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Engine Specifications (continued)

1. 31 Cleaning 112 Lubrication Flow Diagram 32 5 113 Examples of Bearing Failures 3A 33 Reassembly 115 Compression Testing Procedure 3A 33 Installation 3A 115 Valve Cover 3A 35 Oil Pressure Relief Valve And Check Valve Removal TAa EURO eee RS 118 Cleaning 3A 37 Removal 3A 118 INSDECHOM 37 Cleaning 118 Installation 37 Inspection 118 Camshafts 40 Installation 119 Exploded View 3A 40 Oil Filter and Oil Cooler Assembly 120 Removal 41 120 Cleaning 3A 43 Removal 121 Inspection 43 Cleaning 121 Installation 46 Inspection 122 Valve Clearance 3A 50 Installation 3A 122 CMD 4081866 90 863016001 MARCH 2008 Page 3A 1 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29
2. 7 152 a Camshaft Pulley b TDC Alignment Bolt M6 Pulley Bolt Page 3A 142 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 25 Loosen bolts and remove tensioner spring retainer plate if equipped C 77157 Tensioner Spring Retainer Plate b Plate Bolts 26 Loosen bolts and remove dust cover 77157 Bolts b Dust Cover CMD 4081866 90 863016001 MARCH 2008 Page 3A 143 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Cleaning 1 Clean all parts with solvent and dry with compressed air Inspection 1 Inspect timing covers for warp cracks and wear from belts and pulleys Replace covers if worn or damaged 2 nspect pulleys and belts for wear or damage Replace as necessary Installation 1 Install the front dust cover and tensioner spring retainer plate if equipped Torque bolts 71294 Dust Cover b Cover Bolts c Tension Spring Retainer Plate d Plate Bolts Bolts Front Dust Cover M6 x 1 0 Bolts Tensioner Spring Retainer M6 x 1 0 Plate 144 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 2 Install crankshaft timing belt pulley and parts in order Concave side of belt guide flange MUST face the cylinder block 77085 Woodruff Key b Belt Guide Flange c Concave Side d Crankshaft Ti
3. Continue to turn crankshaft in direction of engine rotation until camshaft pairs a and b point upwards These valves are then closed and can be checked a X f ei eet di el 77124 Oylinder Number 1 Intake Camshaft Lobes b Cylinder Number 3 Exhaust Camshaft Lobes C Arrow Points To Front Of Engine 6 Check the valve clearance using a feeler gauge Description mm in vane o Wake 085 045 0 014 0 078 048 055 0 18 0 02 Page 3A 48 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS ADJUSTMENT Avoid possible severe engine damage Ensure that the valves are NOT adjusted when the pistons are at Top Dead Center TDC The valves can strike the pistons if adjusted with the pistons at TDC 1 Turn camshaft follower cup with shim until follower groove points out 2 Press down camshaft follower using appropriate special tool NOTE Different tool versions for exhaust and intake valves VR S IN a Follower Groove Pointing To Outside b Intake Tool c Exhaust Tool d Special Tool Installed 3 Lever shim out from camshaft follower groove using a small screwdriver or similar 4 Remove shim 77125 a Follower Groove b Shim c Thickness Inscription In mm Page 3A 49 CMD 4081 866 90 863016001 MARCH 2008 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29
4. 5 Calculate the thickness of the shim necessary to obtain specified clearance To do so add the current measured clearance A to the thickness of the current shim B Then subtract from that sum C the desired clearance D The difference between them is the thickness of shim needed E Example for determination of shim thickness Current measured clearance 0 45 mm 0 018 in Sum of A B C 3 60 mm 0 142 in Valve clearance desired D 0 40 mm 0 016 in Thickness of shim needed E 3 20 0 126 in 6 Coat needed shim with clean engine oil and insert in camshaft follower with thickness inscription facing downwards 7 Complete adjustments as follows Turn the crankshaft 180 in direction of engine rotation check and adjust valve pair d b Turn the crankshaft 180 in direction of engine rotation check and adjust valve pair e and Tm c Turn the crankshaft 180 in direction of engine rotation check and adjust valve pair g and hi 77126 Valve Pairs For Adjusting 8 Ensure proper valve clearance by re checking all adjusted valves 9 Install the fuel injectors 10 Install the valve cover 11 Install the injection pipes and related fuel components 12 Install the intake air duct Page 3A 50 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Camshaft Carrier Exploded View T 4 G
5. 5 Check clearance between inner and outer oil pump rotors 11329 a Outer Rotor b Inner Rotor Feeler Gauge EN Clearance between inner and 0 13 0 15 0 0051 0059 02000078 outer rotors mesh CMD 4081866 90 863016001 MARCH 2008 Page 3A 112 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Reassembly 1 Coat inner and outer oil pump rotor surfaces with engine oil 2 Install inner and outer oil pump rotors in cylinder block 11323 a Cylinder Block b Outer Pump Rotor Inner Pump Rotor Description Where Used Method of Use Part Number Engine Oil Inner and outer Coat surfaces Obtain Locally oil pump rotors Installation 1 Coat sealing lips of oil seals with silicon grease Install crankshaft seal and oil pump shaft seal in oil pump retainer 77211 a Oil Pump Retainer b Crankshaft Oil Seal c Oil Pump Seal Where Used Method of Use Part Number Stone Grease gie Coatlips Obiain Local CMD 4081866 90 863016001 MARCH 2008 Page 113 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 2 Install a new oil pump O ring in groove on rear side of oil pump retainer 11324 a Oil Pump Retainer b Oil Pump O ring 3 Apply a bead of sealant to sealing surface of oil pump retainer where cross hatch marks are shown in the following A small amount of extra sealant must be added as indicated IMPORTANT Ensure that
6. apj a Nat Housing Cover 74 SS NN 4 2 BotHesEwhamgr 1 2 2 2 9 9 5 Bolt Engine Lifting Eye M8 x 1 25 Nut Exhaust Pipe M10 x 1 25 44 Page 3A 14 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS TIMING COVERS OIL PUMP RETAINER FRONT AND REAR COVER Denn LW 98 x 398 8 M6 x 1 0 3 Bolt Timing Cover Jamo 6 K 7 Bolt Oil Pump Retainer 8 Bolt Timing Cover 9 Bolt Rear Oil Seal Retainer Bolt Rear Oil Seal Retainer M6 x 1 0 98 87 CMD 4081866 90 863016001 MARCH 2008 Page 3A 15 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 OIL FILTER AND ENGINE WATER OUTLET 77088 Description Fitting Oil Cooler Valve Relief M24 x 1 5 Bolt Oil Filter M20 x 1 5 Bolt Water Outlet T z 7 5 Page 3A 16 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS FUEL INJECTORS AND RELATED PARTS 00 m 77089 IR SC e 2 Nut IjectorBracket sl 22 36 D E 8 Bolt Bracket To Mount M8 x 1 25 Bolt Bracket To Injection Pump Mi0x15 38 28 K HE Li w m CMD 4081866 90 863016001 MARCH 2008 Page 3A 17 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER
7. es LIAO eZ MG AA S 4 qF d HOH FEOT HAH P Wo SS OECD 8 77284 Camshaft Bracket Torque Sequence Description Nut Camshaft Bracket Nut Camshaft Bracket We 46 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 9 Install a new camshaft seal in camshaft carrier using special tool 91 883855 Installer Oil Seal 91 883855 Description Installs the camshaft oil seal 10 Install camshaft pulley and camshaft pulley bolt 11 Install TDC alignment bolt Torque camshaft pulley bolt 77163 a Camshaft Pulley b TDC Alignment Bolt M6 c Camshaft Pulley Bolt 111 Desmpion _ L BotCamswtPuey 12 Inspect and agjust valve clearance 13 Install fuel injectors with new O rings and new gaskets 14 Install fuel return inner pipe using hollow bolts with new seal washers 15 Install valve cover 16 Install injection pipes and related fuel components 17 Install timing belt 18 Install timing belt covers CMD 4081866 90 863016001 MARCH 2008 Page 47 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Valve Clearance The valve clearances are checked on a cold engine INSPECTION Remove intake air duct Remove valve cover Remove fuel injectors Turn engine in direction of engine rotation to cylinder number 1 TDC oS
8. 08 00 CMD 4081866 90 863016001 MARCH 2008 Page 3A 5 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Engine Specifications continued NOTICE Unit Of Measurement mm in Valve Adjustment Valve Clearance Valve Intake Valve Stem Diameter Exhaust Valve Stem Diameter Intake Valve Guide Inside Diameter Exhaust Valve Guide Inside Diameter Valve Stem Clearance Head Diameter Face Wiath Face Angle New Valve Margin Production Margin After Grinding 0 35 0 45 014 018 0 45 0 55 18 021 5 945 2341 5 954 5 972 2344 2351 6 000 6 015 mm Production 0 2362 0 2368 6 000 6 015 mm Production 0 2362 0 2368 0 023 0 056 0009 0022 27 35 27 65 1 077 1 088 26 35 26 65 1 037 1 045 Intake Intake CMD 4081866 90 863016001 MARCH 2008 Page 3A 6 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Engine Specifications continued NOTICE Unit Of Measurement mm in Valve Seat Seat Width 90 15 059 epum 26 1 126 5197 un 5 197 DN 06 024 Valve Guide 0090 0667 Maximum Clearance 0098 0087 Upper End Height 11 7 4606 Valve Spring Limit 44 13 1 Compressed Height at Wa n Free Standing Height 1 74 Spring Inclination 1 01 0 040 Valve Closed 33 3 1 31 valve Open CMD 4081 866 90 863016001 MARCH 2008 Page 7 1 7L ENGINE MECHANICAL ALL MODELS SERVIC
9. b TDC Alignment Bolt M6 c Camshaft Pulley Bolt CMD 4081866 90 863016001 MARCH 2008 Page 3A 39 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 8 Remove the rear camshaft bracket 77166 a Rear Camshaft Bracket 9 Lock exhaust camshaft gear and sub gear together with the locking pin 77166 a Camshaft Gear b Sub Gear c Locking Pin 4 x 16 mm 10 Loosen remaining camshaft bracket nuts in a spiral pattern as shown in stages of 1 2 to 1 turn at atime IMPORTANT Camshaft brackets are numbered from one to five Cast arrows in brackets point to front of engine Note location and references before removing SV p EH EE EH 5 77167 Camshaft Bracket Loosening Pattern Page 40 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Cleaning 1 Clean camshafts with solvent and dry with compressed air 2 Clean gasket surfaces and remove sealant residue Inspection 1 Check camshafts for wear and replace as necessary 2 Check bearing brackets for wear and replace as necessary CAMSHAFT JOURNAL DIAMETER 1 Use a micrometer to measure each camshaft journal diameter in two directions X X and Y Y If the measured value is less than specified the camshaft must be replaced Y 79687 26 939 26 960 Production Journal Diameter 1 0605 1 0614 26 92 1 0598 CAMSHA
10. 29 ALTERNATOR TENSIONER AND BRACKET 77721 Description Bolt Automatic Tensioner Nut Alternator 3 Bolt Alternator Bracket 4 Bolt Alternator Bracket M14 x 2 0 5 Bolt Alternator To Bracket M8 x 1 25 6 Bolt Alternator Lower Mounting M10x1 25 46 34 Page 18 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS AFTERCOOLER AND RELATED PARTS 77091 fenes a W xis a banne 9 9 m ba WaerDramBacer 5 24 56 DECH 5 _ 27 mons 9 wee moons 4081866 90 863016001 2008 19 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Standard Torque Values HEX HEAD BOLT Page 3A 20 IMPORTANT The tightening torque values given in the table below are applicable to bolts and fasteners unless otherwise specified NOTICE Unit Of Measurement Nm Ib ft Identifica tion T Diameter x Thread Pitch mm 3 9 7 8 3 4 9 9 8 4 7 8 17 7 6 11 8 22 6 9 Ze 20 6 34 3 27 5 46 1 20 34 M10 x 1 5 19 6 E 25 2 5 45 1 20 33 49 1 73 6 36 54 60 8 91
11. Cylinder Head 11 Set split collars by tapping valve stem with a soft plastic hammer 12 Apply engine oil to camshaft follower and valve shim 13 Install camshaft follower and shim IMPORTANT Ensure that cam followers and valve shims are installed in their original locations 77241 Cylinder Head b Camshaft Follower c Valve Shim Where Used Method of Use Part Number Camshaft Engine Oil follower and Coat surfaces Obtain Locally shim Page 3A 72 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Installation Head gasket thickness is very important on diesel engines If head gaskets are too thin the pistons will hit the valves or heads causing severe damage If head gaskets are too thick cylinder compression may be low When cylinder heads are removed for service but pistons and cylinder liners are not dis turbed use the same thickness gaskets that were removed Refer to Head Gasket Identifi cation Refer to Determine Head Gasket Thickness during a complete engine rebuild or when pis tons are being replaced DETERMINE HEAD GASKET THICKNESS 1 Carefully remove carbon deposits from piston top surface and gasket residue from cylinder block surface Using a dial indicator measure piston protrusion at 2 points Measure piston protrusion for each cylinder Note highest measured value This will determine cylinder head gasket thickness a
12. Hollow bolt and Coat threads Obtain Locally O ring and surfaces OT Fifer Housing 5 Page 3A 120 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 4 Connect oil drain hose to filter housing 5 Install the three new O rings 6 Apply a coat of engine oil to the O rings 7 Install the oil filter element on the top piece 77242 a Oil Filter Element b O rings Top Piece Where Used Method of Use Part Number A Engineoi Obtain Local 8 Install the top piece with the new oil filter element into the oil filter housing 9 Turn the top piece until seated against the oil filter housing 10 Using the filter wrench or socket torque top piece IMPORTANT Overtightening the top piece will cause deformation and oil leaks 79740 Oil Filter Assembly b Filter Housing Description Oil Filter Top Piece CMD 4081866 90 863016001 MARCH 2008 Page 3A 121 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Page 3A 122 11 Ensure water fitting is not leaking Apply specified sealant during installation if previously removed 12 Connect and clamp coolant hoses 77122 a Water Fitting b Hose To Fitting c Hose To Water Pipe d Clamp Where Used Method of Use Part Number Water fitting for oil cooler Loctite 5900 5699 Thread length Obtain Locall
13. Locking Tool 91 883853 Exhaust Camshaft Sub Gear Exhaust Camshaft Gear Adjusting Pin OND sch 3 Position camshafts in cam carrier The mark on exhaust camshaft should be between the two marks on intake camshaft and approximately level with upper edge of camshaft carrier IMPORTANT Ensure that engine is on TDC and timing marks are properly aligned 71254 Exhaust Camshaft Mark b Intake Camshaft Marks Upper Edge Of Carrier Page 44 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 4 Apply sealant to sealing surfaces between carrier and front camshaft bracket OX Qs 1901 77255 Sealant Where Used Method of Use Part Number Between carrier Apply to and front contact Loctite 5699 ai SE Obtain Locally bracket indicated CMD 4081866 90 863016001 MARCH 2008 Page 45 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 5 Install camshaft brackets 1 through 4 Tighten camshaft bracket nuts in a spiral pattern as shown in stages of 1 2 to 1 turn at a time until hand tight NOTE Arrows on individual camshaft brackets point to front of engine a 22 E p Ez EH ES Z 77167 77166 a Camshaft Gears b Locking Pin 7 Install camshaft bracket number 5 8 Torque M8 nuts and M10 nuts in sequence T9
14. On models without power steering install the starboard engine mount bracket to the cylinder block m On models equipped with power steering install the power steering pump bracket and starboard engine mount bracket Refer to Section 9A Torque mount bolts Install the rear bracket to the injection pump and mount bracket Torque rear bracket to mount bolts and rear bracket to injection pump bolts Install pedestal mount assembly to trunion e o s Xu After trunion and mount are adjusted torque trunion clamping bolt 79688 Typical a Starboard Mount Bracket b Rear Bracket c Mount To Cylinder Block Bolt And Washer d Rear Bracket To Injection Pump Bolt And Washers e Rear Bracket To Mount Bolt f Pedestal Mount Assembly g Trunnion Clamping Bolt And Nut WI Bok MounttoGyinderBlock 97 Bok Bracketto jection Pump 3 4 Bot Trunion Clamping 157 1 9 8 On models equipped with power steering install the power steering pump Refer to oection 9A CMD 4081866 90 863016001 MARCH 2008 Page 3A 135 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Port Install the port engine mount bracket to the cylinder block Torque mount bolts Install pedestal mount assembly to trunion After trunion and mount are adjusted torque trunion clamping bolt oY 71775 a Port Mount Bracket b Bo
15. Page 127 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 7 Remove the bolts from the rear oil seal retainer 8 Remove the rear oil seal retainer from the cylinder block Ensure that sealing surfaces are not damaged 7 138 a Bolt b Rear Oil Seal Retainer 9 Carefully pry old rear oil seal out of the rear oil seal retainer using a suitable tool 7 138 a Rear Oil Seal Retainer b Rear Oil Seal Cleaning Clean sealing surfaces 2 Remove sealant residue Inspection Inspect rear oil seal retainer sealing area for nicks and burrs 2 Inspect rear oil seal retainer and crankshaft sealing area for nicks burrs and scoring Page 3A 128 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Installation 1 Coatinner lip of new rear oil seal with clean lubricant Where Used Method of Use Part Number Engine Oil Inner lip of rear Coat surfaces Obtain Locally oil seal 2 Install seal in rear oil seal retainer using a suitable seal driver 77273 a Seal Driver b Rear Oil Seal Retainer 3 Apply a bead of specified sealant to sealing surfaces of rear oil seal retainer 77272 a Sealant b Rear Oil Seal Retainer Description Where Used Method of Use Part Number Obtain Locally Between oil seal Apply a bead to Loctite 5900 retainer and sealing surfaces cylinder block as specified 4 Instal
16. Piston Surface b Cylinder Block Surface Piston Protrusion Range 0 58 0 78 0 023 0 031 5 Piston protrusion must be within the range shown NOTE If piston protrusion is beyond the above range engine should be inspected for worn or damaged components or improper assembly of components CMD 4081866 90 863016001 MARCH 2008 Page 3A 73 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 HEAD GASKET IDENTIFICATION Select a cylinder head gasket of appropriate thickness or grade from chart below 77282 Grade Mark B is shown b Grade Mark Location Highest Piston Projection Thickness mm in mm in 8588 855 87 525 0928 15000058 L G p 372 078 0028 0081 Y58 0061 C CYLINDER HEAD IMPORTANT Head gaskets must be installed DRY Do not use any sealer on gasket 1 Install head gasket on cylinder block 2 Align the cylinder block dowels and the cylinder head dowel holes 3 Carefully set the cylinder head onto cylinder block Avoid engine damage Cylinder head bolts may be installed two times and then must be replaced with new bolts Replace the cylinder head bolts if uncertain of the number of times installed 4 Apply engine oil to threads of cylinder head bolt and washer faces Where Used Method of Use Part Number Cylinder head Coat threads Engine Oil boad vac Obtain Locally Page 3A 74 CMD 4081866 90 863016001 MARCH 2008
17. SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS IMPORTANT Follow torque sequence in each step o Hand tighten the cylinder head bolts 6 Torque the cylinder head bolts 77120 Torque Sequence Diagram Nm ibm bf _ _ 1 9 60 degrees Third Pass 60 degrees 7 Install camshaft tappets and valve shims 8 Install camshaft carrier 9 Install valve cover 10 Install fuel injectors and fuel pipes 11 Install timing belt and timing covers CMD 4081 866 90 863016001 MARCH 2008 Page 75 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Connecting Rod Piston Assembly Exploded View 77177 1 Piston Rings 2 Piston 3 Ring 4 Piston Pin 5 Connecting Rod 6 Connecting Rod Bushing 7 Connecting Rod Bolt 8 Connecting Rod Bearings 9 Connecting Rod Cap 10 Nut Page 76 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Removal 1 Remove cylinder head 2 Remove upper and lower oil pan 3 Remove oil pickup assembly and oil baffle plate 77145 Pickup Assembly b Baffle Plate 4 Using a reamer remove any ridge or combustion deposits from top of cylinder bore 5 Turn crankshaft to gain access to connecting rod bolts IMPORTANT Mark the location of each connecting rod assembly to ensure that the
18. Table of Contents Continued Oil Pan And Oil Pickup Assembly Inspection Removal Installation Cleaning Front Engine Mounts Inspection Starboard Installation Rear Oil Seal Oil Separator Vent System Removal Timing Belt And Related Components 3A 139 Cleaning Removal Inspection Cleaning Installation Inspection Front Oil Seal Removal Installation Cleaning Page 3A 2 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Engine Specifications NOTICE Unit Of Measurement mm in Piston Rings o Groove Width Ring to Groove Clearance 78 78 Grade A 8 930 78 939 3 1075 3 1078 Piston Outside Di Grade 78 940 78 949 iston Outside Diameter 3 1079 3 1082 78 78 rade 8 950 78 959 3 1083 3 1086 Piston To Cylinder Wall Clearance 0 061 0 079 0024 0031 Pin Hole Inner Diameter Production 27 004 27 009 1 0631 1 0633 ae Weight Difference Between Pistons in One 22 gr 77 oz 26 995 27 000 1 063 iston Pin Outer Diameter 26 985 1 0624 xm xe xe xe xeo Ss Jl zs Piston Piston Pin 004 014 0 0001 0 0005 iind 0 04 0 0016 CMD 4081866 90 863016001 MARCH 2008 Page 3A 3 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Engine Specifications continued NOTICE Unit Of Measurement mm in Oil Pump Oil pump shaft clearance in 0 040 0 125 0015 0049 cyli
19. Upper Oil Pan b Bolt 14 c Nuts 2 7 Remove the two M6 bolts and the Aligner Tool 8 Apply a 4 mm 5 32 in bead of specified sealant to sealing surface of upper oil pan 9 Install lower oil pan Torque bolts 10 Install oil dipstick tube assembly with new sealing washers Torque hollow bolt Qc O Werle a oars LT OY N 77279 Lower Oil Pan b Dipstick Tube Hollow Bolt And Washer Bolts 15 Description Where Used Method of Use ran Number Apply a bead to Loctite 5699 ol pong sealing surfaces Obtain geb e as specified Locally Bolt Lower Oil Pan M6 x 1 0 Hollow Bolt Dipstick Tube M14 x 1 5 39 Page 3A 126 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Rear Seal Removal 1 Remove the flywheel housing on sterndrive models Remove the transmission and flywheel housing on inboard models 2 Remove the flywheel coupler on sterndrive models or the drive plate on inboard models Remove lower oil pan Remove upper oil pan Hold flywheel using appropriate lock device Loosen and remove bolts Remove the flywheel washer and flywheel p oO amp X 77137 a Lock Device b Flywheel Washer c Flywheel d Bolts 8 CMD 4081866 90 863016001 MARCH 2008
20. Use Part Number Injector sleeve Engine Oil bore and Coat surfaces Obtain Locally O rings Page 3A 70 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 4 Install the valve spring lower seat 5 Apply a coat of engine oil to valve seal inner surface Install valve seal using valve seal installer ii S ZZ S S 77237 Valve Seal b Valve Seal Installer Where Used Method of Use Part Number SCHER IMPORTANT Ensure that valve components are installed in their original locations 6 Apply a coat of engine oil to valve stem and install valve in cylinder head Where Used Method of Use Part Number Engine Oi Local 7 Turn the cylinder head up to install the valve springs IMPORTANT Ensure that valves stay in cylinder head when turning the head 8 Install valve springs with the fine pitched end the end with more windings facing the cylinder head down 77238 Valve Spring b Fine Pitch CMD 4081866 90 863016001 MARCH 2008 Page 3A 71 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 9 Install valve spring retainer and compress spring using valve spring compressor and adapter 10 Install split collars on valve stem and release valve spring compressor Ensure that collars seat properly in groove of valve stem 71174 a Adaptor b Valve Spring Compressor c
21. Using a straight edge and feeler gauge check the bottom surface of camshaft carrier for straightness 2 Measure the four sides A B E F and the two diagonals C D A NEN Camshaft Carrier Lower Face Less Than 0 05 002 Warp 3 05 0019 Replace camshaft carrier if warp is greater than limit 4 Measure height of camshaft carrier sealing surface to sealing surface Camshaft Carrier Height 29 62 1 166 5 Replace camshaft carrier if height is less than production specification Page 3A 54 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Installation IMPORTANT Refer to Camshafts Installation in this Section for proper sealing and installation of camshafts and brackets if removed previously 1 Ensure that engine and camshafts are set on cylnder number 1 TDC and timing marks are properly aligned Install camshaft carrier on cylinder head using a new gasket 3 Tighten all camshaft carrier bolts and nuts in steps of 1 2 to 1 turn in sequence Torque bolts and nuts in sequence AC RE Sidi d SAC Tia Camshaft Carrier Torque Sequence Description Nm ibin Bolt Camshaft Carrier M8 x 1 25 92 16 T moas 5 1 Install camshaft pulley Install TDC alignment bolt and torque camshaft pulley bolt 77163 a Camshaft Pulley b TDC
22. parts in solvent and dry with compressed air Inspection NOTE The oil pressure relief valve has a built in spring and does not require inspection 1 Check that valves slide freely in their bores when coated with oil Page 116 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Installation 1 Install oil pressure relief valve and check valve into block using new sealing rings 2 Torque the oil pressure relief valve and check valve 77330 Oil Pressure Relief Valve b Check Valve Description NL CMD 4081866 90 863016001 MARCH 2008 Page 117 1 7L ENGINE MECHANICAL ALL MODELS Cil Filter and Oil Cooler Assembly Exploded View Page 3A 118 1 Oil Filter Top Piece 2 Hollow Retaining Bolt Oil Cooler 4 Oil Filter Housing 5 Housing To Cylinder Block O ring 6 Coolant Hose To Cylinder Head Water Fitting 7 Cylinder Head Water Fitting 8 Seal 9 Coolant Hose To Water Pipe 10 Water Pipe 11 Clamp 12 Oil Drain Hose 13 Oil Drain Pipe SERVICE MANUAL NUMBER 29 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Removal Drain coolant Disconnect coolant hoses from oil cooler Remove oil filter top piece and oil filter element e Ej fo a Oil Filter Top Piece b Oil Filter Element 77088 4 Disconnect oil drain hose from filter housing 5 Remove oi
23. pulley to the crankshaft timing belt drive pulley Torque bolts 26 Install water pump pulley Torque the bolts 2 Install serpentine belt Ensure that tensioner returns to initial position 28 On inboard models Install the seawater pump 77292 Engine Plate Upper Timing Belt Cover c Crankshaft Damper Pulley d Water Pump Pulley e Serpentine Belt f Belt Tensioner Description Bolt Engine Plate M10 x 1 5 Nnm 8 Bolt Water Pump Pulley M6x1 0 98 Page 152 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 29 On sterndrive models a install the power steering belt b Pivot the power steering pump to adjust belt Approximately 5 mm 3 16 in deflection should be measured at midpoint between the pulleys on the longest span c Tighten mounting and tensioning bolts and nuts securely 77321 a Mounting Bolts Hidden b Tensioning Stud And Nut Power Steering Pump And Pulley CMD 4081866 90 863016001 MARCH 2008 Page 3A 153
24. ring lands scuffed or damaged skirts and eroded areas at top of piston Replace pistons that are damaged or show signs of excessive wear Inspect grooves for nicks or burrs that might cause rings to hang up Insert edge of rings into respective piston ring groove and roll ring entirely around the groove to make sure that ring is free If binding occurs at any point determine cause If caused by ring groove remove by dressing with a fine cut file Do not remove excess material Verify with feeler gauge and compare to specifications 4 Measure piston outside diameter and determine piston service grade 77205 Piston Outside Diameter a Piston Measuring Point 57 mm 2 1 4 in 78 930 78 rado 8 930 78 939 3 1075 3 1078 LASER DE 18 940 78 949 iston Outside Diameter 3 1079 3 1082 dec 78 950 78 959 3 1083 3 1086 CMD 4081866 90 863016001 MARCH 2008 Page 3A 81 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 o Using a feeler gauge measure the clearance between the piston ring and the piston ring groove at several points around the piston Replace piston if ring groove exceeds the specified limit 77228 Piston Ring and Piston Ring Groove Clearance Description mm 090 122 0 0035 0 0048 070 110 0 0027 0 0043 Ring to Groove Clearance 6 Usea micrometer to measure the piston pin outside diameter at several points Replace pin if measured value is le
25. side 4 Remove and discard the 2 O rings Lect L cont 1 77800 Cross Section Of Injector Sleeve In Cylinder Head a Cylinder Head b Injector Sleeve c O ring d Combustion Chamber Side Remover Description Removes injector sleeve Page 3A 62 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Cleaning 1 Being careful not to damage the aluminum head clean carbon deposits residues and gasket material from combustion chambers and sealing surfaces Using wire wheel remove carbon deposits from valves Wash head and components in cleaning solvent Dry with compressed air Clean head bolt holes in engine block with a thread cleaning tool Inspection GENERAL Inspect glow plug seats for damage Inspect injector sleeves for leakage or damage Inspect injector sleeve bores in cylinder head for damage Inspect all gasket surfaces for deep grooves or pitting Inspect valve seats for cracks excessive wear and looseness in counterbore Inspect valves for cracks excessive wear and bent stems Inspect valve springs for discoloration due to excessive heat po IN SoS e Jw Inspect valve guides for cracks or chips Inspect valve guide bores for seizure marks carbon deposits or scoring Inspect valve guide height 9 Inspect valve spring keepers retainers and spring seats for wear distortion and cracks 10 Inspect valve shims for pitting cracking and di
26. 008 Page 149 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 b Preload the tensioner spring by inserting an appropriate hex tool into the tensioner assembly and rotating the assembly counterclockwise around the center mounting bolt 26380 17 Ensure that tensioner pulley rests against belt under spring load 18 Remove camshaft and injection pump TDC alignment bolts 19 Torque the tensioner pulley assembly upper mounting bolt Temporarily hand tighten lower bolt 77152 Typical a Upper Bolt b Lower Bolt Description Bolt Tensioner Pulley Assembly Plate Type Tensioner Spring 49 Bolt Tensioner Pulley Assembly Coil Type Tensioner Spring Wes ECH 20 Using the crankshaft drive pulley bolt turn crankshaft approximately 780 in direction of engine rotation to cylinder number 1 TDC Verify belt installation and timing 21 Install the lower timing belt cover Torque bolts Page 3A 150 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 22 Remove and retain tensioner pulley assembly lower bolt 77127 Tensioner Pulley b Lower Bolt CMD 4081866 90 863016001 MARCH 2008 Page 151 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 23 Install engine plate Torque bolts including tensioner pulley assembly lower bolt 24 Install upper timing belt cover Torque the bolts 25 Install the crankshaft damper
27. 2 45 67 75 5 114 0 56 84 M12x 1 75 1 75 45 1 68 7 33 51 56 9 84 4 42 62 9 84 4 42 62 71 8 107 0 53 79 ES 76 5 115 0 56 85 93 2 1390 69 103 1140 V M14x2 0 71 6 107 0 53 79 88 3 131 0 65 97 10 0 16 7 30 4 12 22 37 3 62 8 28 46 36 6 59 8 17 44 C T ER 7 7 7 7 104 0 157 0 77 135 0 204 0 100 160 0 240 0 118 116 151 177 i 100 0 149 0 74 129 0 194 0 95 153 0 230 0 113 M16 x 2 0 110 143 170 151 0 226 0 111 195 0 293 0 144 230 0 345 0 170 167 216 255 151 0 226 0 111 196 0 294 0 145 231 0 346 0 170 M18 x 2 5 167 217 255 206 0 310 0 152 270 0 405 0 199 317 0 476 0 234 229 299 339 190 0 286 0 140 249 0 375 0 184 293 0 440 0 176 20 2 5 211 277 325 251 0 414 0 185 363 0 544 0 268 425 0 637 0 314 306 401 470 218 0 328 0 161 338 0 507 0 249 394 0 592 0 291 22 2 5 242 374 437 359 0 540 0 265 431 0 711 0 318 554 0 831 0 409 399 525 613 338 0 507 0 249 406 0 608 0 300 521 0 782 0 385 24 3 0 374 449 577 An asterisk indicates that the bolts are used for female threaded parts that are made of soft materials such as Casting CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL AL
28. 6 1 8081 Crankshaft and Connecting 0 050 0 002 or Less Rod Journal Uneven Wear 0 080 0 003 CMD 4081866 90 863016001 MARCH 2008 Page 3A 93 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 MAIN BEARING CLEARANCE 1 Install the main bearing caps with the bearings 2 Torque the main bearing cap bolts sapien i Bolt Main Bearing Cap 88 65 Use inside dial indicator to measure the main bearing inside diameter and taper Ee 77216 Description Crankshaft Journal and 030 058 0 0012 0 0023 Bearing Clearance 0 08 0 0031 4 fthe main bearing journal clearance exceeds the specified limit the bearing and or the crankshaft must be replaced ROD BEARING INSIDE DIAMETER 1 Install the bearing in the connecting rod 2 Torque the bearing cap bolts mE Bolt Connecting Rod Bearing Cap 25 4 100 18 100 Use a inside dial indicator to measure the connecting rod bearing inside diameter 77217 94 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS ROD BEARING CLEARANCE 1 Ifthe clearance between the measured bearing inside diameter and the crankshaft rod journal exceeds the specified limit the bearing and or the crankshaft must be replaced Connecting Rod Journal and 025 058 0 0009 0 0023 Bearing Clearance 0 100 0 0039 MAIN BEARING CLEARANCE WITH PLASTIGAGE 1 Clean the cyl
29. AL ALL MODELS SERVICE MANUAL NUMBER 29 TIMING PULLEYS AND RELATED PARTS Page 3A 12 Description Ses Fang 5 2 Bolt Camshaft Pulley Mi2x15 64 4 Nut Injection Pump Pulley Mi4x15 69 51 esj o o 8 SN OF Pup Patey Bolt Design 1 Plate Type Spring M10 x 1 5 38 28 Tensioner 7 Bolt Design 2 Coil Type Spring M10 x 1 5 49 36 Tensioner CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS CRANKSHAFT CONNECTING ROD FLYWHEEL AND CRANK PULLEY 10 SE N A O e Le 77085 Nat Connecting Rod 00 100 Fina Pa ee IBI EE Bok DamperPuley 20 bat crak MWexis 1 Minimum torque check after tightening 54 88 Nm 40 64 Ib ft DO NOT reuse flywheel bolts Replace if removed once Use locking compound on threads CMD 4081866 90 863016001 MARCH 2008 Page 3A 13 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 INTAKE MANIFOLD TURBOCHARGER AND HEAT EXCHANGER Description peos _ Nat Weieng el 25 eas Bok Thermostat Housing ell Bor Heat Exchanger Rear Cover 19 7 Nut Turbocharger E Bot WaterPpe 7 4 Nut Heat Exchanger 319
30. AL NUMBER 29 4 Remove fuel injector pipes 5 Disconnect hose from PCV Positive Crankcase Ventilation oil separator 77314 a Injector Pipes b Hose 6 Remove injector covers A I 5009 95 4 Gl M Co c a T oo 77290 a Injector Cover b Valve Cover 7 Remove front lifting eye 8 Remove top two bolts in upper timing cover 9 Remove valve cover bolts 10 Remove valve cover 77289 a Lifting Eye b Timing Cover Bolts 2 c Valve Cover Bolts 9 Page 34 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Cleaning Clean gasket material and oil from cylinder head sealing surfaces 2 Clean valve cover and remove gasket material from sealing surfaces Inspection 1 Inspect sealing surfaces for deep nicks and scratches 2 Replace or repair parts as needed Installation 1 Apply sealant as shown to surfaces of the camshaft carrier where indicated IMPORTANT DO NOT cover oil return bore with sealant S N lt lt Seen SS NS SONS Me SS l Se LSS N Sealant Front Of Carrier b Oil Return Hole Sealant Half Moon Recess Where Used Method of Use Part Number Between camshaft carri
31. Alignment Bolt c Camshaft Pulley Bolt Bolt Camshaft Pulley 64 Install timing belt and timing covers Install injectors and fuel return inner pipe Install valve cover CMD 4081866 90 863016001 MARCH 2008 Page 3A 55 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Intake Manifold Removal 1 Remove the air duct from intercooler to intake manifold 2 Disconnect fuel supply hose Plug hose to prevent fuel from leaking into boat 3 Disconnect fuel return hose 4 Remove fuel filter and bracket 5 Remove fuel injector pipes 6 Remove fuel injection pump 7 Remove air cleaner and oil separator bracket 8 Disconnect oil dipstick tube from intake manifold 9 Disconnect fuel return pipe clip 10 Remove the intake manifold EE ann EE E 2 mor es SE a Bolt b Nut c Intake Manifold d Fuel Return Pipe Clip 11 Discard old gasket Clean Clean with solvent and dry with compressed air 2 Remove sealant residue and clean sealing surfaces Inspection 1 Inspect for cracks Replace if cracked 2 Ensure sealing surfaces are smooth and clean Page 3A 56 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Installation 1 Install a new gasket and the intake manifold 2 Tighten the fastening bolts and nuts in a cross pattern Continuing the pattern torque fasteners OS er 77294 G
32. E MANUAL NUMBER 29 Engine Specifications continued NOTICE Unit Of Measurement mm in Crankshaft Main Journal Outside 51 918 51 928 2 0440 Diameter Grade 1 Size Mark 2 0444 51 912 2 0438 Main Journal Outside Production 91 928 51 998 Diameter Grade 2 Size Mark 2 0444 2 0448 51 922 20442 Connecting Rod Journal 45 930 45 945 1 8083 Outside Diameter 1 8089 0 030 0 058 0011 0023 ain Bearing Clearance 0 080 003 Connecting Rod Journal Outside Diameter 45 930 45 945 1 808 1 811 Connecting Rod Bearing Clearance 0 025 0 058 0010 0023 Crankshaft and Connecting 0 05 0019 or Less Rod Journal Wear or Taper 0 08 003 Crankshaft End Play Thrust 0 05 0 15 0019 0059 Clearance 0 20 0078 Crankshaft Runout 0 05 0019 or Less ranksna unou um 5 06 nas Connecting Rod Crank Pin Bore Blue Mark 48 94 49 00 1 927 1 929 Inner Diameter 1 Black Mark 48 88 48 94 1 924 1 927 Brown Mark 48 82 48 88 1 922 1 924 Allowable W T 0 05 0019 or Less owable Wear or Taper Umi 208 003 Connecting Rod Bushing Connecting Rod Bushing Inner Diameter 27 008 27 015 1 063 1 064 Bushing To Piston Pin Clear 0 008 0 020 0003 0008 ae 305 002 Page 8 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Torque Specifications IMPORTANT Tighten all fasteners n
33. FT HEIGHT 1 Measure the total cam height H with a micrometer Subtract the lobe diameter D The difference is lobe lift LL If the lobe lift is less than the specified limit the camshaft must be replaced L 77207 Production Intake 7 80 0 307 Lobe Lift Limit Intake 7 68 0 302 H D LL Production Exhaust 7 95 0 312 Limit Exhaust 7 77 0 306 CMD 4081866 90 863016001 MARCH 2008 Page 41 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 CAMSHAFT RUNOUT 1 Mount the camshaft on V blocks 2 Measure the runout with a dial indicator If the runout exceeds the specified limit the camshaft must be replaced 77208 e Run 303 00077 208100019 CLEARANCE BETWEEN JOURNAL AND CAMSHAFT BRACKET 1 Clean the camshaft journals and camshaft brackets 2 Position camshafts in camshaft carrier The mark on exhaust camshaft should be between the two marks on intake camshaft and approximately level with upper edge of camshaft carrier IMPORTANT Ensure that engine is on TDC and timing marks are properly aligned 77254 a Exhaust Camshaft Mark Intake Camshaft Marks c Upper Edge Of Carrier 3 Place Plastigage across the full width of the camshaft journals cH zB N e ON 259 ROY 77209 a Plastigage Page 3A 42 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL
34. Install piston pin into piston and connecting rod until it makes slight contact with the first snap ring 77245 a Piston b Piston Pin Where Used Method of Use Part Number Engine Oil Piston and pin Obtain Locally Page 3A 86 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 6 Install second piston pin snap ring into piston snap ring groove 77246 7 Check that connecting rod moves smoothly on piston pin PISTON RINGS 1 Apply engine oil to piston ring surfaces and piston 2 Insert expander coil into oil ring groove so that there is no gap on either side of expander Coil IMPORTANT Use a piston ring expander to avoid damaging the piston rings 3 Using the Piston Ring Expander Tool install oil ring SNC lt UP 7 182 71248 Piston Ring Expander Tool b Oil Ring Coil Expander Type c Second Compression Ring d First Compression Ring Description Where Used Method of Use Part Number piston Piston Ring Expander 91 24697 Description Installs and removes piston rings CMD 4081 866 90 863016001 MARCH 2008 Page 3A 87 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 4 Install compression rings with stamped side facing up 5 Check that the piston rings rotate smoothly in the piston ring grooves or 6 Align piston ring gaps as shown NOTE The gap of each piston ring must be o
35. L MODELS FLANGED HEAD BOLT IMPORTANT The tightening torque values given in the table below are applicable to bolts and fasteners unless otherwise specified NOTICE Unit Of Measurement Nm lb ft Identifica tion Diameter x Thread Pitch mm Mext0 f 66 1220 9 8 1 25 10 55 196 8 15 15 3 28 4 11 21 18 1 33 15 25 M10 x 1 5 22 3 37 2 16 27 40 1 66 9 30 49 54 9 82 3 41 61 85 0 128 0 63 94 51 0 76 5 38 56 79 5 119 0 59 88 162 _ M14x2 0 77 2 116 0 57 86 we eee ER 80 120 128 116 0 173 0 86 171 0 257 0 177 0 265 0 131 128 126 190 196 M16 x 2 0 109 0 164 0 80 163 0 244 0 169 0 253 0 125 121 120 180 187 A bolt with an asterisk is used for female screws of soft material such as cast iron 115 0 172 0 123 0 185 0 91 oe 83 0 125 0 61 92 CMD 4081866 90 863016001 MARCH 2008 Page 3A 21 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Special Tools 1 883844 Description To remove injection pump drive pulley Description Used in combination with typical valve spring compressor to compress valve spring Installer Remover Description Install and remove valve guide RSS NN NN L Description Install front crankshaft oil seal without crankshaft mom PM Sy Description Install front crankshaft oil
36. L NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS ROD JOURNAL AND BEARING CLEARANCE 1 Ensure the crankshaft the connecting rod the bearing cap and the bearings are clean 2 Install the bearing to the connecting rod and the bearing cap IMPORTANT Do not allow the crankshaft to move when installing the bearing cap 3 Prevent the connecting rod from moving 4 Attach the Plastigage to the connecting rod journal o Apply engine oil to the Plastigage to keep it from falling 6 Install the bearing cap and torque the nuts Description 3 8 in Nut Connecting Rod 2AUNF 25 100 how 18 100 IMPORTANT Do not allow the connecting rod to move when installing and tightening the bearing cap 7 Remove the bearing cap 8 Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container 9 If the measured value exceeds the specified limit perform the following additional steps a Use a micrometer to measure the connecting rod journal outside diameter b Use an inside dial indicator to measure the bearing inside diameter c If the connecting rod journal and bearing clearance exceeds the specified limit the crankshaft and or the bearing must be replaced 0 100 6 0053 Connecting Rod Journal and 025 058 0 0009 0 0023 Bearing Clearance CMD 4081866 90 863016001 MARCH 2008 Page 3A 97 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL
37. MODELS 4 nstall the brackets Tighten camshaft bracket nuts in sequence shown in stages of 1 2 to 1 turn at a time Torque nuts IMPORTANT Do not allow the camshaft to turn during bracket installation and tightening 77284 Camshaft Torque Sequence Description Nut Camshaft Bracket M8x1 25 Nut Camshaft Bracket M10x1 25 5 Remove camshaft brackets and compare the width of the Plastigage against the scale printed on the Plastigage container 6 If clearance between cam journal and bracket exceeds the limit the camshaft and or camshaft carrier assembly must be replaced LA 2 77210 Plastigage b Scale 0 040 0 082 Clearance between journal Production 0015 0 0032 and bracket bearing surface 011000049 CMD 4081866 90 863016001 MARCH 2008 43 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Installation To avoid severe engine damage the engine MUST BE set on cylinder number 1 COMPRESSION STROKE at TDC before proceeding 1 Ensure that engine is on TDC of cylinder number 1 compression stroke 2 When using existing exhaust camshaft Coat camshaft journals and lobes with clean engine NOTE When replacing the exhaust camshaft or if locking pin is removed prior to reassembly The exhaust camshaft sub gear must be pre tensioned using special tool 91 883853 and connected to the exhaust camshaft gear using the adjusting pin
38. NUMBER 29 MAIN BEARING SELECTION When installing new main crankshaft bearings or inspecting old bearings refer to the Main Bearing Selection Table ua um Ep al bw he Ww 77222 a Cylinder Block Journal Size Marks b Crankshaft Journal Size Marks c Bearing Color Code Main Bearing Selection Table Cylinder Block Journal Crankshaft Journal i Oil Clearance mm in mm Color Reference Diameter Diameter mm in 51 918 51 928 Blue 0 032 0 058 55 992 56 000 2 0440 2 0444 0013 0023 2 2044 2 2047 51 928 51 938 0 030 0 056 2 0444 2 0448 Black 0012 0022 RN 51 918 51 928 0 032 0 058 55 984 55 992 2 0440 2 0444 0013 0023 0 030 0 056 0012 0022 Brown in 0 032 0 058 55 976 55 984 2 0440 2 0444 0013 0023 2 0444 2 0448 0012 0022 2 2041 2 2044 01 928 51 938 2 0444 2 0448 2 98 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS CONNECTING ROD BEARING SELECTION When installing new connecting rod bearings or inspecting old bearings refer to the Con necting Rod Bearing Selection Table 77223 d Connecting Rod Size Mark e Connecting Rod Bearing Color Code Connecting Rod Bearing Selection Table Clearance Connecti
39. Position the piston ring gaps as shown in the illustration EE As b gort a 77250 Oil Ring b Second Compression Ring c First Compression Where Used Method of Use Part Number Engine Oil ird Obtain Locally e Coat the two HE Disulfide Piston skirt skirts on each Obtain Locally rease piston CMD 4081866 90 863016001 MARCH 2008 Page 3A 106 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 17 Apply a coat of engine oil to the cylinder wall Where Used Method of Use Part Number Engine Oil Cylinder Bores Obtain Locally 18 Use a piston ring compressor to compress the piston rings 19 Position the front mark on the top of piston so that it is facing the front of the cylinder 77265 Top Of Piston b Front Mark 20 Install the piston by tapping on piston top with a suitable device Align connecting rod with crankshaft pin and tap on piston top until the rod bearing contacts crankpin 77265 CMD 4081866 90 863016001 MARCH 2008 Page 107 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 NOTE Do not apply engine oil to the bearing back faces and the connecting rod bearing fitting surfaces 21 Install the connecting rod bearing cap The bearing cap number at the side of the bearing cap and the connecting rod number must be the same and on the same side The bearin
40. SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS ENGINE Section 3A 1 7L Engine Mechanical All Models Table of Contents Engine Specifications 3A 3 Camshaft Piston Rings 3A 3 Exploded View u c PT 3A 3 Removal EECHER sere Re ibisi 3A 3 Cleaning Engine Specifications continued 4 Inspection Oil Pump 3A 4 Installation Cylinder 4 Intake Manifold Cylinder Head 4 Removal Engine Specifications continued 5 KEE rr Camshaft Carrier 5 Jee TEE Camshafts 5 Installation Engine Specifications continued 6 Cylinder Head m Valve Adjustment 3A 6 EXploded VIEW 6 Engine Specifications continued 7 Disassembly Valve Seat 7 Sr Valve Guide 7 INSPOCHON eege b Es Valve Spring 7 Engine Specifications co
41. SS 7 311 1 Valve Cover 2 Camshaft Carrier And Brackets 3 Camshafts 4 Rear Lifting Eye 5 Front Lifting Eye 6 Carrier Gasket 7 Dowel 8 Cylinder Head CMD 4081 866 90 863016001 MARCH 2008 Page 3A 51 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Removal Remove valve cover Remove fuel return inner pipe Remove injectors Ensure that engine is on cylinder number 1 TDC and timing marks are properly aligned Remove timing covers and timing belt Hold the camshaft pulley with TDC alignment bolt and remove camshaft pulley bolt ee oe Remove alignment bolt and remove camshaft pulley 77163 a Camshaft Pulley b TDC Alignment Bolt M6 c Camshaft Pulley Bolt 8 Remove upper dust cover bolts in front 77164 a Upper Dust Cover Bolts Page 3A 52 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 Cleaning 1 7L ENGINE MECHANICAL ALL MODELS 9 Loosen all camshaft carrier bolts and nuts1 2 turn at a time in numbered sequence then remove bolts and nuts E De d Zu TL Camshaft Carrier Bolt Removal Sequence 10 Remove camshaft carrier from cylinder head 11 Discard old gasket 1 Clean all sealing surfaces 2 Remove sealant residue CMD 4081866 90 863016001 MARCH 2008 77165 53 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Inspection 1
42. SURE VALVE STEM CLEARANCE 1 Using a valve with the specified stem diameter or a new valve measure valve stem clearance a Attach a dial indicator to the cylinder head Position it against the valve stem and close to the valve guide b While holding the valve head off the seat about 2 mm 1 16 in move the valve stem side to side in the guide Compare sstem clearance with specifications 0 023 0 056 Intake 0 0009 0 0022 Valve Stem Clearance 0 028 0 610 Exhaust 0 0011 0 0240 CMD 4081 866 90 863016001 MARCH 2008 Page 3A 65 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 VALVES 1 Measure valve stem diameter in three places 2 If the measured value is less than specified limit the valve and valve guide must be replaced as a set 77196 Description in 5 959 5 977 2346 2353 Intake Valve Stem Diameter Limit 5 945 2341 Exhaust Valve Siem 5 954 5 972 2344 2351 Diameter 5 940 2339 3 Measure valve head margin 4 f measured value is less than specified the valve and the valve guide must be replaced as a set EN 77197 Intake Valve Margin Production 1 2 1 4 0 047 0 055 0 Margin After Grinding 1 0 0 039 Page 3A 66 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS VALVE SPRINGS 1 Use a vernier caliper to measure the valve spring free height Replace spring if less tha
43. a small amount of extra sealant is added where indicated 71269 a Sealing Surface b Cross Hatching Marks For Sealant Location c Extra Sealant Areas Description Where Used Method of Use Part Number Between oil Apply a bead to Loctite 5699 pump retainer sealing and cylinder surfaces as block indicated Obtain Locally Page 114 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 4 nstall oil pump retainer to cylinder block Torque the five bolts around the oil pump in a circular pattern 1 5 5 Torque remaining retainer bolts 6 10 23 CO SY 8 O Ic 7 NE 3S6 eG AX NC ND 77270 Oil Pump Retainer Torque Sequence a Oil Pump Retainer b Bolts 10 Boi Oi Pump Retainer 88 9 Install oil pan Install crankshaft pulley and oil pump pulley Install timing belt and covers co e sb On inboard models install seawater pump and belt CMD 4081866 90 863016001 MARCH 2008 Page 115 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Oil Pressure Relief Valve And Check Valve The oil pressure relief valve and check valve are installed in the lower rear port side of the block Removal 1 Remove oil pressure relief valve and check valve from block 77330 a Oil Pressure Relief Valve b Check Valve Cleaning 1 Clean all sealing surfaces 2 Wash all
44. ard models Install the drive plate using the M7 bolts and lockwashers Torque the bolts 79705 Nm i Bolt Drive Plate A Where Method Part Drive Apply to Loctite 271 Plate beginning on bolts threads y CMD 4081866 90 863016001 MARCH 2008 Page 131 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Page 3A 132 12 Install flywheel housing Torque bolts and nuts NOTE There are different thread patterns and fastener combinations involved Ensure the proper placement of each 71371 Sterndrive Shown Inboard Similar a Flywheel Housing b Bolt Washers and Nut M10 x 1 5 c Bolt and Washers M10 x 1 5 d Bolt Washers and Nut M12 x 1 25 e Bolt and Washers M12 x 1 75 f Flat Washer g Lock Washer Bolt and Nut M12 Bolt and Nut 44 1 13 On inboard models Install the transmission Refer to Section 8A CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Front Oil Seal Removal Remove engine drive belts Remove seawater pump inboard models Remove timing belt covers and timing belt Remove crankshaft pulley oe S Iw Remove fastening bolt for timing belt drive pulley Counterhold using special tool 77140 a Crankshaft Pulley Bolt b Special Tool 6 Remove timing belt drive pulley from crankshaft using puller 77141 a Crankshaft Pulle
45. asket b Intake Manifold Bolts M8 x 1 25 d Nuts M8 x 1 25 eege Im miake Wario 3 Reconnect fuel return pipe clip to manifold Torque bolt Nm ibm amp Bolt Fuel Return Pipe Clip 4 Install fuel injection pump fuel injector pipes and pressure hose Refer to Section 5 IMPORTANT Ensure pressure hose from manifold fitting to boost compensator device on the injection pump is connected a Pressure Hose b Manifold Fitting c Boost Compensator CMD 4081866 90 863016001 MARCH 2008 Page 3A 57 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 5 Install the intake manifold air duct with new gasket Torque bolts a Air Duct b Gasket c Bolt 77368 Description Nm im 6 Install fuel filter and bracket Torque bolts Description Nm bim Unplug and connect fuel supply hose to filter inlet fitting pe Connect fuel return hose to filter Connect oil dipstick tube bracket to intake manifold Torque bolt 77299 Bolt Bracket 5 b Bolt Oil Separator 2 Description Bolt Bracket M8 x 1 25 Barv 11 Connect hoses Page 3A 58 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Cylinder Head IMPORTANT If a cylinder head is damaged replacement cylinder heads are only a
46. at of engine oil to the crankshaft journals and the crankshaft bearing surfaces before installing the crankshaft 77260 Where Used Method of Use Part Number A Engine Oil Crankshaft Obtain Locally 4 nstall the crankshaft into the cylinder block and bearings CMD 4081866 90 863016001 MARCH 2008 Page 3A 103 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 o Apply an ample coat of engine oil to the crankshaft thrust bearings IMPORTANT The crankshaft thrust bearing oil grooves MUST face the crankshaft not the cylinder block 6 Install the crankshaft thrust bearings with oil grooves facing cylinder number 2 crankshaft journal 77261 Crankshaft Thrust Bearing b Oil Grooves Description Where Used Method of Use Part Number Engine Oil rankshait Obtain Locally thrust bearings IMPORTANT The bearing cap arrow marks MUST face the front of the engine and number must correspond to the bearing cap journal 7 Apply a coat of engine oil to the threads and mating surfaces of bearing cap bolts Where Used Method of Use Part Number Engine Oil Bearing cap bolt Obtain Locally 8 Tighten the bearing cap bolts a little at a time in numbered sequence 1 10 9 Torque all bearing cap bolts in numbered sequence 1 10 7 O bh oh 0 0 9 49 eL Or FO SECH O 77262 Main Bearing Cap Torque Sequence a Arrow Mark Points To Front b B
47. b Piston Pin Cleaning Clean all parts with solvent Clean oil passages Dry parts with compressed air Clean varnish from piston skirts and pins with a suitable cleaning solvent NOT wire brush any part of piston 5 Clean piston ring grooves Ensure that oil ring holes are clean CMD 4081866 90 863016001 MARCH 2008 Page 3A 79 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Inspection CONNECTING ROD 1 Check for twisted or bent rods and inspect for nicks or cracks Replace damaged connecting rods 2 Use a caliper calibrator and a micrometer to measure the piston pin and connecting rod bushing clearance Replace the piston pin and or the connecting rod bushing if clearance exceeds specified limits 77291 0 008 0 020 eii A rem 0 0003 0 0007 0 050 0 0020 3 Usea connecting rod aligner to measure distortion and parallelism between connecting rod crankshaft pin bore and bushing bore Replace rod if either value exceeds specified limits 77234 Connecting Rod Alignment Per Length of 100 mm 4 in Connecting Rod Distortion standard 0 05 0 002 Per Length of 100 mm 0 10 0 004 Connecting Rod Parallelism 0 075 0 003 Per Length of 100 mm 0 15 0 006 Page 3A 80 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS PISTON 1 Inspect piston for cracked ring lands skirts or pin bosses wavy or worn
48. bm 1 60 degrees 60 degrees CMD 4081866 90 863016001 MARCH 2008 Page 3A 29 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Lubrication Flow Diagram PE VAAN VAN AMEN DIC MOD DIDDY WAYS N c S gt ODI DIDDY m B elm NR TAY SC re S i CG UA ei N ac q JU A JN PN VLA 4 St Sec Sc Nj d i 4 1011 77320 lt Unpressured lt Pressurized Oil 1 Oil Pan 2 Oil Pickup Screen Oil Pump 4 Relief Valve 690 kPa 100 psi 5 Oil Cooler 6 Relief Valve 250 kPa 36 psi 7 Oil Filter 8 Bypass Valve 98 kPa 14 2 psi 9 Oil Drain 10 Sized Orifice 1 5 mm 059 in 11 Cylinder Head Oil Gallery 12 Camshaft Bearings 13 Main Oil Gallery 14 Oil Pressure Sender 15 Oil Pressure Switch Opens at 31 52 kPa 4 5 7 5 psi 16 Turbocharger 17 Crankshaft Bearings 18 Connecting Rod Bearings 19 Check Valve 250 kPa 36 psi 20 Sub Oil Gallery 21 Piston Oiling Jets Page 3A 30 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Examples of Bearing Failures Bri Scratches Overlay ght Polished Imbedded into Wiped Sections Bearing Material Out SCRATCHED LACK OF IMPROPER BY DIRT OIL SEATING Hadius Overlay Gone Ride C
49. der block or on V blocks 2 Seta dial indicator to the center of the crankshaft journal 3 Gently turn the crankshaft in the normal direction of rotation Read dial indicator as crankshaft is turned 4 Replace crankshaft if runout exceeds the specified limit 77213 Crankshaft RunOut Description mm Crankshaft Runout 0 05 0 002 or less ois 0 06 0 002 BEARING TENSION 1 Ensure that main bearing installs under tension It should require firm pressure to fit the bearing into position Y 77214 Main Bearing Tension Page 3A 92 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS MAIN BEARING JOURNAL AND ROD JOURNAL DIAMETER 1 Using a micrometer measure crankshaft journal diameters at points a and b on one side of journal then repeat measurements on opposite side of journal 22215 Main Journal and Connecting Rod Journal Measurement 2 Measure connecting rod journal diameters using same procedure as for crankshaft journals 3 Replace crankshaft if any measured values are less than limit Description mm in Main Journal Outside 01 918 51 928 e P Diameter Grade 1 Size el Producton 2 0440 2 0444 51 912 2 0438 Main Journal Outside 01 928 51 938 Diameter Grade 2 Size Mark 2 0444 2 0448 51 022 10442 45 930 45 945 Connecting Rod Journal Production 1 8083 1 8089 Outside Diameter Limit 45 92
50. earing Cap Bolts mE Page 104 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 10 Manually rotate the crankshaft to ensure that it turns smoothly 11 At the same time rotate the crankshaft until the crankpin is at BDC for cylinder that is ready for first piston to be installed 12 Carefully wipe any foreign material from the connecting rod bearings and the connecting rod bearing fitting surfaces NOTE Do not apply engine oil to the bearing back faces and the connecting rod bearing fitting surfaces 13 Install the upper bearing to connecting rod 14 Insert bearing shells into connecting rod and matching rod cap Coat bearings and crankpin surfaces with a mixture of 2096 SAE 30W engine oil and 8096 Needle Bearing Lubricant SY ey 77251 NOTE Molybdenum disulfide grease will facilitate smooth break in when the engine is first started after reassembly Where Used Method of Use Part Number Rod bearing Needle EES Assembly and crankshaft Coat surfaces 92 802868A1 Lubricant journal 1 Used in a mixture of 2096 SAE30W engine oil and 80 Needle Bearing Lubricant CMD 4081866 90 863016001 MARCH 2008 Page 3A 105 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 15 Apply a coat of engine oil to the circumference of each piston ring and piston Apply a coat of molybdenum disulfide grease to the two skirts on each piston 16
51. er and Apply to sealing Loctite 5699 valve cover surfaces as Obtain Locally including specified half moon recesses CMD 4081 866 90 863016001 MARCH 2008 Page 3A 35 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 2 Place valve cover gasket on valve cover Position O ring seal inside recess in valve cover for valve cover bolt NOTE O ring seal is inside cover on brass insert with recess Install valve cover on camshaft carrier Install valve cover bolts Temporarily hand tighten bolts Install the two timing cover bolts Temporarily hand tighten bolts Install new injector covers on valve cover Torque bolts Torque valve cover bolts Torque upper timing cover bolts 11372 a Gasket b O ring Seal Inside Cover c Valve Cover d Valve Cover Bolt 9 e Timing Cover f Timing Cover Bolt 2 g Injector Cover h Injector Cover Bolt 8 Teens BotVaweCoer peo 98 Bolt injector Cover 98 _ 98 6 36 4081866 90 863016001 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Do not bend fuel injector pipes Bending may cause metal to flake off inside pipes causing injectors or injection pump to malfunction 9 Install injector pipes and torque sleeve nuts 10 Install injector pipe clamps and torque bolts 11 Install intake manifold air duct usi
52. ern as shown in stages of 1 2 to 1 turn until all are loose Remove bolts 77120 6 Remove cylinder head IMPORTANT On engines equipped with glow plugs remove glow plugs lay cylinder head on its side or support on wooden blocks to avoid damage to glow plugs Page 3A 60 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Disassembly IMPORTANT Mark location of all valve components they must be reinstalled in their original locations 1 Using valve spring compressor and Adapter carefully remove split collars retainer spring and spring seat for each valve Place valves in numbered rack according to their position in the engine or label the parts in order for reassembly to the original location a Adapter b Valve Spring Compressor c Split Collars d Retainer e Spring f Spring Seat Adapter Description Used in combination with typical valve spring compressor to compress valve spring 2 Remove valve seals from valve guides Di AN ee AZZ 222225 LLL ZZ 77237 a Valve Seal b Valve Guide CMD 4081866 90 863016001 MARCH 2008 Page 3A 61 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 3 Using the special remover tool and a hammer drive the injector sleeves out of the cylinder head from the combustion chamber
53. ffset by 120 ex 120 C c 120 77250 a Oil Ring Gap b Second Ring Gap c First Ring Gap 88 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Crankshaft Main Bearings And Cylinder Block Exploded View 77304 Cylinder Block Connecting Rod Piston Assembly Thrust Bearing Second Main Bearing Main Bearing Crankshaft Rotor Main Bearing Caps Main Bearing Bolt GA Mi CMD 4081866 90 863016001 MARCH 2008 Page 3A 89 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Removal Page 3A 90 Remove cylinder head Remove oil pump assembly Remove oil pan oil strainer and oil baffle plate Remove flywheel housing coupler flywheel and rear main seal retainer Remove connecting rod piston assemblies p XL XP dc e cn Measure crankshaft end play before removing The thrust bearings will need to be replaced during reassembly if end play exceeds specified limit 77212 Crankshaft End Play Crankshaft End Play 0 05 0 15 0 002 0 006 Thrust Clearance 0 20 0 008 7 Loosen main bearing bolts in sequence shown below and remove IMPORTANT Main bearing caps have arrows pointing toward front of engine and are numbered 1 5 beginning at front They must be reassembled in their original positions 77186 Main Bearing Cap Removal Sequence 8 Remove cranksha
54. ft from cylinder block CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Cleaning Inspection Clean crankshaft in solvent and dry with compressed air 2 Clean oil passages 1 Inspect crankshaft for nicks scratches and cracks 2 Inspect crankshaft journals and oil seal surfaces for excessive wear CRANKSHAFT NITRIDE TREATMENT INSPECTION IMPORTANT To increase crankshaft strength Nitride Treatment has been applied Because of this it is not possible to regrind the crankshaft surfaces A 5 to 1096 solution of ammonium cuprous chloride dissolved in distilled water can be used by trained technicians to test whether the crankshaft s nitride treatment is still effective Ammonium cuprous chloride in solution is highly corrosive The solution can cause corrosion damage to parts of the crankshaft metal that have not had Nitride Treatment The solution should not contact the oil ports and surrounding untreated areas of the crankshaft or damage to the crankshaft could occur n 77211 a No Contact Area b 10 mm c Ammonium Cuprous Chloride If there is no discoloration after 30 40 seconds the crankshaft is considered usable Steam cleaning of the crankshaft surfaces immediately after such a test is required CMD 4081866 90 863016001 MARCH 2008 Page 3A 91 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 CRANKSHAFT RUNOUT 1 Place crankshaft in cylin
55. g caps MUST be installed in the correct direction Reversing the bearing cap direction will result in serious engine damage 22 Apply a coat of engine oil to the threads and mating faces of each connecting rod cap bolt and nut 23 Torque the connecting rod cap nuts af ET S 7726 e Rod Bearing Cap b Cap Number c Rod Number Description Where Used Method of Use Part Number Bolts nuts and Thread length rane octi and mating Obtain Locally connecting rod SE pe Nut Connecting Rod Bearing Cap Su 25 4 100 mM 18 100 Page 3A 108 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Oil Pump Removal Remove belts Remove seawater pump inboard models Remove timing belt covers Remove crankshaft pulley and oil pump pulley Remove oil pan ote 09 Il Remove oil pump retainer X gt 23 ei e 7 Yo rq e 25 LEA So 77270 a Oil Pump Retainer b Bolt 10 c Front Oil Pan Studs And Nuts Disassembly 1 Remove inner and outer pump rotors from cylinder block 77326 a Cylinder Block b Outer Rotor Inner Rotor CMD 4081 866 90 863016001 MARCH 2008 Page 3A 109 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 2 Remove oil pump O ring from back side of oil pump retainer 77324 a Oil Pu
56. guide from upper face of cylinder head OL 77195 Upper End Height 11 7 4606 5 Check the guide inner diameter after installation and ream to the specified production dimension Description mm mm in Intake Valve Guide Inside Production E 000 6 015 mm Diameter 0 2362 0 2368 Exhaust Valve Guide Inside Production 6 000 6 015 mm Diameter 0 2362 0 2368 IMPORTANT If the valve guide has been removed both the valve and the valve guide must be replaced as a set CMD 4081866 90 863016001 MARCH 2008 Page 3A 69 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Reassembly 1 Install O rings on injector sleeves Apply a light coat of engine oil to O rings and cylinder head injector sleeve bores Avoid severe engine damage Injector sleeve O rings form a seal between the combustion chamber coolant passages and lubricating oil in the cylinder head Severe engine damage could result if the O rings are damaged during installation Do not damage the O rings during installation 2 Using a clean fuel injector placed inside the injector sleeve carefully insert the injector sleeve into bore in cylinder head Do this for all injector sleeves 3 Verify all injector sleeves are fully seated in cylinder head after installation Cross Section Of Injector Sleeve In Cylinder Head a Cylinder Head b Injector Sleeve c O ring d Fully Seated Where Used Method of
57. inder block the journal bearing fitting surface the bearing caps and the bearings Install the bearings to the cylinder block Carefully place the crankshaft on the bearings Rotate the crankshaft approximately 30 to seat the bearing ae E Place the Plastigage over the crankshaft journal across the full width of the bearing 2 77218 a Plastigage CMD 4081866 90 863016001 MARCH 2008 Page 3A 95 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 6 Install the main bearing caps with the bearing 7 Tighten the main bearing caps IMPORTANT Do not allow the crankshaft to turn during bearing cap installation and tightening Oe Or S 77219 Main Bearing Cap b Front im Bok Wain Beara Cap as 98 95 8 Remove the bearing cap 9 Compare the width of the Plastigage to the scale printed on the Plastigage container 10 If the measured value exceeds the limit perform the following additional steps a Use a micrometer to measure the crankpin outside diameter b Usean inside dial indicator to measure the bearing inside diameter c If the crankshaft journal and bearing clearance exceeds the specified limit the crankshaft and or the bearing must be replaced 77220 Plastigage b Scale Plastigage Container Main Bearing Clearance 030 058 0011 0023 Page 3A 96 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUA
58. l pan to upper oil pan Loctite 572 or Threebond Anode plu Thread length Loctite 262 Drain plugs Thread length Apply a bead to sealing surfaces Obtain Locally as specified Loctite 5999 Loctite 262 Loctite 962T or Around outside Threebond 1386 Oil spray nozzle Obtain Locally As indicated throughout Engine Oil Coat surfaces Obtain Locally SECTION in steps and tables Silicone Grease Obtain Locally 1 Used in a mixture of 2096 SAE30W engine oil and 8096 Needle Bearing Lubricant CMD 4081866 90 863016001 MARCH 2008 Page 3A 27 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Description Engine Rotation NOTE Engine rotation is described when observed from the rear of the engine transom end looking forward water pump end CI DU E fry e Mr 77122 Left hand Rotation Engine Firing Order Firing Order 1 3 4 2 Page 3A 28 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Cylinder Head Torque Sequence And Torque Specifications IMPORTANT Lubricate the underside of all bolt heads and threads with clean engine oil 77120 1 First Pass Torque bolts in sequence Repeat sequence using same specification to ensure better preload 2 Second Pass In sequence tighten each bolt through an angle of 60 degrees 3 Final Pass In sequence tighten each bolt through ANOTHER angle of 60 degrees Nm i
59. l filter housing hollow retaining bolt and O ring 77088 Oil Drain Hose b Hollow Retaining Bolt c O ring 6 Remove oil filter housing and oil cooler assembly from cylinder block 7 Remove bolts and separate oil cooler from oil filter housing Note position of O ring seals 77088 Oil Cooler b Bolt c O ring Seals Cleaning NOTE The oil filter element cannot be cleaned and reused It must be replaced 1 Clean all sealing surfaces 2 Wash all parts in solvent and dry with compressed air CMD 4081866 90 863016001 MARCH 2008 Page 3A 119 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Inspection 1 Inspect housing and cooler sealing surfaces for nicks and burrs 2 Inspect oil cooler for cracks or deformation 3 Inspect oil filter housing for cracks 4 nspect coolant hoses Replace if damaged or worn Installation 1 Install new O rings and bolt oil cooler to oil filter housing Torque bolts 77088 Oil Cooler b Bolt c O ring Seals Description Nm bim ib _ Bolt O Goole 3 2 Mount oil filter housing with oil cooler onto cylinder block Engage the lug on the oil filter housing with locating stopper 77316 Oil Filter Housing b Lug c Locating Stopper 3 Apply engine oil to hollow retaining bolt threads and seat Install hollow retaining bolt with new O ring Torque bolt Where Used Method of Use Part Number Engine Oil
60. l rear oil seal retainer Torque bolts Nm ibi Bo Rear OT Seal Rener M xio 38 S CMD 4081866 90 863016001 MARCH 2008 Page 3A 129 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 5 Install upper and lower oil pans 6 Suitably clean or chase the threads of flywheel bolt holes in crankshaft before proceeding 7 Install flywheel and flywheel washer Avoid severe engine damage or injury Flywheel mounting bolt are suitable for one time use only They could fail if used more than once Do not reuse flywheel mounting bolts 8 Apply sealant to beginning threads of 8 NEW flywheel bolts and install the flywheel Do not reuse flywheel mounting bolts IMPORTANT The installation time using this sealant including the torque check is 10 minutes maximum 9 Hold flywheel using an appropriate lock device Tighten bolts in the numerical sequence shown Torque bolts rA 7 137 a Flywheel b New Flywheel Bolts 8 Sequence Where Used Method of Use Part Number Loctite 262 NEU TIC Apply to begin Obtain Locally retaining bolts ning threads Nm ib ib amp _ MHxizszsev EEA 130 4081866 90 863016001 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 10 On sterdrive models Install the flywheel coupler using the M10 bolts and lockwashers Torque the bolts 11 On inbo
61. lt And Lock Washer Pedestal Mount Assembly d Trunion Clamping Bolt Flat Washer Lock Washer and Nut Description a Drain Bracket b Bolt mE Page 136 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 Oil Separator Vent System 1 7L ENGINE MECHANICAL ALL MODELS Refer to SECTION 7C Turbocharger for information Timing Belt And Related Components Upper Timing Cover Lower Timing Cover Engine Plate Tensioner Pulley Assembly plate type Tensioner Pulley Assembly coil type Timing Belt Camshaft Pulley a GN CMD 4081866 90 863016001 MARCH 2008 77151 8 Injection Pump Pulley 9 Idle Pulley 10 Oil Pump Pulley 11 Crankshaft Pulley 12 Dust Cover 13 Tensioner spring retainer plate 14 Plate Type Tension Spring Page 3A 137 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Removal Remove engine drive belts Remove seawater pump inboard models Remove crankshaft pulley Remove water pump pulley Remove engine plate p XML oS Remove upper timing belt cover i T s ES zi LP 3 ap 77121 a Serpentine Belt b Belt Tensioner Crankshaft Pulley d Water Pump Pulley e Upper Timing Belt Cover f Engine Plate 7 Reinstall bolt from engine plate for timing belt tensioner Torque the bolt 1 2 xu ed loe 77127 Engine Pla
62. ming Belt Pulley e Flat Washer f Bolt 3 Counterhold the crankshaft pulley using special tool and torque crankshaft pulley bolt lt A Se 77296 a Pulley Bolt b Special Tool ME 5 196 144 4 Install oil pump pulley to oil pump shaft CMD 4081866 90 863016001 MARCH 2008 Page 3A 145 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 5 Install oil pump pulley nut Counterhold pulley using a separate wrench Torque nut N We R N N TUT NN 22 e a Pulley Nut b Separate Wrench 77159 Nm im 4 6 Install the idle pulley Torque pulley bolt a Idle Pulley b Pulley Bolt 77298 Description im Boke Puy 80 146 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 7 Ensure that woodruff key is installed and install injection pump pulley 8 Lock injection pump pulley using TDC alignment bolt 9 Install and torque injection pump pulley nut 77299 a Injection Pump Pulley b TDC Alignment Bolt M8 c Injection Pump Pulley Bolt Description Nm bin b Nu ection Pump Puley maxis 6 10 Ensure that woodruff key is installed and install camshaft pulley 11 Install the camshaft pulley and lock the pulley with TDC alignment bolt 12 Install and torq
63. mp Retainer b Oil Pump O ring 3 Remove seals from retainer using suitable tools 77087 a Oil Pump Retainer b Crankshaft Oil Seal c Oil Pump Seal Cleaning 1 Clean all sealing surfaces 2 sealant residue 3 Wash all parts in solvent and dry with compressed air Page 110 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Inspection 1 Inspect oil pump shaft rotors and cylinder block for excessive wear or damage Replace oil pump assembly if excessive wear or damage is found 2 Check clearance of oil pump shaft in cylinder block 77326 Cylinder Block Inner Rotor c Oil Pump Shaft Oil pump shaft clearance in 0 040 0 125 0015 0049 cylinder block 0 200 0078 3 Check oil pump rotor end float end play NOTE Rotor end float is the difference between the combined cylinder block and retainer depths minus the thickness of the rotors 77327 a Oylinder Block Depth b Retainer Depth c Inner and Outer Rotor Thickness 0 035 0 100 Production End Float 0014 0039 qm EE CMD 4081866 90 863016001 MARCH 2008 Page 3A 111 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 4 Check clearance between outer rotor and cylinder block gk AOL e a Cylinder Block b Outer Rotor c Feeler Gauge Clearance between outer rotor 0 24 0 36 0 0094 0141 and cylinder block 0 40 0 0157
64. n specified limit 77198 Production 44 63 1 76 EES 1 44 13 1 74 2 If the measured value exceeds the specified limit the valve spring must be replaced ER 77199 Production Spring Inclination 1 01 0 040 3 Use a spring tester to measure the valve spring tension Replace spring if less than specified limit 77200 Compressed Height at 33 3 1 81 Pressure Limit at 160 N 36 Ib CMD 4081866 90 863016001 MARCH 2008 Page 3A 67 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Repair VALVE GUIDE REPLACEMENT IMPORTANT To avoid damage to the aluminium head extreme care must be used when replacing the valve guides Only a qualified machine shop should perform this operation The guide inner diameter should be checked after installation and reamed to the specified production dimension 1 Using a hammer and valve guide driver drive the valve guide out of cylinder head from the combustion chamber side of cylinder head 77176 Cylinder Head b Valve Guide Driver 2 Apply engine oil to outside of new valve guide and install on valve guide driver 3 Using a hammer drive valve guide into position from top of cylinder head 77194 Top Of Cylinder Head b Valve Guide Driver Page 3A 68 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 4 Measure the height of valve
65. nder block 0 200 0078 0 035 0 100 0014 0039 Rotor end float 018000059 Clearance between outer rotor 0 24 0 36 0094 0141 and cylinder block 0 40 0015 Clearance between inner and 0 13 0 15 0051 0059 outer rotors mesh Limit 0 20 0078 Cylinder Block 0 05 0 0019 or Less a 0 0029 Crankshaft Journal Hole Diameter 55 976 56 000 2 204 2 205 79 000 6 102 m 79 001 79 010 3 1102 3 1106 Cylinder Bore Diameters COP 79 011 79 020 3 1106 3 1110 T 79 021 79 030 3 1110 3 1114 Cylinder Block Height 272 10 71 Cylinder Head 0 075 0030 Warp and Flatness Per 125 mm 5 in 0 025 0010 Valve Guide Inside Diameter 6 000 6 015 2362 2368 4 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Engine Specifications continued NOTICE Unit Of Measurement mm in Camshaft Carrier Camshaft Carrier Lower Face Less Than 0 05 002 Warp 205 9018 Journal Hole Diameter 27 000 27 021 1 063 1 064 Clearance between journal and 0 040 0 082 0015 0032 bracket bearing surface 0 110 0043 Camshaft Carrier Height 29 62 1 166 26 939 26 960 Production Journal Diameter 1 0605 1 0614 Limit 2692 10598 92 1 0598 Intake Lobe Lift Camshaft g a 307 758 30 Camshafts Geisen Lobe Lift Camshaft 7 95 312 eight 777 306
66. ng Rod Bearing Color Reference Size Mark Code 0 025 0 054 0 0009 0 0021 0 027 0 056 Black 0 0010 0 0022 0 029 0 058 0 0011 0 0023 CMD 4081866 90 863016001 MARCH 2008 Page 3A 99 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 CYLINDER BLOCK SURFACE Cleaning 1 Use compressed air to thoroughly clean the inside and outside surfaces of the cylinder block the bolt and oil holes and the water jackets Measurement 1 Using a straight edge and a feeler gauge measure the four sides A B E F and the two diagonals C D of the cylinder block upper face 2 f the measured value is more than the limit the cylinder block must be replaced Cylinder Block Upper Surface Warp Description mm in 0 05 0 0019 or Less 01100039 3 Measure height of the cylinder block at the four edges to ensure block has been machined 4 fthe measured value is less than indicated the cylinder block must be replaced 77258 Cylinder Block Height Cylinder Block Height 272 10 71 Page 100 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 CYLINDER BLOCK BORE MEASUREMENT 1 1 7L ENGINE MECHANICAL ALL MODELS Take measurements at measuring point a across positions W W X X Y Y and 2 2 at 12 mm 55 mm and 95 mm 15 32 in 2 5 82 in and 3 3 4 in depths inside bore 2 Calculate the average value of the fo
67. ng a new gasket Torque bolts 12 Tighten air duct hose clamps securely 13 Install front engine lifting eye Torque bolt 14 Connect hose from oil separator to valve cover a igo R X NS gt e Ku O int ZS ES m 7 77314 Injector Pipes b Clamps c Gasket d Air Duct e Hose Nm ibm bf Na medo Pipe Seeve meas 20 Clamp injector Pip 98 MN Bot intake Manifold Duct wexi25 5 38 BottngneU ngEye 25 CMD 4081866 90 863016001 MARCH 2008 Page 3A 37 1 7L ENGINE MECHANICAL ALL MODELS Camshafts SERVICE MANUAL NUMBER 29 Exploded View 9 2 e A SUN NC 1 ERE 8577 LA e 77308 Camshafts Camshaft Brackets Camshaft Carrier Nut M8 Nut M10 of GN ch Page 3A 38 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Removal 1 Remove valve cover 2 Remove the 5 hollow bolts and seal washers Remove fuel return inner pipe 77160 a Hollow Bolts b Fuel Return Inner Pipe 3 Remove fuel injectors 4 Remove timing belt covers 5 Remove timing belt 6 Hold the camshaft pulley with TDC alignment bolt and remove camshaft pulley bolt 7 Remove TDC alignment bolt and remove camshaft pulley 77163 Camshaft Pulley
68. ng seal on oil pickup assembly Coat surfaces of O ring with clean engine oil 2 Install oil pickup assembly Torque bolt 77145 a Oil pickup Assembly b O ring c Bolt Where Used Method of Use Part Number A Engine Obtain Local Nm im bf OT Pickup Assembly Mexiz 26 _ Page 124 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 3 Mount the Aligner Tool 91 883859 as shown to align cylinder block and upper oil pan Use 2 M6 x 1 0 x 10mm 16mm long bolts obtained locally to hold in place temporarily 77801 Aligner Tool b Bolts 4 Apply a 4 mm 5 32 in bead of specified sealant to sealing surface of cylinder block Ensure that sealer application is around the outside of studs on front and rear 77277 Sealing Surface b Sealer Sealer Application Around Studs Where Used Method of Use Part Number Upper oil pan to Apply a bead to Loctite 5999 Sider sealing surfaces Obtain Locally as specified CMD 4081866 90 863016001 MARCH 2008 Page 125 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 o Install upper oil pan to cylinder block and position squarely against the Aligner Tool Temporarily hand tighten bolts and nuts 6 Ensure upper oil pan is aligned to cylinder block and torque bolts and nuts 77278 a
69. ntinued 8 Reassembly Crankshaft 3A 8 Installation Connecting Rod Crank Pin Bore 8 Connecting Rod Piston Assembly 8 Connecting Rod Bushing 8 Exploded View 78 Torque Specifications 3A 9 Removal SA 79 Specified Torque Values 9 Disassembly 80 Standard Torque Values 3A 21 81 Special Tools 3A 24 nspection 82 Special Tools continued 3A 25 Installation 3A 87 aoe ee ee Crankshaft Main Bearings And Cylinder Block Special Tools continued AGNES 91 Special Tools continued 27 Exploded View 91 Snap On Special Tools 3A 28 Removal 92 Kent Moore Special Tools 3A 28 Cleaning 3A 93 Lubricants Sealants Adhesives 3A 29 Inspection 3A 93 Description 3A 30 Installation 3A 105 Engine Rotation 3A 30 ME 3A 111 Engine Firing Order 3A 30 Removal 3A 111 Cylinder Head Torque Sequence And Torque Disassembly 111 opecifications
70. oner Spring fe 15 Mark direction of the timing belt and remove timing belt 16 With TDC alignment bolt in place remove injection pump drive pulley retaining nut 77299 Injection Pump Pulley b TDC Adjustment Bolt M8 c Pulley Nut Page 140 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 17 Remove TDC alignment bolt Remove injection pump drive pulley using special tool Note woodruff key in shaft hidden 77156 a Injection Pump Pulley b Special Tool 18 Remove pulley bolt and remove timing belt idler pulley 77153 a Pulley Bolt b Idler Pulley 19 Remove the oil pump drive pulley Counterhold using a separate wrench 9 N TN SUM e NOD b E f 77159 a Pulley Nut b Separate Wrench CMD 4081866 90 863016001 MARCH 2008 Page 3A 141 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 20 Remove fastening bolt for timing belt drive pulley counterhold using special tool 77140 Timing Belt Drive Pulley Bolt b Special Tool 21 Remove timing belt drive pulley from crankshaft using puller Bk IS oe AUC A CS 77141 Timing Belt Drive Pulley b Puller 22 Lock the camshaft pulley with TDC alignment bolt 23 Remove pulley bolt from camshaft pulley 24 Remove TDC alignment bolt and remove camshaft pulley
71. ot listed according to torque values shown in the Standard Torque Values table Specified Torque Values VALVE COVER CAMSHAFT CARRIER AND CYLINDER HEAD Description Bolt Carrier M8 x 1 25 Bolt Cylinder Head M12 x 1 5 s 50 degrees Final Pass 60 degrees Fina Pass 7 Puo Glow Equipped 75 el 24 35 WuCamsatBrader tu Bae _ CMD 4081866 90 863016001 MARCH 2008 Page 3A 9 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 CYLINDER BLOCK AND WATER PUMP Page 3A 10 77082 Description Nm Bolt Water Pump Pulley M6 x 1 0 x 30 Bolt Power Steering Pulley M6 x 1 0 x 30 _ Bok WaterPump 24 ring WaterPpe JE 38 15 Bok Bearing Cap 59 Week 3 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS OIL PAN AND RELATED PARTS Description 2 Bor Or Pickup Assemby 25 39 98 97 Hollow Bok Oi Dipstek Assemby 15 78 98 6 Bor opstoe 98 Guset 4081866 90 863016001 2008 3A 11 1 7L ENGINE MECHANIC
72. r pump timing ES elt LE 73802 Support Block 91 814812 1 Description Used as a base for the Dial Indicator CMD 4081866 90 863016001 MARCH 2008 Page 3A 25 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Snap On Special Tools Part Number Compression Gauge MT33B Torque Angle Gauge Degree Wheel Torquing TA360 Kent Moore Special Tools Can Be Ordered From Kent Moore Tools Inc 29784 Little Mack Roseville 48066 Phone 313 574 2332 Description Part Number Valve Spring Compressor J 8062 Piston Ring Compressor J 8307 Page 3A 26 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Lubricants Sealants Adhesives Where Used Method of Use Part Number Needle Bearing Assembl Rod bearing i 1 y and crankshaft Coat surfaces 92 802868A1 Lubricant emm Molybdenum Disulfide Coat the two Piston skirt skirts on each Obtain Locally Grease Between front camshaft bracket and carrier Apply to contact surfaces as indicated Half moon packing plugs in Apply to both camshaft sides of plug bracket Between Apply to sealing Loctite 5699 camshaft carrier surfaces as Obtain Locally and valve cover indicated Between oil pump retainer pn to and cylinder ITIg surlaces block as specified Water fitting for oil cooler coolant hose at Thread length block Upper oil pan to block lower oi
73. raters or from Entire Surface Pockets TAPERED RADIUS FATIGUE JOURNAL RIDE FAILURE Compression Testing Procedure Periodically check engine compression pressure Lowering of pressure causes loss of pow er greater fuel consumption smoke at the exhaust low acceleration unsteady slow idle difficulty in starting and bearing seizure because of engine overheating 1 Start engine and allow it to reach normal operating temperature 2 Stop engine and shut off fuel supply 3 Ensure that battery is fully charged IMPORTANT To achieve the cranking rpm needed 250 rpm minimum for a proper compression test it will be necessary to remove all of the glow plugs or hole plugs prior to testing 4 Remove all glow plugs or plugs in glow plug holes CMD 4081866 90 863016001 MARCH 2008 Page 3A 31 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 5 Clean glow plug bore and install compression tester adapter in Cylinder number 1 e CN AR 9 Ye Connect gauge to adapter and set gauge to zero reading A Part Number Compression Gauge MT33B 7 Operate starter engine should be cranking at approximately 250 rom and check compression gauge reading 77123 Description Serdara Compression at 250 Minimum rpm Difference Between Cylinders 8 Readings lower than specified or differences between cylinders greater than specified indicate engine problems e
74. scoloration due to excessive heat 11 Inspect combustion chamber for melting of aluminum by faulty fuel injectors CMD 4081866 90 863016001 MARCH 2008 Page 3A 63 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 VALVES 1 Measure valve stem diameter in three places 2 If the measured value is less than specified limit the valve and valve guide must be replaced as a set 77196 Description in 5 959 5 977 2346 2353 Intake Valve Stem Diameter Limit 5 945 2341 Exhaust Valve Siem 5 954 5 972 2344 2351 Diameter 5 940 2339 3 Measure valve head margin 4 f measured value is less than specified the valve and the valve guide must be replaced as a set EN 77197 Intake Valve Margin Production 1 2 1 4 0 047 0 055 0 Margin After Grinding 1 0 0 039 Page 3A 64 CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS MEASURE VALVE GUIDE WEAR 1 Using a caliper calibrator or a telescoping gauge measure the valve guide inside diameter in three places 2 f measured value is greater than specified perform a valve stem clearance check e 77192 Caliper Calibrator b Valve Guide mm _ 000 6 015 Intake Valve Guide Inside Production 0 2362 0 2368 Limit Notavalabe available 000 6 015 mm on Guide Inside Production 0 2362 0 2368 Not available MEA
75. seal with crankshaft Page 22 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Special Tools continued 91 883849 Description Install oil pump seal in oil lt lt pump cover S gt lt 91 823850 Description Valve compressor to adjust valve clearance Description Adapter to check engine compression pressure Locking Tool Description To remove and install exhaust camshaft CMD 4081866 90 863016001 MARCH 2008 Page 3A 23 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Special Tools continued 91 883854 Description Install valve stem seal Description Install camshaft oil seal Remover Description Removes injector sleeve 91 883859 Description Aligns cylinder block to oil pan upper Cil Jet Pipe Installer 91 883860 Description Positions and installs oil jet pipe to cylinder block Page 3A 24 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Special Tools continued Dial Indicator 91 58222A1 Description Measures various distances on engines Description Installs and removes piston rings Metric Dial Indicator Adaptor 91 801333510 Description Used with metric dial indicator to set fuel injector pump timing m uu SAE Dial Indicator Adaptor 91 816997A1 Description Used with SAE dial indicator to set fuel injecto
76. sition nozzles perpendicular and at right angles to the crankshaft Then complete installation Avoid engine damage Oil spray from nozzles cools and lubricates engine components when properly distributed Ensure oil spray nozzles are clean and correctly seated to allow proper oil spray distribution 4 Ensure that nozzles are correctly seated Page 3A 102 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Installation MAIN BEARINGS CRANKSHAFT AND THRUST BEARINGS IMPORTANT The crankshaft upper main bearings have an oil hole and an oil groove The lower bearings do not 1 Carefully wipe any foreign material from the upper main bearing and the upper bearing fitting surfaces 2 Install bearings as indicated NOTE Locate the position mark applied at disassembly if the removed upper main bearings are to be reused Position accoraingly P S ey x 9 9 0 9 LG XO 77259 Cylinder Block Fitting Surface b Upper Bearing Half With Oil Groove c Oil Hole d Bearing Cap Fitting Surface e Lower Bearing Half Without Oil Groove NOTE Do not apply engine oil to the bearing back faces and the cylinder block bearing fit ting surfaces 3 Apply an ample co
77. specified limits J A oe B 77227 2 77190 Piston Ring Gap a Measurement Point b Measurement Point c Oylinder Bore d Feeler Gauge 250 350 0 010 0 014 2nd Compression 200 300 0 008 0 012 End Gap Oil Control 200 400 0 008 0 016 Limit All Rings 0 8 0 031 Page 84 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Installation CONNECTING ROD BUSHING 1 Using the connecting rod bushing tool press a new connecting rod bushing into the connecting rod 77232 Connecting Rod Bushing Tool 2 Ream new bushing to proper diameter 77233 Connecting Rod Bushing Reaming a Connecting Rod b Reamer 27 008 27 01 Connecting Rod Bushing Inner Diameter ds 015 1 0633 1 0635 CMD 4081866 90 863016001 MARCH 2008 Page 3A 85 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 CONNECTING ROD AND PISTON ASSEMBLY 1 Clamp connecting rod in a soft jawed vise Take care not to damage the connecting rod 2 Install one piston pin snap ring to the piston 77243 Piston Pin Snap Ring 3 Install piston on connecting rod IMPORTANT Ensure that the mark indicating piston front is on the same side as the mark raised dots on the connecting rod 77183 Connecting Rod Mark 4 Apply a coat of engine oil to piston pin and piston pin hole 5
78. ss than specified limit 77229 Piston Pin Diameter Standard 26 995 27 000 1 0627 Piston Pin Outer Diameter 1 0629 26 985 1 0624 Page 3A 82 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS PISTON PIN AND CLEARANCE 1 Usean inside dial indicator to measure the diameter of piston pin hole 2 Replace piston if pin hole measurement is greater than specified 77230 Piston Pin Hole Pin Hole Inner Diameter 27 004 3 Subtract piston pin outer diameter measured previously from piston pin hole diameter Replace piston and pin if measured clearance is more than specified limit 004 014 0 0001 0 0005 earance 0 04 0 0016 NOTE Calculate clearance using a new piston pin if measurement is greater than limit with existing piston pin Replace as necessary CMD 4081866 90 863016001 MARCH 2008 Page 3A 83 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 PISTON RING GAP 1 Insert the piston ring horizontally into the cylinder bore 2 Using a piston inserted upside down push the piston ring into the cylinder bore until it reaches measurement point a and measurement point b Cylinder bore diameter is smallest at these 2 points NOTE Ensure that piston ring is not slanted to one side or the other It must be perfectly horizontal Using feeler gauge measure the piston ring gap Replace ring if gap exceeds
79. te b Timing Belt Tensioner c Bolt Description Nm in b Bolt Tensioner mons 35 Page 3A 138 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 8 Remove lower timing belt cover 9 Turn the crankshaft in direction of engine rotation until cylinder number 1 is on TDC The pointer on the oil pump must align with the mark on the crankshaft pulley and exhaust camshaft pair of lobes for cylinder number 1 points upwards 77736 77737 a Pointer b Mark c Exhaust Camshaft Pair Of Lobes For Cylinder Number 1 10 Install TDC alignment bolt in camshaft pulley 11 Install TDC alignment bolt in injection pump drive pulley 71129 a Camshaft Pulley b TDC Alignment Bolt M6 c Injection Pump Pulley d TDC Alignment Bolt M8 CMD 4081866 90 863016001 MARCH 2008 Page 3A 139 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 12 Loosen the mounting bolts for timing belt tensioner pulley assembly 13 Remove the plate type tensioner spring or disconnect the coil type of tensioner spring if equipped 14 Remove the tensioner pulley assembly 957 2 ER D oi EI 5 d Ny p J rr N fas BOOK 77452 Typical Tensioner Pulley Assembly b Mounting Bolts c Plate Type Tensioner Spring d Coil Type Tensi
80. ue the camshaft pulley bolt 77300 a Camshaft Pulley b TDC Alignment Bolt M6 c Camshaft Pulley Bolt Description Im Boi Camshat Puey maas a CMD 4081866 90 863016001 MARCH 2008 147 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 13 Install the tensioner pulley assembly Temporarily hand tighten mounting bolts OS SEEN 77152 Typical Tensioner Asssembly Tension Pulley Assembly b Mounting Bolt 14 Note the direction of timing belt operation and install accordingly Ensure that belt is taut between adjacent pulleys Timing Belt b Direction Of Operation Taut Belt Between Pulleys Page 148 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 15 Install the plate type tensioner spring if equipped NOTE Slightly loosen tensioner pulley bolts if necessary Plate Type Tensioner Spring Installation a Plate Type Tensioner Spring b Tension Pulley Load On Belt 16 Connect the coil type of tensioner spring onto the tensioner stud if equipped a Position the end of the coil spring over the stud as shown and install the tensioner pulley assembly using the screw and washer provided Coil Type Tensioner Spring Installation a Coil Type Tensioner Spring b Tensioner Stud CMD 4081866 90 863016001 MARCH 2
81. ur measurements at indicated depths to determine the correct cylinder grade DEM Ke c 7 3 e 7j L O Ld 77203 d 77204 Cylinder Bore Grade 76000 5 1102 79 001 79 010 3 1102 3 1106 Cylinder Bore Diameters 79 011 79 020 Grade B 3 1106 3 1110 Edom 79 021 79 030 3 1110 3 1114 Avoid engine failure Cylinder bores and pistons are in three standard sizes and correspond to the tolerance grades Grade A Grade B and Grade C Select the correct piston grade designated for matching cylinder bore diameter CMD 4081866 90 863016001 MARCH 2008 Page 3A 101 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 CYLINDER BLOCK OIL SPRAY NOZZLES Removal 1 With crankshaft removed remove oil spray nozzles from near cylinder bores e e x 77715 Oil Spray Nozzles Inspection 1 Clean passages of oil spray nozzles and cylinder block 2 Check for damage on nozzles 3 Replace if necessary Installation 1 Apply sealant around outside of oil spray nozzle Description Where Used Method of Use Part Number GS 262 Loctite 962T or Around outside Threebond 1386 spray nozzle Obtain Locally Insert oil spray nozzles into cylinder block using the Oil Jet Installer tool Cil Jet Pipe Installer 91 883860 Description Positions and installs oil jet pipe to cylinder block 3 Po
82. vailable as assemblies complete with valve components These complete cylinder head assemblies will fit all early model and later model engines Valve components from early model cylinder heads cannot be used on these later model complete cylinder head assemblies Exploded View OO 00 dddo DO DO H 5 t 0000 T pe 77236 1 Oylinder Head 8 Split Collar 2 Valve Spring Lower Seat 9 Camshaft Follower 3 Valve Guide 10 Valve Shim 4 Valve Stem Oil Seal 11 Injector Sleeve 5 Valve 12 Sleeve O rings 2 6 Valve Spring 13 Injector 7 Valve Spring Retainer CMD 4081 866 90 863016001 MARCH 2008 Page 3A 59 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Removal IMPORTANT To avoid distorting cylinder head remove head only when engine is cold 1 Remove valve cover IMPORTANT Ensure that engine is on cylinder number 1 TDC and timing marks are properly aligned before removing timing belt 2 Remove timing covers and timing belt 3 Hemove camshaft carrier 4 Remove valve shims and camshaft followers IMPORTANT The valve shims are used to adjust valve clearance Be sure to keep each valve shim and its corresponding camshaft follower together Mark each camshaft follower location They must be reinstalled in their original locations 77241 a Cylinder Head b Valve Shim c Camshaft Follower 5 Loosen cylinder head bolts in a spiral patt
83. xist such as faulty rings valves cylinders and pistons Refer to appropriate sections and repair as needed 9 Remove compression gauge and adapter 10 Apply anti seize compound to threads and install glow plugs or hole plugs if equipped Torque each glow plug or hole plug Where Used Method of Use Part Number Anti seize Compound Glow Plugs Thread length Obtain Locally o Deon L iim _ GowPuHdePug Jay 11 Install electrical connectors on glow plug terminals if equipped 32 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Valve Cover Removal Remove bolts retaining intake manifold air duct to intake manifold and valve cover Loosen clamps on port side of intake manifold air duct connection hose Remove intake manifold air duct 77325 a Air Duct b Bolts c Clamps Safety glasses should be worn while working on fuel injection system The fuel injection pump will generate pressures in excess of 13 790 27 580 kPa 2000 4000 psi Use caution when removing injectors injector lines or bleeding air from injection system Keep injector and injection pump fittings clean Do allow dirt to enter fittings when removing or installing pipes Dirt will cause injectors or injection pump to malfunction CMD 4081866 90 863016001 MARCH 2008 Page 3A 33 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANU
84. y block 13 Fill closed cooling system 14 Ensure oil level is up to but not over MAX mark on dipstick 15 Pre lubricate turbocharger and engine 16 Operate the engine for a few minutes Stop the engine and wait for about ten minutes 17 Check dipstick to ensure oil level is up to but not over MAX mark on dipstick 18 Start engine and check for leaks CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Oil Pan And Oil Pickup Assembly Removal 1 Remove oil dipstick tube hollow bolt and washers and drain oil into a suitable container 2 Remove lower oil pan IN Ba Al C a Hollow Bolt b Washer Lower Oil Pan d Bolts 15 3 Remove upper oil pan 77278 Upper Oil Pan b Bolts 14 c Nuts 2 4 Remove oil pickup assembly and O ring seal 77145 Oil pickup Assembly b Bolt CMD 4081866 90 863016001 MARCH 2008 Page 3A 123 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Cleaning 1 Wash parts in solvent and dry with compressed air 2 Clean old gasket material and adhesive from all sealing surfaces Inspection 1 Inspect the oil pans and components for fatigue cracks Check all welds for leaks Inspect oil pick up assembly for fatigue cracks or damage Installation 1 Install new O ri
85. y are reassembled in the same location IMPORTANT The mating surfaces of the connecting rods and the connecting rod bearing caps form an individual fit and as a result must not be interchanged or damaged under any circumstances To avoid damage do not lay connecting rods or connecting rod bearing caps on their mating surfaces 6 Mark and remove connecting rod bearing cap 77179 a Bearing Cap IMPORTANT Connecting rod bolt threads can damage crankshaft journal and cylinder bore 7 Cover connecting rod bolt threads with protective caps 8 Push piston and connecting rod out of cylinder CMD 4081866 90 863016001 MARCH 2008 Page 3A 77 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Disassembly 1 Clamp connecting rod in a soft jawed vise as shown 70290 7 182 Description Installs and removes piston rings 3 Using same tool remove lower oil control rings and expanders 20 C 70291 Oil Control Ring b Expander Page 3A 78 CMD 4081866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS 4 Note installation position of connecting rod relative to piston Piston mark raised dots is on the same side as the mark on the connecting rod ce y 77183 Piston Mark b Connecting Rod Mark 5 Hemove snap ring from piston using suitable tool Push piston pin from piston and connecting rod by hand 7 184 a Snap Ring
86. y b Puller 7 Using a suitable tool remove front oil seal from front oil seal retainer Ensure that sealing surfaces and crankshaft are not damaged 77142 Front Oil Seal b Retainer Cleaning 1 Clean bore of seal retainer where seal resides 2 Clean crankshaft sealing area CMD 4081 866 90 863016001 MARCH 2008 Page 3A 133 1 7L ENGINE MECHANICAL ALL MODELS SERVICE MANUAL NUMBER 29 Inspection Installation Page 3A 134 Inspect bore of seal retainer for nicks and burrs Inspect crankshaft seal area for nicks burrs and scoring Coat inner lip of new seal with engine oil Where Used Method of Use Part Number Engine Oil Front oil seal Coat lips Obtain Locally Install seal using seal driver part 91 883848 77370 a Front Oil Seal b Seal Driver Hold flywheel using suitable tool Install crankshaft timing belt pulley parts in order Concave side of belt guide plate faces rear Torque bolt 77085 Belt Guide Plate b Concave Side c Crankshaft Timing Belt Pulley d Flat Washer e Bolt __ M Bolt Crankshaft 196 14 Install timing belt and timing belt covers Install serpentine belt and power steering belt if equipped Install seawater pump inboard models CMD 4081 866 90 863016001 MARCH 2008 SERVICE MANUAL NUMBER 29 1 7L ENGINE MECHANICAL ALL MODELS Front Engine Mounts Starboard

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