Specifications: 1600 Series Industrial Engine
Specifications: 1600 Series Industrial Engine
Specifications: 1600 Series Industrial Engine
May 2012
Specifications
1600 Series Industrial Engine
XGA (Engine)
XGB (Engine)
XGD (Engine)
XGE (Engine)
XGF (Engine)
XGH (Engine)
Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Transfer Pump ............................................. 4
Fuel Filter Base .................................................... 5
Unit Injector Actuation Oil Manifold ....................... 6
Unit Injector Hydraulic Pump ................................ 6
Electronic Unit Injector .......................................... 7
Rocker Shaft ........................................................ 7
Valve Mechanism ................................................. 8
Valve Mechanism Cover ...................................... 9
Cylinder Head Valves ........................................... 9
Cylinder Head ...................................................... 10
Turbocharger ........................................................ 12
Exhaust Gas Valve (NRS) (If Equipped) ............... 13
Exhaust Cooler (NRS) (If Equipped) ..................... 15
Inlet Manifold ....................................................... 16
Exhaust Manifold ................................................. 17
Camshaft ............................................................. 17
Camshaft Bearings .............................................. 18
Engine Oil Filter Base .......................................... 18
Engine Oil Cooler ................................................. 19
Engine Oil Pump .................................................. 19
Engine Oil Pan ..................................................... 21
Crankcase Breather ............................................. 23
Water Temperature Regulator Housing ................ 23
Water Temperature Regulator .............................. 24
Water Pump ......................................................... 24
Cylinder Block ...................................................... 25
Cylinder Liner ....................................................... 26
Crankshaft ........................................................... 27
Vibration Damper ................................................. 30
Connecting Rod Bearing Journal ......................... 30
Main Bearing Journal ............................................ 30
Connecting Rod ................................................... 31
Piston and Rings .................................................. 32
Piston Cooling Jet ................................................. 33
Housing (Front) ..................................................... 33
Gear Group (Front) ............................................... 34
Flywheel ............................................................... 35
Flywheel Housing ................................................ 35
Flywheel Housing Cover ...................................... 36
Belt Tightener ....................................................... 36
Fan Drive ............................................................. 37
Alternator and Regulator ...................................... 37
Electric Starting Motor ......................................... 38
Coolant Temperature Sensor ............................... 39
Engine Oil Pressure Sensor ................................. 39
Engine Oil Temperature Sensor ............................ 40
Inlet Air Temperature Sensor ............................... 40
Inlet Manifold Air Pressure Sensor ....................... 41
Speed/Timing Sensor .......................................... 41
Electronic Control Module ..................................... 42
Index Section
Index ..................................................................... 43
Specifications Section The front of the engine is opposite the flywheel end.
The left side and the right side of the engine are
viewed from the flywheel end. The No. 1 cylinder is
i03945589 the front cylinder.
Engine Design
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Illustration 1
Cylinder and valve location
(A) Exhaust valve
(B) Inlet valve
Valve lash
Inlet valve ......................... 0.48 mm (0.019 inch)
Exhaust valve ................... 0.48 mm (0.019 inch)
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Illustration 3
Typical example
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Illustration 4
Typical example
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Illustration 5
Typical example
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Illustration 8
Typical example
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Illustration 9 Illustration 10
Typical example Tightening sequence
Use a telescoping gauge and outside micrometer to Tighten the fasteners in the sequence that is in
measure rocker arm bore diameter at two locations. illustration 10. Tighten the fasteners to an initial
Measure diameter at (A) to (B) and (C) to (D). If the torque. ............................................. 27 N·m (20 lb ft)
difference between diameters is greater than or equal
to 0.03 mm (0.0012 inch), replace the rocker arm. Tighten the fasteners in the sequence that is in
illustration 10. Tighten the fasteners to a final
Clearance torque. ............................................. 37 N·m (27 lb ft)
Maximum clearance of both the rocker arm
bores. .............................. 0.127 mm (0.005 inch) i04234947
The service limit for both rocker arm
bores ............................. 0.0254 mm (0.001 inch) Valve Mechanism
(4) Rocker shaft
Diameter of the rocker
shaft ............................. 28.66644 ± 0.01270 mm
(1.12860 ± 0.00050 inch)
(5) Locator
(6) Pedestal
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Illustration 11
Typical example
Clearance
Clearance of the lifter ............ 0.064 to 0.115 mm
(0.00252 to 0.00453 inch)
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Illustration 13
Typical example
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Cylinder Head
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Illustration 14
Typical example
Inlet ................................... 1.32 mm (0.052 inch) Tighten the bolts in the sequence that is shown in
Exhaust ............................. 1.16 mm (0.046 inch) illustration 15 to an initial torque. .. 150 N·m (110 lb ft)
Maximum valve face-to-valve stem Tighten the bolts in the sequence that is shown in
runout .................................. 0.038 mm (0.0015 inch) illustration 15 to a second torque. ................ 238 N·m
(175 lb ft)
(3) Valve stem diameter
Inlet .................................. 7.92861 ± 0.0089 mm
(0.31215 ± 0.00035 inch)
Exhaust .............................. 7.9083 ± 0.0089 mm
(0.31135 ± 0.00035 inch)
Clearance
Maximum clearance of the inlet valve
stem .............................. 0.010 mm (0.0004 inch)
Maximum clearance of the exhaust valve
stem ................................... 0.11 mm (0.005 inch) g02278874
Illustration 16
Inlet valve ............................ 145.44 ± 0.203 mm Tighten the bolts in the sequence that is shown in
(5.726 ± 0.008 inch) illustration 16 to the following torque. .......... 238 N·m
Exhaust valve .................... 145.060 ± 0.203 mm (175 lb ft)
(5.711 ± 0.008 inch)
Tighten the bolts in the sequence that is shown in
(5) Valve head illustration 15 to the additional amount. .. 90 degrees
Diameter of inlet valve head .... 39.73 ± 0.13 mm Minimum thickness of cylinder head ....... 159.97 mm
(1.56417 ± 0.00512 inch) (6.298 inch)
Diameter of exhaust valve
head ......................................... 36.55 ± 0.13 mm
(1.43897 ± 0.00512 inch)
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Illustration 17
Typical example
Table 2 g02328933
Illustration 18
Maximum Permissible Typical example
Dimension
Distortion
Width (A) 0.10 mm (0.004 inch) (D) Valve guide height from the top of the valve guide
to the valve spring seat ............ 16.54 ± 0.25 mm
Length (B) 0.10 mm (0.004 inch)
(0.65118 ± 0.00984 inch)
Diagonal Line (C) 0.10 mm (0.004 inch)
(E) Outside diameter of the valve
guides .................................. 14.351 ± 0.010 mm
(0.56500 ± 0.00039 inch)
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Turbocharger
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Illustration 19
Typical example
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Illustration 20
Typical example
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Illustration 22 Illustration 24
Typical example Typical example
(3) Tighten the bolt to the following torque. ... 13 N·m (2) Tighten the bolts to the following torque. .. 13 N·m
(115 lb in) (115 lb in)
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Illustration 25
Typical example
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Illustration 23
Typical example
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Illustration 26 Illustration 28
Typical example Typical example
(4) Tighten the bolts to the following torque. .. 31 N·m (8) Tighten the nuts to the following torque. .. 23 N·m
(23 lb ft) (17 lb ft)
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Illustration 27 Illustration 29
Typical example Typical example
(5) Tighten the nuts to the following torque. .. 31 N·m (9) Tighten the bolts to the following torque. .. 13 N·m
(23 lb ft) (115 lb in)
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Illustration 30
Typical example
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Inlet Manifold
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Illustration 31
Typical example
(1) Inlet manifold
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Illustration 32
Typical example
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Exhaust Manifold
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Illustration 33
Typical example
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Camshaft
Typical example
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Camshaft Bearings
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Illustration 36
Typical example
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Illustration 35
Typical example
Number of lobes
Inner rotor ......................................................... 4
Outer rotor ........................................................ 5
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Illustration 37
Typical example
(2) Engine oil cooler
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Illustration 39
Typical example
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Illustration 38
Typical example
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Illustration 40
Typical example
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Illustration 41
Typical example
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Illustration 42
Typical example
(1) Gasket (4) Oil pan
(2) Gasket (7) Oil suction tube assembly
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Illustration 43
Typical example
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Illustration 44
Tighten the heater plug for the engine oil pan (if
equipped) to the following torque. ... 68 N·m (50 lb ft)
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Crankcase Breather
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Illustration 46
Typical example
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Illustration 47
Typical example
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Illustration 49
Typical example
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Cylinder Block
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Illustration 50
Typical example
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Illustration 51
Typical example
(5) Main bearing cap bolts Bore diameter for the lifters .. 28.5306 ± 0.01905 mm
(1.12325 ± 0.00075 inch)
Use the following procedure in order to install the
main bearing cap bolts:
i04266509
3. Evenly tighten the main bearing cap bolts. The maximum counterbore depth before adding
shims .................................... 10.49 mm (0.413 inch)
Initial torque for the main bearing cap
bolts. ...................................... 136 N·m (100 lb ft) Counterbore depth (including shims - if
any) ............... 8.84 to 8.89 mm (0.348 to 0.350 inch)
Final torque for the main bearing cap
bolts. ...................................... 177 N·m (130 lb ft) The maximum taper of the cylinder liner (bore wear
step, at top of ring travel) ........ 0.10 mm (0.004 inch)
4. Tighten the bolts for the main bearing cap for an
additional 90 degrees. Flange thickness of the cylinder
liner ............... 8.94 to 8.96 mm (0.352 to 0.353 inch)
Note: Ensure that the crankshaft can rotate freely.
Inside diameter of the cylinder
Distance from the centerline of the crankshaft liner .... 116.57 to 116.60 mm (4.5895 to 4.5905 inch)
bore to the top surface of the cylinder
block ... 368.3 ± 0.05 mm (14.49997 ± 0.00197 inch)
i04068119
Crankshaft
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Illustration 52
Typical example
(1) Crankshaft gear
(2) Crankshaft
(3) Crankshaft thrust washer
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Illustration 53
Typical example
Table 3
The Undersize Diameter of the Crankshaft Journals
Dimension 0.25 mm (0.010 inch) 0.51 mm (0.020 inch) 0.76 mm (0.030 inch)
107.685 to 107.715 mm 107.425 to 107.455 mm 107.175 to 107.205 mm
A
(4.23956 to 4.24074 inch) (4.22932 to 4.23050 inch) (4.21948 to 4.22066 inch)
79.741 to 79.771 mm 79.487 to 79.517 mm 79.233 to 79.263 mm
B
(3.13940 to 3.14058 inch) (3.12940 to 3.13058 inch) (3.11940 to 3.12058 inch)
C 39.99 mm (1.57441 inch) 39.99 mm (1.57441 inch) 39.99 mm (1.57441 inch)
34.06 to 34.32 mm 34.06 to 34.32 mm 34.06 to 34.32 mm
D
(1.34094 to 1.35118 inch) (1.34094 to 1.35118 inch) (1.34094 to 1.35118 inch)
33.858 to 34.95 mm 33.858 to 34.95 mm 33.858 to 34.95 mm
E
(1.33299 to 1.37598 inch) (1.33299 to 1.37598 inch) (1.33299 to 1.37598 inch)
F Do not machine this diameter. Do not machine this diameter. Do not machine this diameter.
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Illustration 54
(4) Journal #1 (7) Journal #4 (10) Journal # 7
(5) Journal #2 (8) Journal #5
(6) Journal #3 (9) Journal #6
Refer to Table 4 for the run out of the crankshaft Refer to Specifications, “Connecting Rod Bearing
journals. Journal” for more information on the connecting rod
bearing journals and connecting rod bearings.
Table 4
Journal Run Out of the Journals Refer to Specifications, “Main Bearing Journal” for
information on the main bearing journals and for
(1) Mounting information on the main bearings.
(2) 0.046 to 0.127 mm
(0.00181 to 0.00500 inch)
(3) 0.046 to 0.127 mm
(0.00181 to 0.00500 inch)
(4) 0.046 to 0.127 mm
(0.00181 to 0.00500 inch)
(5) 0.046 to 0.127 mm
(0.00181 to 0.00500 inch)
(6) 0.046 to 0.127 mm
(0.00181 to 0.00500 inch)
(7) Mounting
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Surface finish of bearing journals and crank
Illustration 55 pins ....................................................... 0.15 microns
Typical example
Surface finish of radii .............................. 1.5 microns
(1) Tighten the bolts to the following torque. .. 62 N·m
(46 lb ft) Width of new main bearing journal .. 34.19 ± 0.13 mm
(1.346 ± 0.005 inch)
(2) Tighten the bolts to the following
torque. .................................. 163 N·m (120 lb ft)
The shell for the main bearings
i04066230 The shells for the main bearings are available
for remachined journals which have the following
Connecting Rod Bearing undersize dimensions.
Journal Undersize bearing shell .... 0.25 mm (0.010 inch)
Undersize bearing shell .... 0.51 mm (0.020 inch)
Undersize bearing shell .... 0.76 mm (0.030 inch)
The original size of the connecting rod bearing Width of the main bearing
journal ....... 80.010 ± 0.015 mm (3.15 ± 0.0006 inch) shells ....... 34.1884 ± 0.127 mm (1.346 ± 0.005 inch)
Maximum permissible wear of a bearing journal on a Clearance between the bearing shell and the main
new connecting rod ......... 0.01524 mm (0.0006 inch) bearing journals .......................... 0.046 to 0.127 mm
(0.00181 to 0.00500 inch)
Width of the connecting rod bearing
journals ............................... 39.99230 ± 0.11430 mm
(1.5745 ± 0.0045 inch)
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Illustration 56
Typical example
0.25 mm (0.010 inch) Installed diameter for the finished bore for the
connecting rod bearing ............... 80.05 to 80.10 mm
0.51 mm (0.020 inch) (3.15157 to 3.15354 inch)
0.76 mm (0.030 inch)
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Illustration 59
Typical example
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Illustration 60 Illustration 61
Typical example Typical example
(1) Tighten the bolt to the following torque. ... 13 N·m (1) Tighten the bolts to the following torque. .. 31 N·m
(115 lb in) (23 lb ft)
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Illustration 62
Typical example
(2) Tighten the bolts to the following torque. .. 31 N·m Tighten the bolt for the upper idler gear to the
(23 lb ft) following torque. ................... 326 N·m (240 lb ft)
Width of idler gear and split bearing
(3) Tighten the fasteners to the following assembly ...................... 39.624 mm (1.560 inch)
torque. ...................................... 31 N·m (23 lb ft) Inside diameter of idler gear bearings with
flanges ........................ 34.925 mm (1.3750 inch)
(4) Tighten the fasteners to the following Outside diameter of idler gear hub ... 34.925 mm
torque. ...................................... 31 N·m (23 lb ft) (1.3750 inch)
Clearance of idler gear bearing on
(5) Tighten the fasteners to the following hub .................................... 0.0127 to 0.0381 mm
torque. ...................................... 31 N·m (23 lb ft) (0.0005 to 0.0015 inch)
Idler gear end play with roller
(6) Tighten the fasteners to the following bearings ......................... 0.45720 ± 0.02540 mm
torque. ...................................... 31 N·m (23 lb ft) (0.018 ± 0.001 inch)
Number of teeth .............................................. 68
(7) Tighten the fasteners to the following
torque. ...................................... 31 N·m (23 lb ft) (3) High-pressure oil pump drive gear
Tighten the bolt to the following torque. .. 240 N·m
i04194989 (177 lb ft)
Number of teeth .............................................. 22
Gear Group (Front)
(4) Lower idler gear
Tighten the bolt for the lower idler gear to the
following torque. ................... 639 N·m (470 lb ft)
Width of idler gear and split bearing
assembly ..................... 42.1132 mm (1.658 inch)
Inside diameter of idler gear bearings with
flanges .......................... 41.275 mm (1.625 inch)
Outside diameter of idler gear hub ... 41.275 mm
(1.6250 inch)
Clearance of idler gear bearing on
hub .................................... 0.0127 to 0.0381 mm
(0.0005 to 0.0015 inch)
Idler gear end play with roller
bearings ......................... 0.40640 ± 0.02540 mm
(0.016 ± 0.001 inch)
Number of teeth .............................................. 68
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Flywheel
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Illustration 65
Typical example
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Illustration 64
Typical example
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Illustration 66 Illustration 67
Typical example Typical example
(1) Tighten the bolts to the following torque. .. 13 N·m (1) Tighten the bolt to the following torque. ... 62 N·m
(115 lb in) (46 lb ft)
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Fan Drive
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Illustration 70
Typical example
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Illustration 68 i04262071
Typical example
Alternator and Regulator
(1) Tighten the bolt to the following
torque. ................................... 51.5 N·m (38 lb ft)
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Illustration 69
Typical example g02887576
Illustration 71
Typical example
(2) Tighten the bolts to the following torque. .. 31 N·m
(23 lb ft) (1) Tighten the nut on the battery terminal to the
following torque. ................ 11.25 N·m (100 lb in)
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Illustration 74
Typical example
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Illustration 72
Typical example When the electric starting motor is viewed from
the drive end, the motor rotates in the following
(3) Tighten the nut on the alternator pulley to the direction. ................................................... Clockwise
following torque. ..................... 102 N·m (75 lb ft)
Maximum output ............................................ 5.3 kW
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(5) Motor terminal
Illustration 73
Typical example Tighten the nut on the battery terminal to the
following torque. ....................... 26 N·m (19 lb ft)
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Illustration 75 Illustration 76
Typical example Typical example
(1) Tighten the engine coolant temperature sensor to (1) Tighten the engine oil pressure sensor to the
the following torque. ................. 18 N·m (13 lb ft) following torque. ..................... 12 N·m (106 lb in)
Operating temperature range ............... 60° to 150°C Operating pressure .... 20.7 to 682 kPa (3 to 100 psi)
(140° to 270°F)
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Illustration 77 Illustration 78
Typical example Typical example
(1) Tighten the engine oil temperature sensor to the (1) Tighten the inlet air temperature sensor to the
following torque. ....................... 18 N·m (13 lb ft) following torque. ....................... 18 N·m (13 lb ft)
Operating temperature range ............... 60° to 150°C Operating temperature range ................... 0° to 90°C
(140° to 270°F) (32° to 162°F)
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Illustration 79
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Typical example Illustration 80
Typical example
(1) Tighten the inlet manifold air pressure sensor to
the following torque. ............... 12 N·m (106 lb in) (1) Tighten the bolt to the following torque. ... 13 N·m
(115 lb in)
Operating voltage ........................................... 5 VDC
Operating voltage ........................................... 5 VDC
Operating pressure ... 28.6 to 616.5 kPa (4 to 89 psi)
Camshaft Position Sensor
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Illustration 81
Typical example
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Illustration 82
Typical example
Index
A I
E
S
Electric Starting Motor ........................................... 38
Electronic Control Module ..................................... 42 Specifications Section ........................................... 4
Electronic Unit Injector........................................... 7 Speed/Timing Sensor ............................................ 41
Engine Design ....................................................... 4 Camshaft Position Sensor ................................. 41
Engine Oil Cooler .................................................. 19 Crankshaft Position Sensor ............................... 41
Engine Oil Filter Base............................................ 18
Engine Oil Pan....................................................... 21
Engine Oil Pressure Sensor .................................. 39 T
Engine Oil Pump.................................................... 19
Engine Oil Temperature Sensor ............................ 40 Table of Contents................................................... 3
Exhaust Cooler (NRS) (If Equipped) ..................... 15 Turbocharger ......................................................... 12
Exhaust Gas Valve (NRS) (If Equipped)................ 13
Exhaust Manifold ................................................... 17
U
G
W
Gear Group (Front)................................................ 34
Water Pump........................................................... 24
Water Temperature Regulator ............................... 24
H Water Temperature Regulator Housing ................. 23
Housing (Front)...................................................... 33