6-46.1 REMOVAL. Remove the cylinder block components according to the following steps. Unless otherwise noted, callouts refer to figure 7-37.
a. Remove pipe plugs (8 and 16).
b. Remove expansion plugs (2) from the oil passages and expansion plugs (1, 4, 6, and 7) from the coolant pas- sages.
c. Drive expansion plug (3) from the camshaft bore. Use care not to damage the camshaft bore. d. Drive the turbocharger drain tube from the inside of cylinder block (9).
e. Remove front mounting supports (1 and 3,figure 7-4).
6-46.2 CLEANING AND INSPECTION. Clean and inspect the cylinder block (figure 7-37) according to the following steps.
a. If excessive deposits of scale are present in the coolant passages, the block may be cleaned in an acid bath. Otherwise, clean the block in a hot tank using a soap and water solution.
b. After the block is clean, it will be necessary to deglaze the cylinders to aid the seating of the piston rings. A correctly de-glazed surface will have a cross-hatched appearance with the lines at 15- to 25-degree angles with the top of the cylinder block; 30- to 50-degree angles on the cross-hatch. Use a fine grit flexi-hone drill, a 50-50 mixture of diesel fuel, and 30W engine oil to deglaze the bores.
Figure 6-60. Main Bearing Cap Torque Sequence S9233-C9-MMA-010
WARNING
Never turn a stream of compressed air on anyone. Severe injury or death could result.
c. After deglazing, clean the block in a strong solution of laundry detergent and hot water, then rinse the block and dry with compressed air. Wipe the bores with a white, lint-free, lightly oiled cloth. If grit is still present, re-clean the block.
d. Wash the block in solvent. Clean all the oil passages with a nylon bore brush. Rinse with a clean solvent and dry with compressed air.
e. Inspect the cylinder bores for damage or excessive wear. Measure the bore diameter with a bore gauge (mini- mum 4.0157 inches; maximum 4.0203 inches) and measure 1 inch and 4-1/2 inches from the top surface of the block at two places, each measurement 180 degrees apart (out-of-roundness maximum 0.0015 inch; taper maximum 0.003 inch).
f. Check the top surface of the block for flatness between the cylinders. The variance is 0.002 inch.
g. Inspect the main bearing bores for damage or abnormal wear. Measure the main bearing bore with the bear- ings installed and the bearing caps torqued to 130 lb-ft. Measure it at two points, 180 degrees apart and near both sides of the bearing (maximum 2.2720 inches).
6-46.3 REINSTALLATION. Reinstall the cylinder block components according to the following steps. Unless otherwise noted, callouts refer tofigure 7-37.
a. Apply a bead of Loctite 277 around the outside diameter of the oil passage expansion plugs (2). b. Drive the expansion plugs in until they are even with the countersink in the block.
c. Apply a bead of Loctite 277 to the coolant passage expansion plugs (1, 4, and 6). d. Drive the plugs in until the outer edge is flush with the countersink in the block.
e. Apply a bead of liquid Teflon sealant to pipe plugs (8 and 16). Reinstall the plugs. Refer totable 6-9for cor- rect torques.
f. Apply a bead of Loctite 277 around the outside diameter of the camshaft expansion plug (3). Position the plug with the convex side out. Drive the plug flush with the cylinder block.
g. Reinstall front mounting supports (1 and 3,figure 7-4). 6-47. OIL PAN HEATER.
Replace the oil pan heater according to the following steps. Unless otherwise noted, callouts refer tofigure 7-35.
a. Disconnect the oil heater electrical cord.
b. Loosen and remove plug (7) and sealing washer (6). Drain the engine oil sump. c. Remove the heater element and washer.
d. Reinstall a new heater element and copper washer. Torque the element to 60 lb-ft.
e. If further repairs to the diesel engine are not required, replace plug and sealing washer and refill the oil sump with correct oil. Refer to table 2-3.
f. Reconnect oil heater electrical cord. 6-48. START-UP.
Following engine reinstallation, proceed as follows:
WARNING
To prevent injury or death, ensure extreme care and proper lifting devices are used during handling. The equipment is heavy.
a. Using a spreader bar and engine lifting device, set the engine on a suitable test stand. b. Connect the engine to all necessary piping and electrical systems.
c. After the engine is secured in position, follow pre-operational checks listed in chapter 2, paragraph 2-3.1. Check for proper connection of all systems. Ensure engine operating fluids are at proper levels; refer to table 1-1 ortable 1-2, as applicable.
d. Start the engine and run at idle speed for a sufficient time to check for leaks, proper connection of controls, and for the engine to warm-up to operating temperatures. Ensure the engine is ready for further testing. Com- plete testing as per PMS instructions.
Table 6-6. Clearance Measurements
Item Dimension
Cylinder Bores Min. 4.0157-in. Max. 4.0203-in. Out-of-Roundness .0015-in.
Taper Limit .003-in.
Main Bearing Bores Max. 2.2720-in. Camshaft Bore Min. 2.1324-in. Tappet Bores Min. 0.630-in.
Max. 0.632-in. Installed Cam Bushing Min. 2.1295-in.
Max. 2.1314-in. Main Journal Diameter Min. 3.2662-in.
Max. 3.2682-in. Main Bearing Clearance Max 0.00475-in. Out-of-Roundness 0.002-in.
Taper 0.0005-in.
Piston Skirt Diameter Min 4.0088-in. Max 4.0117-in. Piston Ring Top
Turbocharged Use Keystone Gauge Naturally Aspirated Min 0.003-in.
Max 0.0059-in. S9233-C9-MMA-010
Table 6-6. Clearance Measurements - Continued
Item Dimension
Piston Ring Intermediate Min 0.003-in. Max 0.0059-in.
Oil Control Min 0.0016-in.
Max 0.0051-in. Piston Pin Bore Min 1.5750-in.
Max 1.5758-in. Piston Pin Diameter Min 1.5744-in.
Max 1.5784-in.
Mean Diameter of on the Crankshaft Min 2.7150-in. Max 2.7170-in. Out-of-Roundness 0.002-in.
Taper 0.0005-in.
Valve Guide Bore Min 0.3157-in. Max 0.3185-in. Valve Stem Diameter Min 0.3126-in.
Max 0.3142-in. Valve Seat Angle
Intake 30°
Exhaust 45°
Valve Rim Thickness Min 0.031-in.
Valve Depth Min 0.039-in.
Max 0.060-in. Valve Seat Width Limit Min 0.060-in. Max 0.080-in. Valve Spring
Free Length 2.190-in.
Max Inclination 0.039-in. Turbocharger Shaft Diameter (bearing) Min 0.432-in.
*Shaft End Play Min 0.004-in.
Max 0.006-in.
**Shaft End Play Min 0.001-in.
Max 0.003-in. Radial Clearance Min 0.012-in. Max 0.018-in. Oil Pump
Tip Clearance Max 0.007-in. Body Bore Clearance Max 0.015-in. Port Plate Clearance Max 0.005-in. Gear Backlash Limits for a Used Pump 0.003 to 0.015-in. Starter Motor
Brush Replacement Min 0.5-in.
Cable Size Min.012-in.
*
For turbochargers with a serial number before 840638. **
For turbochargers with a serial number after and including 840638.
Table 6-7. Torque Specifications
Item lb-ft
Alternator Pulley 59
Alternator Link 32
Alternator Mtg Bolt 57
Alternator Support (upper) 18
Belt Tensioner Mtg 32
Cam Thrust Plate 18
Connecting Rod (then rotate 60°) 45
Crankshaft Damper and Pulley 101
Crossover Clamp 4
Exhaust Manifold 32
Exhaust Outlet Pipe Brkt Mtg 32
Exhaust Outlet Pipe, Flanged 18
Exhaust Outlet Pipe, V Band Clamp 6
Flywheel 101
Flywheel Housing 45
Flywheel Housing Plug 32
Front Cover Cap Hand-tighten
Front Engine support 57
Fuel Banjo Screw (in head) 24
Fuel Vent Screw (in banjo) 4
Fuel Filter 1/2 turn after contact
Fuel Low-Pressure Supply 18
Fuel Low-Pressure Return 11
Fuel Filter Adapter Nut 24
Fuel Line Fitting (HP) 18
Fuel Pump Drive Gear 48
Fuel Pump Lock 22
Fuel Pump Mtg Nut 18
Fuel Pump Support Bracket 18
Gear Cover 18 Gear Housing-to-Block 18 Head Mtg Step 1 26 Step 2 (retorque) 70 Step 3 73
Head Thread Plug (front) 90
Injection Nozzle Banjo Screw 6
Injection Nozzle Retaining Nut 44
Intake Manifold Cover/After Cooler 18
Intake Heater Plug 45
Lift Pump Mtg/Cover Plate 18
Lifting Bracket (rear) 57
Main Bearing Cap
Step 1 44
Step 2 88
Step 3 129
Oil Fill Tube Mtg 32
Oil Filter 1/2 turn after contact
S9233-C9-MMA-010
Table 6-7. Torque Specifications - Continued
Oil Filter Head Mtg 18
Oil Pan Drain Plug 55
Oil Pan Heater Plug 90
Oil Pan Mtg 18
Oil Pressure Regulator Plug 90
Oil Pump Mtg 18
Oil Suction Tube (flange) 18
Rear Seal Mtg 7
Rocker Support 18
Rocker Lever Nut 18
12 Point Starter Mtg 32
Tach Drive Retainer 2
Tappet Cover 18
Thermostat Housing 18
Timing Pin Flange Mtg 4
Turbine Housing 8
Turbocharger Compressor Housing Clamp 5
Turbocharger Mounting Nuts 24
Turbocharger Oil Drain Tube 18
Turbocharger Oil Supply Tubes (both ends) 18
Water Hose 4
Water Inlet (lower) 32
Water Inlet Plugs 25
Water Pump Mtg 18
Water Pump Pulley 18
Valve Cover 18
Valve Cover Oil Fill Hand-tighten