Compression Testing

Additional Information

SPECIFICATIONS

This section contains the specifications for servicing the engine.‪

Compression Testing

The specifications for compressions testing are listed in Table "Compression Pressure Test Data" and listed in Table "Torque Values, Tensioning Arm Bolts" .‪

Description‪

Pressure‪

Compression Pressure at Starter Speed‪

2800 kPa (406 psi)‪

Permissible Difference Between Individual Cylinders‪

400 kPa (58 psi)‪

Table 1. Compression Pressure Test Data

Description‪

Torque Value‪

Hex-head Bolt‪

30 N·m (22 lb·ft)‪

12-point Head Bolt with Spherical Collar‪

35 N·m (26 lb·ft)‪

Table 2. Torque Values, Tensioning Arm Bolts

Cylinder Head Cover

The torque specifications for the cylinder head cover are listed in Table "Torque Values, Cylinder Head Cover" .‪

Description‪

Torque Value‪

Hexagon Socket Bolt‪

30 N·m (22 lb·ft)‪

Table 3. Torque Values, Cylinder Head Cover

Cylinder Head

The cylinder head warpage limits are listed in Table "Head Warpage Limits, 6-Cylinder Engine" (6–cylinder engine), listed in Table "Head Warpage Limits, 4-Cylinder Engine" (4–cylinder engine) and listed in Table "Cylinder Block Warpage Limits, 4 — and 6–Cylinder Engines" (cylinder block). Cylinder head bolt length is listed in Table "Cylinder Head Bolts, Length" . The tightening stages are listed in Table "Tightening Stages, Exhaust Manifold Bolts" (exhaust manifold bolts) and listed in Table "Tightening Stages, Cylinder Head" (cylinder head bolts). Oil pressure readings are listed in Table "Oil Pressure Readings" . There are miscellaneous torque values listed in Table "Miscellaneous Torque Values" .‪

Description‪

Limit‪

Over entire length‪

0.07 mm (0.003 in.)‪

Over a length of 150 mm (6 in.)‪

0.02 mm (0.001 in.)‪

Table 4. Head Warpage Limits, 6-Cylinder Engine

Description‪

Limit‪

Over entire length‪

0.05 mm (0.002 in.)‪

Over a length of 150 mm (6 in.)‪

0.02 mm (0.001 in.)‪

Table 5. Head Warpage Limits, 4-Cylinder Engine

Description‪

Limit‪

Over entire length‪

.030 mm (00.0012 in.)‪

Over a length of 150 mm (6 in.)‪

.015 mm (0.0006 in.)‪

Table 6. Cylinder Block Warpage Limits, 4 — and 6–Cylinder Engines

Description‪

Length‪

Shaft length when new‪

149.0 mm (5.87 in. )‪

Maximum shaft length‪

151.0 mm (5.94 in.)‪

Table 7. Cylinder Head Bolts, Length

Size‪

Maximum Shaft Length‪

Tightening Stage‪

Torque Value‪

M10‪

47.5 mm (1.87 in.)‪

Stage 1‪

10 N·m (7 lb·ft)‪

Stage 2‪

55 N·m (41 lb·ft)‪

Stage 3‪

additional 90 degrees‪

Table 8. Tightening Stages, Exhaust Manifold Bolts

Size‪

Max. Shaft Length‪

Tightening Stage‪

Torque Values‪

M16‪

151.0 mm (5.94 inches)‪

Stage 1‪

20 N·m (15 lbf·ft)‪

Stage 2‪

70 N·m (52 lbf·ft)‪

Stage 3‪

170 N·m (125 lbf·ft)‪

Stage 4‪

280 N·m (207 lbf·ft )‪

Stage 5‪

additional 90 degrees‪

Stage 6‪

additional 90 degrees‪

Table 9. Tightening Stages, Cylinder Head

Description‪

Minimum Oil Pressure Reading‪

Engine at Idle Speed‪

50 kPa (7 psi)‪

Engine at Max. rpm‪

250 kPa (36 psi)‪

Table 10. Oil Pressure Readings

Description‪

Torque Value‪

High-Pressure Fuel Injection Lines‪

25 N·m (18 lb·ft)‪

Charge-Air Manifold Fasteners‪

25 N·m (18 lb·ft)‪

Rocker Arm Mounting Bolts‪

30 N·m (22 lb·ft)‪

Inspection Cover on Flywheel Housing‪

25 N·m (18 lb·ft)‪

Protective Sleeve‪

45 N·m (33 lb·ft)‪

Table 11. Miscellaneous Torque Values

Crankshaft

For the crankshaft specifications, see Figure "Cross-section View" . Crankshaft repair specifications are listed in Table "Crankshaft Repair Specifications" . The main bearing repair specifications are listed in Table "Main Bearing Repair Specifications" . The main bearing-cap tightening stages are listed in Table "Tightening Stages, Main Bearing-Cap Bolts" .‪

Description‪

Specification‪

Main and Connecting-Rod Bearing Journals Permissible Difference In Out-Of-Roundness‪

0.005 mm‪

( 0.0002 in.)‪

Permissible Taper at Main Bearing Journals and Connecting-Rod Bearing Journals‪

0.005 mm‪

( 0.0002 in.)‪

Fillet Radii of Main Bearing and Connecting-Rod Bearing Journals‪

2.5 to 3.0 mm‪

(0.0984 to 0.1181 in.)‪

Radial Runout Measured at Middle Main Journal*‪

0.15 mm‪

(0.0059 in.)‪

Lateral Runout (End Play) Measured at Thrust washer Bearing Journal‪

0.16–0.38 mm‪

(0.006–0.015 in.)‪

Crown of Main Bearing Journals and Connecting-Rod Journals‪

0.000 to 0.004 mm‪

(0.000 to 0.0002 in.)‪

Main Bearing and Connecting Rod Journal Hardness (Rockwell hardness)‪

52 HRC‪

Permissible Imbalance of Crankshaft†‪

30 gcm‪

(0.4162 in.-ounce)‪

Table 12. Crankshaft Specifications

*Measure with the crankshaft mounted on the outer main bearing journals.
†With the pin for the flywheel installed, but without the flywheel, and with the crankshaft mounted on the outer bearings.

Size‪

mm (in.)‪

Main Bearing Journal Diameter‪

mm (in.)‪

Main Bearing Journal Width‪

mm (in.)‪

Thrustwasher Bearing Journal Width‪

mm (in.)‪

Connecting-Rod Bearing Journal Diameter‪

mm (in.)‪

Connecting-Rod Bearing Journal Width‪

mm (in.)‪

All Sizes‪

—‪

31.0–31.2‪

(1.220–1.228)‪

—‪

—‪

34.0–34.2 mm‪

(1.339–1.346 in.)‪

Standard‪

85.990–86.010‪

(3.3854–3.3862)‪

—‪

31.000–31.062‪

(1.2205–1.2229)‪

69.995–70.015‪

(2.7557–2.7565)‪

—‪

Undersize –‪

0.10 (0.004)‪

85.890–85.910‪

(.3.3815–3.3823)‪

—‪

—‪

69.895–69.915‪

(2.7518–2.7526)‪

—‪

Undersize –‪

0.25 (0.010)‪

85.740–85.760‪

(3.3756–3.3764)‪

—‪

—‪

69.745–69.765‪

(2.7459–2.7466)‪

—‪

Undersize –‪

0.30 (0.012)‪

—‪

—‪

31.300–31.362‪

(1.2323–1.2347)‪

—‪

—‪

Undersize –‪

0.50 (0.020)‪

85.490–85.510‪

(3.3658–3.3665)‪

—‪

31.500–31.562‪

(1.2402–1.2426)‪

69.495–69.515‪

(2.7360–2.7368)‪

—‪

Undersize –‪

0.75 (0.030)‪

85.240–85.260‪

(3.3559–3.3567)‪

—‪

—‪

69.245–69.265‪

(2.7262–2.7270)‪

—‪

Undersize –‪

1.00 (0.040)‪

84.990–85.010‪

(3.3461–3.3469)‪

—‪

—‪

68.9950–69.015‪

(2.7163–2.7171)‪

—‪

Table 13. Crankshaft Repair Specifications

Size‪

mm (in.)‪

Main Bearing Inner Diameter‪

mm (in.)‪

Standard‪

86.066 to 86.108 (3.388 to 3.390)‪

Undersize – 0.1 (0.0039)‪

85.966 to 86.008 (3.384 to 3.386)‪

Undersize – 0.25 (0.0098)‪

85.816 to 85.858 (3.379 to 3.380)‪

Undersize – 0.5 (0.0197)‪

85.566 to 85.608 (3.369 to 3.370)‪

Undersize – 0.75 (0.0295)‪

85.316 to 85.358 (3.359 to 3.361)‪

Undersize – 1.0 (0.0394)‪

85.066 to 85.108 (3.349 to 3.351)‪

Table 14. Main Bearing Repair Specifications

Size‪

Max. Shaft Length‪

Tightening Stage‪

Torque Value‪

M14 x 2.0‪

(116.0 mm (4.57 in.) or 136.0 mm (5.35 in.)‪

Stage 1‪

30 N·m (22 lb·ft)‪

Stage 2‪

80 N·m (59 lb·ft)‪

Stage 3‪

155 N·m (114 lb·ft)‪

Stage 4‪

additional 90 degrees‪

Table 15. Tightening Stages, Main Bearing-Cap Bolts

Vibration Damper

The tightening stages for the vibration damper mounting bolts are listed in Table "Tightening Stages, Vibration Damper Mounting Bolts" .‪

Maximum Shank Length‪

Tightening Stage‪

Torque Value‪

61.0 mm (2.40 in.)‪

Stage 1‪

50 N·m (37 lb·ft)‪

Stage 2‪

125 N·m (92 lb·ft)‪

Stage 3‪

additional 90 degrees‪

Table 16. Tightening Stages, Vibration Damper Mounting Bolts

Flywheel and Flywheel Housing

Flywheel specifications are listed in Table "Flywheel Specifications" . Ring Gear Specifications are listed in Table "Ring Gear Specifications" . The Flywheel Tightening Stages are listed in Table "Tightening Stages, Flywheel Mounting Bolts" .‪

Description‪

Four and Six Cylinder Engines‪

Specification mm (in.)‪

Flywheel Outer Diameter‪

443 (17.4)‪

Flywheel Shoulder Diameter‪

392.435–392.575 (15.4502–15.4557 )‪

Flywheel Diameter at Crankshaft Flange‪

114.960–115.020 (4.5260–4.5283 )‪

Flywheel Diameter for Mounting Clutch‪

435.000–435.063 (17.1260–17.1285 )‪

Flywheel Minimum Width Between Friction Surface and Mounting Flange After Repairs‪

55 (2.17)‪

Flywheel Maximum Overall Width‪

56 (2.20)‪

Pitch Circle Diameter for Clutch‪

373.7 (14.71)‪

Peak-to-Valley Height (Rz ) of Clutch Friction Surface‪

16 µm (630 µin)‪

Flywheel Permissible Deviation From True (radial and lateral)‪

0.05 (0.002)‪

Table 17. Flywheel Specifications

Description‪

Four- and Six-Cylinder Engines‪

Flywheel Shoulder Diameter (for ring gear mounting )‪

392.435–392.575 mm (15.4502–15.4557 in.)‪

Hole for Mounting Clutch Pressure Plate‪

3/8–16 UNC‪

Thread Depth‪

24 mm (15/16 in.) minimum‪

Ring Gear Inner Diameter‪

392.000–392.140 mm (15.4331–15.4386 in)‪

Ring Gear/Flywheel Overhang‪

0.295–0.575 mm (0.0116–0.0226 in.)‪

Ring Gear/Flywheel Permissible Radial Runout‪

0.5 mm (0.02 in)‪

Ring Gear Width‪

15.6–16.0 mm (0.614–0.630 in.)‪

Ring Gear Fitting Temperature‪

250–280°C (480–540°F)‪

Table 18. Ring Gear Specifications

Size‪

Max. Shank Length‪

Tightening Stage‪

Torque Value N·m (lb·ft)‪

M14 x 1.5‪

61.0 mm (2.40 in.)‪

Stage 1‪

50 (37)‪

Stage 2‪

125 (92)‪

Stage 3‪

additional 90 degrees‪

Table 19. Tightening Stages, Flywheel Mounting Bolts

Pistons and Connecting Rods

The specification for piston protrusion specifications is listed in Table "Piston Protrusion Specifications" . The connecting rod stretch bolts tightening stages are listed in Table "Tightening Stages, Connecting Rod Stretch Bolts" . The piston ring end-gap dimensions are listed in Table "Piston Ring End-Gap Dimensions" . The connecting rod inspection specifications are listed in Table "Connecting Rod Inspection Specifications" . The bearing journal specifications are listed in Table "Bearing Journal Specifications" . ‪

Description‪

mm (in.)‪

Piston Protrusion (from top dead center)‪

0.28 to 0.50 (0.011 to 0.020)‪

Table 20. Piston Protrusion Specifications

Size‪

Max. Shaft Length‪

Tightening Stage‪

Torque Value‪

N·m (lb·ft)‪

M12 x 1.25‪

57.0 mm (2.24 in.)‪

Stage 1‪

11 (8)‪

Stage 2‪

45 (33)‪

Stage 3‪

additional 90 degrees‪

Table 21. Tightening Stages, Connecting Rod Stretch Bolts

Ring Designation‪

Groove‪

Gap When New‪

mm (in.)‪

Maximum End Gap‪

mm (in.)‪

Keystone‪

I‪

0.35 to 0.55 (0.014 to 0.022)‪

1 (.039)‪

Taper-Faced with Internal Angle‪

II‪

0.40 to 0.60 (0.016 to 0.024 )‪

1 (.039)‪

Double-Chamfered Oil Control with Garter Spring‪

III‪

0.25 to 0.50 (0.010 to 0.020 )‪

1 (.039)‪

Table 22. Piston Ring End-Gap Dimensions

Description‪

Dimensions,‪

mm (in.)‪

Distance Between Connecting Rod Bearing Bore and Bushing Inner Surface‪

157.445–157.510 (6.1986–6.2012 )‪

Maximum Difference in Axial Parallelism Between Bearing Bore and Bushing Inner Surface‪

0.025 (0.0010)‪

Distance from Connecting Rod Center Line for Measuring Parallelism‪

50 (2)‪

Bushing Inner Diameter‪

40.03–40.04 (1.5760–1.5764)‪

Bearing Seat Inner Diameter with Bearing Shells Installed‪

Standard‪

70.054–70.093 (2.7580–2.7596 )‪

Repair Stage: Undersize 0.1 mm‪

69.954–69.993 (2.7541–2.7556 )‪

Repair Stage: Undersize 0.25 mm‪

69.804–69.843 (2.7482–2.7497)‪

Repair Stage: Undersize 0.5 mm‪

69.554–69.593 (2.7383–2.7399)‪

Repair Stage: Undersize 0.75 mm‪

69.304–69.343 (2.7285–2.7300)‪

Repair Stage: Undersize 1.0 mm‪

69.054–69.093 (2.7187–2.7202)‪

Basic Bore Diameter for Connecting Rod Bearings‪

75.000–75.019 (2.9528–2.9535)‪

Connecting-Rod Bearing Play‪

Radial‪

0.039–0.098 (0.0015–0.0039)‪

Axial (end play)‪

0.170–0.470 (0.0067–0.0185)‪

Permissible Out-of-Roundness of Basic Bores‪

Bearing Bore‪

0.008 (0.0003)‪

Bushing Bore‪

0.006 (0.0002)‪

Connecting Rod Bolt‪

Thread Diameter‪

M12 x 1.25‪

Shank Length When New‪

56.0 (2.20)‪

Maximum Shank Length‪

57.0 (2.24)‪

Table 23. Connecting Rod Inspection Specifications

Repair Stage‪

Diameter mm (in.)‪

Standard‪

69.995–70.015 ( 2.7557–2.7565)‪

Undersize 0.1 mm‪

69.895–69.915 (2.7518–2.7526)‪

Undersize 0.25 mm‪

69.745–69.765 (2.7459–2.7467)‪

Undersize 0.5 mm‪

69.495–69.515 (2.7360–2.7368)‪

Undersize 0.75 mm‪

69.245–69.265 (2.7262–2.7270)‪

Undersize 1.0 mm‪

68.995–69.015 (2.7163–2.7171)‪

Table 24. Bearing Journal Specifications

Valves

The general valve specifications are listed in Table "General Valve Specifications" . The valve lift specifications are listed in Table "Valve Lift Specifications" . The specifications for valve lash checking and adjustment are listed in Table "Valve Lash Checking and Adjustment" . The specifications for the valve seat bore machining are listed in Table "Valve Seat Bore Machining Repair Stage Specifications" . The general specifications for valve seats are listed in Table "Valve Seat General Specifications" .‪

Description‪

Intake‪

in. (mm)‪

Exhaust‪

in. (mm)‪

Valve Stem Diameter‪

7.935–7.950 (0.3124–0.3130)‪

7.925–7.940 (0.3120–0.3126)‪

Valve Seat Diameter, at Head Mating Surface‪

31.0 (1.22)‪

36.0 (1.42)‪

Valve Head Diameter‪

33.9–34.1 (1.33–1.34)‪

37.9–38.1 (1.49–1.50)‪

Valve Seat Height—After Grinding‪

2.7–3.1 (0.106–0.122)‪

2.5–3.2 (0.098–0.126 )‪

Valve Seat Width, at Valve Head‪

3.3–4.3 (0.130–0.169)‪

3.5–4.2 (0.138–0.165)‪

Valve Seat Angle‪

20 degrees‪

45 degrees‪

Valve Length‪

125.7–126.1 (4.948–4.998)‪

152.5–152.9 (6.004–6.020)‪

Valve Stem Hardness‪

54-60 HRC‪

Maximum Concentricity of Valve Seat to Stem‪

0.03 (0.0012)‪

Difference in Height Between the Two Intake Valves as Measured From the End of the Stem‪

0.20 (0.008)‪

N/A‪

Valve Standback from Cylinder Head‪

1.1-1.5 (0.04-0.08)‪

Table 25. General Valve Specifications

Description‪

Specification‪

Specified Dial Gauge Preload for Checking Valve Lift‪

15 mm (0.60 in.)‪

Valve Lift with Intake Valves Completely Open‪

at least 9.7 mm (0.38 in.)‪

Valve Lift with Exhaust Valves Completely Open‪

at least 10.7 mm (0.42 in.)‪

Inspection Cover Bolt Torque‪

25 N·m (18 lb·ft)‪

Table 26. Valve Lift Specifications

Valve Type‪

Check For:‪

mm (in.)‪

Adjust To:‪

mm (in.)‪

Intake‪

0.30 to 0.60 (0.012 to 0.024 )‪

0.40 (0.016)‪

Exhaust‪

0.50 to 0.80 (0.020 to 0.032)‪

0.60 (0.024)‪

Table 27. Valve Lash Checking and Adjustment

Repair Stage‪

Basic Bore in Cylinder Head‪

Outside Diameter of Valve Seat Insert‪

Intake‪

mm (in.)‪

Exhaust‪

mm (in.)‪

Intake‪

mm (in.)‪

Exhaust‪

mm (in.)‪

Standard‪

35.000–35.025‪

(1.378–1.379)‪

40.000–40.025‪

(1.575–1.576)‪

35.07–35.08‪

(1.3807–1.3811)‪

40.07–40.08‪

(1.5775–1.5779)‪

Standard I‪

35.300–35.325‪

(1.390–1.391)‪

40.300–40.325‪

(1.575–1.588)‪

35.37–35.38‪

(1.3925–1.3929)‪

40.37–40.38‪

(1.5893–1.589)‪

Stage I‪

35.500–35.525‪

(1.398–1.399)‪

40.500–40.525‪

(1.594–1.595)‪

35.57–35.58‪

(1.4004–1.4008)‪

40.57–40.58‪

(1.5972–1.5976)‪

Table 28. Valve Seat Bore Machining Repair Stage Specifications

Description‪

Specification‪

mm (in.)‪

Valve Seat Interference Fit‪

0.045-0.080‪

(0.0018-0.0031)‪

Depth of Bore in Cylinder Head‪

(see Figure , E)‪

11.4-11.6‪

(0.449-0.457)‪

Height of Valve Seat Insert‪

(see Figure , C)‪

Intake‪

7.6-7.7‪

(0.299-0.303)‪

Exhaust‪

8.0-8.1‪

(0.315-0.319)‪

Clearance Between Head mating Surface and Valve Seat Insert Face‪

(see Figure , D)‪

Intake‪

3.7-4.0‪

(0.146-0.157)‪

Exhaust‪

3.3-3.6‪

(0.130-0.142)‪

Table 29. Valve Seat General Specifications

Rocker Arm

Rocker arm specifications are listed in Table "Rocker Arm Specifications" .‪

Description‪

Specifications‪

Bushing Inside Diameter (when installed)‪

22.00-22.021 mm (0.8661-0.8670 in.)‪

Shaft Diameter‪

21.967-21.980 mm (0.8648-0.8654 in.)‪

Rocker Arm Mounting Bolt Torque‪

30 N·m (22 lb·ft)‪

Distance from Front Bracket to First Inside Bracket (see Figure , A)‪

122 mm (4.80 in.)‪

Distance from Last Inside Bracket to Rear Bracket (see Figure , B)‪

110 mm (4.33 in.)‪

Table 30. Rocker Arm Specifications

Camshaft

Camshaft specifications are listed in Table "Camshaft Specifications" . The valve tappet specifications are listed in Table "Valve Tappet Specifications" .‪

Description‪

6-Cylinder‪

mm (in.)‪

4-Cylinder‪

mm (in.)‪

Camshaft Radial Runout When Mounted on Outer Bearing Journals‪

Timing Gear Seat Maximum‪

0.020‪

(0.0001 )‪

0.020‪

(0.0001 )‪

Cam Base Circle Maximum‪

0.025‪

(0.0010 )‪

0.025‪

(0.0010 )‪

All Bearing Points Maximum‪

0.030‪

(0.0012)‪

0.030‪

(0.0012)‪

Cam Rise—Valve Lobes Over Base Circle Diameter‪

Inlet Minimum‪

7.3‪

(0.3)‪

7.3‪

(0.3)‪

Exhaust Minimum‪

8.2‪

(0.32)‪

8.2‪

(0.32)‪

Cam Rise—Unit Pump Over Base Circle Diameter‪

Minimum‪

13.8‪

(0.54)‪

13.8‪

(0.54)‪

Hardness of Cams and Bearing Journals HRc‪

54–60 HRc‪

Table 31. Camshaft Specifications

Description‪

4- and 6-Cylinder:‪

mm (in.)‪

Valve Tappet Outer Diameter‪

Standard‪

17.944–17.965‪

(0.7065–0.7073 )‪

Oversize 0.25‪

18.194–18.215‪

(0.7163– 0.7171 )‪

Valve Tappet Bore in Crankcase Diameter‪

Standard‪

18.000–18.018‪

(0.7087–0.7094 )‪

Oversize 0.25‪

18.250–18.268‪

(0.7185–0.7192 )‪

Table 32. Valve Tappet Specifications


MBE 900 Service Manual - 6SE414
Generated on 10-13-2008