ENGINE REBUILD SHEET 4/ 6 B

F - T&S - 31
Job No. : Eng. Model :
Customer : ESN :
CPL : Pump Code :
Start Date : Finish Date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
1. CYLINDER BLOCK
C - Clean Cylinder Block, all Oil and Coolant Passages.

I - Install Cup Plug and Dowel Pin using the correct size Cup Plug
Driver handle with loctite 648 / Sealant P/N 3375068.

C - Use Soft Hamer to Install Pin Dowel.

CONDITION
CHECK REPORTED BY CHECKED BY
OK REWORKED REPLACED REPAIR
BLOCK CASTING

TOP DECK

CAM BORE

MAIN BORE

CAM IDLER BORE MECHANIC FOREMAN/ SPV Q.A. OFFICER

W/P IDLER BORE date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
2. CAMSHAFT
BUSHING C - Make sure all p/n of bushing are correct.

I - Install Camshaft Bushing with Specified Special Tools P/N

ST.1228 and P/N 3162248 (See tools Catalog).

C - Make sure all oil holes and passages are clean.

INFORMATION REPORTED BY CHECKED BY

BUSHING CONDITION
PART NO. QTY OK REWORKED REPLACED

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
3. MAIN BEARING
SHELL THICKNESS M - Measure the thickness of each bearing shell in accordance with
the bore to which they will be installed. Use ball micrometer.
 SPECIFICATION
MM IN
MIN
MAX

MEASUREMENT RESULT
BEARING 1 2 3 4 5 6 7
T1
UPPER T2
T3
T1
LOWER T2
T3
REPORTED BY CHECKED BY

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
4. MAIN BEARING
CLEARANCE M - Measure main bearing thickness.

M - Measure main bore diameter.

M - Measure main journal crankshaft diameter.

F - Max side = max Bore I.D. - min Main Journal O.D.

F - Min side = min Bore I.D. - max Main Journal O.D.
F Bore I.D. = main bore I.D. - 2.actual sides of bearing shell thickness

MAIN BEARING CLEARANCE RESULT REPORTED BY

JOURNAL NO.
MAXIMUM SIDE MINIMUM SIDE
1
2 MECHANIC, date :
3 CHECKED BY
4
5
6 FOREMAN/ SPV Q.A. OFFICER
7 date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
5. THRUST SIDE
THICKNESS M - Measure the thickness of each thrust bearing.

MEASUREMENT RESULT
SPECIFICATION
POSITION 1 2 3 4
MM IN T1
 MIN T2
MAX T3
REPORTED BY CHECKED BY

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
6. CRANKSHAFT
C - Install Crankshaft.

C - Coat all round main journal with lubriplate P/N 1242.

C - Ensure the Grooves in the Thrust Bearing must point toward

the crankshaft.

C - Do not rotate Crankshaft before main bearing Cap Screw final

torque is done.

INFORMATION
REPORTED BY CHECKED BY
CONDITION
CRANKSHAFT
OK REWORKED REPLACED REPAIR
MAIN JOURNAL

CON ROD JOURNAL

FRONT GEAR

REAR GEAR

MAIN BEARING

CON ROD BEARING MECHANIC FOREMAN/ SPV Q.A. OFFICER

CRANKSHAFT date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
7. MAIN BEARING CAP
C - Install Lower Main Bearing on the Cap.

C - Make sure Cap number has the same number that is stamped
on the block.

C - Use Engine oil, lubricate the Cap Screw Heads, Threads, and
the Washer.

C - Do not use Impact Wrenchs, the Main Bearing Shells can

fall out.

T - Tighten main bearing Cap Screw by following the step.

SPECIFICATION REPORTED BY CHECKED BY

RESULT
N.m STEP ft-lbs
1
2
3
 4
5 MECHANIC FOREMAN/ SPV Q.A. OFFICER
6 date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
8. CRANKSHAFT END
CLEARANCE C - Use a Dial Indicator P/N 3376051 with Magnetic Base P/N
3377399.

M - Measure Crankshaft End Clearance.

CRANKSHAFT INFORMATION SPECIFICATION MM IN RESULT

PART NO. OK REWORKED REPLACED REPAIR MIN
MAX
REPORTED BY CHECKED BY

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
9. CYLINDER
LINER I.D. M - Use a dial bore gauge to measure the ID of the Liner at the Top,
Middle, and Bottom Position.

M - Take 2 measurements at each location with 90 degrees apart.

SPECIFICATION
MM IN
MIN
MAX

POSITION REPORTED BY
I II III
LINER NO.
A-A B-B A-A B-B A-A B-B
1 MECHANIC, date :
2 CHECKED BY
3
4
5 FOREMAN/ SPV Q.A. OFFICER
6 date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
10. PISTON RING
END GAP C - Use a feeler gauge to measure the end gap.

C - Ensure the chrome plating on the Ring is not damaged or the

ring will fail.
 C - Ensure the Cylinder Bore I.D is correct.

SPECIFICATION
MIN MAX
POSITION
MM IN MM IN
TOP
SECOND
OIL

CYLINDER NUMBER
PISTON RING
1 2 3 4 5 6

TOP

2ND

OIL

REPORTED BY CHECKED BY

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
11. CON-ROD BEARING
SHELL THICKNESS M - Measure the thickness of each bearing shell in accordance with
the on rod to which thet will be installed. Use ball micrometer.

SPECIFICATION
MM IN
MIN
MAX

MEASUREMENT RESULT
BEARING 1 2 3 4 5 6
T1
UPPER T2
T3
T1
LOWER T2
T3
REPORTED BY
CONROD BEARING CLEARANCE RESULT
JOURNAL NO.
MAXIMUM SIDE MINIMUM SIDE
1 MECHANIC, date :
 2 CHECKED BY
3
4
5 FOREMAN/ SPV Q.A. OFFICER
6 date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
12. PISTON
C - Install piston rings with stamped mark facing upward and use
special tools P/N. ST-1269.

C - The gap in the oil ring expanding (10) must be turned 180
degrees opposite the gap on the oil ring (11) or the rings and
piston will be damage.

C - Rotate the rings so the gaps are not aligned with the adjacent
ring or a piston pin bore.

C - Check to be sure piston P/N is correct.

ENGINE PISTON SET CONDITION

REMARK
PART PART NO. QTY OK REWORKED REPLACED
TOP RING

2ND RING

OIL RING

PISTON

REPORTED BY CHECKED BY

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
13. CONNECTING ROD
CAP SCREW C - Install lower conrod bearing on the cap.

C - Make sure cap number has the same number that is stamped
on the connecting rod.

C - Use engine oil, lubricate the capcrew heads and threads.

C - Do not use impact wrenchs, or the bearing shells can fall out.

T - Tighten conrod capscrews by following the step bellow.

SPECIFICATION CONDITION
RESULT CHECK
N.m STEP ft.lbs PART NO. QTY OK REWORKED REPLACED REPAIR
 1
2 CON-ROD
3
4
5 CAP SCREW
6
REPORTED BY CHECKED BY

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
14. CONNECTING ROD
SIDE CLEARANCE M - Measure side clearance with a Feeler Gauge or Dial Indicator
P/N 3376051 with magnetic base P/N. 33777399.

C - Make sure that machine number must be the same both rod
and cap.

C - Make sure that Mark Number is according to cylinder number

SPECIFICATION CONNECTING ROD SIDE CLEARANCE RESULT

MM IN 1 2 3 4 5 6
MIN
MAX

REPORTED BY CHECKED BY

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
15. PISTON COOLING
NOOZLE I - For saddle jet piston cooling nozzle, push it into place by hand.
- For j-jet piston cooling nozzle, install it one cylinder at a time
rotating the crankshaft as necessary for accesss.

T - For j-jet piston cooling nozzle, tighten capscrews.

SPECIFICATION
BOLT N.m ft.lbs

PISTON COOLING NOOZLE INFORMATION TORQUED COOLING NOOZLE CAP SCREW RECORD
PART NO. QTY OK REWORKED REPLACED 1 2 3 4 5 6
RESULT
 RESULT

REPORTED BY CHECKED BY

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
16. FRONT GEAR
HOUSING I - Install gear housing.

C - Use sequence shown to tighten the capscrews.

C - Make sure the gasket already installed down on front of

cylinder block with gear housing.

SPECIFICATION
RESULT
BOLT N.m ft.lbs

INFORMATION CHECKED BY
PART NO. OK REWORKED REPLACED REPAIR

REPORTED BY

FOREMAN/ SPV Q.A. OFFICER

MECHANIC, date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
17. LUBRICATING OIL
PUMP I - Install oil pump, make sure the condition is good.

C - Make sure seal o ring already installed on the oil pump.

T - Torque capscrew refer to specification.

M - Use a dial indicator, measure the pump drive gear to

Crankshaft Gear Backlash.

BOLT TIGHTENING LUBRICATING OIL PUMP INFORMATION

SPECIFICATION PART NO. OK REWORKED REPLACED REPAIRED

N.m ft.lbs
OIL PUMP EVALUATION REPORTED BY
END CLEARANCE SPEC.
RESULT
MM IN
MIN MECHANIC, date :
MAX CHECKED BY
RESULT
BACKLASH SPEC.
RESULT
 RESULT
MM IN
MIN FOREMAN/ SPV Q.A. OFFICER
MAX date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
18. CAMSHAFT
I - Install Camshaft.

C - Use Lubriplate, lubricate each camshaft and all Camshaft

Bushings completely.

C - Don't damaged the Camshaft Bushings when installing the

Camshaft, the bushing will fail.

T - Install and torque the Capscrews.

SPECIFICATION
RESULT
N.m STEP ft.lbs
1
2

CAMSHAFT INFORMATION REPORTED BY

PART NO. OK REWORKED REPLACED REPAIR

CAMSHAFT MECHANIC, date :

CHECKED BY

CAM GEAR
FOREMAN/ SPV Q.A. OFFICER
date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
19. CAMSHAFT
GEAR TRAIN M - Measure cam gear backlash to crankshaft.

M - Measure camshaft end clearance.

C - Make sure when do measurement the thrust plate capscrews

have been tighten to specific torque.

SPECIFICATION REPORTED BY CHECKED BY

PARAMETER RESULT
MM IN
MIN
BACKLASH
MAX
MIN MECHANIC FOREMAN/ SPV Q.A. OFFICER
END CLEARANCE
MAX date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
20. INJECTION PUMP
C - Make sure injection pump timing on the position 1 top.
 C - Rotate crankshaft until piston no. 1 at top position.

I - Install injection pump mount bracket to injektion pump.

T - Torque injection pump mounting refer to specification.

T - Torque injection pump drive gear refer to specification.

MOUNTING BRACKET DRIVE GEAR

RESULT RESULT
N.m STEP ft.lbs N.m STEP ft.lbs
1 1
2 2
3 3
4 4

INJECTION PUMP INFORMATION CHECKED BY

PART NO. OK REWORKED REPLACED REPAIR

REPORTED BY

FOREMAN/ SPV Q.A. OFFICER

MECHANIC, date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
21. FRONT GEAR
COVER I - Apply 1.5 to 2.0mm [0.06 to 0.08in] wide bead of sealant.

I - Install the front gear cover to the cylinder block.

I - Install the capsrews.

T - Tighten the capsrews.

SPECIFICATION
RESULT
BOLT N.m ft.lbs

REPORTED BY CHECKED BY

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :
 ENGINE REBUILD SHEET 4/ 6 B
31B-RC-ERB
Job No. : Eng. Model :
Customer : ESN :
CPL : Pump Code :
Start Date : Finish Date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
22. FLYWHEEL
HOUSING C - Install the flywheel housing, push flywheel housing over the
CAP SCREW Dowel Pins and to the Cylinder Block follow the sequences
shown to tighten the cap screws.

T - Follow the sequence shown to tighten the Cap Screw.

SPECIFICATION
RESULT
N.m STEP ft.lbs
1
2
3
4

REPORTED BY CHECKED BY
FLYWHEEL HOUSING INFORMATION

PART NO. OK REWORKED REPLACED REPAIRED

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
23. FLYWHEEL
HOUSING C - Measure the bore and the face of the housing to make sure the
ALIGNMENT alignment with crankshaft the indicator arm must be rigid for an
accurate reading.

C - For face alignment the cranksahft must be pushed in the same

direction every time it is measured.

SPECIFICATION
max TIR MM IN
BORE
FACE

BORE REPORTED BY
POSITION MM IN
12 O'CLOCK
3 O'CLOCK
BORE 6 O'CLOCK
_________TIR
9 O'CLOCK
 TOTAL TIR MECHANIC, date :
FACE CHECKED BY
POSITION MM IN
12 O'CLOCK
3 O'CLOCK
6 O'CLOCK
FACE
9 O'CLOCK FOREMAN/ SPV Q.A. OFFICER
_________TIR
TOTAL TIR date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
24. FLYWHEEL
CAP SCREW C - The flywheel mounting Capscrew must be SAE grade 8
minimum with Rolled Threads.

C - Check to be sure the mating surfaces of the Crankshaft and

Flywheel are clean, dry, and, free of nick or burns.

T - Follow the sequence shown to tighten the Cap Screw.

SPECIFICATION
RESULT
N.m STEP ft.lbs
1
2
3
4

REPORTED BY CHECKED BY
FLYWHEEL INFORMATION

PART NO. OK REWORKED REPLACED REPAIRED

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
25. FLYWHEEL
ALIGNMENT C - Measure the bore and face alignment.

C - Always push the Crankshaft in the same direction when record

the face reading.

SPECIFICATION
max TIR MM IN
BORE
FACE

BORE REPORTED BY
POSITION MM IN
12 O'CLOCK
3 O'CLOCK
BORE 6 O'CLOCK
_________TIR
 _________TIR
9 O'CLOCK
TOTAL TIR MECHANIC, date :
FACE CHECKED BY
POSITION MM IN
12 O'CLOCK
3 O'CLOCK
6 O'CLOCK
FACE
9 O'CLOCK FOREMAN/ SPV Q.A. OFFICER
_________TIR
TOTAL TIR date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
26. CYLINDER HEAD
I - Install Cylinder Head, make sure that good condition.

C - Make sure Gasket - the word "TOP" that is stamped on the

Head Gasket must be visible after the Gasket is installed.

C - Make sure the Gasket must slide easily over groove pins,
check the Pins for damaged.Use engine oil, lubricate the Cap
Screw Heads, Threads, and Washers.

T - Torque Cap Screws.

SPECIFICATION
RESULT
N.m STEP ft.lbs
1
2
3
4

REPORTED BY CHECKED BY
CYLINDER HEAD INFORMATION

PART NO. OK REWORKED REPLACED REPAIRED

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
27. ROCKER LEVER
I - Install Rocker Lever, make sure Adjusting Screw are loose.

C - Be sure that the Pin Dowel that aligns the Rocker Lever Mount
is installed.

C - Make sure push rod already installed correctly.

T - Torque Cap Screw refer to specification.

SPECIFICATION
RESULT
N.m STEP ft.lbs
1
2
 3
4

INFORMATION REPORTED BY CHECKED BY

ROCKER CONDITION
LEVER OK REWORKED REPLACED REPAIR
INTAKE LEVER

EXHAUST LEVER MECHANIC FOREMAN/ SPV Q.A. OFFICER

SHAFT date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
28. TRANSFER TUBE
I - Install Lubricating Oil Transfer Tube.

C - The correct oil transfer tube must be installed or the engine will
be damaged extensively from lack of lubrication.

T - Tighten the Capscrews.

SPECIFICATION
RESULT
BOLT N.m ft.lbs

REPORTED BY CHECKED BY
TRANSFER TUBE INFORMATION

PART NO. OK REWORKED REPLACED REPAIRED

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
29. OIL PAN
C - Check to be sure, oil pan is clean from other material.

I - Use gasket silicon for install oil pan gasket.

C - Clean cylinder block bottom surface from other material.

I - Install oil pan and torgue refer to specification.

OIL PAN INFORMATION REPORTED BY CHECKED BY

PART NO. OK REWORKED REPLACED REPAIRED

SPECIFICATION
RESULT
N.m ft.lbs
MECHANIC FOREMAN/ SPV Q.A. OFFICER
date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
30. VIBRATION
 DAMPER C - Make sure vibration damper in good condition.

T - Torque Lock Nut refer to specification.

VIBRATION DAMPER INFORMATION REPORTED BY CHECKED BY

PART NO. OK REWORKED REPLACED

SPECIFICATION
RESULT
N.m ft.lbs
MECHANIC FOREMAN/ SPV Q.A. OFFICER
date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
31. VALVE
ADJUSTMENT C - Make sure Valve Adjustment mark pointer position and FO
according manual instruction.

C - Use Feeler Gauge refer to specification.

T - Torque Lock Nut refer to specification.

LOCK NUT REPORTED BY CHECKED BY

CLEARANCE
SPECIFICATION
MM IN N.m ft.lbs

INTAKE
RESULT
MECHANIC FOREMAN/ SPV Q.A. OFFICER
EXHAUST
date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
32. EXHAUST
MANIFOLD I - Install exhaust manifold use the guide stud.

I - Use high temperature anti-seize compound to the cap screw

threads.

I - Install the gasket, make sure the position of gasket is true.

T - Torque all cap screw mounting refer the specification.

SPECIFICATION REPORTED BY CHECKED BY

 N.m ft.lbs

RESULT
MECHANIC FOREMAN/ SPV Q.A. OFFICER
date : date : date :

TURBOCHARGER FUEL PUMP ECM ADDITIONAL

Cal. Code : Cal. Code :

P/N : P/N : P/N :
S/N : S/N : S/N :

COMMENT :

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :