

17. Install the fan. See Fan, Install.

18. Set the fuel position adjustment screw for the

maximum fuel setting.

FRONT OIL SEAL

Remove
1. Disconnect the battery.

2. Remove the drive belt. See Drive Belt.

3. Remove the crankshaft pulley. See Crankshaft

Pulley, Remove.
1. HOLE FOR STABILIZING ROD
4. Use a pry bar to remove the front oil seal from 2. REPLACEMENT TOOL NUT AND WASHER
3. ADAPTER PLATE
the timing gear cover. Put the pry bar behind 4. FRONT OIL SEAL
the main lip of the front oil seal. Make sure the 5. RECESS IN HOUSING FOR OIL SEAL
edge of the housing for the oil seal is not damaged 6. ADAPTER NUT
during removal. 7. CRANKSHAFT
8. ADAPTER
Install 9. REPLACEMENT TOOL FOR OIL SEAL

1. Clean the oil seal housing. Inspect the oil seal for
damage. Do not install a front oil seal that has a
scratch or any damage on the lip of the seal.
2. Lubricate the outer circumference of the oil seal
with engine oil and install the front oil seal into
the oil seal housing. Make sure the lip of the seal
is toward the inside of the cover for the timing
gear case and the front oil seal is parallel to the
bore of the oil seal housing.
3. Put the adapter on the front of the crankshaft as
shown in Figure 63. Tighten the adapter nut.
4. Put the adapter plate over the end of the crank-
shaft and against the oil seal. Make sure the 700
mark on the adapter plate is toward the front oil
seal.
5. Install the replacement tool for the front oil seal
on the adapter as shown in Figure 63.
Figure 63. Front Oil Seal Installation
7. Tighten the replacement tool nut against the
washer. This pushes the oil seal into the hous-
ing. Continue to tighten the nut until the rear
face of the oil seal is against the back of the oil
seal housing.
8. Remove the replacement tool, adapter plate, and
adapter.
9. Lubricate the seal area of the crankshaft pulley
with engine oil.
10. Install the crankshaft pulley. See Crankshaft
Pulley, Install.
11. Install the drive belt. See Drive Belt.
12. Install the fan. See Fan, Install.

6. Install a rod through the hole in the end of the

replacement tool so the tool will not turn when
the replacement tool nut is tightened.

33
Timing Case and Timing Gears Repair
IDLER GEAR
Remove
CAUTION
Make sure the crankshaft is not turned while
the idler gear is removed. A piston can hit and
damage a valve. The valve timing and the fuel
injection pump timing will be lost if the crank-
shaft is turned.
1. Remove the timing case assembly. See Timing
Case, Remove.
NOTE: The marked teeth on the idler gear will not
necessarily be aligned with the marked teeth of the
other three gears because of the different speed of
rotation of the idler gear.
2. Turn the crankshaft until the marked teeth of the
crankshaft gear, the camshaft gear for the valves,
and the camshaft gear for the fuel injection pump
are aligned with the idler gear as shown in Fig-
ure 64.
Figure 64. Timing Marks Alignment
3. Remove the idler gear from its hub. See Fig-
ure 65.
4. Inspect the idler gear and bushings for wear and
damage. Replace as necessary. See Idler Gear
Bushings, Replace.
Install
1. Make sure the oil hole in the hub is not restricted
and the hub is clean.
2. Lubricate the bushings in the idler gear with en-
gine oil.
34
600 SRM 706
3. Install the two thrust washers into the idler gear.
Make sure the oil grooves are facing away from
the idler gear.
4. Align the timing marks on the idler gear with the
marks on the crankshaft gear and the camshaft
gear and install the idler gear on the hub.
5. Turn the gear for the fuel injection pump clock-
wise as necessary to align the timing marks when
the teeth of the idler gear engage the other gears.
Make sure all alignment marks are aligned as
shown in Figure 64.
6. Check the timing gear train clearances. See En-
gine Specifications.
7. Install the timing case assembly. See Timing
Case, Install.
IDLER GEAR BUSHINGS, REPLACE
1. With the idle gear removed from the timing gear
train, press the old bushings out of the idler gear.
See Figure 65.
1. HUB 4. THRUST WASHER
2. IDLER GEAR 5. OIL GROOVES
3. BUSHINGS 6. OIL HOLE IN HUB
Figure 65. Idler Gear Components
NOTE: New bushings have an inside diameter of
27.425 to 27.610 mm (1.0797 to 1.0870 in.). After
installation, these bushings must be reamed to a
finished size of 28.077 to 28.098 mm (1.1054 to
1.1062 in.). See Figure 66.
2. Make sure the bore of the idler gear is clean and
not damaged.
600 SRM 706 Timing Case and Timing Gears Repair

1. SIZE AFTER 2. PROTRUSION 1. SLIDE HAMMER 3. OIL HOLE IN HUB

REAMING 3. CUTOUTS
Figure 66. Idler Gear Bushings Installation
3. Press a new bushing into each side of the idler
gear with the cutouts facing outward. Make sure
the edges protrude above the side face of the gear
by 1.5 to 2.0 mm (0.059 to 0.08 in.). See Figure 66.
4. Ream the bushings to the correct size.
5. Install the idler gear. See Idler Gear, Install.
2. SLIDE HAMMER 4. HUB FOR IDLER
ADAPTER GEAR
Figure 67. Idler Gear Installation
3. Put the replacement tool with the universal drive
handle over the hub and continue to install the
hub into the cylinder block. See Figure 68. The
new hub is correctly installed when the front face
of the replacement tool touches the face of the
cylinder block.

IDLER GEAR HUB

Remove
1. Remove timing case assembly. See Timing Case,
Remove.

2. Remove the idler gear. See Idler Gear, Remove.

3. Install the slide hammer with the slide hammer

adapter onto the hub. See Figure 67. Note the
position of the oil hole; it should be toward the
top.
1. HUB FOR IDLER GEAR
4. Use the slide hammer to remove the old hub from 2. REPLACEMENT TOOL AND DRIVE HANDLE
the cylinder block.
Figure 68. Idler Gear Hub Installation
Install
4. Check the hub to make sure it was not damaged
1. Before a new hub is installed, make sure: during installation.
• The oil hole is not restricted.
• The bore is clean and free of debris. 5. Install the idler gear. See Idler Gear, Install.
• The bore is not scratched or damaged.
6. Install the timing case assembly. See Timing
2. With the oil hole facing toward the top of the Case, Install.
engine, install the new hub into the bore of the
cylinder block. Use a soft hammer to just start
the hub into the bore.

35
Timing Case and Timing Gears Repair 600 SRM 706

CAMSHAFT ASSEMBLY, FUEL INJECTION

PUMP
Remove
1. Remove the timing case assembly. See Timing
Case, Remove.

2. Check the axial movement on the end of the

camshaft. See Figure 69. Make sure that
end-float is within the limits shown in .

1. BEARING 2. RETAINING PLATE

CAPSCREW

Figure 70. Camshaft Bearing Removal

8. Remove the camshaft assembly from the cylinder

block. Make sure the cams on the camshaft are
not damaged during removal.

NOTE: If the camshaft is replaced, the fuel injection

Figure 69. Axial Movement Check on Fuel
Injector Pump Camshaft
3. Turn the crankshaft until the marked teeth of the
crankshaft gear, the camshaft gear for the valves,
and the camshaft gear for the fuel injection pump
are aligned with the idler gear as shown in Fig-
ure 64.
4. Remove the oil pump. See Oil Pump, Remove.
5. Remove the fuel injection pump. See Fuel Injec-
tion Pump, Remove.
6. Remove the governor weight assembly. See Gov-
ernor Weight Assembly, Remove.
NOTE: Do not rotate the crankshaft when the fuel
injection pump camshaft assembly is removed. If the
crankshaft is rotated, the TDC must be reset on the
number one cylinder. See Set Timing of Number One
Piston to Top Dead Center (TDC).
7. Loosen the capscrew for the camshaft bearing re-
taining plate. Rotate the plate 180 degrees and
tighten the capscrew. This holds the plate away
from the bearing during removal. See Figure 70.
timing must be reset. See Fuel Pump Timing Check.
9. Inspect the bearings, the cams on the camshaft,
and the gear for wear or damage. Replace if nec-
essary.
Install
1. Make sure all bearing surfaces are clean.
2. Install the camshaft assembly. Make sure the
marks on the camshaft gear and the idler gear
are aligned as shown in Figure 64.
3. Loosen the capscrew for the camshaft bearing re-
taining plate. See Figure 70.
4. Rotate the plate 180 degrees to its original posi-
tion over the bearing and tighten the capscrew.
5. Install the governor weight assembly. See Gov-
ernor Weight Assembly, Install.
6. Install the fuel injection pump. See Fuel Injec-
tion Pump, Install.
7. Install the fuel pump. See Fuel Pump, Install.
8. Install the timing case assembly. See Timing
Case, Install.

36
600 SRM 706 Timing Case and Timing Gears Repair

CAMSHAFT ASSEMBLY, VALVES

Remove
1. Remove the cylinder head assembly. See Cylin-
der Head, Remove.

2. Remove the timing case assembly. See Timing

Case, Remove.

NOTE: Do not rotate the crankshaft when the valve

camshaft assembly is removed. If the crankshaft is
rotated, the TDC must be reset on the number one
cylinder. See .

3. Turn the crankshaft until the marked teeth of the 1. FLAT FACE OF 2. OIL HOLE IN
crankshaft gear, the camshaft gear for the valves, TAPPET TAPPET
and the camshaft gear for the fuel injection pump
are aligned with the idler gear as shown in Fig- Figure 72. Tappets Removal
ure 64.

4. Check the axial movement on the end of the

camshaft. See Figure 71. Make sure that
end-float is within the limits shown in Engine
Specifications.

1. THRUSTPLATE 3. CAMSHAFT
CAPSCREWS ASSEMBLY
2. CAM ON 4. OIL HOLES
CAMSHAFT

Figure 73. Camshaft Removal

Figure 71. Axial Movement Check on Valve
Camshaft
5. Remove the tappets from the cylinder head. Note
their positions so they can be installed in the
same position from which they were removed.
See Figure 72.
7. Remove the camshaft assembly from the cylinder
block. Make sure the cams on the camshaft are
not damaged during removal. See Figure 73.
NOTE: If the camshaft is replaced, the fuel injection
timing must be reset. See Fuel Pump Timing Check.

6. Remove the two capscrews that retain the thrust- 8. Inspect the bearings, the cams on the camshaft,
plate for the camshaft. See Figure 73. and the gear for wear or damage. Replace if nec-
essary.

37
Timing Case and Timing Gears Repair
Install
1. Make sure the oil holes in the camshaft are not
restricted. See Figure 73.
2. Lubricate the camshaft journals, the camshaft
cams, and the teeth of the camshaft gear with
engine oil.
3. Install the camshaft assembly. Make sure the
marks on the camshaft gear and the idler gear
are aligned as shown in Figure 64.
4. Install the two thrustplate capscrews. See Fig-
ure 73.
5. Check the camshaft end-float. See Figure 71.
Make sure end-float is within the limits shown
in Engine Specifications.
6. Make sure the oil drain hole in the tappet is not
restricted. See Figure 72.
7. Lubricate the tappets with engine oil and install
them in the same position from which they were
removed. Make sure the flat face of the tappet is
facing the cam.
8. Install the timing case assembly. See Timing
Case, Install.
9. Install the cylinder head assembly. See Cylinder
Head, Remove.
CRANKSHAFT GEAR
Remove
1. Remove the timing case assembly. See Timing
Case, Remove.
2. Turn the crankshaft until the marked teeth of the
crankshaft gear, the camshaft gear for the valves,
and the camshaft gear for the fuel injection pump
are aligned with the idler gear as shown in Fig-
ure 64.
CAUTION
Make sure the crankshaft is not turned while
the idler gear or the crankshaft gear is re-
moved. A piston can hit and damage a valve.
3. Remove the idler gear. See Idler Gear, Remove.
38
600 SRM 706
4. The crankshaft gear is pressed onto the crank-
shaft. Sometimes a puller will remove the crank-
shaft gear. Sometimes the gear fits so tightly
on the crankshaft that the crankshaft must be
removed from the engine so the gear can be re-
moved.
Install
WARNING
The following procedure requires that the
gear be heated to a high temperature. Use
metal tongs when handling the gear, and wear
leather gloves for protection.
1. Use a temperature-controlled oven to gradually
heat the crankshaft gear. DO NOT heat the gear
more than 300 C (572 F). DO NOT use an open
flame to heat the gear.
2. Install the heated gear onto the crankshaft.
Make sure the alignment marks on the crank-
shaft gear are facing toward the front of the
engine.
3. Install the idler gear. Make sure the alignment
marks on the crankshaft gear and the idler gear
are aligned as shown in Figure 64. See Idler
Gear, Install.
4. Install the timing case assembly. See Timing
Case, Install.
TIMING CASE BACKPLATE
Remove
1. Remove the timing case assembly. See Timing
Case, Remove.
2. Remove the idler gear. See Idler Gear, Remove.
3. Remove the camshaft assembly for the fuel injec-
tion pump. See Camshaft Assembly, Fuel Injec-
tion Pump.
4. Remove the tappets and the camshaft assembly
for the valves. See Camshaft Assembly, Valves.
5. Remove the backplate from the engine block.
6. Remove the gasket from the face of the engine
and the backplate.
600 SRM 706
Install
1. Make sure the face of the engine block and the
backplate is clean.
CAUTION
Do not use a sealant when installing a new gas-
ket for the backplate. This can change the max-
imum fuel setting.
2. Install a new gasket and the backplate over the
engine studs and dowels. See Figure 74.
3. Install the tappets and the camshaft assembly
for the valves. See Camshaft Assembly, Valves,
Install.
4. Install the camshaft assembly for the fuel injec-
tion pump. See Camshaft Assembly, Fuel Injec-
tion Pump, Install.
5. Install the idler gear. See Idler Gear, Install.
Cylinder Block Assembly Repair
DESCRIPTION
The cylinder block is made of cast iron. It is made
without cylinder liners. A bushing is installed in the
front of the cylinder block for the front journal of the
camshaft. The other camshaft journals do not have
bushings and run directly in the cylinder block.
CYLINDER BLOCK
Disassemble
1. Remove the engine from the lift truck. See the
section Frame 100 SRM 505 for procedures to re-
move the engine. See the section Single-Speed
Powershift Transmission, Troubleshooting
and Repair 1300 SRM 501 for procedures to sep-
arate the engine from the transmission.
2. Remove the fan, coolant pump, and thermostat
housing. See the section starting with Thermo-
stat, Replace.
3. Remove the drive belt, alternator, and starter
motor. See the section starting with Drive Belt.
4. Remove the fuel filter, fuel injectors, fuel lines,
fuel pump, and electrical stop solenoid. See the
Cylinder Block Assembly Repair
6. Install the timing case assembly. See Timing
Case, Install.
1. ENGINE STUD 4. ENGINE STUD
2. BACKPLATE 5. CYLINDER BLOCK
3. GASKET 6. DOWEL PINS
Figure 74. Backplate Installation
Fuel System Repair section beginning with Fuel
Filter, Replace.
5. Remove the fuel injection pump. See Fuel Injec-
tion Pump, Remove.
6. Remove the glow plugs. See Glow Plugs, Re-
move.
7. Remove the cylinder head assembly. See Cylin-
der Head, Remove.
8. Remove the crankshaft pulley. See Crankshaft
Pulley, Remove.
9. Remove the timing case assembly and the tim-
ing gears. See the sections starting with Timing
Case.
10. Remove the backplate for the timing case assem-
bly. See Timing Case Backplate, Remove.
11. Remove the oil filter, the oil sump, the oil strainer
and suction pipe, the oil pump, and the relief
valve. See the sections starting with Oil Filter,
Replace.
12. Remove the pistons and connecting rod assem-
blies. See Piston and Connecting Rods.
39
Cylinder Block Assembly Repair
13. Remove the flywheel and the flywheel housing.
See the sections starting with Flywheel.
14. Remove the crankshaft and main bearings. See
Crankshaft, Remove.
15. Remove the rear oil seal. See Rear Oil Seal.
16. Inspect the engine block for wear and damage.
See Inspect.
Inspect
1. Make sure all of the oil and coolant passages in
the engine block are clean.
2. Check the engine block for cracks and damage.
NOTE: The top face of the cylinder block cannot be
machined because the pistons will not fit.
3. Check the front bushing for the camshaft for
wear. If a new bushing must be installed, use a
puller to remove the old bushing. Make sure the
oil hole for the new bushing is away from the
engine when it is installed. Make sure the oil
hole is aligned with the passage in the cylinder
block when it is installed. See Figure 75. Use
a press to install a new bushing and align it in
position in the cylinder block.
1. OIL HOLES IN BUSHING
2. MEASUREMENT POINTS OF BUSHING
Figure 75. Engine Block Bushing Installation
4. After the bushing is installed, check the bushing
diameter in six places as shown in Figure 75.
5. Check the condition of the cylinder bores. See
Cylinder Bore, Check.
40
600 SRM 706
Cylinder Bore, Check
1. Check the cylinder bores for wear and damage.
Check the bores at the top, the center, and the
bottom. Check each area in two directions simi-
lar to the pattern shown in Figure 75. The wear
limit is 0.25 mm (0.010 in.).
CAUTION
If any one cylinder is bored oversize, all cylin-
ders must be bored oversize and new pistons
installed. Special training and equipment are
often needed to correctly machine the fin-
ish on the inner surface of a cylinder bore.
To make sure the engine conforms to emis-
sions standards, the bores must be diamond
honed, silicon carbide base honed, and carbide
plateau honed after the cylinders are bored.
Contact a Perkins distributor for additional
information.
2. If the bore is worn by more than 0.25 mm
(0.010 in.), the bore can be honed 0.5 mm
(0.020 in.) oversize.
3. If the cylinder bore has a very smooth finish
(glaze), the engine will use oil at a rapid rate
even though the cylinder bores are within spec-
ifications.
NOTE: If the glaze in a cylinder bore has been re-
moved, the following recommendations are for the
next 5 hours of engine operation:
• Do not operate the engine at full load.
• Do not operate the engine at high speed.
• Do not permit the engine to operate at idle speed
for long periods.
Assemble
1. Make sure all the parts are clean.
2. Remove the screw plugs from the cylinder block
and clean the threads. Apply a sealant to the
threads of the plugs and install them in the cylin-
der block.
3. Install the rear oil seal. See Rear Oil Seal.
4. Install the crankshaft and main bearings. See
Crankshaft, Install.
5. Install the flywheel and the flywheel housing.
See the sections starting with Flywheel.
600 SRM 706 Engine Timing

6. Install the pistons and connecting rod assem-
blies. See Piston and Connecting Rods.
7. Install the oil filter, the oil sump, the oil strainer
and suction pipe, the oil pump, and the relief
valve. See the sections starting with Oil Filter,
Replace.
14. Install the fuel filter, fuel injectors, fuel lines,
fuel pump, and electrical stop solenoid. See the
Fuel System Repair section beginning with Fuel
Filter, Replace.
15. Install the drive belt, alternator, and starter mo-
tor. See the section starting with Drive Belt.

8. Install the backplate for the timing case assem-
bly. See Timing Case Backplate, Install.
9. Install the timing case assembly and the tim-
ing gears. See the sections starting with Timing
Case.
10. Install the crankshaft pulley. See Crankshaft
Pulley, Install.
11. Install the cylinder head assembly. See Cylinder
Head, Install.
12. Install the glow plugs. See Glow Plugs, Install.
13. Install the fuel injection pump. See Fuel Injec-
tion Pump, Install.
16. Install the fan, coolant pump, and thermostat
housing. See the section starting with Thermo-
stat, Replace.
17. Install the engine in the lift truck. See the sec-
tion Frame 100 SRM 505 for procedures to in-
stall the engine. See the section Single-Speed
Powershift Transmission, Troubleshooting
and Repair 1300 SRM 501 for procedures to con-
nect the engine to the transmission.
18. Make sure all fluid levels are correct.
19. Run the engine until it reaches normal operating
temperature before stopping the engine.

Engine Timing
DESCRIPTION
The correct timing is important for this engine to
meet current emission standards. The correct timing
of the fuel injection pump operates at a static timing
very close to top dead center (TDC) on the compres-
sion stroke.

The timing gears are stamped with timing marks to

make sure they are installed correctly. When the
gears are installed correctly, the marked teeth of the
crankshaft, the camshaft, and the fuel pump gears
should be aligned with the idler gear as shown in
Figure 76. When the number one piston is at TDC
on the compression stroke, the marked teeth of the
idler gear will not necessarily be aligned in this po-
Figure 76. Timing Marks Alignment
sition because of the different speeds at which the
gears rotate. To adjust the timing of the fuel injection pump, a
shim is installed between the flange of the pump and
When the piston for number one cylinder is at TDC,
the flange on the cylinder block. See Figure 77. Six
the mark on the crankshaft pulley will be aligned
different size shims are available. The shims are
with the mark on the timing case.
coated with a sealant to prevent leaking. Do not add
The fuel injection pump is timed at TDC on the com- additional sealant to the shims. See Engine Specifi-
pression stroke of number one cylinder. cations for available sizes.

41
Engine Timing 600 SRM 706

1. TIMING SHIM 1. TIMING MARK ON CRANKSHAFT PULLEY

2. IDENTIFICATION PLATE ALIGNED TO TIMING MARK ON TIMING CASE

Figure 77. Zexel Fuel Injection Pump Figure 78. Timing Mark on Timing Case

When the timing for the fuel pump has been set, it 5. Release the tappet adjustment screw and remove
should not change. If either the fuel injection pump the front rocker lever. Tighten the fasteners of
camshaft or the cylinder block is replaced, the timing the rocker shaft pedestals.
must be checked.

If the fuel injection pump is removed and installed CAUTION

for any reason and the same size shim is installed,
the fuel injection timing should not change.
The part number and code letters for the fuel injec-
tion pump are shown on the identification plate. See
Figure 77.
SET TIMING OF NUMBER ONE PISTON TO
TOP DEAD CENTER (TDC)
When the valve spring is removed, ensure that
the collets do not fall into the holes for the push
rods.
6. Remove the valve spring and the cap from the
front valve with the valve spring compressor and
the adapter. See Figure 79. Allow the valve to be
held by the top of the piston.

WARNING
Wear eye protection while performing this
step.

1. Remove the valve cover. See Valve Cover, Re-

move.

2. Rotate the crankshaft clockwise until the push

rod for the inlet valve of the rear cylinder just
tightens. The piston for number one cylinder
will be near to TDC and the timing mark on the
crankshaft pulley should be near to the timing
mark on the timing case. See Figure 78.
1. VALVE SPRING COMPRESSOR
3. Remove the spring clip and the spacer from the 2. ADAPTER FOR VALVE SPRING COMPRESSOR
front of the rocker shaft.
Figure 79. Valve Spring and Cap Removal
4. Release the fasteners of the first two pedestals of
the rocker shaft.

42
600 SRM 706
7. Install a dial indicator on the cylinder head with
its plunger in contact with the top of the valve
stem. Make sure the indicator has a reading
on the gauge. See Figure 80. Slowly rotate the
crankshaft counterclockwise 45 degrees. Then,
rotate the crankshaft clockwise until the clock-
wise movement of the dial gauge pointer stops.
1. DIAL INDICATOR PLUNGER
Figure 80. Dial Indicator TDC Measurement
8. With the pointer in the maximum clockwise po-
sition, the piston for number one cylinder will be
at TDC on the compression stroke.
VALVE TIMING, CHECK
1. Check the valve tip clearances. Adjust the valves
if the valve tip clearances are not correct. See
Valve Clearance, Adjust.
2. Rotate the crankshaft clockwise from the front
until the valve is fully open. The piston for
number one cylinder is now on the compression
stroke.
3. Set the valve tip clearance for valve number one
to 0.59 mm (0.023 in.). For valve number and
location, see Figure 81.
4. Rotate the crankshaft clockwise from the front
until the push rod for valve number one just
tightens.
5. Check the mark on the crankshaft pulley. If the
mark on the crankshaft pulley is within ±2.5 de-
grees of the mark on the timing case, the valve
timing is correct. See Figure 78.
Engine Timing
Figure 81. Valve Number and Location in
Cylinder Head
NOTE: If the timing is more than 2.5 degrees out of
position, the timing gears are probably not correctly
installed.
NOTE: Use the formula below to find the measure-
ment on the pulley which is equal to 2.5 degrees.
(C × P)
360
Where:
C = the circumference of pulley
P = 2.5 degrees
6. Rotate the crankshaft clockwise until valve
number seven has just opened and valve number
eight has not closed completely. Set the valve tip
clearance of valves number one and number two
to 0.35 mm (0.014 in.).
7. Install the valve cover. See Valve Cover, Install.
FUEL PUMP TIMING CHECK
The method used to check the timing of the fuel in-
jection pump is spill timing.
1. Disconnect the battery.
2. Set the piston for the number one cylinder to
TDC on the compression stroke. See Set Timing
of Number One Piston to Top Dead Center (TDC).
3. With the dial gauge still in place, turn the
crankshaft counterclockwise until the dial gauge
pointer moves 5.08 mm (0.20 in.).
4. Remove the electrical stop solenoid. See Electri-
cal Stop Solenoid, Remove.
43
Engine Timing 600 SRM 706

5. Disconnect the input fuel line from the fuel injec-

tion pump. See Figure 82. CAUTION
DO NOT tighten the delivery valve assembly
unless all the components inside the body are
aligned. The fuel injection pump will be dam-
aged.

8. Install the delivery valve washer and the seat

back into the valve body.

9. Connect the delivery valve assembly to outlet

number one of the fuel injection pump.

10. Install a small fuel tank to the input of the fuel

injector pump. Make sure the fuel tank has a
shutoff valve and a capacity of approximately
0.75 liter (1.59 pt). Install the fuel tank approx-
imately 152 mm (6 in.) above the fuel injection
pump.
1. HIGH-PRESSURE FUEL LINE
2. NUMBER ONE OUTLET, FUEL INJECTION 11. Connect a curved fuel line to the output of the
PUMP delivery valve assembly. See Figure 84.
3. FUEL LINE, INPUT

Figure 82. Fuel Lines to Fuel Injection Pump

CAUTION
DO NOT turn the crankshaft when the deliv-
ery valve assembly is removed from the fuel in-
jection pump. The fuel injection pump will be
damaged.

6. Remove the delivery valve assembly from the

fuel injection pump.

7. Remove the location pin, the spring, and the de-

livery valve from the delivery valve assembly.
See Figure 83.
1. CURVED FUEL LINE
2. DIAL INDICATOR
3. FUEL LEVER IN MAXIMUM FUEL POSITION
4. FUEL INPUT TO FUEL INJECTOR PUMP

Figure 84. Fuel Line Connection to Delivery

Valve Assembly

NOTE: Put a container beneath the outlet of the fuel

line to collect the fuel that will spill during this pro-
cedure.
1. BODY 5. DELIVERY VALVE
2. LOCATION PIN WASHER 12. Add approximately 0.5 liter (1.1 pt) of clean fuel
3. SPRING 6. DELIVERY VALVE to the small fuel tank and open the valve.
4. DELIVERY VALVE SEAT
13. Make sure the fuel lever is held in the maximum
Figure 83. Delivery Valve Assembly fuel position.

44
600 SRM 706
14. Turn the crankshaft slowly in the clockwise di-
rection until the flow of fuel from the curved fuel
line is one drop every 7 to 10 seconds.
15. When the fuel flow is correct, note the reading on
the dial indictor. The dial indicator shows piston
displacement or static timing angles. See Engine
Specifications for correct data.
NOTE: If it is necessary to adjust the timing, remove
the fuel injection pump and install a shim of the cor-
rect thickness. See Fuel Injection Pump.
To retard the timing, install a thicker shim. To ad-
vance the timing, install a thinner shim. The tim-
ing changes approximately 1 degree for each 0.10 mm
(0.004 in.) of shim thickness.
16. If a new shim is installed to correct the timing,
repeat Step 13 through Step 15.
17. Remove the curved fuel line, the collection con-
tainer, and the small fuel tank.
18. Remove the delivery valve assembly from the
fuel pump.
19. Assemble the components of the delivery valve
assembly as shown in Figure 83.
CAUTION
DO NOT tighten the delivery valve assembly
unless all the components inside the body are
Lubrication System Repair
DESCRIPTION
The oil pump is turned by a gear on the crankshaft
through an idler gear. A relief valve on the outlet of
the oil pump controls the maximum oil pressure in
the lubrication system. The engine oil flows from the
oil pump through the oil filter to the main oil passage
in the cylinder block. The oil filter has a bypass that
permits oil flow directly to the main oil passage if the
oil filter becomes too dirty. The normal oil flow is
through the oil filter to the main oil passage in the
cylinder block.
Engine oil from the main oil passage flows to the
main bearings of the crankshaft and through the pas-
sages in the crankshaft to the rod bearings. The pis-
tons and cylinder bores are lubricated by splash and
oil mist.
Lubrication System Repair
aligned. The fuel injection pump will be dam-
aged.
20. Install the delivery valve assembly onto fuel out-
let number one of the fuel injection pump.
21. Tighten the delivery valve assembly to 43 N•m
(32 lbf ft).
22. Install the high-pressure fuel line to the delivery
valve assembly on the fuel injection pump and
tighten the union nut to 22 N•m (195 lbf in).
23. Install the low-pressure fuel line to the input of
the fuel injection pump. Tighten the banjo bolt
to 22 N•m (195 lbf in) and the nut to 12 N•m
(106 lbf in).
24. Remove the dial indicator.
25. Install the valve spring and cap, the rocker
lever, the washer, and the snap ring. Set the
valve clearance for the number one inlet valve to
0.35 mm (0.014 in.).
26. Install the valve cover. See Valve Cover, Install.
27. Install the electrical stop solenoid. See Electrical
Stop Solenoid, Install.
28. Connect the battery and start the engine. Check
for fuel and oil leaks.
Engine oil also flows from the main bearings to
the journals of the camshaft. Some engine oil goes
through the center camshaft bearing to the rocker
arm assembly.
The hub of the idler gear has an oil passage to the
main oil passage. The oil flow through the hub lubri-
cates the timing gears.
OIL FILTER, REPLACE
CAUTION
DO NOT overfill the sump with oil. The engine
will be damaged if it is operated with too much
oil in the sump.
1. Change the oil filter when the engine oil is
changed.
45
Lubrication System Repair 600 SRM 706

2. Put a drain pan under the filter. OIL SUMP

3. Remove the filter cartridge. Make sure the adap- Remove
tor stays in the cylinder block as shown in Fig-
ure 85. Discard the filter cartridge. 1. Drain the engine oil.

2. Remove the capscrews and the two nuts that fas-

ten the oil sump to the engine block and the tim-
ing case.

3. Lower the oil sump.

4. Clean the oil sump with mineral oil solvent.

5. If the suction line and oil strainer must be re-

moved, see Figure 86. Remove the capscrew that
holds the bracket to the cylinder block.

1. OIL STRAINER 4. CAPSCREW

1. OIL FILTER ADAPTER 2. OIL SUCTION LINE 5. O-RING
2. OIL FILTER GASKET 3. MOUNTING 6. GROOVE FOR
BRACKET O-RING
Figure 85. Oil Filter
Figure 86. Oil Strainer and Suction Line
4. Clean the face of the cylinder block.
6. Remove the suction line and screen.
5. Add some clean engine oil to the new filter car-
7. Remove the O-ring from the groove in the cylin-
tridge. Apply clean engine oil to the gasket.
der block.
Turn the filter onto the adapter until the gasket
touches the cylinder block. Tighten the filter 8. Clean and inspect all components. Replace if nec-
cartridge 1/2 to 3/4 turn. essary.
6. When new oil has been added and the engine can Install
be operated, start the engine. Check the area
around the filter for leaks. 1. If the oil strainer and suction line were removed,
install a new O-ring in the O-ring groove in the
7. Run the engine for 15 minutes and check the oil cylinder block.
level. Add oil as necessary.
2. Lubricate the O-ring with engine oil and install
the suction line.

46
600 SRM 706 Lubrication System Repair

3. Make sure that the suction line is aligned cor-

rectly and install the mounting bracket and cap-
screw.

4. Tighten the capscrew that holds the bracket to

the cylinder block to 22 N•m (195 lbf in).

5. Put a bead of silicon adhesive along the flange of

the oil sump and install the sump.

6. Use capscrews on each side of the oil sump to

align and hold the sump in position during as-
sembly. Install the remainder of the capscrews
and the two nuts. Tighten all of the fasteners to
22 N•m (195 lbf in).

7. Install the drain plug in the oil sump. Use a Figure 87. Outer Rotor Clearance Check
new O-ring and tighten the drain plug to 34 N•m
(25 lbf ft).

OIL PUMP
Remove
1. Remove the timing case. See Timing Case, Re-
move.

2. Remove the three capscrews that fasten the oil

pump to the timing case.

3. Clean the face of the timing case and the face of

the oil pump.

Inspect Figure 88. Inner Rotor Clearance Check

If the oil pump is worn so that the performance is
decreased, the oil pump must be replaced.

1. Remove the oil pump from the timing case. See

Oil Pump, Remove.

2. Remove the outer rotor and clean all of the parts.

Check for damage and wear.

3. Install the outer rotor and check the clearances.

See Figure 87. See Engine Specifications for the
wear tolerances.

4. Check the clearances of the inner rotor. See Fig-

ure 88. See Engine Specifications for the wear
tolerances.
Figure 89. Rotor End Clearance Check
5. Check end clearance and axial movement of the
rotor. Use a spacer gauge and a straight edge. 6. When the parts are clean and inspected, install
See Figure 89. See Engine Specifications for the the cover to the oil pump. Tighten the capscrews
wear tolerances. to 28 N•m (249 lbf in).

47
Lubrication System Repair 600 SRM 706

Install Disassemble
1. Make sure that the faces of the oil pump and the 1. Apply pressure to the end of the plunger. See
timing case are clean. Figure 91.

2. Align the two dowels on the oil pump with the

holes in the timing case. Install the oil pump.

3. Tighten the three capscrews to 22 N•m

(195 lbf in).

4. Install the timing case. See Timing Case, Install.

RELIEF VALVE
Remove
1. SNAP RING 4. RELIEF VALVE
The relief valve is installed in the timing case. 2. PLUNGER BODY
3. SPRING 5. O-RING

CAUTION Figure 91. Relief Valve Assembly

The relief valve has a compressed spring. Do
not permit the spring to be released so that it
causes an injury.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
1. Drain the engine oil.
2. Remove the timing case. See Timing Case, Re-
move.
3. Remove the relief valve from the timing case and
discard the O-ring. See Figure 90.
2. Remove and discard the snap ring.
3. Release the pressure on the plunger and remove
the plunger and spring from the relief valve.
4. Remove and discard the O-ring if it is still in
place on the relief valve body.
Inspect
1. Clean the relief valve parts. Check the parts for
wear and damage.
2. Check that the seat of the plunger is not damaged
and the plunger moves easily in its bore.
3. Check the spring compression. See for compres-
sion data.

Assemble
1. Lubricate all parts with engine oil during assem-
bly.

2. Install the spring and the plunger into the body

of the relief valve.

3. Compress the spring and plunger into the bore

and install a new snap ring.

4. Install a new O-ring.

Install
1. TIMING CASE 3. O-RING
2. RELIEF VALVE 1. Make sure that a new O-ring has been installed
on the body of the relief valve.
Figure 90. Relief Valve Removal

48
600 SRM 706
2. Install the relief valve into the timing case.
Fuel System Repair
DESCRIPTION
NOTE: Special tools and training are needed to repair
the Zexel fuel injection pumps. They are normally
sent to an authorized repair station if repairs are nec-
essary. Fuel injectors also require special equipment
and training for repair. Most users have a special re-
pair service do this work.
A Zexel PFR cassette-type fuel injection pump is used
on these engines. The fuel injection pump is installed
directly into the cylinder block. See Figure 92.
1. TIMING SHIM
2. IDENTIFICATION PLATE
Figure 92. Zexel Fuel Injection Pump
The governor weight assembly, which controls engine
speed, is installed on the front of the gear for the fuel
injection pump camshaft. The timing case assembly
contains the linkage that operates the fuel injection
pump.
To assist cold starts, the fuel injection pump returns
automatically to the maximum fuel position when
the engine stops.
The single-stage fuel injector has a threaded body
and installs directly into the cylinder head.
The fuel injectors receive fuel under high pressure
from the fuel injection pump. The fuel injectors are
Fuel System Repair
3. Tighten the relief valve to 20 N•m (178 lbf in).
set by the manufacturer, but must be checked ac-
cording to the maintenance schedules. See Periodic
Maintenance Periodic Maintenance 8000 SRM
707. The operation pressure of a fuel injector can
be changed by adding or removing shims above the
spring in the fuel injector.
The fuel pump has a diaphragm that is actuated by a
lever. The lever is actuated by a lobe on the camshaft.
The fuel pump has a small lever that can be operated
with your hand to prime the fuel pump.
NOTE: Good operation of the fuel injection system re-
quires clean fuel, and no dirt can be permitted in the
system. Always clean carefully around a connection
before it is disconnected. Install covers on open ports
during maintenance. When the fuel system is opened
for maintenance, the air must be removed from the
fuel system before the engine is operated.
FUEL FILTER, REPLACE
The fuel filter is a separate element type that is in-
stalled between the filter head and a bottom cover.
The filter head is installed on the right, rear side of
the cylinder block.
CAUTION
Disposal of diesel fuel and filter must meet lo-
cal environmental regulations.
1. Clean the outside of the fuel filter assembly.
2. Remove the filter element. See Figure 93.
3. Clean the filter head.
4. Replace the upper and lower seals. Replace the
O-ring.
5. Lubricate the seals of the new filter element with
clean fuel. Install the filter element in the filter
head and tighten only with your hand.
6. Remove the air from the fuel system. See Fuel
System Air Removal.
49
Fuel System Repair 600 SRM 706

2. Disconnect the high-pressure line at the inlet to

the fuel injector.

NOTE: Hold the outlet fitting from the fuel injection

pump with a wrench so that it does not turn while
the connection is loosened for the fuel line. Do not
bend the fuel line.

3. Disconnect the other end of the high-pressure

line from the fuel injection pump.

CAUTION
Loosen and tighten the fuel injector with the
body nut (Figure 94). Do not use the injector
nut, as this will split the fuel injector.

4. Remove the fuel injector from the cylinder head.

1. CAPSCREW 4. FILTER ELEMENT

2. UPPER SEAL 5. LOWER SEAL
3. O-RING 6. BOTTOM COVER

Figure 93. Fuel Filter

1. FLAME SHIELD 3. INJECTOR NUT
WASHER 4. BODY NUT
FUEL INJECTORS 2. FUEL INJECTOR 5. SEAT WASHER
BODY 6. THREAD SEALANT
Remove
Figure 94. Fuel Injector
WARNING 5. Remove the flame shield washer from the cylin-
Do not put your hands on fuel lines under pres- der head and discard.
sure. Diesel fuel can be injected into your body
by the hydraulic pressure. Inspect
The engine will run roughly if a fuel injector has a The inspection and repair of fuel injectors require
defect. To find which fuel injector has a defect, op- special tools and training. A special repair service
erate the engine at approximately 1000 rpm. Loosen normally makes repairs on injectors. Fuel injectors
and tighten the connection to the inlet of each fuel that have a malfunction will cause black smoke in
injector in a sequence. When the connection to the the exhaust, a decrease in engine power, and an in-
fuel injector with the malfunction is loosened, there crease in engine noise.
will not be a change in the engine speed.
Install
1. Disconnect the fuel return line from the fuel in-
jector. 1. Make sure the threads of the body nut and the
threads of the cylinder head are clean.

50
600 SRM 706 Fuel System Repair

CAUTION
Do not allow any thread sealant below the
threads of the nut.

2. Put a 2 mm (0.08 in.) bead of thread sealant

onto the first two threads of the nut. Make sure
there is no thread sealant on the body of the fuel
injector.

3. Insert a new flame shield washer into the cylin-

der head with the red identification mark toward
the top of the engine. Make sure the original
flame shield washer was removed from the cylin-
der head, or the fuel injector will not fit correctly.

4. Install a new seat washer onto the fuel injector. Figure 95. Fuel Pump Removal and
Make sure the original seat washer was removed, Installation
or the fuel injector will not fit correctly.

5. Install the fuel injector into the cylinder head.

Disassemble
1. Clean the outside surfaces of the fuel pump.
CAUTION
2. Make a mark across the flanges of the two halves
Do not move the nut after it has been tightened. of the fuel pump to make sure that it is assembled
The seal will be broken and there can be leaks again in the same position.
past the seat of the fuel injector.
3. Remove the screws and separate the two halves
6. Tighten the nut smoothly to 39 N•m (29 lbf ft). of the fuel pump. See Figure 96.
Remove any excess thread sealant.

7. Install the high-pressure fuel line. Tighten the

union nuts to 22 N•m (195 lbf in).

8. Use new seal washers and install the fuel return

line to the connection. Tighten the bolt on the
banjo fitting to 9 N•m (80 lbf in).

9. If the fuel system is empty, remove the air from

the fuel system. See Fuel System Air Removal.

10. When the engine can be operated, check for fuel

leaks.

FUEL PUMP
Remove
1. Disconnect the fuel lines to the fuel pump.

2. Remove the capscrews. Remove the fuel pump. 1. SEAT WASHER 6. LINK ARM
See Figure 95. If the lobe on the camshaft has 2. VALVE 7. DIAPHRAGM
3. DIAPHRAGM SPRING
moved the internal lever of the fuel pump to the ASSEMBLY 8. SEAT WASHER
highest point of its lift, the fuel pump can be dif- 4. STEM SEAL 9. VALVE
ficult to remove. The crankshaft must be rotated 5. SPRING SEAT
one revolution to move the lobe on the camshaft. WASHER

Figure 96. Fuel Pump Disassembly

51
Fuel System Repair
4. Turn the diaphragm assembly 90 degrees to re-
lease the pull rod from the link arm and remove
the diaphragm assembly.
5. Remove the stem seal, the spring seat washer,
and the diaphragm spring from the pull rod. The
diaphragm and pull rod assembly must be re-
placed as a unit.
6. The valves are held in their seats by punchmarks
in the metal. The metal must be made smooth so
valves can be removed.
7. Check the fuel pump components for wear and
damage. If components other than the valves
and the diaphragm are worn, replace the fuel
pump.
Assemble
1. Install new seat washers.
2. Push new valves into position. The valves are
the same, but they are installed in the opposite
directions from each other. To make sure that
the valves are installed in the correct position,
see Figure 96.
3. When the valves are correctly installed, use a
punch on the edge of the valve housings to hold
the valves in position. Use the punch in six
places around each valve to hold the valve in
position.
4. Install the diaphragm spring into its position un-
der the diaphragm assembly.
5. Put the spring seat washer and the new stem
seal into position on the pull rod. Make sure the
small diameter at the top of the stem seal is on
the round part of the pull rod.
6. Put the diaphragm assembly into position over
the lower half of the body of the fuel pump. Align
the blade of the pull rod with the slot in the link
arm. Press down lightly on the diaphragm until
the notch in the pull rod is in the slot in the link
arm. Then, turn the diaphragm 90 degrees in ei-
ther direction. This action will engage and retain
the pull rod in the slot of the link arm.
7. Push the rocker arm toward the body of the
fuel pump until the diaphragm is level with
the flange half. Install the top half of the body
52
600 SRM 706
in position. Align the reference marks. Keep
the pressure on the rocker arm and install the
lockwashers and screws.
8. Tighten the screws evenly around the circumfer-
ence of the fuel pump.
Install
1. The lobe on the camshaft must be in the min-
imum lift position before the fuel pump is in-
stalled. See Figure 95.
2. Use a new gasket and install the fuel pump on
the engine block.
3. Install the lock plates and capscrews. Tighten
the capscrews to 22 N•m (195 lbf in).
4. Connect the fuel lines to the fuel pump.
5. Loosen the vent plug on the side of the fuel injec-
tor pump. See Figure 102.
6. Operate the priming lever on the fuel pump un-
til fuel, without air bubbles, comes from the loos-
ened vent plug. See Figure 102.
7. When the engine can be operated again, check for
leaks.
Test
1. Disconnect the fuel line from the outlet of the fuel
pump.
2. Install a 0 to 70 kPa (0 to 10 psi) pressure gauge
to the outlet of the fuel pump.
3. Loosen the connection at the gauge and operate
the priming lever on the fuel pump to remove
air from the fuel pump and the connection to the
pressure gauge. Then, tighten the connection.
4. Use the starter motor to operate the engine for
10 seconds. See the maximum pressure indicated
on the pressure gauge. If the pressure is less
than 42 kPa (6 psi), repair or replace the fuel
pump. Also, check the rate at which the pressure
reduces to half of the maximum pressure. If the
rate is less than 30 seconds to reduce to half of
the maximum pressure, repair or replace the fuel
pump.
600 SRM 706 Fuel System Repair

5. Remove the pressure gauge from the fuel pump. Install

6. Connect the fuel line to the outlet of the fuel 1. Install the water separator assembly on the en-
pump again. gine.

7. Loosen the vent plug on the side of the fuel injec- 2. Connect the fuel inlet and outlet lines to the wa-
tor pump. See Figure 102. ter separator.

8. Operate the priming lever on the fuel pump un- 3. Connect the water separator sensor to the water
til fuel, without air bubbles, comes from the loos- separator.
ened connection bolt. See Figure 102.
4. Disconnect the battery.
9. When the engine can be operated again, check for
leaks.

WATER SEPARATOR
Remove
1. Disconnect the battery.

2. Remove the drain plug. Drain all fuel and water

from the water separator into an approved con-
tainer. See Figure 97.

3. Disconnect the water separator sensor from the

water separator.

4. Disconnect the fuel inlet and outlet lines from

the water separator, and drain into an approved
container.

5. Remove the water separator assembly from the

engine.

Disassemble
1. Remove the capscrew and two washers from the
top of the water separator assembly.

2. Remove the filter holder from the filter head.

3. Remove the filter element from the filter holder.

Discard both the upper and lower seals.

Assemble
1. Coat the lower seal with diesel fuel and install 1. CAPSCREW 7. FILTER HOLDER
2. WASHER 8. WASHER
into the filter holder. Install the filter element 3. FILTER HEAD 9. WATER SENSOR
into the filter holder. Coat the upper seal with 4. TOP SEAL 10. DRAIN PLUG
diesel fuel and install onto the filter element. 5. FILTER ELEMENT 11. WASHER
6. BOTTOM SEAL
2. Install the filter holder onto the filter head by
installing two washers and the capscrew into the Figure 97. Water Separator
top of the water separator assembly.

53
Fuel System Repair
FUEL INJECTION PUMP
Remove
1. Disconnect the battery.
2. Set the number 1 piston to TDC on the compres-
sion stroke. See Set Timing of Number One Pis-
ton to Top Dead Center (TDC).
CAUTION
Use a second wrench to prevent movement of
the union nuts when the fuel lines are discon-
nected.
3. Disconnect all of the fuel lines from the fuel in-
jection pump.
4. Disconnect the electrical stop solenoid.
5. Disconnect the throttle cable.
6. Remove the blanking plate to provide access to
the rack on the fuel injector pump. See Figure 98.
Note the position of the capscrews. They are dif-
ferent lengths on some engines.
1. BLANKING PLATE
Figure 98. Blanking Plate, Fuel Injection
Pump
CAUTION
When removing the springs from the fuel injec-
tion pump rack, make sure the springs do not
fall inside the engine block.
7. Remove the springs from the grooved peg on the
fuel injection pump rack. See Figure 99.
54
600 SRM 706
1. SPRING 5. GOVERNOR LINK
2. GROOVED PEG 6. CAPSCREW
3. SPRING 7. NUT
4. PIN
Figure 99. Fuel Injector Pump Removal
8. Remove the governor control link from the
grooved peg on the rack.
9. Remove the four capscrews and two nuts from
the fuel injection pump. Lift the fuel injection
pump out of the cylinder block.
Install
1. Clean the surface of the fuel injection pump and
the cylinder block.
NOTE: The shims are coated with a sealant to pre-
vent leaking. Do not add additional sealant to the
shims. See Engine Specifications for available sizes.
2. Install a new shim on the cylinder block. Make
sure the notch in the shim is aligned with the
notch in the cylinder block. See Figure 100.
3. Align the grooved peg on the fuel injection pump
with the notch in the cylinder block and install
the fuel injection pump. Make sure the governor
link is not damaged.
4. Install the nuts and capscrews. Tighten the nuts
and capscrews to 22 N•m (195 lbf in).
5. Connect the governor link to the grooved peg on
the fuel injector pump. See Figure 99.
6. Connect the spring to the grooved peg on the fuel
injection pump. Make sure the spring is installed
before the spring.
600 SRM 706 Fuel System Repair

13. When the engine can be operated, check for

leaks.

1. SHIM
2. GROOVED PEG
3. ALIGNMENT NOTCH
4. ALIGNMENT DOWELS
1. SHIM 3. ALIGNMENT
Figure 100. Fuel Injector Pump Installation 2. GROOVED PEG NOTCH

7. Connect the spring to the grooved peg on the fuel
injection pump. Make sure the spring is installed
after the spring.
8. Clean the surface of the cylinder block where the
blanking plate fits. Install the blanking plate
with a new gasket onto the side of the cylinder
block. See Figure 98.
9. Install the electrical stop solenoid. See Electrical
Stop Solenoid, Install.
Figure 101. Fuel Injector Pump, High-Pressure
Fuel Lines
FUEL SYSTEM AIR REMOVAL
Small amounts of air will be removed from the fuel
injection pump automatically when the engine is in
operation. If the fuel lines have been disconnected,
the fuel filter has been replaced, or the engine has
run out of fuel, air must be removed from the fuel
system.

CAUTION
Use a second wrench to prevent movement of
the union nuts when the fuel lines are con-
nected. Do not tighten the union nuts greater
than 22 N•m (195 lbf in). If there is a leak, make
sure the fuel line is correctly aligned. A union
nut that is too tight can cause a restriction in
the fuel line.
CAUTION
Damage to the fuel injection pump, starter mo-
tor, and battery can occur if the starter motor
is used to remove air from an empty fuel sys-
tem.
1. Loosen the vent plug on the side of the fuel injec-
tion pump. See Figure 102.

10. Install the high-pressure fuel lines. Tighten the
nuts to 22 N•m (195 lbf in). See Figure 101.
11. Connect the fuel lines between the fuel injection
pump and the fuel filter. Tighten the nuts to
20 N•m (177 lbf in). See Figure 101.
2. Operate the priming lever on the fuel pump until
fuel, without air bubbles, comes from the vent
plug.
3. Tighten the vent plug. Clean up the excess fuel
that came from the vent plug.

12. Remove the air from the fuel system. See Fuel 4. Start the engine.
System Air Removal.

55
Fuel System Repair
1. VENT PLUG
2. PRIMING LEVER, FUEL PLUG
Figure 102. Fuel System Air Removal
NOTE: If there is still a small amount of air in the
fuel system, the engine sometimes runs correctly for
a short time and then stops. If a second attempt to
start the engine causes the engine to run correctly for
a short time and then stop, or run roughly, check for
air in the fuel system. Make sure you check for leaks
in the low-pressure (suction) part of the fuel system.
5. After the engine starts, operate the engine at idle
speed for 5 minutes to make sure all of the air is
removed from the fuel system.
GOVERNOR WEIGHT ASSEMBLY
Remove
The governor weight assembly is mounted in the
front of the gear for the fuel injection pump camshaft.
1. Remove the timing case assembly. See Timing
Case, Remove.
56
600 SRM 706
2. Remove the thrust sleeve from the front of the
governor weight assembly. See Figure 103.
1. CAPSCREWS 4. WEIGHT
2. THRUST SLEEVE ASSEMBLY
3. RECESS FOR 5. WEIGHT (4)
THRUST SLEEVE
Figure 103. Governor Weight Assembly Removal
3. Remove the capscrews and remove the weight as-
sembly from the gear.
4. Inspect the components for wear or damage. Re-
place worn or damaged parts.
Install
1. Install the weight assembly into the front of the
gear for the fuel injection pump.
2. Install the four capscrews in the weight assem-
bly.
3. Tighten the capscrews to 7 N•m (62 lbf in).
4. Lubricate the shaft for the thrust sleeve with en-
gine oil and install the thrust sleeve. Make sure
the flange on the thrust sleeve fits into the recess
on the weights.
5. Move the thrust sleeve back and forth on the
shaft to make sure the weights operate correctly.
ENGINE SPEED CONTROL ASSEMBLY
Remove
1. Remove the timing case assembly. See Timing
Case, Remove.
600 SRM 706
2. Remove the nut, the spring washer, and the plain
washer from the shaft (parts not shown).
NOTE: If the shaft and the spring are not being re-
placed, do not separate them.
3. Remove the lever and spring from the shaft. See
Figure 104.
1. LEVER 4. SHAFT
2. BUSHING 5. SPRING
3. FLAT FACE
Figure 104. Engine Speed Control Disassembly
CAUTION
The bushing is permanently installed in the
timing case. Do not try to remove it, or the
timing case will be damaged.
4. From the opposite side of the timing case, remove
the lever from the bushing. See Figure 105.
5. Inspect the components for wear or damage.
Replace
1. Remove the nut from the lever.
2. Remove the lever and the O-rings from the shaft.
Discard the O-rings.
3. Inspect the components and replace as necessary.
4. Install new O-rings and put the lever on the
shaft. Make sure the lever is lined up with the
Woodruff key.
Fuel System Repair
5. Put the nut on the lever and tighten to 45 N•m
(33 lbf ft). Make sure the slot on the lever is
clean.
1. SHAFT 3. BUSHING
2. O-RINGS 4. LEVER
Figure 105. Engine Speed Control Assembly
Install
1. Clean and lubricate the shaft and the O-rings
with a small amount of grease.
2. Insert the lever assembly through the bushing in
the timing case. See Figure 105.
3. Make sure both ends of the spring are attached
to the levers. See Figure 104.
4. Install the lever, with the spring, onto the flat
face of the shaft.
CAUTION
Make sure the Loctite™ does not get into the
bushing in the timing case.
5. Put a small amount of Loctite™ 243 on the
threads of the shaft.
6. Install the plain washer, the spring washer, and
the nut on the shaft.
7. Tighten the nut to 10.5 N•m (93 lbf in).
57
Fuel System Repair 600 SRM 706

FUEL INJECTION PUMP LINKAGE

Remove

CAUTION
When the fuel injection pump linkage is re-
moved or replaced, the maximum fuel setting
can be affected.

1. Remove the timing case assembly. See Timing

Case, Remove.

2. Remove the nut, the spring washer, and the plain

washer from the shaft shown in Figure 104 (parts
not shown).
1. OUTER SHAFT 4. FUEL CONTROL
3. Remove the brass plug from the side of the timing 2. INNER SHAFT LEVER
case. See Figure 106. 3. GOVERNOR 5. SPRING CLIP
CONTROL LEVER

Figure 107. Fuel Injection Pump Linkage

Removal

1. BRASS PLUG

Figure 106. Brass Plug Removal From Timing

Case
4. Remove the spring clips. Remove the shafts. Re-
move the governor control lever and the fuel con-
trol lever. See Figure 107.
1. ANGLEICH (TORQUE CONTROL) UNIT
2. ARM
3. SPRING, ANGLEICH UNIT
Figure 108. Fuel Control Lever Replacement

5. Inspect the components for wear or damage and 3. Inspect the components for wear or damage and
replace if necessary. replace if necessary.

Fuel Control Lever, Replace CAUTION

1. Disconnect the spring on the fuel control lever Make sure the Loctite™ does not get into the
from the pegs on each end of the spring. groove on the shaft of the Angleich unit.

2. Carefully remove the spring from the Angleich 4. Put a small amount of Loctite™ 243 on the first
(torque control) unit and remove the Angleich two threads of the Angleich unit (Figure 109)
unit. See Figure 108. and install the Angleich unit into the fuel con-
trol lever.

58
600 SRM 706 Fuel System Repair

5. Install the small spring onto the link. Make sure

the large hook is farthest from the governor con-
trol lever as shown in Figure 110.

6. Put the large spring on the link.

7. Compress the large spring. Hold the link against

NOTE: LOCTITE ON THE FIRST TWO THREADS
ONLY.
Figure 109. Angleich (Torque Control) Unit
5. Tighten the Angleich unit to 18 N•m (159 lbf in).
6. Put the spring over the shaft of the Angleich unit.
Make sure the closed coils of the spring are facing
toward the arm.
the outside of the governor control lever and in-
sert the pin.
8. Put the snap ring on the pin. Rotate the snap
ring to make sure the snap ring is seated in the
groove.
Install
1. Clean and lubricate the inner and outer shafts
with engine oil.

7. Install the other spring onto the pegs of the arm
and lever.
Governor Control Lever, Replace
1. Remove the snap ring from the end of the pin in
the governor control lever. See Figure 110.
2. Install the inner shaft first, then install the outer
shaft. Place the fuel control lever in position in
the timing case. Push the shafts through the tim-
ing case until the inner shaft just enters the fuel
control lever. See Figure 111.

1. INNER SHAFT
2. OUTER SHAFT
3. LEVER, FUEL INJECTION PUMP LINKAGE
1. LINK 4. PIN
2. SNAP RING 5. LARGE SPRING Figure 111. Fuel Injection Pump Linkage
3. GOVERNOR 6. SMALL SPRING Shafts Installation
CONTROL LEVER
3. Align the holes in the end of the governor con-
Figure 110. Governor Control Lever trol lever with the holes in the fuel control lever.
Replacement Push the shafts through the holes in both the
governor control lever and the fuel control lever
2. Compress the large spring and remove the pin until the inner shaft is seated in the boss in the
from the lever. timing case. See Figure 112.
3. Remove both springs from the link arm.

4. Inspect the components for wear or damage and

replace if necessary.

59
Fuel System Repair
1. GOVERNOR 3. FUEL CONTROL
CONTROL LEVER LEVER
2. BOSS IN TIMING 4. SPRING CLIPS
CASE
Figure 112. Fuel Injection Pump Linkage
Installation
4. Install the spring clips in the inner shaft.
5. Install the brass plug with the sealing washer
into the timing case. See Figure 106. Tighten
the plug to 13 N•m (115 lbf in).
6. Move the levers in both directions to make sure
that movement is not restricted.
7. Make sure that both ends of the spring for the
engine speed control lever are connected. See
Figure 104.
8. Install the lever, with the spring, onto the flat
face of the shaft.
CAUTION
Make sure the Loctite™ does not get into the
bushing in the timing case.
9. Put a small amount of Loctite™ 243 on the
threads of the shaft.
10. Install the plain washer, the spring washer, and
the nut on the shaft.
11. Tighten the nut to 10.5 N•m (93 lbf in).
12. Operate the speed control lever to make sure the
movement of the lever is not restricted.
60
600 SRM 706
RECORD MAXIMUM FUEL POSITION
Record Maximum Fuel Position of Fuel
Rack
CAUTION
The maximum fuel setting can be affected
when the timing case is removed from the en-
gine. Before removing the timing case, record
the maximum fuel setting, the high-idle set-
ting, and the low-idle setting.
The maximum fuel position of the fuel lever (and fuel
control rack) is controlled by the adjustment screw on
the top of the timing case. The position of this screw
is set at the factory and under normal conditions of
operation, it must not be altered. If the timing case
and fuel pump linkage are removed or replaced, the
adjustment screw must be set to the correct maxi-
mum fuel setting.
1. Disconnect the return spring from the engine
speed control lever.
2. Remove the access plug from the timing case. See
Figure 113.
1. BORE IN TIMING CASE
2. LEVER CLAMP TOOL
3. ACCESS PLUG
Figure 113. Access Plug Removal for Lever
Clamp Tool
3. Remove the blanking plate to provide access to
the rack on the fuel injector pump. See Figure 98.
Note the position of the capscrews. They are dif-
ferent lengths on some engines.
600 SRM 706 Fuel System Repair

4. Insert the lever clamp tool into the access hole in 10. Install the rack setting tool to the flange for the
the timing case with the point of the tool pointing electrical stop solenoid. See Figure 115.
down. Make sure the end of the tool is past the
governor control lever. See Figure 114.

1. FACE OF FUEL INJECTION PUMP RACK

2. TIP OF RACK SETTING TOOL
1. LEVER CLAMP TOOL 3. RACK SETTING TOOL
2. END OF TOOL
3. GOVERNOR CONTROL LEVER Figure 115. Rack Setting Tool Installation
4. TOOL ADJUSTMENT KNOB
5. TOOL ROTATED 90
6. TOOL ENGAGING LEVER CAUTION
7. FUEL CONTROL LEVER Make sure the fuel injection pump rack is in
8. GOVERNOR CONTROL LEVER the maximum fuel position during the follow-
9. ANGLEICH UNIT
ing procedure.
Figure 114. Lever Clamp Installation in Timing
11. Push the lever clamp tool and the rack toward
Case
the rear of the engine to the maximum fuel posi-
5. Rotate the tool counterclockwise 90 degrees tion and hold it in position. See Figure 116.
to engage the governor control lever. See Fig-
ure 114.

6. Tighten the tool adjustment knob, by finger, to

compress the Angleich unit. Make sure the sides
of the tool do not touch the bore for the access
plug.

NOTE: To make sure the tool has compressed both

levers, move the tool backward and forward. The peg
on the rack should move with the tool if the tool is
correctly installed.

7. Remove the low-pressure fuel lines and the fuel

filter. See Fuel Filter, Replace.

8. Remove the electrical stop solenoid. See Electri-

1. ADJUSTMENT KNOB
cal Stop Solenoid, Remove. 2. FUEL INJECTION PUMP RACK
3. CLAMP TOOL
9. Clean the gasket material from the front of the 4. LOCK NUT
flange for the electrical stop solenoid.
Figure 116. Rack in Maximum Fuel Position

61
Fuel System Repair 600 SRM 706

NOTE: The maximum travel of the rack from one end

to the other is only 8 mm (0.315 in.).

12. While holding the rack in position, turn the ad-

justment knob on the end of the tool until the
tip of the tool just touches the end of the rack.
Tighten the nut on the tool to hold the tool in this
position.

13. Disconnect the governor link from the peg on

the fuel injection pump rack. See Fuel Injection
Pump, Remove.

14. Remove the capscrew on the maximum fuel

screw. Measure and record the position of the
maximum fuel screw, the high-idle screw, and
the low-idle screw. 1. ADJUSTMENT 4. LOCK NUT
SCREW 5. ADJUSTMENT
Set Adjustment Screw for Maximum Fuel 2. LEVEL CLAMP SCREW
TOOL 6. CAP NUT
Setting 3. SCREWDRIVER

Figure 117. Maximum Fuel Adjustment Screw

CAUTION
The maximum fuel setting can be affected
when the timing case is removed from the
engine. Before removing the timing case,
record the maximum fuel setting, the high-idle
setting, and the low-idle setting. See Record
Maximum Fuel Position of Fuel Rack.
Adjustment
7. Remove the lever clamp from the bore of the tim-
ing case.
8. Apply liquid gasket to the face of the access hole
in the timing case and install the access plug.

1. Make sure the lever clamp and the rack setting 9. Remove the rack setting tool from the electrical
tool are still installed correctly. Make sure the stop solenoid flange. Install the electrical stop
fuel injection pump rack and lever clamp tool are solenoid. See Electrical Stop Solenoid, Install.
in the maximum fuel position. See Record Maxi-
10. Install the low-pressure fuel lines and the fuel
mum Fuel Position of Fuel Rack.
filter. See Fuel Filter, Replace.
2. With the rack and tool in the maximum fuel po-
11. Make sure the governor link and the springs are
sition, turn the maximum fuel adjustment screw
installed correctly. Install the blanking plate,
until the tip of the tool just touches the fuel con-
with a new gasket, on the fuel injection pump.
trol lever inside the timing case. See Figure 117.
12. Connect the return spring to the engine speed
3. Use a screwdriver to hold the adjustment screw
control lever. See Engine Speed Control Assem-
in position and tighten the screw to 12 N•m
bly, Install.
(106 lbf in).
13. Remove the air from the fuel system. See Fuel
4. Make sure the rack and lever clamp tool are still
System Air Removal.
in the maximum fuel position.
14. Connect the fuel linkage cables and install the
5. Install the washer and capscrew on the maxi-
battery.
mum fuel setting screw and tighten to 12 N•m
(106 lbf in). 15. Start the engine and check for leakage.
6. Make sure the high-idle and low-idle speed ad- 16. Check both idle speed and maximum no-load
justment screws are set to the measurement speed.
recorded in Record Maximum Fuel Position of
Fuel Rack.

62
600 SRM 706 Cooling System Repair

17. If speed settings are correct, apply Loctite to the 3. Install the two capscrews and tighten them to
maximum fuel adjustment screw and the high- 9 N•m (80 lbf in).
idle screw.
4. Connect the electrical connector. See Figure 118.
ELECTRICAL STOP SOLENOID
Remove
NOTE: The electrical stop solenoid is installed in the
cylinder block at the rear of the fuel injection pump.

1. Disconnect the electrical connector. See Fig-

ure 118.

2. Remove the two capscrews and remove the elec-

trical stop solenoid.

3. Remove and discard the gasket. 1. ELECTRICAL 3. GASKET

CONNECTOR 4. CAPSCREWS
Install 2. ELECTRICAL STOP 5. CYLINDER BLOCK
SOLENOID
1. Clean the face of the cylinder block and the flange
of the electrical stop solenoid. Figure 118. Electrical Stop Solenoid
Replacement
2. Put a new gasket in position on the flange of the
electrical stop solenoid and install the electrical
stop solenoid in the cylinder block.

Cooling System Repair

DESCRIPTION
Coolant from the bottom of the radiator flows
through the centrifugal coolant pump, which is in-
stalled on the front of the timing case. The coolant
pump is gear driven from the gear for the fuel injec-
tion pump. The coolant goes from the coolant pump
through a passage in the timing case to the front of
the engine block.

THERMOSTAT, REPLACE
1. Drain the cooling system so the coolant level is
below the thermostat position.

2. Disconnect the top hose from the thermostat

1. HOSE CLAMP 4. THERMOSTAT
housing. See Figure 119. 2. CAPSCREWS 5. PIN
3. THERMOSTAT
3. Remove the capscrews and remove the thermo- HOUSING
stat housing.
Figure 119. Thermostat Replacement
4. Remove the thermostat.

63
Cooling System Repair 600 SRM 706

5. Make sure the surfaces for the thermostat in the

housing are clean. Install a new thermostat in
the housing. Make sure the pin is facing up. See
Figure 119.

6. Use a new gasket and install the thermostat

housing. Tighten the capscrews to 22 N•m
(195 lbf in).

7. Connect the top hose and fill the cooling system.

COOLANT PUMP
Remove
1. Drain the cooling system and disconnect the 1. SPACER 2. O-RING
hoses to the coolant pump. See Figure 120.
Figure 121. Coolant Pump Spacer Installation

3. Install the coolant pump on the cylinder block.

Tighten the four nuts to 22 N•m (195 lbf in).

4. Connect the hoses to the coolant pump and

tighten the hose clamps.

5. Put the pulley on the hub. Put the fan extension

on the pulley and install the fan. See Fan.

6. Install the drive belt. See Drive Belt.

FAN
Remove
1. Remove the four capscrews holding the fan to the
1. HOSE CLAMP 2. NUTS
coolant pump.
Figure 120. Coolant Pump Removal and
2. Remove the fan, fan extension, and pulley.
Installation

2. Remove the drive belt and fan. Install

3. Remove the fan extension and the fan pulley.
4. Remove the four nuts that hold the coolant pump
to the cylinder block. Remove the coolant pump
and spacer.
1. Clean the faces of the fan, fan extension, and pul-
ley.
2. Install the fan, fan extension, and pulley onto the
coolant pump.

3. Install the four capscrews and tighten them to

Install
22 N•m (195 lbf in).
1. Clean the faces of the cylinder block, spacer, and
4. Install the drive belt and adjust the tension. See
rear plate of the coolant pump.
Drive Belt.
2. Install a new O-ring on each side of the spacer
and install the spacer. See Figure 121.

64
600 SRM 706
Flywheel and Housing Repair
DESCRIPTION
The steel flywheel has a hardened steel starter ring.
The flywheel housing is made of cast iron.
FLYWHEEL
Remove
WARNING
The flywheel is very heavy. Use lift equipment
to handle this component during removal and
installation.
1. Remove two opposite capscrews from the fly-
wheel and temporarily install two studs to help
control the flywheel when the other capscrews
are removed.
2. Remove the other capscrews that fasten the fly-
wheel to the crankshaft. Remove the flywheel.
3. Check the flywheel and ring gear for damage.
See Ring Gear, Replace.
Install
1. Make sure the surfaces of the crankshaft and fly-
wheel are clean so that the two parts will fit to-
gether correctly.
2. Install the flywheel over the guide studs.
3. Apply Loctite 603 to the first three threads of the
capscrews. Install four capscrews.
4. Remove the two studs and install the remain-
der of the capscrews. Tighten the capscrews in
a cross pattern to 100 N•m (74 lbf ft).
5. Check the flywheel run-out with a dial indica-
tor. The run-out must be less than 0.30 mm
(0.012 in.) in total indicator reading.
6. Check the alignment of the flywheel face with
a dial indicator. The error in alignment must
not be more than 0.03 mm (0.001 in.) for every
25 mm (1.0 in.) of the flywheel radius from the
crankshaft axis to the dial indicator plunger.
NOTE: Keep the crankshaft pressed toward the front
to remove the effect of crankshaft end-float.
Flywheel and Housing Repair
RING GEAR, REPLACE
WARNING
Wear eye protection for this operation to pre-
vent eye injury from metal chips. You will be
using a hammer and chisel to break the ring
gear.
1. Before the ring gear is removed, make note of the
position of the chamfer on the teeth.
2. Use a hammer and chisel to break the ring gear.
Make sure you do not damage the flywheel.
3. The ring gear must be heated before it can be
installed on the flywheel. Use an oven that has a
temperature control. Make sure the ring gear is
not heated to more than 250 C (480 F).
4. Install the ring gear on the flywheel. Make sure
the chamfer on the teeth is in the direction noted
during removal.
FLYWHEEL HOUSING
Remove
WARNING
The flywheel housing is very heavy. Use lift
equipment to handle this component during re-
moval and installation.
1. Remove the starter. See Starter Motor, Remove.
2. Remove the flywheel. See Flywheel, Remove.
NOTE: It may be necessary to hit the flywheel hous-
ing with a soft-faced hammer to remove it from the
dowels.
3. Remove the eight capscrews holding the flywheel
housing to the cylinder block and remove the fly-
wheel housing.
Install
1. Clean the face of the cylinder block and the face
of the flywheel housing.
2. Install the housing onto the dowels and insert
the capscrews. Tighten the capscrews to 44 N•m
(32 lbf ft).
65
Electrical System Repair 600 SRM 706

3. Install the flywheel. See Flywheel, Install. 4. Install the starter. See Starter Motor, Install.

Electrical System Repair

DRIVE BELT
1. Check the drive belt for wear and damage. Re-
place if necessary.

2. A gauge is available that will indicate the tension

in the drive belt. Install the gauge at the center of
the longest length of the drive belt and measure
the tension. See Figure 122. The correct tension
is approximately 355 N (80 lbf).

1. FIXED CAPSCREW
2. MOVABLE CAPSCREW
3. PIVOT FASTENER

Figure 123. Drive Belt Tension Check and

Adjustment

ALTERNATOR
Figure 122. Drive Belt Tension Check Gauge Remove
NOTE: Many service people press on the drive belt 1. Disconnect the electrical connections.
with their thumb at the center of the longest length
of the drive belt and check the deflection. See
Figure 123. When the thumb pressure is 100 N CAUTION
(20 lbf), the correct deflection is approximately Do not loosen the capscrew shown in Fig-
13 mm (0.5 in.). ure 124. It can cause a coolant leak.

2. Loosen the pivot bolt on the lower part of the

CAUTION
Do not loosen the capscrew shown in Fig-
ure 123. It can cause a coolant leak.
3. Loosen the bolt on the adjustment link and the
pivot fasteners to adjust the tension of the drive
belt.
4. Move the alternator pulley against the drive belt
to adjust the tension. Tighten the adjustment
link and pivot fasteners.
The drive belt is removed from the engine by loos-
ening the tension and then removing it from the
pulleys.
alternator and the capscrew on the adjustment
arm. See Figure 124.
3. Move the alternator toward the engine to remove
the belt tension and remove the drive belt.
4. Remove the pivot bolt and the capscrew loosened
in Step 2. Note the position of all washers and
spacers so that they can be installed in the cor-
rect position.
5. Remove the alternator.

66
600 SRM 706 Electrical System Repair

Install
1. Install the starter motor in position on the fly-
wheel housing.

2. Install and tighten the capscrews.

3. Connect the cables to the starter motor.

4. Connect the battery.

GLOW PLUGS
Remove
NOTE: The glow plugs are installed in the cylinder
1. FIXED CAPSCREW head near the fuel injectors. There is one glow plug
2. MOVABLE CAPSCREW
3. PIVOT FASTENER for each cylinder.

Figure 124. Alternator Removal 1. Disconnect the battery.

2. Remove the nut from the glow plug terminal. See

Install Figure 125.
1. Put the alternator in position and insert the pivot
3. Remove the electrical connectors from the glow
bolt and the capscrew. Make sure all washers
plug.
and spacers are installed in the correct position.
Do not tighten the pivot bolt or the capscrew. 4. Remove the glow plug.
Make sure the alternator pulley is aligned to the
crankshaft pulley within ±24 mm (0.9 in.).

2. Install the drive belt and adjust the tension. See

Drive Belt.

3. Tighten the pivot bolt and the capscrew and

check the tension again.

4. Connect the electrical connections.

STARTER MOTOR
Remove
See the section Starter, Delco 2200 SRM 106 for
troubleshooting and repairs for the starter motor. 1. NUT
2. ELECTRICAL CONNECTOR
1. Disconnect the battery.
Figure 125. Electrical Connectors Removal
2. Disconnect the cables to the starter motor. From Glow Plugs
3. Remove the capscrews and remove the starter
motor.

67
Electrical System Repair 600 SRM 706

Continuity Check 8. Make sure the electrical connectors do not touch

any other engine components.
1. Disconnect the electrical connection to the glow
plug. 9. Connect the battery cable.

2. Connect one end of a device for checking continu- Install

ity to the glow plug terminal and the other end
to engine ground. If the glow plug does not show 1. Install the glow plugs into the cylinder head and
continuity, replace the glow plug. tighten to 17 N•m (150 lbf in).

3. After checking continuity on all glow plugs, con-
nect the electrical connectors to the glow plug ter-
minals.
Operation Check
2. Install the electrical connectors onto the glow
plug terminals. Install the connector with the
straight end toward the rear of the engine. Make
sure the connectors do not touch any other en-
gine component.

1. Disconnect the power supply cable. 3. Install the nuts onto the glow plug terminals and
tighten to 1.2 N•m (10.6 lbf in).
2. Disconnect the electrical connection to the glow
plug.

3. Connect an ammeter between the power supply

cable and the terminal of the glow plug.

4. Connect a voltmeter between the glow plug ter-

minal and engine ground.

5. Turn the ignition key to the R position (Fig-

ure 126) and check the readings of the ammeter
and the voltmeter. With 12 volts applied, there
should be an initial current reading on the am-
meter of 12.5 amps. The current should reduce
to 6.5 ±1 amps after 30 seconds.

NOTE: If the ammeter reading is low, replace the

glow plug. If the voltmeter does not show a reading, O. OFF S. START
check the battery and the cable. R. RUN

6. After all the glow plugs have been checked, re- Figure 126. Ignition Switch
move the ammeter and the voltmeter.

7. Install the electrical connections to the terminals

of the glow plugs.

68
600 SRM 706 Engine Specifications

Engine Specifications
CYLINDER HEAD ASSEMBLY Table 3. Valve Guides

Refer to the following tables, Figure 127, Figure 128, Inside diameter 7.027 to 7.052 mm
and Figure 129 for specifications of the Cylinder (0.2767 to 0.2776 in.)
Head Assembly.
Outside diameter 12.034 to 12.047 mm
Table 2. Cylinder Head (0.4738 to 0.4743 in.)
Interference fit of 0.007 to 0.047 mm
Angle of valve seat valve guide in cylinder (0.0003 to 0.0019 in.)
– Inlet 45 (90 included angle) head
– Exhaust 45 (90 included angle) Total length 45.2 to 45.7 mm
(1.78 to 1.80 in.)
Diameter of parent 12.000 to 12.027 mm
bore for valve guide (0.4724 to 0.4735 in.)
Leak test pressure 200 kPa (29 psi)
Head thickness 79.95 to 80.05 mm
(3.148 to 3.152 in.)
Minimum thickness of 79.8 mm (3.142 in.)
head in service
Maximum distortion of cylinder head. See
Figure 127.

Inlet Valve:
1 = Maximum Radius 0.38 mm (0.015 in.)
2 = 45 Chamfer
3 = 46.9 to 47.1 mm (1.846 to 1.854 in.)
4 = 43.325 to 43.350 mm (1.7057 to 1.7067 in.)
5 = 8.2 to 8.4 mm (0.32 to 0.33 in.)
Exhaust Valve:
1 = Maximum Radius 0.38 mm (0.015 in.)
1. = 0.08 mm (0.003 in.)
2 = 45 Chamfer
2. = 0.15 mm (0.006 in.)
3. = 0.15 mm (0.006 in.) 3 = 38.7 to 38.9 mm (1.52 to 1.53 in.)
4 = 35.125 to 35.150 mm (1.3829 to 1.3839 in.)
Figure 127. Cylinder Head Distortion Check 5 = 8.28 to 8.4 mm (0.326 to 0.331 in.)

Figure 128. Valve Seat Inserts Dimensions

69
Engine Specifications 600 SRM 706

Table 4. Inlet Valves (Continued)

Angle of valve face 45

Depth of valve head below face of cylinder head:
– Production limit 0.325 to 0.675 mm
(0.0128 to 0.0266 in.)
– Service limit 0.72 mm (0.028 in.)
Total length 106.275 to 106.625 mm
(4.184 to 4.198 in.)
Seal arrangement Rubber seal installed on
valve guide

Inlet Valve:
1 = 1.5 mm (0.06 in.) Table 5. Exhaust Valves
2 = 19.0 mm (0.7 in.)
3 = 6.1 mm (0.24 in.) Diameter, valve stem 6.945 to 6.960 mm
4 = 60.0 mm (2.4 in.) (0.2734 to 0.2740 in.)
5 = 37.15 to 37.22 mm (1.46 to 1.47 in.)
Clearance in valve 0.067 to 0.107 mm
6 = 42.75 to 43.25 mm (1.683 to 1.703 in.)
guide (0.0026 to 0.0042 in.)
7 = 0.8 mm (0.03 in.)
8 = 1.5 mm (0.06 in.) Maximum clearance in 0.15 mm (0.0059 in.)
9 = 1.5 mm (0.06 in.) valve guide
10 = 6.95 to 6.97 mm (0.2736 to 0.2744 in.)
Diameter, valve head 33.9 to 34.1 mm
Exhaust Valve: (1.33 to 1.34 in.)
1 = 1.5 mm (0.06 in.)
Angle of valve face 45
2 = 19.0 mm (0.7 in.)
3 = 6.1 mm (0.24 in.) Depth of valve head below face of cylinder head:
4 = 60.0 mm (2.4 in.)
To production limit 0.425 to 0.775 mm
5 = 28.95 to 29.02 mm (1.140 to 1.143 in.)
(0.0167 to 0.0305 in.)
6 = 35.08 to 35.10 mm (1.3811 to 1.3819 in.)
7 = 0.8 mm (0.031 in.) To service limit 0.72 mm (0.028 in.)
8 = 1.5 mm (0.06 in.) 106.275 to 106.475 mm
Total length
9 = 1.5 mm (0.06 in.) (4.1841 to 4.1919 in.)
10 = 6.95 to 6.97 mm (0.2736 to 0.2744 in.)
Seal arrangement Rubber seal installed on
Figure 129. Pilot Tool to Insert Valve Seats valve guide

Table 4. Inlet Valves Table 6. Single Valve Springs

Diameter, valve stem 6.970 to 6.985 mm Installed length 32.0 mm (1.26 in.)
(0.2744 to 0.2750 in.)
Load, installed length 375 to 415 N
Clearance in valve 0.042 to 0.082 mm (84.3 to 93.3 lbf)
guide (0.0017 to 0.0032 in.)
Active coils, number 3.9
Maximum clearance in 0.107 mm (0.0042 in.)
valve guide Direction of coils Left hand

Diameter, valve head 41.9 to 42.1 mm

(1.65 to 1.66 in.)

70
600 SRM 706 Engine Specifications

Table 7. Tappets Table 11. Piston Rings

Diameter, tappet stem 26.959 to 26.980 mm Top compression ring Barrel face, chromium
(1.0614 to 1.0622 in.)
Second compression Taper face, cast iron
Diameter, tappet bore 27.000 to 27.021 mm ring
in cylinder block (1.063 to 1.064 in.)
Oil ring Coil spring loaded,
Clearance of tappet in 0.020 to 0.062 mm chromium face
engine block (0.0008 to 0.0024 in.)
Width of top ring 1.97 to 1.99 mm
(0.0776 to 0.0783 in.)
Table 8. Rocker Arm Shaft Width of second ring 1.97 to 1.99 mm
(0.0776 to 0.0783 in.)
Outside diameter 21.962 to 21.987 mm
Width of third ring 3.97 to 3.99 mm
(0.8646 to 0.8656 in.)
(0.156 to 0.157 in.)
Clearance of top ring in 0.003 to 0.005 mm
Table 9. Rocker Arm groove (0.0001 to 0.0002 in.)
Clearance of second 0.07 to 0.11 mm
Bore diameter 22.013 to 22.051 mm
ring in groove (0.003 to 0.004 in.)
(0.8667 to 0.8682 in.)
Clearance of third ring 0.05 to 0.09 mm
Clearance between 0.026 to 0.084 mm
in groove (0.002 to 0.004 in.)
rocker arm and rocker (0.0010 to 0.0033 in.)
arm shaft Gap of top ring 0.20 to 0.48 mm
(0.008 to 0.019 in.)
Maximum clearance 0.124 mm (0.0049 in.)
(service) between Gap of second ring 0.30 to 0.63 mm
rocker arm and rocker (0.012 to 0.025 in.)
arm shaft Gap of third ring 0.20 to 0.48 mm
(0.008 to 0.019 in.)
PISTON AND CONNECTING RODS
Refer to the following tables and Figure 130 for spec- Table 12. Connecting Rods
ifications of the pistons and connecting rods.
Type "H" Section
Table 10. Pistons
Diameter, parent bore 50.000 to 56.015 mm
Type Flat top with recess for at big end (1.9685 to 2.2053 in.)
valves Diameter, parent bore 32.930 to 32.955 mm
Height of piston above 0.386 to 0.511 mm at small end (1.2965 to 1.2974 in.)
top face of engine block (0.0152 to 0.0201 in.) Length between 159.975 to 160.025 mm
Diameter, bore for 30.003 to 30.009 mm centers (6.2982 to 6.3002 in.)
piston pin (1.1812 to 1.1815 in.)
Width of groove for top 2.08 to 2.10 mm
ring (0.082 to 0.083 in.)
Width of groove for 2.06 to 2.08 mm
second ring (0.081 to 0.082 in.)
Width of groove for 4.04 to 4.06 mm
third ring (0.159 to 0.160 in.)

71
Engine Specifications 600 SRM 706

Table 15. Small End Bushings

Type Steel back, lead bronze

bearing material
Inside diameter 30.012 to 30.025 mm
(reamed) (1.1816 to 1.1821 in.)
Clearance between 0.008 to 0.023 mm
bushing and piston pin (0.00031 to 0.00091 in.)

CRANKSHAFT ASSEMBLY
Refer to the following tables for specifications of the
NOTE: THE LARGE AND SMALL BORES IN THE crankshaft assembly.
CONNECTING ROD MUST BE SQUARE AND PAR-
ALLEL WITH EACH OTHER WITHIN THE LIMITS OF Table 16. Crankshaft
±0.20 mm (0.007 in.). THE MEASUREMENT IS MADE
AT 130 mm (5.1 in.) ON EACH SIDE OF THE AXIS OF Diameter, main journal 64.951 to 64.970 mm
THE CONNECTING ROD. (2.5571 to 2.5579 in.)

Figure 130. Connecting Rod Alignment Check Maximum wear and 0.04 mm (0.0016 in.)
oval wear on journals
and crank pins
Table 13. Piston Pins
Width of front journal 32.80 to 34.20 mm
(1.29 to 1.35 in.)
Type Full floating
Width of number four 33.00 to 33.02 mm
Outside diameter 29.995 to 30.000 mm
journal (1.299 to 1.300 in.)
(1.1809 to 1.1811 in.)
Width of all other main 32.95 to 33.05 mm
Clearance fit in piston 0.003 to 0.014 mm
journals (1.297 to 1.301 in.)
(0.0001 to 0.0006 in.)
Diameter of crank 52.95 to 52.97 mm
journal (2.0847 to 2.0854 in.)
Table 14. Connecting Rod Bearings
Width of crank journals 30.05 to 32.95 mm
(1.183 to 1.297 in.)
Type Steel back, aluminum to
tin bearing material Diameter of flange 94.965 to 95.000 mm
(3.7388 to 3.7402 in.)
Width 22.87 to 23.13 mm
(0.900 to 0.911 in.) Axial movement 0.040 to 0.275 mm
(0.0016 to 0.0108 in.)
Thickness 1.500 to 1.506 mm
(0.0591 to 0.0593 in.) Maximum axial 0.405 mm (0.0159 in.)
movement (service)
Bearing clearance 0.018 to 0.064 mm
(0.0007 to 0.0025 in.) Fillet radii, all journals 3.3 to 3.7 mm
(0.13 to 0.15 in.)
Available undersize 0.25 mm ( 0.010 in.)
bearings Undersize journals, all 0.25 mm ( 0.010 in.)
0.51 mm ( 0.020 in.)
0.50 mm ( 0.020 in.)
0.76 mm ( 0.030 in.)
0.75 mm ( 0.030 in.)

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600 SRM 706 Engine Specifications

Crankshaft Heat Treatment Check the crankshaft for cracks before and after it
is machined (ground). Remove any magnetism after
The crankshaft is induction hardened. the crankshaft has been checked for cracks.

Crankshaft Overhaul
Induction-hardened crankshafts do not need to be
hardened after they have been machined undersize.
After the crankshaft has been machined, remove any
sharp edges from the oil holes for lubrication.
Surface finish and fillet radii must be according to
the specifications. The finished sizes for machined
crankshafts are shown in Table 17.

Table 17. Crankshaft Overhaul Specifications

Item Undersize
0.25 mm (0.010 in.) 0.51 mm (0.020 in.) 0.76 mm (0.030 in.)
1 64.70 to 64.72 mm 64.45 to 64.47 mm 64.20 to 64.22 mm
(2.547 to 2.548 in.) (2.537 to 2.538 in.) (2.5275 to 2.5283 in.)
2 52.70 to 52.72 mm 52.45 to 52.47 mm 52.20 to 52.22 mm
(2.075 to 2.076 in.) (2.065 to 2.066 in.) (2.055 to 2.056 in.)
3 32.95 to 33.05 mm (1.297 to 1.301 in.)
4 32.8 to 34.3 mm (1.29 to 1.35 in.)
5 33.00 to 33.04 mm (1.299 to 1.301 in.)
6 30.05 to 32.95 mm (1.183 to 1.297 in.)
7 94.965 to 95.000 mm (3.7388 to 3.7402 in.)
8 3.3 to 3.7 mm (0.13 to 0.15 in.)
Surface finish for all bearing journals, crank pins, and fillet radii must be 0.4 microns (16 micro inches).
Surface finish for the seal area of the crankshaft must be 0.4 to 1.1 microns (16 to 43 micro inches).

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Engine Specifications 600 SRM 706

Table 17. Crankshaft Overhaul Specifications (Continued)

When the crankshaft is on mounts at the front and rear main journals, the maximum variation (run-out)
(total indicator reading) at the other main journals cannot be greater than the following.
The "run-out" must not be opposite. The difference in run-out between one journal and the next one must
not be more than 0.10 mm (0.004 in.).
Journal 4-Cylinder Crankshafts
1 Mount
2 0.08 mm (0.003 in.)
3 0.15 mm (0.006 in.)
4 0.08 mm (0.003 in.)
5 Mount

Table 18. Main Bearings TIMING CASE AND GEAR ASSEMBLY

Type Steel back, 20% tin Refer to the following tables for specifications of the
to aluminum bearing timing case and gear assembly.
material
Table 20. Camshaft
Bearing width 25.70 to 26.00 mm
(1.01 to 1.02 in.) Diameter, journals 47.945 to 47.975 mm
(1.8876 to 1.8888 in.)
Bearing thickness 1.993 to 1.999 mm
(0.0785 to 0.0787 in.) Clearances:
Bearing clearance 0.032 to 0.092 mm Journal number one 0.025 to 0.155 mm
(0.0013 to 0.0036 in.) (0.0010 to 0.0060 in.)
Available undersize 0.25 mm ( 0.010 in.) Journals two to five 0.050 to 0.115 mm
bearings (0.0020 to 0.0050 in.)
0.50 mm ( 0.020 in.)
Cam lift:
0.75 mm ( 0.030 in.)
– Inlet 7.06 to 7.16 mm
(0.278 to 0.282 in.)
Table 19. Crankshaft Thrust Washers
– Exhaust 7.35 to 7.45 mm
(0.289 to 0.293 in.)
Type Steel back, lead bronze
bearing material Maximum out of round 0.05 mm (0.002 in.)
and wear on journals
Position Each side of the number
four main bearing Axial movement
Thickness: – Production limit 0.10 to 0.25 mm
(0.004 to 0.010 in.)
– Standard 2.38 to 2.44 mm
(0.0937 to 0.0961 in.) – Service limit 0.35 mm (0.014 in.)
– Oversize 2.58 to 2.64 mm
(0.102 to 0.104 in.)

74
600 SRM 706 Engine Specifications

Table 21. Camshaft Thrust Washer ENGINE BLOCK ASSEMBLY

Type 360 CAUTION

Thickness, thrust 2.30 to 2.40 mm Special training and equipment are needed to
washer (0.091 to 0.095 in.) correctly finish the internal bore of a cylinder
with a hone. Contact your nearest Perkins
dealer.
Table 22. Camshaft Gear
Refer to the following table for specifications of the
Number of teeth 60 engine block assembly.

Table 26. Engine Block

Table 23. Gear for Fuel Injection Pump
Height between top 360.95 to 361.05 mm
and bottom faces (14.211 to 14.215 in.)
Number of teeth 60
Diameter of bore for 69.000 to 69.019 mm
Axial movement 0.000 to 0.020 mm
main bearing (2.7165 to 2.7173 in.)
(0.0000 to 0.0008 in.)
Diameter, camshaft bore:
– No. 1 51.85 to 51.87 mm
Table 24. Crankshaft Gear
(2.041 to 2.042 in.)
Number of teeth 30 – No. 2, 3, 4, 5 48.025 to 48.50 mm
(1.8908 to 1.9095 in.)
Diameter, bore 31.936 to 31.961 mm
(1.2573 to 1.2583 in.) Diameter, cylinder bore 91.000 to 91.025 mm
(3.5827 to 3.5837 in.)
Diameter, hub for gear 31.979 to 32.000 mm
on crankshaft (1.2590 to 1.2600 in.) Maximum wear of bore 0.25 mm (0.010 in.)
Press fit of gear on 0.018 to 0.064 mm Diameter of oversize 91.35 to 91.42 mm
crankshaft ( 0.0008 to 0.0025 in.) cylinder bores (before (3.596 to 3.599 in.)
honing)
Surface finish RA 3.0 to 5.0
Table 25. Idler Gear and Hub

Number of teeth 59 TIMING DATA

Diameter of bore of 28.077 to 28.098 mm Refer to the following tables for specifications on tim-
bushings in gear (1.054 to 1.062 in.) ing data.
Diameter of hub 28.048 to 28.061 mm
Table 27. Fuel Injection Pump
installed in cylinder (1.1043 to 1.1048 in.)
block
Make Zexel PFR-KX in-line
Clearance of gear on 0.016 to 0.050 mm cassette
hub (0.0006 to 0.0020 in.)
Direction of rotation Clockwise from drive
Backlash for gears end
– Crankshaft to oil 0.76 mm (0.03 in.)
pump and idler gears minimum
– All other gears 0.05 mm (0.002 in.)
minimum

75
Engine Specifications 600 SRM 706

Table 28. Timing Data Table 31. Relief Valve (Continued)

Code Position Piston

Clearance of plunger in 0.018 to 0.048 mm
Letters Before Displacement
bore (0.007 to 0.0019 in.)
TDC
Length of spring, 25.5 mm (1.004 in.)
CJ 14 1.93 mm (0.100 in.)
installed
DJ 10 1.004 mm (0.040 in.)
Load on spring, 26.2 to 27.7 N
installed (5.9 to 6.2 lbf)
Table 29. Fuel Injection Pump Timing Shims Pressure to open valve 240 to 290 kPa
(34.8 to 42.1 psi)
Part Number Thickness
3621F011 0.1 mm (0.004 in.)
Table 32. Oil Filter
3621F012 0.2 mm (0.008 in.)
Type Full flow, canister
3621F013 0.3 mm (0.012 in.)
Pressure to open bypass 55 to 83 kPa
3621F014 0.4 mm (0.016 in.)
valve in oil filter (8 to 12 psi)
3621F015 0.5 mm (0.020 in.)
FUEL SYSTEM
LUBRICATION SYSTEM
Refer to the following tables for specifications of the
Refer to the following tables for specifications of the fuel system.
lubrication system.
Table 33. Fuel Injection Pump
Table 30. Oil Pump
Make Zexel PFR-KX in-line
Type Differential rotor, gear cassette
driven
Direction of rotation, Clockwise
Number of lobes Inner rotor 4, outer rotor (from drive end)
5
Pump code letters CJ, DJ
Maximum clearance 0.19 mm (0.007 in.)
of outer rotor to pump
body Table 34. Fuel Pump
Maximum clearance 0.25 mm (0.0010 in.)
Type Diaphragm
of inner rotor to outer
rotor Method of drive Eccentric on camshaft
Inner and outer rotor 0.15 mm (0.006 in.) Static pressure (no 42 to 70 kPa (6 to 10 psi)
end clearance delivery)
Test pressure (75% 31 kPa (4.5 psi)
of minimum static
Table 31. Relief Valve
pressure)
Diameter, bore for 11.000 to 11.018 mm
plunger (0.4331 to 0.4338 in.)
Outside diameter, 10.970 to 10.982 mm
plunger (0.4319 to 0.4324 in.)

76
600 SRM 706 Engine Specifications

Table 35. Fuel Injector Codes

Set Pressure 1 Reset Pressure 2

Code
atm psi MPa atm psi MPa
UB 122 1769 12.2 130 1915 13.2
1
Original fuel injectors
2
Repaired fuel injectors (fitted with new springs)

Table 36. Electrical Stop Solenoid Table 38. Thermostat (Continued)

Pull-in current 36.5 A – "Start to open" 67 to 75 C

Hold current 1A (152.6 to 167.0 F)
Voltage 12 V – "Fully open" 85 to 88 C
(185.0 to 190.4 F)
Cable color:
Valve lift, fully open 9.0 mm (0.35 in.)
– Pull-in current White
– Hold current Red ELECTRICAL EQUIPMENT
– Ground Black
Refer to the following tables for specifications of the
electrical equipment.
COOLING SYSTEM
Table 39. Alternator
Refer to the following tables for specifications of the
cooling system. Type Magnetti Marelli
A127-65
Table 37. Coolant Pump
Rating 12 V, 65 A
Type Centrifugal, belt drive

Table 40. Starter Motor

Table 38. Thermostat
Type Magnetti Marelli 2M113
Type, Engine AR Single, wax element Voltage 12 V
Nominal Temperature 82.0 C (179.6 F) Number of pinion teeth 10
(stamped on
thermostat) Maximum starter cable 0.0012 ohm
resistance at 20 C
– "Start to open" 77 to 85 C (68 F)
(170.6 to 185.0 F)
– "Fully open" 92 to 98 C
(197.6 to 208.4 F) Table 41. Glow Plugs
Nominal Temperature 71.0 C (159.8 F) Current 6.5 amperes after 30
(stamped on seconds
thermostat)

77
Torque Specifications 600 SRM 706

Torque Specifications
CYLINDER HEAD ASSEMBLY Capscrews, Timing Case to Timing Case
M8 22 N•m (195 lbf in)
Capscrews, Cylinder Head 1/2 UNF (Special
Procedure, see Cylinder Head, Install) Capscrews, Timing Case to Blanking Plate
M10 44 N•m (32 lbf ft)
Capscrews, Rocker Arm Brackets
M6 9 N•m (80 lbf in) LUBRICATION SYSTEM
Nuts, Rocker Arm Brackets Plug, Oil Sump
M8 22 N•m (195 lbf in) 3/4 UNF 34 N•m (25 lbf ft)
Cap Nuts, Valve Cover Capscrews, Oil Pump to Timing Case
M8 11 N•m (97 lbf in) M6 9 N•m (80 lbf in)
Capscrews, Inlet Manifold to Cylinder Head Capscrews, Oil Sump
M8 22 N•m (195 lbf in) M8 22 N•m (195 lbf in)
Nuts, Exhaust Manifold to Cylinder Head Relief Valve
M8 18 N•m (159 lbf in) M18 20 N•m (177 lbf in)
Capscrews, Engine Lift Brackets FUEL SYSTEM
M8 22 N•m (195 lbf in)
Nuts, High-Pressure Fuel Lines
PISTON AND CONNECTING ROD M12 22 N•m (195 lbf in)
ASSEMBLIES
Capscrews, Fuel Injector Clamps
Nuts, Connecting Rods M8 12 N•m (106 lbf in)
M9 54 N•m (40 lbf ft)
Fuel Injectors
CRANKSHAFT ASSEMBLY M20 39 N•m (29 lbf ft)

Capscrews, Main Bearings Nuts, Low-Pressure Fuel Lines

M14 147 mm (108 lbf ft) M12 20 N•m (177 lbf in)

Capscrews, Crankshaft Pulley to Crankshaft Capscrews, Fuel Pump to Engine Block

M16 185 mm (136 lbf ft) M8 22 N•m (195 lbf in)

TIMING CASE AND DRIVE ASSEMBLY Capscrews, Fuel Injection Pump to

Engine Block
Capscrews, Timing Case to Engine Block M8 22 N•m (195 lbf in)
M8 22 N•m (195 lbf in)
Nuts, Fuel Injection Pump to Engine Block
Capscrews, Timing Case to Engine Block M8 22 N•m (195 lbf in)
M10 44 N•m (32 lbf ft)
Screw, Fuel Drain
Capscrews, Retainer Plate - Camshaft M6 12 N•m (106 lbf in)
for Fuel Injection Pump
M6 9 N•m (80 lbf in) Nuts, Maximum Fuel Adjustment Screw
M8 14 N•m (124 lbf in)
Capscrew, Thrust Washer - Engine Camshaft
M6 9 N•m (80 lbf in) Angleich Unit
M16 18 N•m (159 lbf in)
Nuts, Timing Case to Blanking Plate
M8 22 N•m (195 lbf in) Governor Assembly to Camshaft Gear
M5 7 N•m (62 lbf in)

78
600 SRM 706 Special Tools

COOLING SYSTEM Capscrews, Air Breather

M6 9 N•m (80 lbf in)
Nuts and Screws, Coolant Pump to
Engine Block ELECTRICAL EQUIPMENT
M8 22 N•m (195 lbf in)
Nut, Alternator Pulley
Capscrews, Fan and Pulley to Hub M17 60 N•m (44 lbf ft)
M8 22 N•m (195 lbf in)
Bolt and Nut, Alternator to Timing Case
Capscrews, Fan and Pulley to Hub M10 24 N•m (212 lbf in)
M6 9 N•m (80 lbf in)
Capscrew, Adjusting Lever to Alternator
FLYWHEEL M8 12 N•m (106 lbf in)

Capscrews, Flywheel to Crankshaft Glow Plugs

M12 100 N•m (77 lbf ft) M10 17 N•m (150 lbf in)

VALVE COVER Glow Plug Connections

M4 1.5 N•m (13 lbf in)
Cap Nuts, Valve Cover
M8 11 N•m (987 lbf in)
M6 9 N•m (80 lbf in)

Special Tools
Tool Number Description
PD.1D Remove and replace tool for valve guides
PD.1D/2 Spacer used with PD.1D
PD.1D-13 Adapter tool for use with PD.1D
PD.41D Gauge for piston height and valve depth
PD.170 Replacement tool for front oil seal
PD.184 Slide hammer
PD.208 Dial gauge for use with PD.41D
PD.243 Rubber plug replacement tool
PD.244 Adapter for use with PD6118B
PD.249 Adapter for valve guide depth, for use with PD.1D-13
PD.254 Kit, governor arm lock, consists of tools to measure rack movement
PD.255 Replacement tool for rear oil seal, for use with MS.550
PD.256 Replacement tool for idler gear, for use with MS.550
PD.258 Adapter and removal tool for idler hub, for use with PD.184
PD.259 Adapter, main tool to crankcase, for use with PD.170
PD.260 Adapter for front seal, for use with PD.170

79
Special Tools 600 SRM 706

Tool Number Description

PD.6118B Valve spring compressor
MS.76A Set of adjustable cutters for valve seats
MS.550 Universal drive handle
MS.1519A Valve spring compressor
No. 8 Piston ring compressor

80
 TECHNICAL PUBLICATIONS

600 SRM 706 12/04 (12/03)(1/99)(11/97) Printed in U.S.A.