Uenr3426 00 00 - Manuals Service Modules

UENR3426
October 2013
Specifications
C18 Marine Auxiliary and Marine
Generator Set Engines
TNA 1-Up (Engine)
GTB 1-Up (Engine)
JHL 1-Up (Generator Set)
DTP 1-Up (Generator Set)
SAFETY.CAT.COM
i05296198
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of the
product in the location of use, including site-specific rules and precautions applicable to the
worksite. If a tool, procedure, work method or operating technique that is not specifically
recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others.
You should also ensure that you are authorized to perform this work, and that the product will not be
damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
UENR3426 3
Table of Contents
Table of Contents Piston and Rings ...................... ...................... 69

Housing (Front)........................ ....................... 71
Specifications Section Front Housing and Covers............... ............... 72
Gear Group (Front)..................... .................... 73
Engine Design ......................... ......................... 4 Gear Group (Front)..................... .................... 75
Fuel Transfer Pump ..................... ..................... 5 Flywheel .......................................................... 78
Fuel Transfer Pump ..................... ..................... 6 Flywheel .......................................................... 78
Fuel Filter Base......................... ........................ 7 Flywheel .......................................................... 79
Fuel Filter Base......................... ........................ 8 Flywheel Housing ...................... ..................... 80
Fuel Filter Base......................... ........................ 9 Flywheel Housing ...................... ..................... 81
Electronic Unit Injector Mechanism ........ ........ 10 Belt Tension Chart ..................... ..................... 83
Electronic Unit Injector Rocker Arm..................11 Alternator and Regulator................. ................ 84
Valve Mechanism ............................................ 12 Alternator and Regulator................. ................ 85
Valve Mechanism Cover................. ................ 13 Alternator and Regulator................. ................ 86
Cylinder Head Valves ................... .................. 13 Alternator and Regulator................. ................ 87
Cylinder Head......................... ........................ 15 Coolant Temperature Sensor............. ............. 87
Turbocharger ......................... ......................... 17 Coolant Temperature Sensor............. ............. 88
Turbocharger ......................... ......................... 18 Coolant Temperature Sensor............. ............. 89
Exhaust Manifold...................... ...................... 20 Coolant Level Sensor ................... .................. 90
Exhaust Manifold...................... ...................... 22 Fuel Temperature Sensor ................ ............... 91
Camshaft ............................ ............................ 24 Fuel Temperature Sensor ................ ............... 92
Camshaft ............................ ............................ 25 Fuel Pressure Sensor................... .................. 93
Camshaft ............................ ............................ 27 Engine Oil Pressure Sensor .............. ............. 94
Engine Oil Filter Base ................... .................. 29 Boost Pressure Sensor.................. ................. 94
Engine Oil Filter Base ................... .................. 30 Atmospheric Pressure Sensor............ ............ 95
Engine Oil Filter Base ................... .................. 32 Inlet Air Temperature Sensor............. ............. 95
Engine Oil Pump....................... ...................... 33 Inlet Air Temperature Sensor............. ............. 96
Engine Oil Pump....................... ...................... 35 Speed/Timing Sensor ................... .................. 97
Engine Oil Pan........................ ........................ 38 Tachometer........................... .......................... 99
Engine Oil Pan........................ ........................ 39 Tachometer Calibration Chart............ ........... 100
Engine Oil Pan........................ ........................ 41 Circuit Breakers ...................... ...................... 101
Engine Oil Pan........................ ........................ 42 Circuit Breakers ...................... ...................... 101
Engine Oil Pan........................ ........................ 45
Engine Oil Pan........................ ........................ 47 Index Section
Water Temperature Regulator ............ ............ 49
Index............................... .............................. 102
Water Pump.......................... .......................... 50
Auxiliary Water Pump ................... .................. 51
Auxiliary Water Pump ................... .................. 52
Heat Exchanger....................... ....................... 53
Cylinder Block......................... ........................ 54
Cylinder Block......................... ........................ 57
Cylinder Liner......................... ......................... 60
Crankshaft ........................... ........................... 61
Vibration Damper and Pulley............. ............. 63
Connecting Rod Bearing Journal.......... .......... 65
Main Bearing Journal................... ................... 66
Main Bearing Journal................... ................... 66
Connecting Rod....................... ....................... 67
4 UENR3426
Specifications Section
i03526822
Engine Design
SMCS Code: 1201
C18
Illustration 1 g01611394
(A) Inlet
(B) Exhaust
(1) Flywheel end of engine
(2) Cylinder number
Bore ..............................................145 mm (5.71 inch)
Stroke ........................................... 183 mm (7.20 inch)
Displacement..................................18.1 L (1105 cu in)
Cylinder arrangement .....................In-line six cylinder
Valves per cylinder .................................................... 4
Inlet valve lash .................................... 0.38 ± 0.08 mm

(0.015 ± 0.003 inch)
Exhaust valve lash.............................. 0.76 ± 0.08 mm

(0.030 ± 0.003 inch)
Firing order (injection sequence) ...........1, 5, 3, 6, 2, 4
Crankshaft rotation from the flywheel end

.........................................................Counterclockwise
Note: The front end of the engine is opposite the

flywheel end. The left side and the right side of the
engine are viewed from the flywheel end. The No. 1
cylinder is the front cylinder.
UENR3426 5
i04379778
Fuel Transfer Pump

SMCS Code: 1256
(1) Weep hole (3) Inlet port

(2) Pressure regulating valve (4) Outlet port
Table 1
Specification for the 316-6864 Fuel Transfer Pump Gp, 316-6863 Fuel Transfer Pump Gp, 295-9260 Fuel Transfer Pump Gp
295-9261 Fuel Transfer Pump Gp, 272-5930 Fuel Transfer Pump Gp, 316-6865 Fuel Transfer Pump Gp, and 290-8866 Fuel Trans-
fer and Priming Pump Gp
Item Qty Part Specification Description
When the fuel transfer pump is using diesel fuel, the fuel transfer pump has the following specifications:
Run the pump at 2940 rpm. The full bypass pressure should be 716 to 786 kPa (104 to 114 psi).
Run the pump at 840 rpm. The flow at 550 kPa (80 psi) must be 3.0 L/min (0.8 US gpm).
Run the pump at 2940 rpm. The flow at 650 kPa (94 psi) must be 4.5 L/min (1.19 US gpm).
- - - Run the pump at 120 rpm. Keep the inlet open to the atmosphere for 10 seconds. Block the inlet. The
pump must maintain the vacuum of 30 kPa (4.5 psi) minimum in 30 seconds.
Run the pump at 840 rpm. Keep the inlet open to the atmosphere for 10 seconds. Block the inlet. The
pump must maintain the vacuum of 45 kPa (6.5 psi) minimum in 30 seconds.
Run the pump at 120 rpm with a blocked inlet for 30 seconds. The pump inlet must have a suction lift of
60.9 kPa (9 psi) minimum.
6 UENR3426
i05255116
Fuel Transfer Pump

SMCS Code: 1256
Table 2
Specification for 292-5906 Fuel Transfer Pump Gp
1 2 0S-0699 Stud Before assembly, apply red Loctite 271 to the threads.
2 2 9S-8752 Full Nut Torque to 30 ± 5 N·m (266 ± 44 lb in).

UENR3426 7
i05255367
Fuel Filter Base

SMCS Code: 1261; 1262
Table 3
Specification for 8H-7204 Fuel Filter Gp
1 1 7N-1628 Nut Torque to 24 ± 4 N·m (18 ± 3 lb ft).
Length under test force is 27.94 mm (1.100 inch).

2 1 7S-9323 Spring Test force is 27.7 to 32.3 N (6.2 to 7.3 lb).
Free length after test is 42.67 mm (1.680 inch).
8 UENR3426
i05255378
Fuel Filter Base

SMCS Code: 1261; 1262
Table 4
Specification for 127-0291 Base As
Before assembly, apply red Loctite 271 to the tapered end of the taperlock stud for
B - -
the length of 7.7 ± 0.8 mm (0.303 ± 0.032 inch).
1 1 9S-4167 Hollow Stud Torque to 70 ± 15 N·m (52 ± 11 lb ft).

UENR3426 9
i05390999
Fuel Filter Base

SMCS Code: 1261; 1262
Table 5
Specification for 6N-6259 Fuel Filter Base As
Apply red Loctite 271 to the threads on the tapered end of the hollow stud to the dis-
B 2 9S-4167 Hollow Stud
tance of 7.6 mm (0.30 inch).
Distance from the sealing surface of the filter base to the end of the hollow stud is
C - -
25.0 ± 1.6 mm (0.98 ± 0.06 inch).
10 UENR3426
i04403749
Electronic Unit Injector Mechanism

SMCS Code: 1290
(3) Spacer (4) Unit injector clamp
Table 6
Specification for the 190-0009 Fuel Pump and Valve Mechanism, 148-7482 Fuel Pump and Valve Mechanism, 128-8510 Fuel Injec-
tor Gp, 130-9701 Fuel Injection Pump Gp, 153-2875 Fuel Injector Gp, 235-1401 Fuel Injection Pump Gp, 297-1027 Fuel Injection
Pump Gp, 252-5786 Fuel Injection Pump Gp, 253-8352 Fuel Injection Pump Gp, 261-0048 Fuel Injection Pump Gp and 235-1402
Fuel Injection Pump Gp
Before installation of the unit injector, lubricate the O-ring seals (5) with a 50/50 mixture of clean engine oil and 8T-2998 Lubricant.
1 1 - Torque the locknut to 100 ± 10 N·m (74 ± 7 lb ft).
Use the following procedure to tighten the bolt:
1. Tighten the bolt to 55 ± 10 N·m (41 ± 7 lb ft).

2 1 -
2. Loosen the bolt until the bolt is finger tight.
3. Again, tighten the bolt to 55 ± 10 N·m (41 ± 7 lb ft).
A - - Adjust the unit injector height to 78.0 ± 0.2 mm (3.07 ± 0.01 inch).
UENR3426 11
i02794899 New parts ............................... 40.065 ± 0.015 mm

(1.5774 ± 0.0006 inch)
Electronic Unit Injector Rocker Maximum dimension for worn parts.... 40.193 mm
Arm (1.5824 inch)
SMCS Code: 1123 (C) Bearing for the rocker arm and the pin must not
extend beyond either face of the rocker arm.
Typical example
(1) Shaft assembly
(2) Rocker arm
View A-A
Typical example
(3) Bearing joint
(B) Bore
12 UENR3426
i05336175
Valve Mechanism
SMCS Code: 1102
(1) Rocker arm (5) Camshaft

(3) Adjusting screw (7) Valve bridge
Table 7
Specification for 190-0009 Fuel Pump and Valve Mechanism, 224-5136 Fuel Pump and Valve Mechanism, and 235-0382 Fuel Pump
and Valve Mechanism
2 1 276-5317 Nut Torque for the nuts 30 ± 7 N·m (265 ± 60 lb in)
307-8322 Rocker Diameter of a new rocker shaft assembly is 40.000 ± 0.010 mm (1.5748 ± 0.0004 inch).
4 1
Shaft Assembly Bore in the rocker arm for rocker shaft is 40.065 ± 0.015 mm (1.5774 ± 0.0006 inch).
Valve lash setting:

6 - - Inlet valve is 0.38 ± 0.08 mm (0.015 ± 0.003 inch).
Exhaust valve is0.76 ± 0.08 mm (0.030 ± 0.003 inch).
For engines that are equipped with variable valve actuators, refer to Specifications, “Variable valve Actuator” for information on installation of the
rocker arm assembly.
For engines that are equipped with CAT Compression Brakes, refer to Specifications, “CAT Compression Brake” for the correct procedure on in-
stallation of the rocker arm assembly.
UENR3426 13
i01765227 i02997793
Valve Mechanism Cover Cylinder Head Valves

SMCS Code: 1107 SMCS Code: 1105
Valve mechanism cover
Note: Apply clean engine oil to the valve stems prior

to installation in the cylinder head.
(1) 247-9908 Spring
Length under test force ..... 67.12 mm (2.643 inch)

Test force.......................320 ± 25 N (71.9 ± 5.6 lb)
Approximate free length after test......... 76.70 mm
(3.020 inch)
Outside diameter...................36.3 mm (1.43 inch)
(2) 211-3122 Spring

Test force.......................150 ± 12 N (33.7 ± 2.7 lb)
Approximate free length after test......... 71.70 mm
Illustration 12 g00285630 (2.823 inch)
Tightening Sequence For Valve Cover And Base Outside diameter...............25.17 mm (0.991 inch)
Note: Apply 4C-4030 Thread Lock Compound to (A) Height to top of valve guide ........ 35.00 ± 0.50 mm
the bolts that fasten the wiring for the electronic unit (1.378 ± 0.020 inch)
injectors to the valve cover base.
(B) Bore of installed new valve guide
(1) Torque for bolts..................18 ± 3 N·m (13 ± 2 lb ft) ...................9.502 ± 0.013 mm (0.3741 ± 0.0005 inch)
Note: The valve cover seal and the cover base seal Note: Do not use a combination of a valve and a
are cut to size at assembly. Coat seal joints with valve guide that has a difference of 0.13 mm
3S-6252 Sealant. (0.005 inch) or more.
(C) Dimension for valve recess
Inlet.............2.20 to 2.80 mm (0.087 to 0.110 inch)

Exhaust ..... 1.20 to 1.80 mm (0.047 to 0.071 inch)
14 UENR3426
Illustration 14 g01401264 Illustration 15 g01401267
(D) Dimension for valve face angle (J) Width of the valve seat
Inlet ..................................... 60.75 ± 0.25 degrees Inlet..................................2.377 mm (0.0936 inch)

Exhaust ..............................45.75 ± 0.25 degrees Exhaust ........................... 1.508 mm (0.0594 inch)
(E) Dimension for valve stem diameter (K) Depth of bore in the cylinder head for the valve
seat insert
New valve stem diameter......... 9.427 ± 0.010 mm
(0.3711 ± 0.0004 inch) Inlet............ 14.00 ± 0.05 mm (0.551 ± 0.002 inch)
Minimum recommended valve stem diameter Exhaust ..... 13.90 ± 0.05 mm (0.547 ± 0.002 inch)
........................................9.309 mm (0.3665 inch)
(L) Inside diameter of valve seat insert
(F) Diameter of valve head
Inlet............ 41.00 ± 0.50 mm (1.614 ± 0.020 inch)
Inlet............ 47.00 ± 0.13 mm (1.850 ± 0.005 inch) Exhaust ..... 36.50 ± 0.50 mm (1.437 ± 0.020 inch)
Exhaust ..... 41.81 ± 0.13 mm (1.646 ± 0.005 inch)
(M) Angle of valve seat face
(G) Dimension for valve lip thickness
Inlet .....................................30.25 ± 0.25 degrees
Inlet.............. 4.00 ± 0.20 mm (0.158 ± 0.008 inch) Exhaust .............................. 45.25 ± 0.25 degrees
Exhaust ....... 3.56 ± 0.20 mm (0.140 ± 0.008 inch)
(N) Outside diameter of valve seat insert
Note: Refer to Reuse And Salvage Guidelines,
SEBF8034 for additional information for the valves Inlet.... 48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)
and the valve springs. Exhaust ..................................42.840 ± 0.013 mm
(1.6866 ± 0.0005 inch)
(H) Overall length of valve
Diameter of the bore in the cylinder head for the
Inlet.......... 202.00 ± 0.45 mm (7.953 ± 0.018 inch) valve seat insert
Exhaust .................................... 202.06 ± 0.45 mm Inlet.... 47.950 ± 0.025 mm (1.8878 ± 0.0010 inch)
(7.955 ± 0.018 inch) Exhaust ..................................42.774 ± 0.025 mm
(1.6840 ± 0.0010 inch)
UENR3426 15
i02873801
Cylinder Head
SMCS Code: 1100
Cylinder head
16 UENR3426
The following bolts are 216 mm (8.5 inch) long: 11,

12, 13, 14, 16, 18, 20, 22, 24 and 26. The following
bolts are 198.8 ± 1.0 mm (7.83 ± 0.04 inch) long: 2, 8
and 10. The rest of the bolts are 194 mm (7.6 inch)
long.
Apply 6V-4876 Lubricant to the bolt threads and
both sides of the washers. Tighten the bolts in the
following step sequence:
1. In a numerical sequence, tighten bolts 1 through

26.
Torque for bolts ...............270 ± 15 N·m (200 ± 11 lb ft)
2. In a numerical sequence, tighten bolts 1 through

26.
Torque for bolts ...............450 ± 15 N·m (330 ± 11 lb ft)
3. In a numerical sequence, again tighten bolts 1

through 26. Illustration 18 g01430709
(27) Oil gallery
Torque for bolts ...............450 ± 15 N·m (330 ± 11 lb ft) (28) Bearing joint
(29) Oil holes
Note: The flatness of the cylinder head should be (30) Camshaft bearing
within a total of 0.13 mm (0.005 inch). Also, the
flatness of the cylinder head should be within a
maximum of 0.05 mm (0.002 inch) for any 150 mm NOTICE
(5.9 inch) span. Camshaft bearings must be installed into their correct
position. Failure to do so will result in engine damage.
(A) Cylinder Head Thickness Illustration 19 g01430712

(28) Bearing joint
Thickness of a new cylinder head (29) Oil holes
................120.00 ± 0.15 mm (4.724 ± 0.006 inch)
Minimum thickness of a used cylinder head Orientation of bearing joint (B) .............20° ± 5° above
........................................ 119.50 mm (4.705 inch) horizontal
UENR3426 17
(1) Apply 4C-5599 Anti-Seize Compound to the

threads and the bearing surface of four locknuts
before assembly.
The depth of installation of the camshaft bearings is

very important. Install bearings (30) to the following
depths:
Installation depth for camshaft bearings (30)
C.......................... 8.0 ± 0.5 mm (0.32 ± 0.02 inch)

D...................... 178.1 ± 0.5 mm (7.01 ± 0.02 inch)
E .................... 349.5 ± 0.5 mm (13.76 ± 0.02 inch)
F .................... 521.0 ± 0.5 mm (20.51 ± 0.02 inch) Illustration 22 g01460237
G.................... 692.4 ± 0.5 mm (27.26 ± 0.02 inch) Typical example

H.................... 863.8 ± 0.5 mm (34.01 ± 0.02 inch)
I ...................1035.3 ± 0.5 mm (40.76 ± 0.02 inch) Use the following procedure to tighten the
compressor clamp assembly (2) and the turbine
clamp assembly (3) for the turbocharger group:
i02946141
1. Tighten the clamp assemblies to 14.0 ± 1.0 N·m
Turbocharger (125 ± 9 lb in).
SMCS Code: 1052 2. Lightly tap around the clamp assemblies with a soft
faced hammer.
3. Again, tighten the clamp assemblies to
14.0 ± 1.0 N·m (125 ± 9 lb in).
Typical example
Rear view of engine
18 UENR3426
i05391863
Turbocharger
SMCS Code: 1052
Typical example
Right side view of engine
Table 8
Specification for 201-7251 Turbocharger Gp, 201-7252 Turbocharger Gp, 241-9421 Turbocharger Gp, and 301-4315 Turbocharger
Gp
Before assembly, apply Loctite C5A Copper Anti-seize to the threads and to the
1 4 2N-2766 Locknut
bearing surfaces.
UENR3426 19
Typical example
Table 9
2 1 7W-7778 Clamp As Use the following procedure to tighten the clamps for the turbocharger.
1. Tighten to 14.0 ± 1.0 N·m (123.9 ± 8.9 lb in).

3 1 5S-4517 Clamp As 2. Lightly tap around the clamp assemblies with a soft faced hammer.
3. Again, tighten to 14.0 ± 1.0 N·m (123.9 ± 8.9 lb in).
20 UENR3426
i03560842
Exhaust Manifold
SMCS Code: 1059
Typical example
UENR3426 21
Tightening sequence
Note: Before assembly, apply 4C-5599 Anti-Seize

Compound to the threads and to the bearing surfaces
of the locknuts (1).
(1) Tighten the locknut 1 through locknut 12 in the
numerical sequence that is shown in Illustration 26 to
the torque of 38 ± 5 N·m (28 ± 4 lb ft).
(2) Lightly lubricate the bore of the O-ring seals at
each end of the exhaust manifold with the glycerin.
Note: Before assembly, apply 4C-5599 Anti-Seize

Compound to the threads and to the bearing surfaces
of the taperlock studs (3).
(3) Torque for the taperlock studs...............27 ± 4 N·m

(239 ± 35 lb in)
22 UENR3426
i05393012
Exhaust Manifold
SMCS Code: 1059
Tightening sequence
Table 10
Specification for 310-5809 Exhaust Manifold Gp
1 12 106-1792 Taperlock Stud Torque to 35 ± 5 N·m (26 ± 4 lb ft).
Before assembly, lubricate the threads and bearing surfaces with Loctite C5A Copper
Anti-Seize .
2 12 2N-2766 Locknut
Torque to 50 ± 5 N·m (37 ± 4 lb ft).
Refer to Illustration 28 for the locknut tightening sequence.
3 2 109-0072 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
UENR3426 23
Table 11
4 1 6V-4367 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
5 1 109-0073 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
24 UENR3426
i05391856
Camshaft
SMCS Code: 1210
UENR3426 25
Table 12
Specification for 201-0566 Camshaft Gp
A - - Diameter of camshaft bearing journal is 84.850 ± 0.020 mm (3.3405 ± 0.0008 inch).
Lubricate the camshaft bearings with clean engine oil before the installation of
- - -
camshaft.
Lubricate the camshaft lobes with a 50/50 mixture of 8T-2998 Lubricant and clean
- - -
engine oil.
1 - - Maximum exhaust lobe lift at zero degrees is 8.515 mm (0.3352 inch).
2 - - Maximum injector lobe lift at zero degrees is 10.445 mm (0.4112 inch).
3 - - Maximum inlet lobe lift at zero degrees is 9.702 mm (0.3820 inch).
4 3 119-0036 Flat Head Screw Torque to 13 ± 3 N·m (115 ± 27 lb in).
Use the following procedure to find the actual lobe lift (B):
- - -
1. Measure the camshaft lobe height (C).
- - - 2. Measure the base circle (D).
3. Subtract the base circle measurement in Step 2 from the camshaft lobe height in
- - -
Step 1. The difference is the actual lobe lift (B).
The maximum permissible difference between the actual lobe lift in Step 3 and the
- - -
specified camshaft lobe lift of a new camshaft is ± 0.10 mm (± 0.003 inch).
i02650563 Note: Lubricate the camshaft bearings with clean

engine oil prior to installing the camshaft.
Camshaft (5) Front of camshaft
SMCS Code: 1210
Illustration 32 g01096494 (A) Camshaft lobe lift

(1) Exhaust lobe Specified camshaft lobe lift
(2) Injector lobe Exhaust lobe ...................8.515 mm (0.3352 inch)
Inlet lobe.......................... 9.702 mm (0.3820 inch)
(3) Inlet lobe Injector lobe................... 10.445 mm (0.4112 inch)
Note: Prior to installation, lubricate the camshaft (B) Camshaft lobe height
lobes with a 50/50 mixture of 8T-2998 Lubricant and
clean engine oil. (C) Base circle
(4) Bearing journal To find the lobe lift, use the procedure that follows:
Diameter of the bearing journals 1. Measure camshaft lobe height (B).

..................84.85 ± 0.02 mm (3.341 ± 0.001 inch) 2. Measure base circle (C).
26 UENR3426
3. Subtract the base circle measurement (Step 2)

from the camshaft lobe height (Step 1). The
difference is the actual lobe lift.
Maximum permissible difference between the actual

lobe lift (Step 3) and the specified lobe lift of a new
camshaft ......................................0.1 mm (0.004 inch)
(6) Screw
Tighten the screws that fasten the cover to the

cylinder head to the following torque.
.........................................13 ± 3 N·m (10 ± 2 lb ft)
UENR3426 27
i04383994
Camshaft
SMCS Code: 1210
Typical example
(4) Front of camshaft
Table 13
A - - Diameter of camshaft bearing journal is 84.850 ± 0.020 mm (3.3405 ± 0.0008 inch).
- - - Lubricate the camshaft bearings with clean engine oil before you install the camshaft.
- - - Lubricate the camshaft lobes with a 50/50 mixture of 8T-2998 Lubricant and clean engine oil.
1 - - Maximum exhaust lobe lift at zero degrees is 8.51521 mm (0.33524 inch).
2 - - Maximum injector lobe lift at zero degrees is 10.33845 mm (0.40702 inch).
3 - - Maximum inlet lobe lift at zero degrees is 9.431116 mm (0.37130 inch).
Use the following procedure to find the actual lobe lift (B):
- - -
1. Measure the camshaft lobe height (C).
- - - 2. Measure the base circle (D).
3. Subtract the base circle measurement in Step 2 from the camshaft lobe height in Step 1. The dif-
- - -
ference is the actual lobe lift (B).
The maximum permissible difference between the actual lobe lift in Step 3 and the specified cam-
- - -
shaft lobe lift of a new camshaft is ± 0.10 mm (± 0.0034 inch).
28 UENR3426
Table 14
5 3 119-0036 Flat Head Screw Torque to 13 ± 3 N·m (115 ± 27 lb in).

UENR3426 29
i02493629
Engine Oil Filter Base

SMCS Code: 1306
Section A-A
(B) Apply 154-9731 Thread Lock Compound to the

threads of the stud to the following length.
................................. 10.2 ± 1.5 mm (0.40 ± 0.06 inch)
(5) Tighten the stud (3) to the following torque.

............................................80 ± 14 N·m (59 ± 10 lb ft)
Engine oil filter base
(1) Engine oil filter bypass valve
The oil filter bypass valve must open at the

following pressure: ........ 255 ± 21 kPa (37 ± 3 psi)
(2) 4N-8150 Spring
4N-8150 Spring
Test force...........................75 ± 6 N (17.0 ± 1.3 lb)
Free length after test ............. 93.7 mm (3.69 inch)
Outside diameter................... 20.6 mm (0.81 inch)
(3) Engine oil cooler bypass valve
The oil cooler bypass valve must open at the

following pressure: ........ 255 ± 21 kPa (37 ± 3 psi)
(4) Apply clean engine oil to the gasket of the engine
oil filter. Install the filter until the filter contacts the
base. Tighten the filter for an additional 3/4 of a turn
(270 degrees).
30 UENR3426
i05255565

SMCS Code: 1306
Table 15
Specification for 295-5551 Oil Filter Base As
The engine oil filter bypass valve must open at the following pressure of
- - -
255 ± 20 kPa (37 ± 3 psi).

1 2 4N-8150 Spring Test force is 75.619 ± 5.800 N (17.000 ± 1.304 lb).
UENR3426 31
Table 16
2 1 296-6642 Taperlock Stud Torque to 68 ± 7 N·m (50 ± 5 lb ft).
3 1 2P-4304 Hollow Stud Torque to 68 ± 7 N·m (50 ± 5 lb ft).
Before assembly, apply red Loctite 271 on the tapered end of the hollow stud to a
B - -
distance of 10.5 ± 1.5 mm (0.41 ± 0.6 inch).
32 UENR3426
i04556068

SMCS Code: 1306
Table 17
Specification for the 176-4109 Engine Oil Filter Gp 268-6625 Engine Oil Filter Gp
Apply red Loctite 271 on the tapered end of the hollow stud to a distance of
B - -
10.5 ± 1.5 mm (0.41 ± 0.06 inch).
1 2 2P-4304 Hollow Stud Torque to 68 ± 7 N·m (50 ± 5 lb ft).
2 2 319-6234 Plug As Torque to 100 ± 15 N·m (75 ± 11 lb ft).
3 2 4N-8150 Spring Test force is 75.619 ± 5.800 N (17.000± 1.304).
4 - - Apply clean lubricating oil to the filter gasket.

UENR3426 33
i04380864
Engine Oil Pump

SMCS Code: 1304
NOTICE
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by
hand or damage to parts can be the result.
34 UENR3426
Table 18
Specification for the 161-4113 Engine Oil Pump Gp
127-6356 Pump
1 1 Flush 8S-6511 Bushing with the face of the pump cover.
Cover
2 1 2S-2760 Spring Test force is 499 ± 24 N (112 ± 5 lb).
Approximate free length after test is 152.91 mm (6.020 inch).
4N-5273 Pump Diameter of pump drive shaft is 22.217 ± 0.005 mm (0.8747 ± 0.0002 inch).
A 1
Drive Shaft Bore in oil pump cover for bushing for pump drive shaft is 25.400 ± 0.013 mm (1.0000 ± 0.0005 inch).
Length of the gear is 79.375 ± 0.025 mm (3.1250 ± 0.0010 inch).

B 1 1W-7240 Gear
Depth of bore is 79.502 ± 0.020 mm (3.1300 ± 0.0008 inch).
Install the bushings so that the bushings are even with the outside of the oil pump body.
3 1 -
Angle from the centerline of the oil pump body to the bushing joint of the bushing is 30 ± 15 degrees.
D 1 8M-8489 Dowel Installation depth of the dowel in the oil pump is 6.4 ± 0.5 mm (0.25 ± 0.02 inch).
E 1 - Installation depth of the bushing in the oil pump housing is 0.30 ± 0.25 mm (0.012 ± 0.010 inch)
UENR3426 35
i05256627
Engine Oil Pump

SMCS Code: 1304
36 UENR3426
Table 19
Specification for 226-1191 Engine Oil Pump Gp
Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure that the pump rotates
freely.
1 1 236-6733 Spring Test force is 709 ± 35 N (159 ± 8 lb).
Free length after test is 130 mm (5.1 inch).
Depth of the bore in the oil pump body for the gear is 79.502 ± 0.020 mm
(3.1300 ± 0.00079 inch).
2 1 236-9918 Body
Before installation, bore in the body for 7N-2156 Bushing is 26.960 ± 0.013 mm
(1.0614 ± 0.0005 inch).
3 2 8M-8489 Dowel Extension of the dowel from the oil pump body is 6.4 ± 0.5 mm (0.25 ± 0.02 inch).
Before installation, bore in the cover for 8S-6511 Bushing is 25.400 ± 0.013 mm
4 1 7N-0285 Oil Pump Cover
(1.0000 ± 0.0005 inch).
Outside diameter is 25.451 ± 0.013 mm (1.002 ± 0.0005 inch).

5 2 8S-6511 Bushing
Thickness is 1.557 ± 0.013 mm (0.0613 ± 0.0005 inch).
Diameter of the 4N-5273 Pump Drive Shaft is 22.217 ± 0.005 mm

6 1 1W-7238 Pump Drive Shaft As
(0.8749 ± 0.0002 inch).
7 2 1W-7240 Gear Length of the gear is 79.375 ± 0.025 mm (3.1250 ± 0.0010 inch).
Diameter of the 4N-5271 Pump Drive Shaft is 22.217 ± 0.005 mm

8 1 1W-7239 Idler Shaft Assembly
(0.8749 ± 0.0002 inch).
Installation depth of the bushing in the oil pump body is 0.30 ± 0.25 mm
(0.012 ± 0.010 inch).
9 2 7N-2156 Bushing
Outside diameter is 27.013 ± 0.013 mm (1.0635 ± 0.0005 inch).
Thickness is 2.340 ± 0.013 mm (0.0921 ± 0.0005 inch).

UENR3426 37
Table 20
Position of bearing joints from the centerline through the bearing bores is 30 ± 15
A - -
degrees.
38 UENR3426
i03022662 (3) Torque for 24 bolts.............38 ± 6 N·m (28 ± 4 lb ft)
Engine Oil Pan (4) Torque for the drain plug .....................70 ± 15 N·m
(50 ± 11 lb ft)
SMCS Code: 1302
Top view
(1) Lubricate the bore for the O-ring seals with the
lubricant that is being sealed.
View A-A
(2) Torque for the pipe plug.......................82 ± 10 N·m

(60 ± 7 lb ft)
Right side view
UENR3426 39
i04374357
Engine Oil Pan

SMCS Code: 1302
Top view
Table 21
Specification for 228-0880 Oil Pan Gp
Apply ultra blue Loctite 587 on the top across the entire length of joints of the oil pan gasket as
1 2 353-5065 Oil Pan Gasket
shown in Illustration 49 .
2 3 8T-6761 Pipe Plug Torque to 82 ± 10 N·m (60 ± 7 lb ft).
3 1 9X-6451 Drain Plug Torque to 70 ± 15 N·m (50 ± 11 lb ft).

40 UENR3426
Table 22
Specification for the 228-0880 Oil Pan Gp
Use the following procedure during assembly of engine oil pan:
Note: The sealing surfaces of the oil pan shall be free of oil, debris, gasket material, or any other sealant.
Note: The oil pan must be assembled and tightened to the cylinder block within 10 minutes of applying sealant.
1. Apply 3 to 5 mm (0.1 to 0.2 inch) of ultra blue Loctite 587 to the following locations:
Connecting joint of the front housing and the front of the cylinder block.
Connecting joint of the flywheel housing and the rear of the cylinder block.
2. Tighten bolt 1 through bolt 40 in the numerical sequence as shown in Illustration 50 to 40 ± 5 N·m (30 ± 4 lb ft)
2. Again, tighten bolt 1 through bolt 40 in the numerical sequence as shown in Illustration 50 to 47 ± 5 N·m (35 ± 4 lb ft)
UENR3426 41
i02876838
Engine Oil Pan

SMCS Code: 1302
(1) Torque for pipe plug.........82 ± 10 N·m (60 ± 7 lb ft)
(2) Torque for the oil pan bolts ..................55 ± 10 N·m

(41 ± 7 lb ft)
(3) Front face of block
(4) Torque for drain plug .....70 ± 15 N·m (52 ± 11 lb ft)

42 UENR3426
i04395735
Engine Oil Pan

SMCS Code: 1302
UENR3426 43
Table 23
1 2 353-5065 Oil Pan Gasket
2 1 5P-5846 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

44 UENR3426
Table 24
UENR3426 45
i04395707
Engine Oil Pan

SMCS Code: 1302
Top view
Table 25
1 2 188-0210 Gasket

46 UENR3426
Table 26
UENR3426 47
i05391049
Engine Oil Pan

SMCS Code: 1302
Top view
Table 27
Specification for 228-1644 Oil Pan Gp
Right side view
48 UENR3426
Table 28
3 - - Apply Ultra Blue Loctite 587 on the top across the entire length of joints of the gasket.

UENR3426 49
i04907651
Water Temperature Regulator

SMCS Code: 1355
Table 29
Specification for 248-5513 Temperature Regulator
A - - Minimum opening distance at fully open temperature is 10.4 mm (0.41 inch).
- - - Opening temperature is 81 to 84 °C (178 to 183 °F).
- - - Fully open temperature is 92 °C (198 °F).
- - - Leakage at the seat and sleeve shall not exceed minimum 10.0 cc (0.6 cubic inch) at 207 kPa (30 psi).
Force required to separate valve from seat is 165 ± 9 N (37 ± 2 lb), measured at temperature 75 °C
- - -
(167 °F).
50 UENR3426
i04557743
Water Pump
SMCS Code: 1361
Table 30
Specification for the 174-5986 Water Pump Gp, 161-0969 Water Pump Gp, and 100-9347 Water Pump Gp
1 1 9M-3786 O-Ring Seal Lubricate the bore of the O-ring seal lightly with 5P-3975 Rubber Lubricant.
2 1 0S-1591 Bolt Torque to 39 ± 3 N·m (29 ± 2 lb ft).
With an installation tool, press the water pump seal onto the water pump shaft until
3 1 349-2654 Water Pump Seal
the stationary cup is fully seated inside the pump housing.
By using an installation tool, install the lip type seal with the primary lip toward water
4 1 153-1256 Lip Type Seal pump drive gear. Press the lip type seal with a press until the lip type seal is flush with
the face inside the housing. Do not install the lip type seal by hand.
Diameter of the water pump shaft at the carbon seal assembly seat area is
A 1 135-4928 Water Pump Shaft
19.100 ± 0.010 mm (0.7520 ± 0.0004 inch).
UENR3426 51
i02494989
Auxiliary Water Pump

SMCS Code: 1371
Auxiliary water pump
52 UENR3426
(1) Tighten the bolts to the following torque. i02872740

..........................................21.5 ± 2.5 N·m (16 ± 2 lb ft)
Auxiliary Water Pump
(2) Tighten the plug to the following torque.
SMCS Code: 1371
.................................................9 ± 1 N·m (80 ± 9 lb in)
(3) Tighten the bolts to the following torque.

.................................................6 ± 1 N·m (53 ± 9 lb in)
(4) Tighten the bolts for the housing to the following

torque.......................................6 ± 1 N·m (53 ± 9 lb in)
(5) Tighten bolts to the following torque........6 ± 1 N·m

(53 ± 9 lb in)
(6) Tighten the impeller to the following torque.

........................................103 ± 13 N·m (76 ± 103 lb ft)

..........................................................103 N·m (76 lb ft)
(8) Tighten the bolts to the following torque.

.....................................1.9 ± 0.2 N·m (16.8 ± 1.8 lb in)
Auxiliary water pump
(1) Torque for clamps..........................20 N·m (15 lb ft)
(2) Apply 155-0695 Thread Lock Compound to the

threads of the stud. Tighten the nut to the following
torque......................................40 ± 5 N·m (30 ± 4 lb ft)
(9) The distance of the impeller below ring (10)

..........................0.11 to 0.16 mm (0.004 to 0.006 inch)
(10) Ring
Top view of auxiliary water pump
(3) Tighten the three bolts for the housing to the

following torque......................6 ± 1 N·m (50 ± 10 lb in)
UENR3426 53
i03362921
Heat Exchanger
SMCS Code: 1379
Section A-A Use the following procedure to tighten the bolts:
1. Install guide studs in locations (5) and (6). Use

(4) Torque for three bolts .......6 ± 1 N·m (50 ± 10 lb in)
three incremental steps to hand tighten bolt (1)
(5) Tighten the impeller to the following torque. through bolt (4).
..........................................103 ± 13 N·m (80 ± 10 lb ft)
2. Remove the guide studs from locations (5) and (6).
(6) Torque for plug..................9 ± 1 N·m (80 ± 10 lb in)
3. Install the spacers in locations (5) and (6).
..........................................103 ± 13 N·m (80 ± 10 lb ft) 4. Tighten bolt (1) through bolt (10) in numerical order.
Torque...................................108 ± 7 N·m (80 ± 5 lb ft)
Front view of auxiliary water pump
(8) Torque for four bolts.....21.5 ± 2.5 N·m (16 ± 2 lb ft)
(9) Tighten the four bolts for the housing to the

following torque...................... 6 ± 1 N·m (50 ± 10 lb in)
54 UENR3426
i03289191
Cylinder Block
SMCS Code: 1201
Right side view
UENR3426 55
Note: The bottom of the spacer plate (2), the top of

the cylinder block, and both surfaces of the gasket (1)
must be free of fuel, oil, water, adhesives, assembly
compounds or any other contaminants during
assembly.
Note: Apply 4C-4032 Bearing Mount Compound to

the dowel before installation.
(A) Extension of dowel above the top surface of the

cylinder block ........... 18.5 ± 0.5 mm (0.73 ± 0.02 inch)
(1) Thickness of the gasket ................ 0.20 ± 0.02 mm

(0.008 ± 0.001 inch)
(2) Thickness of the spacer plate ... 8.585 ± 0.025 mm

(0.3380 ± 0.0010 inch)
Projection of cylinder liner above the spacer plate

.................0.025 to 0.152 mm (0.0010 to 0.0060 inch)
(3) Torque for the cylinder block plug group Illustration 69 g01628135
........................................145 ± 13 N·m (105 ± 10 lb ft) Section F-F
(B) Extension of dowel above the top surface of the (4) Lubricate the O-ring seals and the bore with clean
engine oil.
Note: Apply 4C-4032 Bearing Mount Compound to (G) Installation depth of the plug..............2.0 ± 2.0 mm
the dowel before installation. (0.08 ± 0.08 inch)
(C) Extension of dowel above the top surface of the

(E) Extension of the dowel beyond the end of the

View D-D
56 UENR3426
Front view of engine
Note: The total flatness of the top contact surface of

the cylinder block must be within 0.10 mm
(0.004 inch). The flatness must also be within
0.05 mm (0.002 inch) for any 150.0 mm (5.91 inch)
section of the surface.
(H) Dimension from the centerline of the crankshaft

bearing bore to the top of the cylinder block
New ............................... 425.45 mm (16.750 inch)

Minimum........................ 425.02 mm (16.733 inch)
(J) Bore in the cylinder block for the main bearings Right side view
............... 129.891 ± 0.013 mm (5.1138 ± 0.0005 inch) (8) Straight thread O-ring plug
(K) New dimension from the centerline of the Note: To prevent damage to the piston cooling jets
crankshaft bearing bore to the bottom of the cylinder during service, the piston cooling jets must be
block pan rails........................ 165.10 mm (6.500 inch) removed.
(L) Width of the main bearing cap............ 215.900 mm (9) Minimum permissible clearance between the
(8.5000 inch) piston, the piston cooling jet, and the crankshaft
................................................... 0.63 mm (0.025 inch)
Width of the cylinder block for the main bearing cap
...............215.900 ± 0.020 mm (8.5000 ± 0.0008 inch)
Torque-turn tightening method for main bearing cap
bolts
Use the following procedure in order to tighten the

main bearing cap bolts (5) :
1. Apply clean engine oil to the threads of the bolts.
2. Tighten the bolt (7) first on the bearing tab side of

the cap to 258 ± 14 N·m (190 ± 10 lb ft).
3. Tighten the bolt (6) on the opposite end to the tab

end of the cap to 258 ± 14 N·m (190 ± 10 lb ft).
4. Put a mark on each bolt and each cap.
5. Tighten the bolt (6) on the opposite end to the tab

end of the cap from the mark to angle (M) of 120 ±
5 degrees (2 flats).
6. Tighten the bolt (7) on the bearing tab side of the

cap from the mark to angle (M) of 120 ± 5 degrees
(2 flats).
UENR3426 57
i04557816
Cylinder Block
SMCS Code: 1201
58 UENR3426
Table 31
Specification for 261-0191 Cylinder Block Gp
Item Qty Parts Specification Description
The bottom of spacer plate (2), the top of cylinder block, and both surfaces of gasket
(1) must be free of fuel, oil, water, adhesives, assembly compounds or any other con-
1 1 227-1204 Gasket
taminants during assembly.
Thickness of the gasket is 0.20 ± 0.02 mm (0.008 ± 0.001 inch).
Apply green Loctite 609 to the dowel before installation.

A 1 4N-1650 Dowel Extension of dowel above the top surface of the cylinder block is 18.5 ± 0.5 mm
(0.73 ± 0.02 inch).
2 1 6I-4421 Spacer Plate Maximum thickness of the spacer plate is 8.585 ± 0.025 mm (0.3380 ± 0.0010 inch).
Extension of dowel above the top surface of the cylinder block is 16.0 ± 0.5 mm
B 1 1S-9540 Dowel (0.63 ± 0.02 inch).
Apply green Loctite 609 to the dowel before installation.

C 1 6I-1055 Dowel Extension of dowel above the top surface of the cylinder block is 20.0 ± 0.5 mm
(0.79 ± 0.02 inch).
Extension of the dowel beyond the end of the cylinder block is 19.1 ± 0.5 mm
E 2 4N-0683 Dowel (0.75 ± 0.02 inch).
3 - - Lubricate the bore of the O-ring seal lightly with the fluid that is being sealed.
G - - Installation depth of the plug 2.0 ± 2.0 mm (0.08 ± 0.08 inch)

UENR3426 59
Table 32
Specification for 261-0191 Cylinder Block Gp
Item Qty Parts Specification Description
Thoroughly lubricate the full inner diameter of the cylinder liner with clean en-
4 1 322-1126 Cylinder Block Liner
gine oil.
5 - - Lubricate the bore of the O-ring seal lightly with the fluid that is being sealed.
Dimension from the centerline of the crankshaft bearing bore to the top of a
H - - new cylinder block is 425.45 mm (16.750 inch).
Minimum dimension should be 425.02 mm (16.733 inch).
Bore in the cylinder block for the main bearings is 129.891 ± 0.013 mm
J - -
(5.1138 ± 0.0005 inch).
Width of the main bearing cap is 215.9 mm (8.50 inch).

K - - Width of the cylinder block for the main bearing cap is 215.900 ± 0.020 mm
(8.5000 ± 0.0008 inch).
Dimension from the centerline of the crankshaft bearing bore to the bottom of
L - -
cylinder block pan rails is 165.1 mm (6.50 inch).
Use the following procedure in order to tighten the main bearing cap bolts:
1. Apply clean engine oil to the threads of the bolts.
2. Tighten the bolts that are in the tab end to 258 ± 14 N·m (190 ± 10 lb ft).
3. Tighten the bolts that are opposite to the tab end to 258 ± 14 N·m
(190 ± 10 lb ft).
6 14 3P-1323 Bearing Cap Bolts
4. Again, tighten the bolts that are opposite to the tab end to an additional an-
gle of 120 ± 5 degrees.
4. Again, tighten the bolts that are in the tab end to an additional angle of 120
± 5 degrees.
Repeat the procedure for each bolt.
The total flatness of the top contact surface of the cylinder block must be within 0.10 mm (0.004 inch). The flatness must also be within 0.05 mm
(0.002 inch) for any 150 mm (5.9 inch) section of the surface.
60 UENR3426
i04399232
Cylinder Liner
SMCS Code: 1216
Table 33
Specification for the 253-8766 Cylinder Block Liner, 215-2985 Cylinder Block Liner, 322-1126 Cylinder Block Liner, and 304-9856
Cylinder Block Liner
A - - New liner bore is 145.000 ± 0.025 mm (5.7086 ± 0.0010 inch).
Thickness of flange on liner is 8.890 ± 0.020 mm (0.3500 ± 0.0008 inch).

B - -
The minimum thickness of the part that can be used again is 8.870 mm (0.3492 inch).
Use the following procedure for installing the cylinder liner into the cylinder block:
1. Apply 5P-3975 Rubber Lubricant on the surfaces of the cylinder liner bore. Apply 5P-3975 Rubber Lubricant on the rubber seals on the low-
er part of the cylinder liner.
2. Put filler band (1) completely in clean engine oil for a moment.
3. Install the filler band in the groove under the liner flange without delay.
4. Install the liner in the bore immediately, before the filler band expands.
Refer to Guideline For Reusable Parts, SEBF8068, “Cylinder Liners” for more information. Also, refer to Testing and Adjusting, “Cylinder Liner
Projection - Inspect” for the procedure for inspecting the projection of the cylinder liners.
UENR3426 61
i05391039
Crankshaft
SMCS Code: 1202
Table 34
Specification for 189-4917 Crankshaft Gp
Refer to Specifications, “Connecting Rod and Main Bearing Journals” for more information about the crankshaft journals.
For the correct procedure of measuring for a bent crankshaft, refer to the Guideline for Reusable Parts and Salvage Operations, SEBF8054,
“Procedure to Measure and Straighten Bent Crankshafts”.
1 2 253-1752 Thrust Plate Install the thrust plates on the center main bearing journal of the crankshaft only.
A 1 4N-0684 Dowel Maximum protrusion of the dowel from the face of the crankshaft is 6.4 mm (0.25 inch).
2 Average diameter of the crankshaft gear after assembly is 220.34 ± 0.19 mm

1 223-9135 Crankshaft Gear (8.675 ± 0.007 inch).
B Maximum diameter of the crankshaft gear after assembly is 220.56 mm (8.683 inch).
D End play with new thrust plates is 0.11 ± 0.57 mm (0.004 ± 0.022 inch).
62 UENR3426
View C-C
Table 35
Specification for 189-4917 Crankshaft Gp
E 1 7S-5005 Dowel Protrusion of the dowel from the surface of the crankshaft is 4.1 ± 0.5 mm (0.16 ± 0.02 inch).
UENR3426 63
i05255405
Vibration Damper and Pulley

SMCS Code: 1205
Typical example
Table 36
Specification for 324-7482 Damper and Pulley Gp and 209-3600 Damper and Pulley Gp
Before assembly, lubricate the threads of the bolts with molybdenum disulfide or graphite
1 6 131-7880 Bolt
base lubricant.
2 12 2D-8155 Taperlock Stud Torque to 65 ± 10 N·m (48 ± 7 lb ft).
3 12 1F-7958 Full Nut Torque to 135 ± 20 N·m (100 ± 15 lb ft).

64 UENR3426
i05255429
Vibration Damper and Pulley

SMCS Code: 1205
Table 37
Specification for 324-7481 Damper and Pulley Gp
Before assembly, lubricate the threads of the bolts with molybdenum disulfide or graphite base
1 6 131-7880 Bolt
lubricant.
2 12 2D-8155 Taperlock Stud Torque to 65 ± 10 N·m (48 ± 7 lb ft).
3 12 1F-7958 Full Nut Torque to 135 ± 20 N·m (100 ± 15 lb ft).

UENR3426 65
i03565193 Clearance between the new bearing and the journal

................................................0.062 mm to 0.160 mm
Vibration Damper and Pulley (0.0024 inch to 0.0063 inch)
SMCS Code: 1205
Maximum permissible clearance between the bearing
and the journal ........................... 0.20 mm (0.008 inch)
Note: Before assembly, lubricate the threads of the

bolts (1) with molybdenum disulfide or graphite base
lubricant.
(1) Torque for the bolts............................270 ± 25 N·m

(199 ± 18 lb ft)
(2) Torque for the taperlock studs.............65 ± 10 N·m

(48 ± 7 lb ft)
(3) Torque for the full nuts .......................135 ± 20 N·m

(100 ± 15 lb ft)
i03001867
Connecting Rod Bearing

Journal
SMCS Code: 1202; 1219; 1225
Refer to Guideline For Reusable Parts, SEBF8009,
“Main and Connecting Rod Bearings” and Guideline
For Reusable Parts, SEBF8041, “Specifications for
Crankshaft in Caterpillar Engines”.
Table 38
Connecting Rod Bearing Journal
97.000 ± 0.020 mm
Original Size Journal
(3.8189 ± 0.0008 inch)
Undersize Journal 0.63 mm

96.37 mm (3.794 inch)
(0.025 inch)
Undersize Journal 1.27 mm

95.73 mm (3.769 inch)
(0.050 inch)
66 UENR3426
i04379811
Main Bearing Journal

SMCS Code: 1202; 1203
Table 39
Specification for the 221-9360 Crankshaft, 189-4918 Crankshaft, and 337-0201 Crankshaft
Main bearing journal original size is 120.650 ± 0.020 mm (4.7500 ± 0.0008 inch).
Diameter of 0.63 mm (0.025 inch) undersize main bearing journal is 120.015 ± 0.020 mm
(4.7250 ± 0.0008 inch).
Diameter of 1.27 mm (0.050 inch) undersize main bearing journal size is 119.380 ± 0.020 mm
(4.7000 ± 0.0008 inch).
- - - Clearance between new bearing and new journal of Main bearing cap with two bolts is
0.076 to 0.186 mm (0.0030 to 0.0073 inch).
Clearance between new bearing and new journal of Main bearing cap with four bolts is
0.071 to 0.178 mm (0.0028 to 0.0070 inch).
Original size of the main bearing bore in the block is 129.891 ± 0.013 mm (5.1138 ± 0.0005 inch).
Diameter of 0.63 mm (0.025 inch) oversize main bearing bore in the block is 130.521 ± 0.013 mm
(5.1387 ± 0.0005 inch).
i02776201 Table 41
Main Bearing Bore
Main Bearing Journal
Original Size of the Bore In the 129.891 ± 0.013 mm
SMCS Code: 1202; 1203 Block (5.1138 ± 0.0005 inch)
Refer to Guideline For Reusable Parts And Salvage Oversize Bore 0.63 mm 130.526 ± 0.013 mm
Operations, SEBF8009, “Main and Connecting Rod (0.025 inch) (5.1388 ± 0.0005 inch)
Bearings” and Guideline For Reusable Parts and
Salvage Operations, SEBF8041, “Specifications for
Crankshaft in Caterpillar Engines”.
Table 40
Main Bearing Journals
120.650 ± 0.020 mm
Original Size Journal
(4.7500 ± 0.0008 inch)
Undersize Journal 0.63 mm 120.015 ± 0.020 mm

(0.025 inch) (4.7250 ± 0.0008 inch)
Undersize Journal 1.27 mm 119.380 ± 0.020 mm

(0.050 inch) (4.7000 ± 0.0008 inch)
Main bearing cap with two bolts
Clearance between new bearing and new journal

..........0.076 to 0.186 mm (0.0030 to 0.0073 inch)
Main bearing cap with four bolts
Clearance between new bearing and new journal

..........0.071 to 0.178 mm (0.0028 to 0.0070 inch)
UENR3426 67
i05393058
Connecting Rod
SMCS Code: 1218
68 UENR3426
Table 42
Specification for 283-7669 Piston and Rod Gp, and 224-3245 Rod As
A - - Location of the bearing joint from the horizontal centerline of the pin bore is ± 5 degrees.
Inside diameter of connecting rod for bearing for the piston pin is 64.592 ± 0.013 mm
B - -
(2.5430 ± 0.0005 inch).
C - - Bore diameter of bearing for the piston pin is 60.035 ± 0.008 mm (2.3636 ± 0.0003 inch).
Maximum length for heating the connecting rod during the installation of bearing for piston pin is
93.0 mm (3.66 inch).
D - -
Temperature for heating the connecting rod is 175 to 260 °C (347 to 500 °F).
Note : Apply heat to the connecting rod prior to installation of bearing for piston pin.
Distance between the center of the bore for the bearing for piston pin and the center of the bore for
E - -
the crankshaft journal is 270.76 mm (10.660 inch).
Inside diameter of connecting rod for the bearing for crankshaft journal is 103.200 ± 0.013 mm
F - -
(4.0630 ± 0.0005 inch).
G - - Bore in the bearing for crankshaft is 97.088 ± 0.016 mm (3.8224 ± 0.0006 inch).
Use the following procedure in order to tighten the bolts for the rod cap. Refer Illustration 81 for tight-
ening sequence.
1. Before assembly, lubricate the threads of the bolts and the seating face of the bolt heads with
clean engine oil.
1 4 213-3217 Bolt 2. Tighten bolt 1 and bolt 3 to 70 ± 4 N·m (52 ± 3 lb ft).
3. Tighten bolt 2 and bolt 4 to 70 ± 4 N·m (52 ± 3 lb ft).
4. Tighten bolt 2 and bolt 4 by an additional angle of 60 ± 5 degrees.
5. Again tighten bolt 1 and bolt 3 to 70 ± 4 N·m (52 ± 3 lb ft).
6. Tighten bolt 1 and bolt 3 by an additional angle of 60 ± 5 degrees.
UENR3426 69
i05391024
Piston and Rings

SMCS Code: 1214; 1215
Typical example
Table 43
Specification for 235-6393 Piston and Rod Gp, 283-7669 Piston and Rod Gp, 308-4486 Piston and Rod Gp, 235-6394 Piston and
Rod Gp, and 324-5618 Piston and Rod Gp
Install the top piston ring with the side marked “UP-1” toward the top of the piston. The
purple colored stripe faces to the right of the piston ring end gap.
1 1 223-9159 Top Piston Ring Thickness of new top piston ring is 3.845 mm (0.1514 inch)
Clearance between the ends of the piston ring in a cylinder liner bore of 144.975 mm
(5.7077 inch) is 0.40 ± 0.10 mm (0.016 ± 0.004 inch)
Install the intermediate piston ring with the side marked “ UP-2” toward the top of the pis-
ton. The white-colored stripe faces to the right of the piston ring end gap.
2 1 238-2707 Piston Ring Thickness of new intermediate piston ring is 2.94 mm (0.116 inch)
(5.7077 inch) is 0.600 ± 0.125 mm (0.0236 ± 0.0049 inch)
The spring ends of the oil control ring should be assembled 180 degrees from the ring end
gap. The colored faces to the right or left of the piston ring end gap.
3 1 246-5659 Piston Ring
Width of groove in new piston for oil control piston ring is 3.020 ± 0.010 mm
(0.1189 ± 0.0004 inch)
(continued)
70 UENR3426
(Table 43, contd)

Thickness of new oil control piston ring is 2.980 ± 0.010 mm (0.1173 ± 0.0004 inch)
(5.7077 inch) is 0.55 ± 0.15 mm (0.022 ± 0.006 inch)
Thoroughly lubricate the piston pin with clean engine oil before the piston is inserted into
the piston body and the connecting rod (6).
Diameter of the new piston pin is 59.975 ± 0.005 mm (2.3612 ± 0.0002 inch)
4 1 180-7350 Piston Pin
Length of the piston pin is 89.80 ± 0.15 mm (3.535 ± 0.006 inch)
Install the retainer ring (5) with the gap at the bottom of the piston. Refer to Illustration 82 .
7 1 151-5925 Bolt Torque to 40 ± 8 N·m (30 ± 6 lb ft)
Thoroughly lubricate the entire piston in zone (A) with clean engine oil prior to assembly into the cylinder block
After the piston rings have been installed, rotate the piston rings so that the end gaps are placed at 120 degrees distance from each other.
UENR3426 71
i05256843
Housing (Front)
SMCS Code: 1151
Table 44
Specification for 291-4880 Front Housing Gp and 206-1211 Front Housing Gp
During assembly, front and the rear faces of front plate, front face of block, and the rear face of housing assembly must be free of oil, fuel, water,
dirt, and any other contaminants.
Use the following procedure in order to tighten the bolts that fasten the plate to
the cylinder block.
(1)Use hand tools to tighten the bolts.
1 8 5P-4255 Locking Bolt
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
(2)Use hand tools to tighten the bolts again.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Before assembly, apply ultra blue Loctite 587 in order to fill the space at the cyl-
2 - -
inder block, front plate, and oil pan joint.
Before assembly, apply ultra blue Loctite 587 to the bottom of the seal at the in-
3 - -
terface with the block. Apply sealant immediately prior to installation of the seal.
- - - After assembly, trim 166-9144 Gasket flush to face (4).

72 UENR3426
i05256759
Front Housing and Covers

SMCS Code: 1162; 1166
Table 45
Specification for 159-6159 Front Housing Cover Gp
1 12 297-1813 Head Screw Torque to 21 ± 3 N·m (186 ± 27 lb in).
Apply 155-0695 Thread Lock Compound to the threads of the stud that engage the front
2 2 175-1366 Stud
housing.
UENR3426 73
i02393955 Apply 9S-3263 Thread Lock Compound to the

four bolts that fasten the cluster gear to the stub
Gear Group (Front) shaft.
Tighten the four bolts that fasten the cluster gear
SMCS Code: 1206
to the stub shaft to the following torque.
.......................................55 ± 10 N·m (41 ± 7 lb ft)
(1) Water pump drive gear (3) Camshaft gear
(12) Bolts for the sealing plate for the camshaft
(13) Seals
(14) Camshaft gear bolts
Stub shaft for cluster gear
(2) Cluster gear Illustration 88 g00593987
Apply 9S-3263 Thread Lock Compound to the Bolt locations for the camshaft gear
five bolts for the stub shaft.
Tighten the five bolts for the stub shaft in the (3) Camshaft gear
following sequence. See Illustration 86 for the
numbering of the bolts. .......1, 3, 4, 5, 2, 1, 2, 3, 4,
5, 1
74 UENR3426
Lightly lubricate the O-ring seal on the outside of (11) Oil pump drive gear
the camshaft sealing plate with a 50/50 mixture of
8T-2998 Lubricant and clean engine oil. Apply Tighten the bolt for the oil pump drive gear to the
9S-3263 Thread Lock Compound to the three following torque..............55 ± 10 N·m (41 ± 7 lb ft)
bolts for the camshaft sealing plate.
Tighten the three camshaft sealing plate bolts to
the following torque. See Illustration 87 .
...........................................12 ± 3 N·m (9 ± 2 lb ft)
Tighten the camshaft bolts in the following
sequence. See Illustration 88 for the numbering
of the bolts. ..............................1, 4, 2, 5, 3, 6, 1, 4
Tighten the six camshaft gear bolts to the
following torque........240 ± 40 N·m (177 ± 30 lb ft)
(4) Align the timing mark on the camshaft gear with
the timing mark on the front housing when the No. 1
piston is at top center.
(5) Adjustable idler gear
Install the plate with the oil groove toward the

gear face. Apply 9S-3263 Thread Lock
Compound to the three bolts that fasten the
adjustable idler gear to the stub shaft.
Tighten the three bolts for the adjustable idler
gear to the stub shaft to the following torque.
.......................................55 ± 10 N·m (41 ± 7 lb ft)
Refer to Testing and Adjusting, “Gear Group

(Front) - Time” for the backlash adjustment
procedure.
Backlash between the camshaft gear and the
adjustable idler gear..................0.216 ± 0.114 mm
(0.0085 ± 0.0045 inch)
Apply 9S-3263 Thread Lock Compound to the
one bolt and five studs for the stub shaft.
Tighten the one bolt and five nuts for the stub
shaft to the following torque. ..............55 ± 10 N·m
(41 ± 7 lb ft)
(6) Air compressor gear (if equipped)
(7) Idler gear

one bolt and five studs for the stub shaft.
Tighten the one bolt and five nuts for the stub
shaft to the following torque. ..............55 ± 10 N·m
(41 ± 7 lb ft)

three bolts that fasten the idler gear to the stub
shaft.
Tighten the three bolts that fasten the idler gear to
the stub shaft to the following torque.
.......................................55 ± 10 N·m (41 ± 7 lb ft)
(8) Gear for the fuel transfer pump drive
(9) Align the timing mark on the crankshaft gear with
the timing mark on the cluster gear.
(10) Crankshaft gear
UENR3426 75
i05206414
Gear Group (Front)

SMCS Code: 1206
(1) Water pump drive gear (7) Gear assembly (11) Oil pump drive gear
(5) Gear assembly (8) Gear for the fuel transfer pump
(6) Air compressor drive gear (if equipped) (10) Crankshaft gear
Note: Refer to the following procedure when any bolt

or any nut is loosened for service:
1. Remove the bolt or the nut.
2. Clean the bolt, the nut and/or the stud with a wire
brush.
3. Apply blue Loctite 242 to the threads of the bolts,
nuts and/or studs before assembly.
4. A new bolt with a previously applied thread lock is
acceptable for use.
5. Tighten the bolts, the nuts and/or the studs to the
standard torque.
Note: Refer to Testing and Adjusting, “Gear Group
(Front) - Time” for the backlash adjustment
procedure.
76 UENR3426
Table 46
Specifications for 208-9490 Front Gear Gp, 207-0449 Front Gear Gp, and 248-6767 Front Gear Gp
Before tightening the bolts for the stub shaft, set distance (A) between the centers of
A - - camshaft gear (3) and gear assembly (5) with a gauge in order to obtain the gear back-
lash of 0.3556 ± 0.254 mm (0.0140 ± 0.010 inch) .
Torque sequence for the stub shaft for cluster gear
Table 47
Tighten five bolts for the stub shaft of the cluster gear assembly to the standard torque in
2 1 197-4971 Stub Shaft
the following sequence. Refer to Illustration 90 - 1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1
UENR3426 77
Torque sequence for the camshaft gear
78 UENR3426
Table 48
Align the timing mark on the camshaft gear with the timing mark on the front housing when
4 -
the No. 1 piston is at top center.
Align the timing mark on the crankshaft gear with the timing mark on the cluster gear
9 -
assembly.
Lightly lubricate O-ring seal (12) with 50/50 mixture of 8T-2998 Lubricant and clean en-
gine oil.
13 1 031-3185 Bolt
Tightening sequence for bolts (13) 1, 4, 2, 5, 3, 6, 1, 4
Torque bolts (13) to 240 ± 40 N·m (177 ± 30 lb ft)
14 - - Install the oil groove of the thrust plate toward the face of gear assembly (7).
15 - - Install the oil groove of the thrust plate toward the face of gear assembly (5).
16 - - Install the oil groove of the thrust plate toward the face of cluster gear assembly (2).
i02867219 i03293175
Flywheel Flywheel
SMCS Code: 1156 SMCS Code: 1156
Illustration 93 g01222011 Illustration 94 g01248855

(2) Ring gear (1) Flywheel
(3) Flywheel ring gear
Note: Refer to the System Operation, Testing &
Adjusting, “Flywheel Runout” for the correct method Note: Refer to Systems Operation/Testing and
of flywheel inspection. Adjusting for the correct method of inspecting the
flywheel.
(1) Apply engine oil, molybdenum disulfide, or a
graphite based lubricant to the threads of the bolts. (2) Bolts
Tighten the bolts to the following torque. Lubricate the threads of the bolts with molybdenum
........................................270 ± 40 N·m (200 ± 30 lb ft) disulfide before assembling the flywheel.
Tighten the bolts to the following torque.

........................................300 ± 40 N·m (220 ± 30 lb ft)
UENR3426 79
i05391840
Flywheel
SMCS Code: 1156
Table 49
Specification for 9Y-7571 Flywheel Gp
Before assembly, lubricate the threads with molybdenum disulfide-based lubricant (molylube).
Use the following procedure to tighten the 12 bolts in a circular pattern. The circular pattern
can be in a clockwise direction or in a counterclockwise direction.
1 12 9Y-8545 Bolt
1. Torque to 100 ± 5 N·m (74 ± 4 lb ft).
2. Turn the bolts by an additional 90 ± 5 degrees.
Replace the bolts at service.
80 UENR3426
i02685927
Flywheel Housing
SMCS Code: 1157
(25) Torque for the plug ......35 ± 14 N·m (26 ± 10 lb ft)
Note: During assembly, inspect the following

components for any foreign materials: the front face
of the flywheel housing, the two sides of the flywheel
housing gasket and the rear face of the cylinder
block. These components must be free of the
following substances: oil, fuel, water, gasket
adhesive, assembly compounds and any other
foreign material. Apply a small amount of 8T-9022
Silicone Gasket in order to fill the space between the
cylinder block, the flywheel housing, and the oil pan
before installing the oil pan gasket and the oil pan.
Use the following procedure to tighten the flywheel
housing bolts:
1. Tighten bolt (1) through bolt (9) to 100 ± 20 N·m

(75 ± 15 lb ft).

(30 ± 7 lb ft).

(100 ± 15 lb ft).

(41 ± 7 lb ft).
UENR3426 81
i05391033
Flywheel Housing
SMCS Code: 1157
82 UENR3426
Table 50
Specification for 178-8579 Flywheel Housing Gp, and 248-0312 Flywheel Housing Gp
Front face of the flywheel housing and rear face of the cylinder block must be free of oil, fuel, water, gasket adhesive, and any other contaminants
during assembly. Apply ultra blue Loctite 587 to seal the joints between the cylinder block, flywheel housing, and engine oil pan.
Before assembly, apply ultra blue Loctite 587 to the locations (4). After assembly, apply ultra blue Loctite 587 to the locations (5).
1 8 165-3929 Bolt Use the following procedure to tighten the bolts of the flywheel housing:
2 7 165-3931 Bolt
1.Tighten bolt 1 through bolt 9 in the numerical sequence as shown in the Illustration 99 to
100 ± 20 N·m (75 ± 15 lb ft)
2. Tighten bolt 10 through bolt 24 in the numerical sequence as shown in the Illustration 99
to 40 ± 10 N·m (30 ± 7 lb ft) in the numerical sequence.
3 9 5J-5793 Bolt 3. Again, tighten bolt 1 through bolt 9 in the numerical sequence as shown in the Illustration
99 to 135 ± 20 N·m (100 ± 15 lb ft) in the numerical sequence.
4. Again, tighten bolt 10 through bolt 24 in the numerical sequence as shown in the Illustra-
tion 99 to 55 ± 10 N·m (41 ± 7 lb ft) in the numerical sequence.
UENR3426 83
i05084397
Belt Tension Chart

SMCS Code: 1357
Table 51
Specification for the 7N-9693 Tension Chart
The new belt tension chart has been standardized. The belt tension chart eliminates confusion about the
correct belt tension to use. Studies were completed with different belt suppliers and the information that
was gathered from the studies was developed into a new belt tension for each belt size.
The chart does not apply to belts that use a spring loaded tensioner.
For more accurate results, a Clavis frequency gauge should be used in order to measure the natural fre-
quency of the belt. By the use of a formula, the natural frequency is converted into the belt tension force. If
the Clavis frequency gauge cannot be used, then use the appropriate Kent-Moore belt tension gauge to
- - -
measure the belt tension force.
When matched sets of belts are used, check the tension of all the belts in order to verify that the lowest belt
is in the acceptable tolerance range. Variations in tension between the belts can vary by as much as 65
pounds.
In order to determine the tension of a “banded” belt, refer to the chart above. Multiply the tension value of
the belt by the number of belts that are banded together.Two 1/2 inch belts would require a used belt ten-
sion equal to twice the value of the used belt tension for one 1/2 inch belt (2 X 80 = 160 lb).
Table 52
Belt Tension Chart
SAE or RMA Belt SIze Width of Belt (Top Belt Tension “Initial”” (1) Belt Belt Tension “Used”” (3) (4)
Reference) Tension
Used(2)
IN MM IN MM LB N LB N LB N
3/8 (0.380) 10A 0.42 10.72 145±10 645±44 115±10 510±44 70±10 311±44
7/16 (0.440) 11A 0.46 11.68 155±10 689±44 125±10 560±10 75±10 333±44
1/2 (0.500) 13A 0.55 13.89 165±10 734±44 130±10 580±10 80±10 356±44
5V/5VX 5V 0.63 15.88 180±10 801±44 145±10 645±10 85±10 378±44

11/16 (0.600) 15A 0.69 17.48 180±10 801±44 145±10 645±10 85±10 378±44
3/4 (0.660) 17A 0.75 19.05 205±10 912±44 165±10 730±44 95±10 422±44
7/8 (0.790) 20A 0.88 22.23 205±10 912±44 165±10 730±44 95±10 422±44
15/16 N/A 0.98 23.83 205±10 912±44 165±10 730±44 95±10 422±44
4K 4PK 0.54 13.72 145±10 645±44 115±10 510±44 60±10 267±44
6K 6PK 0.82 20.94 215±10 956±44 170±10 755±10 90±10 400±44
8K 8PK 1.1 27.82 285±10 1179±44 230±10 1025±10 115±10 511±44
10K 10PK 1.38 35.05 355±10 1579±44 285±10 1270±10 145±10 645±44
12K 12PK 1.66 42.16 425±10 1891±44 340±10 1510±10 175±10 778±44
14K 14PK 1.94 49.28 495±10 2202±44 395±10 1755±10 205±10 912±44
15K 15PK 2.08 52.83 530±10 2358±44 425±10 1890±44 215±10 956±44
(1) Belt Tension “Initial ” is for a new belt.
(2) Belt tension with less than 10 hours of operation
(3) Belt tension “Used” is for a belt that has operated for more than 30 minutes of operation at the rated speed..
(4) If a belt falls below the “Used” belt tension, the belt should be tightened again to 80% of the “Initial” belt tension.
84 UENR3426
i02685929 Output voltage .........................................14.0 ± 0.5 V
Alternator and Regulator (1) Torque for the locknut......102 ± 7 N·m (75 ± 5 lb ft)
SMCS Code: 1405; 1410 (2) Torque for output terminal nuts..........7.1 ± 0.8 N·m
(65 ± 7 lb in)
(3) 3E-5451 Voltage Regulator As
Voltage setting .....................................No adjustment
Permissible voltage range ....................13.5 to 14.5 V
Voltage rating .......................................................24 V
Note: Load the battery with a carbon pile 4C-4911

Battery Load Tester in order to get the maximum
alternator output.
Polarity ..............................................Negative ground
Rotation ............................................... Either direction
Minimum full load current at 5000 rpm ...........96 Amp
Minimum full load current at 1500 rpm ...........42 Amp

UENR3426 85
i04557209
Alternator and Regulator

SMCS Code: 1405; 1410
Table 53
Specification for 4N-3986 Charging Alternator Gp
Load the battery with a carbon pile 4C-4911 Battery Load Tester in order to
- - -
get the maximum alternator output.
1 1 187-2034 Flange Nut Torque to 102 ± 7 N·m (75 ± 5 lb ft).
Use a 7/16 ring terminal for (B+) terminal.

2 - 6V-8187 Nut
(B+) terminal. Torque to 6.75 ± 1.50 N·m (59.74 ± 13.28 lb in).
3 1 4B-2047 Nut Torque to 2.25 ± 0.25 N·m (20.00 ± 2.00 lb in)
4 - 6V-8187 Nut (B-) terminal. Torque to 6.75 ± 1.50 N·m (59.74 ± 13.28 lb in).
Voltage setting is not adjustable.

3T-6354 Voltage Regulator
5 1
As Permissible voltage range is 27 to 29 V.
- - - Voltage is 24 V.
- - - Amperage is 60 amp.
- - - Polarity is negative ground.
- - - Rotation is either direction.
- - - Maximum turn on speed is 2000 rpm.
- - Alternator performance at 25 °C (77 °F).
- - - Minimum full load current at 5000 rpm is 68 amp.
- - - Minimum full load current at 2000 rpm is 42 amp.
- - - Output voltage is 28 ± 1 V.
86 UENR3426
i03194075 Minimum full load current at 5000 rpm ...........45 Amp
Alternator and Regulator Minimum full load current at 1500 rpm ........14.5 Amp
SMCS Code: 1405; 1410 Output voltage .........................................13.8 ± 0.2 V
(1) Final installation torque for the nut ........60 ± 7 N·m

(44 ± 5 lb ft)
Note: The peak voltage for (R) terminal must not be

less than the output voltage for (B+) terminal.
(2) (R) terminal. Final installation torque for two nuts

.......................................2.25 ± 0.25 N·m (20 ± 2 lb in)
(3) (B+) terminal. Final installation torque for the nut

...........................................4.1 ± 0.4 N·m (35 ± 4 lb in)
(4) (B-) terminal. Final installation torque for the nut

.......................................2.25 ± 0.25 N·m (20 ± 2 lb in)
(5) Voltage regulator group
Voltage setting ...............................No adjustment

alternator output.
Voltage .................................................................12 V
Amperage .......................................................51 Amp
Polarity ..............................................Negative ground
Rotation ............................................... Either direction

UENR3426 87
i02499698 Minimum full load current at 1500 rpm ........10.8 Amp
Alternator and Regulator Output voltage ............................................28 ± 1.0 V

SMCS Code: 1405; 1410 (1) Shaft nut torque.................60 ± 7 N·m (44 ± 5 lb ft)
(2) Torque for three terminal nuts .......2.25 ± 0.25 N·m

(20 ± 2 lb in)
(3) Torque for the large terminal nut .......4.1 ± 0.4 N·m
(36 ± 4 lb in)
(4) 134-8278 Regulator Kit
Voltage setting .....................................No Adjustment
Permissible voltage range .......................... 27 to 29 V
Voltage rating .......................................................24 V
i02870347
Coolant Temperature Sensor

SMCS Code: 1906

Typical example
(2) Plug
(1) Final installation torque .....20 ± 3 N·m (15 ± 2 lb ft)
Operating voltage ............................4.75 to 8.50 Volts
Output type ......................................................Analog
6T-1395 Alternator
alternator output.
Polarity .............................................Negative Ground
Rotation ...............................................Either Direction
Minimum full load current at 5000 rpm ........27.9 Amp

88 UENR3426
i04405418

SMCS Code: 1906
Table 54
Specification for 264-4297 Temperature Sensor and 256-6453 Temperature Sensor
1 1 - Torque to temperature sensor 20 ± 3 N·m (177 ± 27 lb in).
- - - Output type is Passive.

UENR3426 89
i04448859

SMCS Code: 1906
Table 55
Specification for 130-9811 Temperature Sensor Gp, 274-7396 Temperature Sensor Gp, 197-8392 Temperature Sensor Gp, and
256-6453 Temperature Sensor
Torque to 20 ± 3 N·m (175 ± 25 lb in).

1 1 -
Output type is passive.
90 UENR3426
i04935270
Coolant Level Sensor

SMCS Code: 7470-NS
Table 56
Specification for 204-2518 Liquid Level Sensor Gp and 239-9957 Liquid Level Sensor Gp
Torque to 20 ± 3 N·m (177 ± 27 lb in).

1 1 -
Operating voltage is 7 to 32 VDC.
UENR3426 91
i04385495
Fuel Temperature Sensor

SMCS Code: 1922
Table 57
Specification for the 130-9811 Temperature Sensor Gp, 197-8391 Temperature Sensor Gp, and 256-6453 Temperature Sensor
Torque to 20 ± 3 N·m (175 ± 25 lb in).

1 1 -
Output type is passive.
92 UENR3426
i04390215
Fuel Temperature Sensor

SMCS Code: 1922
Table 58
Specification for the 264-4297 Temperature Sensorand 256-6453 Temperature Sensor
Torque to 20 ± 3 N·m (15 ± 2 lb ft).

1 - -
Output type is Passive.
UENR3426 93
i04935269
Fuel Pressure Sensor

SMCS Code: 1718
Table 59
Specification for 161-1705 Pressure Sensor
Torque to 10 ± 2 N·m (89 ± 18 lb in).

1 1 161-1705 Pressure Sensor
Operating voltage is 5.00 ± 0.25 VDC.
94 UENR3426
i04402163
Engine Oil Pressure Sensor

SMCS Code: 1924
Table 60
Specification for the 161-1705 Engine Oil Pressure Sensor
Torque the pressure sensor to 10 ± 2 N·m (90 ± 18 lb in).
Prior to installing the pressure sensor onto the engine, apply 5P-3413 Pipe
1 - -
Sealant to the first three threads of the sensor.
Operating voltage is 5.00 ± 0.25 VDC.
i02870383
Boost Pressure Sensor

SMCS Code: 1917

(2) Plug
(1) Final installation torque .........................10 ± 2 N·m

(90 ± 18 lb in)
Operating voltage ............................4.75 to 5.25 VDC

UENR3426 95
i05309728
Atmospheric Pressure Sensor

SMCS Code: 1923

Typical example
Table 61
Specifications for 161-9932 Pressure Sensor Gp, and 163-8492 Pressure Sensor Gp
1 - - Final installation torque is 10 ± 2 N·m (89 ± 18 lb in).
- - - Operating temperature is −40 to 125 °C (−40 to 225 °F).
- - - Operation voltage is 5.00 ± 0.25 VDC.
i03001907 Output type .....................................................Passive
Inlet Air Temperature Sensor

SMCS Code: 1921
(1) Final installation torque for the temperature sensor

group.......................................20 ± 5 N·m (15 ± 4 lb ft)
Operating temperature .......................... −40 to 150 °C

(−40 to 302 °F)
96 UENR3426
i04390275
Inlet Air Temperature Sensor

SMCS Code: 1921
Table 62
Specification for the 264-4297 Temperature Sensor and 256-6453 Temperature Sensor
Torque to 20 ± 3 N·m (15 ± 2 lb ft).

1 1 -
Output type is Passive.
UENR3426 97
i05393037
Speed/Timing Sensor
SMCS Code: 1907; 1912
Primary Speed/Timing Sensor
Table 63
Specification for 189-9266 Speed Sensor Gp, and 191-8303 Speed Sensor Gp
- - - Lubricate the O-ring seal lightly with the lubricant that is being sealed.
2 2 133-0260 Bracket Ensure that the bracket is installed in the orientation, as shown. Refer to Illustration 119 .
Torque for the bolt is 28 ± 7 N·m (248 ± 62 lb in).

3 - -
Ensure that the sensor (1) is seated before the bolt (3) is tightened.
98 UENR3426
Secondary Speed/Timing Sensor
Table 64
Specification for 188-7513 Speed Sensor Gp, and 201-6617 Speed Sensor Gp
- - - Lubricate the O-ring seal lightly with the lubricant that is being sealed.
5 2 133-0260 Bracket Ensure that the bracket is installed in the orientation, as shown. Refer to Illustration 120 .
Torque for the bolt is 28 ± 7 N·m (248 ± 62 lb in).

6 - -
Ensure that the sensor (4) is seated before the bolt (6) is tightened.
UENR3426 99
i05261085
Tachometer
SMCS Code: 7462
(1) Magnetic pickup terminals
Table 65
Specification for 7C-1072 Electric Tachometer Gp
2 2 6V-8372 Fitting Nut Torque to 0.9 ± 0.1 N·m (8.1 ± 1.0 lb in)
In order to calibrate the tachometer, remove the plug and tighten to 0.6 ± 0.1 N·m
3 - -
(5 ± 1 lb in).
- - - Refer to the Specifications, “Tachometer Calibration Chart” for calibration settings.
General specifications:
Operating temperature range is −20 to 85° C (−4 to 185° F)
Accuracy of tachometer is ± 0.5 percent.
- - -
Input frequency range is 75 to 9000 Hz
Time that is required for the update (maximum) is 1.0 second.
Time that is required for the update (minimum) is 0.25 second.
100 UENR3426
i03288363
Tachometer Calibration Chart

SMCS Code: 7462

UENR3426 101
i05255395
Circuit Breakers
SMCS Code: 1420

Typical example
Table 66
Specification for 171-2213 Circuit Breaker As, 171-2209 Circuit Breaker As and 171-2205 Circuit Breaker As
1 2 8T-0122 Full Nut Final installation torque to 6.3 ± 0.5 N·m (55.8 ± 4.4 lb in).
i02870411
Circuit Breakers
SMCS Code: 1420
(1) Tighten the nuts to the following torque.

.......................................2.25 ± 0.25 N·m (20 ± 2 lb in)
102 UENR3426
Index Section
Index
A G
Alternator and Regulator............................ 84–87 Gear Group (Front).....................................73, 75
Atmospheric Pressure Sensor......................... 95
Auxiliary Water Pump ................................ 51–52
H
Heat Exchanger............................................... 53
B Housing (Front)................................................ 71
Belt Tension Chart ........................................... 83
Boost Pressure Sensor.................................... 94
I
Important Safety Information ............................. 2
C Inlet Air Temperature Sensor..................... 95–96
Camshaft ............................................. 24–25, 27
Circuit Breakers ............................................. 101
Connecting Rod............................................... 67 M
Connecting Rod Bearing Journal..................... 65 Main Bearing Journal....................................... 66
Coolant Level Sensor ...................................... 90
Coolant Temperature Sensor..................... 87–89
Crankshaft ....................................................... 61 P
Cylinder Block.............................................54, 57 Piston and Rings ............................................. 69
Cylinder Head.................................................. 15
Cylinder Head Valves ...................................... 13
Cylinder Liner................................................... 60 S
Specifications Section ....................................... 4
E Speed/Timing Sensor ...................................... 97
Primary Speed/Timing Sensor ..................... 97
Electronic Unit Injector Mechanism ................. 10 Secondary Speed/Timing Sensor ................ 98
Electronic Unit Injector Rocker Arm..................11
Engine Design ................................................... 4
C18 ................................................................ 4 T
Engine Oil Filter Base .......................... 29–30, 32 Table of Contents............................................... 3
Engine Oil Pan................... 38–39, 41–42, 45, 47 Tachometer...................................................... 99
Engine Oil Pressure Sensor ............................ 94 Tachometer Calibration Chart........................ 100
Engine Oil Pump.........................................33, 35 Turbocharger ............................................. 17–18
Exhaust Manifold........................................20, 22
V
F
Valve Mechanism ............................................ 12
Flywheel .................................................... 78–79 Valve Mechanism Cover.................................. 13
Flywheel Housing ...................................... 80–81 Vibration Damper and Pulley..................... 63–65
Front Housing and Covers............................... 72
Fuel Filter Base.............................................. 7–9
Fuel Pressure Sensor...................................... 93 W
Fuel Temperature Sensor .......................... 91–92 Water Pump..................................................... 50
Fuel Transfer Pump ....................................... 5–6 Water Temperature Regulator ......................... 49
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All Rights Reserved dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.

Uenr3426 00 00 - Manuals Service Modules

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Uenr3426 00 00 - Manuals Service Modules

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UENR3426

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Piston and Rings ...................... ...................... 69

Bore ..............................................145 mm (5.71 inch)

Stroke ........................................... 183 mm (7.20 inch)

Displacement..................................18.1 L (1105 cu in)

Cylinder arrangement .....................In-line six cylinder

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

Inlet valve lash .................................... 0.38 ± 0.08 mm

Exhaust valve lash.............................. 0.76 ± 0.08 mm

Firing order (injection sequence) ...........1, 5, 3, 6, 2, 4

Crankshaft rotation from the flywheel end

Note: The front end of the engine is opposite the

Fuel Transfer Pump

(1) Weep hole (3) Inlet port

Item Qty Part Specification Description

Fuel Transfer Pump

Item Qty Part Specification Description

2 2 9S-8752 Full Nut Torque to 30 ± 5 N·m (266 ± 44 lb in).

Fuel Filter Base

Item Qty Part Specification Description

1 1 7N-1628 Nut Torque to 24 ± 4 N·m (18 ± 3 lb ft).

Length under test force is 27.94 mm (1.100 inch).

Fuel Filter Base

Item Qty Part Specification Description

1 1 9S-4167 Hollow Stud Torque to 70 ± 15 N·m (52 ± 11 lb ft).

Fuel Filter Base

Item Qty Part Specification Description

Electronic Unit Injector Mechanism

(3) Spacer (4) Unit injector clamp

Item Qty Part Specification Description

1 1 - Torque the locknut to 100 ± 10 N·m (74 ± 7 lb ft).

Use the following procedure to tighten the bolt:

1. Tighten the bolt to 55 ± 10 N·m (41 ± 7 lb ft).

3. Again, tighten the bolt to 55 ± 10 N·m (41 ± 7 lb ft).

i02794899 New parts ............................... 40.065 ± 0.015 mm

(1) Rocker arm (5) Camshaft

Item Qty Part Specification Description

2 1 276-5317 Nut Torque for the nuts 30 ± 7 N·m (265 ± 60 lb in)

Valve lash setting:

Valve Mechanism Cover Cylinder Head Valves

Note: Apply clean engine oil to the valve stems prior

(1) 247-9908 Spring

Length under test force ..... 67.12 mm (2.643 inch)

(2) 211-3122 Spring

Length under test force ..... 60.14 mm (2.368 inch)

(C) Dimension for valve recess

Inlet.............2.20 to 2.80 mm (0.087 to 0.110 inch)

Illustration 14 g01401264 Illustration 15 g01401267

Inlet ..................................... 60.75 ± 0.25 degrees Inlet..................................2.377 mm (0.0936 inch)

The following bolts are 216 mm (8.5 inch) long: 11,

1. In a numerical sequence, tighten bolts 1 through

Torque for bolts ...............270 ± 15 N·m (200 ± 11 lb ft)

2. In a numerical sequence, tighten bolts 1 through

Torque for bolts ...............450 ± 15 N·m (330 ± 11 lb ft)

3. In a numerical sequence, again tighten bolts 1

(A) Cylinder Head Thickness Illustration 19 g01430712

(1) Apply 4C-5599 Anti-Seize Compound to the

The depth of installation of the camshaft bearings is

Installation depth for camshaft bearings (30)

C.......................... 8.0 ± 0.5 mm (0.32 ± 0.02 inch)