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Products
Perkins 1103 and 1104 Diesel Engine Repair Technical Specifications


Detailed Description:

Technical specifications

1103 and 1104E engines

DC (machine)

DD (machine)

DJ (machine)

DK (machine)

RE (machine)

RG (machine)

RJ (machine)

RR (machine)

RS (machine)

DF (Engine)

DG (Engine)

This document is printed from SPI². Not for RESALE


Important safety matters

Most accidents in the operation, maintenance and repair of the product are caused by failure to observe basic safety rules or precautions. If it works

Therefore, before the occurrence of various potential dangers, accidents can often be avoided. Staff must be alerted to potential dangers

Report. Staff must also be trained to acquire the necessary skills and the proper use of tools.

Improper handling, lubrication, maintenance or repair of the product is dangerous and can cause personal injury or death.

You must read and understand the information on the operation, lubrication, maintenance and repair of the product before performing these tasks.

Safety precautions and warnings are provided in this manual and on the product. Failure to heed these warnings will give you or others

Causes personal injury or death.

Identify hazards with "safety warning symbols" and "mark text" such as "danger", "warning", or "beware". The Warning label is shown below.

The meaning of the safety warning symbol is as follows:

note! Be alert! It's about your safety.

Below the warnings are described dangerous situations, some written in words and some graphically.

Operations that can cause product damage are indicated on the product and in this manual by the "Caution" sticker.

Not every situation that could be dangerous can be expected. Therefore, the warnings presented in this manual and the product do not cover all

Happening. If tools, procedures, work methods or techniques are not specifically recommended by Perkins, you must protect yourself and yourself

The safety of others. Also ensure that the method of operation, lubrication, maintenance or repair procedures you choose will not damage the product or cause unsafe conditions.

The materials, technical specifications and diagrams in this manual have been compiled based on information available at the time of writing. Listed technical specifications, torque, pressure

Forces, measured values, adjusted values, charts, and other items are subject to change at any time, and these changes will affect the repair of the product. So in progress

Before carrying out various operations, you must obtain complete and up-to-date information. The agent has the latest information.

When this product needs to be replaced, it is recommended to use

Perkins original parts or parts of the same technical specification

Pieces. The same technical specifications include, but are not limited to, overall dimensions,

Type, strength and material.

Ignoring this warning can cause premature failure, product damage, or even human

Casualties.

This document is printed from SPI². Not for RESALE


SCNR9778-02

3

table of Contents

table of Contents

Technical specifications

Engine Design ... ..... 4

Fuel high pressure oil pipe .................. ... 5

High Pressure Fuel Pump (Delphi DP210 DPA and DPG Fuel Injection

Pump) ................................................ ....................... 5

High pressure oil pump (Bosch EPVE only on 1104 engine). 6

High Pressure Oil Pump (Delphi STP) ..................... 7

Injector ............................ ............. 8

Fuel delivery pump .................... ...... 8

Tappet assembly .................... ........... 9

Rocker shaft ........................ ............. 9

Exhaust mechanism cover .................. ..... 9

Cylinder head valve .................. .......... 10

Cylinder head ............ ............... 11

Turbocharger.............................................. ....... 13

Exhaust Manifold .............................. ........... 14

Camshaft .................................. ............ 14

Camshaft bearing ............... ... 15

Engine oil filter ........................... 16

Engine oil pump .................. ... 16

Engine oil pressure ............................ 18

Engine oil bypass valve ..................................... 19

Engine oil pan ............... .... 20

Crankcase Breather .............................. .... twenty one

Water temperature regulator and housing ... 22

Water Pump ........................ .............. twenty three

Cylinder block ...................................... ............... twenty three

Crankshaft ........................ .............. 25

Crankshaft seal .............. .............. 28

Connecting rod bearing journal ................... ..... 29

Main bearing journal .............................. ....... 29

link................................................ ............... 29

Pistons and piston rings ............... .... 31

Piston cooling nozzle .................. ... 32

Front case and cover ............... ........ 32

Gear Assembly (Front) ............... ............. 33

flywheel................................................. .............. 35

Flywheel housing ............ ............ 35

Crankshaft Pulley .............. ..... 35

Fan drive ............ ......... 36

Engine lifting bracket .................. 36

Alternator .................................. ... 36

Starter motor ............ ......... 37

Glow Plug ............... ............. 38

Index section

index................................................. .............. 40

This document is printed from SPI². Not for RESALE


4

Technical specifications

SCNR9778-02

Technical specifications

Engine design

Four-cylinder engine

The front end of the engine is the opposite of the flywheel end. The left and right sides of the engine are

Confirm by looking at the engine from the flywheel end. The first cylinder is the most

The front cylinder.

i03874462

Three-cylinder engine

g01014247

figure 2

Cylinder and valve positions

(A) Intake valve

(B) Exhaust valve

g00984281

figure 1

Bore .............. 105 mm (4.133 in)

Stroke .............. 127 mm (5.000 in)

Cylinder and valve positions

(A) Intake valve

(B) Exhaust valve

Displacement .............. 3.3 L (201 in)

3

Bore .............. 105 mm (4.133 in)

Stroke .............. 127 mm (5.000 in)

Arrangement of cylinder ................. Inline

Combustion chamber type .................. Straight Spray

Compression ratio

Displacement .............. 4.4 L (269 in)

3

Arrangement of cylinder ................. Inline

Combustion chamber type .................. Straight Spray

Compression ratio

Naturally Aspirated Engine .................. 19.3: 1

Turbocharged Engine .................. 18.2: 1

Turbocharged Engine .... 17.2: 1

Number of cylinders ............ .............. 3

Valves per cylinder .................. ......... 2

Valve clearance

Naturally Aspirated Engine .................. 19.3: 1

Turbocharged Engine .................. 18.2: 1

Turbocharged Engine .... 17.2: 1

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

Valves per cylinder .................. ......... 2

Valve clearance

Intake valve .............. 0.20 mm (0.008 in)

Exhaust valve .............. 0.45 mm (0.018 in)

Order of fire ... ... 1, 2, 3

Intake valve .............. 0.20 mm (0.008 in)

Exhaust valve .............. 0.45 mm (0.018 in)

When viewing the crankshaft from the front of the engine, the crankshaft rotation direction is as follows

Bottom: ................................................ ........ clockwise

Order of fire ... 1, 3, 4, 2

When viewing the camshaft from the front of the engine, the direction of rotation of the camshaft is

Bottom: ................................................ ........ clockwise

When viewing the crankshaft from the front of the engine, the crankshaft rotation direction is as follows

Bottom: ................................................ ........ clockwise

The front end of the engine is the opposite of the flywheel end. The left and right sides of the engine are

Confirm by looking at the engine from the flywheel end. The first cylinder is the most

The front cylinder.

When viewing the camshaft from the front of the engine, the direction of rotation of the camshaft is

Bottom: ................................................ ........ clockwise

This document is printed from SPI². Not for RESALE


SCNR9778-02

5

Technical specifications

i03874437

Note: The solenoid valve on the fuel injection pump is a serviceable item. Fuel injection

The oil pump is a non-repairable item.

Fuel high pressure oil pipe

(1) O-ring

(2) lock screw

(3) washer

Lock shaft

Loosen the locking screw (2) and move the washer (3) to the locked position.

Tighten the bolts to the following torque. ........... 17 N · m (12 lb ft)

Unlock the shaft

Loosen the locking screw (2) and install the washer (3) to the unlocked position.

Tighten the bolts to the following torque. ............. 12 N · m (9 lb ft)

g00923498

image 3

Typical fuel line

(1) Tighten the injector joint nut to the following torque. ........ 30 N · m

(22 lb ft)

Note: Tighten the injection pump connector nut to the following torque. 30 N · m (22 lb ft)

i03874446

High pressure pump

(Delphi DP210 DPA and DPG

(Oil injection pump)

g00986531

Figure 5

Support bracket

(4) Tighten the mounting bolts to the following torque. .... 44 N · m (32 lb ft)

Delphi DP210

(5) Tighten the mounting bolts and nuts to the following torque. ........ 22 N · m

(16 lb ft)

Note: The fuel injection pump shaft must be locked before removing the fuel injection pump from the engine. screw

The piston of the first cylinder of the engine must be pressed before tightening the locking screw.

Position of top dead center of retract stroke. The locking screw prevents the shaft from turning.

Remove if engine timing marks and shaft locking operations are not recorded

The fuel injection pump, the fuel needs to be determined by trained personnel

Timing mark of the fuel injection pump.

Note: The support bracket must be installed after the coolant pump is installed. for

To prevent distortion of the timing shell, you can tighten the bolts by hand first

(4), then tighten the nuts and bolts (5). Tighten the bolts (4).

Tighten the bolts that secure the fuel pump to the front housing to the following torque

Moment. ..................................... 25 N · m (18 lb ft)

Delphi DPA

DPA fuel injection pump support bracket and DP 210 fuel injection pump support bracket

Shelves are similar.

g00922601

Figure 4

Delphi DP 210 fuel injection pump

This document is printed from SPI². Not for RESALE


6

Technical specifications

SCNR9778-02

g00986530

Figure 7

Bosch EPVE Fuel Injection Pump

Note: The solenoid valve on the fuel injection pump is a serviceable item. Fuel injection

The oil pump is a non-repairable item.

(1) O-ring

(2) lock screw

(3) Spacer

g01111240

Figure 6

(1) Support bracket

(2) lock screw

(3) washer

Note: The torque of Delphi STP fuel injection pump lock screw is the same as Delphi

DPA and DPG fuel injection pump lock screws have the same torque.

The Delphi DPA fuel injection pump has a larger support bracket. Two

The torque of the mounting bracket mounting bolts of this fuel injection pump is the same.

Lock shaft

Remove the spacer (3) and tighten the lock screw (2) to the following torque

Moment. ... 31 N · m (23 lb ft)

Delphi DPG

Unlock the shaft

Loosen the bolt and place the spacer (3) behind the lock screw (2).

Tighten the bolts to the following torque. ............. 12 N · m (9 lb ft)

DPG fuel injection pumps are used only on engines running at a fixed speed. in

There is no support bracket on this fuel injection pump.

Lift of ER fuel injection pump plunger ... 1.55 mm (0.0610 in)

i03874439

High pressure pump

(Bosch EPVE only for 1104 launches

on board)

Note: The fuel injection pump shaft must be locked before removing the fuel injection pump from the engine. screw

The piston of the first cylinder of the engine must be pressed before tightening the locking screw.

Position of top dead center of retract stroke. The locking screw prevents the shaft from turning.

Remove if engine timing marks and shaft locking operations are not recorded

The fuel injection pump, the fuel needs to be determined by trained personnel

Timing mark of the fuel injection pump.

g00988408

Figure 8

Installed EVEP fuel injection pump

This document is printed from SPI². Not for RESALE


SCNR9778-02

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Technical specifications

(4) Tighten the fuel injection pump plunger plug to the following torque. : 29 N · m

(21 lb ft)

g00986295

Figure 9

Support bracket

Note: The support bracket must be installed after the coolant pump is installed. In order to prevent

When the housing is distorted, you can tighten the bolts (5) by hand first.

Then tighten the nuts and bolts (6). Tighten the bolts (5).

g01061708

Figure 10

Delphi STP Fuel Injection Pump

(5) Tighten the bolts to the following torque. ........... 44 N · m (32 lb ft)

(6) Tighten the nuts and bolts to the following torque. : 22 N · m (16 lb ft)

Note: The solenoid valve on the fuel injection pump is a serviceable item. Fuel injection

The oil pump is a non-repairable item.

(1) Locking screw

(2) washer

Tighten the bolts that secure the fuel pump to the front housing to the following torque

Moment. ..................................... 25 N · m (18 lb ft)

Lock shaft

i03874467

High pressure pump

Loosen the locking screw (1) and turn the washer (2) to the locked position.

Tighten the bolts to the following torque. ........... 13 N · m (10 lb ft)

(Delphi STP)

Unlock the shaft

Loosen the locking screw (2) and install the washer (3) to the unlocked position.

Tighten the bolts to the following torque ... 12 N · m (9 lb ft)

Note: The injection pump shaft must be locked before removing the injection pump from the engine. screw

The piston of the first cylinder of the engine must be pressed before tightening the locking screw.

Position of top dead center of retract stroke. The locking screw prevents the shaft from turning.

Remove if engine timing marks and shaft locking operations are not recorded

The fuel injection pump, the fuel needs to be determined by trained personnel

Timing mark of the fuel injection pump.

g00986531

Figure 11

Support bracket

(4) Tighten the mounting bolts to the following torque. .... 44 N · m (32 lb ft)

(5) Tighten the mounting bolts and nuts to the following torque. ........ 22 N · m

(16 lb ft)

This document is printed from SPI². Not for RESALE


8

Technical specifications

SCNR9778-02

Note: The support bracket must be installed after the coolant pump is installed. for

To prevent distortion of the timing shell, you can tighten the bolts by hand first

(4), and then tighten the nuts and bolts (5). Tighten the bolts (4).

i03874435

Fuel transfer pump

Tighten the bolts that secure the fuel pump to the front housing to the following torque

Moment. ..................................... 25 N · m (18 lb ft)

i03874454

Injector

g00908211

Figure 12

Injector clamp

(1) Tighten the bolt on the injector clamp to the following torque

Moment. ... 35 N · m (26 lb ft)

g00986823

Figure 13

The injectors should be tested at the pressures in Table 1.

(1) Fastening bolt

(2) Clip

Leakage in 10 seconds .............................. 0 drop

Table 1

Set value when servicing the injector

Jet pressure

(3) Spacer

(4) Fuel transfer pump

29.4 + 0.8 MPa (4264 + 116 psi)

Type ............ 12 or 24 Volt Electric Motor

(5) Fuel filter

(6) O-ring

(7) Fuel filter cup

NOTE: Tighten the fuel filter cup by hand. Turn the cup again by hand 1/8

ring.

This document is printed from SPI². Not for RESALE


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9

Technical specifications

i03874466

Inside diameter of rocker hole for mounting bushing: 25.01 to 25.05 mm

(0.9847 to 0.9862 in)

Tappet assembly

Rocker bushing

Clearance between rocker bushing and rocker shaft: 0.03 to 0.09 mm

(0.0010 to 0.0035 in)

Maximum allowable interval between rocker bushing and rocker shaft

Gap .............. 0.17 mm (0.007 in)

(5) Spring

NOTE: Install the longest screw on the front of the rocker shaft assembly.

(6) Tighten the screws evenly. Tighten gradually from the center to both sides. screw

Tighten the screws to the following torque ... 35 N · m (26 lb ft)

(7) Rocker shaft

Rocker shaft diameter ... 24.96 to 24.99 mm

(0.9827 to 0.9839 in)

g00629433

Figure 14

(1) Taper body diameter ........ 18.99 to 19.01 mm

(0.7475 to 0.7485 in)

(8) Be sure to machine the rocker shaft when installing the rocker shaft assembly

This square surface is facing up.

Install the tappet between the tappet and the mounting hole after the cylinder hole

Gap ............... 0.04 to 0.09 mm (0.0015 to 0.0037 in)

(9) lock nut

Locknut Torque .............. 27 N · m (20 lb ft)

i03874469

i03874450

Rocker shaft

Exhaust mechanism cover

Note: Rocker shaft assembly installed on 3- and 4-cylinder engines

Contains the same parts. The difference is the length of the rocker shaft.

Four-cylinder engine valve cover

g00985174

g00908011

Figure 15

Figure 16

Rocker shaft

Valve cover

Note: The 27610227 spacer tool is required to install the rocker shaft.

Tighten the valve housing cover bolts in the order shown in the illustration to the following torque

Moment. ................................................... 9 N · m (7 lb ft)

(1) Snap ring

(2) washer

(3) Rocker

(4) Rocker hole

This document is printed from SPI². Not for RESALE


10

Technical specifications

SCNR9778-02

Three-cylinder engine valve cover

Preload force for valve spring installation ......... 254 N (57.1 lb)

Turbocharged engine

Mounting height of valve spring ... 34.5 mm (1.358 in)

Preload force for valve spring installation ............ 229 N (51.4 lb)

(2) Valve spring groove

(3) Finished valve guide

Inner diameter of valve guide ... 9.000 to 9.022 mm

(0.3543 to 0.3552 in)

Exhaust valve duct outer diameter ... 13.034 to 13.047 mm

(0.5131 to 0.5137 in)

Outer diameter of intake valve guide ... 13.034 to 13.047 mm

(0.5131 to 0.5137 in)

Interference fit of valve guide in cylinder head

Volume ... 0.007 to 0.047 mm (0.0003 to 0.0019 in)

Valve guide length ... 51.00 to 51.50 mm

(2.018 to 2.027 in)

g01018519

Figure 17

The valve guide is longer than the valve spring groove (2)

Degree ... 12.35 to 12.65 mm (0.486 to 0.498 in)

Valve cover

Tighten the valve housing cover bolts in the order shown in the illustration to the following torque

Note: When installing a new valve guide, a new valve and a new valve must be installed

Seat ring. Valve guides and valve seat inserts are semi-machined parts. will

Rough-machined valve guide and rough-processed valve seat inserts are mounted on the cylinder head

Inside. Then, cut the valve guide and valve seat insert;

With a special tool, the valve guide and valve seat

Reaming operations performed in circles. This step ensures that the valve seat and valve guide

The tubes are concentric and thus produce a tight sealing effect. See the

Uninstallation and Installation Manual for information on the removal and installation process.

Moment. ................................................... 9 N · m (7 lb ft)

i03874458

Cylinder head valve

(4) Exhaust valve

Exhaust valve stem diameter .............. 8.938 to 8.960 mm

(0.3519 to 0.3528 in)

Clearance between valve stem and valve guide ... 0.040 to 0.840 mm

(0.0016 to 0.033 in)

Exhaust valve total length ... 128.92 to 129.37 mm

(5.075 to 5.093 in)

The dimensions of the exhaust valve surface recessed below the cylinder head are as follows.

Naturally Aspirated Engine ........ 0.53 to 0.81 mm

(0.021 to 0.032 in)

Limit of use .................. 1.06 mm (0.042 in)

Turbocharged engine ........ 1.53 to 1.81 mm

(0.060 to 0.071 in)

g00294082

Figure 18

Limit of use ... 2.06 mm (0.0811 in)

(5) Intake valve

Cylinder head cross section

(1) Valve spring

Intake valve stem diameter .............. 8.953 to 8.975 mm

(0.3525 to 0.3533 in)

Naturally aspirated engine

Mounting height of valve spring ... 33.5 mm (1.318 in)

This document is printed from SPI². Not for RESALE


SCNR9778-02

11

Technical specifications

Between the valve stem and the valve guide

Naturally aspirated engine exhaust valve seat groove

Gap: 0.025 to 0.069 mm (0.001 to 0.0027 in)

(A) .... 9.910 to 10.040 mm (0.3901 to 0.3952 in)

(B): 42.420 to 42.445 mm (1.6701 to 1.6711 in)

(C) Maximum radius ........ 0.38 mm (0.015 in)

Total intake valve length ... 128.92 to 129.37 mm

(5.075 to 5.093 in)

Turbocharged engine intake valve seat groove

The dimensions of the intake valve surface recessed below the cylinder head are as follows.

(A): 10.910 to 11.040 mm (0.4295 to 0.4346 in)

(B): 47.820 to 47.845 mm (1.8826 to 1.8836 in)

(C) Maximum radius ........ 0.38 mm (0.015 in)

Naturally Aspirated Engine ........ 0.58 to 0.84 mm

(0.023 to 0.033 in)

Turbocharged engine intake valve seat groove

Limit of use .................. 1.09 mm (0.043 in)

(A): 10.910 to 11.040 mm (0.4295 to 0.4346 in)

(B): 42.420 to 42.445 mm (1.6700 to 1.6710 in)

(C) Maximum radius ........ 0.38 mm (0.015 in)

Turbocharged engine ........ 1.58 to 1.84 mm

(0.062 to 0.072 in)

Limit of use ... 2.09 mm (0.0823 in)

(6) The angle between the exhaust valve cone and the vertical axis

i03874452

Cylinder head

Valve cone angle .................. 30 degrees

Valve seat cone angle .............. 30 degrees

Table 3 shows the maximum distortion of the cylinder head.

(7) Exhaust valve

Valve head diameter ... 41.51 to 41.75 mm

(1.634 to 1.443 in)

Table 2

Required tools

(8) Inlet valve head diameter: 46.20 to 46.45 mm

(1.818 to 1.828 in)

Parts

Part Name

Numbering

Quantity

1

21825607

Angle gauge

(9) The angle between the cone of the intake valve and the vertical axis

Valve cone angle .................. 30 degrees

Valve seat cone angle .............. 30 degrees

There are two types of cylinder head bolts. The following is required to tighten the cylinder head bolts

Desired torque value.

The valve clearance when the engine is cold is as follows:

Four-cylinder engine

Intake valve .............. 0.20 mm (0.008 in)

Exhaust valve .............. 0.45 mm (0.018 in)

g00809016

Figure 19

Valve seat ring groove

(10) Machine the valve seat insert groove in the cylinder head as follows.

Naturally aspirated engine intake valve seat groove

(A) .... 9.910 to 10.040 mm (0.3901 to 0.3952 in)

(B): 47.820 to 47.845 mm (1.8826 to 1.8836 in)

(C) Maximum radius ........ 0.38 mm (0.015 in)

g00987480

Figure 20

Tightening sequence

This document is printed from SPI². Not for RESALE


12

Technical specifications

SCNR9778-02

Three-cylinder engine

Four-cylinder engine

g01006568

Figure 23

Three-cylinder engine

g01017007

Figure 21

Tightening sequence

Apply a clean engine to the bolt threads and under the bolt head

Oil for lubrication.

Tighten the cylinder head bolts in the order shown to the following torque

Moment. ...................... 50 N · m (37 lb ft)

Tighten the cylinder head bolts again to the following torque. ......... 100 N · m

(74 lb ft)

g01017008

Figure 24

table 3

size

Maximum allowable deformation

Width (A)

Length (B)

Diagonal (C)

0.03 mm (0.0018 in)

0.05 mm (0.0019 in)

0.05 mm (0.0019 in)

g00905621

Figure 22

Cylinder head bolts require an additional tightening step. Number (1, 3, 4)

Represents three long cylinder head bolts. All other bolts are short bolts. screw

The tight sequence is shown in the figure.

Place an angle gauge on top of each bolt head. Tighten the short bolts again

tight. ........................................ : 225 degrees

Place an angle gauge on top of each bolt head. Retighten the long bolts

tight. ........................................ : 270 degrees

Cylinder head thickness: 117.95 to 118.05 mm (4.643 to 4.647 in)

Cylinder head minimum thickness ........ 117.20 mm (4.614 in)

Note: The maximum distortion of the cylinder head is given in Table 3.

This document is printed from SPI². Not for RESALE


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13

Technical specifications

Four-cylinder engine

i03874443

Turbocharger

Table 4

Turbocharger part number

Wastegate valve pressure

2674A200

2674A201

2674A202

2674A209

2674A211

2674A215

2674A223

2674A224

2674A225

2674A226

2674A227

100 ± 5 kPa

(14.5040 ± 0.7252 psi)

110 ± 5 kPa

(15.9544 ± 0.7252 psi)

128 ± 5 kPa

(18.5651 ± 0.7252 psi)

100 ± 5 kPa

(14.5040 ± 0.7252 psi)

128 ± 5 kPa

(18.5651 ± 0.7252 psi)

128 ± 5 kPa

(18.5651 ± 0.7252 psi)

136 ± 5 kPa

(19.7254 ± 0.7252 psi)

136 ± 5 kPa

(19.7254 ± 0.7252 psi)

136 ± 5 kPa

(19.7254 ± 0.7252 psi)

g00991357

Figure 25

100 ± 5 kPa

(14.5040 ± 0.7252 psi)

Typical turbocharger

(1) Actuator lever

(2) Actuator

128 ± 5 kPa

(18.5651 ± 0.7252 psi)

Three-cylinder engine

(3) Turbocharger

table 5

(4) Tighten the nut to the following torque. ........... 47 N · m (34 lb ft)

(5) Tighten the bolts to the following torque. ............ 9 N · m (80 lb in)

(6) Tighten the bolts to the following torque. ........... 22 N · m (16 lb ft)

Maximum test pressure of wastegate valve ... 205 kPa (30 psi)

Actuator rod movement range ... 1 mm (0.0394 in)

Turbocharger part number

Wastegate valve pressure

2674A405

2674A421

2674A422

100 ± 3 kPa

(14.5040 ± 0.4351 psi)

100 ± 3 kPa

(14.5040 ± 0.4351 psi)

200 ± 3 kPa

(29.0080 ± 0.4351 psi)

This document is printed from SPI². Not for RESALE


14

Technical specifications

SCNR9778-02

i03874453

i03874431

Exhaust manifold

Camshaft

Four-cylinder engine

g00987750

Figure 28

Check camshaft axial clearance

g00907527

Figure 26

(1) New camshaft axial clearance ... 0.10 to 0.55 mm

(0.004 to 0.022 in)

Tightening sequence

NOTE: The exhaust manifold must be aligned with the cylinder head. See Disintegration and

Assembly Manual.

Allowable axial clearance of worn camshaft .............. 0.60 mm

(0.023 in)

Tighten the exhaust manifold bolts as shown in Figure 26 to the following torque

Moment. ........................... 33 N · m (24 lb ft)

Three-cylinder engine

g00976195

Figure 29

Typical camshaft

(2) Bolt

g01017009

Tighten the bolts to the following torque. ........... 95 N · m (70 lb ft)

Figure 27

NOTE: The exhaust manifold must be aligned with the cylinder head. See Disintegration and

Assembly Manual.

(3) Camshaft thrust washer

Thrust Washer Thickness .............. 5.49 to 5.54 mm

(0.216 to 0.218 in)

Tighten the exhaust manifold bolts in the order shown in Figure 27 to the following torque

Moment. ........................... 33 N · m (24 lb ft)

The depth of the groove on the cylinder block pushed by the washer

Degrees ......... 5.54 to 5.64 mm (0.218 to 0.222 in)

Thrust washer on the front surface of the cylinder

Difference ..............− 0.154 to −0.003 mm

(−0.0006 to −0.0001 in)

(4) The diameter of the camshaft journal is shown in the table below.

This document is printed from SPI². Not for RESALE


SCNR9778-02

15

Technical specifications

Table 6

Turbocharged

Intake cam .... 31 ... 7.131 mm

(0.2768 to 0.2807 in)

1104 Camshaft journal diameter

Camshaft journal

1

Standard diameter

Exhaust Cam ................. 7.963 to 8.063 mm

(0.3135 to 0.3174 in)

50.71 to 50.74 mm

(1.9965 to 1.9975 in)

(6) Camshaft cam height

50.46 to 50.48 mm

(1.9865 to 1.9875 in)

2

3

(7) base circle

49.95 to 49.98 mm

(1.9665 to 1.9675 in)

The following steps can be used to determine the camshaft cam lift:

1. Measure the camshaft cam height (6).

2. Measure the base circle (7).

Table 7

1103 Camshaft journal diameter

Camshaft journal

1

Standard diameter

3. Subtract step 2 from the camshaft cam height obtained in step 1.

The base circle value obtained in. The difference is the actual cam

Shaft cam lift.

50.71 to 50.74 mm

(1.9965 to 1.9975 in)

50.46 to 50.48 mm

(1.9865 to 1.9875 in)

2

3

4

The difference between the actual cam lift of a new camshaft and its design value

Large allowable deviation .............. 0.05 mm (0.021 in)

50.46 to 50.48 mm

(1.9865 to 1.9875 in)

i03874440

49.95 to 49.98 mm

(1.9665 to 1.9675 in)

Camshaft bearings

Camshaft journal wear: 0.05 mm (0.0021 in)

g00997348

Figure 31

g00629702

Figure 30

Typical four-cylinder engine

(5) Camshaft cam lift

Naturally aspirated

Intake cam ................. 7.382 to 7.482 mm

(0.2906 to 0.2946 in)

Exhaust cam ................. 7.404 to 7.504 mm

(0.2914 to 0.2954 in)

This document is printed from SPI². Not for RESALE


16

Technical specifications

SCNR9778-02

Replaceable filter

g00915985

Figure 34

NOTE: Apply clean hair to the oil filter housing before installation.

The engine oil is sealed with lubricating oil.

Types of................................................. ....... full flow

g01017012

Figure 32

Three-cylinder engine

Oil filter bypass valve opening pressure ........... 130 to 170 kPa

(19 to 25 psi)

(1) Camshaft bearings

(1) Install the oil filter housing on the oil filter support and screw it

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

Camshaft bearings measured straight after installation

Diameter: 50.790 to 50.850 mm (1.9996 to 2.020 in)

(2) Tighten the drain plug of the oil filter to the following torque. : 12 N · m

(9 lb ft)

i03874460

Engine oil filter

NOTE: The drain plug for the horizontally mounted oil filter is located on the filter cover

(3) 1/2 in square mounting groove

Spin-on oil filter

i03874449

Engine oil pump

Four-cylinder engine with balancer

Type ........................ Gear drive, rotor type

Number of bulges

Inner rotor ...................................... ........ 6

Outer rotor ............................ ........ 7

g00915984

Figure 33

(1) Oil seal

Note: Apply a clean engine to the upper surface of the oil seal before installation

Engine oil for lubrication.

Types of................................................. ....... full flow

Oil filter bypass valve opening pressure ......... 80 to 120 kPa

(12 to 18 psi)

This document is printed from SPI². Not for RESALE


SCNR9778-02

17

Technical specifications

g00989248

g00989217

Figure 35

Fig. 37

Oil pump for four-cylinder engine with balancer

Axial clearance of the rotor

(1) Clearance between outer rotor and pump body ... 0.130 to 0.24 mm

(0.0050 to 0.0094 in)

(3) Axial clearance of the rotor assembly

Inner rotor: 0.04 to 0.11 mm (0.0016 to 0.0043 in)

Outer rotor: 0.04 to 0.00 mm (0.0016 to 0.0043 in)

g00938724

Figure 38

End cap

(4) Torque of oil pump end cover bolts ..... 26 N · m (19 lb ft)

g00989236

Fig. 36

Inner rotor

(2) Clearance between inner rotor and outer rotor: 0.050 to 0.200 mm

(0.0020 to 0.0079 in)

This document is printed from SPI². Not for RESALE


18

Technical specifications

SCNR9778-02

g00989519

g00938061

Figure 39

Figure 41

Idler gear and oil pump gear

Check gap

NOTE: Replace idler gear bolt (5) and oil pump gear nut (6).

(5) Tighten the idler bolts to the following torque. : 26 N · m (19 lb ft)

(2) Clearance between inner rotor and outer rotor: 0.040 to 0.127 mm

(0.0015 to 0.0050 in)

Note: Place the engine in the TC position. See Testing and Tuning,

"Determine the top dead center position of cylinder 1 compression". Install the balancer.

See the Disassembly and Assembly Manual. Install the oil pump gear and

Tighten the nut (6).

(6) Tighten the nut to the following torque. ........... 95 N · m (70 lb ft)

Tighten the bolts that secure the balancer to the cylinder to the following torque

Moment. ........................... 54 N · m (40 lb ft)

Four- and three-cylinder engines without balancer assembly

Type ........................ Gear drive, rotor type

Number of bulges

g00938799

Fig. 42

Check axial clearance

Inner rotor ...................................... ........ 5

Outer rotor ............................ ........ 6

(3) Axial clearance of the rotor assembly

Inner rotor .............. 0.038 to 0.089 mm

(0.0014 to 0.0035 in)

Outer rotor .............. 0.025 to 0.076 mm

(0.0010 to 0.0029 in)

Tighten the bolts that secure the front cover of the oil pump assembly to the following torque

Moment. ........................... 26 N · m (19 lb ft)

i03874447

Engine oil pressure

The minimum oil pressure of the engine at the highest speed and normal operating temperature is

The following values. ..................... 300 kPa (43 psi)

g00938064

Figure 40

Oil pump

(1) Clearance between outer rotor and pump body ... 0.152 to 0.330 mm

(0.0059 to 0.0129 in)

This document is printed from SPI². Not for RESALE


SCNR9778-02

19

Technical specifications

i03874455

Engine oil bypass valve

Installed in the oil pump

g00919890

Figure 45

Screw plug

g00919893

Figure 43

Typical engine oil pump

g00921379

Figure 46

Balancer pressure relief valve

(1) Tighten the balancer relief valve plug to the following torque. .... 35 N · m

(26 lb ft)

(2) plunger

g00921377

Figure 44

Plunger diameter ........... 14.46 to 14.48 mm

(0.5692 to 0.5700 in)

Pressure relief valve and spring

(1) Tighten the pressure relief valve cover to the following torque ... 35 N · m (26 lb ft)

(2) plunger

Clearance of plunger in the hole ........ 0.04 to 0.08 mm

(0.0015 to 0.0031 in)

Plunger diameter ........ 19.186 to 19.211 mm

(0.7554 to 0.7563 in)

Clearance of plunger in hole ...

(0.0015 to 0.0045 in)

Installed in a balancer

1104 engine only

This document is printed from SPI². Not for RESALE


20

Technical specifications

SCNR9778-02

i03874436

Engine oil pan

Front sealant

g00990254

Fig. 47

Apply sealant

(1) Apply 1861108 Powerpart Silicone Sealant to the cylinder block and

Timing gear housing.

g00990252

Fig. 49

NOTE: Apply 3.5 mm (0.1378 in) sealant as shown in Figure 47.

Typical oil pan

Rear sealant

(3) Tighten the first four bolts to the following torque. : 22 N · m (16 lb ft)

(4) Tighten the remaining bolts to the following torque. .... 22 N · m (16 lb ft)

Note: Install oil seal before applying sealant on the bridge.

g00990255

Fig. 48

Apply sealant

(2) Apply 1861108 Powerpart silicon sealant to the bridge. dense

Sealant must not exceed 5 mm (0.1969 in) beyond the bridge.

Note: The oil pan must be installed within 10 minutes after applying the sealant.

This document is printed from SPI². Not for RESALE


SCNR9778-02

twenty one

Technical specifications

Cast iron oil pan

g00990677

Figure 51

Drain valve

(8) Drain valve

Screw the drain valve into the connector and tighten to the following torque

Moment. ..................... 34 ± 5 N · m (25 ± 4 lb ft)

(9) Connector

Screw the connector into the oil pan and tighten to the following torque

Moment. ..................... 34 ± 5 N · m (25 ± 4 lb ft)

i03874464

g00990249

Crankcase respirator

Figure 50

Cast iron oil pan

NOTE: The rear of the cast iron oil pan (5) must be aligned with the rear of the cylinder block.

(5) The maximum allowable error value. .......... 0.1 mm (0.0039 in)

(6) Bolts

Tighten the first four bolts. Refer to Figure 49. Tighten the rest to

Bolts and nuts securing oil pan to cylinder block

Moment. ... 22 N · m (16 lb ft)

NOTE: Apply sealant to new bolts. To be able to reuse snails

Bolt, smeared 21810117 Powerpart thread locker and nut lock

Glue to the first three threads of the old bolt.

Note: Organic oil drain plug or oil drain may be installed on the engine

valve.

(7) Oil drain plug

Tighten the oil drain plug of the engine oil pan to the following torque

Moment. ..................... 34 ± 5 N · m (25 ± 4 lb ft)

g00926199

Fig. 52

Respirator valve

(1) Plastic cover

(2) Cover

(3) Screw

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twenty two

Technical specifications

SCNR9778-02

Tighten the cover fastening screws attached to the plastic valve cover

Down torque. ................. 1.3 N · m (11.5 lb in)

Tighten the cover fixing screws attached to the metal valve cover

Down torque. .............. 1.8 N · m (16 lb in)

(4) diaphragm

(5) Cover

(6) Spring

g01121867

Fig. 54

(1) Plastic cover

(2) Screw

(3) Cover

(4) Sealing ring

(2) Tighten the cover fixing screws attached to the plastic valve cover

Down torque. ................. 1.3 N · m (11.5 lb in)

i03874444

g00926200

Fig. 53

Water temperature regulator and housing

(7) O-ring

Note: Apply 21820221 Powerpart Red Rubber Grease to O

Seal before attaching the respirator tube to the valve housing cover.

Tighten the bolts (not shown) securing the housing to the following torque

Moment. ........................... 22 N · m (16 lb ft)

(8) Tighten the fastening bolts fixing the respirator tube to the cylinder head

Down torque ... 9 Nm (80 lb in)

Engine models DK and DJ

Note: The valve cover is not installed on such a three-cylinder engine.

Suction valve.

g00997234

Fig. 55

O-ring

Note: Apply 21820221 Powerpart Red Rubber Grease to O

Seal (1) before installing the thermostat housing.

This document is printed from SPI². Not for RESALE


SCNR9778-02

twenty three

Technical specifications

Water temperature regulator

i03874434

Cylinder block

Four-cylinder engine

g00906121

Fig. 56

A typical water temperature regulator

Opening temperature ... 79 ° to 84 ° C (174 ° to 151 ° F)

Full Opening Temperature .................................. 93 ° C (199 ° F)

Minimum opening at full opening temperature ... 10 mm (0.3937 in)

g00924764

Fig. 58

Cylinder block

(1) Cylinder block

i03874456

Water pump

(2) Bore .............. 105.000 to 105.025 mm

(4.1338 to 4.1348 in)

The first enlarged size aperture ............... 105.5 to 105.525 mm

(4.1535 to 4.1545 in)

The second largest size aperture ... 106.000 to 106.025 mm

(4.1732 to 4.1742 in)

Maximum allowable bore size: 0 to 0.15 mm (0 to 0.0059 in)

(3) Four-cylinder engine camshaft bearings

No. 1 camshaft bearing hole in the cylinder straight

Diameter: 55.563 to 55.593 mm (2.1875 to 2.1887 in)

No. 2 camshaft

Diameter: 50,, .546 to 50.597 mm (1.9900 to 1.9920 in)

g00915951

No. 3 camshaft

Diameter: 50.038 to 50.089 mm (1.9700 to 1.9720 in)

Fig. 57

Tightening sequence

(4) Four-cylinder engine main bearing

Note: Apply 21820117 Powerpart thread locker before installation

And nut lock glue to the first three threads of the bolt.

Straight holes of the main bearing in the cylinder

Diameter: 80.416 to 80.442 mm (3.1660 to 3.1670 in)

Tighten the pump to the front housing in the order of the numbers marked in the figure

Nine bolts to the following torque. ............. 22 N · m (16 lb ft)

(5) Four-cylinder engine main bearing cap bolt

Note: See the Disassembly and Assembly Manual for pump repair information

interest.

Use the following steps to install the main bearing cap bolts:

This document is printed from SPI². Not for RESALE


twenty four

Technical specifications

SCNR9778-02

Three-cylinder engine

1. Apply clean engine oil to the threads of the main bearing cap bolts.

2. Place the main bearing cap on the top of the main bearing cap.

Exact location. When installing the main bearing cap, the convex key must

The grooves are aligned.

3. Tighten the main bearing cap bolts evenly.

Torque of main bearing cap bolts. ............. 245 N · m (180 lb ft)

g01018250

Fig. 60

g00938203

Fig. 59

(8) Cylinder block

Use the following steps to install the hex head bolts for the bridge:

NOTE: Install the rear seal before applying the sealant.

(9) Bore .............. 105.000 to 105.025 mm

(4.1338 to 4.1348 in)

The first enlarged size aperture ............... 105.5 to 105.525 mm

(4.1535 to 4.1545 in)

1. Use a ruler to ensure that the bridge is aligned with the back of the cylinder.

2. Tighten the hex head bolts (6) of the bridge.

The second largest size aperture ... 106.000 to 106.025 mm

(4.1732 to 4.1742 in)

Hex Head Bolt Torque ... 16 N · m (12 lb ft)

Maximum allowable bore size: 0 to 0.15 mm (0 to 0.0059 in)

(10) Four-cylinder engine camshaft bearings

3. After mounting the bridge on the cylinder, apply 21826038

POWERPART Silicone Adhesive to slots (7) at both ends of the bridge. in

Squeeze the sealant into the groove until the sealant reaches the bottom of the groove at the bridge.

No. 1 camshaft bearing hole in the cylinder straight

Total height of the cylinder between top and bottom

degree. ............ 441.173 to 441.274 mm

(17.3689 to 17.3729 in)

Diameter: 55.563 to 55.593 mm (2.1875 to 2.1887 in)

No. 2 camshaft

Diameter: 50.546 to 50.597 mm (1.9900 to 1.9920 in)

No. 3 camshaft

Diameter: 50.546 to 50.597 mm (1.9900 to 1.9920 in)

No. 4 camshaft

Diameter: 50.038 to 50.089 mm (1.9700 to 1.9720 in)

(11) Three-cylinder engine main bearing

Straight holes of the main bearing in the cylinder

Diameter: 80.416 to 80.442 mm (3.1660 to 3.1670 in)

(12) Four-cylinder and three-cylinder engine main bearing cap bolts

Use the following steps to install the main bearing cap bolts:

1. Apply clean engine oil to the threads of the main bearing cap bolts.

This document is printed from SPI². Not for RESALE


SCNR9778-02

25

Technical specifications

2. Place the main bearing cap on the top of the main bearing cap.

Exact location. When installing the main bearing cap, the convex key must be connected with the

The grooves are aligned.

i03874459

Crankshaft

3. Tighten the main bearing cap bolts evenly.

Torque of main bearing cap bolts. ............. 245 N · m (180 lb ft)

g01018262

Fig. 61

Use the following steps to install the hex head bolts for the bridge.

NOTE: Install the rear seal before applying the sealant.

1. Use a ruler to ensure that the bridge is aligned with the back of the cylinder.

2. Tighten the hex head bolts (13) of the bridge.

Hex Head Bolt Torque ... 16 N · m (12 lb ft)

g00992214

Fig. 62

3. After mounting the bridge on the cylinder, apply 21826038

POWERPART Silicone Adhesive to slots (14) at both ends of the bridge.

Squeeze the sealant into the groove until the sealant reaches the bottom of the groove at the bridge

end.

Four-cylinder engine crankshaft

(1) Four-cylinder engine crankshaft

Crankshaft Max Axial Clearance ........ 0.51 mm (0.0201 in)

Total height of the cylinder between top and bottom

degree. ............ 441.173 to 441.274 mm

(17.3689 to 17.3729 in)

(2) Thrust washer

Standard thickness ... 2.26 to 2.31 mm (0.089 to 0.091 in)

Increase Dimensions .............. 2.45 to 2.50 mm

(0.097 to 0.098 in)

(3) Crankshaft gear

Maximum allowable temperature of gears mounted on the crankshaft ... 180 ° C

(356 ° F)

Note: After the gear is mounted on the crankshaft, the timing mark faces outside the crankshaft

side.

Note: All turbocharged engines and turbocharged aftercooled engines

The crankshafts are all nitrocarburized. If nitrocarburizing is not possible

The crankshaft can also be nitrided for 20 hours. Crankshaft machining

It must be re-quenched afterwards. Check before and after machining

No cracks. The naturally aspirated engine is equipped with an induction hardened crankshaft.

This document is printed from SPI². Not for RESALE


26

Technical specifications

SCNR9778-02

g01017233

Fig.63

1104 engine crankshaft

NOTE: See Figure 63 to use Table 8.

Four-cylinder engine

Table 8

Reduced diameter of crankshaft journal

0.25 mm (0.010 in) 0.51 mm (0.020 in)

Numbering

1

0.76 mm (0.030 in)

75.909 mm (2.9885 in) to

75.930 mm (2.9894 in)

75.649 mm (2.9783 in) to

75.670 mm (2.9791 in)

75.399 mm (2.9685 in) to

75.420 mm (2.9693 in)

63.220 mm (2.4890 in) to

63.240 mm (2.4898 in)

62.960 mm (2.4787 in) to

62.982 mm (2.4796 in)

62.708 mm (2.4688 in) to

62.728 mm (2.4696 in)

2

3

4

5

6

7

39.47 mm (1.5539 in) maximum

37.44 mm (1.4740 in) maximum

44.68 mm (1.7591 in) max.

40.55 mm (1.5965 in) maximum

Do not machine this diameter.

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

3.68 mm (0.1449 in) to

3.96 mm (0.1559 in)

8

Not applicable

Not applicable

See Table 9 for the maximum radial runout of the crankshaft journal.

This document is printed from SPI². Not for RESALE


SCNR9778-02

27

Technical specifications

Maximum difference of radial runout between two adjacent crankshaft journals: 0.10 mm

(0.0039 in)

Table 9

Journal

(1)

Excessive runout

installation

(2)

0.08 mm (0.0031 in)

0.15 mm (0.0059 in)

0.08 mm (0.0031 in)

installation

(3)

(4)

(5)

Please refer to the "Technical Data", "Link journal" section for details

More information on connecting rod journals and connecting rod bearings.

Refer to the “Technical Data”, “Spindle” section for the main

More information on journals and main bearings.

g01017747

Fig. 64

Three-cylinder engine crankshaft

This document is printed from SPI². Not for RESALE


28

Technical specifications

SCNR9778-02

Three-cylinder engine crankshaft

Table 10

Reduced diameter of crankshaft journal

Numbering

1

0.25 mm (0.010 in)

0.51 mm (0.020 in)

0.76 mm (0.030 in)

75.926 mm (2.9892 in) to

75.905 mm (2.9884 in)

75.672 mm (2.9792 in) to

75.651 mm (2.9784 in)

75.418 mm (2.9692 in) to

75.397 mm (2.9684 in)

63.236 mm (2.4896 in) to

63.216 mm (2.4888 in)

62.982 mm (2.4796 in) to

62.962 mm (2.4788 in)

62.728 mm (2.4696 in) to

62.708 mm (2.4688 in)

2

3

4

39.74 mm (1.5646 in) maximum

44.68 mm (1.7591 in) max.

Not applicable

Not applicable

Not applicable

Not applicable

40.551 mm (1.5965 in) max

value

5

6

7

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

Not applicable

133.17 mm (5.2429 in) Don't

Machine the diameter.

3.68 mm (0.1449 in) to

3.96 mm (0.1559 in)

See Table 11 for the maximum radial runout of the crankshaft journal.

i03874471

Crankshaft seal

Maximum difference of radial runout between two adjacent crankshaft journals: 0.10 mm

(0.0039 in)

Table 11

Journal

(1)

Excessive runout

Mounting diameter

(2)

0.051 mm (0.0020 in)

0.051 mm (0.0020 in)

Mounting diameter

(3)

(4)

Please refer to the "Technical Data", "Link journal" section for details

More information on connecting rod journals and connecting rod bearings.

Please refer to the "Technical Data", "Spindle" section for the main

More information on journals and main bearings.

g00915078

Fig. 65

(1) Crankshaft

(2) Plastic bushing

(3) crankshaft oil seal

(4) Positioning tool

This document is printed from SPI². Not for RESALE


SCNR9778-02

29

Technical specifications

Original dimensions of the main journal ... 76.159 to 76.180 mm

(2.9984 to 2.9992 in)

Allowable wear of main journal ...... 0.040 mm (0.0016 in)

Chamfering radius of main journal .... 68 to 3.69 mm

(0.1448 to 0.1452 in)

Rough surface of bearing journal, crank pin and excessive arc

Degrees ..................... 0.4 micron (16 microinches)

Spindle bush

The following reduced size spindle bush can be used for the main

Journal.

Reduced size bearing pads ........ 0.25 mm (0.010 in)

Reduced size bearing pads .. 0.51 mm (0.020 in)

Reduced size bearing pads .... 75 mm (0.030 in)

Center thickness of bearing pads ..... 2.083 to 2.089 mm

(0.0820 to 0.0823 in)

g00915076

Fig. 66

(5) Align the bolts 1, 2, 3, 4, 5, 6, 7 and 10 as shown in Figure 66.

Tighten to the following torque. ............... 22 N · m (16 lb ft)

Spindle shoe width: 31.62 to 31.88 mm (1.244 to 1.255 in)

Clearance between main bearing and main journal ... 0.057 to 0.117 mm

(0.0022 to 0.0046 in)

Remove the positioning tool.

Tighten the bolts 8 and 9 to the

Moment. ........................... 22 N · m (16 lb ft)

i03874441

link

i03874465

Connecting rod bearing journal

See "Technical Data", "Crankshaft" section for more information

More information on reduced size crankshaft journals.

Original dimensions of connecting rod journals 63.47 to 63.49 mm

(2.4988 to 2.4996 in)

Allowable wear of connecting rod journal ..... 0.04 mm (0.0016 in)

Width of connecting rod journal ..... 40.35 to 40.42 mm

(1.589 to 1.591 in)

Chamfering radius of connecting rod journal .... 68 to 3.96 mm

(0.145 to 0.156 in)

Rough surface of connecting rod journal and excessive arc

Degrees ... Ra 0.4 micron (16 micro inches)

g00907738

Fig. 67

i03874472

Main bearing journal

The mating surface of the connecting rod is formed by hydraulically forging the connecting rod.

(1) Tighten the hexagonal screws of the connecting rod to the following torque. ........ 18 N · m

(13 lb ft)

See the "Technical Data", "Crankshaft" section for information on reducing

Information on the size of the main journal and the width of the main journal.

This document is printed from SPI². Not for RESALE


30

Technical specifications

SCNR9778-02

Tighten the hexagonal screws of the connecting rod again to the following torque. ... 70 N · m

(52 lb ft)

Tighten the hexagonal screws of the connecting rod again 120 degrees. After this step you must change

Replace the hex screws of the connecting rod (1).

Note: When the assembly is disengaged from the engine, be sure to tighten the connecting rod cover

On the pole. Tighten the assembly to the following 20 N · m (14 lb ft).

(2) connecting rod bearing

g00995584

Fig. 68

Bearing bush alignment

g00907744

Note: After installation, the distance between the connecting rod bush and the left and right sides of the connecting rod must be the same.

with. See (A) in Figure 68. See Disassembly and Assembly

Booklet for information on positioning tools.

Fig. 69

(3) Piston pin hole diameter ... 43.01 to 43.04 mm

(1.693 to 1.694 in)

Table 12

(4) Distance between the center of the piston pin hole and the center of the connecting rod head hole

From ... 219.05 to 219.10 mm (8.624 to 8.626 in)

31.62 to 31.88 mm

Connecting rod bearing width

(1.245 to 1.255 in)

31.55 to 31.88 mm

Connecting rod cover bearing width

(5) Bore hole diameter of connecting rod .. 67.21 to 67.22 mm

(2.6460 to 2.6465 in)

(1.2405 to 1.255 in)

1.835 to 1.842 mm

连杆轴承中央的厚度

(0.0723 至0.0725 in)

1.835 至 1.842 mm

连杆盖轴承中央的厚度

(0.0722 至0.0725 in)

0.030 至 0.081 mm

轴承间隙

(0.0012 至0.0032 in)

表13

减小尺寸的连杆轴承

0.25 mm (0.010 in)

0.51 mm (0.020 in)

0.76 mm (0.030 in)

g00915056

Fig. 70

对连杆进行颜色编码。 颜色代码用以表示连杆长度

(Y)。 请参阅表14 以了解连杆的不同长度。

This document is printed from SPI². Not for RESALE


SCNR9778-02

31

技术规格部分

表14

环开口间隙............................ 0.30 至0.55 mm

(0.0118 至0.0216 in)

连杆的长度等级

颜色代码

注: 安装新的第一道气环时一定要确保字母 “TOP” 朝

向活塞的顶部。 在每一个新的用做第一道活塞环的

活塞环上均有一个红色识别标记。当将第一道活塞

环安装在垂直放置的活塞上时,必须确保这些红色

标记位于活塞环端隙的左侧。

等级字母

F

长度 (Y)

165.728 至165.761 mm

(6.5247 至6.5260 in)

red

Orange

white

green

purple

blue

165.682 至165.715 mm

(6.5229 至6.5242 in)

G

H

J

(2) 中间气环

165.637 至165.670 mm

(6.5211 至6.5224 in)

中间气环的形

状........... 外侧下边缘呈阶梯型,具有锥形表面

165.591 至165.624 mm

(6.5193 至6.5206 in)

中间气环的宽度 ..................... 2.47 至2.49 mm

(0.097 至0.098 in)

165.545 至165.578 mm

(6.5175 至6.5188 in)

K

L

中间气环与活塞环槽之间的间

隙............. 0.05 至0.09 mm (0.002 至0.003 in)

165.499 至165.532 mm

(6.5157 至6.4961 in)

环开口间隙............................ 0.70 至0.95 mm

(0.0275 至0.0374 in)

i03874442

活塞和活塞环

注: 安装新的中间气环时必须确保字母 “TOP” 朝向活

塞的顶部。 在每一个新的用做中间活塞环的活塞环

上均有一个绿色识别标记。当将第一道活塞环安装

在垂直放置的活塞上时,必须确保这些绿色标记位

于活塞环端隙的左侧。

(3) 油环

油环的形状........... 有两道刮油唇,带螺旋撑簧

油环的宽度............................ 3.47 至3.49 mm

(0.1366 至0.1374 in)

油环与活塞环槽之间的间隙 ..... 0.03 至0.07 mm

(0.0011 至0.0027 in)

环开口间隙............................ 0.30 至0.55 mm

(0.0118 至0.0216 in)

注: 用一个销将油环弹簧两端固定到合适的位置。 oil

环的弹簧端必须与油环开口间隙相对安装。

g00888215

图71

活塞和活塞环的一个典型实例

注: 必须确保所有活塞环开口间隙的位置彼此间隔

120 度。

(1) 第一道气环

自然吸气式

第一道气环的形状 ........... 矩形,具有筒形表面

piston

注: 活塞顶部的箭头标记必须指向发动机前部。

涡轮增压式发动机的燃烧杯凹角 ................... 80 度

自然吸气式发动机的燃烧杯凹角 ................... 70 度

第一道气环的宽度 ................ 2.475 至2.49 mm

(0.097 至0.098 in)

第一道气环与活塞环槽之间的间

隙........... 0.09 至.15 mm (0.0035 至0.0059 in)

活塞高于缸体的高度 .................... 0.21 至0.35 mm

(0.008 至0.014 in)

环开口间隙............................ 0.30 至0.55 mm

(0.0118 至0.0216 in)

涡轮增压式

第一道气环的形状 ........... 梯形,具有筒形表面

自然吸气式发动机第一道活塞环槽的宽

度............... 2.58 至2.60 mm (0.1016 至0.1024 in)

涡轮增压式发动机第一道活塞环槽的宽度 ....... 锥形

第一道气环的宽度 ................................... 锥形

This document is printed from SPI². Not for RESALE


32

技术规格部分

SCNR9778-02

第二道活塞环槽的宽度 ................. 2.54 至2.56 mm

(0.1000 至0.1008 in)

采取以下步骤检查活塞冷却喷嘴是否对准。

1. 将杆(3) 插入活塞冷却喷嘴 (2) 的末端。 杆(3)

的直径为1.70 mm (0.067 in)。 杆(3) 必须高出

缸体顶部。

第三道活塞环槽的宽度 ................. 3.52 至3.54 mm

(0.1386 至0.1394 in)

Piston pin

2. 尺寸(A) 为55.25 mm (2.1752 in),尺寸 (B) 为

14 mm (0.5512 in)。 尺寸(A) 和尺寸 (B) 分别与

气缸孔(4) 相切。

新活塞销直径 ................ 39.694 至39.700 mm

(1.5628 至1.5630 in)

3. 杆(3) 的位置必须在尺寸 (C) 范围内。 尺寸(C)

为14 mm (0.5512 in)。

活塞销孔的直径 ............. 39.703 至39.709 mm

(1.5631 至1.5633 in)

i03874445

i03874448

前壳体和盖

Piston cooling nozzle

前壳体必须对准缸体表面。 ..... + 0.05 至- 0.05 mm

(+ 0.0020 至- 0.0020 in)

注: 活塞冷却喷嘴已经作为选装件安装在三缸自然

吸气式发动机上。

g00942652

Fig. 72

(1) 已安装好的活塞冷却喷嘴

弹簧加载阀必须能够自由移动。 拧紧螺栓至以下扭

矩。 ............................................... 9 N·m (7 lb ft)

活塞冷却喷嘴的对准

g00995663

图74

对准

(1) 拧紧将前盖固定到前壳体的螺栓至以下扭

矩。 ...................................... 22 N·m (16 lb ft)

g01006929

Fig. 73

(2) 活塞冷却喷嘴

(3) 杆

(4) 缸体

This document is printed from SPI². Not for RESALE


SCNR9778-02

33

技术规格部分

(1) 燃油喷油泵主动齿轮

拧紧螺母至以下扭矩。 ........... 24 N·m (18 lb ft)

松开燃油喷油泵轴上的锁。 拧紧螺母至以下扭

矩。 ...................................... 90 N·m (66 lb ft)

齿数.......................................................... 68

注: 请参阅《技术参数》, “燃油喷油泵”部分,以获取

燃油喷油泵轴的扭矩。

(2) 凸轮轴齿轮

拧紧凸轮轴齿轮紧固螺栓至以下扭矩。 .. 95 N·m

(70 lb ft)

凸轮轴齿轮的孔径 .............. 34.93 至34.95 mm

(1.3750 至1.3760 in)

凸轮轴轮毂的外径 .............. 34.90 至34.92 mm

(1.3741 至1.3747 in)

凸轮轴齿轮与凸轮轴轮毂之间的间

g00918672

图75

The front cover

隙...... 0.003 至0.048 mm (0.0001 至0.0019 in)

齿数.......................................................... 68

(2) 拧紧将水泵固定到前壳体的螺栓至以下扭

矩。 ...................................... 22 N·m (16 lb ft)

(3) 惰齿轮及其轮毂

拧紧惰齿轮螺栓至以下扭矩。 .. 44 N·m (33 lb ft)

注: 请参阅《技术参数》, “水泵”以便获得水泵螺栓

的正确拧紧次序。

惰齿轮的孔径 .................... 57.14 至57.18 mm

(2.2495 至2.2512 in)

带滚柱轴承的惰齿轮的孔径.. 72.35 至72.36 mm

(2.8484 至2.8488 in)

i03874433

齿轮总成(前)

惰齿轮和分离式轴承组件的宽

度......... 30.14 至30.16 mm (1.186 至1.187 in)

带法兰的惰齿轮轴承的内径.. 50.78 至50.80 mm

在1104 机械式发动机上使用的燃油喷油泵有两种

类型。 一种是 Delphi 210 型燃油喷油泵,一种是

Bosch EPVE 型燃油喷油泵。

9 至2.000 in)

(1.99

惰齿轮轮毂的外径 .............. 50.70 至50.74 mm

(1.9961 至1.9976 in)

带滚柱轴承的惰齿轮轮毂的外

径.. 49.975 至49.988 mm (1.9675 至1.9680 in)

惰齿轮轮毂与惰齿轮轴承之间的间

隙......... 0.04 至0.10 mm (0.0016 至0.0039 in)

惰齿轮轴向间隙 ..................... 0.10 至0.20 mm

(0.004 至0.008 in)

带滚柱轴承的惰齿轮的轴向间

隙......... 0.10 至0.75 mm (0.0039 至0.0295 in)

最大容许轴向间隙 .............. 0.38 mm (0.015 in)

齿数.......................................................... 73

g00995886

图76

齿轮传动系

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34

技术规格部分

SCNR9778-02

水泵齿轮(未显示)与喷油泵齿轮 (1) 之间的齿

隙...... 0.073 至0.133 mm (0.0028 至0.0052 in)

动力输出装置(如果配备)与惰齿轮 (3) 之间的

齿隙... 0.112 至0.172 mm (0.0044 至0.0068 in)

带平衡器的发动机

g00996214

图77

机油泵的齿轮传动系

(4) 曲轴齿轮

曲轴齿轮的孔径 ............. 47.625 至47.650 mm

(1.8750 至1.8760 in)

g00996003

图78

曲轴轮毂的外径 ............. 47.625 至47.645 mm

(1.8750 至1.8758 in)

平衡器齿轮

(7) 带平衡器的机油泵惰齿轮

曲轴上齿轮的间隙 ............ 0.020 至+0.020 mm

(-0.0008 至+0.0008 in)

齿轮的齿数................................................ 44

惰齿轮的孔径 ................ 37.197 至37.212 mm

(1.4644 至1.4650 in)

齿数.......................................................... 34

(5) 机油泵惰齿轮

惰齿轮轮毂直径 ............. 37.152 至37.162 mm

(1.4627 至1.4631 in)

惰齿轮轴向间隙 ..................... 0.12 至0.27 mm

(0.0047 至0.0106 in)

机油泵惰齿轮轴承的内径.. 16.012 至16.038 mm

(0.6304 至0.6314 in)

机油泵惰齿轮轴的外径 ... 15.966 至15.984 mm

(0.6286 至0.6293 in)

(8) 带平衡器的机油泵的齿轮

齿轮的齿数................................................ 17

轴上的机油泵惰齿轮轴承的间

隙...... 0.028 至0.072 mm (0.0011 至0.0028 in)

机油泵齿轮 (8) 与惰齿轮(7) 之间的齿

隙.............. 0.097 至0.17 mm (0.0038 至0.0067 in)

机油泵惰齿轮的轴向间隙 .... 0.050 至0.275 mm

(0.0019 至0.0108 in)

(6) 机油泵齿轮

机油泵齿轮的齿数 ...................................... 17

齿隙值

惰齿轮(5) 与机油泵驱动齿轮 (6) 之间的齿

隙...... 0.046 至0.106 mm (0.0018 至0.0041 in)

机油泵惰齿轮 (5) 与曲轴齿轮 (4) 之间的齿

隙...... 0.095 至0.160 mm (0.0037 至0.0063 in)

惰齿轮 (3) 与曲轴齿轮 (4) 之间的齿

隙...... 0.064 至0.124 mm (0.0025 至0.0049 in)

凸轮轴齿轮 (2) 与惰齿轮 (3) 之间的齿

隙...... 0.052 至0.107 mm (0.0020 至0.0042 in)

喷油泵齿轮 (1) 与惰齿轮 (3) 之间的齿

隙...... 0.054 至0.109 mm (0.0021 至0.0043 in)

This document is printed from SPI². Not for RESALE


SCNR9778-02

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技术规格部分

i03874470

i03874468

flywheel

Flywheel housing

Four cylinder

g00631781

Fig. 80

(1) 螺栓

拧紧铸铁飞轮壳体螺栓至以下扭矩:

g00584712

Fig. 79

M10 “8.8” .................................. 44 N·m (33 lb ft)

M10 “10.9” ................................ 63 N·m (47 lb ft)

M12 “8.8” .................................. 75 N·m (55 lb ft)

M12 “10.9” .............................. 115 N·m (85 lb ft)

标准飞轮

(1) 飞轮齿圈

将飞轮齿圈加热至以下温度。 .. 250 °C (480 °F)

注: 不要采用氧乙炔火焰加热飞轮齿圈。

(2) 飞轮

三缸

在三缸发动机上装有背板。

(3) 螺栓

i03874451

Crankshaft pulley

拧紧飞轮螺栓至以下扭矩。 ... 105 N·m (77 lb ft)

非标准飞轮

注: 将非标准飞轮与曲轴上的销子对齐。

g00915497

Fig.81

标准皮带轮

注: 在安装以前先在螺栓的螺纹上涂上清洁的发动

机机油进行润滑。

This document is printed from SPI². Not for RESALE


36

技术规格部分

SCNR9778-02

风扇驱动壳体

(1) 拧紧曲轴皮带轮的三个紧固螺栓至以下扭

矩。 .................................... 115 N·m (85 lb ft)

拧紧将风扇驱动壳体固定到气缸盖上的紧固螺栓(图

中没有显示)至以下扭矩。 .......... 44 N·m (32 lb ft)

注: 再检查三个紧固螺栓 (1) 的扭矩两次。

(2) 止推块

壳体轴承孔内径................... 61.986 至62.005 mm

(2.4404 至2.4411 in)

(3) 曲轴皮带轮

轴承外径............................. 61.987 至62.000 mm

(2.4404 至2.4409 in)

非标准皮带轮

轴承过盈配合量..................... 0.014 至- 0.018 mm

(0.0006 至- 0.0007 in)

轴的外径............................. 25.002 至25.011 mm

(0.9843 至0.9847 in)

轴的最大允许轴向间隙 ............ 0.20 mm (0.0079 in)

i03021694

发动机提升支架

g01126584

图82

所有发动机都配置两个发动机提升支架。

(1) T 标记

(2) 对准标记

将每个发动机提升支架上的两个螺栓拧紧至以下

扭矩。 .................................. 44 N·m (32 lb ft)

注: 当将皮带轮安装到发动机上以后,皮带轮上的标

记(1 和2) 必须处于垂直位置。 发动机第一缸的活塞

必须处于上止点的位置。

i03874463

Alternator

i03874457

风扇驱动

12 伏和24 伏交流发电机

g00926178

图83

典型的风扇驱动

(1) 拧紧风扇紧固螺栓至以下扭矩。 ........... 22 N·m

(16 lb ft)

g00959541

拧紧将风扇皮带轮固定到轮毂上的紧固螺栓(图中

没有显示)至以下扭矩。 ............. 22 N·m (16 lb ft)

图84

典型的交流发电机

This document is printed from SPI². Not for RESALE


SCNR9778-02

37

技术规格部分

(1) 拧紧端子螺母“W” 至以下扭矩 .. 2 N·m (17 lb in)

(2) 拧紧端子螺母“D+” 至以下扭矩 ............ 4.3 N·m

(38 lb in)

(3) 拧紧端子螺母“B+” 至以下扭矩 ............ 4.3 N·m

(38 lb in)

拧紧皮带轮螺母(图上未显示)至以下扭

矩。 ........................................... 80 N·m (59 lb ft)

交流发电机皮带轮和曲轴皮带轮对准 ....... ± 2.4 mm

(0.0945 in)

旋转方向.................................................. 顺时针

极性 ..................................................... 负极接地

V 形皮带

注: 必须采用测量仪器检查 V 形皮带是否合格。 请参

阅《测试和调整》, “V 形皮带测试”,以便获取检测

V 形皮带所需测量仪器方面的信息。

V 形皮带张紧力 .............................. 535 N (120 lb)

i03874438

Starter motor

24 V starter motor

g00974968

图85

24 V 起动马达电气接头示意图

(1) 拧紧负极端子螺母至以下扭矩。 ........... 15 N·m

(11 lb ft)

(2) 拧紧正极端子螺母至以下扭矩。 ........... 21 N·m

(15 lb ft)

This document is printed from SPI². Not for RESALE


38

技术规格部分

SCNR9778-02

(3) 拧紧电磁阀端子至以下扭矩。 ............. 3.5 N·m

(31 lb in)

额定电压..................................................... 24 伏

吸拉电压..................................................... 16 伏

12 V 起动马达

g00977365

i03874432

图86

12 V 起动马达电气接头示意图

(1) 拧紧电磁阀端子至以下扭矩。 .. 8 N·m (70 lb in)

Glow plug

(2) 拧紧正极端子螺母至以下扭矩。 ............. 6 N·m

(53 lb in)

(3) 拧紧负极端子螺母至以下扭矩。 ............. 8 N·m

(70 lb in)

额定电压..................................................... 12 伏

吸拉电压...................................................... 8 伏

g00955714

图87

典型实例

(1) 拧紧缸盖上的预热塞 (3) 至以下扭矩 ..... 15 N·m

(11 lb ft)

拧紧安装在预热塞顶部的汇流板 (1) 的紧固螺母(2)

至以下扭矩 .................................. 2 N·m (18 lb in)

电压 .................................................. 12 或24 伏

This document is printed from SPI². Not for RESALE


SCNR9778-02

39

技术规格部分

注: 并不是所有发动机上都安装了预热塞。 在没有安

装预热塞的发动机上装配了螺纹塞。

This document is printed from SPI². Not for RESALE


40

Index section

SCNR9778-02

index

排气歧管......................................................... 14

四缸发动机................................................... 14

三缸发动机................................................... 14

摇臂轴............................................................. 9

主轴承轴颈...................................................... 29

主轴瓦......................................................... 29

交流发电机...................................................... 36

12 伏和24 伏交流发电机............................... 36

V 形皮带...................................................... 37

曲轴................................................................ 25

曲轴密封......................................................... 28

曲轴皮带轮...................................................... 35

非标准皮带轮............................................... 36

曲轴箱呼吸器................................................... 21

发动机型号DK 和DJ ......................................... 22

凸轮轴............................................................. 14

凸轮轴轴承...................................................... 15

water

水泵................................................................ 23

水温调节器和壳体............................................ 22

水温调节器................................................... 23

活塞冷却喷嘴................................................... 32

活塞冷却喷嘴的对准 ..................................... 32

活塞和活塞环................................................... 31

活塞............................................................. 31

涡轮增压器...................................................... 13

四缸发动机................................................... 13

三缸发动机................................................... 13

Knife

前壳体和盖...................................................... 32

发动机提升支架 ............................................... 36

发动机机油压力 ............................................... 18

发动机机油旁路阀............................................ 19

安装在机油泵中............................................ 19

安装在平衡器中............................................ 19

发动机机油泵................................................... 16

带平衡器的四缸发动机 .................................. 16

不带平衡器总成的四缸和三缸发动机 .............. 18

发动机机油滤清器............................................ 16

旋装式机油滤清器......................................... 16

可更换滤芯................................................... 16

发动机油底壳................................................... 20

前部密封胶................................................... 20

后部密封胶................................................... 20

铸铁油底壳................................................... 21

发动机设计...................................................... 4

四缸发动机................................................... 4

三缸发动机................................................... 4

燃油输油泵...................................................... 8

燃油高压油管................................................... 5

Head

目录................................................................ 3

缸体................................................................ 23

四缸发动机................................................... 23

三缸发动机................................................... 24

缸盖................................................................ 11

四缸发动机................................................... 11

三缸发动机................................................... 12

四缸发动机................................................... 12

三缸发动机................................................... 12

缸盖气门......................................................... 10

mouth

喷油器............................................................. 8

hand

技术规格部分................................................... 4

挺杆总成......................................................... 9

排气机构罩盖................................................... 9

四缸发动机气门室罩 ..................................... 9

三缸发动机气门室罩 ..................................... 10

起动马达......................................................... 37

24 V 起动马达............................................... 37

12 V 起动马达............................................... 38

This document is printed from SPI². Not for RESALE


SCNR9778-02

41

Index section

连杆................................................................ 29

连杆轴承轴颈................................................... 29

in

重要安全事项................................................... 2

预热塞............................................................. 38

风扇驱动......................................................... 36

风扇驱动壳体............................................... 36

飞轮................................................................ 35

非标准飞轮.................................................. 35

飞轮壳............................................................. 35

四缸............................................................. 35

三缸............................................................. 35

bone

高压油泵(Bosch EPVE 仅用于1104 发动机上)... 6

高压油泵 (Delphi DP210 DPA 和DPG 燃油喷油

泵)........................................................................ 5

Delphi DP210..................................................... 5

Delphi DPA ........................................................ 5

Delphi DPG........................................................ 6

高压油泵(Delphi STP).......................................... 7

齿轮总成(前) ......................................................... 33

带平衡器的发动机......................................... 34

This document is printed from SPI². Not for RE

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