7.

8L 210 HP ENGINE
 IMPORTANT SAFETY NOTICE
Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor
vehicles, as well as the personal safety of the individual doing the work. This manual provides general directions
for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability.

There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in
the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide
advice or cautions as to each. Accordingly, anyone who departs from instructions provided in this manual must
first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods,
tools or parts.

As you read through the procedures, you will come across NOTES, CAUTIONS, AND WARNINGS. Each one is
there for a specific purpose. NOTES give you added information that will help you to complete a particular pro-
cedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS
remind you to be especially careful in those areas where carelessness can cause personal injury. The following
list contains some general WARNINGS that you should follow when you work on a vehicle.
• Always wear safety glasses for eye protection. • Keep yourself and your clothing away from moving
parts when the engine is running, especially the fan
• Use safety stands whenever a procedure requires
and belts.
you to be under the vehicle.
• Be sure that the ignition switch is always in the OFF • To prevent serious burns, avoid contact with hot metal
position, unless otherwise required by the procedure. parts such as the radiator, exhaust manifold, tail pipe,
catalytic converter and muffler.
• Set the parking brake when working on the vehicle.
If you have an automatic transmission, set it in • Do not smoke while working on the vehicle.
NEUTRAL unless instructed otherwise for a specific
service operation. If you have a manual transmission, • To avoid injury, always remove rings, watches, loose
it should be in REVERSE (engine OFF) or NEUTRAL hanging jewelry, and loose clothing before beginn-
(engine ON) unless instructed otherwise for a specific ing to work on a vehicle. Tie long hair securely
service operation. behind head.

• Operate the engine only in a well-ventilated area to • Keep hands and other objects clear of the radiator
avoid the danger of carbon monoxide. fan blades.

The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealer-
ship parts and/or service department operations. These recommendations and suggestions do not supersede or over-
ride the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions
of the Warranty and Policy Manual shall govern.

The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook
was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change
specifications, design, or testing procedures without notice and without incurring obligation. Any reference to
brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc.
recommended for use. Equivalents if available may be used. The right is reserved to make changes at any time
without notice.

Copyright © 1986, Ford Motor Company

Produced and Coordinated by

A. P. Roussey
Training and Publications Department
Ford Parts and Service Division

,-},.,-
 TABlE Of CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.8L INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CHANGES FROM 1985 PHASE 1 ENGINE .. .. .. .. .. . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 4

EXPLANATION Of DESIGN CHANGES AND NEW SERVICE PROCEDURES . . . . . . . . . . . 5

CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OIL PAN ......................................................................... 6
CYLINDER HEAD AND VALVE TRAIN ............................................. 6
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WATER PUMP AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Water Pump Service Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL SYSTEM . .. . .. . .. . . . .. . . . . . . . . . . . . . .. . . . . .. . . . . . . .. . . . . . .. . .. . . . . . . . . .. . . . . . 14
Fuel Shufoff Solenoid Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel Box Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FRONT COVER ................................................................... 15
FRONT CRANKSHAFT OIL SEAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REAR CRANKSHAFT OIL SEAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankshaft Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FLYWHEEL ....................................................................... 18
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CONNECTING ROD ASSEMBLY .................................................... 20
BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PISTONS ......................................................................... 20
TURBOCHARGERS ................................................................ 22
LUBRICATION SYSTEM ........................................................... 22
TIMING - STATIC AND DYNAMIC .................................................. 23
Dynamic Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Static Timing Procedure (Pump On Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Static Timing Procedure (Pump Removed From Engine/Timing Bracket Removed Or
Loosened Using Same Bracket From Signal Production Installation And Chisel
Marking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Static Timing (Injection Pump Off Engine - Timing Bracket Undisturbed) . . . . . . . . . . . . . . 27

191:17 ENGINE PERFORMANCE ......................................................... 28

ENGINE PERFORMANCE SPECIFICATIONS ......................................... 28
ENGINE PERFORMANCE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ENGINE SPECIFICATIONS ............................................................. 33

TORQUE SPECIFICATIONS ............................................................ 37

1
 INTRODUCTION

6.6L 160 HP - Turbocharger No Aftercooling, "A'' Type Fuel Injection Pump

7.8L 210 HP - Turbocharged Jacket Water Aftercooled

7.8L 240 HP - Turbocharged Air-to-Air Aftercooling

2
 INTRODUCTION

The 1987 model year brings in an expanded 6 cylinder from 4.4 to 5.2 in. over the 6.6L. The deck height of
Ford diesel engine family including design changes to the block has increased 1.5 in. to accommodate the
the 6.6L engine and a series of more powerful 7.8L longer stroke. Also, some engines are equipped with
engines (Figure I). aftercoolers to further increase their power output and
combustion efficiency.
Demand for the engines is coming from several different
markets which require a range of horsepower
capabilities. Therefore the Phase 2 6.6L and 7.8L engines
are being offered in six horsepower versions for 1987,
rather than one 165 hp (Phase I) model available in 1986.
With the addition of the 7.8L engines, Ford offers a com-
plete horsepower range of engines for the medium truck
market. Availability of the engines in different Figure 2. Horsepower Availability
horsepower versions is shown in this chart (Figure 2).

The purpose of this book is to point out the new prod-
uct and service features that are new to the 1987 models.
Service on the new Phase 2 6.6L and 7.8L engines is
however very similar to the Phase I.
1.3l INTRODUCTION
The 7.8L diesel engine increased size and power is
primarily accomplished through an increase in stroke
Design changes in Phase 2 engines have been made
primarily to commonize the new 7.8L version and 6.6L
engines. Many of the changes do not affect service, but
do affect the interchangeability of components between
Phase I and 2. Therefore it is always important to refer
to the Parts Book when ordering parts. The changes that
do affect service, will be highlighted, along with any
new special tool requirement.
The design changes are shown here in Figure 3.

Figure 1. 7.8l Engine (210 HP version)

 CHANGES FROM THE 1986 PHASE 1 ENGINE
PHASE 1 TO PHASE 2 DESIGN CHANGES

Flywheel Housing X X Redesigned to allow clearance for changing rear seal and
retainer
Cylinder Block X Deck height increased - 1.5 in.
Piston Cooling Jets X X Installed to reduce piston head temperatures by spraying oil
on underside of piston, as well as lubricating piston pin
through hole in top of con-rod
Torsional Vibration Damper X X Sheet metal cover removed, new design, double damper on
7.8L
Connecting Rod X X New TP design for 6.6L, 7.8L has larger diameter at pin end
Front Crankshaft Seal X X New installation depth, new special tool required
Rear Crankshaft Seal and Retainer X X Seal now contained in a retainer - new service tool and
bolt tightening sequence
Flywheel X X Bolt pattern changed, number of bolts increased
Crankshaft X X Throw increased for 7.8L, flywheel mounting changed -
nose diameter increased on 7.8L
Crankshaft Gear X Aligned by a pin
Bracket X X Position changed - new timing pin
Oil Pan X X Internal baffle added (running change Phase 1)
Core Plugs X X Stainless steel
Front Cover X X Changes to accommodate new coolant flow, timing bracket &
miscellaneous attachments
Pistons X Pin diameter increased
CYLINDER HEAD AND COMPONENTS
\
Cylinder Head X X Valve center-to-center spacing changed
Valves X X Head diameter Increased on Intake and exhaust valves
Valve Seats X X Larger size, new installation tool required on exhaust only
Exhaust Rocker Arm X X New design deletes spacer
Valve Guides X Production Inserts
Positive Valve Rotators X X Used only on exhaust valves
Valve Seals X New design, requires special tool for installation
Intake/Exhaust Manifolds X X New bolt tightening sequence
LUBRICATION SYSTEM
Oil Cooler X X New block mounted design
Lubrication System Flow X X Changed to account for piston cooling jets and oil cooler
New Oil Filler Location X X Enters the right side of the block
COOLING SYSTEM
Water Pump X X New higher capacity design, new tools required for teardown
and rebuild
Cooling System Flow X X Changed to account for oil cooler, and jacket water aftercooler
(210 hp only)
FUEL AND AIR INTAKE SYSTEMS
Bosch ''Iii'· Type Fuel Injection Pump X Used on 49-state 160 hp version only
Intake Manifolds X Aftercooler added on 210 hp Oacket water type), 225 and
240 hp (air-to-air type) engines

Figure 3. 1986 to 1987 Design Changes

4
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
CYLINDER BlOCK
The following changes have occurred to the cylinder
block:

The 7.8L engine block (Figure 4) has a deck height in-

crease of approximately 38mm (1.5 in.) over the 6.6L.
This is to accommodate a 20.32mm (0.800 in.) increase
in stroke and dimensional changes in the piston and con-
nection rod.

New piston cooling jets (Figure 5) are being installed

on all engines. There is no special installation procedure
for the piston cooling jets if they are removed. They are
simply pushed into place from the crank side of the
casting.

The cylinder block core plugs are now made of stainless

steel. Their sizes remain the same. Installation pro-
cedures for the core plugs have not changed. Figure 5. Piston Cooling Jets

1
+38mm
(1.5 in.)
7.8L DECK
HEIGHT
INCREASED
OVER 6.6L

CYLINDER BLOCK C/L OF CRANKSHAFT

ASSEMBLY (6010)
RIGHT SIDE

Figure 4. 7.8L Deck Height Increase

5
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
Oil PAN
An internal batlle has been placed in the oil pan (Figure
6). It was added to eliminate low oil pressure warning
signals caused by oil surge in the sump during severe
braking.
CYLINDER HEAD AND VAlVE TRAIN
The cylinder head was changed slightly in the Phase
2 engine. The valve center spacing has increased in a
lengthwise direction (Figure 7) and moved in a crosswise
direction.
The 7.8L engine is equipped with intake and exhaust
valve guide inserts. The 6.6L retains the use of parent
bore guides with inserts available for service repair if
desired. The parent bore guides can also be reamed and
oversize valves installed using the same procedures
employed on the Phase 1 6.6L engine. A new Valve
Guide Replacer T87T-6510-A and Valve Guide Reamer
T87T-6510-B have been added for the 7.8L engine.
Both the intake and exhaust valves have larger heads.
Stem size remains the same. The valve seats have also
increased in size. Because of the larger size valve seat,
a new installation tool, T87T-6084-A, is required for the
exhaust valve seat only. Installation procedures remain
the same.
A new positive valve rotator has been added to the ex-
haust valve (Figure 8). Positive rotation of the valve every

OIL PAN
BAFFLE

Figure 6. Oil Pan Internal Baffle Figure 8. Positive Valve Rotator

VALVE CENTER-TO-CENTER SPACING INCREASED

OF BORE TO VALVE
CROSSWISE

Figure 7. Valve Spacing Increase

6
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
time it is actuated by the rocker arm helps to prevent
the buildup of carbon on the valve and aids in heat
dissipation and the prevention of leaky exhaust valves.
The 7.8L engine has new intake and exhaust valve seals
(Figure 9). These seals require a special tool for
installation.

When installing the new valve seals use the following

procedure (Figure 10):
• Install valve stem protective cap.
• Lubricate both the valve stem and the new seal with
engine oil.
• Install the valve seal onto the stem.
• Tap it lightly into position with the installation tool.
• Remove protective cap.
6.6L 7.8L
PHASE 1 & 2 The exhaust rocker arms (Figure 11) are a new, wider
design which eliminates the need for spacers along the
length of the rocker arm shaft.

Figure 9. Intake and Exhaust Valve Seals

NOTE: INSTALLATION TOOL MUST

STOP AGAINST HEAD SURFACE TO
AVOID SEAL DAMAGE DURING
INSTALLATION.

Figure 10. Installing Valve Seal

7
 EXPlANATION OF DESIGN CHANGES AND
I NEW SERVICE PROCEDURES
)
ROCKER ARM
SPACER (6590) SHAFT (6563)
SPRING
SUPPORT (6531)

I I .
'

PUSH ROD
ARM (6529)

EXHAUST ROCKER .
ARM (6529)
(NO SPACER)
I
f>li~!!i;2 1

Figure 11. Old and New Rocker Arm Designs

INTAKE MANIFOLD The 225 hp and 240 hp 7.8L engines use a special design
intake manifold for air to air aftercooling (Figure 13).
The 210 hp 7.8L engine uses a split design intake
It functions in much the same way as the jacket water
manifold which contains the jacket water aftercool-
aftercooler except instead of using engine coolant to
ing core (Figure 12). Engine coolant is pumped through
the aftercooler core by the water pump (coolant enter- reduce air temperature and increase density, outside air
ing the aftercooler is approximately l80°F, coolant leav- is used.
ing the aftercooler is approximately 190°F). Incoming
air (at approximately 300°F) moving from the com- The air to air aftercooler is very efficient at reducing
pressor side of the turbocharger through the intake air inlet temperature as can be seen here:
manifold passes through the aftercooler core. This
AIR TEMPERATURE:
reduces the air temperature to approximately 195°F in-
Tnrbo Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300°F
creasing its density.
Intake In . . . . . . . . . . . . . . . . . . .. . .. . • . . . . l20°F
Reduction .. .. .. .. .. .. .. .. .. .. .. .. .. .. . !80•F
Removal and installation procedures for the jacket water
aftercooler are included in Section 22-11 of the Shop
Manual. Note the special torque sequence which must
be followed when bolting the aftercooler together.

,·'21.'
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES

CROSS-OVER

190'F

Figure 12. Jacket Water Aftercooler and Core

AFTERCOOLER

300'F
20 PSI
600 CFM TURBOCHARGER

Figure 13. Air To Air Aftercooler

9
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
EXHAUST MANIFOLD The water pump used on the 210 hp. 7.8L engine is the )
same as that used on the other Phase 2 engines except
The Phase 2 exhaust manifold is similar to the one used
that it has extra plumbing attached to it to accommodate
on the Phase 1 engine. However, there is a torque se-
coolant flow to (180°F) and from (190°F) the jacket water
quence for the exhaust manifold installation which was
aftercooler (Figure 17).
not used for the Phase I engine. It is shown here (Figure
14).

WATER PUMP AND COOLING SYSTEM GASKET (8507)

(BETWEEN PUMP
The Phase 2 water pump (Figure 15) is a larger capaci- & BLOCK)
ty type - 100 gpm (gallons per minute) @ 2600 rpm
vs 65 gpm used on Phase 1 6.6L engine.

WATER PUMP FLOW (approx.)

To JWAC* (210hp) . . . . . . . . . . . . . . . . Recirculated
To Block (front) . . . . . . . . . . . . . . . 50 gpm @40psi
To Oil Cooler & Block (rear) . . 50 gpm @40psi
Total . . . . . . . . . . . . . . . . . . . . . . . 100 gpm @ 40psi
*JWAC - Jacket Water Aftercooler

The new water pump has a larger housing design to ac-

commodate the added coolant flow through the exter-
nally mounted engine oil cooler (Figure 16). This water
pump features a new impeller design in which the ramp
angle on blades changed. New assembly and
Figure 15. Phase 2 6.6L and 7.8L Water Pump
disassembly procedures are required to service this water
pump, along with new special tools.

-df41
FRONT

EXHAUST
MANIFOLD
(9430)

Figure 14. Exhaust Manifold Torque Sequence

10

... ~
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES

OIL FLOW
IN-AROUND
CORE

Figure 16. Externally Mounted Engine Oil Cooler

(390490)

PUMP

CLAMP (383523)
(8 REQUIRED)

TUBE (9L444)
HOSE (9K436)

Figure 17. Jacket Water Aftercooler Water Pump Plumbing (7.8L 210 HP)

11
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
Water Pump Service Procedures )
The water pump used on the 6.6L Phase 2 and 7.8L
engines are fully serviceable with individual repair parts
available. When servicing the water pump follow the
recommended procedures.

Disassembly

TWO JAW
PULLER
D81L-1002-A
1. Remove the three bolts that secure the front and rear
covers of the pump housing. Separate the pump covers
and discard the gasket.
2. Using bearing splitter D84L-!123-A or equivalent to Figure 18. Pulley Removal
support the rear surface of the pulley and Two Jaw
Puller DSIL-1002-A and Shaft Protector DSOL-630-1
or -2, remove the pump pulley from the shaft (Figure
18).
3. Once removed, inspect the boss area of the pulley
for cracking. Replace the pulley if cracks are present.
4. Using a press, press the shaft and bearing assembly
out of the impeller and pump housing (Figure 19).

5. Push the seal assembly out of the impeller side of

the pump housing. Discard the seal.
Figure 19. Shaft and Bearing Removal

12

,·':1.1 .'':hi ,.:;,.,•

 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
Assembly
1. Support the rear face of the pump housing with shaft
and bearing diameter square to the rear face. Using
Water Pump Shaft and Bearing Installer T87T-6312-C
or a suitable sleeve which passes over the shaft and
rests on the outside diameter of the bearing, press
the bearing into the housing from the front face un-
til the bearing is flush with the face of the housing.
(Figure 20). Use a straight edge to check the final
position.
2. Turn the pump housing over and position in a press
with the seal bore facing upwards, and nose resting
in bearing installer T87T-6312-C.
3. Coat the outer diameter of the seal flange with a thin
application of thread sealer, and position the seal
assembly over the shaft in the center bore of the
housing.
4. Place Seal Replacer T87T-6312-A over the shaft and Figure 21. Seal Installation
onto the seal assembly. Press the seal assembly into
the bore until it seats fully in the bore against the seal 5. Support the shaft on a block of wood and use hn-
flange (Figure 21). peller Installer from Kit No. T86T-6312-A or an
equivalent length of pipe of suitable internal diameter
No/Eise¥Riri~cet1'87T-~si2:f\illusth~lls~~··•·••·•· to press the impeller onto the shaft. The final
•..•. •. ~~.itrs~lttlles~l.asse!IIhly be¢:~pse itestab!ishes clearance between the housing and impeller should
< t~e proper workjl'!g heiglitofthe s¢ai, •. .· : ·.•.· · · be 1.9 ± 0.25mm (0.075 ± 0.010 in.) (Figure 22).

WATER PUMP SHAFT

AND

BEARING

WATER PUMP
COVER

Figure 20. Bearing Installation Figure 22. Impeller Installation

13
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
6. Apply a loctite-type sealer (RC 620 or equivalent) /
to the inside diameter of the pulley shaft mounting

mmPRE\~~~
surface. Press the pulley onto the shaft to the dimen-
sion shown (Figure 23). The measurement is made
from the rear face of the front cover of the putnp to 83.82 • 84.83
the center of the V-groove of the pulley. After installa- (3.30 • 3.34 ln.) ~~
tion, be sure the pulley runs true on the shaft .

. N~=i~~;not.l'eins~fi~e ~~~ ~t91~Y<1nihe ·

! •· .. ~~af\!1l<l,[ethl!fl~l\~; l]se~.J1e~p)il!eyfors~bse-
• quent s~tyi¢~ ~~~@.l!JU()ns; ·• ·.· · · ·· • '

7. Assemble the front and rear halves of the pump

together using a new gasket. Tighten the bolts to
specification.

FUEl SYSTEM
The Bosch "N' pump (Figure 24) is used on the 160
hp. 49-state engine. All other engines use the larger
Bosch "P" pump. Primary differences between the "N' Figure 23. Water Pump Pulley Installation Height
and "P" pumps are:
"At pump is smaller in basic size.
- Delivery valves are threaded into the pump housing. INJECTOR PUMP DRIVE
GEAR PULLER
- Smaller drive gear hub pulling threads on "N' pump T87T·6312·B
require a new service tool to pull the gear.

Fuel Shutoff Solenoid Bracket Installation

A special procedure has been developed for installing
the fuel shuttoff solenoid bracket when the fuel injec-
tion pump has been removed (Figure 25). This installa-
tion sequence is critical to the proper function of the
shutoff solenoid. Failure to use the procedure may cause
binding or inoperative solenoid.

Bracket Installation Procedure

I. Install bolts in the bracket (loose).
2. Install the fuel injection pump mounting bolts. Tighten
these bolts to specification.
Figure 24. Bosch "A" Pump
3. Tighten the bracket bolts to specification.

14
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
BRACKET (6N072)
Figure 25. Fuel Shutoff Solenoid Bracket
Fuel Box Mounting
The fuel box mounting is different between Phase 2 6.6L
and 7.8L engines (Figure 26). Install using the lower
mounting bosses for the 6.6L engine; use the upper two
mounting bosses for the 7.8L engine.
fRONT COVER
The front cover casting (Figure Z7) is changed to ac-
commodate a new coolant flow path and to mount
miscellaneous attaching hardward.
15
BOLT (56538)
(4 REQUIRED)
FRONT CRANKSHAFT Oil SEAl
ASSEMBLY
The front crankshaft oil seal (Figure 28) is slightly larger
to accommodate the change in crank nose diameter from
44.45 to 50.8mm (1.75 to 2.00 in.) on the 7.8L models.
Also, the new front crankshaft oil seal has a new in-
stallation depth. Installation requires a new special tool.
Install the oil seal by pressing it into position until it
seats gently against the bottom of the seal bore.
' ' '' ,,, ' ; '; ..
NO'fE: Installatio~,On J:>hase .1 etigihe Vl'as t111sh'',
with the front cover., ,,'',',,' , ,,,,',••' ;,,,, , ','',,' ••
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES

FUEL
BOX
(9RS270)

UPPER MOUNTING
BOSSES • 7.8L
0

Figure 26. Fuel Box

WATER PAS!lAGE

FRONT COVER
CRANKSHAFT
SEAL INSTALLER
T87T-6019·A

Figure 27. Front Cover Figure 28. Front Crankshaft Oil Seal and Installa-
tion Tool

16
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES

REAR CRANKSHAFT OIL SEAL ASSEMBLY

The rear oil crankshaft seal is now mounted in its own
separate retainer. The installation depth of the seal has
been changed and a new seal installation tool is required
(Figure 29). The seal can be installed using the special
tool with the retainer either on or off the engine. Use
an arbor press to install the seal with the retainer off
the engine. Use 4 crankshaft to flywheel bolts to push
the new seal into position with the retainer on the engine.
v,
Tighten the bolts turn each until the tool bottoms on
the shoulder of the retainer.

Check oil seal runout after installation. Seal runout must

not exceed 0.38mm (0.015 in.). When installing the seal
retainer, tighten the bolts in the sequence shown (Figure
30).

Figure ·ao. Rear Oil Seal Retainer Tightening

Sequence
CRANKSHAFT
The crankshaft throw has been increased by 10.16mm
(0.400 in.) on the 7.8L to increase its stroke (Figure 31).
Also, the diameter of front nose increased from 44.45mm
(1.75 in.) to 51.76mm (2.038 in.). A 2-key system is
used, one for the damper and one for the timing gear.

There is a new bolt pattern on the flywheel flange and

an increase in the number of bolt holes from 6 to 8.

Figure 31. 7.8L Crankshaft

Figure 29. Oil Seal Installation

17
 I EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
Crankshaft Gear Installation )
The 7.8L crankshaft gear installation procedure is dif-
ferent from the 6.6L because it uses an alignment pin
instead of a woodruff key (Figure 32). To install the 6.6L
or 7.8L crankshaft gear, heat it to approximately 380
- 420°F in an oven. This will expand the metal so the
gear will fit over the crankshaft. Then, using heat resis-
tant gloves, slide the gear onto the crankshaft. Index the
pin with the hole drilled for it in· the crankshaft.

FLYWHEEL
FLYWHEEL
BOLTS FLYWHEEL
The number of bolts used to hold the flywheel (Figure
33) to the crankshaft has been increased from six to
eight. The eight bolts are in an evenly spaced pattern.
Figure 33. Flywheel

CRANKSHAFT (6303)

CRANKSHAFT
GEAR

CRANKSHAFT

WOODRUFF
KEY (390676)

7.8L

Figure 32. 6.6L and 7.8L Crankshaft Gears

18

,··:hi ,.·:1_:
 EXPLANATION Of DESIGN CHANGES AND
NEW SERVICE PROCEDURES
VIBRATION DAMPER The 7.8L has double damper design (Figure 35). The
damper which bolts to the crankshaft is designed to ab-
There have been several changes in the vibration
sorb low frequency torsional vibration. The second
dampers between the Phase I and 2 engines. The Phase
damper bolts to the front of the low frequency damper
I 6.6L damper had a stamped metal cover which is
and absorbs high frequency vibrations.
deleted for Phase 2 6.6L and 7.8L applications. The new
damper (Figure 34) is the same basic viscous rubber
type, but has the timing slots milled directly into the
damper body.

DAMPER COVER DAMPER (6316)

FRONT COVER
(6059)

Figure 34. 6.6l Vibration Dampera

19
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES

LOW FREQUENCY
VIBRATION DAMPER
(6316)

FRONT COVER

CRANKSHAFT
ASSEMBLY (6303)

KEY (390507-S)

Figure 35. 7.8L Vibration Damper

CONNECTING ROD ASSEMBlY BEARINGS

The Phase 2 6.6L connecting rod has two design
changes. The first is that the rod incorporates the new
"TP" design on the small end of the rod bushing (Figure
36). Because of the new "TP" design, bushing replace-
ment requires a new special tool (Figure 37) used for
both removal and installation. The second change is that
the oil orifice through the connecting rod shank, found
in Phase I engine has been deleted in Phase 2. Piston
pin lubrication is through a drilling in the top of the rod.
It is fed by the splash from the piston cooling jet.
The 7.8L connecting rod (Figure 38) is quite different
from that used on the 6.6L. The big end is split at a
35° angle. Also, the top of the rod is drilled to provide
piston pin lubrication. The crank center to pin center
dimension is also changed.
The connecting rod bearings have a grooveless full length
design to reduce oil film stresses and increase oil film
strength. Also bearing clearances have increased slightly
for both the 6.6L and 7.8L engines:
- Rod Bearings:
6.6L - 0.043 - 0.097mm (0.0017 - 0.0038 in.)
7.8L - 0.069 - 0.119mm (0.0027 - 0.0047 in.)
- Main Bearings:
6.6 & 7.8L - 0.086 - 0.150mm (0.0034 - 0.0059 in.)
PISTONS
The 7.8L piston pin diameter is 44.45mm (1.75 in.), in-
creased from 41.275mm (1.625 in). on 6.6L.

Piston length is also changed.

20

··1<1
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES

TP DESIGN

CYLINDER
NUMBER
STAMPED
HERE

Figure 36. 6.6l Phase 2 Connecting Rod

CONNECTING ROD
ASSEMBLY (6200)
NOTE: Connecting rod bushing in-
staller/replacer not developed at
time of printing. Tool will be available
after engine introduction. Explana-
tion of tool usage will be included
in an upcoming technical service 35' SPLIT
bulletin (TSB).

CYLINDER
NUMBER
STAMPED
HERE ONLY

Figure 37. Connecting Rod Bushing Installation Figure 38. 7.8l Connecting Rod

21
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
TURBOCHARGERS between the different horsepower ratings. Turbochargers
/
are serviced in three main parts:
All turbochargers are basic Garrett T04 E design with
the same external attaching dimensions (Figure 39). Thr- Compressor end housing
hines and compressors differ between the different - Turbine end housing
horsepower ratings to provide air flow to match the - Center housing core assembly
engine needs. The turbochargers are not interchangeable
These parts are available for service along with the
necessary attaching hardware.

WBRICATION SYSTEM
The lubrication system (Figure 40 and 40a) of the Phase
2 6.6L and 7.8L engines is quite different from that used
on the Phase I 6.6L. This is primarily due to the use
of an exterior, block mounted oil cooler and the new
style piston cooling jets. The Phase 2 engine oil pump
is similar to the one used on the Phase I engine, and
has individual service parts available.

Figure 39. Garrett AiResearch T04E

I
I
I
I
I
I
I
I
I
I
I
I
I
I
I I
~~===~---------]
I I
- - - - PRESSURE LINE
-- - - - -SPLASH OR EXHAUST

Figure 40. Phase 2 6.6L and 7.8L Lubrication Schematic

22
 EXPlANAT~ON OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
There are two vertical full flow oil filters mounted to
the oil cooler support assembly.
When servicing the two engine mounted oil filters, coat
the seals with clean engine oil, then tighten them until
they seat against their mounting. Once seated, tum them
an additional V2 to l4 turn.
Timing is still determined using both the static and
dynamic timing methods although procedures have
changed slightly. Visually, the most noticeable change
is that the timing pin & probe bracket have been moved
from near the 12 o'clock position to near the 9 o'clock
position on the front cover (Figure 41). Also, the tim-
ing lock pin used to engage the vibration damper has

AIR BRAKE
COMPRESSOR

COOLANT
IN

OIL

jlt~l Unfiltered Oil

OIL
(SECONDARY) ~~:::;;;~:::;~( Filtered 011

Figure 40a. Phase 2 6.6L and 7.8L Lubrication System

23
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
\
/

• Do not overtighten the transducer; snug fit is all that

is needed. Do not use hand tool to tighten.
• Attach the transducer at the same location along the
high-pressure line each time a check is made. The
timing reading will change if the transducer is plac-
ed at a different location along the injector line.
• The transducer should be dry; wet conditions will
give erratic readings. If erratic readings are observ-
ed, remove transducer, wipe line and transducer with
a clean, dry cloth. Spray the transducer and line with
Figure 41. Timing Pin and Probe Bracket
a water-displacing material, and clamp on the injec-
changed in appearance. As mentioned earlier, the vibra- tor line.
tion damper no longer has a sheet metal cover with the 3. Connect the timing meter to the battery and adjust
timing grooves cut into it. Timing grooves are now the offset angle on the meter to zero degrees.
machined directly into the vibration damper. The in-
jection pump lock timing hole remains in the adapter
plate.
MAGNETIC
PICKUP
Dynamic Timing Procedure
Dynamic timing is used to check for proper timing
without going through the static timing procedure, us-
ing the timing lock pins. Do not under any circumstances
change or set engine timing based only on dynamic tim-
ing readings. Timing is to be set only with the Timing
Lock Pins T87T-6379-A and T87T-9000-B or equivalent.

I. With the engine stopped, install Rotunda Dynamic

TIMING PIN
Timing Meter 078-00100 or equivalent. Place the AND PROBE
magnetic pickup into the timing bracket hole (Figure BRACKET
42). Attach the connector from the pickup to the meter
lead. Figure 42. Inserting Magnetic Pickup Into
Timing Bracket

TRANSDUCER

2. Attach the pressure transducer to the No. l injector

line (Figure 43) at the injector. Be sure the injector
line is clean and free of paint where the transducer
is attached. Tighten the thumbscrew on the transducer
finger-tight when attaching to the injector line. Figure 43. Pressure Transducer Attachment

24
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
. ;W~(}:,~~s~r~~at.~t'Nitei§M~~~e"I~d~t\1d
·.a.way ff\llll !lje •.fropt l)~cessorydriy~belts.•;ll)dc<iol".·.
. (pg[ant\l ayoid e~tartgl~lll~nt. < . .•·. ·•·. . · . . ·
4. With the transmission in NEUTRAL or PARK and
the parking brake set, start the engine. Set the engine
speed at 1000 rpm with no load, and observe the tim-
ing meter. Check the Engine Performance Specifica-
tions for the correct timing specification for the engine
being serviced and see if this matches the meter
reading.
5. Turn the engine off and remove the dynamic timing
components.
6. If timing is off more than 2 degrees and there are
indications of incorrect timing, such as poor perfor-
mance or smoke, check the static timing using the
timing lock pins. If the engine is performing normally
and there is no evidence of excessive smoke or poor
performance, check all meter connections, and if
necessary, have meter calibration verified.
6.6l
e5~~ 49S • 160 HP
@~q 49S • 170 HP
CAL· 170 HP
DYNAMIC PICK·
UP HOLE
STATIC TIMING
PIN HOLE
Figure 44. Damper Timing Grooves
Static Timing Procedure (Pump On Engine)
·
Checking Static Timing
1. Rotate engine clockwise. Set engine at correct static
timing angle with No. 1 piston on compression stroke.
Fit timing lock pin T87T-6379-A through the timing
bracket into the correct crankshaft damper timing
groove (Figure 44). Timing grooves are not the same
for all engine models, so it is important to know
engine model number and horsepower.
&art: ~he ]Jtopertlrhlllg apgl~~~~6ic6Iif~£~~- >
····• •.~ionstroky¥No. ·.l ~1\nd~rj~indl~~~te46y'ri;~oy'-'.
·· in~ \'l'o: Jjnject?~ lUI<I feeling for.sorn~ressi'!n ·.· ·
~w~¢ (Ut~ipg. we.~hglp~i~· tJ:e direct\on.qfro~~>·····
•tion.•)\"ll~~co!'llpr~s~~(jn)~fel~,•. ~()~t(nllet!l~ni~g· ·•
.. ·t~e ~~gine until . :he~igplpen~pit! <]r9psillt\l t!lS
•···~?rr<!ctgroQ~eilltJ:~ ?¥!till<Sl!af'td~~~er.z~h)~ i!l".•·····•
·- .di~~tes. wat.t~(l··~ngine'~ ¢~!till<Sha~ts~f.theis~tic ..•.
·· timillg.·.arg~e'.Yith]'{9.•fJ1ist<Jn o~. tl!e·.~.\l!lll?r~s~ ·•·•·
••·•··~ib!l str<Jke..•Al~aysil!PJ?rpafhllre'~<JP~Pi1lgf<J()'Y~.······
.· •.·.wh~e •.t!lrning.th9.~ngi!l~cl?ciru>.~~.~·.t<Ji~SSJXre.that·······
g<ll),tb~cklash ~~ll !l<Jti~ffeft #Ill~rig. ·· ·· ·
7.8l
49S" 185
G::~~ 210, 240 HP
CAL· 225 HP
25
 EXPLANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES

•.· ·~prE: Ofi f~Serie~ ~ppiflati~t!s · a~cess toth~ · c1-ui~oN::i~9:; h.qt ull~~f Circull!~~~¢~s •.••
lfu¥
v~btapqll!IJI)pPe~ l)qlt (\lsell<tp rotate the e~gin,~) .< ·• .loose1.1.<>r re:move the timing oiack¢t~; •• . .; ·. ;.·. ; ;
~ ()Q&tru~,ystjtl~\)Joll()\y~pJ:()Ctlll~tJ? ,rqta~·.
th~ erigi11e (Figurll45);· ·
2. Remove the plug from the injector pump adapter plate
. • ~ !i~m~¢ ~~ ertgiii~ ~cte~~ .•cuy~rlrt tlle.c~l>. to and install timing lock pin T87T-9000-B into the
> ;expp~~ til~ rear Qf thl:l engine. . •...•.•..··. •..·•·.. ·..•.. adapter plate (Figure 46).
• .~··· R.elllqve the tach sensl.lr (~r p!ug) frqm thl)tel!)' 3. It is important that the lock pin seats fully in the slot
• oftlle ell$ine: ; .•. . .· .· .. ·..· . ·. •. ~ .. •.. . . . • • in the injection pump hub (to within 3mm (1/8 in.)
...••• . Rgt;l(.e the~ngine by~g the flywheel witll a of the shoulder of the lock pin as shown in Figure
•.•.. :···I~;S,pft:W!I~lY€lr(Po/i!lg
t.eet~J<): • . . .. . !lgainst•the.f!y~h~l· . . .... . . . . •· 46). This verifies proper engine timing. If the lock
pin is not fully seated, the pump timing is incorrect.

(CAUTION: Do ngt . nun c\"lln!csh!tft. W:itli timing

lqck piJ\S i!l pla9~· .· · ·· . .

FUEL INJECTION
PUMP ADAPTER
PLATE

TIMING LOCK 3mm (1/8 ln.)

PIN T87T-9000·B
Figure 45. F-Series Access to Tach Sensor (or plug)
Figure 46. Timing Lock Pin in Adapter Plate
Installation

26

··S.C
 EXPlANATION OF DESIGN CHANGES AND
NEW SERVICE PROCEDURES
Adjusting Static Timing
NOTE: Be surethedampet timing lock]Jin is in- ·
stalled in the proper location with the #1. piston
on the compression stroke. .
4. To adjust timing, loosen the four adjusting screws on
the injection pump gear hub (Figure 47), and rotate
the pump shaft until the timing leek pin can be pushed
into position and fully seated as shown in Figure 46.
Figure 47. Injection Pump Gear Hub Adjusting
Screws
5. Thrn gear counterclockwise by hand to remove
backlash (it will move slightly). Tighten the four ad-
justing screws to 10 N•m (7lb-ft). Remove the tim-
ing lock pins and tighten the adjusting screws to
specification.
6. Rotate the engine counterclockwise 90 degrees and
then clockwise to the point where the timing lock pin
can be inserted in the crankshaft damper. Insert tim-
ing lock pins into crankshaft damper and into fuel
injection pump hub. If pin seats in injection pump
gear hub, timing is correct. If it does not seat, repeat
the timing procedure.
27
Static Timing Procedure (Pump Removed
From Engine/Timing Bracket Removed or
Loosened Using Same Bracket From
Original Production Installation and Chisel
Marking)
1. Align timing bracket chisel mark with chisel mark
on engine front cover. Tighten the timing bracket
screws to specification.
NOTE: If a new timing bracket is being instai!eq, ··.
it is necessary to accurately position and chisel
mark the timing bracket with the correct damper ..
timing groove. This requires a special procedure ·.. ·
found in the Shop Manual, Section22·1L .· ..... .
2. Lock the fuel injection pump at port closure by in-
serting the lock pin into the fuel injection pump
adapter housing so that it locks into the slot in the
injection pump hub.
3. Set the engine, with No. 1 cylinder on the compres-
sion stroke, at static timing angle using the timing
bracket and lock pin. Rotate the engine at least 20
degrees counterclockwise, then clockwise until the
lock pin in the timing bracket engages the correct
groove in the damper cover.
4. Loosen the four adjusting screws on the injection
pump gear hub.
5. Install the injection pump on the engine and align the
adapter bolt holes to holes on the engine. Then in-
stall pump bolts and tighten them to specification.
6. Rotate the pump gear counterclockwise to remove the
pump gear backlash and tighten the four adjusting
screws to 7 N•m (5 lb-ft). Remove the timing lock
pin from the pump. Tighten the four adjusting screws
to specifications. Install the timing lock pin hole plug
and torque to specifications. Pump is now timed to
specification.
7. Install engine components and recheck dynamic tim-
ing as outlined.
Static Timing Procedure (Injection Pump
Off Engine - Timing Bracket Undisturbed)
1. Perform Steps 2 through 7 of Static Timing Procedure
(Pump Removed From Engine/Timing Bracket
Removed or Loosened Using Same Bracket From
Original Production Installation and Chisel Marking).
 1987 ENGINE PERFORMANCE

ENGINE PERFORMANCE SPECIFICATIONS \

'"

Performance specifications vary between the engines

because of the many different versions available. This
chart shows performance specifications fur each of the
engines (Figure 48).

1 Equipped with Jacket Water Aftercooler.

2 Equipped with Air·tcrAfr Aftercooler.

Figure 48. Engine Performance Specifications

I
I

28

..:;,.,- ··'l.l
 1987 ENGINE PERFORMANCE SPECIFICATION

ENGiNE PERFORMANCE DIAGNOSIS 4. Crankcase Pressure - Checking crankcase pressure

Engine diagnosis using the Rotunda Gauge Bar Kit requires a new adapter, 014-00742-1 (Fig. 52). This
014-00742 or equivalent has changed slightly between adapter is screwed into the oil dipstick tube located
Phase I and Phase 2 in the following ways: on the right side of the engine.

I. Turbo Boost Pressure - Turbo boost pressure is

checked at the same spot on all engines (Phase I and
2) except when equipped with air-to-air aftercooling
(7.8L 225 HP & 240 HP). The same adapter No. 5643
is used, but it attaches to an access port at the top
of the intake manifold (Fig. 49). FUEL
BOX

2. Lift Pump Suction - Lift pump suction is checked

at the same place on Phase 2 engines as on Phase
1, but a new adapter is used; 014-00742-2 (Fig. 50).

3. Fuel Return Pressure - Fuel return pressure is

checked at the same point on Phase 2 as on Phase
I except a different fitting is used (Fig. 51). Use fit-
ting No. 12094, that was used to check "lift pump ---0--
inlet suction" on the Phase I engine.

Figure 50. Checking Lift Pump Suction

Figure 49. Checking Turbo Boost Pressure on 7.8L

225 HI' & 240 HI' Engines (Air-To-Air
Aftercooled) Figure 51. Checking Fuel Return Line Pressure

29
 1987 ENGINE PERFORMANCE SPECIFICATION

Figure 52. Checking Crankcase Pressure

5. Oil Pressure - Oil pressure is checked in a different OIL PRESSURE

SWITCH
area on the Phase 2 engines (Fig. 53). Use adapter
11950 that was used to check fuel return line pressure
on the Phase 1 engine. Adapter is placed at a junc-
tion in the line to the oil pressure switch.

All other system pressure adapters and fittings remain

the same as on the Phase 1 engine.
Figure 53. Checking Oil Pressure (L & F Series
225 HP & 240 HP)

30

,.·!,t
 SPECIAL TOOLS

The following special tools have been developed for use

with the Phase 2 6.6L and 7.8L engines.

• .
.

Exhaust Valve Seat Replacer

T87T-6084·A

Valve Stem Seal Replacer

T87T-6571-A

NOT AVAILABLE AT TIME OF PRINTING

Connecting Rod Bushing Remover/Replacer

T87T-TBD

Valve Guide Reamer

T87T-6510·B Injection Pump Aligning Pin
T87T-9000-B

Valve Guide Replacer

T87T-6510·A

Damper Aligning Pin

T87T-6379-A

31
 SPECIAL TOOLS

Front Crankshaft Seal Replacer Injector Pump Drive Gear Puller

T87T-6019-A T87T-6312-B

Water Pump Shaft and Bearing

Installer/Support
T87T-6312-C

Rear Crankshaft Seal Replacer

T87T-6701-A

Water Pump Seal Replacer

T87T-6312·A

32

,.·:lo!
 ENGINE SPECIFICATiONS

GENERAL SPECIFICATIONS PISTON OIL CONTROL RINGS

Description 6.6L 7.8L Description Specification
Displacement 6580 em> (401 in.') 7767 em' (474 in.') Type Slotted with Expander
Bore 111.8 mm (4.4 in.) 111.8 mm (4.4 in.) Number and Location One (1) Above Piston Pin
Stroke 111.8 mm (4.4 in.) 132.1 mm (5.2 in.) Material Cast Iron
Compression Ratio 16.7:1 16.7:1 Finish Chrome Plate
Firing Order 1·5·3·6·2·4 1-5·3-6·2·4 Width 4.714-4.740mm (0.1856.0.1866 in.)
Engine Type Overhead Valve - ln~Line Cylinder Block Gap Width 0.33·0.58mm (0.13-0.23 in.)
Number of Cylinders 6 16 Side Clearance 0.047-0.093mm (0.0018·0.0036 in.)

CYLINDER BLOCK SPECIFICATIONS PISTON COMPRESSION RINGS

Description Specification Description Specification
Cylinder Bore Taper (Total) 0.025 mm (0.001 in.) Top Ring: Keystone
Type Lower Ring: Straight Face ~
Cylinder Bore Out of Round
0.025 mm (0.001 in.) Inner Bevel
(Total)
Number and Location Two (2) Above Piston Pin
111.m • 111.841 mm
Cylinder Bore Diameter Material Cast Iron
(4.4007 • 4.4023 in.)
Plugs- Finish Chrome Plate
39048 Plug 50 • 68 N•m (37 - 50 ft. lbs.) Top Ring: None Keystone
M

67651 Pipe Plug 24 • 34 N•m (18 • 25 ft. lbs.) Side Clearance Lower Ring: 0.102·0.152 mm
87654 Pipe Plug 68 • 95 N•m (50 - 75 ft. lbs.) (0.004·0.006 in.)
Drain Cock 14 • 20 N•m (10- 15 ft. lbs.) Gap Width (Both) 0.330.0.580 mm (0.013-0.023 in.)

PISTON SPECIFICATIONS
Description Specification
Material Aluminum Alloy
Oversizes Available 0.10, 0.50, 0.76 and 1.00 mm (0.004, 0.020, 0.030, 0.040 in.)
No. of Compression Rings 2
No. of Control Rings 1
Skirt to Cylinder Clearance 0.10- 0.15 mm (.004 • .006 in.)
6.6L 7.8L
Piston Pin Clearance 0.0030 - 0.0139 mm O.ot06 - O.ot65 mm
(0.00012. 0.00055 in.) (0.00042 • 0.00065 in.)
Piston Crown to Block Face +0.00- +0.30 mm (0.00- 0.012 in.)

PISTON PIN SPECIFICATIONS SPECIAL SERViCE TOOLS (6.6L Phase 1 and 7.8L)
Description 6.6L 7.8L TKIT-1987-HT
41.270·41.275mm 44.442-44.447mm
Outside Diameter Tool Number Description
(1.6248·1.6250) (1.7497-1.7499 ln.)
TB?T-6571-A Valve Stem Seal Replacer
T87T-6084·A Exhaust Valve Seat Replacer
T67T-6019·A Front Crank Seal Replacer
T87T-6701·A Rear Crank Seal Replacer
T87T-6312·C Water Pump Shaft and Bearing
Installer/Support
T87T-6312·A Water Pump Seal Replacer
T87T-6379·A Damper Aligning Pin
T87T-6510-A Valve Guide Replacer
T87T-9000-B Injection Pump Aligning Pin
TB?T-6510-B Valve Guide Reamer
T87T-6312·B Injection Pump Drive Gear Puller
Con Rod Bushing Reniover/lnstaller
T87T-fBD
(6.6L)

33
 ENGINE SPECIFICATIONS

CONNECTING ROD SPECIFICATIONS )

Description 6.6L 7.8L
41.263. 41.290 mm 44.457 • 44.465 mm
Small End Bushing • Internal Dia.
(1.6253. 1.6256 in.) (1.7503 • 1.7506 in.)
Bushing to Pin Clearance
.008 • .020 mm 0.010 • 0.023 mm
(0.003 • 0.006 in.) (0.004 • 0.009 in.)
0.13 • 0.33 mm 0.13 • 0.33 mm
Side Clearance
(0.005 • 0.013 in.) (0.005 • 0.013 in.)
Maximum Twist 0.26 mm (0.011 in.) 0.33 mm (0.013 ln.)
Maximum Bend 0.10 mm (0.004 in.) 0.10 mm (0.004 in.)
35.56 • 35.81 mm 31.50 • 31.75 mm
Big End Bearing Length
(1.40 • 1.41 in.) (1.24 • 1.25 in.)
0.043. 0.177 mm 0.069 • 0.142 mm
Big End Bearing Clearance - Service
(0.0017 • 0.0046 in.) (0.0027 • 0.0056 in.)
Big End Bearing Clearance - Service 0.127 mm (MAX.). 0.152 mm (MAX.)
Wear Limit 0.005 in. (MAX.) 0.006 in. (MAX.)

BIG END BEARING IDENTIFICATION

Crankpin Journal
Color Diameter
Code Designation Undersize MM IN. Bearing Thickness
Red STD - - 69.860 • 69.870 2.7500. 2.7504 2.395 • 2.408 mm (0.0943 • 0.0946 in.)
- Undersize 1.02 mm (0.040 in.) 66.634 . 68.844 2.7100. 2.7104 2.903 • 2.916 mm (0.1143 • 0.1146 in.)
- Undersize 0.76 mm (0.030 in.) 69.088 • 69.098 2.7200. 2.7204 2.776 • 2.789 mm (0.1093 • 0.1098 in.)
- Undersize 0.51 mm (0.020 in.) 69.342 • 69.352 2.7300. 2.7304 2.649 • 2.662 mm (0.~

~.431 • 2.443 mm (0.0957 • 0.0962 in.)

White Undersize 0.25 mm (0.010 in.) 69.956 • 69.966 2.7400. 2.7404
Green Undersize 0.05 mm (0.002 in.) 69.769 • 69.799 2.7476. 2.7460
\
!

CRANKSHAFT SPECIFICATIONS
6.6L 7.6L
Description
MM IN. MM IN.
Red 65.644 • 85.656 3.3716 • 3.3723 85.644 • 85.656 3.3718 • 3.3723
Main Journal Diameter
Blue 65.634 • 65.644 3.3713 • 3.3716 65.631 • 85.644 3.3713. 3.3716
Main Journal Length 36.0. 36.82 1.42. 1.50 36.0 • 38.82 1.42. 1.50
Main Journal Wear Limits - Max. 0.010 0.0004 0.010 0.0004
Thrust Bearing Journal Length 36.91 • 36.96 1.453. 1.455 36.91 .• 36.96 1.453. 1.455
Intermediate Bearing - Journal Length 27.9. 28.2 1.10. 1.11 27.9. 28.2 1.10. 1.11
Rod Bearing Journal Length 35.6. 35.8 1.40. 1.41 31.50. 31.75 1.24. 1.25
Red Liner 74.706. 74.717 2.9412 • 2.9416 74.706 • 74.717 2.9412 • 2.9416
Rod Bearing Journal Diameter
Blue Liner 74.717. 74.727 2.9416 • 2.9420 74.717. 74.727 2.9416 • 2.9420
End Play 0.10. 0.20 0.004 • 0.006 0.10. 0.20 0.004 • 0.008
Rod Bearing Out-of-Round - Total Indicator Reading 0.005 0.0002 0.005 0.0002
Taper Surface Parallel to Center Line of Main Journal 0.005 0.0002 0.005 0.0002
Crankshaft Rear Oil Seal Journal Diameter 122.12. 122.28 4.608 • 4.614 122.12. 122.28 4.808 • 4.614
Crankshaft Pulley Journal Diameter 44.45 • 44.48 1.750. 1.751 51.79 • 51.61 2.039 • 2.040
Crankshaft Timing Gear Journal Diameter 46.23 • 46.25 1.820. 1.821 65.5. 66.0 2.58. 2.60
Crank Pin Fillet Radius 3.0. 3.6 0.12. 0.14 5.1 • 5.6 0.20. 0.22
Main Fillet Radius 3.0. 3.6 0.12. 0.14 3.0. 3.6 0.12. 0.14

34

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 ENGINE SPECIFICATIONS

CRANKSHAFT DRIVE GEAR TAPPET SPECIFICATIONS

Description Specification Description Specification
Number of Teeth 26 Tappet Diameter 25.1180-25.1307 mm (0.9889-0.9894 in.)
Timing Mark Punch Mark on Tooth Tappet Bore Diameter 25.146-25.171 mm (0.990-0.991 in.)
Installation Temperature 203°C (400°F) Clearance to Bore 0.0152-0.0530 mm (0.0006-0,0021 in.)

DAMPER SPECIFICATIONS ROCKER ARM AND SHAFT SPECIFICATIONS

Description 6.6L 7.8L Description Specification
Damper to Crankshaft 25.400 - 25.425 mm
Press Fit Shaft Diameter
(1.000- 1.001 in.)
Tolerance (.0003-.0023 in.) (.0009-.0025 in.)
.008 - .058 mm .0029 - .0635 mm Shaft Support Internal 25.450 - 25.501 mm
Diameter (1.002- 1.004 in.)
Pressure Required 48,900-93,400 N 48,900-93,400 N
(11,000-21,000 lbs.) (11,000-21,000 lbs.) 25.476 - 25.501 mm
Rocker Arm Inside Diameter
(1.003- 1.004 in.)
Locating Bolt Torque 271 - 298 N•m 271 - 298 N•m
200 - 220 ft. lbs. 200 - 220 ft. lbs.
Front Damper Torque 68- 81 N•m CAMSHAFT IDENTIFICATION
- (50 - 60 ft. lbs.)
Description Specification
Timing Marks 120' Apart 120° Apart
60.6933 - 60.7187 mm
Static Timing Slots 2 1 Bearing Journal Diameter
(2.3895 - 2.3905 in.)
Dynamic Timing Slots 1 1 0.025 - 0.076 mm
Bearing Clearance
(0.001 - 0.003 in.)
.050 -.228 mm
MAIN BEARING SPECIFICATIONS End Play
(0.002 - 0.009 in.)
Description Specification
Exhaust 7.936 mm (0.312 in.)
Bearing Length 27.94 - 28.19 mm Lobe Lift
Intake 7.587 mm (0.298 in.)
(Except Thrust Bearing) (1.10- 1.11 in.)
36.91 - 36.96 mm
Thrust Bearing Length
(1.453- 1.455 in.) CAMSHAFT GEAR SPECIFICATIONS
0.086 - 0.170 mm Description Specification
Bearing Clearance - Service
(0.0034 - 0.0067 in.)
Number of Teeth 52
Bearing Clearance - Service 0.179 mm (MAX.)
Timing Mark Punch Mark on Tooth
Wear Limit 0.007 in. (MAX.)

MAIN BEARING IDENTIFICATION

Corresponding Main
Color Journal Diameter Bearing Thickness
Code Designation Undersize MM IN. MM IN •
.Red STD - - 85.643 - 85.656 3.3718 - 3.3723 3.150- 3.162 0.1240- 0.1245
- Undersize 1.02 mm (0.040 in.) 84.628 - 84.640 3.3318 - 3.3323 3.658 - 3.670 0.1440 - 0.1445
- Undersize 0.76 mm (0.030 in.) 84.882 - 84.894 3.3418 - 3.3423 3.531 - 3.543 0.1390- 0.1395
- Undersize 0.51 mm (0.020 in.) 85.136- 85.148 3.3518 - 3.3523 3.404 - 3.416 0.1340- 0.1345
White Undersize 0.25 mm (0.010 in.) 85.390 - 85.402 3.3618 - 3.3623 3.277 - 3.289 0.1290- 0.1295
Green Undersize 0.05 mm (0.002 in.) 85.580 - 85.593 3.3693 - 3.3698 3.185- 3.198 0.1254- 0.1259

CAMSHAFT DRIVE GEAR SPECIFICATIONS

Description Specification
Adapter Outside Diameter 50.757- 50.770 mm (1.9983- 1.9988 in.)
Adapter to Gear Clearance 0.05 - 0.06 mm (0.002 - 0.0025 in.)
End Play 0.076 - 0.035 mm (0.003 - 0.014 in.)
Bushing Inside Diameter 50.81 - 50.83 mm (2.005 - 2.0015 ln.)
Bearing Clearance 0.03 - 0.08 mm (0.001 - 0.003 ln.)
Number of Teeth 47
Timing Marks Punch Mark (Three Places) on Tooth
Backlash With Crankshaft Gear 0.025 - 0.228 mm (0.001 - 0.009 in.)
Backlash With Camshaft Gear 0.025 - 0.228 mm (0.001 - 0.009 in.)
Backlash With Fuel Injection Pump Drive Gear 0.025 - 0.304 mm (0.001 - 0.012 in.)

35
 ENGINE SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS EXHAUST VALVE SPECIFICATIONS

)
Specification Description Specification
Six Bolts Per Cylinder Face Angle 44.5°
9.469-9.487 mm (0.3728-0.3738 in.) 9.4005 • 9.4183 mm
Stem Diameter - Standard
0.08 mm (0.003 in.) In Any (0.3701 • 0.3708 in.)
152.00 mm (6.0 in.) Change 9.4787 • 9.4945 mm
O.D76 mm (.003 in.) - Oversize
Head to Block Surface Flatness Must Be Gradual And Must (0.3731 • 0.3738 in.)
Not Exceed .039 mm (.001 in.) 9.7851 - 9.7993 mm
In Any 2.54 mm (1.00 in.). 0.381 mm (.015 in.) • Oversize
(0.3851 - 0.3858 in.)
10.1625 • 10.1803 mm
0.762 mm (.030 in.)· Oversize
(0.4001 • 0.4008 in.)
INTAKE VALVES SPECIFICATIONS Head Diameter 42.74 mm (1.683 in.)
Description Specification 0.0508 • 0.094 mm
Stem To Guide Clearance
Face Angle 29.5' (0.0020 • 0.0037 in.)
9.4259 • 9.4437 mm Lash Clearance 0.46 mm (0.018 in.)
Stem Diameter w Standard
(0.3711 - 0.3718 in.)
9.5021 • 9.5199 mm VALVE SEAT SPECIFICATIONS
0.076 mm (.003 in.) • Oversize
(0.3741 - 0.3748 in.)
9.8069 - 9.8247 mm Description Specification
0.381 mm (.015 in.) • Oversize Intake 30'
(0.3861 - 0.3868 in.) Seat Angle·
10.1879 • 10.2057 mm Exhaust 45'
0.762 mm (.030 in.) • Oversize Seat Runout 0.063 mm (0.002 in.)
(0.4011 • 0.4018 in.)
Head Diameter 47.99 mm (1.870 in.) Intake 1.98-2.49 mm (0.078-0.098 in.)
Seat Width ·
Exhaust 1.80·2.31 mm (0.071-0.091 in.)
0.0254 • 0.0686 mm
Stem to Guide Clearance Intake
(0.0010 • 0.0027 in.) Valve Recession 0.84·1.32 mm (0.033-0.052 in.)
Lash Clearance 0.38 mm (0.015 in.)
Exhaust

FLYWHEEL SPECIFICATIONS
VALVE SPRING SPECIFICATIONS Description Specification \
Description Specification Clutch Face Runout 0.13 mm (0.005 in.) /
Type Cylindrical Coil w One Per Valve Ring Gear Runout 0.64 mm (0.025 in.)
Free Length 59.69 mm (2.35 in.) Crankshaft Flywheel Flange
0.38 mm (0.015 in.)
Load at 44.0 mm (1.74 in.) Runout
445-489 N (100-110 lbs.)
Length Max. Material Removal From
1.143 mm (0.045 in.)
Assembled Height 46.48-48.00 mm (1.83-1.89 in.) Flywheel
Out of Square (MAX) 2.0 mm (0.080 in.)
THERMOSTAT SPECIFICATIONS
VALVE TIMING SPECIFICATIONS Description Specification
Opening Temperature 82'C (180'F)
Description Specification
Full Open Temperature 96'C (205'F)
Intake Opening .13.5' BTDC
Intake Closing 38.5° ABDC
Intake Duration 232° OIL FILL SPECIFICATIONS
Exhaust Opening 58.5' BBDC Description 6.6L 7.8L
Exhaust Closing 11.5' ATDC Engine-With New Filters 18.9L (20.0 Qts.) 18.9L (20.0 Qts.)
Exhaust Duration 2480 Fuel Injection Pump 280 ML (0.6 Pint) 280 ML (.06 Pint)

OIL PUMP SPECIFICATIONS

Description Specification
Rotor Tip Clearance 0.025 • 0.152 mm (0.001 • 0.006 in.)
Rotor To Pump Housing Clearance 0.152 • 0.279 mm (0.006 • 0.011 in.)
Rotor End Play 0.025 • 0.102 mm (0.001 • 0.004 in.)
Pump Pressure As Measured In Engine Oil Gallery At 104'C (220'F) 6.6L 7.8L
800 RPM 1 Bar (15 PSI) 1 Bar (15 PSI)
2600 RPM 4.1 • 5.5 Bar (60 • 80 PSI) 3.8 • 5.2 Bar (55 • 75 PSI)
Relief Valve Spring Tension 280 • 293 N (63 • 66 Lbs.) @ 35.3 mm (1.39 in.)
Oil Pump Idler Gear To Crankshaft Gear Backlash 0.30 • 0.76 mm (0.012 • 0.030 in.)
Oil Pump Gear To Idler Gear Backlash 0.08 • 0.41 mm (0.003 • O.D16 in.)

36

··S.· .. ·'1:_·
 TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
6.6L 7.8L
Description N•m Ft·Lb N•m Ft·Lb
Boost Control Pipe, Fittings 7-11 5-8 7-11 5·8
Camshaft Drive Gear, Bolt 203-244 150-180 203-244 150-180
Camshaft Gear, Bolt 54-61 40-45 54-61 40-45
Camshaft Thrust Plate, Bolts 47-54 35-40 47-54 35-40
Camshaft Rear Cover Plate, Screws N/A N/A 14-16 10-12
Connecting Rod Bearing, Nuts 106-108 78-80 142-152 105-112
Crankshaft Rear Seal Retainer, Bolts 16-20 6-8 16-20 6-8
Crankshaft Vibration Damper, Bolt 271-298 200-220 271-298 200-220
Crankshaft Vibration Damper, Bolts N/A N/A 68-81 50-60
Cylinder Head, Bolts 2 210-224 155-165 210-224 155-165
Engine Lift Eye, Bolts 95-108 70-80 95-108 70-80
Engine Front Support Insulators 102-142 75-105 102-142 75-105
Auto. Trans. 102-142 75-105 102-142 75-105
Engine Rear Support Insulators Man. Trans. 102-142 75-105 102-142 75-105
Engine Front Bracket Mounting 298-406 220-300 298-406 220-300
Flywheel Housing (Side), Bolts 210-264 155-195 210-264 155-195
Flywheel Housing (Top), Bolts 339-420 250-310 339-420 250-310
Flywheel To Crankshaft Flange, Bolts 169-223 125-165 169-223 125-165
Front Cover, Screws 27-34 20-25 27-34 20-25
Front Plate, Bolts 16-20 12-15 16-20 12-15
Fuel Box, Bolts 31-38 23-28 31-38 23-28
Fuel Filter Mounting Bracket, Bolts 27-34 20-25 27-34 20-25
Fuel Injection Pump Oil Fill, Plug 27-37 20-27 27-37 20-27
Fuel Injection Pump Gear & Hub, Bolt (A-Pump) 80-89 59-66 N/A N/A
Fuel Injection Pump Gear & Hub, Bolt (P-Pump) 179-199 132-147 179-199 132-147
Fuel Injection Pump Gear & Hub Adjusting Screws 21-25 16-19 21-25 16-19
Fuel Injection Pump Mounting, Bolts 27-34 20-25 27-34 20-25
Fuel Injection Pump Hold Down Bracket, Bolts 20-24 15-18 20-24 15-18
Fuel Injector Leak Off Pipe, Bolts 5.8-6.8 4-5 Ft.-Lbs. 5.8-6.8 4-5 Ft.-Lbs.
Fuel Injection ~ High Pressure Fuel Line, Bolts 22-27 16-20 22-27 16-20
Intercooler ~ Air-To-Water/Cover, Bolts N/A N/A 16-20 12-15
Manifold - Intake, Bolts 31-38 23-28 31-38 23-28
Manifold ~ Exhaust, Bolts 81-87 60-65 81-87 60-65
Main Bearing Cap, Bolts 190-203 140-150 190-203 140-150
Oil Cooler - Tube Assembly Rear Mounting Flange, Bolts 27-34 20-25 27-34 20-25
Oil Cooler - Tube Assembly Support Bracket, Bolts 61-68 45-50 61-68 45-50
Oil Cooler End Caps, Bolts 9.5-14.2 7-10 Ft.-Lbs. 9.5-14.2 7-10 Ft.-Lbs.
Oil Cooler Support Assembly, Bolts 54-61 40-45 54-61 40-45
Oil Cooler To Support, Bolts 61-68 45-50 61-68 45-50
Oil Pan, Bolts 20-27 15-20 20-27 15-20
Oil Pan Return Port, Plug 47-68 35-50 47-68 35-50
Oil Pan Drain, Plug 34-47 25-35 34-47 25-35
Oil Pump Mounting, Bolts 68-81 50-60 68-81 50-60
Oil Pump Outlet Tube Special Brass, Nut 3 190 Max 140 Max 190 Max 140 Max
Oil Pump Pick-Up Tube, Bolts 42-57 31-42 42-57 31-42
Oil Pump Pick-Up Tube Support, Bolt 95-122 70-90 95-122 70-90
Oil Gallery - Rear, Plug 50-68 37-50 50-68 37-50
Oil Gallery - Side, Pipe Plugs 24-34 18-25 24-34 18-25
Road Draft Tube Support, Bolt 14-20 11-15 14-20 11-15
Rocker Arm Cover, Bolts 20-27 15-20 20-27 15-20
Rocker Arm Shaft Support, Bolts 210-224 155-165 210-224 155-165
Rocker Arm Adjusting, Screws 12 Min. 9 Min. 12 Min. 9 Min.
Timing Bracket 9-12 7-9 9-12 7-9

37
 TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
6.6L 7.8L
Description N•m Ft-Lb N•m FI·Lb
Thermostat To Block, Bolts 61·68 45-50 61-68 45-50
Thermostat Cover, Bolts 18-24 13-18 18-24 13·18
Turbocharger To Manifold, Bolts 27-34 20-25 27-34 20-25
Turbocharger To Manifold, Nuts 47-54 35·40 47-54 35-40
Turbocharger Oil Return Tube, Nut 27-34 20-25 27-34 20-25
Turbocharger Oil Return, Nut To Connector 41-47 30-35 41-47 30-35
Turbocharger Oil Return, Connector To Block 34·47 25-35 34-47 25-35
Turbocharger Pressure Feed Line, Bolt 16-20 12-15 16·20 12-15
Turbocharger Pressure Feed, Nut To Connector 20-27 15-20 20-27 15-20
Turbocharger Pressure Feed, Connector To Block SNUG FIT
Water Pump To Block, Bolt I 61·68 I 45-50 I 61-68 I 45-50
N/A - NOT APPLICABLE.

NOTE:
t The following torque specifications with lubricated threads, except as noted apply to any operation not listed.

THREAD SIZE TORQUE FT-LB TORQUE N•m

1/4-20 6-9 8-12

1/4-28 6-9 8-12
5/16-18 12-15 16-20
5/16-24 15-18 20-24
3/8-16 20-25 27-34
3/8-24 30-35 41-47 \
7116-14 45-50 61-68 )
7/16-20 50-60 68-81
1/2-13 60-70 81-95
1/2-20 70-80 95-108
9/16-18 85-95 115-129
5/8-18 130-145 176-197
1/8-27 NPT 6-10 8-14
1/4-18 NPT 18-25 24-34
3/8·18 NPT 35-50 47-68
1/2·14 NPT 35-50 47-68
3/4-14 NPT 50-70 68·95
1·11 1/2 NPT 65-75 a8-102

On national pipe threaded plugs which enter oil or water cavities, apply sealer to both internal and external threads. Do not use sealer on
plugs at end of main oil gallery.

2 Tighten the head bolts in the sequence shown below in the following progressive steps:
Step 1 - 156 N•m (115 ft·lbs)
Step 2 - 190 N•m (140 ft-lbs)
Step 3 - 217 N•m (160 ft-lbs)

a Special outlet oil tube nut (brass) instructions (new nut only):
1. Oil brass nut threads.
2. Tighten fitting 7 N•m (5 ft-lbs) enough to shear off sleeve.
3. Turn nut 1-1/4 to 1-1/2 turns. DO NOT EXCEED 190 N•m (140 ft-lbs).

Reuse of existing special outlet oil tube nut (brass) instructions:

1. Oil brass nut threads.
2. Tighten fitting until sharp torque increase (fitting begins to seat).
3. Turn fitting an additional 1/8 to 1/4 turn (do not exceed 190 N•m (140 ft-lbs))
NOTE: Fitting reuse is limited to 3 times. If rebuilds exceed 3 times, a new outlet tube and fitting is required.

38
•s:
CERTIFIED
WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION

AUGUST, 1986 LITHO IN U.S.A. ORDER NUMBER 2202-011