‘SERIES 40 SERVICE MANUAL 8.4 CAMSHAFT, TAPPETS AND PUSH RODS NOTE: Refer to the appropriate manual sections for removal instructions for fuel, turbocharger, cylinder head and front cover items. 1. Remove roller tappets and roller tappet guides from their bores. Refer to FIGURE 8-16. NOTE: ‘Mark the tappets as to location in the engine block, so they can be returned to their original position. 1. Roller Tappets 2. Roller Tappet Guide FIGURE 8-16 carga wre rete. a VE) ‘ber oss DETROTT DES CORPORATION BsROCKER ARM ASSEMBLY, CAMSHAFT, TAPPETS & PUSH RODS CAMSHAFT, TAPPETS AND PUSH RODS EG-2345 1. Rear Half Front Cover 6. Lower Idler Gear/Crankshaft Timing Marks 2. Fuel Injection Pump Timing Gear 7. Crankshaft 3. Upper Idler Gear 8. Pressure Regulator Valve (80 Ib/in.2) 4, Upper Idler/Lower idler Gear Timing Marks 9- Camshaft Gear 5. Lower Idler Gear 10.Camshatt FIGURE 8-17 Align Gear Train Timing Marks 2. Refer to FIGURE 8-17 for location of 3. Remove the fuel injection pump timing gear gears and timing marks, as outlined in Section 14 “Fuel Injection { Pump.” A etemates nti tune eto rate Gs 104) 8.16 (058406 Tope DETRONT DIESEL CORPORMIONCAMSHAFT, TAPPETS AND PUSH RODS 1. Camshaft Gear 2. Access Hole/bolt FIGURE 8-18 TON 1. Camshaft Assembly 2. Crankcase FIGURE 8-19 ‘Antena nei nage ston reten (ae 104) steo 190s DETRO DIESEL CORPORATION ‘SERIES 40 SERVICE MANUAL 4, Rotate the engine so that timing marks on lower and upper idler gears, crankshaft and camshaft gear are aligned. NOTICE: Prior to removing any gear, mount a magnetic base dial indi- cator onto the engine for gear backlash and end play. Refer to Section 11, “Timing Gear Train And Front Cover” for instructions. 5. Remove idler gears as described in Section 11, “Timing Gear Train and Front Cover.” NOTE: When the engine Is mounted In a turn-over stand, rotate engine so front of engine is facing up (engine in vertical position). This position allows for easy removal of cam- shaft assembly. 6. Rotate the camshaft gear so the access holes in the gear align with the thrust plate retain- ing bolts. 7. Remove the two thrust plate bolts and wash- ers. Refer to FIGURE 8-18. 8. Remove the camshaft from the crankcase by lifting the assembly straight up. Refer to FIGURE 8-19. NOTE: This method reduces the risk of damaging the camshaft journals and/or bushings. 8.47‘ROCKER ARM ASSEMBLY, CAMSHAFT, TAPPETS & PUSH RODS CAMSHAFT, TAPPETS AND PUSH RODS 8.4.1 Camshaft Disassembly NOTE: The camshaft gear is a shrink fit and must be pressed off. 1. Using a suitable arbor press, press camshaft, from the gear. 2. With gear removed, remove woodruff key and the thrust plate. 8.4.2 Camshaft Cleaning and Inspec- tion 1. Wash the camshaft in a suitable solvent us- ing a soft bristle brush. 1. Camshaft Lobe 2. Visually inspect camshaft. If any lobes are 2. Micrometer scuffed, scored or cracked, replace camshaft. 3. Evaluate camshaft journal and lobe condi- FIGURE 8-20 tion using a micrometer. Refer to FIGURE 8-20. To check camshaft lobe wear using a micrometer: a, Measure across (A-C) and across (B-D). b. Subtract (B-D) from (A-C). This will give cam lobe lift. (See “‘Specifica- tions”.) Replace camshaft when cam lobe wear exceeds specifications. 4, Visually inspect thrust plate for wear, cracks or distortion. Use a micrometer to measure thrust plate thickness (see “Specifications”). Replace thrust plate if worn, damaged or if excessive end play is measured. 5. Visually inspect camshaft gear for worn or damaged teeth and gear bore for damage. Replace gear if any of these conditions exist Repeat for each cam lobe. NOTE: If camshaft gear backlash exceeds specifications, replace the gear. aac 818 ‘S800 Isee DernorT DIESEL CORPORATIONSERIES 40 SERVICE MANUAL ‘CAMSHAFT, TAPPETS AND PUSH RODS 8.4.3 Camshaft Reassembly CAUTION ea Se eh RC eee Rect Reassemble the camshaft, thrust plate and camshaft gear as follows: 1. Support the camshaft in an appropriate arbor press. 2. Place the thrust plate on the keyway end of the camshaft against the bearing journal. 3. Insert the woodruff key into the keyway. 4, Heat the camshaft gear in an oven, to approximately 400 F (206°C). ‘ NOTE: Use a thermomelt stick, available at any welding supply house, to determine temperature. 5. Press gear against shoulder on camshaft with timing mark pointed outward as shown in FIGURE 8-21. FIGURE 8-21 Athan mo cge wn oe.) (Geev0 os DermoT? BSE: CORPORATION e19ROCKER ARM ASSEMBLY, CAMSHAFT, TAPPETS & PUSH RODS ‘CAMSHAFT, TAPPETS AND PUSH RODS 8.4.4 Camshaft Bushing Inspection : Inspect the four camshaft bushings for wear and proper running clearance as follows: 1, Measure camshaft bushing journal diameter usitig a'micromieter. Measure at two loca- tions (at 90°) and record the readings. . Using a telescoping gauge and micrometer, measure the camshaft bushing I.D. with bushing installed in the crankcase). Record the readings. 3. Subtract the readings obtained in steps 1 and 2, to determine running clearance. y 4, If maximum allowable running clearance is exceeded (see “Specifications”), replace the camshaft bushings using the camshaft bush- ing remover and installer (J39537). NOTICE: When servicing the camshaft bushings, the crankshaft and main bearing must be removed from the crankcase to avoid de- bris contamination. Areata note tare was t08 Fe 24) 8-20 ‘Seesce 19s DeTROTT DIESEL CORPORATION‘SERIES 40 SERVICE MANUAL CAMSHAFT, TAPPETS AND PUSH RODS 8.4.5 Camshaft Bushing Removal (Puller screw extension Expanding collet 1. Use the camshaft bushing service set Polling nut (139537) to remove the camshaft bushings. 339537 includes: Q) Back-up nut Puller screw Thrust bearing Expanding mandrel Refer to FIGURE 8-22. FIGURE 8-22 are sete ure ete. 14) (68€4¢6 19s DETRONT DIESEL CORPORATION 821ROCKER ARM ASSEMBLY, CAMSHAFT, TAPPETS & PUSH RODS CAMSHAFT, TAPPETS AND PUSH RODS. NOTE: NOTICE: Because of the different size out- The four camshaft bushings have side diameters of the bushings, the same inside diameter, but the the order of removal is limited as outside diameter and widths of pc pl ltd olga each bushing are different, as is rear bushings jonirecneye! the crankcase bore into which ani oniaciesieaitiad each bushing fits. Refer to the eae ree ce chart below. - Camshaft Bushing Chart BUSHING BORE BUSHING BUSHING DIA.IN BUSHING POSITION on. wipTH 2.5088 in. Front 2.5050 in, 1.00 in, Intermediate’ 2.4865 in, 0.708 in. Front 2.4850 in. 0.889 in, Intermediate’ 2.4665 in. 2.4620 in. 0.7091n, Rear 2.4650 in. 2.4608 in. 0.689 in, 2.4485 in. 2.4420 in. 0.740 in, Rear 2.4450 in 2.4405 in. 0.660 in. Atnematen nb care betes Ys 8) 822 ‘SeE4ee 1004 DETNOMT DIESEL CORPORATIONSERIES 40 SERVICE MANUAL CAMSHAFT, TAPPETS AND PUSH RODS 2. Using the camshaft bushing remover and installer tool (J39537), select the proper size expanding collet and back-up nut and as- semble onto the expanding mandrel. With the expanding collet collapsed, install the collet assembly into the camshaft bushing to be removed and tighten the back-up nut onto the expanding mandrel until the collet fits the camshaft housing. Refer to FIGURE 8-22 and FIGURE 8-23, 3. Assemble the puller screw and extension, if necessary, and install onto the expanding mandrel. Tighten the pulling nut against the thrust bearing and pulling plate to remove the camshaft bushing. NOTE: Be sure to hold the end of the pull- er screw with a wrench to prevent it from turning, when tightening the pulling nut. 4, Repeat the procedure for each bushing. NOTE: To remove the front bushing, install the puller screw from the rear of the crankcase. All other bushings are removed by going through the front of the crankcase. 8.4.6 Crankcase Bushing Bore Inspec- tion 1, Visually inspect each bushing bore in the crankcase for burrs or debris that could dam- ‘age new bushings when they are installed. . Remove any burrs and clean bores thorough- ly before installing new camshaft bushings. FIGURE 8-23 x ‘Arman nt edge wo ote. 04) a GSEeL0 1st DeTROT DIESEL CORPORATIONROCKER ARM ASSEMBLY, CAMSHAFT, TAPPETS & PUSH RODS CAMSHAFT, TAPPETS AND PUSH RODS ‘TURN BACKUP 8.4.7 Camshaft Bushing Installation 1, Identify each bushing by its outside diame- ter. Refer to the “Camshaft Bushing Chart?” v . Lubricate new camshaft bushings as well as crankcase bushing bore with clean engine oil. » . Install new bushing onto expanding collet and tighten collet by turning backup nut un- til bushing is held securely. Refer to 4. Bushing FIGURE 8-24, 2. Expanding Collet a |. Mark oil hole location on back-up nut of pounela 34 installation tool to aid in alignment of bush- ing and crankcase oil holes. Refer to FIGURE 8-25. NOTE: This step must be repeated for each bushing Installed. 5. Install rear intermediate bushing through front of crankcase, then pull it into place at rear of crankcase by turning pulling nut on puller screw. Remove tool and inspect oil hole alignment. NOTE: 1. Bushing oll Hole The bushings must be installed in 2. Alignment Mark, the proper order because of the different size outside diameters of FIGURE 8-25 the bushings. A recmaten nth cange test an, (4) a4 £476 Toes DetnOnt DIESEL CORPORATIONSERIES 40 SERVICE MANUAL CAMSHAFT, TAPPETS AND PUSH RODS. 6. Install front intermediate bushing next. 8. The rear camshaft bushing must be pulled Install through front of crankcase and pull into place from front of crankcase. into place from rear. Refer to NOTICE: All bushing oll holes must be in FIGURE 8-26. alignment with oll holes In crank- 7. Next install front camshaft bushing by pull- pore: ing it into place from rear. Atign bushing with the correct bore in the crankcase. Assemble the pulling plate, thrust bearing and pulling nut on the puller screw. Then pull bushing into place. FIGURE 8-26 Locus arti SeaSinesemon n° aROCKER ARM ASSEMBLY, CAMSHAFT, TAPPETS & PUSH RODS ‘CAMSHAFT, TAPPETS AND PUSH RODS 8.4.8 Tappet Inspection Visually inspect all roller tappets and rollers for pitting, roughness and free rotation of roller. Check dimensionally, if “Specifications” are exceeded replace the tappet. 8.4.9 Push Rod Cleaning And Inspec- tion 1. Thoroughly clean each push rod using a suitable solvent and dry using filtered com- pressed air. 2. Visually inspect each rod for wear at ends. Replace as required. 3. Check all push rods for straightness by rol- ling on a flat surface, FIGURE 8-27. Re- place any rod which is bent. 4. Check push rod run-out. If “Specifica- tions” are exceeded, replace the rod. FIGURE 8-27 ‘A atone rg rst rt, Ge 18) £26 (SS2676 Tos Bertone se. ConroRATOnSERIES 40 SERVICE MANUAL 8.5 CAMSHAFT, TAPPET AND PUSH ROD ASSEMBLY AND INSTALLATION 1. With the engine in the vertical position, Iu- bricate the camshaft and the camshaft bush- ings using clean engine oil. . Gently slide camshaft assembly into crank- case. Be careful not to damage camshaft bushings, 3. Align camshaft gear so bolts can be inserted through gear access holes into thrust plate. Tighten each bolt to special torque value. Refer to FIGURE 8-28. 4, Install idler gears as described in Section 11 “Timing Gear Train and Front Cover?” FIGURE 8-28 5. Align gear train timing marks. Refer to FIGURE 8-28. 6. Check camshaft gear backlash and camshaft end play as described in Section 11 “Timing Gear Train and Front Cover”. Specifications must be met. 8.5.1 Tappets Install the roller tappets and guides into their original bores, unless new tappets are used. 8.5.2 Push Rods Install push rods with the cup end up. Refer to Section 8. v aman mc charge not a Fs) deter ooeDeTnon Bisel CORPORATION 8-27ROCKER ARM ASSEMBLY, CAMSHAFT, TAPPETS & PUSH RODS aa ‘At erat st a onge wa en, (a 88) (Stes te DeTnOrT DESL CORPORATIONSERIES 40 SERVICE MANUAL 9 CONNECTING RODS, PISTONS, RINGS AND SLEEVES 9.1 CONNECTING RODS, PISTONS, RINGS AND LINERS EXPLODED VIEW .. 9-3 9.2. SPECIFICATIONS . 9-5 92.1. Special Torque Values - 9-7 92.2 Special Tools... 9-8 93 CONNECTING RODS, PISTONS, RINGS AND D LINERS DISASSEMBLY «2.20 .0--0.-.. 9-9 93:1 Piston and Rod Assembly Removal 9-9 93.2 Ojlinder Liner Removal .... 9-12 933 CONNECTING ROD, PISTON & RING DISASSEMBLY - 9-12 93.4 Cylinder Liner Disassembly . 9-13 93.5 Cleaning Connecting Rod, Piston & Rings .. 9-13 93.6 Inspect Cylinder Liners & Pistons «..... 9-14 937 : 9-16 93. ‘i : 9-17 93.72 Connecting Rod Bend and Twist... 9-18 93.8 Inspect Pistons Pins ...........20s0. 9-19 93.9 Inspect Cylinder Liners ...... : 9-19 9.3.10 Method One ~ Telescoping Gauge Method . 9-20 93,11 Method Two ~ Dial Bore Gauge Method 9-21 93,12 Method Three — Feeler Gauge Method . 9-22 933.13 Bearing Fitting Procedure 9-23 93.14 Oylinder Liner Fitting Procedure 9-26 93.14.1 Surface Gauge Method 9-26 9.3.14.2 Depth Micrometer Method . 9-26 93.15 Setting the Depth of the Cut 9-28 9.3.15. Method One ~ Use Graduated Marks On Tool . 9-28 93.15.2 Method Two ~ Use Feeler Gauge .... 9-29 9.4 REASSEMBLY OF CONNECTING RODS, PISTONS & RINGS » 9-32 94.1 Cylinder Liners... 9-34 9.4.2, Piston & Rod Assembly 9-35 9413 Connecting Rod Bearing Tnscrs & Cops 9-36 944 Priming The Lubricating System 9.44.1 Preferred Method . 9442 Alternate Method .. 9.45 Engine Run~in Procedure ‘Athena sti care tent rt. sv) saeer isp BerRorr DSI CORPORATION o4SERIES 40 SERVICE MANUAL 9.1 CONNECTING RODS, PISTONS, RINGS AND LINERS EXPLODED VIEW €0-1026 1. Piston Ring (Top Compression) (6) 7. Piston Pin Bushing (6) 2. Piston Ring (Intermediate Compression) (6) 8. Connecting Rod Bearing (6) 3, Piston ring (Oil Regulating) (6) 8. Connecting Rod And Cap (6) 4. Piston Pin Retainer (12) 10. Bolt (12) 5. Piston Pin (6) 11. Sloeve Seals 6. Piston (6)_ 12. Sleeve (6) FIGURE 9-1 Connecting Rods, Pistons, Rings and Sleeves, ‘At emt ef charg tere.) {E446 190s DETROM DIESEL CORPORATION 93SERIES 40 SERVICE MANUAL. — 9.2 SPECIFICATIONS DIMENSION VALUES CONNECTING RODS: Center-to-Center Distance between Connecting Rod Bearing Bore and Piston Pin Bushing ..............5 8.638 in. (219.4 mm)/ 8.642 in. (219.5 mm) Bushing Bore Diameter (Pin End) ...........-.00 005 1.9235 in. (48.8 mm)/ 1.9255 in, (48.9 mm) Piston Pin Bushing I.D. (Installed) ..........-.2.005 1.8257 in, (46.3 mm)/ 1.8260 in. (46.3 mm) 3.3516 in. (85 mm) 0.002 in. (0.05 mm) 0.005 in, (0.013mm) 3.1533 in, (80.094 mm) 3.1535 in. (80.099 mm) Bearing Running Clearance .......0...000sceee0 es 0.0018 in. (0.046 mm) 0.0050 in. (0.127 mm) Bearing Bore Diameter (Crankshaft End) Maximum Out-of-Round .... Maximum Taper/Inch . Connecting Rod Bearing L.D. (Installed) . Maximum Permissible Bearing Running Clearance (Before Reconditioning) ............2..e022008+ 0.007 in, (0.18 mm Connecting Rod Side Clearance on Crankshaft . . . 0.012 in. (0.30 mm) Maximum Permissible Side Clearance on Crankshaft ... 0.0165 in. (0.425 mm) Connecting Rod Alignment Twist... fee eeeeeeeeeeeeeceseeeeees 0,002 in, (051 mm) Bend ..........0ccseeeeeeeeeeeeseeeseeesereeses 0.0015 in, (0.42 mm) PISTONS: Running Clearance between Piston and Cylinder Liner(6.7L & 7.6L) 0.0025 in. (0.064 mm)/ 0.0045 in. (0.081 mm) (Measured 90° from pin bore and Skirt Diameter 3.174 4.297 in. (109.14 mm)/ in. (80.6mm) below bottom ring land) (6.7L) . 4.298 in. (109.17 mm) (Measured 90° from pin bore and Skirt Diameter 3.271 4.297 in. (109.14 mm in, (83mm) below bottom ring land) (7.6L) . . ++ 4.298 in. (109.17 mm) Number of Rings per Piston ‘A rsmaion mt care wire. Yo) Getet0 19 BeTROTT DIESEL CORPORATION osCONNECTING RODS, PISTONS RINGS, AND SLEEVES SPECIFICATIONS ; i DIMENSION VALUES Piston Ring Groove Widths: ‘Top Compression Ring - Measure over 0.1150 in. gauge pins (6.7L & 7.6L) . 4.3118 in, (110 mm) ‘Top Compression Ring — Measure over 0. 1150 in. gauge pins (8.7L) 4.5015 in. (114 mm) (Full Keystone) (6.7L & 7.6L) 4.2794 in. (109 mm) (Full Keystone) (8.7L) 4.4676 in. (113 mm) Intermediate Compression Ring — Measured over 0.1150 in. gauge pins (6.71. & 7.6L) Measured over 0.1150 in. gauge pins (8.7L) .. 4.3168 in. (110 mm) 4.6050 in. (118 mm) Full Keystone) (6.7L & 7.6L) . 4.2844 in. (109 mm) (Full Keystone) (8.7L) ....... 4.5712 in. (116 mm) Side Clearance: Oil Control Ring 0.002 in. (0.0508 mm)/ 0.0040 in. (0.1016 mm) PISTON RINGS - COMPRESSION: ( Number of rings perpiston .............000000000 2 ‘Type (face and finish): Full Keystone (barrel faced) ~ Plasma Coated Full Keystone (taper crown) — Chromeless Ring Gap with New Liner: Top Ring es 0.014 in, (0.040 mmy/ 0.026 in. (0.066 mm) litermedinte Rig ee ee 0.065 in. (1.65 mm)/ 0.075 in. (1.91 mm) PISTON RINGS - OIL CONTROL: Number of Rings Per Piston . 1 Type One Piece Slotted — Chrome Ring Gap (6.7L & 7.6L) 0.012 in. (0.305 mm)/ 0.022 in. (0.559 mm) MMe MO AR eu Cie CieeCiieey 0.014 in, (0.356 mm)/ i 0,026 in. (0.660 mm) oman nate charge tet an. 18) 96 (S$E7o tt Deter DSL CORPORATION‘SERIES 40 SERVICE MANUAL SPECIFICATIONS DIMENSION VALUES PISTON PINS: 1,8249 in, (46.3 mmy 1.8251 in. (46.3 mm) 3.480 in. (88.4 mm)/ 3.490 in. (88.6 mm) 0.0006 in, (0.015 mm)/ 0.0011 in. (0.028 mm) Maximum Permissible Clearance in Rod, before replacing . CYLINDER LINERS: PRUNE AM cle RE NPRM eget eCee See 0.0006 in. (0.015 mm/ 0.0011 in, (0.028 mm) 0.003 in. (0.08 mm) ‘Maximum Permissible Clearance in Piston, before replacing . Inside Diameter (ew) .. . 0.003 in. (0.08 mm) 4.3005 in. (109.233 mm)/ 4.3015 in. (109.258 mm) ‘Maximum Permissible Diameter Liner Wear, at Top of Ring Travel before Replacement (liner Taper) .... 0.004 in. (0.10 mm)/0.350 in, (8.89 mm) Inside Diameter (New) . . 4.5895 in, (116.6 mm)/ 4.5905 in. (114.5 mm) Counterbore Dimension in Crankease .............. 0.348 in, (8.84 mm) Maximum Allowable Variation of Counterbore Depth (Between Four Points) ..........ecccseeeeeeees 0.001 in. (0.025 mm) Maximum Cylinder Liner Counterbore Allowable Depth (used with shim kit) ...... in, (8.97 mmy/0.413 in. (10.49 mm) Flange Thickness ... . (0.13 mm) 0.0352 in. (0.894 mm) Protrusion above Crankcase .......... 0.00005 «+ 0,002 in. (0.05 mm) 1 Special Torque Values ‘Connecting Rod Bolts 115 Ib-ft (156 N-m) oman et ers wt rte. Geter nse DETROMT DEEL CORPORATION oFCONNECTING RODS, PISTONS RINGS, AND SLEEVES De ee eee SPECIFICATIONS 9.2.2 Special Tools Tool No. Description PT2200-55 Counter Bore Tool PT2250A . Counter Bore Cutter Head PT6410.. Cylinder liner Puller Piston Groove Wear Measuring Tool Piston Ring Compressor (8.7L) 329511 141166 At rtemate neha cere bos reteset) (e€es0 I9o4 DETROMT DIESEL CORPORATIONSERIES 40 SERVICE MANUAL 9.3 CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 02007 i freee a 1. Connecting Rod Bolt (12) 2. Connecting Rod Cap (6) 9. Crankcase FIGURE 9-3 Al benate het cane nos ete (Ree 136) {E440 1904 DETROMT DIES. CORPORATION Remove the following: Fuel injection lines (high pressure) Fuel leak-off lines (low pressure) Aneroid tube =| Valve cover/Intake manifold Turbocharger oil inlet and oil drain tubes Valve lever assembly Cylinder head assembly Vibration damper Oil pan Oil pick-up tube Refer to the appropriate manual section for detailed removal procedures. 9.3.1 Piston and Rod Assembly Removal 1, Using a razor knife, scrape the carbon ridge from the top of the cylinder liner. Refer to FIGURE 9-2. NOTICE: The carbon ridge must be re- moved before removing the pis- ton and rod assembly. This re- duces the chance of piston ring land damage during removal. 2. Loosen the connecting rod bolts using a socket and breaker-bar, FIGURE 9-3. 3. Remove the bolts by hand. NOTE: The bolts should turn out of the connecting rod freely. If binding exists, check thread condition carefully.CONNECTING RODS, PISTONS RINGS, AND SLEEVES CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 4, Remove the connecting rod cap and bearing insert. Refer to FIGURE 9-4, 5. Remove the piston and connecting rod as- semblies as follows: a. Push the piston and rod assembly from the cylinder bore using a wood or plastic handle. Refer to FIGURE 9-5. 1. Connecting Rod Cap (6) 2. Crankease 3. Crankshatt FIGURE 9-4 4, Connecting Rod 2. Crankcase 3. Hammer FIGURE 9-5 Aptana nett car mien ten, (8) o410 (Sean isos DETROIT DIESEL CORPORATION‘SERIES 40 SERVICE MANUAL CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY b. Once the piston rings are free of cylinder bore, the assembly can be removed from the top of the crankcase. Refer to FIGURE 9-6. . Rotate engine and remove all of the re- maining pistons as outlined. Be sure to replace each bearing cap on its respective connecting rod after removal of the pis- ton from the engine. Identify the connecting rod and piston assemblies upon removal so they can be reinstalled in their respective cylinder bores. Se 1. Connecting Rod/ Piston Assembly 2. Crankcase FIGURE 9-6 {emacs nto arg ote, SECC ia DeTROTT BSE CORPOMTON sal(CONNECTING RODS, PISTONS RINGS, AND SLEEVES CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 9.3.2 Cylinder Liner Removal Use the liner puller PT6410 to remove the cylinder liners as follows: (Refer to FIGURE 9-7). NOTICE: Prior to installing the puller, bar the engine over so the crankshaft Jour (low point) of its travel. This pre- vents possible damage to the Journal by the puller lifting jaws during puller installation. 1. Forcing Nut . Position the puller in the liner and spread the 2. Liner Puller lifting jaws so the tangs grip the bottom of 3. Lifting Bridge and liner the liner. 4, Cylinder Liner 5. Lifting Bridge 2. With the lifting bridge firmly on the crank- 6, Lifting Jaws case top deck, turn the forcing nut to break i the cylinder liner loose from the crankcase. FIGURE 9-7 3. Lift the liner and puller from the crank- case. 4. Remove liner from puller and mark liner with its cylinder bore number, also mark lin- et position in block for purposes of inspec- tion and reassembly. 9.3.3 CONNECTING ROD, PISTON & RING DISASSEMBLY 1. Using pliers, remove the two piston retain- ing rings. Refer to FIGURE 9-8. FIGURE 9-8 tonne at, (1) w12 asCee spe Beton DIESE. CORPORATIONSERIES 40 SERVICE MANUAL CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 2z oats 1. Connecting Rod 2. Retaining Ring (2) 3, Piston Pin 4. Piston FIGURE 9-9 1. Ring Expander 2, Top Ring 3. Intermediate Ring 4, Oll Control Ring 5. Retaining Ring (2) 6. Piston 7. Connecting Rod 8. Piston Pin FIGURE 9-10 Athlete uth canon tat non, Ga ot) (SEA tone Demon? DEL CORPORATION. 2. Remove the piston pin from its bore, by hand. Refer to FIGURE 9-9. Then separate the connecting rod from the piston. 3. Use a piston ring expander tool to remove the piston rings. Remove the top ring first, then the intermediate ring and the oil control ting. Refer to FIGURE 9-10. 4, Tag or mark the components with the cylin- der number from which they were removed, so they may be reinstalled in their respective cylinders once inspected. 9.3.4 Cylinder Liner Disassembly 1. Use a pick to remove two (2) O-rings at the lower counterbore area of each cylinder liner, 2. Discard the O-rings. 9.3.5 Cleaning Connecting Rod, Piston & Rings 1, Clean the aluminum pistons using a soap and water solution; soak and then clean pis- ton, using a non-metallic brush, NOTE: Never use a caustic solution or a wire brush for cleaning the alumi- num pistons. 2. Alll piston ring grooves must be cleaned thoroughly. Be sure the two drilled or cast oil holes in the oil ring groove are open. 3. The following disassembled components may be cleaned using a suitable solvent: a. Piston rings b. Piston pins c. Piston pin retainers d. Connecting rods e. Connecting rod caps f. Connecting rod bolts 43CONNECTING RODS, PISTONS RINGS, AND SLEEVES CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 4, Clean all rod bolt holes and threads. 5. Clean the oil hole at the top of the rod. Make sure it is not blocked. 9.3.6 Inspect Cylinder Liners & Pistons 1, Soak the cylinder liners in a soap and water solution and clean thoroughly using a non— metallic brush. 2. Dry with filtered compressed air. . Visually inspect the pistons for scuffed or scored skirts and cracked or worn lands, Replace the pistons as required. NOTICE: These engines use full keystone compression rings (first and se- cond groove) and a rectangular oil control ring. The piston ring groove configuration corre- sponds to the shape of the piston ring (FIGURE 9-11). The key- stone compression ring grooves are measured over gauge pins to determine wear. The rectangular oll control ring groove does not use gauge pins, but side clear- ance to determine piston ring groove wear. 4, To check top and intermediate compression ring groove widths for wear install the 0.1150 in. (2.921 mm) gauge pins from the piston groove wear gauge pin set (Tool No. 329511), into the groove to be measured. 1. Piston 2. Top Ring 3. Intermediate Ring 4, Oil Control Ring FIGURE 9-11 Figure Refer to FIGURE 9-11. NOTE: 1. Micrometer Gauge pins must be parallel 2. Pleton Ring Gauge 5. Measure the piston diameter over gauge pins 3. Platon using an outside micrometer, FIGURE 9-12, FIGURE 9-12 o44 SSz0TS To BEtworT OSE. CORPORATION‘SERIES 40 SERVICE MANUAL CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 6. Ifthe measurement over the gauge pins is NOT within specifications, excessive piston groove wear exists and the piston must be replaced with new. Refer to “Specifica- tions”. 7. Check the rectangular oil control ring groove for side clearance as follows: a, Using a new ring, place the outer edge of the ring in the oil control ring groove. b. Roll the ring, in its respective groove, entirely around the piston. Make sure the ring is free in the groove. 1. Piston c. With a feeler gauge check the side clear- 2, Olt Control Ring ance of each oil control ring in its re- 23, Foaler Gauge spective groove, FIGURE 9-13. d. Excessive side clearance indicates ring FIGURE 9-13 groove wear and requires piston replace- ment. . Check piston to cylinder liner running clear- ance, as follows: a. Measure and record the piston skirt di- ameter. With the piston at room tempera- ture, place an outside micrometer 1.080 in, (27.43 mm) below the bottom land of the oil control ring, 90 degrees from the pin bore. Refer to FIGURE 9-14, Measure cylinder liner inside diameter, refer to “Cylinder Liner Inspection” later in this section for the procedure. Record the reading. .. Subtract the piston skirt diameter from ace the cylinder liner 1.D. The resulting di- mension is the piston to cylinder liner running clearance, s 2. Piston { . If running clearance is not within “Spec : FIGURE 9-14 ifications”, replace the piston. Aton ee vgs vo nei, er 0) ‘SeE4d ioe DETROFT DESEL CORPORATION ousCONNECTING RODS, PISTONS RINGS, AND SLEEVES CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY NOTE: Faulty rings cannot always be de- tected by visual inspection. When a piston Is removed from a cylin- der, replace the piston rings. 1. Visually inspect NEW rings for cleanliness. 2. Prior to installing the rings on the piston, check each ring for proper gap as follows: a. Push the ring down into the cylinder bore making sure the ring is square with the cylinder wall. Measure the gap between the ends of each ring with a feeler gauge as shown in FIGURE 9-15. Refer to “Specifica- tions” for ring gap. Discard any used ring which does not meet the specifica- tions. s 9.3.7 Inspect Connecting Rods 1. Visually inspect the connecting rod bolts for nicks or damage. Pp . Visually inspect the rod and cap mating sur- faces for fretting. Replace as required. 3. Inspect the connecting rod piston pin bush- ing for wear using a telescoping gauge and an outside micrometer, Measure the pin bore at two locations 90 degrees from one another and record the readings. Refer to FIGURE 9-16. NOTICE: When lubricated with clean en- gine oil, the bolts must screw into the rod by hand. If resis- tance is met, clean the rod threads again and try a new bolt. If a new bolt does not screw in freely, the rod must be discarded, Rod threads cannot be retapped. 9-16 PISTON RING ‘TOBE CHECKED FIGURE 9-15 1, Micrometer 2. Telescoping Gauge 3. Connecting Rod FIGURE 9-16 ‘emanates urge morte ie 8) (E406 19 DETROIT NESE CORPORATION‘SERIES 40 SERVICE MANUAL CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 4. Refer to “Specifications”. If piston pin out bearing insert. Tighten bolts to specified bushing LD. exceeds minimum specifica- torque value, don, it is wom and must be replaced, 2. Use an inside micrometer or a dial bore ‘gauge and measure connecting rod in three eee aan locations as shown in FIGURE 9-17. Check connecting rod bearing bore for 3, }. If the difference between point “B” and av- “out-of-round” as follows: erage of points ““A” and “C” ([A + C] +2), 1, Lubricate connecting rod bolts with clean exceeds “Specifications”, rod must be re- engine oil and assemble the cap to rod with- _ placed. MEASURING LOCATIONS 1. Connecting Rod 2. Inside Micrometer FIGURE 9-17 ‘rience net args wrt ae (Gstare i Bermorr sen COMPORATIN orCONNECTING RODS, PISTONS RINGS, AND SLEEVES CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 4, Measure connecting rod bearing bore taper (FIGURE 9-18), by measuring bore LD. on cach side of bearing bore. Record the read- ings. The difference between two readings is bore taper. (See “Specifications.”) Replace rod as required. 5. With connecting rod cap removed, visually inspect surface finish of connecting rod bearing bore. The bore must be smooth and free of scoring, nicks or burrs. Replace as required. 9.3.7.2 Connecting Rod Bend and Twist Often engine component wear patterns canbe 4, Micrometer identified and used to diagnose a problem. ee ge Some common examples of connecting rod i coc aa ‘wear patterns include: 1. A shiny surface on edge of piston pin bush- FIGURE 9-18 ing usually indicates that a connecting rod is bent or piston pin hole is not in proper rela- tion to piston skirt and ring grooves. 2. Abnormal connecting rod bearing wear can be caused by either a bent connecting rod. or a tapered connecting rod bore. 3, Twisted connecting rods will not create an easily identifiable wear pattern, but badly twisted rods will disturb action of entire pis- ton, rings, and connecting rod assembly and may be the cause of excessive oil consump- tion. If any of these conditions exist, check the connecting rods for bends or twists using a suitable alignment fixture. Follow the instructions of the fixture manufacturer. If bend or twist exceeds “Specifications”, replace the rod. 8 Arla rte. Fe 4) tie ‘S844 1904 DETROM DIESEL CORPORATION‘SERIES 40 SERVICE MANUAL CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 9.3.8 Inspect Pistons Pins NOTICE: If the connecting rods do not meet the requirements set forth In pages 9-16 through 9-18, re- place the entire connecting rod assembly. . Visually inspect piston pins for corrosion or wear. Replace as required. .. Use a micrometer to measure piston pin OD. at two locations, Record the read- ings. Refer to FIGURE 9-19. If piston pin wear exceeds “Specifications”, replace the pin. |. Check piston pin clearance in rod as fol- lows: 1, Micrometer 2. Piston Pin a. Subtract piston pin O.D. from piston pin bushing LD. measurement. Refer to alealemepidi hee FIGURE 9-16. FIGURE 9-19 b. Ifclearance exceeds “Specifications”, ( replace the bushing. 9.3.9 Inspect Cylinder Liners 1. Visually inspect inside surface of liner for scuffing or scoring and polishing. Replace liner (and piston) as required. Examine out- er surface of liner for cavitation erosion, re~ place as required. 2. Check cylinder liners for wear (taper) using any one of the three methods described. ‘A ntmaten meet care wou rete. es 4) {G3E44 © 19 DETRONT DUESEL CORPORATION ou9CONNECTING RODS, PISTONS RINGS, AND SLEEVES CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 9.3.10 Method One ~ Telescoping Gauge Method (Refer to FIGURE 9-20 and FIGURE 9-21). Using a telescoping gauge, and an outside micrometer: 1. Measure liner LD. at top of piston ring trav- el (just below carbon ridge area) (FIGURE 9-20) and record reading. 2. Measure liner. LID. below ring travel area (FIGURE 9-21) and record reading. 3, The difference between two readings is cyl- inder liner taper. If specifications are ex- ceeded, replace liner. 920 THE RING TRAVEL AREA + RECORD READING cost088 1. Micrometer 2. Telescoping Gauge 3, Cylinder Liner FIGURE 9-21SERIES 40 SERVICE MANUAL CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 9.3.11 Method Two Dial Bore Gauge —_ (Refer to FIGURE 9-22 and Method FIGURE 9-23). = Using a dial bore gauge: 1. Measure at the top of the piston ring travel just below the carbon ridge area) (FIGURE 9-22) and record the reading. 2, Measure below ring travel area (FIGURE 9-23) and record the reading. The difference between the two readings is the cylinder liner taper. If specifications are exceeded, replace liner. 1. Dial Bore Gauge 2. Liner FIGURE 9-23 eaten mht change waa ee 4) GSeaTe Tose DbTROM BESS. CORPORATION 9-21(CONNECTING RODS, PISTONS RINGS, AND SLEEVES CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 9.3.12 Method Three - Feeler Gauge Method (Refer to FIGURE 9-24 and FIGURE 9-25). 1. Install a top compression ring squarely at top of ring travel (FIGURE 9-24) and mea- sure ring end gap with a feeler gauge. Re- cord reading. 2, Install same piston ring squarely below ring travel area (FIGURE 9-25) and measure ring end gap. Record readings. NOTE: FIGURE 9-24 Use a piston to be sure ring is seated squarely into bore. ae Every 0.003 in. (0.07 mm) i inti fc below The very 0.003 in. (0.07 mm) increase in ring gap equals a 0.001 in. (0.025 mm) increase in bore | + imeacune ex penne size. a 3, If liner is worn beyond specifications, re- place liner. cotta FIGURE 9-25 9.22 ‘egret ntet ewes emo cas, me 10) ‘S8ea7 tons DeTROn BUSH. CORPORSSERIES 40 SERVICE MANUAL CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 9.3.13 Bearing Fitting Procedure 1. If bearing-to-crankshaft running clearances exceed specifications because of wear on the crankshaft, replace or regrind the crankshaft and install undersize precision type bearing shells. NOTE: Do not attempt to reduce journal-to~ bearing running clearances by re- working bearing cap, bearings or both. Regrind or replace the crank- shaft only. Refer to Section 10. NOTICE: Reworking the bearing cap will CEREAP OF BEATING. destroy the engineered fit of the = bearing shells In their bores. 2. Tighten the connecting rod bolts alternately FIGURE 9-26 and evenly to the specified torque. NOTE: About Bearing Crush and Spread! Bearing shells must fit tightly in the bore. When bearing shells are in- serted into the connecting rod and cap, they protrude above the parting line. This protrusion is required to achieve “Bearing Crush”. Bearing shells are designed with “Spread”. That is, the width across the open ends are slightly larger than the di- ameter of the connecting rod bore into which they are assembled, as shown in FIGURE 9-26. This condi- tion is designed into the bearing shell causing it to spread outward at the parting line when “Crush” load is applied by tightening the bolts. Some snap may be lost in normal use, but bearing replacement Is not required because of a nominal loss of snap. f Y Y ‘ 1 ' ul ©. D. OF BEARING nrg nn ae e180) (Gaeere ims Bemorr Doser CORPORATION 923CONNECTING RODS, PISTONS RINGS, AND SLEEVES CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY When the assembly is drawn up tight, the bearing is compressed, assuring a positive contact between the bearing back and the bore as shown in FIGURE 9-27. 3. Fit connecting rod bearings and measure bearing running clearance as follows: a. With bearing cap removed, wipe oil from the face of the bearing insert and exposed portion of the crankshaft jour- nal. b. Place a piece of “Plastigage®” across the full width of the bearing about ¥ in. (6mm) off center. ¢. Install the cap and tighten bolts evenly and alternately to specified torque. NOTE: Do not turn the crankshaft during running clearance check. 4, Remove bearing cap. The “Plastigage®” ‘material will be found adhering to either the bearing shell or the crankshaft. DO NOT REMOVE “PLASTIGAGE®”. DIFFERENCE BETWEEN DIAMETERS (A) AND (B) IS BEARING CRUSH (C) DIAMETER (A) AT RIGHT ANGLES WITH BEARING CAP DRAWN TO PARTING LINES GREATER UP TIGHT DIAMETERS (A) THAN DIAMETER (8) ‘AND (B) ARE EQUAL, 60-11600 FIGURE 9-27 Areca seeure ims DeTaOr Oh charg ext ten (e 4) anon‘SERIES 40 SERVICE MANUAL CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 1. Bearing 2. Crankcase 3. Scale 4, Connecting Rod FIGURE 9-28 FIGURE 9-29 e. Use “Plastigage®” scale to measure widest point of flattened plastic material, FIGURE 9-28. The number within the graduated marks on the scale indicates the clearance in thousandths of an inch or millimeters (See “Specifications”. Remove the test material and the repeat test for each connecting rod bearing. NOTE: With the precision bearings used, no problem should be encoun- tered. If proper clearance is NOT achieved, a problem with the crankshaft may exist which re- quires regrinding and the use of undersize bearings. (Refer to Sec- tion 10 for crankshaft rework in- formation.) Bearing cap torque Is very important. Repeat running clearance check procedure before condemning the crankshaft. 4. Check connecting rod side clearance using a dial indicator as follows: a. Place the tip of the dial indicator on the connecting rod cap as shown in FIGURE 9-29. Pry the connecting rod towards the rear of the engine and zero the dial indicator. Pry the connecting rod toward the front of the engine and read the indicator, Re- fer to “Specifications” and repeat for all connecting rods. NOTE: The connecting rod side clearance must be checked to be certain that the specified clearance exists. Lack of clearance could indicate a damaged rod ora rod bearing out of position. Excessive clearance may require replacement of the rods or crankshaft. Correct as required. x ‘Atom eco tage nooo. (he Ve) ‘GaE4s 194 DETROrT DIESEL CORPORATION 9-25CONNECTING RODS, PISTONS RINGS, AND SLEEVES CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 9.3.14 Cylinder Liner Fitting Procedure Check the crankcase counterbore depth using the surface gauge or a depth micrometer. 9.3.14.1 Surface Gauge Method (Refer to FIGURE 9-30). 1, “Zero” the dial indicator on the crankcase deck. 2. Move the indicator onto the counterbore ledge and check the depth at four points. 3. Refer to “Specifications” for counterbore depth and maximum variation between the four measurement points. 4, If maximum variation between the four points exceeds specifications, resurface the counterbore. 9.3.14.2 Depth Micrometer Method (Refer to FIGURE 9-31). 1. Check the counterbore depth at four points around the crankcase counterbore, 2. Record the measurements. 3. Refer to “Specifications”, and resurface the counterbore if the maximum variation be- tween measurement points is exceeded. 9-26 os 1 eoezr 1. Dial indicator 2, Counter Bore Ledge 3. Crankcase FIGURE 9-30 1. Depth Micrometer 2. Counter Bore Ledge 3. Crankcase FIGURE 9-31 At reratan mej sarge mieten. Pu 8) ‘SSE440 1904 DETROTT DIESEL CORPORATION‘SERIES 40 SERVICE MANUAL CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 4, Resurface the counterbore using the counter- boring tool, PT2200-55 along with the ap- propriate cutter head as follows: NOTE: The counterboring tool is a low Profile tool which can be used in chassis. a, PRE-SET TOOL BIT by placing a 0.008 in. to 0.010 in.(0.20 to 0,25 mm) feeler gauge on the O.D. of the cutter head PT2250A. Push the tool bit out un- 1. Allen Wrench z aan til it touches the feeler gauge. Lock the ae accion busi: tool bit in place using an Allen wrench : as shown in FIGURE 9-32. FIGURE 9-32 s INSTALL THE CUTTER HEAD PT2250A onto the driver unit and adapt- er plate of the counterboring tool. Refer to FIGURE 9-33. 1, Cutting Too! 2. Tool Bit 3. Foeler Gauge 4. Washers (2) 5. Mounting Bolts (2) 6. Spacer (2) 7. Locking Plate (7) FIGURE 9-33 ‘About wt rage wo 8 S9E6 1 BeTmorrDtSSE, CORPORATION 927‘CONNECTING RODS, PISTONS RINGS, AND SLEEVES CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY c. RAISE THE CUTTER HEAD by pull- ing the plunger and lifting up on the han- dle. Mount the counterboring tool as- sembly to the crankcase as shown in FIGURE 9-34. Tighten the cap screw with washers finger—tight than apply 33 Ib-ft (45 N-m) torque. 4. LOWER THE CUTTING HEAD by loosening locking screws on turn knuckles. Pull plunger up, to desired height. tighten turn knuckle in position and lock in place with locking screws. 9.3.15 Setting the Depth of the Cut Set the depth of the cut using one of two methods. 9.3.15.1 Method One - Use Graduated Marks On Tool Use the following steps: . Loosen locking screw. 2. Rotate the adjusting nut in a counterclock- wise direction until the nut contacts the driv- er unit housing. » . Back off the adjusting nut by the amount of cut desired. NOTE: Each graduated marking equals 0.001 in. If 0.002 in. material is to be removed, you must back off the adjusting nut two marks. 4, Tighten the adjusting nut lock screw. NOTICE: Never attempt to remove more than 0.002 in. material at a time as damage to block may occur. 4. Handle 2, Upper Turn Knuckle 3. Lower Turn Knuckle 4. Cylinder Head FIGURE 9-34 Abt nth charg ib rte. fms.) ‘$40 1994 DETMOTT DIESEL CORPORATION‘SERIES 40 SERVICE MANUAL CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 9.3.15.2 Method Two — Use Feeler Gauge (See FIGURE 9-35) Use the following steps: 1. Loosen locking screw. 2. Insert an appropriate size feeler gauge (0.002 in,{0.05 mm} max.) between upper and lower turn knuckle. Rotate upper turn knuckle until feeler gauge is just held in Cylinder Block feeler gauge. Lower Tum Knuckle 1. Handle place. 2. Upper Turn Knuckle 3, Feeler Gauge 3. Tighten the locking screw and remove the 4 5 4, Cut the counterbore by rotating handle smoothly in a clockwise direction until unit tums freely and is bottomed out between ad- jjusting nut and top of driver unit housing, Refer to FIGURE 9-36. FIGURE 9-35 5. Remeasure counterbore depth once counter- bore has been resurfaced and cleaned up. Refer to “Cylinder Liner Fitting Procedure”, step one in this section. a Check cylinder liner protrusion as follows: a. Clean cylinder bore and crankcase counter bore area. 1, Handle 2. Upper Turn Knuckle NOTE: 3. Lower Turn Knuckle To avoid damage to the too! bit, 4, Crankease never rotate counterclockwise when tool bit is in contact with FIGURE $-36 counterbore ledge. Ar rtematen nc eargs st te. 20) Geeare ose Dernorr Oibse, CORPORATION 29CONNECTING RODS, PISTONS RINGS, AND SLEEVES CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 'b. Place each liner in crankcase without O— rings, Clamp liner down using three holding adapters. cc. Install the liner into its bore and install the holding adapters as shown in FIGURE 9-37. Fasten the holding adapters using grade 8 bolts and hard- ened washers. Tighten the bolts in two stages as follows: a. 40 lb-ft (55 N-m) b. 80 Ib-ft (110 N-m) c. Using a surface gauge, place the dial in- dicator tip on the cylinder liner flange. 1. Wrench 2. Crankcase 3. Holding Adapters. 4. Sleeve FIGURE 9-37 30 Agr sare owe meena, 80SERIES 40 SERVICE MANUAL CONNECTING RODS, PISTONS, RINGS AND LINERS DISASSEMBLY 1, Dial indicator 2, Holding Adapters 4. Crankcase FIGURE 9-38 d, Zero the indicator and move the block 7. Adjust the liner protrusion, as follows: until the indicator tip slides off the flange to the crankcase deck. Record the read- ing. Refer to FIGURE 9-38. NOTE: b. Clean the top deck of the crankcase and ‘Take readings at three points the cylinder liner counterbore. around the liner and use the aver- age reading to determine which shim(s), If any, is needed to bring the cylinder liner protrusion within the specification. a, Remove the holding adapters and cylin- der liner. A bate nthe tage mitoses. (Pe 180) ‘E440 194 DETROFT DRSEL CORPORATION 331CONNECTING RODS, PISTONS RINGS, AND SLEEVES REASSEMBLY OF CONNECTING RODS, PISTONS, RINGS AND LINERS . Install the shim(s){two maximum), as required to bring the protrusion above the crankcase deck within specifications. Refer to FIGURE 9-39. NOTE: ‘Shims are avallable as a package consisting of the following: ‘Shim Quantity ShimSize Shim Si 2 .05 mm 2 10 mm. 1 .25 mm 1 50 mm 2 8imm d. Follow cylinder liner installation instruc- tions. 9.4 REASSEMBLY OF CONNECTING RODS, PISTONS & RINGS 1, Install the rings onto the pistons using a pis- ton ring expander tool as follows: Refer to FIGURE 9-40, 2. Install rings in the following order: Oil control ring ve 2nd compression ring ° Top compression ring 2 Identification marks must face up. (Top ring has UP-TOP. 2nd ring has UP-2ND). NOTE: The oll ring does NOT have identi- fication marks. There is no top or bottom, it may be installed in el- ther direction. e. Stagger the ring gaps 120° apart. FIGURE 9-39 ca.5752 Piston Ring Expander Too! ‘Top Ring Intermediate Ring ll Control Ring Piston FIGURE 940 ‘A nematic thane wet rte. (a 98) (E46 198 DETROTT DIESEL CORPORATIONSERIES 40 SERVICE MANUAL REASSEMBLY OF CONNECTING RODS, PISTONS, RINGS AND LINERS C 7 3. Assemble the piston and connecting rod as follows: Refer to FIGURE 9-41, pea a. Lubricate the connecting rod piston pin lea bushing with clean engine oil. b. Install the retaining ring at one end of the piston pin bore. . Insert the connecting rod into the piston aligning bored holes of the rod and pis- ton (the short side of the split on the = crank end of the rod is to be toward the 4. Piston Crown side of the piston marked “Camside”). (2. Top Ring pian d. Align the pin bores and insert the piston 4, Oll Control Ring a 5. Retaining Ring ¢. Install the second retaining ring. 6. Piston Pin t 7. Piston Skirt NOTE: 8. Connecting Rod Connecting rod and cap matching numbers must be opposite the FIGURE 9-41 camside of piston. eet to cage naa, te) AaCONNECTING RODS, PISTONS RINGS, AND SLEEVES REASSEMBLY OF CONNECTING RODS, PISTONS, RINGS AND LINERS 9.4.1 Cylinder Liners 1. Lubricate the O-rings with Lubriplate and install one into each cylinder liner groove, (without twist). Refer to FIGURE 9-42. NOTE: Lightly lubricate O-ring area of lin- er and lower counterbore of crank- case to ease installation and avoid O-ring twist or pinch. NOTE: Each oylinder liner usestwoO- oi can 2. Liner 2. If required, assure the proper shim(s) is 3. Crankease installed, in the crankcase counterbore, so cylinder liner protrusion is within specifica- FIGURE 9-42 tions. Refer to “Cylinder Liner Fitting Pro- cedure”, FIGURE 9-7. 9-34 ‘Al btematon net ange wos rtee es 18) (E44 Iso DETROMT DIESEL CORPORATION‘SERIES 40 SERVICE MANUAL REASSEMBLY OF CONNECTING RODS, PISTONS, RINGS AND LINERS 1. Crankease 2. Cylinder liner FIGURE 9-43 41. Crankcase 2, Ring Compressor 3, Hammer FIGURE 9-44 3. Be sure the O-rings are properly aligned in the groove, 4. Apply Lubriplate to the lower crankcase counterbore, then install the liner carefully. If reusing liner, rotate 90° from original position and install in the same bore from which it was removed. Refer to FIGURE 9-43. 9.4.2 Piston & Rod Assembly 1. Lubricate the piston rings with clean engine oil and stagger the ring gaps 120° apart. 2. Install the piston ring compressor J41166 over the piston rings. » . Lubricate the cylinder liner with clean en- gine oil. NOTE: The piston and rod assemblies can be installed by turning the crank- shaft three times. Position the No. 1 and 6 crankpins at BDC. Install the No, 1 and 6 piston assemblies. Repeat this procedure for the Nos. 2 and 5 and Nos. 3 and 4 piston and rod assemblies. 4, Insert piston and connecting rod assembly into liner. ‘The numbers on connecting rod must face away from camshaft while mark- ings on top of piston faces toward the cam- shaft side of the engine. 5. Push piston into the liner with a wooden or plastic handle. Refer to FIGURE 9-44. ‘A pheraon ecto care mien te. 8) {S5€400 195 DETROMT DIESEL CORPORATION 9.35CONNECTING RODS, PISTONS RINGS, AND SLEEVES REASSEMBLY OF CONNECTING RODS, PISTONS, RINGS AND LINERS 6. Guide the connecting rod into place on the crankpin, Refer to FIGURE 9-45. 9.4.3 Connecting Rod Bearing Inserts & Caps NOTE: Refer to “Bearing Fitting Proce- dure” earlier in this section for running and side clearance proce- dures, 1. With the bearing inserts lubricated, install the connecting rod cap so the numbers on the cap and rod match. Refer to FIGURE 9-46. FIGURE 9-46SERIES 40 SERVICE MANUAL REASSEMBLY OF CONNECTING RODS, PISTONS, RINGS AND LINERS 2. Install mounting bolts, by hand into connect- ing rods until finger-tight. Tighten mount- ing bolts to special torque. Refer to FIGURE 9-47, 3. Check connecting rod side clearance (See “Specifications”.) Refer to FIGURE 9-29. 9.4.4 Priming The Lubricating System ‘When the engine has been assembled, it is recommended to lubricate the engine with oil before starting. This is done to prevent any damage to internal parts. The following procedure is the preferred method to use when priming the lubricating system. 9.4.4.1 Preferred Method FIGURE 8-47 NOTE: Install new lube oil filters. 1. Pressure prime the lubrication system with oil, prior to starting as follows: a. Inject sufficient oil into the engine to fill the oil filters and charge the entire sys- tem. 1. Crankcase 2, Connecting Rod Mounting Bolt (12) 3. Torque Wrench CAUTION Ye MOC CRU may Pach uR RC! Brera Sites At hlomatanuicharg tot nao (2) E446 1854 DETRON DIESEL CORPORATION 937CONNECTING RODS, PISTONS RINGS, AND SLEEVES REASSEMBLY OF CONNECTING RODS, PISTONS, RINGS AND LINERS b. After priming, check the oil level before 9.4.5 Engine Run-in Procedure the engine is put back into service. Re- fer to chart for proper oil capacity. NOTE: Piast pam isan After Installing new pistons and/ : ‘or new rings, the engine must be O 28 ats. with filter change “run_in” ao follows: 2241s. without filter change : NOTE: 1. Operate engine at low idle (no load) for 5 Engines equipped with a bypass minutes. filtering system require additional a. Check for leaks in the water, Iube oil, oil. fuel and air induction systems. 9.4.4.2 Alternate Method 2. Operate engine at 3/4 rated speed (1/min) NOTE: and 1/2 to 3/4 throttle for 10 minutes. Be sure the engine was well oiled : during reassembly In order to use 3- Operate engine at rated speed and full this procedure, Ifthe engine was _throttle for 30 minutes. Recheck for lube not well oiled do not use this pro- _oil, fuel, water and air leaks. cedure, refer to Section 9.4.4 Prim- ing The Lubricating System and 9.4.4.1 Preferred Method, in this section for further information. ‘Use the following instructions prior to starting the engine. This is done to prevent any damage to internal parts. 1. Spin but DO NOT start, the engine using the cranking motor until oil pressure is read on the oil pressure gauge. 2. When oil pressure is read, the engine may be started, 9.38 ‘Atma bjt sarge nar tee. et. 04) (S3£4d6 1954 DETROIT DIESEL CORPORATION‘SERIES 40 SERVICE MANUAL 10 VIBRATION DAMPER, CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE 10.1 CRANKSHAFT, BEARINGS, FLYWHEEL AND RELATED COMPONENTS EXPLODED VIEW ....0....0s000+0++ sere 10-3 10.2 SPECIFICATIONS cess 10-9 10.2.1 Special Torque Values . + 10-11 10.2.2 Special Service Tools .. 10-12 SREAR ESR NO WEARER EOWA oo 10.3.1 In—Chassis Procedure 10-13 13g eee wo-1 10.33 Flywheel Housing Removal 10-14 10.34 Rear Oil Seal Carrier Removal. 10-15 10.35 Installing Rear Oil Seal Cartier . 10-15 10.36 Oil Seal Removal . : 10-17 10.3.7 Wear Liner Removal ~ In—chassis 10-18 10.3.8 Wear Liner Removal — Out—of-Chassis + 10-19 1039 Rear Oil Seal and Wear Liner Installation ......4.00.0++ ses 10-20 10.4 FLYWHEEL RECONDITIONING AND REASSEMBLY + 10-20 10.4.1 Cleaning and Inspection . = 10-20 10.4.2 Ring Gear Replacement .. 10-21 1043 Flywheel Housing Installation . 10-21 10.44 Flywheel Installation . 10-22 105 OIL LEVEL GAUGE TUBE REMOVAL AND REASSEMBLY 10-23 10.5.1 Cleaning And Inspection + 10-23 10.5.2 Reassembly ..... + 10-23 10.533 Oil Pan Removal + 10-24 10.6 DAMPER, CRANKSHAFT AND MAIN BEARINGS RECONDITIONING... . 10-25 106.1 Pulley Damper Assembly + 10-25 10,622 Oil Pick-up Tube Removal ...... + 10-27 10.6.3 Removal Of Miscellaneous Components . 10-28 10.6.4 Removal of Crankshaft and Main Bearings . + 10-28 10.65 Cleaning the Vibration Damper . + 10-30 10.6.6 Cleaning the Crankshaft and : = 10-30 10.6.7 Pulley Damper Assembly Inspection and Repair ........0.cs.sscss0e 10-31 10.68 Crankshaft and Main Bearings .. + 10-31 1069 GEAR REPLACEMENT .. 10-35 106.10 CLEANING ..... 10-36 eaten met cor no ae. SSEst 8 DETR DESL CORPORATION 10-41VIBRATION DAMPER 10-2 10.6.11 Inspection And Repair . 30.6111 Check Crankeate Integy - 10.7 INSTALLATION i 10.7.1 Bearing Fitting Procedure ..... 10.72 Main Bearing and Cap 10.73 Oil Pickup Tube Reassembly . 10:74 OiPan ...... 10:75 Vibration Damper and Pulley Assembly 10.7.6 Miscellaneous Installation .... 10-37 10-38 10-40 10-40 10-41 10-43 10-44 10-46 10-47 At rlonatn nh carga wit rates. 88) ‘S644 193 DETRON DIESEL CORPORATIONSERIES 40 SERVICE MANUAL 10.1 CRANKSHAFT, BEARINGS, FLYWHEEL AND RELATED COMPONENTS EXPLODED VIEW 1. Damper Retaining Plate 12, Thrust Bearing 2. Woodruff Key 13. Flywheel Ring Gear 3, Vibration Damper 14, Flywheel 4, Front Wear Liner 1, Rear Oil Seal 5. Seal Washer 16. Crankshaft To Flexplate Adapter 6. Oll Pump Drive Spline 17, Flywheel Adapter 7. Crankshaft Gear 18, Flexplato (Automatic Transmission) 8. Roll Pin 19. Flexplate (Automatic Transmission) 9. Crankshaft 20, Reinforcing Ring 10. Crankshaft Bearings 21, Flywheel Mounting Bolt 14. Connecting Rod Bearings FIGURE 10-1 Crankshaft, Bearings, Flywheel and Related Components. ‘iterates meet args woe we ‘Getere ios Beton RSE CORPORATION 103‘SERIES 40 SERVICE MANUAL £02005 1. Cup Plug 16. Main Bearing Cap Mounting Bolt 2. Oil Jet Cooling Tube 17. Main Bearing Caps 3, Cup Plug 18. Oil Level Gauge Tube Seal Cylinder Head Alignment Dowel 19. Lower Counterbore Insert . Camshaft Bearing Set 20. Oil Filler Tube 3. Cylinder Liner 21. Ol Level Gauge Cylinder Liner O-rings (2) 22, Oil Inlet Tube Support Bracket (If Applied) Cylinder Liner Shim 23. Oil Level Gauge Lower Tube . Plug 24, Oil Filler Tube Clamp . Plug 25. Crankcase . Camshaft Seal Ring 28. Oil Filler Tube Brace Plug 27. Oil Filler Tube Brace Clamp Plug 28, Rear Oil Seal Carrier Number 7 Main Bearing Cap (Thrust) 29. Rear Oil Seal Carrier Gasket 15. Plug ‘30. Flywheel Housing FIGURE 10-2 Crankcase and Related Parts. SSeee0 imernorr Da. CORPORATION 10-5‘SERIES 40 SERVICE MANUAL EG.1018 FIGURE 10-3 { 1. O11 Pan 2. Oll Drain Plug Gasket 3, Oil Drain Plug A rtm eg et S564 6 ios BETROMT DISSE CORPORATION 10-7‘SERIES 40 SERVICE MANUAL 10.2 SPECIFICATIONS DIMENSION VALUES CRANKSHAFT: Type Steel Forging, Induction Hardened, Grindable Main Bearing Journal Diameter Standard Size . 3.535 + 0.0006 in. (89.7 + 0.00152mm) .010” Undersize . - 3.525 + 0.0006 in. (89.5 + 0.00152 mm) .020” Undersize . 3.515 + 0.0006 in. (89.2 + 0.00152 mm) .030” Undersize . 3,505 + 0.0006 in. (89.0 + 0.00152 mm) Main Bearing Width (Except Rear Thrust) ... 1.286 +t 0.010 in, (32.7 + 0.254 mm) Main Bearing Journal Max. Out-of-Round .. 0,002 in, (0.05 mm) Main Bearing Thrust Face Runout (TIR Max.) ....0.... 66 Main Bearing Journal Taper (Max/In.) . Main Bearing Journal Fillet Radius . Rod Journal Fillet Radius : Rear Oil Seal Journal Runout (Max.) . . 0,003 in. (0.08 mm) Damper Mounting Area Runout (Max.) ...... 0.0005 in, (0,013 mm) Flywheel Mounting Surface Runout (Max.).. 0.002 in. (0.05 mm) 0.001 in, (0.025 mm) 0.0028 in. (0.0076 mm) ++ 0.225/0.050 in. (5.72/1.27 mm) 0.225/0.050 in. (5.72/1.27 mm) Number of Main Bearings 7 Thrust Taken By Rear Main ‘Thrust Bearing Journal Length Standard Size to .020” Undersize .......... 1.3545 + .010 in. (34.4 + 0.254 mm) .030” Undersize .............- = 1.3545 + .010 in. (34.4 + 0,254 mm) Main Bearing to Crankshaft Clearance 0.0047/0.0018 in. (0.120/0.046 mm) Connecting Rod Journal Diameter Standard Size . = 3.1500 + 0.0006 in. (80.0 + 0.0152 mm) 010” Undersize . 3.1400 ++ 0.0006 in. (79.7 + 0.0152 mm) 020” Undersize 3.1300 + 0.0006 in. (79.5 + 0.0152 mm) 030” Undersize . - 3.1200 + 0.0006 in, (79.2 + 0.0152 mm) Connecting Rod Bearing Wi 1.385 in, (35.2 mm) Connecting Rod Jounal Max. Out-of-Round .......0..6.6e 0c ee eee eee 00025 in. (0.0064 mm) At ean mt narnia fa 8) ‘sees e tse Denon DIESEL CORPORATION 10-9