ENGINE REBUILD INSPECTION SHEET C SERIES

F - T&S - 31

Job No : Eng. Model :

Customer : ESN :
CPL : Pump Code :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
CYLINDER BLOCK
C - Clean Cylinder Block, All Oil and Coolant Passages.

I - Install Cup Plug and Dowel Pin using the correct size Cup
Plug Driver handle with loctite 648 / Sealant P/N 3375068.

C - Use Soft Hamer to Install Pin Dowel.

M - Cylinder Block Flatness Specification Result

End-to-End mm 0.075 in 0.003
Side-to-Side mm 0.075 in 0.003
Recorded Main Bore

M - Main Bore xx
1# 2# 3# 4# 5# 6# 7#
yy

M - Cylinder Bore Dimensions Specification

Bore Inner Diameter
MIN - mm (114.00 ) in ( 4.488 ) MAX - mm (114.04 ) in (4.990 )

Recorded Bore Dimensions

xx
1# 2# 3# 4# 5# 6#
yy

M - Bore Out of Round Specification

MAX - mm (0.08 ) in (0.003)

Recorded Bore Out of Round

xx
1# 2# 3# 4# 5# 6#
yy

I - Install Camshaft Bushing with Specified Special Tools P/N

ST.1228 and P/N 3165045 (See tools Catalog).

C - Make sure all oil holes and passages are clean. MECHANIC BY,

C - Bushing Camshft P/N Qty

C Condition Bushing Camshaft Reworked Brand New DATE

 ASSEMBLING
CHECK POINT KETERANGAN
WORK PROCESS
CYLINDER BLOCK
C - Use a gauge block, P/N. 3823495, or equivalent.

M - Liner P/N SPECIFICATION

C - Liner Condition MM ID IN
Reworked 0.025 Min 0.001

Brand New 0.122 Max 0.005

Recorded Cylinder Liner protution

POSITION 1 2 3 4 5 6
12 O" (clock)
3 0" (clock)
6 O" (clock)
9 O" (clock )
CRANKSHAFT
V - Clean the crankshaft and gallery oil hole from dirt

M - Measurement the crankshaft main and connecting rod jurnas

M - Measurement cap screw main bearing reuse

V - Check the thrust bearing surfaces for damage or excessive wear

C - Use alight preservative oil to lubricate the crankshaft to prevent rust

Recorded Main Bearing jurnal Specification
Point
1 2 3 4 5 6 7 mm / inc
X-X Min:
Y-Y
Z-Z Max:

Recorded Connecting rod Bearing jurnal Specification

Point
1 2 3 4 5 6 mm / inc
X-X Min:
Y-Y
Z-Z Max:
Crankshaft Condition: Reworked Brand New Griding Polish

CRANKSHAFT I - Check Front Gear Train engines are equipped with

1. Saddle Jet Piston Cooling Nozzles

I - Check Rear Gear Train engines are equipped with:

2. J-jet Piston Cooling Nozzles
C - Install Crankshaft.
C - Coat all round main journal with lubriplate P/N 1242.
I - Install Thrust Bearing with lubriplate P/N 1242. MECHANIC BY,
 C - Do not rotate Crankshaft before main bearing Cap Screw
final Torque is done. DATE

ASSEMBLING
CHECK POINT KETERANGAN
WORK PROCESS
CRANKSHAFT I - Install Lower Main Bearing on the Cap.And Upper Main
Bearing on The Block
C - Make sure Cap number has the same number that is
stamp on the block.
C - Use Engine oil, lubricate the Cap Screw Heads, Threads and
the washers
C - Do not use Impact Wrenchs, the Main Bearing Shells can
fall out.
T - Tighten main bearing capscrew by following the step bellow.
Specification Torque Value Result Torque value
Step Torque Value Step Torque Value
1 50 n.m   [37 ft-lb] 1
2 95 n.m   [70 ft-lb] 2
3 Turn all capscrews through 60 degrees 3
'- Tool dial indicator P/N. 3376050
M - Measure Crankshaft End Clearance.

SPECIFICATION Result Measurement

CLEARENCE MM IN
Min 0.127 0.005
Max 0.330 0.013

PISTON & RING C - Use a feeler gauge to measure the end Gap.

C - Ensure the chrome plating on the Ring is not damaged

or the ring will fail.
C - Ensure the Cylinder Bore I.D is correct

SPECIFICATION Ring Piston P/N

POSITION MIN MAX Top
Piston Ring MM IN MM IN Second

TOP 0.30 0.012 046 0.018 Oil

SECOND 0.82 0.032 1.18 0.047
OIL 0.022 0.58 0.010 0,023 Reworked New

RESULT RECORDED RING GAP CYLINDER NUMBER

POSITION
1 2 3 4 5 6
TOP
SECOND
OIL
PISTON & RING C - Install piston Rings with stamped mark facing upwards and
with tools P/N. ST-1269.

C - The Gap in the oil Ring expanding (10) must be turned 180
degrees opposite the Gap on the Oil Ring (11) or the Rings
 and Piston will be damaged.Tools P/N 3823290 MECHANIC BY,

C - Rotate the Rings so the Gaps are not aligned with the
adjacent Ring or the Piston Pin Bore. DATE

C - Piston P/N Reworked Brand New

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
CONNECTING ROD T - Tighten the Capscrew alternately and evenly using the
folowing Torque Increments.

C - Use the Connecting Rod Capscrew tools P/N. 3376846.

C - Be sure the anvilis centered in the hole of the Rod Capscrew
and the tools contacts the head correctly
T Specification Torque Value
Step Torque Value
1 30 n.m    [22 ft-lb]
2 70 n.m    [52 ft-lb]
3 Turn all capscrews through 90 degrees
Record Cap screw torque value
1# 2# 3# 4# 5# 6#
R
L
M - Measure side clearance with a Feeler gauge or Dial indicator
P/N. 3376051 with Magnetic Base P/N. 33777399.

C - Make sure that machine number must be the same both

Rod and Cap.

C - Make sure that Mark Number is according to Cylinder number

Recorded Side clearence
1# 2# 3# 4# 5# 6#

GEAR HOUSING I - Install Gear housing

C - Use Sequence Shown to tighten the Cap Screws.

C - Make sure the Gasket already installed down on front

of block with Housing Gear.
- Install and tighten the gear housing mounting capscrews
Torque Value:  24  n.m  [212 in-lb]

C Recorded Gear Housing Reworked

Brand New

CAMSHAFT I - Install Camshaft Use Lubriplate, Lubricate each camshaft and

all of the camshaft bushings completely.

C - Don't damaged the Camshaft Bushings when installing the

Camshaft, the bushing will fail.

I - Install the trust bearing and two Cap Screws and torque refer
to specifications
 - Align the timing marks on the camshaft with the timing marks on
the crankshaft MECHANIC BY,

T - Install and tighten the camshaft thrust plate capscrews

Torque Value:  24  n.m  [212 in-lb] DATE

Recorded Camshaft Reworked

P/N Brand New
ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
CAMSHAFT M - Measure Camshaft End Clearance

C - Make sure when do measurement the thrust plate Cap Screws

have been tighten to specified torque.

M Specification Camshaft End Clearance

Min '0.012mm - '0.005 in Max '0,46mm - 0.018 in

Recorded
M - Measure Camshaft Gear Backlash

C - Make sure when do measurement the Cap Screw has been

tighten to specified torque

M Specification Camshaft Gear Backlash Limits

Min '0.08mm - Max '0.003in Max '033mm - Max '0.013in

Recorded
FUEL PUMP
C - Make sure injektion pump timing on the position 1 top

C - Rotate crackshaft until Cyl No 1 Top Position

I - Install injektion pump mont bracket to injektion pump

T - Torque injektion pump mounting refer to Specifications

T - Install and tighten the fuel injection pump retaining nut and washer.

Torque Value:  12  n.m  [106 in-lb]

Recorded FIP CONDITION

RECON
FLY WHEEL HOUSING BRAND NEW
C - Install the flywheel housing, push the housing over the
Dowel Pins and to the Cylinder Block follow the sequences
shown to tighten the cap screws.

T - Tighten the flywheel housing capscrews in the sequence shown

Torque Value:  77  n.m  [57 ft-lb]

Recorded

C - Measure the bore and the face of the housing to make sure
the alignment with the crankshaft. The indicator arm
must be rigid for an accurate reading.
C - For face alignment the cranksahft must be pushed in the same
direction every time it is measured.
 Determine the total indicator reading (TIR)
SAE Bore Diameter TIR POSITION RESULT
NO mm in mm in 12 O'CLOCK MECHANIC BY,
2 447.68 to 447.80 7.625 to 17.30 0.20 0.008 3 O'CLOCK
3 409.58 to 409.70 16.125 to 16.130 0.20 0.008 6 O'CLOCK
9 O'CLOCK DATE
TOTAL TIR

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
FLYWHEEL - Install the flywheel

C - The flywheel mounting Capscrew must be SAE grade 8

minimum with Rolled Threads.
Check to be sure the mating surfaces of the Crankshaft and
Flywheel are clean, dry, and free of nick or burns.

C - Barring Tool, Part Number 3824591

T - Tightening the flywheel capscrews.

T - Torque Value: 137 n.m [101 ft-lb] Recorded

Flywheel condition Reworked Brand New

C - Inspect the bore runout again.

- Measure the distance from the centre of the Crankshaft to
the indicator tip. Multiply (X) the distance by 0,027 mm
(0,005 inch) to obtain the maximum run out for the face
alignment
C - Measure the bore and face alignment.
C - Always push the Crankshaft in the same direction when record
the face reading.
Specification the total indicator ( TIR)
Flywheel Radius (A) Maximum of Flywheel Face Record Bore
mm in mm in
203 8 0.203 0.008
254 10 0.254 0.010
305 12 0.305 0.012
356 14 0.356 0.014 TIR
406 16 0.406 0.016
LUBRICATING PUMP
I - Install Oil Pump, make sure the condition is good.

C - Make sure seal o ring already install at the oil pump

T - Torque cap acrew refer to specification

Torque Value:  24  n.m  [18 ft-lb]

Recorded P/N

Oil pump condition Brand New

Reworked

M - Use a Dial Indicator, measure the Pump Drive Gear to front

 gear idler backlash

Specification Backlash Limits

A MIN '0.076 mm ('0.003 in) Max '0,330mm ('0.013in)

B Min '0.076mm ('0.003in) Max '0.330mm ('0.013in) MECHANIC BY,

M Recorded

DATE

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
CYLINDER HEAD I - Install Cylinder Head, make sure that they are in good condition

C - Make sure Gasket - the word "TOP" that is stamped on the

Head Gasket must be visible after the Gasket is installed.

C - Make sure the Gasket must slide easily over groove Pins.
Check the Pins for damaged.Use engine Oil Lubricate the
Cap Screw Heads, Thread and Washers.

T - Torque Cap Screws Refer To Specification

C Pre - 1991 Certifications
Follow the numbered sequence and tighten all capscrews
Torque Value: Follow the numbered tighten all 26 capscrews.
Step 1 40 n.m   [27 ft-lb] Torque Value:  70  n.m  [52 ft-lb]
Step 2 150 n.m   [110 ft-lb] (Number 1, 2, 7, 8, 9, 10, 15, 16, 17, 18, 23,
Step 3 220 n.m   [162 ft-lb] 24,25. AND 26)
Torque Value:  145  n.m  [105 ft-lb]
Recorded Pre - 1991 Certifications
Recorded capscrews 90 degrees
all 26 capscrews

Brand New Repair

Cylinder Head Condition Reworked
INJECTOR
I - Assemble the injector, sealing sleeve, a new copper sealing
washer, and the hold-down clamp.

C - Lubricate the sealing lips of the sleeve with anti-seize lubricant,

Part Number 3824879
- Install and tighten the hold-down capscrew.
Torque Value:  28  n.m  [21 ft-lb] Recorded

Injector Condition Brand New Repair

Reworked P/N
ROCKER LEVER I - Install Rocker Lever. Make sure Adjusting Screw are loose.
washer, and the hold-down clamp.
C - Be sure that the Pin Dowel that aligns the Rocker Lever Mount
is installed

C - Make sure push Rod already true installing.

T - Tighten the pedestal capscrews.

 Torque Value:  55  n.m  [41 ft-lb] Recorded
I - Install Lubricating Oil Transfer Tube
C - The correct Oil transfer tube must be installed or the engine
will be damaged extensively from lack of lubrication.
T - Torque cap screww mounting refer to specification MECHANIC BY,
6-mm Capscrews Torque Value: 10 n.m [89 in-lb]
Recorded
10-mm Capscrews Torque Value: 24 n.m [18 ft-lb] DATE
Recorded

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
OIL PAN
C - Make sure oil pan clean from other material
I - Use gasket silicon for install oil pan gasket

C - Clean cylinder block bottom surface from other materia

I - Install oil pan and torgue refer to specifications

Torque Value:  24  n.m  [212 in-lb]

Recorded
FRONT GEAR COVER
I - Install three guide pins, Part Number 3164977
- Apply a 4-mm wide bead of ThreeBond, Part Number 3823494

I - Install the front gear cover and tighten the capscrews

T - Tighten the long cover capscrews with 11-mm heads to:

Torque Value:  40  n.m  [30 ft-lb]
T - Tighten the short cover capscrews with the 10-mm heads to
Torque Value:  30  n.m  [22 ft-lb]
VIBRATION DAMPER
I - Install Vibration Damper, Make sure it's good condition

C - Make sure front seal already install

T - Torque all cap screw refer to specification

Torque Value: Step 1 50 n.m   [37 ft-lb]

Step 2 Rotate 90 degrees

ADJUSTING VALVE
C - Make sure Valve Adjustment mark pointer position and FO
according manual instruction.
C - Use Feeler Gauge refer to Specifications.

T - Torque Lock Nut refer to specifications.

Torque Value: 24 n.m [212 in-lb]

Intake clearance: 0.30 mm [0.012 in].

Exhaust clearance: 0.61 mm [0.024 in].

 M - Locate top dead center for cylinder Number 1
Check/adjust the valves indicated for STEP A (I = intake; E = exhaust)
- Set the valves indicated for STEP B.
I - Install the valve cover and wastegate sensing tube
Torque Value:  24  n.m  [212 in-lb]
EXHAUST MANIFOLD C - Make sure the condition is good
I - Install exhaust manifold use the guide stud
I - Use high temperature anti-siize compound to the cap screw MECHANIC BY,
threads
I - Install the gasket, make sure the position of gasket is true
T - Torque all cap screw mounting refer the specification
Torque Value:  43  n.m  [32 ft-lb] DATE

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
TURBO CHARGER
I - Install the turbocharger Torque Value:  45  n.m  [33 ft-lb]

- Install the turbocharger oil drain line

C - Lubricate the bearings by pouring 59 to 89 ml [2 to 3 oz] of clean 15W40 engine oil
into the turbocharger oil supply line fitting.Rotate the turbine wheel to allow oil to enter
the bearing housing.
I - Install the turbocharger oil supply line

M - Radial Clearance Check

Min 0.30 mm (0.012in) Max 0.46 mm (0.018in )

Recorded
M - Axial Clearance Check Use dial depth gauge, Part Number ST-537

Min 0.038mm (0.0015in) Max 0.093 mm ( 0.0037in )

Recorded

I - Install and tighten the intake manifold capscrews.

T Torque Value:  24  n.m  [18 ft-lb]
Recorded

CHECKED BY, APPROVED BY,

MECHANIC BY
FOREMAN SUPERVISOR
DATE: DATE:
Note : I = Install C = Caution T = Torque M = Measuremen V = Visual DATE