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Pistons and Connecting Rods
7 - 13
9.612.0.006.7160 - 05/04
T
ur
n the bore gauge 90° and perf
orm the second
measurement of the diameter
.
Check connecting rod torsion.
Maximum
T
orsion = 0.10 mm
Check connecting rod warping.
Maximum
W
arping = 0.03 mm
80
82
Table of Contents
Main Page
Table of Contents
3
Introduction
4
How to Use this Workshop Manual
4
Important Safety Remarks
5
General Instructions
6
Cleaning General Instructions
7
Cylinder Numeration
9
Table of Contents
15
Engine Operation
16
Cooling Fluid and Coolant
19
Level Check
19
Cooling Fluid Filling Procedure
20
Maintenance Table
21
Conservation for Inactive Engines for Long Periods
22
Table of Contents
25
Disassembly Notes
26
Pre-Assembly Inspections and Measurements
27
Liner Protrusion Specification
27
Liners Specification
28
Liners and Pistons Assembly Specifications
29
Engine Block Specifications
30
Inspections and Measurements
32
Assembly
35
Table of Contents
37
Disassembly Notes
38
Crankshaft Specification
39
Main Journals Specification
40
Crankpins Specification
41
Out-Of-Roundness and Taper Specification
42
Radial Clearance
43
Fillets
44
Pre-Assembly Inspections and Measurements
45
Crankshaft
45
Engine Block Bearings
46
Bearing Shells
47
Main Bearings Specifications
47
Crankshaft
51
Assembly
53
Measurements after Assembly
56
Axial Clearance Specification
56
Table of Contents
57
Disassembly Notes
58
Camshaft Specifications
59
Tappets and Lock Plate Specification
60
Pre-Assembly Inspections and Measurements
61
Bolts Tightening Specification
64
Assembly
65
Table of Contents
69
Disassembly Notes
70
Pre-Assembly Inspections and Measurements
72
Piston Grooves Specifications
74
Connecting Rods Specification
77
Piston and Pin
78
Pre-Assembly Inspections and Measurements
79
Connecting Rod Bolts Tightening Specification
84
Assembly
85
Table of Contents
89
Disassembly Notes
90
Valve Seats Specification
91
Valves Specification
92
Valve Guides Specification
93
Specification of Guide Height and Distance to Cylinder Head Surface
94
Valves Course
95
Rocker Arm, Cold Clearance
96
Valves Diagram
98
Pre-Assembly Inspections and Measurements
99
Bolts Tighten Torques Specifications
105
Assembly
106
Cylinder Head Gasket
109
Table of Contents
133
Disassembly Notes
134
Pre-Assembly Inspections
135
Bolts Tightening Torques Specification
136
Assembly
137
Inspections after Assembly
138
Table of Contents
141
Disassembly Notes
142
Remark
142
Assembly
143
Bolts Tightening Torques Specification
144
Measurements after Assembly
145
Table of Contents
149
Lubrication System
150
Lubrication Circuit
150
Disassembly Notes
151
Inspections and Measurements
151
Tightening Torques Specification for Components of the Lubrication System
153
Tightening Torques Specification for Oil Cooler Connections
153
Tightening Torques Specification for Lubrication Connections of the Compressor
154
Assembly
155
Table of Contents
157
Cooling Circuit
158
Disassembly Notes
159
Inspections
159
Thermostat Test Procedure
160
Bolts Tightening Torques Specification
161
Assembly
162
Table of Contents
165
Cautions
166
Common Rail Modulated Pressure Fuel Injection System
167
Common Rail Harness "4.12
168
CP 3.3 Pump - Rear Part View
169
High Pressure Pump Removal
172
Bolts Tightening Torques Specification
174
Electronic Control Module (ECM) Disassembly/Assembly
179
Inspection
180
Assembly
182
High Pressure Pump Assembly
184
Fuel Injection System Assembly
186
Desaeração Do Sistema de Baixa Pressão
194
Disassembly Notes
196
Inspections
196
Intake Manifold and Elbow Tightening Torques Specification
197
Exhaust Manifold Tightening Torques Specification
198
Turbocharger Tightening Torques Specification
198
Assembly
199
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