Onan L Series User manual

Service
Manual
L series
DieselEngine
934-0750
6-86
Printed in USA.

Important Safety Precautions
Read andobservethese safety precautionswhen using
or working on electric generators, engines and related
equipment. Also read and follow the literatureprovided
withthe equipment.
Proper operationand maintenanceare criticalto perfor-
manceand safety. Electricity, fuel, exhaust, moving parts
and batteries present hazards that can cause severe
personalinjuryor death.
FUEL, ENGINEOIL, AND FUMES ARE
FLAMMABLEAND TOXIC
Fire, explosion, and personal injury can resultfrom im-
properpractices.
Used engine oil, and benzene and lead, found in
some gasoline, havebeen identifiedby government
agencies as causing cancer or reproductivetoxicity.
When checking, drainingor adding fuel or oil, do not
ingest, breathe the fumes, or contact gasoline or
usedoil.
Do notfilltanks with engine running. Do not smoke
around the area. Wipe up oil or fuel spills. Do not
leave ragsinenginecompartment or on equipment.
Keepthisand surroundingarea clean.
Inspectfuel systembeforeeach operation and peri-
odically while running.
Equipfuel supply with a positivefuel shutoff.
Do not store or transport equipmentwith fuel intank.
Keepan ABGrated fire extinguisheravailable near
equipmentand adjacent areas for use on alltypes of
fires except alcohol.
Unlessprovidedwith equipment or notedotherwise
in installationmanual, fuel lines must becopper or
steel, secured, free of leaks and separated or
shieldedfrom electricalwiring.
Useapproved, nonconductiveflexible fuel hosefor
fuel connections. Do not usecopper tubing as aflex-
ible connection. Itwill work-harden and break.
EXHAUST GAS ISDEADLY
Engine exhaust contains carbon monoxide (CO),
an odorless, invisible, poisonous gas. Learn the
symptomsof CO poisoning.
Neversleepinavessel, vehicle, or roomwith agen-
set or engine runningunlessthe area is equipped
with an operating CO detector with an audible
alarm.
Eachtime the engine or gensetisstarted, or at least
every day, thoroughly inspectthe exhaust system.
Shutdownthe unit andrepair leaksimmediately.
Warning: Engineexhaust is known to the State of
Californiato cause cancer, birthdefects and other
reproductiveharm.
Make sure exhaust is properly ventilated.
Vessel bilge must have an operating power
exhaust.
Vehicle exhaust system must extend beyond ve-
hicle perimeter and not near windows, doors or
vents.
Do not use engineor genset coolingair to heat an
area.
Do not operate enginelgenset in enclosed area
without amplefresh air ventilation.
Expel exhaust away from enclosed, sheltered, or
occupiedareas.
Make sure exhaust system components are se-
curelyfastenedand notwarped.
MOVING PARTS CAN CAUSESEVERE
PERSONAL INJURY OR DEATH
Do not remove any guardsor coverswith the equip-
ment running.
Keephands, clothing, hair, andjewelry away from
movingparts.
Before performing any maintenance, disconnect
battery (negative
[-I cablefirst) to preventacciden-
tal starting.
Makesure fasteners andjoints are secure. Tighten
supports and clamps, keepguards in positionover
fans, drive belts, etc.
If adjustments must be made while equipment is
running, useextreme caution around hot manifolds
and moving parts, etc. Wear safety glasses and pro-
tectiveclothing.
BATTERYGAS IS EXPLOSIVE
Wear safety glassesand do not smokewhileservic-
ingbatteries.
Always disconnect battery negative
(-) lead first
andreconnect itlast. Makesure you connect battery
correctly. Adirect short across batteryterminalscan
causean explosion. Do not smokewhile servicing
batteries. Hydrogengas given off duringcharging is
explosive.
Do notdisconnect or connect battery cables
if fuel
vaporsare present. Ventilate the areathoroughly.

DO NOT OPERATE IN FLAMMABLEAND
EXPLOSIVE ENVIRONMENTS
Flammablevapor can be ignitedby equipmentoperation
or cause a diesel engineto overspeed and become diff
i-
cultto stop, resulting in possible fire, explosion, severe
personal injuryand death. Do not operatediesel equip-
mentwhere a flammable vapor environment can be
createdbyfuel spill, leak, etc., unlessequipped with
anautomatic safety device toblocktheair intakeand
stoptheengine.
HOT COOLANT CAN CAUSE SEVERE
PERSONAL INJURY
Hot coolant is under pressure. Do not loosen the
coolant pressurecapwhile the engine is hot. Let the
enginecool before openingthe pressurecap.
ELECTRICALSHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
Do not service control panelor enginewith unit run-
ning. Highvoltages are present. Work that must be
done while unit is runningshould be done only by
qualifiedservice personnel.
Do not connect thegenerator set to the publicutility
or to any other electricalpower system. Electrocu-
tioncan occur at a remotesite where line or equip-
ment repairsare beingmade. An approvedtransfer
switch must be used if morethan one powersource
isconnected.
Disconnectstarting battery (negative
[-I cablefirst)
before removingprotectiveshields or touching elec-
tricalequipment. Use insulativemats placedon dry
wood platforms. Do notwear jewelry, dampclothing
or allow skin surface to be damp when handling
electricalequipment.
Use insulatedtools. Do not tamper with interlocks.
Follow all applicable state and local electrical
codes. Haveall electricalinstallationsperformedby
a qualifiedlicensedelectrician. Tag open switches
to avoidaccidentalclosure.
With transfer switches, keep cabinet closed and
locked. Only authorized personnel should have
cabinet or operationalkeys. Due to serious shock
hazardfrom highvoltageswithincabinet, all service
andadjustmentsmust be performedby an electri-
cianor authorizedservice representative.
Ifthe cabinet must be opened for any reason:
1. Move genset operation switch or StopIAutol
Handcrankswitch (whicheverapplies) to Stop.
2. Disconnectgenset batteries(negative [-I lead
first).
3. Remove AC power to automatic transfer
switch. If instructions require otherwise, use
extremecautiondue to shock hazard.
MEDIUMVOLTAGE GENERATOR SETS
(601 V TO 15kV)
Medium voltage acts differently than low voltage.
Specialequipmentandtrainingare requiredto work
on or aroundmedium voltage equipment. Operation
and maintenance must be done only by persons
trained and qualified to work on such devices. Im-
proper use or procedureswill result in severe per-
sonal injury or death.
Donot work on energizedequipment. Unauthorized
personnel must not be permitted near energized
equipment. Induced voltage remains even after
equipment isdisconnected from the power source.
Plan maintenance with authorized personnel so
equipment can be de-energized and safely
grounded.
GENERALSAFETY PRECAUTIONS
Do not work on equipmentwhen mentallyor physi-
cally fatigued or after consumingalcohol or drugs.
Carefullyfollow allapplicablelocal, state andfeder-
al codes.
Neverstep on equipment(as when enteringor leav-
ing the engine compartment). It can stress and
break unit components, possibly resulting in dan-
gerous operating conditionsfrom leakingfuel, leak-
ing exhaustfumes, etc.
Keepequipmentandareaclean. Oil, grease, dirt, or
stowed gear can cause fire or damage equipment
byrestrictingairflow.
Equipment owners and operators are solely re-
sponsible for operating equipment safely. Contact
your authorizedOnanICumminsdealer or distribu-
tor for moreinformation.
KEEP THIS DOCUMENT NEAR EQUIPMENT FOR
EASY REFERENCE.

Safety Precautions
It is recommended that you read your engine manual and
become thoroughly acquainted with your equipment before
you
start the engine.
This symbd mlbn to a hazard or
/I ~nS8kpractice which can result in
severe personal iniury or
death.
Thk symbol refers to a hazard or
unsafe practice which can result in
personal injury or product or pmW
damage.
Fuels, electrical equipment, batteries. exhaust gases and
moving parts present potential hazards that can result in
serious, personalinjury.Take careinfollowingtheserecom-
mendedprocedures.All local,stateandfederalcodesshould
beconsultedandcompliedwith.
Thh engine is not designed or in-
I to/ ,or usein any type of airera&
Useof thisengineinaircraftcanmsullinenginefailurn
and causer sodous personal injury or Wth.
Gonemi
Provideappropriatefireextinguishersandinstallthem in
convenientlocations.
Use an extinguisherratedABC by
NFPA.
Makesurethatallfastenerson
the enginearesecureand
accurately torqued. Keep guards in positionover fans
driving
belts, etc.
Ifitisnecessarytomakeadjustmentswhiletheengineis
running,useextremecautionwhenclose
to hotexhausts.
moving
parts, etc.
Prote~tA~MovingP~
Do notwear loose clothinginthevicinityof moving parts,
such as PTO shafts, flywheels, blowers, couplings,fans,
Wts. etc.
Keep your handsaway from moving parts.
Battah
Beforestartingwork on theengine, disconnect batteries
to preventinadvertentstartingof the engine.
DO NOT SMOKE while servicing
batteria Lead acid
batteries giveoff a highlyexplosivehydrogengas which
can
be ignitedbyflame. dectricalarcingor by smoking.
Verify barn polarity before connm battery cables
Connectnegativecabiotast
Fud Systm
DO NOTfillfueltanks whileengine isrunning.
DO NOTsmokeor useanopenflameinthevicinityof the
engineorfueltank Internalcombustionenginefuelsant
highlyflamfnabl8.
Fuellines must
be of steel piping, adequately secured, ..
and free from leaks. Piping at the engine should be
approved flexible line. Do not use copper piping for
flexible lines as copper will work harden and become
brittleenough to break.
Be sureallfuel supplies have a positiveshutoff valve.
Exhaust System
Exhaust productsof any internalcombustionengineare
toxicandcan causeinjury,ordeath ifinhaled.All engine
applications. especially those within a confined area,
should
be equippedwithanexhaustsystemtodischarge
gasesto the outsideatmosphere.
Do notuseexhaustgasesto heat a compartment.
Make sure that your exhaust system is free
of leaks.
Ensure that exhaust manifolds are secure and are not
warped by
bolts unevenlytorqued.
Exhaust Gas h Dudlyl
Exhaust gases contain carbon monoxide, a poisonous gas
that can cause unconsciousnessanddeath. Itisan odorless
andcolorlessgas formedduringcombustionof hydrocarbon
fuels. Symptomsof carbonmonoxidepoisoningare:
Dizziness Vomiting
Headache MuscularTwitching
W- aMSleepiness ThrobbinginTemples
Ifyouexperienceany ofthesesymptoms.getoutintofreshair
immediately, shut down the unitand do not use until
it has
been inspected.
The best protectionagainst carbon monoxide inhalation is
proper installation and regular, frequent inspections of the
completeexhaustsystem. If you noticeachangeinthesound
or appearance of exhaust system. shut the unit down
immediatelyandhave it inspectedand repairedatonceby a
competent mechanic.
codkr0a-n
Coolantsunderpressurehaveahigherboilingpointthan
watetr. 00 NOT open a radiator pressure cap when
coolant temperature is above 212OF
(lOO°C) or while
engineisrunning
Keoptheltnitmd~AnrCkan
Makesurethatoilyragsarenotleftonor neartheengine.
Remove all unnecessary grease and oil from the untt
Accumulatedgre8seand
oil cancause overheating and
subsequentengine
damage and presenta potential fire
haz8a

Foreword
Thismanual is designed toassistall servicepersonnel withthemaintenance and overhaul of Onan L series
dieselengines. Itpresentsadescription ofeachsystemsfunctiontogether withinstructions onservicing and
overhaul procedures. A
DIMENSIONS AND CLEARANCES SECTION is provided and must be closely
followed whenoverhauling or servicing any part of engine.
Unless otherwise specified the information applies to all
L diesel engines. Whereinformation applies to a
specific engine it is so noted.
These engines have a counterclockwise rotation when viewed from the rear, flywheel end of engine.
Throughoutthismanual, "right-handMand"left-handMsidesaredetermined by facing thedriveend (flywheel)
of engine.
The manner in which the engine is operated and the maintenance performed on it will determine its
performance, safety, and durability. Equally important is the use of proper procedures during engine over-
haul. Beforeoperating,servicing, or beginningan overhaul,read thismanualcarefully tofamiliarize yourself
with the engine procedures involved, and the tools required. Keep this manual handy and refer to it often.
This manual is divided into 11 SECTIONS covering the topics listed on the CONTENTS page. At the
beginning of each
SECTION is an index of the subjects covered. Pages are numbered consecutively,
beginning with a new Page
1 at the outset of each SECTION. Each page number is preceded by the
appropriate reference number for that
SECTION. All illustrations are numbered consecur~vely,beginning
witha new Figure
1 in each SEC'TION.
Alwaysgivecomplete MODEL and SERIALNO. ofenginebeingserviced when ordering replacementparts.

Contents
SECTION AND TITLE
1. Specifications
2. Dimensions and Clearances
3. Torques
4. Special Tools
5. Troubleshooting
6. Start-Up
7. Maintenance
8. Oil System
9. Cooling System
10. Fuel System
11. Exhaust System
12. ElectricalSystem
13. Engine Disassembly
14. Turbocharger
!-GziGZl
INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN
SEVERE PERSONAL lNJURY AND/OR EQUIPMENT DAMAGE. SERVICE
PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTREAL AND/OR
MECHANICAL SERVICE.

1. Specifications
SUBJECT PAGE
ENGINE
.. ... ... .. ...... . . . ... . .. . ...... . . . .. . .... .. , . . . . .. ... . . . . . ... . -1-1
STATIC PUMPTlMlNG . . .. .. .. . .... .. . ..... .. .. . .. . . . . .. . . .. . .. . . . . . . . . -1-5

INDUSTRIAL ENGINE
UNITOF L SERIES
SPECIFICATION MEASURE L317 L423 L634 L634T
Number of Cyl~nders 3 4 6 6
Diesel Fuel ASTM2-D ASTM2-D ASTM2-0 ASTM2-D
Bore mm 89 89 89 89
(in) (3.50) (3.50) (3.50) (350)
Stroke mm 92 92 92 92
(in) (3.62) (3.62) (3.62) (3.62)
Displacement litre 1.7 2.3 3.4 3.4
(cuin) (105)
( 140) (210) (210)
Compression Ratio 21.5 to 1 21.5 to 1 21.5 to 1 21 5to1
Rated Speed (Maximum) RPM 3600 3600 3600 3600
Power (rntermrttent) at kW 31.3 43.3 65.0 85.8
Rated Speed' (BHP) (42.0) (58.0) (87.0) (115.0)
Power (continuous) at kW 28.5 39.4 59.1 78.0
RatedSpeed' (BHP) (38.0) (52.7) (79.1
) (1045)
Firing Order 132 1243 153624 153624
Crankshaft Rotation Counter
- Counter Counter Counter
(viewedfrom flywheel) Clockwise Clockwise Clockwise
Clockwise
Governor Variable Speed Mechan~cal Variable Speed Mechanical
Valve Lash(Spec
A to C) +
Intake mm 0.20 0.20 0.20 0.30
(in) (0.008) (0.008) (0.008) (0.01
2)
Exhaust mm 0.30 0.30 0.30 0.30
(in) (0.012) (0.012) (0.012) (0.012)
OilFilter FullFlow FullFlow FullFlow FullFlow
Crankcase Capacity litre 5.7
5.7
8.5 11.4
with filter change (qt) (6)
(6) (9) (12)
All dtmensions~nmetr~c (U S customary unitsof measure ~nparentheses) unlessotherw~sespecified
- Power obtained and corrected tn accordance with SAEJ1349 [I00 kPa (29 61 ~nchesHg)barometric pressureat 2S°C (77°F) alr tnlet
temperature] wtthout air cleaner.fan, and exhaust muffleron naturally
aspirated englnes
Power lossesfor typlcal air cleaner and muffler tnstallations ~ncludedon turbochargedengtnes
+ - Begtnn~ng Spec 0 no valve lash adjucmnerrt requtred.

MARINE ENGINE
UNITOF L SERIES
SPECIFICATION MEASURE
L317D-M L4230-M
Number of Cylinders 3 4
Diesel Fuel ASTM2-D ASTM2-D
Bore (in) (3.50) (3.50)
Stroke mm 92 92
Displacement litre 1.7 2.3
(cuin)
( 105) (140)
Compression Ratio 21.5 to
1 21.5 to 1
RatedSpeed (Maximum) RPM 3600 3600
Power (intermittent)at kW 32.4 44.7
RatedSpeed* (BHP) (43.5) (60.0)
Power (continuous) at kW 29.5 40.7
Rated Speed' (BHP) (39.5) (54.5)
FiringOrder 132 1243
Crankshaft Rotation Counter Counter
(viewedfrom flywheel) Clockwise Clockwise
Governor Variable Speed Mechanical
Valve Lash(Spec
A to C) +
Intake mm 0.20 0.20
(in) (0.008) (0.008)
Exhaust mm 0.30 0.30
(in)
(0 012) (0.012)
Oil Filter Full Flow Full Flow
Crankcase Capacity litre 5.7
5.7
with filter change
(9t) (6) (6)
Coolant Capacity litre
6.8 9.1
with heat exchanger (qt) (7.2)
(9.6)
All dimensionsin metric (US. customaryunitsof measurein parentheses) unlessotherwisespecified.
- Power obtained with 100 kPa (29 .92 inchw Hg) barometric pressureat 1S0C (60°F) air inlet
temperature without air cleaner or exhaust muffler.
+ - Beg~nntng Spec D no valve lash adjustment required.

POWER UNlT
UNIT OF L SERIES
SPECIFICATION MEASURE
L423 L634 L634T
Number of Cyl~nders 4 6 6
Dtesel Fuel ASTM2-D ASTM2-D ASTM2-D
Bore mm 89 89 89
(in) (3.50) (3.50) (3.50)
Stroke mm 92 92 92
(in) (3.62) (3.62) (3.62)
Displacement litre 2.3 3.4 34
(CU~n) (140) (210) (210)
compresslon Ratlo 21.5 to 1 21.5 to 1 20.5 to 1
RatedSpeed (Maximum) RPM 2600 3600 3200
Power
(intermittent) at kW 33.9 59.7 80.2
Rated Speed* (BHP) (45.5) (80.0) (107.5)
Power
(continuous) at kW 30.9 54.2 72.9
RatedSpeed* (BHP) (41.4) (72.7) (97.7)
FirlngOrder 1243 153624 153624
CrankshaftRotation Counter Counter Counter
(v~ewedfrom flywheel) Clockwise Clockw~se Clockwlse
Governor Var~ableSpeed Mechan~cal
Valve Lash (SpecA to C)
'
Intake mm 0.20 0.20 0.30
(in) (0.008) (0.008) (0.012)
Exhaust mm 0.30 0.30 0.30
(in) (0.012) (0.012) (0.012)
Oil Filter Full Flow Full Flow Full Flow
Crankcase Capacity litre 5.7 8.5 11.4
wlth fllter change (qt) (6) (9) (12)
CoolingSystemCapacity
Englnesw~thout litre 13.1 16.6
oil cooler (qt) (1
3.9) (17.5)
Englneswlth litre 13.5 17.1 17.1
oil cooler (qt) (14.2) (18.1) (18.1)
All dlmens~onsIn metrlc (US.customary un~tsof measure in parentheses)unless othemlse specified.
* - Power obta~nedand corrected in accordance wlth SAW1349 [I00 kPa (29.61 Inches HG) barometr~cpressure at 2S°C (77°F) alr Inlet
temperature],wlth air cleaner and fan.
- - Beglnn~ngSpec 0 no valve lash adjustment required.

AUTOMOTIVE ENGINE
UNIT OF L SERIES
SPECIFICATION
MEASURE L634T-A
Numberof Cylinders
6
Diesel Fuel ASTM2-D
Bore mm 89
(in) (3.50)
Stroke mm 92
(in) (3.62)
Displacement litre 3.4
(CU in) (21 0)
Compression Ratio 20.5 to 1
RatedSpeed (Maximum)
RPM 2800 3600
Power at
kW 83.5 89.5
RatedSpeed*
(BHP) (112.0) (120.0)
FiringOrder 153624
CrankshaftRotation Counter
(viewedfrom flywheel) Clockwise
Governor Min.-Max.
Valve Lash(Spec Ato C)
+
Intake mm 0.30
(in1 (0.012)
- -
Exhaust mm 0.30
(in) (0.012)
Oil Filter FullFlow
CrankcaseCapacity
l itre Referto
withfilter change
(@) EngineNameplate
All dimensions in metric (U.S. customary unitsof measurein parentheses) unlessotherwise3pecified.
- Power obtatned and corrected in accordance with SAEJ1349 1100 kPa (29.61 inch- HG) barometric pressure at 25OC (77'F) alr lnlet
temperature], without
fan.
Power lossesfor typical air cleaner and muffler installationsincludedon turbocharged engnes.
Refer
to engine nameplats for rated speed and powof.
+ - Beg~nning Spec 0 no valve lash adjumemtrequired.

STATIC PUMPTIMING SPECIFICATIONS
In February 1983 a change Was made in the internal timing of the fuel injection pump and to the pump part
numberingsystem. ASa result of these changes, itmay be necessaryto change the engine static timing when
installinga replacementfuel injection pump.
~11 fuel injection pumpsbuiltbeforeFebruary1983are markedwithasevendigit (Example:147-0453)Onan part
number.Fuelinjectionpumpsbuiltafter February f983aremarkedwithaninedigit(Example:147-0462-02)Onan
pafi number,The Onan part number is stamped On the injection pump nameplate. Engine performance is the
same for both injection pumpswhen engtnestatic timing is correctly set.
Findthe seven or ninedigit Onan part number stamped on the replacement pump and referto Table 1for the
correctstatic timing specification.
Referto
SECTION 10, FUEL SYSTEM for completefuel injection pump installation instructions.
TABLE 1. STATIC PUMPTIMING SPECIFICATIONS
Replacement Pump OriginalPump Static Timing
9digit 7 digit 15' BTDC* All Engineapplications.
9digit 9 digit 15' BTDC All engine applications. Nochange to
engine model label required.
7digit 9 digit 14.5' BTDC* 4 cylinder (700-3600 rpm)
15' BTDC* 6 cylinder (700-3600 rpm)
19' BTDC* 4 and
6 cylinder (1500and 1800rpm)
7 digit 7 digit Refer toengine model !abel for correct static
timing specification.
'Change static timingspecification on engine model label.

2. Dimensions and Clearances
SUBJECT PAGE
DIMENSIONSAND CLEARANCES . .. . . .. . . . .. .. . ..... . . ... ... . . . . ... .. .. 2-1

DIMENSIONS AND CLEARANCES
All clearances given at room temperature of 21°C (7o0F). All dimensions in millimetre~~approximateinch dimensions in
parentheses)unless otherwise specified.
Maximumallowablewear limitof
a partisthe pointatwhichitsproperfunction becomesimpaired.Eventhough partsarestill
within the specifiedwear limitsat timeof rebuild,other considerations shouldalso be used inevaluating the partscontinued
use.
Metric measuring tools, metric dimensions,and clearances must be used when servicing the
IPCAUTIONI onan L Engine. The use ot inch measuring tools and approximate inch dimensions and
clearances will cause stack up tolerances to be greater than specified.
DESCRIPTION DIMENSION
OF
NEW PARTS
millimetre (inch)
CYLINDER BLOCK
Cylinder BoreHoned Diameter .............. 88.987-89.013 (3.5034-3.5044)
Cylinder BoreOut-of-Round
Cylinder BoreTaper
Main Bearing Bore (Cap in placewithout bearing,
and capscrews properly torqued.)
.......... 80.880-80.906 (3.1843-3.1853)
Main Bearing Bore (Bearingsinstalled and
capscrews properly torqued.)
.............. 76.040-76.090 (2.9937-2.9956)
UndersizeMain Bearings(Availablefor
N.A. EnginesOnly). ..................... 0.25 mm,0.50 mm, and0.75 mm
Camshaft Bearing Bore (Without bearing)
.... 53.164-53.188 (2.0930-2.0940)
Camshaft Bearing Bore (Bearing installed)
... 50.044-50.116 (1.9702-1.9730)
Valve Tappet Bore
.......................... 26.070-26.100 (1.0263-1.0276)
CRANKSHAFT
................
Main BearingJournal Diameter .75.99-76.01 (2.9917-2.9925)
......................... Main Bearing Clearance .0.03-0.10 (0.0012-0.0039)
........................
Main BearingJournal Out-of-Round 0.007 (0.0003)
................................
Main BearingJournal Taper 0.005 (0.0002)
Connecting RodJournal Diameter
............. .55.99-56.01 (2.2043-2.2051)
Connecting RodJournal Out-of-Round..
.................... 0.005 (.0.0002)
............................. Connecting RodJournal Taper 0.005 (0.0002)
............................ CrankshaftEndPlay .0.10-0.33 (0.0039-0.0129)
Crankshaft StraightnessRunoutof Center Main..
............. 0.05-(0.0019)
CONNECTING ROD
Large Bearing Boreto Small Bearing Bore
(Center-to-Center)
...................... 155.975-156.025 (6.1407-6.1427)
Large Bore Diameter(Withoutbearing installed
and rodnuts properlytorqu,&.
............. 59.860-59.875 (2.3567-2.3572)
~earing"toCrankshaftCleafgktce.
.. : , ......:... .0.030-0.091 (0.0012-0.0036)
Connecting RodSide Clearance
.: ............... .0.05-0.45 (0.0019-0.0177)
PistonPin Bushing Bore (Withoutbearing)
..... .35.20-35.23 (1.3858-1.3870)
PistonPin Bushing Borewith Bearing,
(Finishedbore)
: ............................. .32.01-32.02 (1.2602-1.2606)
Large Bore Diameter(With bearing installed and
rod nuts properly torqued).
................ 56.040-56.081 (2.2063-2.2079)
UndersizeConnecting Rod Bearings(Availablefor
N.A. EnginesOnly). ..................... 0.25 mm, 0.50 mm, and0.75 mm
MAXIMUM
ALLOWABLE
WEAR LIMIT
millimetre
80.906
See main bearing
journal clearance
53.188
See camshaft
bearingclearance
See valve tappet
clearanceinbore
See main bearing
journal clearance
0.15
0.010
0.007
See connecting rod
bearing-to-crankshaft
clearance
0.007
0.007
0.38
0.10
59.875
0.1
5
($45
35.23
See clearance
connecting rod
bushing
See connecting rod
bearing-to-crankshaft
clearance

DESCRIPTION DIMENSION
OF
NEW PARTS
millimetre
(inch)
CAMSHAFT
......................
BearingJournal Diameter 49.988-50.014 (1.9680-1.9691)
..............................
BearingClearance 0.030-0.127 (0.0011-0.0050)
.........................................
End Play .0.10-0.50 (0.0039-0.01 97)
...............................................
Journal Runout 0.05 (0.0019)
Intakeand Exhaust Lobe, Base-to-Tip
.................................
(SpecAto C) 42.95-43.15(1.6909-1.6988)
..........
Intake Lobe, Base-to-Tip(BeginSpec D) 42.56-42.86 (1.6756-1.6874)
.........
Exhaust Lobe, Base-to-Tip(BeginSpec D) 42.86-43.16 (1.6874-1.6992)
PISTON
Clearance in Cylinder (Measure90' to pin, 13 mm below oil ring)
....................
NaturallyAspirated Engines 0.145-0.201 (0.0057-0.0079)
.........................
TurbochargedEngines 0.137-0.193 (0.0054-0.076)
Diameter (Measure
90' to pin, 13mm below oil ring)
..................
Naturally Aspirated Engines 88.812-88.842 (3.4965-3.497
7)
......................
TurbochargedEngines 88.820-88.850 (3.4969-3.4980)
................................
PistonPin Bore 32.003-32.009 (1.2599-1.2601
Y
RingGrooveWidth
.......................
Top 1CompressionRing.. .2.04-2.10 (0.0803-0.0827)
.........................
No. 2 CompressionRing .2.54-2.56 (0.1000-0.1007)
...........................
No. 3 Oil Control Ring .4.04-4.06 (0.1590-0.1598)
*Top 1CompressionRingGroove
Dimensionover 2.60 mm diameter
.................................
gauge wire.. 88.13-88.33 v.4697-3.4776)
.........................
*No. 2 CompressionRing 2.59-2.61 (0.101
9- 0.1028)
PISTON PIN
.............................
Clearance in Piston 0.003-0.014 (0.0001-0.0005)
..............
Clearance, ConnectingRod Bushing 0.010-0.025 (0.0004-0.0010)
......................................
Diameter 31.995-32.00 (1.2596-1.2598)
PISTON RINGS
Clearance
....................................
Top Groove .0.05-0.13 (0.0019-0.0051)
........................
*Top Groove Ring Drop 0.027-0.52 (0.0011-0.0205)
...................................
2nd~roove .0.05-b.e (0.0419-0.0035)
......................
............
*2nd Groove r .0.10-.0.14 (0.w-0.w)
..................................
Oil eoove 0.050-0.095 (0.0019-0-0037)
EndGap
.............................
Top 1Compression .0.31-0.57 (0.0-122-0.02a-
..............................
No. 2 Compression .0.3 -0.57 (0.0122-0.0224)
/-
.......................................
No. 3 Oil .0.22-0.58 (0.0087-0.0228)
Oversize Pistonsand RingsAvailable
..........................
for Service 0.25mm,
QSOmm, 0.75mm. and l.Omm
MAXIMUM
ALLOWABLE
WEAR LIMIT
millimetre
See camshaft bearing
clearance
0.150
0.70
0.10
See pistonto
cylinder clearance
See pistonto
cylinderclearance
See pistonpin
clearancein piston
0.03
0.05
See clearance,
connecting bushing
-.-, 025
Seb piston.top.
groove dimension
0.25
Turbochargedengine.

DIMENSION
OF
NEW PARTS
millimetre (inch)
..............................
*StemDiameter.. .7.95-7.97 (0.3130-0.3138)
......................
clearance(Stemto Guide) .0.04-0.08 (0.0016-0.0031)
....................
'Clearance (Stemto Guide) .0.02-0.06 (0.0008-0.0024)
.................................
Clearance(Lash)(Spec Ato C)
0.20 (0.0078)
...............................
*clearance(Lash)(Spec A to C) 0.30 (0.0118)
TOP of Valve Recessed
.....................
Below Cylinder HeadDeck 0.48-1.1 3 (0.0189-0.0445)
valveFace Angle
.................................................... 2g0
INTAKE VALVE SEAT INSERT
Seat InsertCylinder Head Bore Diameter
....... .40.30-40.32 (1.5866-1.5874)
.............
Seat InsertCylinder Head Bore Depth .8.40-8.50 (0.3307-0.3346)
..................
Seat InsertOutside Diameter .40.37-40.40 (1.5894-1.5906)
................................
Valve Seat Width .0.88-2.30 (0.0346-0.0906)
.....................................................
Valve Seat Angle 30°
..........................................
Valve Seat Runout 0.05 (0.0019)
.....................
Available InsertSizes.. Std., 0.25mm, and0.50 oversize
Naturallyaspirated enginesdo not have intake valve seat inserts.
EXHAUSTVALVE
.................................
Stem Diameter. .7.93-7.95 (0.3122-0.3130)
......................
Clearance(Stem to Guide) .0.04-0.08 (0.0016-0.0031
)
................................
Clearance (Lash)(SpecAto C) 0.30 (0.011
Top of Valve Recessed
below Cylinder HeadDeck
.................... .0.67-1.33 (0.0264-0.0524)
....................................................
Valve FaceAngle 44O
EXHAUSTVALVE
SEAT INSERT
Seat InsertCylinder HeadBoreDiameter ....... .36.93-36.95 (1.4539-1.4547)
Seat InsertCylinder HeadBore Depth
............ .8.49-8.59 (0.3342-0.3381)
Seat InsertOutside Diameter
.................. .37.00-37.03 (1.4567-1.4579)
Valve Seat Width..
....... :-. .........,.. ; ....... .0.88-2.30 (0.0346-0.0906)
Valve Seat Angle..
.................................................... 45'
Valve Seat Runout
........................................... 0.05 (0.0019)
Available InsertOversize
................................ .0.25 and0.50mm
VALVE
GUIDE . .
Length
l ntake ........................................ .56.5-57.3 (2.2244-2.2560)
Exhaust
............................... -1.. ... .62.5--63.3 (2.4606-2.4921 )
InsideDiameter(afterreaming) .
Intake ........................................ .7.99-8.01 (0.3146-0.3154)
Exhaust
........................... .,., ........ .7.99-8.01 (0.3146-0.3154)
HeightAbove Counterbore
Without Valve Rotators (Spec
A & 6) ............. 15.6-16.4 (0.6142-0.6457)
:
(i Without Valve Rotators(BeginSpec C) .......... 14.8-15.6 (0.5827-0.6142)
WithValve Rotatemor Spacer (Begin Spec
C) .. .22.3-23.1 (0.8779-0.9094)
Valve guides innew andfactory serviceheadsdo not require reaming.
MAXIMUM.
ALLOWABLE
WEAR LIMIT
millimetre
See stem to
guide clearance
See stem to
guide clearance
0.16
0.14
Adjustable
Adjustable
See stem to
guide clearance
0.16
Adjustable
' Turbochargedengine.

DESCRIPTION DIMENSION
OF
NEW PARTS
s millimetre (inch)
TAPPET
Body Diameter (Spec A to C) ................... 26.000-26.015 (1.0236-1.0242)
Body Diameter (BeginSpec D).
................. 26.027-26.043 (1.0247-1.0253)
Overall Length(Spec
A to C) ..................... 50.00-50.50 (1.9685-1.9882)
Clearance in Bore(Spec
A to C) .................. 0.055-0.100 (0.0022-0.0039)
Clearance in Bore(BeginSpec 0).
................. 0.043-0.057 (0.0016-0.002)
VALVE SPRINGS INTAKEAND EXHAUST
.............................
Valve Spring Free Length (Approx.) .51.0 (2.0)
Valve Spring Length
.................................................
Valve Open .32.8 (1.29)
...............................................
Valve Closed .42.5 (1.67)
.............
Spring Load @ 42.5 mm (ValveClosed). 29.2-31.2 kg (64-69 Ib)
.............
Spring Load @ 32.8 mm (ValveOpen) 62.7-66.7 kg(138-147 Ib)
GEAR BACKLASH
............................
Crankshaftto Idler .0.050-0.223 (0.0019-0.0087)
.............................
Idlerto Camshaft .0.045-0.264 (0.0017-0.0104)
........................
Idlerto Injection Pump .0.075-0.326 (0.0030-0.0128)
Oil Pump Idlerto Crankshaft..
................. .0.041-0.256 (0.0016-0.0101)
Oil Pump Idlerto Oil Pump Drive..
............. .0.044-0.262 (0.0017-0.0103)
......................
Oil Pump ElementGears .0.076-0.430 (0.0029-0.0169)
CYLINDER HEAD
.......................
Flatness(In 150.0 mm [5.91] of length) 0.03 (0.0012)
IDLER GEAR ASSEMBLY - OIL PUMP
BearingBore ............................... 25.030-25.054 (0.9854-0.9863)
...................
Idler Gear Shaft Diameter 24.986-25.000 (0.9837-0.9842)
Boreto Shaft Clearance
....................... .0.030-0.068 (0.0012-0.0027)
End Play
.......................................... 0.05-0.25 (0.002-0.010)
IDLER GEAR ASSEMBLY - CAMAND INJECTIONPUMP
Bearing Bore ............................... 40.030-40.054 (1.5760-1.5770)
IdlerGear Shaft Diameter
................... 39.98640.000 (1.5742-1.5748)
Boreto Shaft Clearance
.......................
.0.030-0.068 (0.0012-0.0027)
End Play
.......................................
.0.15-0.35 (0.0059-0.0138)
MAXIMUM
ALLOWABLE
WEAR LIMIT
millimetre
See tappet clearance
inbore
See tappet clearance
inbore
-
0.150
0.125
See boreto
shaft clearance
See boreto
shaft clearance
0.100
0.30
See boreto
shaft clearance
See boreto
shaft clearance
0.100
0.40
INJECTIONNOZZLE
Opening Pressure
New'Nozzle Tipand Spring
............ 13,000-13.800 kPa (1890-2000 psi) $11,,000 kPa
'Opening Pressure
New NozzleTipand Spring
............ 17.000-17,800 kPa(2470-2580 psi) $13,800 kPa
$ Nozzleopening pressurebetweencylinders must notvary morethan f600 kPa (87 psi).
' Turbocharged engine

OIL PUMP BODY
DIMENSION
OF
NEW PARTS
millimetre
(inch)
ShaftBore Diameter
.....................................
Idler
11.918-11.942 (0.4692-0.4702)
.....................................
Drive
11.918-11942 (0.4692-0.4702)
...................
pump Gear Bore Diameter..
.35.69-35.74 (1.4051-1.4071)
pump Gear Bore Depth
.................................
L317, L423. .15.07-15.12 (0.5933-0.5953)
.......................................
L634 .24.07-24.12 (0.9476-0.9496)
......................................
L634T .32.07-32.12 (1.2626-1.2646)
OIL PUMPSHAFTS
Diameter
.............................
Drive-in Body
11.888-11.902(0.4680-0.4686)
..........................
Drive-in Bushing 15.986-16.000 (0.6294-0.6299)
.....................................
Idler
11.955-11.970(0.4707-0.4713)
DriveShaft Clearance in Body ................. .0.016-0.054 (0.0006-0.0021)
..............
DriveShaft Clearance in Bushing .0.017-0.103 (0.0007-0.0041)
Idler Shaft Clearance inGear .................. .0.016-0.045 (0.0006-0.0018)
OIL PUMP GEARS
......................
InsideDiameter (Both) 11.986-12.000 (0.4719-0.4724)
....................
Outside Diameter (Both) 35.474-35.500 (1.3966-1.3976)
............... Radial Clearancein Body Bore..
.0.095-0.133 (0.0037-0.0052)
........................
End Clearanceto Body
.0.056-0.134 (0.0022-0.0053)
Gear Length (Both)
.......................
3 and 4 Cylinder N.A..
.14.986-15.014 (0.59-0.5911)
6
Cylinder N.A. ........................... 23.986-24.014 (0.9443-0.9454)
6
Cylinder Turbocharged .................. 31.986-32.014 (1.2592-1.2604)
TURBOCHARGER
Holset
End Play
........................................ 0.10-0.16 (0.004-0.006)
RadialPlay ...................................... 0.30-0.46 (0.012-0.018)
Airesearch
End
Play ........................................ 0.03-0.08 (0.001-0.003)
Radial Play ...................................... 0.08-0.1 5 (0.003-0.006)
MAXIMUM
ALL0WABLE
WEAR LIMIT
millimetre
-
11.97
See oil pump gear
radial clearance
in body bore
See oil pump
gear end clearance
to body
See drive shaft
clearance in body
See drive shaft
clearance inbushing
See idler shaft
clearance
in gear
0.07
0.15
0.060
See ldler shaft
clearance ingear
See clearance
inbody bore
0.175
0.150
See end
clearance
to body

3 . Torques
SUBJECT PAGE
..................................
ENGINEASSEMBLY TORQUES 3-1
....................................
INJECTIONPUMPTORQUES 3-2