Especificaciones Técnicas
Especificaciones Técnicas
Especificaciones Técnicas
December 2004
Specifications
1103 and 1104E Engines
DC11-Up (Machine)
DD11-Up (Machine)
DJ11-Up (Machine)
DK11-Up (Machine)
RE11-Up (Machine)
RG11-Up (Machine)
RJ11-Up (Machine)
RR11-Up (Machine)
RS11-Up (Machine)
DF11-Up (Engine)
DG11-Up (Engine)
i01658146
SENR9778-02
Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Injection Lines .............................................. 5
Fuel Injection Pump (Delphi DP210 DPA and DPG
fuel injection pumps) ........................................... 5
Fuel Injection Pump (Bosch EPVE for the 1104
engines only) ....................................................... 6
Fuel Injection Pump (Delphi STP) ........................ 7
Fuel Injectors ....................................................... 8
Fuel Transfer Pump ............................................. 8
Lifter Group ........................................................... 9
Rocker Shaft ........................................................ 9
Valve Mechanism Cover ...................................... 10
Cylinder Head Valves ........................................... 10
Cylinder Head ...................................................... 12
Turbocharger ....................................................... 13
Exhaust Manifold ................................................. 14
Camshaft ............................................................. 15
Camshaft Bearings .............................................. 16
Engine Oil Filter ................................................... 17
Engine Oil Pump .................................................. 17
Engine Oil Pressure ............................................. 19
Engine Oil Bypass Valve ...................................... 20
Engine Oil Pan ..................................................... 21
Crankcase Breather ............................................. 22
Water Temperature Regulator and Housing ......... 23
Water Pump ......................................................... 24
Cylinder Block ...................................................... 24
Crankshaft ........................................................... 26
Crankshaft Seals ................................................. 30
Connecting Rod Bearing Journal ......................... 31
Main Bearing Journal ............................................ 31
Connecting Rod ................................................... 32
Piston and Rings .................................................. 33
Piston Cooling Jet ................................................. 34
Front Housing and Covers ................................... 35
Gear Group (Front) ............................................... 36
Flywheel ............................................................... 38
Flywheel Housing ................................................ 38
Crankshaft Pulley ................................................. 38
Fan Drive ............................................................. 39
Engine Lifting Bracket ........................................... 39
Alternator ............................................................. 40
Starter Motor ........................................................ 41
Glow Plugs ........................................................... 42
Index Section
Index ..................................................................... 43
3
Table of Contents
4
Specifications Section
SENR9778-02
Specifications Section
Engine Design
Illustration 1
g00984281
Illustration 2
g01014247
Compression ratio
Compression ratio
Valve lash
Valve lash
SENR9778-02
5
Specifications Section
g00922601
g00923498
(1) Tighten the union nuts for the fuel injector to the
following torque. ....................... 30 Nm (22 lb ft)
Note: Tighten the union nuts at the fuel injection
pump to the following torque.30 Nm (22 lb ft)
i02199305
Illustration 5
g00986531
Support bracket
6
Specifications Section
SENR9778-02
i02074846
Tighten the bolts that hold the fuel pump to the front
housing to the following torque. ...... 25 Nm (18 lb ft)
Delphi DPA
The DPA injection pump has a support bracket that is
similar to the DP 210 injection pump.
Illustration 6
g01111240
Delphi DPG
The DPG injection pump is only installed on engines
that operate at a fixed speed. The support bracket is
not installed on this injection pump.
Illustration 7
g00986530
SENR9778-02
7
Specifications Section
Tighten the bolts that hold the fuel pump to the front
housing to the following torque. ...... 25 Nm (18 lb ft)
i02074902
Illustration 8
g00988408
Illustration 10
g01061708
g00986295
Support bracket
8
Specifications Section
SENR9778-02
i01957629
g00986531
Support bracket
Fuel Injectors
Illustration 13
g00986823
g00908211
(1) Tighten the bolt in the clamp for the fuel injector
to the following torque. ............. 35 Nm (26 lb ft)
The fuel injector should be tested at the pressure in
Table 1.
SENR9778-02
9
Specifications Section
Lifter Group
Illustration 14
g00629433
Rocker Shaft
Illustration 15
g00985174
(9) Locknut
Torque for the locknut ............... 27 Nm (20 lb ft)
10
Specifications Section
SENR9778-02
i01948695
Illustration 16
g00908011
Cover
Illustration 18
g00294082
Illustration 17
Cover
g01018519
SENR9778-02
11
Specifications Section
Illustration 19
g00809016
12
Specifications Section
SENR9778-02
Cylinder Head
g00987480
Required Tools
Part
Number
Part Description
Qty
21825607
Angle gauge
Illustration 21
g01017007
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13
Specifications Section
Illustration 22
g00905621
Illustration 24
g01017008
Table 3
Dimension
Maximum Permissible
Distortion
Width (A)
Length (B)
i02224103
Turbocharger
Illustration 23
g01006568
Illustration 25
Typical turbocharger
g00991357
14
Specifications Section
SENR9778-02
100 3 kPa
(14.5040 0.4351 psi)
2674A421
100 3 kPa
(14.5040 0.4351 psi)
2674A422
200 3 kPa
(29.0080 0.4351 psi)
i01957427
Exhaust Manifold
Table 4
2674A200
100 5 kPa
(14.5040 0.7252 psi)
2674A201
110 5 kPa
(15.9544 0.7252 psi)
2674A202
128 5 kPa
(18.5651 0.7252 psi)
2674A209
100 5 kPa
(14.5040 0.7252 psi)
2674A211
128 5 kPa
(18.5651 0.7252 psi)
2674A215
128 5 kPa
(18.5651 0.7252 psi)
2674A223
136 5 kPa
(19.7254 0.7252 psi)
2674A224
136 5 kPa
(19.7254 0.7252 psi)
2674A225
136 5 kPa
(19.7254 0.7252 psi)
2674A226
100 5 kPa
(14.5040 0.7252 psi)
2674A227
128 5 kPa
(18.5651 0.7252 psi)
Illustration 26
g00907527
Tightening sequence
SENR9778-02
15
Specifications Section
g00976195
Illustration 29
Illustration 27
g01017009
Camshaft
Typical camshaft
(2) Bolt
Tighten the bolt to the following torque. ... 95 Nm
(70 lb ft)
(3) Camshaft thrust washer
Thickness of the thrust washer .. 5.49 to 5.54 mm
(0.216 to 0.218 inch)
Depth of the recess in the cylinder block for the
thrust washer ............................ 5.54 to 5.64 mm
(0.218 to 0.222 inch)
Tolerance of the thrust washer in cylinder block
front face ........................... 0.154 to 0.003 mm
(0.0006 to 0.0001 inch)
(4) The diameters of the camshaft journals are given
in the following tables.
Table 6
Illustration 28
Camshaft Journals
Standard Diameter
50.71 to 50.74 mm
(1.9965 to 1.9975 inch)
50.46 to 50.48 mm
(1.9865 to 1.9875 inch)
49.95 to 49.98 mm
(1.9665 to 1.9675 inch)
g00987750
16
Specifications Section
SENR9778-02
Table 7
Camshaft Journals
Standard Diameter
50.71 to 50.74 mm
(1.9965 to 1.9975 inch)
50.46 to 50.48 mm
(1.9865 to 1.9875 inch)
50.46 to 50.48 mm
(1.9865 to 1.9875 inch)
49.95 to 49.98 mm
(1.9665 to 1.9675 inch)
i01914527
Illustration 30
g00629702
Camshaft Bearings
Illustration 31
A typical four cylinder engine
g00997348
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17
Specifications Section
Replaceable Element
Illustration 34
Illustration 32
g01017012
g00915985
g00915984
(1) Seal
Note: Lubricate the top of the seal with clean engine
oil before installation.
Type ............................................................. Full flow
Number of lobes
Inner rotor ......................................................... 6
Outer rotor ........................................................ 7
18
Specifications Section
Illustration 35
SENR9778-02
g00989248
Illustration 37
g00989217
Illustration 38
g00938724
g00989236
Inner rotor
SENR9778-02
19
Specifications Section
Illustration 39
g00989519
Note: Replace the idler gear bolt (5) and the nut for
the oil pump gear (6).
Illustration 41
Illustration 42
g00938799
Illustration 40
The oil pump
g00938064
20
Specifications Section
SENR9778-02
i01958107
Illustration 45
g00919890
Plug
Illustration 43
g00919893
Illustration 46
g00921379
g00921377
(2) Plunger
Diameter of the plunger ..... 19.186 to 19.211 mm
(0.7554 to 0.7563 inch)
Clearance of plunger in bore .. 0.039 to 0.114 mm
(0.0015 to 0.0045 inch)
SENR9778-02
21
Specifications Section
i02242687
Illustration 47
g00990254
Applying sealant
Rear sealant
Note: Install the rear oil seal before sealant is applied
to the bridge.
Illustration 48
g00990255
Applying sealant
Illustration 49
g00990252
22
Specifications Section
SENR9778-02
Illustration 51
g00990677
Illustration 50
g00990249
Crankcase Breather
Note: The rear face of the cast iron oil pan (5) must
be aligned to the rear face of the cylinder block.
(5) The maximum allowed value of the rear face
misalignment. ................. 0.1 mm (0.0039 inch )
(6) Bolt
Tighten the front four bolts. Refer to illustration
49. Tighten the remaining bolts and the nuts that
fasten the engine oil pan to the cylinder block to
the following torque. ................. 22 Nm (16 lb ft)
Note: The sealant is applied to new bolts. In order
to reuse the bolts, apply 21820117 Powerpart
threadlock and nutlock to the first three threads of
the used bolts.
Note: The engine may be equipped with an oil drain
plug or the engine may be equipped with a drain
valve.
(7) Drain plug
Tighten the drain plug for the engine oil pan to
the following torque. ...... 34 5 Nm (25 4 lb ft)
Illustration 52
Breather valve
g00926199
SENR9778-02
23
Specifications Section
(3) Screws
Tighten the screws for the cover plate with a
plastic valve mechanism cover to the following
torque. .................................. 1.3 Nm (11.5 lb in)
Tighten the screws for the cover plate with a
metal valve mechanism cover to the following
torque. ..................................... 1.8 Nm (16 lb in)
(4) Diaphragm
(5) Cap
(6) Spring
Illustration 54
(1)
(2)
(3)
(4)
g01121867
Plastic cover
Screw
Cover plate
Seal
Illustration 53
g00926200
(7) O-ring
Note: Apply 21820221 Powerpart red rubber grease
to the O-ring before installing the breather pipe in the
valve mechanism cover.
Illustration 55
g00997234
O ring
24
Specifications Section
SENR9778-02
Cylinder Block
Four Cylinder Engine
Illustration 56
g00906121
Water Pump
Illustration 58
g00924764
Cylinder block
Illustration 57
g00915951
Tightening sequence
SENR9778-02
25
Specifications Section
Illustration 60
g01018250
Illustration 59
g00938203
26
Specifications Section
SENR9778-02
Crankshaft
Illustration 62
Illustration 61
g01018262
g00992214
SENR9778-02
27
Specifications Section
Illustration 63
The 1104 engine crankshaft
g01017233
28
Specifications Section
SENR9778-02
Table 8
39.47 mm
(1.5539 inch)maximum
N/A
N/A
37.44 mm
(1.4740 inch)maximum
N/A
N/A
44.68 mm
(1.7591 inch)maximum
N/A
N/A
40.55 mm
(1.5965 inch)maximum
N/A
N/A
N/A
N/A
N/A
N/A
Journal
(1)
Mounting
(2)
(3)
(4)
(5)
Mounting
SENR9778-02
Illustration 64
The crankshaft for the three cylinder engine
29
Specifications Section
g01017747
30
Specifications Section
SENR9778-02
Table 10
39.74 mm
(1.5646 inch)maximum
N/A
N/A
44.68 mm
(1.7591 inch)maximum
N/A
N/A
40.551 mm
(1.5965 inch)maximum
N/A
N/A
N/A
N/A
N/A
N/A
i01958114
Crankshaft Seals
Journal
(1)
Mounting Dia
(2)
(3)
(4)
Mounting Dia
Illustration 65
(1) Crankshaft
(2) Plastic sleeve
(3) Crankshaft seal
(4) Alignment tool
g00915078
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31
Specifications Section
i01958141
g00915076
32
Specifications Section
SENR9778-02
i01958156
Connecting Rod
g00995584
Illustration 68
Alignment of the bearing shell
g00907738
31.62 to 31.88 mm
(1.245 to 1.255 inch)
31.55 to 31.88 mm
(1.2405 to 1.255 inch)
Thickness of Connecting
Rod Bearing at the
Center
1.835 to 1.842 mm
(0.0723 to 0.0725 inch)
Thickness of Connecting
Rod Bearing for the Cap
at the Center
1.835 to 1.842 mm
(0.0722 to 0.0725 inch)
Bearing Clearance
0.030 to 0.081 mm
(0.0012 to 0.0032 inch)
Table 13
SENR9778-02
33
Specifications Section
Table 14
Color Code
Length (Y)
Red
165.728 to 165.761 mm
(6.5247 to 6.5260 inch)
Orange
165.682 to 165.715 mm
(6.5229 to 6.5242 inch)
White
165.637 to 165.670 mm
(6.5211 to 6.5224 inch)
Green
165.591 to 165.624 mm
(6.5193 to 6.5206 inch)
Purple
165.545 to 165.578 mm
(6.5175 to 6.5188 inch)
Blue
165.499 to 165.532 mm
(6.5157 to 6.4961 inch)
i01958185
Illustration 69
g00907744
g00888215
Illustration 70
g00915056
34
Specifications Section
SENR9778-02
Piston
Note: An arrow which is marked on the piston crown
must be toward the front of the engine.
The combustion bowl re-entrant angle for the
turbocharged engine ............................... 80 degrees
Illustration 72
g00942652
SENR9778-02
35
Specifications Section
Illustration 73
g01006929
Illustration 74
(1) Tighten the bolts that fasten the front cover to the
front housing to the following torque. ....... 22 Nm
(16 lb ft)
g00995663
Alignment
g00918672
Front cover
(2) Tighten the bolts that fasten the water pump to the
front housing to the following torque. ....... 22 Nm
(16 lb ft)
Note: Refer to Specifications, Water Pump for the
correct bolt tightening sequence for the water pump.
36
Specifications Section
SENR9778-02
i01912958
Illustration 76
g00995886
Gear train
Illustration 77
The gear train for the oil pump
g00996214
SENR9778-02
37
Specifications Section
Illustration 78
g00996003
Balancer gears
(7) Idler gear for the oil pump that has a balancer
The number of teeth on the gear .................... 44
The bore diameter of the idler
gear .................................. 37.197 to 37.212 mm
(1.4644 to 1.4650 inch)
The hub diameter for the idler
gear .................................. 37.152 to 37.162 mm
(1.4627 to 1.4631 inch)
The end play for the idler gear .. 0.12 to 0.27 mm
(0.0047 to 0.0106 inch)
(8) Gear for the oil pump that has a balancer
The number of teeth on the gear .................... 17
Backlash between the oil pump gear (8) and the idler
gear (7) ... 0.097 to 0.17 mm (0.0038 to 0.0067 inch)
38
Specifications Section
SENR9778-02
i02234222
Flywheel
i01957025
Flywheel Housing
Four cylinder
Illustration 80
g00631781
(1) Bolt
Illustration 79
g00584712
Standard flywheel
Three cylinder
The three cylinder engine is equipped with a back
plate.
(3) Bolt
Tighten the flywheel bolts to the following
torque. .................................... 105 Nm (77 lb ft)
i02234223
Crankshaft Pulley
Non-standard flywheel
Note: A special flywheel is aligned to a dowel on the
crankshaft.
Illustration 81
A standard pulley
g00915497
SENR9778-02
39
Specifications Section
Non-standard pulley
Illustration 82
g01126584
(1) T Mark
(2) Alignment mark
Fan Drive
Illustration 83
g00926178
40
Specifications Section
SENR9778-02
i01958367
Alternator
12 Volt and 24 Volt Alternator
Illustration 84
g00959541
A typical alternator
V-Belt
Note: The V-belt must be checked by a gauge. Refer
to the Testing and Adjusting, V-Belt-Test for the
correct type of gauge in order to check the V-belt.
V-belt tension ..................................... 535 N (120 lb)
SENR9778-02
41
Specifications Section
i01958653
Starter Motor
24 Volt Starter Motor
Illustration 85
The 24 volt starter motor which shows the electrical connections
g00974968
42
Specifications Section
SENR9778-02
g00977365
Illustration 86
The 12 volt starter motor which shows the electrical connections
Tighten the nuts (2) for the bus bar (1) that is
installed on top of the glow plugs to the following
torque. ............................................... 2 Nm (18 lb in)
Glow Plugs
Illustration 87
Typical example
g00955714
SENR9778-02
43
Index Section
Index
A
Alternator ............................................................... 40
12 Volt and 24 Volt Alternator ............................ 40
V-Belt ................................................................. 40
C
Camshaft ...............................................................
Camshaft Bearings ................................................
Connecting Rod.....................................................
Connecting Rod Bearing Journal...........................
Crankcase Breather...............................................
Engine model DK and DJ...................................
Crankshaft ............................................................
Crankshaft Pulley ..................................................
Non-standard pulley...........................................
Crankshaft Seals ...................................................
Cylinder Block........................................................
Four Cylinder Engine .........................................
Three Cylinder Engine .......................................
Cylinder Head........................................................
Four Cylinder engine..........................................
Four Cylinder Engine .........................................
Three Cylinder engine........................................
Three Cylinder Engine .......................................
Cylinder Head Valves ............................................
15
16
32
31
22
23
26
38
39
30
24
24
25
12
12
13
12
13
10
E
Engine Design ....................................................... 4
Four Cylinder Engine ......................................... 4
Three Cylinder Engine ....................................... 4
Engine Lifting Bracket............................................ 39
Engine Oil Bypass Valve ....................................... 20
Installed in the Balancer..................................... 20
Installed in the Oil Pump .................................... 20
Engine Oil Filter ..................................................... 17
Replaceable Element......................................... 17
Spin-on Oil Filter ................................................ 17
Engine Oil Pan....................................................... 21
Front sealant ...................................................... 21
Rear sealant....................................................... 21
The cast iron oil pan........................................... 22
Engine Oil Pressure............................................... 19
Engine Oil Pump.................................................... 17
Four Cylinder and Three Cylinder Engines without
Balancer Group ................................................ 19
Four Cylinder Engines with Balancer Group...... 17
Exhaust Manifold ................................................... 14
Four Cylinder Engine ......................................... 14
Three Cylinder Engine ....................................... 15
F
Fan Drive ............................................................... 39
Fan drive housing .............................................. 39
Flywheel ................................................................ 38
Non-standard flywheel ....................................... 38
Flywheel Housing .................................................. 38
Four cylinder ...................................................... 38
Three cylinder .................................................... 38
Front Housing and Covers..................................... 35
Fuel Injection Lines................................................ 5
Fuel Injection Pump (Bosch EPVE for the 1104
engines only) ....................................................... 6
Fuel Injection Pump (Delphi DP210 DPA and DPG
fuel injection pumps)............................................ 5
Delphi DP210..................................................... 5
Delphi DPA......................................................... 6
Delphi DPG ........................................................ 6
Fuel Injection Pump (Delphi STP) ......................... 7
Fuel Injectors ......................................................... 8
Fuel Transfer Pump............................................... 8
G
Gear Group (Front)................................................ 36
Engines that have a Balancer ............................ 37
Glow Plugs ............................................................ 42
I
Important Safety Information ................................. 2
L
Lifter Group............................................................ 9
M
Main Bearing Journal............................................. 31
The shell for the main bearings.......................... 31
P
Piston and Rings ...................................................
Piston .................................................................
Piston Cooling Jet..................................................
Piston Cooling Jet Alignment .............................
33
34
34
35
R
Rocker Shaft.......................................................... 9
S
Specifications Section ........................................... 4
Starter Motor.......................................................... 41
12 Volt Starter Motor .......................................... 42
24 Volt Starter Motor .......................................... 41
T
Table of Contents...................................................
Turbocharger .........................................................
Four Cylinder Engine .........................................
Three Cylinder Engine .......................................
3
13
14
14
V
Valve Mechanism Cover........................................ 10
The Cover for the Four Cylinder Engine ............ 10
The Cover for the Three Cylinder Engine .......... 10
W
Water Pump........................................................... 24
Water Temperature Regulator and Housing .......... 23
Water Temperature Regulator............................ 24
Printed in U.K.