4993 RENR3968_nh 3/30/06 12:56 PM Page 1

RENR3968
June 2004

C7 Crankshaft Torque Procedure

Connecting Rod Bolt
a. Put engine oil on threads and nut seat.
b. Tighten both Bolts to 70 ± 5 N-m (51.22 ± 3.66 lb ft).

Engine Design c. Mark each nut and end of bolt.

d. Tighten both nuts from mark 120 o ± 5o (1/3 of a turn)
Bore 110 mm (4.33 inch)
Stroke 127 mm (5 inch) Main Bearing Bolt
Wear Sleeve and Seal Installation Tools Required
Number of Cylinders 6 Part No. Description Part No. Description a. Put engine oil on threads and washer face.
Cylinder Arrangement *In-line 9S-8871 Locator 9S-8858 Nut
b. Tighten all bolts to 54 ± 7 N·m (39.51 ± 5.12 lb ft).
9S-8890 Bolt (three) 5P-7299 Installer
Firing Order (Injection Sequence) 1, 5, 3, 6, 2, 4 5P-7298 Installer 7F-8022 Bolt c. Mark each bolt and cap.
Direction of Rotation Counterclockwise d. Tighten all bolts from mark 90 o ± 5o (1/4 of a turn)
(Viewed from flywheel end)
Note: Lubricate the Main Bearing Cap Bolt Threads and Washer Face
with SAE 30 Or Molylube.
Literature References Note: For aluminum pistons, assemble so the marking "FRONT" on the
piston and the forging number on the connecting rod point in
Form Number Title opposite directions.
NENG2500 Dealer Service Tool Catalog Note: Install the piston and connecting rod so that the forging number
on the connecting rod points toward the flywheel end of the
Special Instruction SMHS7100 gives the procedure for using the engine.
installation tools Piston, Rings and Connecting Rods

Note: There are holes in the bores for the main bearings, between
cylinders 1 and 2, 3 and 4, 5 and 6 for piston cooling orifices.
These holes must have either orifices or plugs installed. Find this

Engine Assembly Procedure information in OIL LINES in the parts book for your engine
arrangement.
1. Connecting Rod Journal
70 ± 0.020 mm (2.9992 ± 0.0008 inch)
Q - Denotes Critical Checkpoints Diameter
Sub Assembly Sub Assembly Installation Parts Assembly Connecting Rod Journal -2- Maximum: 0.127 mm (0.005 inches)
Sub Assembly Installation Parts Assembly
Sub Assembly Parts Sequence Procedure bearing clearance Minimum: 0.029 mm (0.001 inches)
Parts Sequence Procedure
a. Time fuel pump camshaft 2. Main Bearing Journal
Q – 25 96 ± 0.020 mm (3.4992 ± 0.0008 inch)
Q–1 Clean oil passages. Fuel Injection with timing pin. Diameter
Pump
Block Assembly b. Install fuel injection pump
Governor Main Bearing Journal -2- Maximum: 0.155 mm (0.006 inches)
Covers Position block on engine (Sleeve housing assembly and fuel bearing clearance
Block Fuel Filter Minimum: 0.073 mm (0.003 inches)
Plugs 2 stand with accessory drive Metering filter.
Assembly
Camshaft side up. Gear
Fuel System) 3. Do not heat gear or wear sleeve too more than 204.4oC (400oF) before
c. Install fuel pump drive
Bearings installation.
Install main bearings to gear and torque.
3 block and caps. 4. Crankshaft End Play 0.07 to 0.32 mm (0.002 to 0.0126 inch)
26 Install valve filters.
4 Oil main bearings.
27
Install gasket and spacer
5. Clearance between main bearing cap and cylinder block 0.003 mm
(0.0001 inch) Tight to 0.043 mm (0.0017 inch) Loose.
Cylinder Head
Install crankshaft and plate.
5 Main bearing cap width 159.995 ± 0.020 mm (6.2990 ± 0.0008 inch)
thrust plates. Install gasket and cylinder
28 Width of cylinder block for
Crankshaft Crankshaft Install and torque main head. 160 ± 0.018 mm (6.2992 ± 0.0007 inch)
Q–6 Plate main bearing cap
Gear Assembly bearing caps. 29 Install push rods.
Cylinder Head Cylinder Head
Rotate crankshaft and 30 Install rocker arm assembly.
Q–7
check endplay.
Push Rods Assembly
Torque cylinder head and
Piston, Rings and Connecting Rods
Rocker Arm Q – 31
Connecting Oil liners, rings and rocker arm bolts. Installation Tool Required
8 Assembly
Rods bearings. Part No. Description
Q – 32 Adjust valve lash.
Rings Piston & Rod Install pistons and rod 173-5529 Piston Ring Compressor
Install valve cover, breather
Pistons Assembly caps. Check alignment of 33 View from right side of engine
Q–9 and glow plug leads.
Pins "V" marks on pistons and
cylinder block. Front Housing Install front housing. Lubricate Piston Assembly and bearings with clean engine oil.
Bearings Housing 34 Note: Put 8T-2998 Lubricant on threads and tighten bolts in the
Assembly Ring gaps must minimum of 120o apart. following Step sequence:
10 Install piston-cooling jets.
Install wear sleeve and seal Step 1. Tighten bolts 1 thru 14 by numerical 300 ± 15 N·m
Q – 11 Torque rod nuts. 35
to crankshaft. Piston Cooling Jets sequence to a torque of: (219.5 ± 11 lb ft)
Rotate crankshaft and 36 Install front support.
Q – 12 Step 2. Loosen bolts 1 thru 14 to a torque of: 0 N·m (0 lb ft)
recheck endplay.
Install crankshaft damper Step 3. Tighten bolts 1 thru 14 by numerical 130 ± 15 N·m
Flywheel 13 Install flywheel housing. Q – 37
and pulley and torque. sequence to: (95.1 ± 11 lb ft)
Housing Check flywheel housing
Flywheel Q – 14 Pump Install water pump, regulator Step 4. Retighten bolts 1 thru 14 by numerical 130 ± 15 N·m
Covers bore and face runout. Water Pump and elbows.
Housing Regulator 38 sequence to: (95.1 ± 11 lb ft)
Plugs Assembly
Assembly Install wear sleeve and Elbows Step 5. Turn bolts 1 thru 14 by numerical
Seals 15 seal to crankshaft and 90° (1/4 turn)
39 Install exhaust manifold. sequence an additional:
Sleeve flywheel housing.
40 Install turbocharger. 55 ± 7 N·m
Q – 16 Install flywheel and torque. Step 6. Tighten bolts 15 thru 20 to a torque of:
(40.2 ± 5.1 lb ft)
41 Install engine oil cooler.
Check flywheel bore and 42 Install oil filter base and filter.
Q – 17
face runout.
Install transmission oil
43
cooler. Flywheel Housing
Pump, Install oil pump.
18 44 Install tube assemblies.
Gears Oil Pump
Tube Assembly Assembly 45 Install air compressor.
19 Install oil pan.
Suction Bell 46 Install fuel lines.
20 Set engine upright. 47 Install starter motor.
Put No. 1 piston at top 48 Install alternator.
21 center. Put timing bolt in
flywheel. Install miscellaneous covers,
lines, and accessories.
Install camshaft, thrust 49
Camshaft Camshaft Q – 22 Compare completed engine
washers, gear & torque. with photos.
Gear Assembly
23 Install fuel pump idler gear.
Accessory Drive a. Install accessory drive
Q – 24
Assembly housing assembly. a. 112.69 ± 0.25 mm (4.44 ± 0.010 inch)
Pump b. Time accessory drive b. 121.30 ± 0.25 mm (4.78 ± 0.010 inch) 1. Maximum permissible "run out" (radial 0.30 mm
Governor Fuel Injection shaft with timing plate. eccentricity) of the flywheel housing bore. (0.012 inch)
c. 55.3 mm (1.51 inch)
Gear Assembly c. Install fuel pump drive 2. Maximum permissible "run out' (axial 0.30 mm
gear and torque. d. 15.45 ± 0.25 mm (0.61 ± 0.010 inch) eccentricity) of the flywheel housing face. (0.012 inch)
Fuel Filter
Fuel Transfer d. Install fuel pump and e. 121.30 ± 0.25 mm (4.78 ± 0.010 inch)
Pump governor assembly. Tighten the cooling jet bolt to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
4993 RENR3968_nh 3/30/06 12:56 PM Page 2

Timing Gears Valve Clearance

Exhaust 0.64 mm (0.025 inch)

Intake 0.38 mm (0.015 inch)

Adjust
Adjust following
following valves
valvesat
atNo.
No.11TC
TC Adjust
Adjustfollowing
followingvalves
valvesatatNo.
No.66TC
TC
Note: Apply 9S-3263 Thread Lock Compound to the threads of the oil
pump idler gear bolt. Valves
Valves Cylinder
Cylinder Valves
Valves Cylinder
Cylinder
Intake
Intake 1,2,4
1,2,4 Intake
Intake 3,5,6
3,5,6
35 ± 8 N·m Exhaust
Exhaust 1,3,5
1,3,5 Exhaust
Exhaust 2,4,6
2,4,6
1. Camshaft Gear Bolt; torque to:
(25.61 ± 5.85 lb ft)
2. Hydraulic Pump Drive Gear Bolt;
torque to:
120 ± 20 N·m Valve Cover
(87.8 ± 14.63 lb ft)
70 ± 15 N·m
3. Camshaft Idler Gear Bolt; torque to:
(50 ± 11 lb ft)
4. Crankshaft Gear Bolt; torque to: Heat and Press Fit
70 ± 15 N·m
5. Oil Pump Idler Gear Bolt; torque to:
(50 ± 11 lb ft)
70 ± 15 N·m
6. Oil Pump Drive Gear Bolt; torque to:
(50 ± 11 lb ft)
Maximum permissible end play 0.64 mm (0.025 inch)

Flywheel

Tighten all bolts in number sequence to 15 ± 3 N·m

(11 ± 2.2 lb ft)

Exhaust Manifold

1. Maximum permissible runout (radial eccentricity) 0.15 mm

off center of bore (total indicator reading) (0.006 inch)
2. Maximum permissible runout (axial eccentricity) of 0.15 mm
face (total indicator reading) (0.006 inch)
3. Maximum permissible runout (radial eccentricity) 0.13 mm
for pilot bearing off center of bore (total indicator (0.005 inch) Note A: Put 1E-2078 Anti-Seize Compound on threads of bolts.
reading) Note B: Apply thin coat of sealer to outer diameter of male end of
manifold before assembly. Remove excess sealer from
4. Torque for flywheel bolts 120 ± 20 N·m assembled joint.
(90 ± 15 lb ft))
Tighten bolts 1 thru 12 in numerical 4 ± 1 N·m
sequence to: (2.93 ± 0.73 lb. ft.)
Retighten bolts 1 thru 12 in numerical 45 ± 5 N·m
Crankshaft Hub and Vibration Damper sequence to: (32.93 ± 4 lb. Ft.)
35 ± 5 N·m
Tighten stud 13 to the following torque
(26 ± 4 lb. Ft.)

Turbocharger

1. Tighten bolt holding hub to crankshaft to 200 ± 25 N·m

(148 ± 20 lb ft)
Hit bolt with hammer and again tighten bolt to 200 ± 25 N·m
(148 ± 20 lb ft)

Torque the nuts that secure the turbocharger to 54 ± 5 N·m

the exhaust manifold: (40 ± 4 lb ft)
Note: Put 5P-3931 Anti-Seize Compound on threads of studs.

©2004 Caterpillar Inc.

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