1103 1104 Mechanical
1103 1104 Mechanical
1103 1104 Mechanical
Specifications Section
g00984281 g01014247
Illustration 1 Illustration 2
Cylinder and valve location Cylinder and valve location
(A) Inlet valve (A) Inlet valve
(B) Exhaust valve (B) Exhaust valve
Bore ......................................... 105 mm (4.133 inch) Bore ......................................... 105 mm (4.133 inch)
Stroke ...................................... 127 mm (5.000 inch) Stroke ...................................... 127 mm (5.000 inch)
Displacement ...................................... 4.4 L (269 in3) Displacement ...................................... 3.3 L (201 in3)
Cylinder arrangement ..................................... In-line Cylinder arrangement ..................................... In-line
Type of combustion ............................ Direct injection Type of combustion ............................ Direct injection
Compression ratio Compression ratio
Naturally aspirated engines ...................... 19.3:1 Naturally aspirated engines ...................... 19.3:1
Turbocharged engines .............................. 18.2:1 Turbocharged engines .............................. 18.2:1
Number of cylinders ................................................ 4 Number of cylinders ................................................ 3
Valves per cylinder .................................................. 2 Valves per cylinder .................................................. 2
Valve lash Valve lash
Inlet valve ......................... 0.20 mm (0.008 inch) Inlet valve ......................... 0.20 mm (0.008 inch)
Exhaust valve ................... 0.45 mm (0.018 inch) Exhaust valve ................... 0.45 mm (0.018 inch)
Firing order ................................................. 1, 3, 4, 2 Firing order ..................................................... 1, 2, 3
When the crankshaft is viewed from the front of When the crankshaft is viewed from the front of
the engine, the crankshaft rotates in the following the engine, the crankshaft rotates in the following
direction: ................................................... Clockwise direction: ................................................... Clockwise
5
Specifications Section
i01914111
g00922601
Illustration 4
The Delphi DP 210 fuel injection pump
(1) O-ring
(3) Washer
Note: The support bracket must be installed after Unlocking the shaft
the coolant pump is installed. In order to stop the
distortion of the timing case, finger tighten the bolt Loosen the bolt and place spacer (3) behind
(4) and then tighten the nut and bolt (5). Tighten the locking screw (2). Tighten the bolt to the following
bolt (4). torque. ........................................ 12 N·m (9 lb ft)
Tighten the bolts that hold the fuel pump to the front The lift of the ER fuel injection pump plunger
housing to the following torque. ...... 25 N·m (18 lb ft) ............................................... 1.55 mm (0.0610 inch)
i02074846
g00988408
Illustration 7
Installed EVEP fuel injection pump
g00986530
Illustration 6
Bosch EPVE fuel injection pump
(5) Tighten the bolt to the following torque. ... 44 N·m Unlocking the shaft
(32 lb ft)
Loosen locking screw (2) and install the washer
(6) Tighten the nut and the bolt to the following (3) to the unlocked position. Tighten the bolt to
torque. ..................................... 22 N·m ( 16 lb ft) the following torque. ................... 12 N·m (9 lb ft)
Tighten the bolts that hold the fuel pump to the front
housing to the following torque. ...... 25 N·m (18 lb ft)
i02074902
Tighten the bolts that hold the fuel pump to the front
housing to the following torque. ...... 25 N·m (18 lb ft)
i01899210
Fuel Injectors
g01061708
Illustration 9
The Delphi STP fuel injection pump
(2) Washer
g00908211
Illustration 11
Locking the shaft Fuel injector clamp
Loosen locking screw (1) and move the washer
(2) to the locked position. Tighten the bolt to the (1) Tighten the bolt in the clamp for the fuel injector
following torque. ...................... 13 N·m (10 lb ft) to the following torque. ............. 35 N·m (26 lb ft)
8
Specifications Section
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g00629433
Illustration 13
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Rocker Shaft
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Illustration 12
(2) Clip
(3) Spacer
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g00985174
Illustration 14
The rocker shaft
(4) Rocker arm bore Tighten the bolts for the valve mechanism cover
in the sequence that is shown to the following
Diameter of the rocker arm bore for the torque. ................................................. 9 N·m (7 lb ft)
bushing ................................. 25.01 to 25.05 mm
(0.9847 to 0.9862 inch)
The Cover for the Three Cylinder
Rocker arm bushing Engine
Clearance between the rocker arm bushing and
the rocker shaft ......................... 0.03 to 0.09 mm
(0.0010 to 0.0035 inch)
Maximum permissible clearance between
the rocker arm bushing and the rocker
shaft .................................. 0.17 mm (0.007 inch)
(5) Spring
The load for the installed valve springs ..... 254 N The face of the exhaust valve is recessed below the
(57.1 lb) cylinder head by the following amount.
Turbocharged engines Naturally aspirated engines ............ 0.53 to 0.81 mm
The installed length of the valve (0.021 to 0.032 inch)
springs .............................. 34.5 mm (1.358 inch)
Service limit ............................ 1.06 mm (0.042 inch)
The load for the installed valve spring ....... 229 N
(51.4 lb) Turbocharged engines .................... 1.53 to 1.81 mm
(0.060 to 0.071 inch)
(2) Valve spring recess
Service limit ........................... 2.06 mm (0.0811 inch)
(3) The finished valve guides
Inside diameter of valve (5) Inlet valve
guide ..................................... 9.000 to 9.022 mm Diameter of the inlet valve
(0.3543 to 0.3552 inch) stem ...................................... 8.953 to 8.975 mm
Outside diameter of the exhaust valve (0.3525 to 0.3533 inch)
guide ................................. 13.034 to 13.047 mm Clearance of valve in valve
(0.5131 to 0.5137 inch) guide .. 0.025 to 0.069 mm (0.001 to 0.0027 inch)
Naturally aspirated engines ............ 0.58 to 0.84 mm (B) ..................................... 42.420 to 42.445 mm
(0.023 to 0.033 inch) (1.6701 to 1.6711 inch)
(C) Maximum radius ......... 0.38 mm (0.015 inch)
Service limit ............................ 1.09 mm (0.043 inch)
Recess for Inlet Valve Seat for Turbocharged
Turbocharged engines .................... 1.58 to 1.84 mm Engines
(0.062 to 0.072 inch) (A) ...................................... 10.910 to 11.040 mm
(0.4295 to 0.4346 inch)
Service limit .......................... 2.09 mm (0.0823 inch) (B) ..................................... 47.820 to 47.845 mm
(1.8826 to 1.8836 inch)
(6) Exhaust valve face angle from the vertical axis (C) Maximum radius ......... 0.38 mm (0.015 inch)
Valve face angle ............................... 30 degrees Recess for Exhaust Valve Seat for Turbocharged
Valve seat angle ............................... 30 degrees Engines
(A) ...................................... 10.910 to 11.040 mm
(7) Diameter of the exhaust
(0.4295 to 0.4346 inch)
valve head ............................ 41.51 to 41.75 mm (B) ..................................... 42.420 to 42.445 mm
(1.634 to 1.643 inch)
(1.6700 to 1.6710 inch)
(C) Maximum radius ......... 0.38 mm (0.015 inch)
(8) Diameter of the head of the inlet
valve ... 46.20 to 46.45 mm (1.818 to 1.828 inch)
i01899306
(9) Angle of the inlet valve face from the vertical axis
Cylinder Head
Valve face angle ............................... 30 degrees
Valve seat angle ............................... 30 degrees
The valve lash is the following value when the engine The maximum distortion of the cylinder head is given
is cold: in table 3.
Inlet valves ........................ 0.20 mm (0.008 inch) Table 2
Exhaust valves ................. 0.45 mm (0.018 inch)
Required Tools
Part
Part Description Qty
Number
21825607 Angle gauge 1
g00809016
Illustration 18
Recess for the valve seat insert
g00905621
Illustration 21
g01017007
Illustration 20
The tightening sequence
Three Cylinder Engine (4) Tighten the nuts to the following torque. .. 47 N·m
(34 lb ft)
Illustration 23
g01017008 Four Cylinder Engine
Table 4
Table 3
The part number for The pressure for the
Maximum Permissible the turbocharger waste gate
Dimension
Distortion
2674A200 100 ± 5 kPa
Width (A) 0.03 mm (0.0018 inch) (14.5040 ± 0.7252 psi)
Length (B) 0.05 mm (0.0019 inch) 2674A201 110 ± 5 kPa
Diagonal Line (C) 0.05 mm (0.0019 inch) (15.9544 ± 0.7252 psi)
2674A202 128 ± 5 kPa
(18.5651 ± 0.7252 psi)
i01904467
2674A209 100 ± 5 kPa
Turbocharger (14.5040 ± 0.7252 psi)
2674A211 128 ± 5 kPa
(18.5651 ± 0.7252 psi)
2674A215 128 ± 5 kPa
(18.5651 ± 0.7252 psi)
2674A223 136 ± 5 kPa
(19.7254 ± 0.7252 psi)
2674A224 136 ± 5 kPa
(19.7254 ± 0.7252 psi)
2674A225 136 ± 5 kPa
(19.7254 ± 0.7252 psi)
2674A226 100 ± 5 kPa
(14.5040 ± 0.7252 psi)
2674A227 128 ± 5 kPa
(18.5651 ± 0.7252 psi)
(2) Actuator
(3) Turbocharger
14
Specifications Section
i01957427 i01956585
g00987750
Illustration 27
Checking the end play of the camshaft
g00907527
Illustration 25
(1) End play of a new camshaft ..... 0.10 to 0.55 mm
Tightening sequence (0.004 to 0.022 inch)
Note: The exhaust manifold must be aligned to Maximum permissible end play of a worn
the cylinder head. Refer to the Disassembly and camshaft ................................. 0.60 mm (0.023 inch)
Assembly manual.
g00976195
Illustration 28
Typical camshaft
(2) Bolt
Tighten the bolt to the following torque. ... 95 N·m
(70 lb ft)
g01017009
Illustration 26
(3) Camshaft thrust washer
Note: The exhaust manifold must be aligned to Thickness of the thrust washer .. 5.49 to 5.54 mm
the cylinder head. Refer to the Disassembly and (0.216 to 0.218 inch)
Assembly manual.
Depth of the recess in the cylinder block for the
Tighten the exhaust manifold bolts in the sequence thrust washer ............................ 5.54 to 5.64 mm
that is shown illustration 26 to the following (0.218 to 0.222 inch)
torque. ............................................. 33 N·m (24 lb ft)
15
Specifications Section
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Illustration 29 Illustration 30
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Replaceable Element
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Illustration 33
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Illustration 31 Note: Lubricate the seal on the oil filter housing with
A three cylinder engine clean engine oil before installation.
Engine Oil Filter (2) Tighten the drain plug on the oil filter housing to
the following torque. ................... 12 N·m (9 lb ft)
i01957426
Illustration 32
g00915984 Number of lobes
Inner rotor ......................................................... 6
(1) Seal
Outer rotor ........................................................ 7
Note: Lubricate the top of the seal with clean engine
oil before installation.
g00989248 g00989217
Illustration 34 Illustration 36
The oil pump for the balancer The end play for the rotor
(1) Clearance of the outer rotor to the (3) End play of rotor assembly
body .. 0.130 to 0.24 mm (0.0050 to 0.0094 inch)
Inner rotor .................................. 0.04 to 0.11 mm
(0.0016 to 0.0043 inch)
Outer rotor ................................ 0.04 to 0.00 mm
(0.0016 to 0.0043 inch)
g00938724
Illustration 37
The end cover
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Illustration 35 (4) Torque for cover bolts for oil pump .......... 26 N·m
Inner rotor (19 lb ft)
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Illustration 38 Illustration 39
Idler gear and pump gear The oil pump
Note: Replace the idler gear bolt (5) and the nut for (1) Clearance of the outer rotor to the
the oil pump gear (6). body ...................................... 0.152 to 0.330 mm
(0.0059 to 0.0129 inch)
(5) Tighten the idler gear bolt to the following
torque. ...................................... 26 N·m (19 lb ft)
g00938799
Illustration 41
Checking the end play
Inner rotor ............................. 0.038 to 0.089 mm (1) Tighten the plug for the relief valve to the
(0.0014 to 0.0035 inch) following torque. ....................... 35 N·m (26 lb ft)
Outer rotor ............................ 0.025 to 0.076 mm
(0.0010 to 0.0029 inch) (2) Plunger
Tighten the bolts that hold the front cover of the oil Diameter of the plunger ..... 19.186 to 19.211 mm
pump assembly to the following torque. ........ 26 N·m (0.7554 to 0.7563 inch)
(19 lb ft) Clearance of plunger in bore .. 0.039 to 0.114 mm
(0.0015 to 0.0045 inch)
i01958104
i01958107
g00919893
Illustration 42
Typical engine oil pump
g00921379
Illustration 45
The relief valve for the balancer
(2) Plunger
Diameter of the plunger ........ 14.46 to 14.48 mm
(0.5692 to 0.5700 inch)
Clearance of the plunger in the
bore .... 0.04 to 0.08 mm (0.0015 to 0.0031 inch)
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Illustration 43
Relief valve and spring
20
Specifications Section
Front sealant
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Illustration 46
Applying sealant
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Illustration 47
Applying sealant
g00990677
Illustration 50
The drain valve
(9) Adapter
Tighten the adapter into the engine oil pan to the
following torque. ............ 34 ± 5 N·m (25 ± 4 lb ft)
i01958112
g00990249
Illustration 49
The cast iron oil pan
Crankcase Breather
Note: The rear face of the cast iron oil pan (5) must
be aligned to the rear face of the cylinder block.
(6) Bolt
Tighten the front four bolts. Refer to illustration
48. Tighten the remaining bolts and the nuts that
fasten the engine oil pan to the cylinder block to
the following torque. ................. 22 N·m (16 lb ft)
Note:
(3) Bolts
22
Specifications Section
(4) Diaphragm
(5) Cap
(6) Spring
g00997234
Illustration 53
O ring
g00926200
Illustration 52
(7) O-ring
Tighten the bolts (not shown) that fasten the housing Minimum stroke at full open temperature ...... 10 mm
to the following torque. .................... 22 N·m (16 lb ft) (0.3937 inch)
23
Specifications Section
i01904883 i01908154
g00915951
Illustration 55
Tightening sequence
(4) Main bearings for the four cylinder engine Total height of the cylinder block between the top and
the bottom faces. ................ 441.173 to 441.274 mm
Bore in the cylinder block for the main (17.3689 to 17.3729 inch)
bearings ............................ 80.416 to 80.442 mm
(3.1660 to 3.1670 inch)
Three Cylinder Engine
(5) Main bearing cap bolts for the four cylinder
engine
Torque for the main bearing cap bolts. .... 245 N·m
(180 lb ft)
g01018250
Illustration 58
Diameter of the bore in the cylinder 3. When the bridge is installed on the cylinder block,
block for the number 4 camshaft apply 21826038 POWERPART Silicon Adhesive
journal ............................... 50.038 to 50.089 mm into groove (14) at each end of the bridge. Apply
(1.9700 to 1.9720 inch) the sealant into the groove until the sealant is
forced through the bottom end of the groove in
(11) Main bearings for the three cylinder engine the bridge.
Bore in the cylinder block for the main Total height of the cylinder block between the top and
bearings ............................ 80.416 to 80.442 mm the bottom faces. ................ 441.173 to 441.274 mm
(3.1660 to 3.1670 inch) (17.3689 to 17.3729 inch)
(12) Main bearing cap bolts for the four cylinder and
three cylinder engines i01956920
Torque for the main bearing cap bolts. .... 245 N·m
(180 lb ft)
g00992214
g01018262 Illustration 60
Illustration 59
The crankshaft for the four cylinder engine
Use the following procedure in order to install the
Allen head bolts for the bridge. (1) Crankshaft for the four cylinder engine
Note: Install the rear seal before sealant is applied. The maximum end play of the crankshaft ... 0.51 mm
(0.0201 inch)
1. Use a straight edge in order to ensure that the
bridge is aligned with the rear face of the cylinder (2) Thrust washers
block.
Standard thickness ................... 2.26 to 2.31 mm
(0.089 to 0.091 inch)
2. Tighten the Allen head bolts (13) for the bridge.
Oversize thickness ................... 2.45 to 2.50 mm
Torque for the Allen head bolts .. 16 N·m (12 lb ft) (0.097 to 0.098 inch)
g01017233
Illustration 61
The 1104 engine crankshaft
Table 8
The undersize diameter of the Crankshaft Journals
NUMBER 0.25 mm (0.010 inch) 0.51 mm (0.020 inch) 0.76 mm (0.030 inch)
75.909 mm (2.9885 inch) to 75.649 mm (2.9783 inch) to 75.399 mm (2.9685 inch) to
1
75.930 mm (2.9894 inch) 75.670 mm (2.9791 inch) 75.420 mm (2.9693 inch)
63.220 mm (2.4890 inch) to 62.960 mm (2.4787 inch) to 62.708 mm (2.4688 inch) to
2
63.240 mm (2.4898 inch) 62.982 mm (2.4796 inch) 62.728 mm (2.4696 inch)
39.47 mm
3 N/A N/A
(1.5539 inch)maximum
37.44 mm
4 N/A N/A
(1.4740 inch)maximum
44.68 mm
5 N/A N/A
(1.7591 inch)maximum
40.55 mm
6 N/A N/A
(1.5965 inch)maximum
7 Do not machine this diameter. N/A N/A
3.68 mm (0.1449 inch) to
8 N/A N/A
3.96 mm (0.1559 inch)
Table 9
Journal Excessive run out
(1) Mounting
(2) 0.08 mm (0.0031 inch)
(3) 0.15 mm (0.0059 inch)
(4) 0.08 mm (0.0031 inch)
(5) Mounting
g01017747
Illustration 62
The crankshaft for the three cylinder engine
Table 10
The undersize diameter of the Crankshaft Journals
NUMBER 0.25 mm (0.010 inch) 0.51 mm (0.020 inch) 0.76 mm (0.030 inch)
75.926 mm (2.9892 inch) to 75.672 mm (2.9792 inch) to 75.418 mm (2.9692 inch) to
1
75.905 mm (2.9884 inch) 75.651 mm (2.9784 inch) 75.397 mm (2.9684 inch)
63.236 mm (2.4896 inch) to 62.982 mm (2.4796 inch) to 62.728 mm (2.4696 inch) to
2
63.216 mm (2.4888 inch) 62.962 mm (2.4788 inch) 62.708 mm (2.4688 inch)
39.74 mm
3 N/A N/A
(1.5646 inch)maximum
44.68 mm
4 N/A N/A
(1.7591 inch)maximum
40.551 mm
5 N/A N/A
(1.5965 inch)maximum
133.17 mm (5.2429 inch) Do
6 N/A N/A
not machine this diameter.
3.68 mm (0.1449 inch) to
7 N/A N/A
3.96 mm (0.1559 inch)
Table 11
Journal Excessive run out
(1) Mounting Dia
(2) 0.051 mm (0.0020 inch)
(3) 0.051 mm (0.0020 inch)
(4) Mounting Dia
i01958141
i01958156
Connecting Rod
g00995584
Illustration 66
Alignment of the bearing shell
Table 12
Bearing Width for the 31.62 to 31.88 mm
g00907738
Illustration 65 Connecting Rod (1.245 to 1.255 inch)
Bearing Width for the 31.55 to 31.88 mm
The mating surfaces of the connecting rod are Connecting Rod Cap (1.2405 to 1.255 inch)
produced by hydraulically fracturing the forged
connecting rod. Thickness of Connecting
1.835 to 1.842 mm
Rod Bearing at the
(0.0723 to 0.0725 inch)
(1) Tighten the torx screws for the connecting rod to Center
the following torque. ................. 18 N·m (13 lb ft) Thickness of Connecting
1.835 to 1.842 mm
Rod Bearing for the Cap
Tighten the torx screws for the connecting rod again (0.0722 to 0.0725 inch)
at the Center
to the following torque. .................... 70 N·m (52 lb ft)
0.030 to 0.081 mm
Bearing Clearance
(0.0012 to 0.0032 inch)
Tighten the torx screws for the connecting rod for
an additional 120 degrees. The torx screws for
the connecting rod (1) must be replaced after this Table 13
procedure. Undersized Connecting Rod Bearing
Note: Always tighten the connecting rod cap to the 0.25 mm (0.010 inch)
connecting rod, when the assembly is out of the
engine. Tighten the assembly to the following torque 0.51 mm (0.020 inch)
20 N·m (14 lb ft). 0.76 mm (0.030 inch)
Table 14
Length Grades for Connecting Rods
Grade Letter Color Code Length (Y)
165.728 to 165.761 mm
F Red
(6.5247 to 6.5260 inch)
165.682 to 165.715 mm
G Orange
(6.5229 to 6.5242 inch)
165.637 to 165.670 mm
H White
(6.5211 to 6.5224 inch)
165.591 to 165.624 mm
J Green
(6.5193 to 6.5206 inch)
165.545 to 165.578 mm
K Purple
(6.5175 to 6.5188 inch)
165.499 to 165.532 mm
L Blue
(6.5157 to 6.4961 inch)
i01958185
g00907744
Illustration 67
g00888215
Illustration 69
A typical example of a piston and rings
Connecting rods are color coded. The color code Ring gap ................................... 0.30 to 0.55 mm
is a reference for the length (Y) of the connecting (0.0118 to 0.0216 inch)
rod. Refer to table 14 for the different lengths of
connecting rods.
33
Specifications Section
Ring gap ................................... 0.30 to 0.55 mm Piston height above cylinder block .. 0.21 to 0.35 mm
(0.0118 to 0.0216 inch) (0.008 to 0.014 inch)
Note: When you install a new top compression ring, Width of top groove in piston for the naturally
make sure that the word “TOP” is facing the top of the aspirated engine ............................. 2.58 to 2.60 mm
piston. New top piston rings have a red identification (0.1016 to 0.1024 inch)
mark which must be on the left of the ring end gap
when the top piston ring is installed on an upright Width of top groove in piston for the turbocharged
piston. engine .......................................................... Tapered
(2) Intermediate compression ring Width of second groove in piston .... 2.54 to 2.56 mm
(0.1000 to 0.1008 inch)
The shape of the intermediate compression
ring ......................................... Internal step in the
Width of third groove in piston ........ 3.52 to 3.54 mm
bottom edge with a tapered face (0.1386 to 0.1394 inch)
Width of intermediate compression
ring .......... 2.47 to 2.49 mm (0.097 to 0.098 inch) Piston pin
Ring gap ................................... 0.70 to 0.95 mm Diameter of the bore for the piston
(0.0275 to 0.0374 inch) pin ..................................... 39.703 to 39.709 mm
(1.5631 to 1.5633 inch)
Note: When you install a new intermediate
compression ring, make sure that the word “TOP” is i01957425
facing the top of the piston. New intermediate rings
have a green identification mark which must be on Piston Cooling Jet
the left of the ring end gap when the top piston ring is
installed on an upright piston.
(3) Oil control ring Note: The three cylinder naturally aspirated engine
may have installed piston cooling jets as an option.
Shape of oil control
ring ............... two-piece coil that is spring loaded
Width of oil control ring ............. 3.47 to 3.49 mm
(0.1366 to 0.1374 inch)
Clearance between the oil control ring and the
groove in the piston .................. 0.03 to 0.07 mm
(0.0011 to 0.0027 inch)
Ring gap ................................... 0.30 to 0.55 mm
(0.0118 to 0.0216 inch)
g01006929
Illustration 71
(2) Piston cooling jet
(3) Rod
(4) Cylinder block
i01957083
g00918672
Illustration 73
Front cover
(2) Tighten the bolts that fasten the water pump to the
front housing to the following torque. ....... 22 N·m
(16 lb ft)
Illustration 74
g00995886 Idler gear end play with roller
bearings .................................... 0.10 to 0.75 mm
Gear train
(0.0039 to 0.0295 inch)
(1) Fuel injection pump drive gear Maximum permissible end play ............ 0.38 mm
(0.015 inch)
Tighten the nut to the following torque. ... 24 N·m
(18 lb ft) Number of teeth .............................................. 73
Release the lock on the fuel injection pump shaft.
Torque the nut to the following torque. .... 90 N·m
(66 lb ft)
Number of teeth .............................................. 68
i01913541 i01957025
Four cylinder
g00631781
Illustration 78
(1) Bolt
Illustration 77
g00584712 Tighten the bolts for the cast iron flywheel
housing to the following torque:
(1) Flywheel ring gear M10 “8.8” .................................. 44 N·m (33 lb ft)
M10 “10.9” ................................ 63 N·m (47 lb ft)
Heat the flywheel ring gear to the following
M12 “8.8” .................................. 75 N·m (55 lb ft)
temperature. .............................. 250 °C (480 °F)
M12 “10.9” ............................... 115 N·m (85 lb ft)
Note: Do not use an oxyacetylene torch to heat the
flywheel ring gear. Three cylinder
(2) Flywheel The three cylinder engine is equipped with a back
plate.
(3) Bolt
Tighten the flywheel bolts to the following i01958322
torque. .................................... 105 N·m (77 lb ft)
Crankshaft Pulley
g00915497
Illustration 79
A typical pulley
38
Specifications Section
Note: Lubricate the threads of the bolts with clean Maximum permissible end play of the shaft .. 0.20 mm
engine oil before installation. (0.0079 inch)
Alternator
g00926178
Illustration 80
A typical fan drive
V-Belt
Note: The V-belt must be checked by a gauge. Refer
to the Testing and Adjusting, “V-Belt-Test” for the
correct type of gauge in order to check the V-belt.
i01958653
Starter Motor
g00974968
Illustration 82
The 24 volt starter motor which shows the electrical connections
g00977365
Illustration 83
The 12 volt starter motor which shows the electrical connections
(1) Tighten the solenoid terminal to the following (1) Tighten the glow plugs (3) in the cylinder head to
torque. ....................................... 8 N·m ( 70 lb in) the following torque. ................. 18 N·m (13 lb ft)
(2) Tighten the positive terminal nut to the following Tighten the nuts (2) for the bus bar (1) that is
torque. ....................................... 6 N·m ( 53 lb in) installed on top of the glow plugs to the following
torque. ............................................... 2 N·m (18 lb in)
(3) Tighten the negative terminal nut to the following
torque. ....................................... 8 N·m (70 lb in) Voltage ................................................. 12 or 24 volts
i01957005
Glow Plugs
g00955714
Illustration 84
Typical example