SENR9833-02

May 2006

Specifications
800C Industrial Engine
UE (Engine)
UF (Engine)
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
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 information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information 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.
SENR9833-02 3
Table of Contents

Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Injection Lines .............................................. 4
Fuel Injection Pump ............................................. 4
Fuel Injectors ....................................................... 5
Fuel Transfer Pump ............................................. 6
Lifter Group ........................................................... 6
Rocker Shaft ........................................................ 7
Valve Mechanism Cover ...................................... 7
Cylinder Head Valves ........................................... 8
Cylinder Head ...................................................... 9
Exhaust Manifold ................................................. 9
Camshaft ............................................................. 9
Engine Oil Relief Valve ........................................ 11
Engine Oil Pump .................................................. 11
Engine Oil Pressure ............................................. 12
Engine Oil Bypass Valve ...................................... 12
Engine Oil Pan ..................................................... 13
Water Temperature Regulator .............................. 14
Cylinder Block ...................................................... 14
Crankshaft ........................................................... 16
Crankshaft Seals ................................................. 17
Connecting Rod Bearing Journal ......................... 17
Main Bearing Journal ............................................ 17
Connecting Rod ................................................... 17
Piston and Rings .................................................. 18
Front Housing and Covers ................................... 20
Gear Group (Front) ............................................... 20
Flywheel ............................................................... 21
Crankshaft Pulley ................................................. 21
Belt Tension Chart ............................................... 22
Alternator and Regulator ...................................... 23
Electric Starting Motor ......................................... 23
Glow Plugs ........................................................... 24

Index Section
Index ..................................................................... 25
4 SENR9833-02
Specifications Section

Specifications Section When the camshaft is viewed from the flywheel end
of the engine, the camshaft rotates in the following
direction: ....................................... Counterclockwise
i01955627
Note: The left side and the right side of the engine
Engine Design are viewed from the flywheel end. The No. 1 cylinder
is the front cylinder.

i01891782

Fuel Injection Lines

g01016767
Illustration 1
Cylinder and valve location
(A) Inlet valve
(B) Exhaust valve

Bore ............................................. 94 mm (3.70 inch)

Stroke ........................................ 120 mm (4.72 inch)

Displacement ...................................... 3.3 L (203 in3)

Cylinder arrangement ..................................... In-line

g00993243
Illustration 2
Type of combustion
(1) Tighten the nuts for the fuel injection lines to the
Naturally aspirated engines ...... Indirect injection following torque. ..... 27 to 32 N·m (20 to 24 lb ft)
Turbocharged engines ................. Direct injection

Compression ratio i01906880

Naturally aspirated engines ......................... 22:1 Fuel Injection Pump

Turbocharged engines ................................. 19:1

Number of cylinders ................................................ 4

Note: The engine is equipped with an axial piston
Valves per cylinder .................................................. 2 distributor injection pump that is mechanically
governed. Parts that are inside of the fuel injection
Valve lash pump are only serviceable by an authorized dealer.

Inlet valve ....................... 0.25 mm (0.0098 inch)

Exhaust valve ................. 0.25 mm (0.0098 inch)

Firing order ................................................. 1, 3, 4, 2

Fuel injection timing ....................................... 5° BTC

When the crankshaft is viewed from the flywheel end

of the engine, the crankshaft rotates in the following
direction: ....................................... Counterclockwise
SENR9833-02 5
Specifications Section

i02506427

Fuel Injectors

Naturally Aspirated Engines

g00993641
Illustration 3

(1) Tighten the overflow valve for the fuel injection

pump to the following torque. ......... 22 to 31 N·m
(16 to 23 lb ft)

(2) Screw for adjusting the full load setting

g01010241
Illustration 4
(3) Tighten the nut for the fuel injection pump gear
to the following torque.
(1) Tighten the body in the retaining nut to the
Naturally aspirated engines ............ 59 to 69 N·m following torque. ..... 34 to 39 N·m (25 to 29 lb ft)
(43 to 51 lb ft)
Turbocharged engines .................... 83 to 98 N·m Note: The fuel injector should only be disassembled
(62 to 72 lb ft) and assembled by personnel with the proper training.

(4) Fuel shutoff solenoid (2) Tighten the fuel injector in the engine to the
following torque. ..... 53 to 65 N·m (39 to 48 lb ft)
(5) Bolt for attaching to the gear case cover
Type of fuel injector ............................... single orifice
(6) Delivery valves for the fuel
Injection pressure
Standard at assembly .......... 11.77 to 12.75 MPa
(1707 to 1849 psi)
6 SENR9833-02
Specifications Section

Turbocharged Engines i01907139

Fuel Transfer Pump

g00993511
Illustration 5

(1) Tighten the retaining nut to the following

torque. .................... 25 to 34 N·m (18 to 25 lb ft) g00993469
Illustration 6

Note: The fuel injector should only be disassembled

(1) Fuel transfer pump
and assembled by personnel with the proper training.
(2) Torque for one fitting ... 6 to 8 N·m (53 to 71 lb in)
Tighten the clamp bolt that secures the fuel
injector in the cylinder head to the following
(3) Fuel filter/water separator
torque. ........................... 21 to 23 N·m (15 to 17 lb ft)

Type of fuel injector ............................ multiple orifice i01900860

Injection pressure Lifter Group

Standard at assembly .......... 18.14 to 19.12 MPa
(2631 to 2773 psi)

g00988934
Illustration 7

Clearance between the lifter and the bore in the

engine for the lifter
Standard at assembly ........... 0.016 to 0.052 mm
(0.0006 to 0.0020 inch)
SENR9833-02 7
Specifications Section

Repair limit ...................... 0.08 mm (0.0031 inch)

i02509351

Rocker Shaft

Part No.: 233-5501

Table 1
Required Tools
Part
Tool Number Part Description Qty
g01256133
Illustration 9
A 21825617 Dial Indicator Group 1
B - V Block 2 (5) Pushrods

Place the pushrod in Tooling (B). Use Tooling (A)

in order to check all pushrods for runout. Replace
the pushrod if the runout exceeds the following
value. ..................................... 0.30 mm (0.0118 inch)

i01892068

Valve Mechanism Cover

g00984738
Illustration 8

(1) Rocker shaft

Diameter of the rocker
shaft .................................. 18.980 to 19.000 mm
(0.7472 to 0.7480 inch)

(2) Rocker arm

Inside diameter of the rocker arm
bushings ........................... 19.010 to 19.030 mm Illustration 10
g00984870
(0.7484 to 0.7492 inch)
Clearance between the rocker arm bushing and (1) Tighten the bolts for the valve mechanism cover
the rocker shaft ..................... 0.010 to 0.050 mm to the following torque. ................... 10 to 13 N·m
(0.0004 to 0.0020 inch) (7 to 10 lb ft)
Maximum permissible clearance between
the rocker arm bushing and the rocker
shaft .............................. 0.070 mm (0.0028 inch)

(3) Spring

(4) Tighten the bolts evenly. Tighten the long

bolt first. Tighten the bolts to the following
torque. ...................... 10 to 20 N·m (7 to 15 lb ft)
8 SENR9833-02
Specifications Section

i01892207 Valve depth of the exhaust valve below the cylinder

head face
Cylinder Head Valves
Standard at assembly ................... 0.4 to 0.6 mm
(0.016 to 0.024 inch)
Service limit ........................ 1.0 mm (0.039 inch)

(5) Inlet valve

Diameter of the inlet valve
stem ...................................... 7.940 to 7.955 mm
(0.3126 to 0.3132 inch)
Service limit diameter of the inlet valve
stem ............................... 7.900 mm (0.3110 inch)
Clearance of the inlet valve stem in the inlet valve
guide ..................................... 0.065 to 0.095 mm
(0.0026 to 0.0037 inch)
Maximum allowable clearance of the inlet valve
stem in the inlet valve guide ............... 0.150 mm
(0.0059 inch)

Valve depth of the inlet valve below the cylinder head

face
Standard at assembly ................... 0.3 to 0.5 mm
(0.012 to 0.020 inch)
Service limit ........................ 1.0 mm (0.039 inch)
g01010358
Illustration 11
(6) Angle of the exhaust valve face from the
(1) Valve spring horizontal axis
Free length of the valve springs ......... 48.85 mm Valve face angle ............................... 30 degrees
(1.92 inch) Valve seat angle ............................... 30 degrees
Service limit for free length of the valve
springs .............................. 47.60 mm (1.87 inch) (7) Angle of the inlet valve face from the horizontal
Length of the valve springs under set axis
force ....................................... 43 mm (1.69 inch)
Set force of the valve springs ......... 176 to 196 N Valve face angle ............................... 30 degrees
(40 to 44 lb) Valve seat angle ............................... 30 degrees
Service limit for set force of the valve
springs ........................................... 147 N (33 lb)

(2) Valve spring recess

(3) Valve guides

Projection of the valve guide above the valve
spring recess ... 14 ± 0.1 mm (0.55 ± 0.004 inch)

(4) Exhaust valve

Diameter of the exhaust valve
stem ...................................... 7.920 to 7.940 mm
(0.3118 to 0.3126 inch)
Service limit diameter of the exhaust valve Illustration 12
g00985069
stem .............................. 7.850 mm (0.3091 inch)
Bore in the cylinder head for the valve seats
Clearance of the exhaust valve stem in the
exhaust valve guide ............... 0.080 to 0.115 mm
Bore for the inlet valve seat
(0.0031 to 0.0045 inch)
Maximum allowable clearance of the exhaust A ....................................................... 45 degrees
valve stem in the exhaust valve guide .. 0.200 mm B ....... 46 to 46.0025 mm (1.8110 to 1.8111 inch)
(0.0079 inch) C ...................... 2 ± 0.1 mm (0.079 ± 0.004 inch)
SENR9833-02 9
Specifications Section

D ...................... 8 ± 0.1 mm (0.315 ± 0.004 inch) i01892688

Bore for the exhaust valve seat Exhaust Manifold

A ....................................................... 45 degrees
B .......... 37 to 37.0025 mm (1.457 to 1.458 inch)
C ...................... 2 ± 0.1 mm (0.079 ± 0.004 inch)
D ...................... 8 ± 0.1 mm (0.315 ± 0.004 inch)

i01892090

Cylinder Head

g00985166
Illustration 15

(1) Bolt

Tighten the exhaust manifold bolts to the following

torque.
Naturally aspirated engines ............ 15 to 22 N·m
(11 to 16 lb ft)
g00984896 Turbocharged engines .................... 28 to 33 N·m
Illustration 13 (21 to 24 lb ft)
Tighten the cylinder head bolts in the sequence that Maximum warpage of the flange for the exhaust
is shown to the following torque. ....... 113 to 123 N·m manifold .................................. 0.20 mm (0.008 inch)
(83 to 91 lb ft)

i02506460

Camshaft

g00984909
Illustration 14

The permissible distortion of the cylinder head is

given below.
Maximum at assembly .... 0.05 mm (0.0020 inch)
g00988290
Repair limit ...................... 0.20 mm (0.0079 inch) Illustration 16

(1) End play of a new camshaft ...... 0.10 ± 0.25 mm

(0.0039 ± 0.0098 inch)

Maximum permissible end play of a worn

camshaft ................................ 0.30 mm (0.0118 inch)
10 SENR9833-02
Specifications Section

(2) Tighten the thrust plate bolts to the following (B) Camshaft lobe height
torque. ...................... 10 to 13 N·m (7 to 10 lb ft)
(C) Base circle
(3) The diameters of the camshaft journals are given
in the following table. To determine the lobe lift, use the procedure that
follows:
Table 2

Diameters of Camshaft Journals 1. Measure the camshaft lobe height (B).

Camshaft Standard Service Limit 2. Measure the base circle (C).
Journals Diameter
No. 1,2 53.94 to 53.96 53.90 mm 3. Subtract the base circle that is found in Step 2
mm (2.123 to (2.122 inch) from the camshaft lobe height that is found in Step
2.124 inch) 1. The difference is the camshaft lobe lift.
No. 3 52.94 to 52.96 52.90 mm
mm (2.084 to (2.083 inch) If the camshaft lobe lift is less than the service limit,
2.085 inch) replace the camshaft.

g01014070
Illustration 18

(4) Camshaft

Deflection over the full length of the camshaft

Maximum at assembly .... 0.02 mm (0.0008 inch)
Illustration 17
g00987844 Repair limit ...................... 0.05 mm (0.0020 inch)

(A) Camshaft lobe lift

Naturally aspirated engines
Inlet lobe ....................... 6.722 mm (0.2646 inch)
Exhaust lobe ................. 6.720 mm (0.2645 inch)
Turbocharged engines
Inlet lobe ....................... 6.682 mm (0.2631 inch)
Exhaust lobe ................. 6.722 mm (0.2646 inch)

The service limit for camshaft lobe lift is given below:

Naturally aspirated engines
Inlet lobe ....................... 6.222 mm (0.2450 inch)
Exhaust lobe ................. 6.220 mm (0.2449 inch)
Turbocharged engines
Inlet lobe ....................... 6.182 mm (0.2434 inch)
Exhaust lobe ................. 6.222 mm (0.2450 inch)
SENR9833-02 11
Specifications Section

i01893227

Engine Oil Relief Valve

g00987876 g01256201
Illustration 19 Illustration 20

(1) Tighten the engine oil relief valve to the following (1) Clearance between the outer rotor and the body
torque. .................... 44 to 54 N·m (33 to 40 lb ft)
Standard ................................... 0.20 to 0.30 mm
Opening pressure of engine oil relief (0.0079 to 0.0118 inch)
valve ................................. 350 ± 50 kPa (50 ± 7 psi) Service limit .................... 0.50 mm (0.0197 inch)

Note: The engine oil relief valve is located on the left

side of the cylinder block.

i02509468

Engine Oil Pump

Table 3
Required Tools
Part
Tool Number Part Description Qty
A - Feeler Gauge 1

Type ............................. Gear-driven differential rotor

g01256201
Illustration 21
Number of lobes
Inner rotor ......................................................... 4 (2) Clearance between the outer rotor and the inner
Outer rotor ........................................................ 5 rotor
Standard ................................... 0.13 to 0.15 mm
(0.0051 to 0.0059 inch)
Service limit .................... 0.20 mm (0.0079 inch)
12 SENR9833-02
Specifications Section

Standard ................................ 0.025 to 0.111 mm

(0.0010 to 0.0044 inch)
Service limit .................. 0.200 mm (0.0079 inch)

i02502471

Engine Oil Pressure

Table 4
Oil Pressure(1)
Oil Pressure at 1500 rpm 262 ± 48 kPa (38 ± 7 psi)
Oil pressure at idle 200 ± 48 kPa (29 ± 7 psi)
(1) The oil temperature must be 70 ° to 90 °C (158 ° to 194 °F).

The minimum acceptable oil pressure at low

idle .................................................. 152 kPa (22 psi)

g01256204
Illustration 22
i01935709

(3) Clearance between the rotors and the body Engine Oil Bypass Valve
Standard ................................... 0.04 to 0.09 mm
(0.0016 to 0.0035 inch)
Service limit .................... 0.15 mm (0.0059 inch)

g00996150
Illustration 23

(4) Diameter of main shaft (near

body) ................................. 15.985 to 16.000 mm
(0.6293 to 0.6299 inch) g00987878
Illustration 24
Clearance between the main shaft and the body
Engine oil bypass valve
Standard ............................... 0.032 to 0.074 mm
(0.0013 to 0.0029 inch) Tighten the engine oil bypass valve to the
Service limit .................... 0.15 mm (0.0059 inch) following torque. ..... 64 to 74 N·m (47 to 55 lb ft)
Opening pressure of engine oil bypass
(5) Diameter of main shaft (near
valve ....................................... 1.1 MPa (160 psi)
bushing) ............................ 13.957 to 13.975 mm
(0.5495 to 0.5502 inch)
Note: The engine oil bypass valve is mounted on
the inside of the engine oil pan along the left side
Clearance between the main shaft and the bushing
oil pan rail.
SENR9833-02 13
Specifications Section

i02509965

Engine Oil Pan

Table 5
Required Tools
Part
Tool Number Part Description Qty
21826038 POWERPART Silicone
A 1
Sealant
21826051 POWERPART Sealing
B 1
Compound
21820117 POWERPART Threadlock
C 1
and Nutlock

g01020644
Illustration 26

Note: Apply Tooling (C) in order to reuse the bolts

for the oil pan. Apply Tooling (C) to the first 13 mm
(0.5118 inch) of the thread.

(1) Tighten the oil pan bolts to the following

torque. ...................... 10 to 13 N·m (7 to 10 lb ft)

g01256709
Illustration 25

Apply tooling (A) or Tooling (B) to the flange of the oil

pan. Refer to illustration 26.
g01256710
Illustration 27

(2) Tighten the oil pan drain plug to the following

torque. .................... 34 to 44 N·m (25 to 33 lb ft)
14 SENR9833-02
Specifications Section

i01893737

Water Temperature Regulator

g00877006
Illustration 28

g00987933
The water temperature regulator starts to open at the Illustration 29
following temperature. .... 82° ± 1.5°C (180° ± 2.7°F)
(1) Cylinder bore
The water temperature regulator has a lift of
Table 7
more than 8 mm (0.3 inch) at the following
temperature. ...................................... 95 °C (203 °F) Tolerances of Cylinder Bores
Standard at Repair Service
i02510338 Assembly Limit(1) Limit(2)

Cylinder Block Inside

94.000 to
94.035 mm
94.200 mm 94.700 mm
(3.7087 (3.7283
Diameter (3.7008 to
inch) inch)
3.7022 inch)
Table 6 0.010 mm
Out of
(0.0004 N/A N/A
Required Tools Round
inch)
Part 0.015 mm
Tool Number Part Description Qty Taper (0.0006 N/A N/A
21826038 POWERPART Silicone inch)
A 1
Sealant (1) Bore the cylinder to the specified oversize dimension if the
repair limit has been reached.
21826051 POWERPART Sealing
B 1 (2) Install a cylinder liner or replace the cylinder block if the service
Compound limit has been reached.
27610013 POWERPART Rubber
C 1
Plug Replacer Bore the cylinder to the oversize dimension if the
cylinder has uneven wear. Refer to Table 8.

Table 8
Oversize Bore Cylinder Bore Size
94.250 to 94.285 mm
0.250 mm (0.0100 inch)
(3.7106 to 3.7120 inch)
94.500 to 94.535 mm
0.500 mm (0.0197 inch)
(3.7205 to 3.7218 inch)

The permissible distortion of the contact surface of

the gasket is given below.
Maximum at assembly .... 0.05 mm (0.0020 inch)
SENR9833-02 15
Specifications Section

Repair limit ...................... 0.20 mm (0.0079 inch)

(2) Main bearing cap bolts

Use the following procedure in order to install the

main bearing cap bolts:

1. Apply engine oil to the bearings and install the

bearings to the caps.

Note: Apply a small amount of Tooling (A) or Tooling

(B) to the corners of the cylinder block for the rear
main bearing cap. After the rear main bearing cap is
installed, remove any excess sealant from the inside
of the recess for the rear oil seal. Excess sealant
prevents the correct seating of the rear oil seal.

2. Install the cap to the crankcase so that the rear

face of the cap is even with the rear face of the
crankcase.

3. Apply clean engine oil to the threads of the main Illustration 31

g01007117
bearing cap bolts.
(6) Seal for the front and rear main bearing caps.
Tighten the main bearing cap bolts to the following
torque. .................... 98 to 108 N·m (72 to 80 lb ft) (7) The seals for the front and the rear main bearing
caps have a curve at one end. The curved side
must be installed toward the side of the engine.
The curved end is inserted first into the hole.

Note: Use Tooling (C) in order to install the seal

correctly.

(8) Before installing the seals, inject a small quantity

of Tooling (A) or Tooling (B) in the holes for the
seals.

g01007113
Illustration 30

(3) Rear main bearing cap

(4) Main bearing caps should have a marking that

indicates placement and orientation.

(5) Front main bearing cap

g01007175
Illustration 32

(9) Seal for the front main bearing cap.

16 SENR9833-02
Specifications Section

Standard at assembly ........... 0.100 to 0.264 mm

(0.0039 to 0.0104 inch)
Repair limit ..................... 0.300 mm (0.0118 inch)

Crankshaft deflection
Maximum at assembly .... 0.02 mm (0.0008 inch)
Repair limit ...................... 0.05 mm (0.0020 inch)

Clearance between crankshaft bearing and

crankshaft journal
Standard at assembly ............ 0.050 to 0.110 mm
(0.0020 to 0.0043 inch)
Repair limit .................... 0.200 mm (0.0079 inch)

g00988954
Illustration 33

(10) Inside diameter of the lifter bore

Standard at assembly ....... 14.000 to 14.018 mm
(0.5512 to 0.5519 inch)
Service limit ................ 14.100 mm (0.5551 inch)

g00994009
i01894898 Illustration 35

Crankshaft (A) Original width of the rear crankshaft

journal ............................... 31.000 to 31.039 mm
(1.2205 to 1.2220 inch)

Table 9
Width of Crankshaft Journal for Oversize
Thrust Washers
Oversize Width Oversize Width
Oversize Thrust
for Front OR for Front AND
Washer
Rear Rear
31.150 to 31.189 31.300 to 31.339
0.15 mm
mm (1.2264 to mm (1.2323 to
(0.006 inch)
1.2279 inch) 1.2338 inch)
31.300 to 31.339 31.450 to 31.489
0.30 mm
mm (1.2323 to mm (1.2382 to
(0.012 inch)
1.2338 inch) 1.2397 inch)
31.450 to 31.489 31.600 to 31.639
0.45 mm
mm (1.2382 to mm (1.2441 to
(0.018 inch)
1.2397 inch) 1.2456 inch)

Refer to Specifications, “Connecting Rod Bearing

Journal” for information on the connecting rod bearing
Illustration 34
g00987940 journals.

(1) Crankshaft end play Refer to Specifications, “Main Bearing Journal” for
information on the main bearing journals and the
main bearings.
SENR9833-02 17
Specifications Section

i01059939 i01907583

Crankshaft Seals Main Bearing Journal

Table 11
Diameter of Crankshaft Journal (Bearing
Surface) For Main Bearings
77.955 to 77.970 mm
Original Size Journal(1)
(3.0691 to 3.0697 inch)
Undersize Journal 77.705 to 77.720 mm
0.25 mm (0.010 inch) (3.0592 to 3.0598 inch)
Undersize Journal 77.455 to 77.470 mm
0.50 mm (0.020 inch) (3.0494 to 3.0500 inch)
Undersize Journal 77.205 to 77.220 mm
0.75 mm (0.030 inch)(2) (3.0396 to 3.0402 inch)
(1) Regrind the main bearing journals to the next undersize
g00554030
Illustration 36 dimension if the repair limit of 77.850 mm (3.0650 inch) is
exceeded.
(2) Service limit 77.100 mm (3.0354 inch)
(1) Oil seal

(2) Oil seal sleeve The clearance between a new main bearing
and a new main bearing journal is the following
Inspect the contact surface between the oil seal and value. ..... 0.050 to 0.110 mm (0.0020 to 0.0043 inch)
the crankshaft for wear. If the crankshaft is worn,
replace the oil seal with an oil seal and a sleeve
i01895665
assembly.
Connecting Rod
i01907581

Connecting Rod Bearing

Journal

Table 10
Diameter of Crankshaft Journal (Bearing Surface)
For Connecting Rod Bearings
57.955 to 57.970 mm
Original Size Journal(1)
(2.2817 to 2.2823 inch)
Undersize Journal 57.705 to 57.720 mm
0.25 mm (0.010 inch) (2.2718 to 2.2724 inch)
Undersize Journal 57.455 to 57.470 mm
0.50 mm (0.020 inch) (2.2620 to 2.2626 inch)
Undersize Journal 57.205 to 57.220 mm
0.75 mm (0.030 inch) (2.2522 to 2.2528 inch)
(1) Regrind the connecting rod bearing journals to the next
undersize dimension if the repair limit of 57.800 mm
(2.2756 inch) is exceeded.
g00987949
Illustration 37
The clearance between a new connecting rod
bearing and a new connecting rod bearing journal is Prior to assembly, apply engine oil to the bearing.
the following value. ..................... 0.030 to 0.090 mm
(0.0012 to 0.0035 inch) (1) Install the bearing cap to the connecting rod
and tighten the cap nuts to the following
Service limit for clearance between a connecting torque. .................... 49 to 59 N·m (36 to 44 lb ft)
rod bearing and a connecting rod bearing
journal ................................. 0.200 mm (0.0079 inch) Inside diameter of the piston pin bearing
18 SENR9833-02
Specifications Section

Nominal value ........................ 30 mm (1.18 inch) Standard at assembly ....... 29.994 to 30.000 mm
Standard at assembly ....... 30.020 to 30.045 mm (1.1809 to 1.1811 inch)
(1.1819 to 1.1829 inch)
Clearance between the piston pin and the bore
Clearance between the piston pin and the piston pin
bearing Standard at assembly ........... 0.000 to 0.016 mm
(0.0000 to 0.0006 inch)
Standard at assembly ........... 0.020 to 0.051 mm Service limit .................. 0.050 mm (0.0020 inch)
(0.0008 to 0.0020 inch)
Service limit .................. 0.080 mm (0.0031 inch) Refer to table 13 for the outside diameters of the
pistons.
End play of the connecting rod that is attached to the
crankshaft. Table 13
Standard at
Standard at assembly ............... 0.15 to 0.35 mm Item
Assembly
Service Limit
(0.0059 to 0.0138 inch)
Service limit ...................... 0.50 mm (0.020 inch) 93.955 to 93.985
93.770 mm
Standard mm (3.6990 to
(3.6917 inch)
3.7002 inch)
i02510694
0.25 mm 94.205 to 94.235
94.020 mm
Piston and Rings (0.0098 inch)
oversize
mm (3.7089 to
3.7100 inch)
(3.7016 inch)

0.50 mm 94.455 to 94.485

94.270 mm
(0.0197 inch) mm (3.7187 to
(3.7114 inch)
oversize 3.7199 inch)
Table 12
Maximum difference in weight of the piston per
Required Tools
engine ........................................ 0.005 kg (0.0110 lb)
Part
Tool Number Part Description Qty
A - Feeler Gauge 1
B 21825617 Dial Indicator Group 1

g01256908
Illustration 39

Use Tooling (A) in order to measure the piston ring

end gap.

g00996359 Standard at assembly ............... 0.30 to 0.50 mm

Illustration 38
(0.0118 to 0.0197 inch)
Service limit .................... 1.50 mm (0.0591 inch)
(1) Diameter of the piston pin
Nominal value ........................ 30 mm (1.18 inch)
SENR9833-02 19
Specifications Section

Standard at Assembly
Naturally aspirated engines .... í0.25 to 0.15 mm
(í0.0098 to 0.0059 inch)
Turbocharged engines .............. 0.05 to 0.45 mm
(0.0020 to 0.0177 inch)

Compressed thickness of cylinder head

gasket ................. 1.2 ± 0.05 mm (0.05 ± 0.002 inch)

g01256909
Illustration 40

g00987977
Use Tooling (A) in order to measure the clearance Illustration 42
between the piston groove and a new piston ring.
(3) Piston from naturally aspirated engines
No. 1 ring
Standard at assembly ................ 0.07 to 0.11 mm (4) Piston from turbocharged engines
(0.0028 to 0.0043 inch)
Repair limit .................... 0.200 mm (0.0079 inch) (5) “WEIGHT” mark
No. 2 ring (6) “MATCHING” mark
Standard at assembly ........... 0.045 to 0.085 mm
(0.0018 to 0.0033 inch) Note: Assemble the piston and the connecting rod
Repair limit .................... 0.150 mm (0.0059 inch) with the “WEIGHT” mark on the piston and with the
“MATCHING” mark on the rod on the same side.
Oil ring
Standard at assembly ........... 0.025 to 0.065 mm
(0.0010 to 0.0026 inch)
Repair limit .................... 0.150 mm (0.0059 inch)

g00987981
Illustration 43

(7) Camshaft side

Illustration 41
g01256910 (8) End gap of No. 1 compression ring

Use Tooling (B) in order to measure the protrusion of (9) End gap of No. 2 compression ring
the piston (2).
(10) Side with the inlet valve

(11) End gap of oil ring

20 SENR9833-02
Specifications Section

Apply engine oil to the piston rings. Refer to i02296835

Illustration 43 for the assembled configuration of the
ends of the piston rings. Gear Group (Front)
Note: Install the piston with the “O” mark toward the
front of the engine.

i02506518

Front Housing and Covers

g00988013
Illustration 46
g00987995
Illustration 44
(1) Camshaft gear
(1) Tighten the bolts that fasten the front
plate to the cylinder block to the following (2) Idler gear
torque. ...................... 10 to 13 N·m (7 to 10 lb ft)
End play of idler gear
(2) Remove the excess gasket with a cutter. Standard at assembly ............... 0.05 to 0.20 mm
(0.0020 to 0.0079 inch)
Service limit .................... 0.35 mm (0.0138 inch)

Clearance between idler gear bushing and shaft

Standard at assembly ........... 0.009 to 0.050 mm
(0.0004 to 0.0020 inch)
Service limit .................. 0.100 mm (0.0039 inch)

(3) Fuel Injection pump gear

Tighten the bolts for the fuel injection pump gear
to the following torque.
Naturally aspirated engines ............ 59 to 69 N·m
(43 to 51 lb ft)
Illustration 45
g00987996 Turbocharged engines .................... 83 to 98 N·m
(62 to 72 lb ft)
(3) Tighten the bolts that fasten the timing
gear case to the front plate to the following (4) Crankshaft gear
torque. .................... 17 to 20 N·m (12 to 15 lb ft)
(5) Oil pump gear

(6) Tighten the thrust plate bolts for the idler gear to
the following torque. ....................... 29 to 39 N·m
(21 to 29 lb ft)
SENR9833-02 21
Specifications Section

(7) Tighten the locknut for the oil pump gear to the i01896629
following torque. ..... 28 to 38 N·m (21 to 28 lb ft)
Flywheel
Backlash for gears
Helical gears at assembly ......... 0.03 to 0.18 mm
(0.0012 to 0.0071 inch) Flatness of friction surface of the flywheel
Spur gears at assembly ................ .03 to .20 mm
(0.0012 to 0.0079 inch) Maximum at assembly .... 0.15 mm (0.0059 inch)
Service Limit ................... 0.25 mm (0.0098 inch) Repair limit ........................ 0.50 mm (0.020 inch)

Face and bore runout’s of flywheel

Engines that have a Balancer
Maximum at assembly .... 0.15 mm (0.0059 inch)
Repair limit ........................ 0.50 mm (0.020 inch)

g01152815
Illustration 47

1. Measure the balancer shaft. Refer to illustration

g00988073
47. Illustration 48

2. For information on the diameter of the balancer (1) Tighten the bolts for the flywheel to the following
shaft, refer to table 14. torque. .................... 79 to 88 N·m (58 to 65 lb ft)

Table 14
i02510696
Balancer Shaft
Shaft diameter Service limit 53.900 mm
Crankshaft Pulley
53.940 to 53.960 mm (2.1220 inch)
(2.1236 to 2.1244 inch)
Clearance between Service limit 0.15 mm Table 15
balancer shaft and the (0.0059 inch)
bushing 0.04 to 0.09 mm Required Tools
(0.0016 to 0.0035 inch) Part
Tool Number Part Description Qty
Backlash for the balancer gears 21826038 POWERPART Silicone
A 1
Sealant
Backlash between left hand gear and the right
hand gear ................................. 0.07 to 0.14 mm
(0.0028 ± 0.0055 inch)
Service Limit ................... 0.25 mm (0.0098 inch)
Backlash between right hand gear and the
crankshaft gear ......................... 0.03 to 0.17 mm
(0.0012 to 0.0067 inch)
Service Limit ................... 0.25 mm (0.0098 inch)
22 SENR9833-02
Specifications Section

g00988100
Illustration 49

Note: Apply Tooling (A) to the threads of the

crankshaft before the pulley nut is installed.

(1) Tighten the nut that fastens the crankshaft

pulley to the crankshaft to the following
torque. ............ 480 to 500 N·m (354 to 369 lb ft)

(2) Crankshaft pulley

g00988022
Illustration 50

(3) Maximum depth for the top of the V-belt in the

groove ................................... 1.6 mm (0.06 inch)

i02506524

Belt Tension Chart

Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.
SENR9833-02 23
Specifications Section

Table 16
Belt Tension Chart
Belt Type Deflection Applied Force for Specified Deflection
Type B 10 to 12 mm (0.4 to 0.6 inch) 98 N (22 lb)

i02535554 i02506531

Alternator and Regulator Electric Starting Motor

Note: Apply a suitable Load to the battery in order to

get the maximum alternator output.

g01024163
Illustration 52
The starting motor

(1) Electric starting motor

(2) Tighten the nut on the starting motor terminal to

the following torque. ....................... 18 to 25 N·m
(13.3 to 18.4 lb ft)

g01268996 (3) Tighten the starting motor terminal to the

Illustration 51
following torque. ........................... 2.6 to 4.6 N·m
(23.0119 to 40.7134 lb in)
(1) Alternator and regulator
Voltage ...................................................... 13.5 V No load conditions at 25 °C (77 °F)

Output current at 1500 rpm ..... 20 amp or higher Speed .................................. 3000 rpm minimum
Current draw ......................... 200 amp maximum
Output current at 3000 rpm ..... 50 amp or higher Voltage ......................................................... 11 V
Output current at 5000 rpm ..... 60 amp or higher When the electric starting motor is viewed from
the drive end, the motor rotates in the following
Adjusting voltage of the regulator at 5000 rpm with a direction. ................................................... Clockwise
load of 5 amp or lower .................... 14.2 V to 14.8 V
24 SENR9833-02
Specifications Section

i01899831 Current (30 second rating) .................... 5.5 amperes

Glow Plugs

Naturally Aspirated Engines

g00988137
Illustration 53

(1) Tighten the glow plugs in the cylinder head to the

following torque. ...... 15 to 20 N·m (11 to 15 lb ft)

Type ............................................................... 12 Volt

Current (30 second rating) .................... 9.7 amperes

Turbocharged Engines

g00988138
Illustration 54

(1) Tighten the glow plugs in the cylinder head to the

following torque. ..... 20 to 30 N·m (15 to 22 lb ft)

Type .............................................................. 12 Volt

SENR9833-02 25
Index Section

Index
A L

Alternator and Regulator ....................................... 23 Lifter Group............................................................ 6

B M

Belt Tension Chart ................................................. 22 Main Bearing Journal............................................. 17

C P

Camshaft ............................................................... 9 Piston and Rings ................................................... 18

Connecting Rod..................................................... 17
Connecting Rod Bearing Journal........................... 17
Crankshaft ............................................................ 16 R
Crankshaft Pulley .................................................. 21
Crankshaft Seals ................................................... 17 Rocker Shaft.......................................................... 7
Cylinder Block........................................................ 14
Cylinder Head........................................................ 9
Cylinder Head Valves ............................................ 8 S

Specifications Section ........................................... 4

E

Electric Starting Motor ........................................... 23 T

Engine Design ....................................................... 4
Engine Oil Bypass Valve ....................................... 12 Table of Contents................................................... 3
Engine Oil Pan....................................................... 13
Engine Oil Pressure............................................... 12
Engine Oil Pump.................................................... 11 V
Engine Oil Relief Valve .......................................... 11
Exhaust Manifold ................................................... 9 Valve Mechanism Cover........................................ 7

F W

Flywheel ................................................................ 21 Water Temperature Regulator ............................... 14

Front Housing and Covers..................................... 20
Fuel Injection Lines................................................ 4
Fuel Injection Pump............................................... 4
Fuel Injectors ......................................................... 5
Naturally Aspirated Engines............................... 5
Turbocharged Engines....................................... 6
Fuel Transfer Pump ............................................... 6

Gear Group (Front)................................................ 20

Engines that have a Balancer ............................ 21
Glow Plugs ............................................................ 24
Naturally Aspirated Engines............................... 24
Turbocharged Engines....................................... 24

Important Safety Information ................................. 2

26 SENR9833-02
Index Section
SENR9833-02 27
Index Section
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