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珀金斯Perkins1506A-E88TA、1506C-E88TA、1506D-E88TA发动机维修技术资料

详细描述

Specifications

1506A-E88TA, 1506C-E88TA and 1506D-

E88TA Industrial Engines

LG

(Engine)

PK9 (Engine)

This document has been printed from SPI2. NOT FOR RESALE


 

Important Safety Information

Most  accidents    tha t involve  produc  t  op eration,  ma intena nc e and   repair   are  caus  ed  by  failure  to

ob serve  basic   safety   rules  or  precautions  .  An accident    can   often  be  avoided   by  recog nizing  pote ntially

ha za rdous  situations   before   an  accident    oc curs . A person    mus t be  alert   to pote ntial  ha za rds.  This

person   should   also  ha ve  the  ne cessary   training,  skills  and   tools  to perform   the se  func tions 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 have

read and understood the operation, lubrication, maintenance and repair information.

Sa fety precautions     and  warning s  are   provided   in this  ma nua l and   on  the  produc t.  If the se  ha za rd

warning s  are  not  he eded,   bod ily injury  or death   could   oc cur to  you  or to  othe r persons  .

The  ha za rds are   identified   by  the  “Safety  Alert  Symb ol”  and  followed  by  a  “Signa l  Word” suc h  as

“DANGER”, “WARNING”  or “CAUTION”.  The Sa fety  Alert  “WARNING” label  is  shown   below.

The  me aning  of  this safety   alert   symb ol is  as  follows:

Attention! Become Alert! Your Safety is  Involved.

The  me ssage   tha t appears     und er the   warning  explains    the  ha za rd and   can  be   either  written  or

pictorially   presente  d.

Op erations  tha t  ma y caus e  produc  t dama  ge  are  identified   by  “NOTICE” labels   on  the  produc  t and   in

this  pub lication.

Perkins 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. If a tool, procedure,

work method or operating technique that is not specifically recommended by Perkins is used,

you must satisfy yourself that it is safe  for you and for others. You should also ensure that the

product will not be damaged or be  made unsafe by the operation, lubrication, maintenance or

repair procedures that you choose.

The  informa tion, specifications   ,  and  illustrations   in  this  pub lication  are   on the  basis    of informa tion tha t

was  available    at  the  time  tha t the  pub lication   was  written.   The  specifications   , torque  s,  pressure  s,

me asure me nts , adjustme  nts , illustrations ,  and  othe r  items  can  cha  ng e at  any  time.  These  cha ng es  can

affect   the  service   tha t is given   to the  produc  t.  Ob tain the  comp  lete  and  mos t current   informa tion before

you  start any   job. Pe  rkins  dealers   or   Pe rkins  distributors     ha ve  the  mos t current   informa tion  available.

When  replacement  parts  are  required  for  this

product Perkins recommends using Perkins

 replacement  parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

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UENR4509

3

Table of Contents

Table of Contents

Electric Starting Motor .................. .................. 40

Electric Starting Motor (Model PK9) ....... ....... 40

Coolant Temperature Sensor............. ............. 41

Fuel Temperature Sensor................ ............... 41

Fuel Pressure Sensor................... .................. 41

Injection Actuation Pressure Sensor ....... ....... 42

Engine Oil Pressure Sensor.............. ............. 42

Atmospheric Pressure Sensor............ ............ 43

Inlet Air Temperature Sensor............. ............. 43

Speed/Timing Sensor................... .................. 44

Electronic Control Module ............... ............... 44

SpecificationsSection

Engine Design ......................... ......................... 4

Fuel Filter Base (Primary Fuel Filter Base)... ... 4

Fuel Filter Base (Secondary Fuel Filter Base). 5

Fuel Filter Base (Secondary Fuel Filter Base,

Model PK9)........................... .......................... 5

Unit Injector Hydraulic Pump.............. .............. 6

Unit Injector............................ ........................... 6

Lifter Group............................ ........................... 8

Valve Mechanism ....................... ...................... 8

Valve Mechanism Cover.................. ................. 9

Cylinder Head Valves ................... .................. 10

Cylinder Head......................... ........................ 13

Turbocharger......................... ......................... 15

Turbocharger (Model PK9)............... .............. 16

Air Inlet Elbow......................... ........................ 17

Exhaust Manifold...................... ...................... 18

Camshaft............................ ............................ 18

Engine Oil Filter Base................... .................. 19

Engine Oil Pan........................ ........................ 20

Crankcase Breather.................... .................... 21

Water Temperature Regulator Housing..... ..... 21

Water Temperature Regulator Housing..... ..... 22

Water Temperature Regulator ............ ............ 22

Water Pump.......................... .......................... 24

Water Pump (Model PK9)............... ............... 26

Cylinder Block Cover Group.............. ............. 27

Cylinder Block......................... ........................ 27

Cylinder Liner......................... ......................... 29

Crankshaft........................... ........................... 30

Crankshaft Seals ...................... ...................... 30

Vibration Damper and Pulley............. ............. 31

Connecting Rod Bearing Journal.......... .......... 31

Main Bearing Journal................... ................... 31

Connecting Rod....................... ....................... 32

Piston and Rings ...................... ...................... 33

Piston Cooling Jet...................... ..................... 34

Front Housing and Covers............... ............... 34

Gear Group (Front)..................... .................... 35

Flywheel .......................................................... 36

Flywheel Housing...................... ..................... 36

Belt Tension Chart ..................... ..................... 36

Belt Tensioner (Model PK9).............. .............. 37

Refrigerant Compressor (Model PK9) ...... ...... 38

Fan Drive............................ ............................ 38

Alternator and Regulator................. ................ 38

Alternator and Regulator (Model PK9)...... ..... 39

Index Section

Index................................ ............................... 45

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4

UENR4509

Specifications Section

SpecificationsSection

i06004069

Fuel Filter Base

(Primary Fuel Filter Base)

i02841820

Engine Design

If necessary, install a new fuel primary fuel filter (5).

Refer to Operation and Maintenance Manual, “Fuel

System Primary Filter (Water Separator) Element -

Replace” for the correct procedure.

Illustration 1

g01101255

Cylinder and valve location

(A) Exhaust valves

(B) Inlet valves

Bore ............................................112.0 mm (4.41 inch)

Stroke ........................................149.0 mm (5.87 inch)

Displacement.....................................8.8 L (537 cu in)

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

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

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

Valve lash with engine stopped (cold)

Illustration 2

g03767316

Typical example

(1) Tighten the bolts to the following torque......55 N·m

(41 lb ft)

Inlet..............0.38 ± 0.08 mm (0.015 ± 0.003 inch)

Exhaust.......0.64  ± 0.08 mm (0.025 ± 0.003 inch)

(2) Tighten the adaptor to the following torque.

............................................................30 N·m (22 lb ft)

Note: The front of the engine is opposite of the

flywheel end of the engine. The left side and the right

side of the engine are viewed from the flywheel end of

the engine. The no. 1 cylinder is the front cylinder.

(3) Tighten the plugs to the following torque.

.........................................................22 N·m (195 lb in)

(4) Tighten the plug to the following torque. .....30 N·m

(22 lb ft)

Crankshaft rotation direction (view from the flywheel

end) .................................................Counterclockwise

(6) Tighten the bolts to the following torque.

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

..........................................................100 N·m (74 lb ft)

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UENR4509

5

Specifications Section

i06004049

(7) Tighten the bolt to the following torque. ......12 N·m

(106 lb in)

Fuel Filter Base

(Secondary Fuel Filter Base)  

(8) Tighten the plugs to the following torque.

............................................................40 N·m (30 lb ft)

i06228953

Fuel Filter Base

(Secondary Fuel Filter Base,

Model PK9)

If necessary, install a new secondary fuel filter (5).

Refer to Operation and Maintenance Manual, “Fuel

System Secondary Filter - Replace” for the correct

procedure.

If necessary, install a new secondary fuel filter (8).

Refer to Operation and Maintenance Manual, “Fuel

System Secondary Filter - Replace” for the correct

procedure.

Illustration 3

g03767376

Typical example

(1) Tighten the bolts to the following torque......55 N·m

(41 lb ft)

Illustration 4

g03863013

(2) Tighten the connector to the following torque.

Typical example

............................................................50 N·m (37 lb ft)

(1) Tighten the bolts to the following torque......28 N·m

(21 lb ft)

(3) Tighten the elbows to the following torque.

............................................................50 N·m (37 lb ft)

(2) Tighten the adaptor to the following torque.

............................................................40 N·m (30 lb ft)

(4) Tighten the valves to the following torque.

............................................................65 N·m (48 lb ft)

(3) Tighten the bolts to the following torque......55 N·m

(41 lb ft)

(6) Tighten the bolt to the following torque. ......28 N·m

(21 lb ft)

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6

UENR4509

Specifications Section

(4) Tighten the elbow to the following torque.

............................................................40 N·m (30 lb ft)

Use the following procedure in order to torque the

cover bolts.

1. Torque the bolts to 8 N·m  (70 lb in).

(5) Tighten the elbow to the following torque.

............................................................40 N·m (30 lb ft)

2. Turn the bolts for an additional 24 degrees.

(6) Tighten the nipple to the following torque.

............................................................30 N·m (22 lb ft)

3. Ensure that the torque of the bolts is 10.2 N·m

(90 lb in).

(7) Tighten the bolt to the following torque. ......28 N·m

(21 lb ft)

(5) Oil outlet port

Torque for mating fitting................48 N·m (35 lb ft)

(6) Fuel outlet port

(9) Tighten the bolt to the following torque. ......12 N·m

(106 lb in)

Torque for mating fitting................23 N·m (17 lb ft)

(7) Tie bolts for pump housing

i05982963

Unit Injector Hydraulic Pump

Use the following procedure in order to tighten the tie

bolts for the pump housing.

1. Torque the bolts to 17 N·m  (13 lb ft).

2. Turn the bolts for an additional 35 degrees.

3. Ensure that the torque of the bolts is 33 N·m

(24 lb ft).

(8) Fuel inlet port

Torque for mating fitting................23 N·m (17 lb ft)

Pump performance.

Rated pump speed ..............................3312 RPM

Maximum intermittent speed of the pump .... 5000

RPM

Maximum continuous operating pressure

.................................................28 MPa (4050 psi)

Relief valve opening pressure ..................31 MPa

(4500 psi)

Nut for the pump gear (not shown)

Use the following procedure to tighten the nut for the

pump gear.

1. Torque the nut to 50 N·m  (37 lb ft).

2. Turn the nut for an additional 35.5 degrees.

Illustration 5

g01101301

i02820444

Typical example

Unit Injector  

(1) Unit injector hydraulic pump

(2) Oil inlet port

Torque for mating fitting................40 N·m (30 lb ft)

(3) Fuel transfer pump

(4) Cover bolts

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UENR4509

7

Specifications Section

Note: Lubricate the bore in the cylinder head lightly

with the lubricant that is being sealed.

Note: Install the fuel injector group (1) so the

electrical connector is facing toward the exhaust side

of the cylinder head.

Use the following procedure to install the fuel injector

group:

1. Seat the fuel injector group in the bore.

2. Tighten the bolt (2) which is closest to the exhaust

side (5) of the cylinder head until the bolt is seated.

3. Tighten the bolt (3) which is closest to the inlet side

(6) of the cylinder head to 12 ± 1 N·m

(105 ± 9 lb in).

Illustration 6

g01407502

(4) O-ring seal

Illustration 8

g01407507

View B-B

(7) Backup ring

(8) O-ring seal

(9) O-ring seal

(10) Backup ring

Illustration 7

g01407503

View A-A

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8

UENR4509

Specifications Section

i05966860

Valve Mechanism  

Illustration 9

g01407504

Top view of fuel injector group

Note: The top of the fuel injector group has four bolts

(11) that are used for securing the top cover on the

fuel injector group. There are two holes (12) in the top

of the fuel injector group that are used for assembly

purposes only. Do not install bolts in the two bolt

holes (12).

i02820477

Lifter Group  

Illustration 11

g01417772

Typical example

(1) Valve bridge

(3) Valve pushrod

Valve lash

Inlet valve.... 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

Exhaust valve...............................0.64 ± 0.08 mm

(0.025 ± 0.003 inch)

Note: Tighten the nut (2) after you set the valve lash.

Illustration 10

g01407530

(2) Torque for the nut ..............30 ± 7 N·m (22 ± 5 lb ft)

(1) Valve lifter insert

(3) Valve lifter roller

(4) Lubricate the bore in the cylinder block for the

valve lifter assemblies with clean engine oil before

installation.

(A) Diameter of a new valve lifter body

.................29.464 ± 0.013 mm (1.1600 ± 0.0005 inch)

(A) Bore diameter of the valve rocker arm

.................28.050 ± 0.013 mm (1.1043 ± 0.0005 inch)

(2) Lubricate the roller pin with clean engine oil.

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UENR4509

9

Specifications Section

Illustration 12

g01417771

Typical example

(B) Diameter of the new rocker arm shaft

.................28.000 ± 0.013 mm (1.1024 ± 0.0005 inch)

(C) Depth of installation of the two cup plugs from the

end of the rocker arm shaft to the top edge of the cup

plugs .................. 1.25 ± 0.25 mm (0.049 ± 0.010 inch)

Illustration 13

g01454259

i05998651

Typical example

Note: Tighten the bolts in a numerical sequence that

is shown in Illustration 13 to standard torque.

Valve Mechanism Cover  

(5) Spring

Quantity ..............................................................6

Length under test force.........14.5 mm (0.57 inch)

Test force.....................65.0 ± 3.5 N (14.6 ± 0.8 lb)

Approximate free length after test......... 30.75 mm

(1.211 inch)

Outside diameter...............34.80 mm (1.370 inch)

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10

UENR4509

Specifications Section

i06000949

Cylinder Head Valves

Illustration 14

g01061297

A typical example of a valve mechanism cover base

Tighten the bolts for the valve cover base in the

sequence that is shown in Illustration 14  to the

following torque...................................28 N·m (21 lb ft)

Illustration 16

g01417779

A typical example of a section view of cylinder head

valves

Note: Fully coat the assembled valve guide inner

diameter with engine oil prior to valve installation.

(1) Inlet valve

Illustration 15

g00728341

A typical example of a valve mechanism cover

Valve stem diameter................. 8.000 ± 0.010 mm

(0.3150 ± 0.0004 inch)

Diameter of valve head..............39.00 ± 0.13 mm

(1.535 ± 0.005 inch)

Note: Some engines may not be equipped with an oil

filler cap that is located on the valve mechanism

cover.

(2) Exhaust valve

Tighten the bolts for the valve mechanism cover in

the sequence that is shown in Illustration 15  to the

following torque...................................20 N·m (15 lb ft)

Valve stem diameter................. 9.441 ± 0.010 mm

(0.3717 ± 0.0004 inch)

Diameter of valve head..............36.00 ± 0.13 mm

(1.417 ± 0.005 inch)

Note: The valve cover seal is cut to size at assembly.

Coat seal joints with Loctite 5940 Black RTV Silicone

Sealant.

(3) Outer Inlet Valve Spring

Length under test force.........42.8 mm (1.69 inch)

Test force...................152.5 ± 7.0 N (34.3 ± 1.6 lb)

Approximate free length after test......... 56.68 mm

(2.231 inch)

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UENR4509

11

Specifications Section

Outside diameter................. 21.33 mm (0.84 inch)

Note: Shrink the valve seat inserts by reducing the

temperature. Shrinking the valve seat inserts allows

placement into the counterbore.

(4) Outer Exhaust Valve Spring

Length under test force.....37.70 mm (1.484 inch)

Test force.......................350 ± 17 N (78.7 ± 3.8 lb)

Approximate free length after test......... 57.80 mm

(2.276 inch)

(C) Depth of the bore in the cylinder head for the

valve seat insert

Depth (inlet)..................................9.30 ± 0.05 mm

(0.366 ± 0.002 inch)

Outside diameter...............31.79 mm (1.252 inch)

Depth (exhaust).......................... 10.40 ± 0.05 mm

(0.409 ± 0.002 inch)

(5) Inner Exhaust Valve Spring

Length under test force.........36.5 mm (1.44 inch)

Test force.........................187 ± 8 N (42.0 ± 1.8 lb)

Approximate free length after test......... 57.80 mm

(2.276 inch)

(D) Outside diameter of the valve seat insert

Diameter (inlet)....................... 40.060 ± 0.013 mm

(1.5772 ± 0.0005 inch)

Bore in the cylinder head for the valve seat insert

(inlet) ......................................40.000 ± 0.015 mm

(1.5748 ± 0.0006 inch)

Outside diameter...............23.18 mm (0.913 inch)

(6) Inner Inlet Valve Spring

Length under test force.........44.0 mm (1.73 inch)

Test force.......................305 ± 15 N (68.6 ± 3.3 lb)

Approximate free length after test......... 67.69 mm

(2.665 inch)

Diameter (exhaust) ................37.560 ± 0.013 mm

(1.4787 ± 0.0005 inch)

Bore in the cylinder head for the valve seat insert

(exhaust)................................37.500  ± 0.015 mm

(1.4764 ± 0.0006 inch)

Outside diameter...............28.56 mm (1.124 inch)

Note: Lubricate the bores in the cylinder head for the

valve guides with clean engine oil prior to installation.

(A) Height of the valve guides above the top of the

cylinder head ........... 12.0 ± 0.5 mm (0.47 ± 0.02 inch)

(7) Valve guide (inlet)

Outside diameter.................... 13.030 ± 0.008 mm

(0.5130 ± 0.0003 inch)

Bore in the cylinder head for the valve guide

.......... 13.000 ± 0.013 mm (0.5118 ± 0.0005 inch)

(8) Valve guide (exhaust)

Illustration 18

g03761157

Outside diameter.................... 16.000 ± 0.008 mm

(0.6299 ± 0.0003 inch)

View E-E of Detail B

Bore in the cylinder head for the valve guide

..........15.970 ± 0.013 mm (0.6287 ± 0.0005 inch)

(G) Angle of the face of the valve seat insert

Angle (inlet) ........................30.25 ± 0.25 degrees

Illustration 17

g02137754

Detail B

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12

UENR4509

Specifications Section

Illustration 19

g03761176

View E-E of Detail B

(H) Angle of the face of the valve seat insert

Angle (exhaust) ..................45.00 ± 0.25 degrees

Illustration 21

g03761020

View F-F of Detail B

(K) Angle of the face of the valve

Angle (exhaust) ..................45.75 ± 0.25 degrees

Illustration 20

g03761019

View F-F of Detail B

(J) Angle of the face of the valve

Angle (inlet) .......................... 60.5 ± 0.25 degrees

This document has been printed from SPI2. NOT FOR RESALE


 

UENR4509

13

Specifications Section

i05985395

Cylinder Head  

Illustration 22

g01417896

Typical example

This document has been printed from SPI2. NOT FOR RESALE


 

14

UENR4509

Specifications Section

Note: The top face of the gasket and the top face of

the cylinder block, cylinder liners, and the bottom face

of the gasket and the bottom face of the cylinder head

must be free of oil, fuel, water, and other

contaminants before assembly.

Note: Use clean engine oil to lubricate the threads of

the cylinder head bolts before assembly.

Use the following procedure to tighten the cylinder

head bolts:

1. Torque the bolt (1) through bolt (26) in a numerical

sequence to 130 N·m (95 lb ft).

2. Again torque the bolt (1) through bolt (26) in a

numerical sequence to 130 N·m (95 lb ft).

3. Place a mark on bolt (1) through bolt (26). Rotate

the bolt (1) through bolt (26) in the clockwise

direction in a numerical sequence to 90 degrees

(1/4 turn).

4. Loosen the bolt (1) through bolt (26) in a numerical

sequence to 0 N·m (0 lb ft).

5. Repeat Step 1 through Step 3.

6. Torque the bolt (27) through bolt (31) in a numerical

sequence to 28 N·m (21 lb ft).

Illustration 23

g01417900

Typical example

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UENR4509

15

Specifications Section

Note: Apply Loctite to the bore of the cup plugs

before assembly.

(C) The cup plugs (Y) are measured from the head

face to the top edge of the plug. Depth of installation

...................................2.0 ± 0.5 mm (0.08 ± 0.02 inch)

(D) The cup plugs (X) are measured from the head

face to the top edge of the plug. Depth of installation

...................................1.5 ± 0.5 mm (0.06 ± 0.02 inch)

Illustration 25

g03763957

Typical example

Note: Apply CV60889 Anti-Seize Compound to the

faces of the washers and the nuts before assembly of

the turbocharger.

Illustration 24

g01417914

Typical example

(32) Torque for the plugs................350 N·m (260 lb ft)

(1) Tighten the nuts that fasten the turbocharger to

the exhaust manifold to the following torque.

............................................................54 N·m (40 lb ft)

(E) Height of new cylinder head ..... 130.00 ± 0.15 mm

(5.118 ± 0.006 inch)

Note: The flatness of the cylinder head should be

within 0.15 mm (0.006 inch). The flatness should

also be a maximum of 0.05 mm  (0.002 inch) for any

150.00 mm (5.906 inch) span.

i06004320

Turbocharger

Illustration 26

g03764056

Typical example

(2) Tighten the clamp for the turbine housing to the

following torque................................14 N·m (125 lb in)

(3) Tighten the clamp for the compressor housing to

the following torque............................10 N·m (89 lb in)

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16

UENR4509

Specifications Section

(7) Tighten the bolts to the following torque......28 N·m

(21 lb ft)

i06228941

Turbocharger

(Model PK9)

Illustration 27

g03764137

Typical example

(4) Tighten the tube nuts for hose assembly to the

following torque...................................45 N·m (33 lb ft)

(5) Tighten the bolts to the following torque......28 N·m

(21 lb ft)

Illustration 29

g03863182

Typical example

Wastegate setting with a 1 mm (0.04 inch) movement

for the rod actuator.............................190 kPa (28 psi)

Note: Apply CV60889 Anti-Seize Compound to the

faces of the washers and the nuts before assembly of

the turbocharger.

(1) Tighten the nuts that fasten the turbocharger to

the exhaust manifold to the following torque.

............................................................54 N·m (40 lb ft)

Illustration 28

g03765960

Typical example

(6) Tighten the elbow to the following torque.

............................................................80 N·m (59 lb ft)

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UENR4509

17

Specifications Section

Illustration 30

g03863180

Illustration 32

g03863140

Typical example

Typical example

(2) Tighten the clamp for the turbine housing to the

following torque................................14 N·m (125 lb in)

(6) Tighten the elbow to the following torque.

............................................................80 N·m (59 lb ft)

(3) Tighten the clamp for the compressor housing to

the following torque............................10 N·m (89 lb in)

(7) Tighten the bolts to the following torque......28 N·m

(21 lb ft)

i05985469

Air Inlet Elbow

Illustration 31

g03863163

Typical example

(4) Tighten the tube nuts for hose assembly to the

following torque...................................45 N·m (33 lb ft)

(5) Tighten the bolts to the following torque......28 N·m

(21 lb ft)

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18

UENR4509

Specifications Section

Illustration 34

g01434396

Typical example

(1) Cylinder head

(2) Torque for the 12 taperlock studs................35 N·m

(26 lb ft)

Illustration 33

g03765697

(3) Torque for the four taperlock studs..............35 N·m

(26 lb ft)

Typical example

(1) Tighten the studs to the following torque.

............................................................28 N·m (21 lb ft)

(4) Install the six gaskets with the tabs upward, as

shown.

(2) Tighten the bolts to the following torque......28 N·m

(21 lb ft)

(5) Apply CV60889 Anti-Seize Compound to the

threads of the 12 locknuts before assembly.

i05983006

Exhaust Manifold

Illustration 35

g01329313

Tightening sequence (typical example)

Tighten the nuts in the numerical sequence that is

shown in Illustration 35 to the following torque.

............................................................55 N·m (41 lb ft)

i02843361

Camshaft  

This document has been printed from SPI2. NOT FOR RESALE


 

UENR4509

19

Specifications Section

3. Subtract the base circle (E) from the camshaft lobe

height (D). The difference is the actual camshaft

lobe lift (C).

Maximum permissible difference between the actual

lobe lift and the specified lobe lift of a new camshaft

................................................± 0.10 mm (0.004 inch)

i05985333

Engine Oil Filter Base  

Illustration 36

g01417861

(A) Diameter of the four camshaft journals

.................65.126 ± 0.013 mm (2.5640 ± 0.0005 inch)

(B) Thickness of new thrust plate .................... 4.7 mm

(0.19 inch)

End play of a new camshaft................ 0.10 ± 0.08 mm

(0.004 ± 0.003 inch)

Maximum permissible end play of a worn camshaft

...................................................0.46 mm (0.018 inch)

Illustration 38

g01421171

Bolt tightening sequence for oil filter base

Use the tightening sequence that is shown in

Illustration 38 in order to torque the bolts for the oil

filter base.

Illustration 37

g01417862

(C) Specified camshaft lobe lift

Exhaust lobe ...................6.858 mm (0.2700 inch)

Inlet lobe..........................8.655 mm (0.3407 inch)

To find the actual camshaft lobe lift, use the following

procedure:

1. Measure the camshaft lobe height (D).

2. Measure the base circle (E).

This document has been printed from SPI2. NOT FOR RESALE


 

20

UENR4509

Specifications Section

(16) Torque for the hollow stud...........68 N·m (50 lb ft)

(17) Torque for the cover ....................70 N·m (50 lb ft)

i05999049

Engine Oil Pan

Illustration 39

g01421173

Typical example

(13) Oil cooler bypass valve

(14) Oil filter bypass valve

(18) Engine oil filter assembly

(15) Spring

Length under test force.....43.18 mm (1.700 inch)

Test force.........................................43.7 N (9.8 lb)

Free length after test.................. 58.50 ± 0.50 mm

(2.303 ± 0.020 inch)

Illustration 41

g01104928

Outside diameter.........................11 mm (0.4 inch)

Typical example

Apply Loctite 5940 Black RTV Silicone Sealant  to

four areas on the sealing surface of the oil pan. The

areas are marked location (Y). The areas are at the

corners of the oil pan in 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

Make sure that all surfaces are clean and that all

surfaces are free of oil and debris. The sealant must

be applied with a consistent bead of the sealant that

is 5 mm (0.2 inch) diameter in cross section on the

block. The joint must be assembled within 5 minutes

of the application of the sealant.

Use the following procedure to tighten the bolts for

the oil pan.

Tighten the four bolts (X) to the following torque.

............................................................28 N·m (21 lb ft)

Illustration 40

g01421172

Typical example

Start with bolt (Z) and tighten all the remaining bolts in

a counterclockwise sequence.

(A) Length for applying Loctite 575 to the threads of

the hollow stud......... 10.0 ± 1.5 mm (0.39 ± 0.06 inch)

Tighten the bolts to the following torque...........28 N·m

(21 lb ft)

This document has been printed from SPI2. NOT FOR RESALE


 

UENR4509

21

Specifications Section

Start again with bolt (Z) and tighten all bolts in a

counterclockwise sequence.

i06003992

Water Temperature Regulator

Tighten the bolts to the following torque...........31 N·m

(23 lb ft)

Housing  

Tighten the oil drain plug to the following torque.

............................................................40 N·m (30 lb ft)

i05976165

Crankcase Breather  

Illustration 43

g01446597

Typical example

(1) Lubricate the sealing lip of the lip type seal lightly

with glycerin or an approved equivalent.

Illustration 42

g03744941

Typical example

(1) Tighten the bolt to the following torque. ......15 N·m

(11 lb ft)

(2) Tighten the bolt to the following torque. ......55 N·m

(41 lb ft)

(3) Tighten the bolt to the following torque. ......28 N·m

(21 lb ft)

This document has been printed from SPI2. NOT FOR RESALE


 

22

UENR4509

Specifications Section

(1) Lubricate the sealing lip of the lip type seal lightly

with glycerin or an approved equivalent.

Illustration 44

g03763496

Typical example

Illustration 46

g03862995

(2) Tighten the bolts to the following torque......55 N·m

(41 lb ft)

Typical example

(2) Tighten the bolts to the following torque......55 N·m

(41 lb ft)

i06226158

Water Temperature Regulator

Housing  

i05982950

Water Temperature Regulator  

Illustration 47

g02542379

, ,

Illustration 45

g01417881

Typical example

Typical example

Opening temperature........ 86 to 90 °C (187 to 194 °F)

This document has been printed from SPI2. NOT FOR RESALE


 

UENR4509

23

Specifications Section

Fully open temperature.........................98 °C (208 °F)

(A) Minimum opening distance at 98 °C  (208 °F)

.....................................................10.4 mm (0.41 inch)

This document has been printed from SPI2. NOT FOR RESALE


 

24

UENR4509

Specifications Section

i06004153

Water Pump  

Illustration 48

g01354632

Typical example

(1) Shaft assembly

This document has been printed from SPI2. NOT FOR RESALE


 

UENR4509

25

Specifications Section

(2) The bearing must be flush with the edge of the

housing.

(3) The plug must be flush with the edge of the

housing. Refer to Illustration 48 for the correct

orientation of the plug. If necessary, adjust the

orientation of the plug.

(B) Clearance between the pump impeller and the

housing..............0.75  ± 0.25 mm (0.030 ± 0.010 inch)

(C) Working height of the installed water pump seal

assembly...... 11.303 ± 0.127 mm (0.445 ± 0.005 inch)

(D) Distance from the front of the hub to the face of

the housing....122.79  ± 0.30 mm (4.834 ± 0.012 inch)

Note: Refer to Disassembly and Assembly for the

complete procedure for installing the shaft and seal.

Illustration 49

g03763676

Typical example

(4) Tighten the bolts to the following torque......55 N·m

(41 lb ft)

(5) Tighten the bolts to the following torque......28 N·m

(21 lb ft)

This document has been printed from SPI2. NOT FOR RESALE


 

26

UENR4509

Specifications Section

i06226144

Water Pump

(Model PK9)

Illustration 50

g02529516

Typical example

This document has been printed from SPI2. NOT FOR RESALE


 

UENR4509

27

Specifications Section

(A) Clearance between the pump impeller and the

housing..............0.75  ± 0.25 mm (0.030 ± 0.010 inch)

(1) The shaft assembly must be flush with the edge of

the housing.

(2) The plug must be flush with the edge of the

housing. Refer to Illustration 50 for the correct

orientation of the plug. If necessary, adjust the

orientation of the plug.

(3) Tighten the bolts to the following torque......30 N·m

(266 lb in)

(B) Operating height is the following value.

.........................12.19 ± 0.13 mm (0.480 ± 0.005 inch)

(C) Distance from the front face of the pulley to the

face of the housing .........................132.88 ± 0.30 mm

(5.231 ± 0.012 inch)

Illustration 52

g03744524

Typical example

Use the following procedure to tighten the bolts for

the cylinder block cover group:

1. Tighten bolt (1) through bolt (11) to a torque of

28 N·m (21 lb ft). Tighten the bolts in the numerical

sequence that is shown in illustration 52 .

2. Again tighten bolt (1) through bolt (11) to a torque

of 28 N·m (21 lb ft). Tighten the bolts in the

numerical sequence that is shown in illustration 52

.

i06192227

Cylinder Block

Illustration 51

g03862638

Typical example

(4) Tighten the bolts to the following torque......55 N·m

(41 lb ft)

i05975801

Cylinder Block Cover Group  

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