kenr6230-00

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KENR6230-00

August2006

Specifications2506-15 Industrial Engine

MGA(Engine)MGB(Engine)MGD(Engine)

This document has been printed from SPI². Not for Resale

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i01658146

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread 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 warningsare 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 pictoriallypresented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis 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 thatthe 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 thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Perkins dealers have the most current information available.

When replacement parts are required for thisproduct Perkins recommends using Perkins

replacement parts or parts with equivalentspecifications including, but not limited to, phys-

ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury or death.

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KENR6230 3Table of Contents

Table of Contents

Specifications Section

Engine Design ..................................................... 4Fuel Transfer Pump ............................................. 4Fuel Filter Base .................................................... 5Fuel Filter (Primary) .............................................. 5Fuel Priming Pump .............................................. 6Electronic Unit Injector Mechanism ..................... 6Electronic Unit Injector Rocker Arm ...................... 7Electronic Unit Injector Wiring ............................... 7Valve Mechanism ................................................. 8Valve Mechanism Cover ...................................... 8Cylinder Head Valves ........................................... 9Cylinder Head ...................................................... 11Turbocharger ....................................................... 13Exhaust Manifold ................................................. 14Exhaust Elbow ..................................................... 14

Camshaft ............................................................. 15Engine Oil Filter Base .......................................... 15Engine Oil Pump .................................................. 16Engine Oil Pan ..................................................... 17Water Lines ........................................................... 17Water Temperature Regulator .............................. 18Water Pump ......................................................... 18Cylinder Block ...................................................... 19Cylinder Liner ....................................................... 21Crankshaft ........................................................... 22Crankshaft Seals ................................................. 22Vibration Damper ................................................. 23Connecting Rod Bearing Journal ......................... 23Main Bearing Journal ............................................ 23

Connecting Rod ................................................... 24Piston and Rings .................................................. 25Housing (Front) ..................................................... 26Gear Group (Front) ............................................... 26Flywheel ............................................................... 28Flywheel Housing ................................................ 29Flywheel Housing Cover ...................................... 29Belt Tightener ....................................................... 30Fan Drive ............................................................. 30

Alternator and Regulator ...................................... 31 Alternator Mounting ............................................. 31Electric Starting Motor ......................................... 32Coolant Temperature Sensor ............................... 32Fuel Temperature Sensor ..................................... 33

Engine Oil Pressure Sensor ................................. 33 Atmospheric Pressure Sensor .............................. 33Inlet Manifold Air Pressure Sensor ....................... 33Inlet Air Temperature Sensor ................................ 34Speed/Timing Sensor .......................................... 34

Index Section

Index ..................................................................... 35


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4 KENR6230Specifications Section

Specifications Section

i02555165

Engine Design

2506

g01096864Illustration 1

Cylinder and valve location

(A) Inlet(B) Exhaust(C) Flywheel end of engine

Bore ........................................ 137.2 mm (5.40 inch)

Stroke ..................................... 171.5 mm (6.75 inch)

Displacement ........................... 15.2 L (927.56 cu in)

Cylinder ar rangement .................................... In-Line

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

The adjustment for the inlet valve lash is the followingvalue. .............. 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

The adjustment for the exhaust valve lash is thefollowing value. ................................ 0.76 ± 0.08 mm

(0.030 ± 0.003 inch)

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

Crankshaft rotation ........................ counterclockwise

Note: The fr ont end of the engine is opposite theflywheel end. The left side and the right side of theengine are viewed from the flywheel end. The No. 1cylinder is the front cylinder.

i02576024

Fuel Transfer Pump


(1) Pressure regulating valve

(2) Inlet port

(3) Weep hole

(4) Outlet port


(5) Bolts


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KENR6230 5Specifications Section

Tighten the bolts to the following torque. .. 47 N·m(35 lb ft)

When the fuel transfer pump is using diesel fuel, thefuel transfer pump has the following specifications.

Run the pump at 2940 rpm. The bypass pressure

must be between 716 kPa (103.8 psi) and 786 kPa(114.0 psi).

Run the pump at 840 rpm. The flow at 550 kPa(80 psi) must be 3.0 L/min (0.80 US gpm).

Run the pump at 100 rpm with the inlet to theatmosphere for 10 seconds. The pump must maintaina vacuum of 60 kPa (9 psi) for 30 seconds once theinlet is blocked.

Run the pump at 2940 rpm. The flow at 650 kPa(94 psi) must be 4.5 L/min (1.19 US gpm).

i02570754

Fuel Filter Base


(1) Retaining setscrews ................. 47 N·m (35 lb ft)

(2) Plug ........................................... 15 N·m (11 lb ft)

(3) Plug ........................................... 15 N·m (11 lb ft)

(4) Plug .......................................... 41 N·m (30 lb ft)

i02570891

Fuel Filter (Primary)


Typical example

(1) Tighten the primary fuel filter housing (1)to the fuel filter base (2) to the followingtorque. ......................... 80 ± 10 N·m (59 ± 7 lb ft)

(2) Fuel filter base

(3) Tighten the secondary fuel filter housing (3)to the fuel filter base (2) to the followingtorque. ......................... 80 ± 10 N·m (59 ± 7 lb ft)

(4) Drain Plugs


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i02570837

Fuel Priming Pump


Typical example

(1) Tighten the bolt to the following torque. ... 25 N·m(220 lb in)

(2) Priming pump

(3) Tighten the bolt to the following torque. ... 12 N·m(105 lb in)

i02555267

Electronic Unit Injector Mechanism


(1) Cap nut

Tighten the cap nuts to the followingtorque. .................... 2.5 ± 0.25 N·m (22 ± 2 lb in)

(2) Locknut for the adjustment screw

Tighten the locknut for the adjustment screw tothe following torque. .. 100 ± 10 N·m (75 ± 7 lb ft)

(3) Unit injector height

Adjust the unit injector height to the followingdimension. ...... 78.0 ± 0.2 mm (3.07 ± 0.01 inch)

(4) Unit injector clamp retaining bolt

1. Tighten the unit injector clamp retaining bolt to

55 ± 10 N·m (41 ± 7 lb ft).

2. Loosen the retaining bolt until the bolt is finger tight.

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

(5) Spacer

(6) Unit injector clamp


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(7) O-ring seals

Before installation of the unit injector, lubricate thetop two O-ring seals with clean engine oil.

Note: Refer to Testing and Adjusting, “Electronic UnitInjector - Adjust” for the correct procedure for setting

the lash on the electronic unit injector.

i02555275

Electronic Unit Injector Rocker Arm


(A) Bore in the rocker arm bearing for the rocker arm shaft

Dimension for bore of new bearing after installation ............................ 40.065 ± 0.015 mm

(1.5774 ± 0.0006 inch)Maximum dimension for wornbearing ........................ 40.193 mm (1.5824 inch)

(1) Location of bearing joint

The rocker arm bearing must not extend beyondeither face of the rocker arm.

i02555277

Electronic Unit Injector Wiring


(1) Tighten the nuts that are on the cap assembly tothe following torque. .................... 2.5 ± 0.25 N·m

(22 ± 2 lb in)

Position connectors so that the wires are not

contacting any other surfaces.


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i02556086

Valve Mechanism


Typical example

(1) Valve rocker arm assembly

(2) Adjusting the screw locknut

Tighten the locknut to the followingtorque. ........................... 30 ± 7 N·m (22 ± 5 lb ft)

(3) Bolt

Tighten the bolts to the followingtorque. ..................... 109 ± 15 N·m (80 ± 11 lb ft)

(4) Rocker arm shaft

Diameter of a new rocker armshaft ..................................... 40.000 ± 0.010 mm

(1.5748 ± 0.0004 inch)Bore in a new rocker arm bearing for the rocker arm shaft .............................. 40.065 ± 0.015 mm

(1.5774 ± 0.0006 inch)

(5) Valve lash

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

Exhaust valves .......................... 0.76 ± 0.08 mm(0.030 ± 0.003 inch)

Note: Refer to Testing and Adjusting, “Engine ValveLash - Inspect/Adjust” for the correct procedure onsetting the engine valve lash.

(6) Camshaft

(7) Valve bridge assembly

i02571284

Valve Mechanism Cover


Valve cover


Tightening sequence

Refer to Illustration12 for the tightening sequenceof the valve cover bolts.


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(1) Bolts

Torque for bolts ......................... 20 N·m (15 lb ft)

(2) Valve mechanism cover

(3) Harness connector

(4) Integral breather

i02575732

Cylinder Head Valves


Note: Apply engine oil to the valve stems prior toinstallation in the cylinder head.

(1) Valve springs

Inner Spring

Assembled length ........... 60.14 mm (2.368 inch)Load at assembled length ................. 150 ± 12 N

(34 ± 3 lb)Operating length (minimum) ............... 44.02 mm(1.733 inch)

Load at minimum operating length .... 400 ± 18 N(90 ± 4 lb)

Free length after test ...... 71.70 mm (2.823 inch)Outside diameter ............ 25.17 mm (0.991 inch)

Outer Spring

Assembled length ........... 67.12 mm (2.643 inch)Load at assembled length ................. 320 ± 25 N

(72 ± 6 lb)Operating length (minimum) ............... 51.00 mm

(2.008 inch)

Load at minimum operating length .... 900 ± 45 N(202 ± 10 lb)

Free length after test ...... 76.70 mm (3.020 inch)Outside diameter ............ 36.30 mm (1.429 inch)

(2) Valve guide

Bore of installed valve guide (newparts) ..................................... 9.502 ± 0.026 mm(0.3741 ± 0.0010 inch)

Maximum recommended diameter of the valveguide bore ..................... 9.538 mm (0.3755 inch)

Note: Do not use a combination of a valve anda valve guide that has a difference of 0.13 mm(0.005 inch) or more.

(3) Height to top of valve guide ..... 35.00 ± 0.50 mm(1.378 ± 0.020 inch)

(4) Valve recessInlet (new parts) ........................ 2.20 to 2.80 mm

(0.087 to 0.110 inch)Exhaust (new parts) .................. 1.20 to 1.80 mm

(0.047 to 0.071 inch)Inlet (reconditioned parts) ......... 2.20 to 3.29 mm

(0.087 to 0.129 inch)Exhaust (reconditioned parts) ... 1.20 to 2.29 mm

(0.0472 to 0.090 inch)


(5) Valve face angle

Inlet .................................... 29 1/4 ± 1/4 degreesExhaust .............................. 44 1/4 ± 1/4 degrees

(6) Valve stem diameter

New valve stem diameter ...... 9.427 ± 0.010 mm(0.3711 ± 0.0004 inch)

Minimum recommended valve stemdiameter ........................ 9.309 mm (0.3665 inch)

(7) Diameter of valve head

Inlet ................................. 47.00 mm (1.850 inch)Exhaust ........................... 41.81 mm (1.646 inch)


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(8) Minimum recommended valve lip thickness

Inlet ................................... 2.75 mm (0.108 inch)Exhaust ............................. 2.05 mm (0.081 inch)

(9) Overall length of valve

Inlet ........................................ 202.00 ± 0.45 mm(7.953 ± 0.018 inch)

Exhaust .. 202.06 ± 0.45 mm (7.955 ± 0.018 inch)


(10) Width of the valve seat

Inlet ............................... 2.377 mm (0.0936 inch)Exhaust ......................... 1.508 mm (0.0594 inch)

(11) Depth of bore in the cylinder head for the valveseat insert

Inlet ......... 14.00 ± 0.05 mm (0.551 ± 0.002 inch)

Exhaust ... 13.90 ± 0.05 mm (0.547 ± 0.002 inch)

(12) Inside diameter of valve seat insert

Inlet ......... 41.00 ± 0.50 mm (1.614 ± 0.020 inch)Exhaust ... 36.50 ± 0.50 mm (1.437 ± 0.020 inch)

(13) Angle of valve seat face

Inlet .......................................... 30.25 ± 1 degreeExhaust .................................... 45.25 ± 1 degree

(14) Outside diameter of valve seat insert

Inlet .. 48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)Exhaust ................................ 42.840 ± 0.013 mm

(1.6866 ± 0.0005 inch)

Diameter of the bore in the cylinder head for thevalve seat insert

Inlet .. 47.950 ± 0.025 mm (1.8878 ± 0.0010 inch)Exhaust ................................ 42.774 ± 0.025 mm

(1.6840 ± 0.0010 inch)


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i02555225

Cylinder Head


Table 1

Required Tools

Tool Part Number Part description

A CV60895 POWERPARTSpecial Lubricant

The bolts that are marked “X” are 216 mm (8.5 inch)long. The remainder of the bolts are 194 mm(7.6 inch) long.

Apply Tooling (A) to the bolt threads and both sidesof the washers. Tighten the bolts in the following stepsequence:

1. In a numerical sequence, tighten bolts 1 through26.

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

2. In a numerical sequence, tighten bolts 1 through26.


3. In a numerical sequence, again tighten bolts 1through 26.


Note: The flatness of the cylinder head should bewithin a total of 0.13 mm (.005 inch). Also, the flatnessof the cylinder head should be within a maximum of 0.05 mm (.002 inch) for any 150 mm (5.9 inch) span.


(A) Cylinder Head Thickness

Thickness of a new cylinder head ...... 120.00 ± 0.15 mm (4.724 ± 0.006 inch)Minimum thickness of a used cylinder head ................................. 119.7 mm (4.713 inch)


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(27) Oil gallery

(28) Bearing joint

(29) Oil holes

(30) Camshaft bearing

NOTICECamshaft bearings must be installed into their correctposition. Failure to do so will result in engine damage.


(B) Orientation of bearing joint(28) Bearing joint(31) Diameter of Camshaft Bore

(31) Diameter of camshaft bore .. 90.985 ± 0.020 mm(3.582 ± 0.001 inch)

Orientation of bearing joint(B) ..................................... 15° ± 5° above horizontal


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The depth of installation of the camshaft bearings isvery important. Install bearings (30) to the followingdepths:

Installation depth for camshaft bearings (30)

C ................. 19.12 ± 0.50 mm (0.75 ± 0.02 inch)D ................... 154.7 ± 0.5 mm (6.09 ± 0.02 inch)E ................. 326.2 ± 0.5 mm (12.84 ± 0.02 inch)F ................. 497.6 ± 0.5 mm (19.59 ± 0.02 inch)G ................. 669.1 ± 0.5 mm (26.34 ± 0.02 inch)H ................. 840.5 ± 0.5 mm (33.09 ± 0.02 inch)

I ................. 1012.0 ± 0.5 mm (39.84 ± 0.02 inch)

i02576026

Turbocharger

Table 2

Required Tools

Tool Part Number Part Description

A CV60889 Anti-SeizeCompound


Typical example

(1) Tighten the clamp nuts to the following

torque. ...................................... 14 N·m (10 lb ft)

Lightly hit the clamps with a soft faced hammer. Again tighten the clamp nuts to the followingtorque. ............................................. 14 N·m (10 lb ft)

(2) Tighten the bolts to the following torque. .. 47 N·m(35 lb ft)

(3) Apply Tooling (A) to the fasteners for theturbocharger and tighten to the followingtorque. ...................................... 55 N·m (41 lb ft)


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i02571665

Exhaust Manifold

Table 3

Required Tools




Typical example


Tightening sequence

(1) Spacer

(2) Washer

(3) Tighten the locknuts to the followingtorque. ...................................... 38 N·m (28 lb ft)

(4) Taperlock studs

Apply Tooling (A) to the threads of the studs thatengage the locknuts.

Tighten the studs (4) in the cylinder head to thefollowing torque. ....................... 35 N·m (26 lb ft)

i02576087

Exhaust Elbow


Typical example

(1) Tighten the nut for the clamp to the followingtorque. ................................... 13.5 N·m (10 lb ft)


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i02555167

Camshaft


(1) Exhaust lobe

(2) Injector lobe

(3) Inlet lobe

Note: Lubricate the camshaft lobes with clean engineoil.

(4) Bearing journal

Diameter of the bearing

journals ... 84.85 ± 0.02 mm (3.341 ± 0.001 inch)

Note: Lubricate the camshaft bearings with cleanengine oil prior to installing the camshaft.

(5) Front of camshaft


(6) Camshaft lobe lift

Specified camshaft lobe lift

Exhaust lobe ................. 8.515 mm (0.3352 inch)Inlet lobe ....................... 9.431 mm (0.3713 inch)

Injector lobe ................ 10.336 mm (0.4069 inch)

(7) Camshaft lobe height

(8) Base circle

To find the lobe lift, use the procedure that follows:

1. Measure camshaft lobe height (7).

2. Measure base circle (8).

3. Subtract the base circle measurement (Step2) from the camshaft lobe height (Step 1). Thedifference is the actual lobe lift.

Maximum permissible difference between the actuallobe lift (Step 3) and the specified lobe lift of a newcamshaft ................................... 0.1 mm (0.004 inch)


(9) Screw

Tighten the screws that fasten the cover to thecylinder head to the following torque. .. 6 ± 1 N·m

(53 ± 9 lb in)

i02571743

Engine Oil Filter Base

Table 4

Required Tools


A 21820117 POWERPARTThread Lock and

Nut Lock


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(1) Apply Tooling (A) on the tapered end of the studto the following dimension. .......... 10.5 ± 1.5 mm

(0.41 ± 0.06 inch)

Tighten the stud to the following torque. .. 68 ± 7 N·m(50 ± 5 lb ft)

(2) Apply engine oil to the oil filter seal. Put the oilfilter in position. Turn the oil filter by hand until theseal makes contact with the base. Additionallytighten the oil filter by 3/4 of a turn.


View A-A

(3) Spring

Length under test force ... 55.25 mm (2.175 inch)Test force ...................... 76 ± 5.8 N (17 ± 1.30 lb)Free length after test .......... 93.7 mm (3.69 inch)Outside diameter ................ 20.6 mm (0.81 inch)The filter and the cooler bypass valveswill open with the following pressuredifference. ................... 255 ± 20 kPa (37 ± 3 psi)

(4) Tighten the plug to the followingtorque. ..................... 100 ± 15 N·m (74 ± 11 lb ft)

i02571764

Engine Oil Pump


NOTICE

Before operation, the pump must be lubricated withcleanengine oil and the pump must turn freely by handor damage to parts can be the result.

(1) Diameter of shafts ............... 22.217 ± 0.005 mm(0.8747 ± 0.0002 inch)

Diameter of bores in cover for shafts .... 22.258 ± 0.008 mm (0.8763 ± 0.0003 inch)

(2) Length of gears .................... 79.375 ± 0.025 mm(3.1250 ± 0.0010 inch)

Depth of bores for gears ............ 79.502 ± 0.020 mm(3.1300 ± 0.0008 inch)

(3) Spring

Length under test force ...... 117.9 mm (4.64 inch)Test force ................... 150 ± 8 N·m (110 ± 6 lb ft)Free length after test ........ 152.9 mm (6.02 inch)Outside diameter ................. 27 mm (1.063 inch)


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Pump body

(4) Bearings

Install the bearings so the bearings are even with

the outside of the pump body.(A) Position of bearing joint from the centerline

through bearing bores ........ 30 ± 15 degrees

i02571769

Engine Oil Pan


Typical example


Tightening sequence

(1) Joint

(2) Washer

(3) Plug

Torque ....................................... 45 N·m (33 lb ft)

(4) Engine Oil Pan


i02556087

Water Lines


(1) Seal bores

Apply a light coat of glycerin to the seal bores.


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i02556089

Water Temperature Regulator


Typical example

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

Minimum opening distance at 98 °C(208 °F) ..................................... 10.4 mm (0.41 inch)

i02556088

Water Pump


Typical example

(1) Bolt

Tighten the bolt that holds the impeller to thefollowing torque. ............ 39 ± 3 N·m (29 ± 2 lb ft)

(2) The shaft diameter at the carbon sealassembly seat area is the followingdimension. ............................... 19.10 ± 0.01 mm

(0.7520 ± 0.0004 inch)

(3) Coolant seal

Press the seal assembly onto the water pump shaftuntil the stationary cup is fully seated in the pumphousing.

(4) Oil seal

Install the oil seal with the primary lip toward thewater pump drive gear. Press the oil seal into thecounterbore with a press.


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i02555212

Cylinder Block


Right side view

(1) Dowel

The dowel extends above the top surfaceof the cylinder block by the followingdistance. ...................................... 18.5 ± 0.5 mm

(0.73 ± 0.02 inch)

(2) Spacer plate

Thickness of the spacer plate .. 8.585 ± 0.025 mm(0.3380 ± 0.0010 inch)

Thickness of the gasket that is placedbetween the spacer plate and the cylinder block .......................................... 0.20 ± 0.02 mm

(0.008 ± 0.001 inch)

Cylinder liner projection above the spacer plate ...................................... 0.025 to 0.152 mm

(0.0010 to 0.0060 inch)

(3) Dowel


(0.63 ± 0.02 inch)

(4) Dowel


(0.79 ± 0.02 inch)

(5) Plug

Tighten the plug to the followingtorque. ............................................. 70 ± 10 N·m

(52 ± 7 lb ft)


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(6) Dowel

The dowels extend past the end of the cylinder block by the following distance. ... 19.1 ± 0.5 mm

(0.75 ± 0.02 inch)


View A-A


View B-B

(7) Installation depth of the plug .......... 2.0 ± 2.0 mm(0.08 ± 0.08 inch)


Front view

(8) Dimension from the centerline of the crankshaftbearing bore to the top of the cylinder block

New ....................................... 425.45 ± 0.15 mm

(16.750 ± 0.006 inch)Minimum ........................................... 425.02 mm

(16.733 inch)

Note: The total flatness of the top contact surfaceof the cylinder block must be within 0.10 mm(0.004 inch). The flatness must also be within0.05 mm (0.002 inch) for any 177.5 mm (6.99 inch)section of the surface.

(9) Bore in the cylinder block for the main bearings

(10) Main bearing cap

Main bearing cap width ...... 215.900 ± 0.025 mm(8.5000 ± 0.0010 inch)Width of the cylinder block for the main bearingcap ..................................... 215.900 ± 0.013 mm

(8.5000 ± 0.0005 inch)

(11) New dimension from the centerline of thecrankshaft bearing bore to the bottom of thecylinder block pan rails .......... 165.10 ± 0.10 mm

(6.500 ± 0.004 inch)

(12) Main bearing cap bolts


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i02572794

Vibration Damper

Table 5

Required Tools




(1) Adapter

(2) Damper

(3) Tighten the bolts to the followingtorque. .................................... 105 N·m (77 lb ft)

(4) Apply Tooling (A) to the bolts and tighten the boltsto the following torque. ......... 270 N·m (200 lb ft)

i02555179

Connecting Rod BearingJournal

Table 6

Connecting Rod Bearing Journal

Original Size Journal 97 ± 0.02 mm

(3.819 ± 0.0008 inch)

Undersize Journal0.63 mm (0.025 inch)

96.37 mm (3.794 inch)


95.73 mm (3.769 inch)

Clearance between the new bearing and the

journal .................................. 0.062 mm to 0.160 mm(0.0024 inch to 0.0063 inch)

Maximum permissible clearance between the bearingand the journal ........................ 0.20 mm (0.008 inch)

i02556083

Main Bearing Journal

Table 7

Main Bearing Journals

Original Size Journal 120.650 ± 0.020 mm

(4.7500 ± 0.0008 inch)


120.015 ± 0.020 mm(4.7250 ± 0.0008 inch)


119.380 ± 0.020 mm(4.7000 ± 0.0008 inch)

Clearance between the new bearing and the journal .................................. 0.091 mm to 0.186 mm

(0.0036 inch to 0.0073 inch)

Maximum permissible clearance between the bearingand the journal ........................ 0.25 mm (0.010 inch)

Table 8

Main Bearing Bore

Original Size of the BoreIn the Block

129.891 ± 0.013 mm(5.1138 ± 0.0005 inch)

Oversize Bore 0.63 mm(0.025 inch)

130.526 ± 0.013 mm(5.1388 ± 0.0005 inch)


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i02555176

Connecting Rod



Positioning the piston pin bearing

(1) Bore for piston pin bearing

Dimension ............................ 64.592 ± 0.013 mm(2.5430 ± 0.0005 inch)

Tight fit between connecting rod eye and pistonpin bearing ................................ 0.05 to 0.10 mm

(0.002 to 0.004 inch)

To install the piston pin bearing, the connectingrod must be heated. Do not use a torch to heatthe connecting rod.

Maximum temperature for heating of connectingrod .............. 175 °C to 260 °C (347 °F to 500 °F)

(A) The bearing junction and the locating hole areangled 180 degrees from each other. The bearing

junction and the locating hole must be assembledwithin area (A).

(X) Tolerance for installation of bearing junction andlocating hole .................................... ± 5 degrees

(2) Dimension

Distance between center of bearings ...................... 270.76 mm (10.660 inch)

(3) Bore

Bore in the connecting rod bearing after torquingof the connecting rod bolts .... 103.2 ± 0.013 mm

(4.063 ± 0.0005 inch)


(4) Piston pin

Bore in new bearing for pistonpin ..... 60.035 ± .008 mm (2.3636 ± 0.0003 inch)Diameter of new piston pin .. 59.975 ± 0.005 mm

(2.3612 ± 0.0002 inch)Maximum clearance between bearing and wornpiston pin .......................... 0.08 mm (0.003 inch)

(5) Crankshaft bearing

Bore in bearing for crankshaft ............................ 97.088 ± 0.016 mm

(3.8224 ± 0.0006 inch)Clearance between new bearing andcrankshaft .............................. 0.088 ± 0.036 mm

(0.0035 ± 0.0014 inch)


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Connecting rod bolts

(6) Connecting rod bolts

Use the following procedure to tighten the connectingrod bolts:

1. Put engine oil on the bolt threads and the contactsurfaces before assembly.

2. Tighten the bolts in the following order.

Tighten the bolts (A) and (C). ............. 70 ± 4 N·m(52 ± 3 lb ft)

Tighten the bolts (B) and (D). ............. 70 ± 4 N·m(52 ± 3 lb ft)

Additionally tighten each bolt. (B) and (D)...................................................... 60 ± 5 degrees

Again, tighten the bolts (A) and (C). ... 70 ± 4 N·m(52 ± 3 lb ft)

Additionally tighten each bolt. (A) and (C)...................................................... 60 ± 5 degrees

(7) Bolt for piston cooling jet

Tighten the bolt to following torque. ... 40 ± 8 N·m(30 ± 6 lb ft)

To prevent damage to the piston cooling jet duringservice, the piston cooling jets must be removed.

Minimum permissible clearance between the piston,the piston cooling jet, and the crankshaft ... 0.63 mm

(0.025 inch)

i02556085

Piston and Rings


(1) Top piston ring

Install the piston ring with “UP-1” mark toward thetop of the piston.

There is a clearance between the ends of the pistonring. When the piston ring is installed in a cylinder liner with a bore of 144.975 mm (5.7077 inch), theclearance is the following value. ........ 0.4 ± 0.10 mm

(0.02 ± 0.004 inch)

There is an increase in the clearance betweenthe ends of the piston rings for each 0.030 mm(0.0012 inch) increase in the cylinder liner bore.Increase .................................. 0.08 mm (0.003 inch)

(2) Intermediate piston ring

Install the piston ring with “UP-2” mark toward thetop of the piston.

There is a clearance between the ends of the pistonring. When the piston ring is installed in a cylinder liner with a bore of 144.975 mm (5.7077 inch), theclearance is the following value. ........ 0.6 ± 0.10 mm

(0.02 ± 0.004 inch)


(3) Oil Control Ring

The spring ends of the oil control ring should beassembled 180 degrees from the ring end gap.

Width of groove in new piston for oil controlring .............. 4.02 ± 0.010 mm (0.158 ± 0.0004 inch)


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Thickness of new piston ring .................. 3 ± 0.2 mm(0.118 ± 0.0079 inch)

Clearance between groove and new pistonring .................... 0.8 to 1.2 mm (0.031 to 0.047 inch)

There is a clearance between the ends of the piston

ring. When the piston ring is installed in a cylinder liner with a bore of 144.975 mm (5.7077 inch), theclearance is the following value. ...... 0.55 ± 0.15 mm

(0.028 ± 0.006 inch)


(4) Piston pin bore

Bore in piston assembly for pin ..... 60.0925 ± 0.0075 mm (2.3658 ± 0.0003 inch)

Diameter of the new piston pin .. 59.975 ± 0.005 mm(2.3612 ± 0.0002 inch)

Clearance between the piston pin and the bore in thepiston ...... 0.105 to 0.13 mm (0.0041 to 0.0051 inch)

i02572848

Housing (Front)


(1) Housing

(2) Joint


i02573279

Gear Group (Front)

Table 9

Required Tools


A 21820221 POWERPARTRubber Grease

B 21820117 POWERPART

Thread Lock andNut Lock


(1) Water pump drive gear


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Stub shaft for cluster gear

(2) Cluster gear

Apply Tooling (B) to the five bolts for the stub

shaft.Tighten the five bolts for the stubshaft in the following sequence. SeeIllustration 54 for the numbering of thebolts. ......................... 1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1

Apply Tooling (B) to the four bolts that fasten thecluster gear to the stub shaft.

Tighten the four bolts that fasten the cluster gear to the stub shaft to the following torque. .. 28 N·m

(21 lb ft)


(3) Camshaft gear (12) Sealing plate for the camshaft bolts(13) Seals(14) Camshaft gear bolts


Camshaft gear

(4) Align the timing mark on the camshaft gear withthe timing mark on the front housing when theNo. 1 piston is at top center.

(3) Camshaft gear


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Lightly lubricate the O-ring seal on the outside of the camshaft sealing plate with a 50/50 mixtureof Tooling (A) and clean engine oil. Apply Tool (B)to the three bolts for the camshaft sealing plate.

Tighten the six bolts for the camshaft gear in thefollowing sequence. refer to 56 for the numberingof the bolts. ........................... 1, 4, 2, 5, 3, 6, 1, 4Tighten the three camshaft sealing plate bolts tothe following torque. See Illustration 55. .. 12 N·m

(106 lb in)Tighten the camshaft bolts in the followingsequence. See Illustration 56 for the numberingof the bolts. ........................... 1, 4, 2, 5, 3, 6, 1, 4Tighten the six camshaft gear bolts to thefollowing torque. ................... 240 N·m (177 lb ft)

(5) Adjustable idler gear

Install the plate with the oil groove toward thegear face. Apply Tooling (B) to the three bolts thatfasten the ad justable idler gear to the stub shaft.

Tighten the three bolts for the adjustableidler gear to the stub shaft to the followingtorque. ...................................... 28 N·m (21 lb ft)

Refer to Testing and Adjusting, “Gear Group(Front) - Time” for the backlash adjustmentprocedure.

Backlash between the camshaft gear and theadjustable idler gear ............... 0.216 ± 0.114 mm

(0.0085 ± 0.0045 inch)

Apply Tooling (B) to the one bolt and five studsfor the stub shaft.

Tighten the one bolt and five nuts for the stubshaft to the following torque. ..... 55 N·m (41 lb ft)

(6) Air compressor gear (if equipped)

(7) Idler gear

Apply Tooling (B) to the one bolt and five studsfor the stub shaft.

Tighten the one bolt and five nuts for the stubshaft to the following torque. ..... 55 N·m (41 lb ft)

Apply Tooling (B) to the three bolts that fasten theidler gear to the stub shaft.

Tighten the three bolts that fasten the idler gear to the stub shaft to the following torque. .. 28 N·m

(21 lb ft)

(8) Gear for the fuel transfer pump drive

(9) Align the timing mark on the crankshaft gear withthe timing mark on the cluster gear.

(10) Crankshaft gear

(11) Oil pump drive gear

Tighten the bolt for the oil pump drive gear to thefollowing torque. ....................... 55 N·m (41 lb ft)

i02575327

Flywheel

Table 10

Required Tools




Note: Refer to the System Operation, Testing & Adjusting, “Flywheel Runout” for the correct methodof flywheel inspection.

(1) Apply Tooling (A) to the threads of thebolts. Tighten the bolts to the followingtorque. .................................. 270 N·m (200 lb ft)

(2) The maximum temperature of the ring gear for installation .................................... 316°C (600°F)


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i02575335

Flywheel Housing

Table 11

Required Tools

Tool Part Number PartDescription

A CH10879 liquid Gasket


Tightening sequence

Note: During assembly, inspect the followingcomponents for any foreign materials: the frontface of the flywheel housing, the two sides of theflywheel housing gasket and the rear face of thecylinder block. These components must be free of the following substances: oil, fuel, water, gasketadhesive, assembly compounds, and any other foreign material. Apply a small amount of Tooling (A)in order to fill the space between the cylinder block,the flywheel housing, and the oil pan before installing

the oil pan gasket and the oil pan. The componentsmust be assembled within twenty minutes of applyingthe sealant.

Use the following procedure to tighten the flywheelhousing bolts.

1. In a numerical sequence, tighten bolt 1 throughbolt 9 to a torque of 100 N·m (74 lb ft).



4. In a numerical sequence, tighten bolt 10 throughbolt 24 to a tor que of 55 N·m (41 lb ft).

i02555302

Flywheel Housing Cover

g01072994

Illustration 59

(1) Bolt

Tighten the three bolts on the cover to thefollowing torque. ....................... 48 N·m (35 lb ft)


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i02575337

Belt Tightener



(1) Nut

Tighten the nut to the following torque. .. 102 N·m

(75 lb ft)

(2) Tension bolt

(3) Belt Tightener

(4) Bolt

Tighten the bolt to the following torque. ... 47 N·m(35 lb ft)

(5) Pulley

(6) Grease fitting

i02575698

Fan Drive


Typical example


Typical example

(1) Fan drive assembly

(2) Pulley


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(3) Tighten the nuts to the following torque................................................. 105 N·m (77 lb ft)

(4) Tighten the Bolts to the following torque. .. 47 N·m(35 lb ft)

(5) Tighten the Bolts to the following torque. .. 47 N·m

(35 lb ft)

i02577725

Alternator and Regulator


Typical example


Typical example

Polarity ........................................... Negative Ground

Rotation ............................................ Either Direction

Minimum full load current at 5000 rpm ...... 42.3 Amp

Minimum full load current at 2000 rpm .... 165.8 Amp

Output voltage ............................................. 28 ± 1 V

(1) Torque for the ground terminalnut ......................... 2.25 ± 0.25 N·m (20 ± 2 lb in)

(2) Torque for the pulley nut .................. 102 ± 7 N·m(75 ± 5 lb ft)

(3) Torque for the output terminal nut .. 6.2 ± 0.6 N·m(55 ± 5 lb in)

Regulator Assembly

Voltage setting ................................... No Adjustment

Permissible voltage range ........................ 27 to 29 V

Voltage rating ..................................................... 24 V

i02575721

Alternator Mounting


Typical example

(1) Tighten the bolt to the following torque. ... 70 N·m(52 lb ft)

(2) Alternator


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(3) Tighten the nut to the following torque. .. 105 N·m(77 lb ft)

(4) Tighten the bolt (4) for the link to the followingtorque. .................................... 105 N·m (77 lb ft)

i02578029

Electric Starting Motor



When the electric starting motor is viewed fromthe drive end, the motor rotates in the followingdirection. ................................................... Clockwise

No load conditions at 25°C (77°F)

Speed ...................................... 7643 ± 1683 rpmCurrent draw ............................. 76.5 ± 14.5 ampVoltage ......................................................... 23 V

(1) Tighten the nut on the battery terminal to thefollowing torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)

(2) Tighten the nut on the ground terminal to thefollowing torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)

(3) Tighten the bolts to the followingtorque. .................................. 215 N·m (160 lb ft)

(4) Tighten the nut on the ground terminal to thefollowing tor que. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)

(5) Tighten the nut on the switch terminal to the

following tor que. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)

(6) Tighten the nut on the motor terminal to thefollowing tor que. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)

(7) Tighten the nut on the motor frame terminal tothe following torque. ..... 8 ± 3 N·m (71 ± 27 lb in)

i02576787

Coolant Temperature Sensor


Typical example

(1) Sensor assembly

Tighten the sensor assembly to the followingtorque. ..................................................... 20 N·m

(15 lb ft)


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i02576790

Inlet Air Temperature Sensor


Typical example

(1) Sensor assembly

Torque for sensor ............................ 20 N·m (15 lb ft)

i02576795

Speed/Timing Sensor

Crankshaft Position Sensor


Typical example

(1) Sensor

(2) Bracket

Ensure that the bracket is installed in the orientationthat is shown.

(3) Tighten the bolt for the sensor to the followingtorque. ...................................... 25 N·m (18 lb ft)

Ensure that the sensor is seated before the bolt is

tightened.

Camshaft Position Sensor


Typical example

(1) Sensor

(2) Bracket

Ensure that the bracket is installed in the orientationthat is shown.

(3) Tighten the bolt for the sensor to the followingtorque. ...................................... 25 N·m (18 lb ft)

Ensure that the sensor is seated before the bolt istightened.


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KENR6230 35Index Section

Index

A

Alternator and Regulator ....................................... 31 Alternator Mounting ............................................... 31

Atmospheric Pressure Sensor............................... 33

B

Belt Tightener ........................................................ 30

C

Camshaft ............................................................... 15Connecting Rod..................................................... 24Connecting Rod Bearing Journal........................... 23Coolant Temperature Sensor................................. 32Crankshaft ............................................................ 22Crankshaft Seals ................................................... 22Cylinder Block........................................................ 19Cylinder Head........................................................ 11Cylinder Head Valves ............................................ 9Cylinder Liner ........................................................ 21

E

Electric Starting Motor ........................................... 32Electronic Unit Injector Mechanism ....................... 6Electronic Unit Injector Rocker Arm....................... 7Electronic Unit Injector Wiring ............................... 7Engine Design ....................................................... 4

2506................................................................... 4Engine Oil Filter Base............................................ 15Engine Oil Pan....................................................... 17Engine Oil Pressure Sensor .................................. 33Engine Oil Pump.................................................... 16Exhaust Elbow....................................................... 14Exhaust Manifold ................................................... 14

F

Fan Drive............................................................... 30

Flywheel ................................................................ 28Flywheel Housing .................................................. 29Flywheel Housing Cover........................................ 29Fuel Filter (Primary)............................................... 5Fuel Filter Base ..................................................... 5Fuel Priming Pump ................................................ 6Fuel Temperature Sensor...................................... 33Fuel Transfer Pump............................................... 4

G

Gear Group (Front)................................................ 26

H

Housing (Front)...................................................... 26

I

Important Safety Information ................................. 2Inlet Air Temperature Sensor................................. 34Inlet Manifold Air Pressure Sensor........................ 33

M

Main Bearing Journal............................................. 23

P

Piston and Rings ................................................... 25

S

Specifications Section ........................................... 4Speed/Timing Sensor............................................ 34

Camshaft Position Sensor ................................. 34Crankshaft Position Sensor ............................... 34

T

Table of Contents................................................... 3Turbocharger ......................................................... 13

V

Valve Mechanism .................................................. 8Valve Mechanism Cover........................................ 8Vibration Damper................................................... 23

W

Water Lines ........................................................... 17Water Pump........................................................... 18Water Temperature Regulator ............................... 18


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kenr6230-00

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