Professional Documents
Culture Documents
January 2005
Specifications
1104E Engine
RF11-Up (Machine)
RH11-Up (Machine)
RK11-Up (Machine)
i01658146
SENR9976
3
Table of Contents
Table of Contents
Specifications Section
Engine Design .....................................................
Fuel Injection Lines ..............................................
Fuel Injection Pump .............................................
Fuel Injectors .......................................................
Fuel Transfer Pump .............................................
Lifter Group ...........................................................
Rocker Shaft ........................................................
Valve Mechanism Cover ......................................
Cylinder Head Valves ...........................................
Cylinder Head ......................................................
Turbocharger .......................................................
Exhaust Manifold .................................................
Camshaft .............................................................
Camshaft Bearings ..............................................
Engine Oil Filter ...................................................
Engine Oil Pump ..................................................
Engine Oil Pressure .............................................
Engine Oil Bypass Valve ......................................
Engine Oil Pan .....................................................
Crankcase Breather .............................................
Water Temperature Regulator and Housing .........
Water Pump .........................................................
Cylinder Block ......................................................
Crankshaft ...........................................................
Crankshaft Seals .................................................
Connecting Rod Bearing Journal .........................
Main Bearing Journal ............................................
Connecting Rod ...................................................
Piston and Rings ..................................................
Piston Cooling Jet .................................................
Front Housing and Covers ...................................
Gear Group (Front) ...............................................
Flywheel ...............................................................
Flywheel Housing ................................................
Crankshaft Pulley .................................................
Fan Drive .............................................................
Engine Lifting Bracket ...........................................
Alternator .............................................................
Starter Motor ........................................................
Coolant Temperature Sensor ...............................
Engine Oil Pressure Sensor .................................
Boost Pressure Sensor .........................................
Inlet Manifold Temperature Sensor .......................
Speed/Timing Sensor ..........................................
Voltage Load Protection Module ...........................
Electronic Control Module .....................................
Glow Plugs ...........................................................
4
4
4
5
6
6
6
7
7
9
10
11
11
12
12
13
15
15
16
18
18
19
20
21
23
24
24
25
26
27
28
29
30
31
31
31
32
32
33
34
35
35
36
36
37
37
37
Index Section
Index ..................................................................... 38
4
Specifications Section
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Specifications Section
Engine Design
i01914111
Illustration 1
g00984281
Illustration 2
g00923498
(1) Tighten the union nuts for the fuel injector to the
following torque. ....................... 30 Nm (22 lb ft)
i02242475
Bosch VP30
Valve lash
Inlet valve ......................... 0.20 mm (0.008 inch)
Exhaust valve ................... 0.45 mm (0.018 inch)
Firing order ................................................. 1, 3, 4, 2
When the crankshaft is viewed from the front of
the engine, the crankshaft rotates in the following
direction: ................................................... Clockwise
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Specifications Section
i02207945
Fuel Injectors
Illustration 3
g00925395
(1) O-ring
Note: Lubricate the O-ring with clean engine oil
before installing the fuel injection pump in the timing
case.
g00908211
Illustration 5
Fuel injector clamp
(1) Tighten the bolt in the clamp for the fuel injector
to the following torque. ............. 35 Nm (26 lb ft)
Table 1
(3) Spacer
Illustration 4
g00925394
6
Specifications Section
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i01957629
i01714153
Lifter Group
Illustration 7
g00629433
Rocker Shaft
Illustration 6
g00986823
Illustration 8
g00985174
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Specifications Section
i01958092
Illustration 10
g00294082
i01776124
Turbocharged engines
The installed length of the valve
springs .............................. 34.5 mm (1.358 inch)
The load for the installed valve spring ....... 229 N
(51.4 lb)
(2) Valve spring recess
(3) The finished valve guides
Inside diameter of valve
guide ..................................... 9.000 to 9.022 mm
(0.3543 to 0.3552 inch)
Illustration 9
g00908011
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Specifications Section
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Illustration 11
g00809016
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Specifications Section
Cylinder Head
Illustration 12
g00987480
Required Tools
Part
Number
Part Description
Qty
21825607
Angle gauge
Illustration 13
g00905621
10
Specifications Section
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Illustration 14
g01006568
Table 3
Dimension
Maximum Permissible
Distortion
Width (A)
Length (B)
i02242611
Turbocharger
Illustration 15
Typical turbocharger
g00991357
Table 4
2674A200
100 5 kPa
(14.5040 0.7252 psi)
2674A201
110 5 kPa
(15.9544 0.7252 psi)
2674A202
128 5 kPa
(18.5651 0.7252 psi)
2674A209
100 5 kPa
(14.5040 0.7252 psi)
2674A211
128 5 kPa
(18.5651 0.7252 psi)
2674A215
128 5 kPa
(18.5651 0.7252 psi)
2674A223
136 5 kPa
(19.7254 0.7252 psi)
2674A224
136 5 kPa
(19.7254 0.7252 psi)
2674A225
136 5 kPa
(19.7254 0.7252 psi)
2674A226
100 5 kPa
(14.5040 0.7252 psi)
2674A227
128 5 kPa
(18.5651 0.7252 psi)
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Specifications Section
i02242613
Exhaust Manifold
Four Cylinder Engine
g00976195
Illustration 18
Typical camshaft
(2) Bolt
Tighten the bolt to the following torque. ... 95 Nm
(70 lb ft)
Illustration 16
g00907527
Tightening sequence
Camshaft
Standard Diameter
50.71 to 50.74 mm
(1.9965 to 1.9975 inch)
50.46 to 50.48 mm
(1.9865 to 1.9875 inch)
49.95 to 49.98 mm
(1.9665 to 1.9675 inch)
g00987750
12
Specifications Section
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i02242618
Camshaft Bearings
Illustration 19
g00629702
Illustration 20
g00997348
Illustration 21
(1) Seal
g00915984
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Specifications Section
Replaceable Element
Illustration 23
g00989248
g00915985
Illustration 24
g00989236
Inner rotor
14
Specifications Section
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Illustration 27
g00989519
Note: Replace the idler gear bolt (5) and the nut for
the oil pump gear (6).
Illustration 25
g00989217
g00938724
Illustration 28
The oil pump
g00938064
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Specifications Section
i02242638
Illustration 29
g00938061
Illustration 30
g00938799
Illustration 31
g00919893
Illustration 32
g00921377
(2) Plunger
Diameter of the plunger ..... 19.186 to 19.211 mm
(0.7554 to 0.7563 inch)
Clearance of plunger in bore .. 0.039 to 0.114 mm
(0.0015 to 0.0045 inch)
16
Specifications Section
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i02242687
Illustration 33
g00919890
Plug
Illustration 35
g00990254
Applying sealant
g00921379
Rear sealant
Note: Install the rear oil seal before sealant is applied
to the bridge.
(2) Plunger
Diameter of the plunger ........ 14.46 to 14.48 mm
(0.5692 to 0.5700 inch)
Clearance of the plunger in the
bore .... 0.04 to 0.08 mm (0.0015 to 0.0031 inch)
Illustration 36
g00990255
Applying sealant
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Specifications Section
Illustration 37
g00990252
Illustration 38
g00990249
Note: The rear face of the cast iron oil pan (5) must
be aligned to the rear face of the cylinder block.
(5) The maximum allowed value of the rear face
misalignment. ................. 0.1 mm (0.0039 inch )
(6) Bolt
Tighten the front four bolts. Refer to illustration
37. Tighten the remaining bolts and the nuts that
fasten the engine oil pan to the cylinder block to
the following torque. ................. 22 Nm (16 lb ft)
Note: The sealant is applied to new bolts. In order
to reuse the bolts, apply 21820117 Powerpart
threadlock and nutlock to the first three threads of
the used bolts.
Note: The engine may be equipped with an oil drain
plug or the engine may be equipped with a drain
valve.
(7) Drain plug
Tighten the drain plug for the engine oil pan to
the following torque. ...... 34 5 Nm (25 4 lb ft)
18
Specifications Section
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(3) Screws
Tighten the screws for the cover plate with a
plastic valve mechanism cover to the following
torque. .................................. 1.3 Nm (11.5 lb in)
Tighten the screws for the cover plate with a
metal valve mechanism cover to the following
torque. ..................................... 1.8 Nm (16 lb in)
(4) Diaphragm
(5) Cap
(6) Spring
Illustration 39
g00990677
Crankcase Breather
Illustration 41
g00926200
(7) O-ring
Note: Apply 21820221 Powerpart red rubber grease
to the O-ring before installing the breather pipe in the
valve mechanism cover.
(8) Tighten the bolts that secure the breather pipe to
the cylinder head to the following torque. .. 9 Nm
(80 lb in)
i01914256
g00926199
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Specifications Section
i01904883
Water Pump
Illustration 42
g00997234
O ring
Illustration 44
g00915951
Tightening sequence
Illustration 43
g00906121
20
Specifications Section
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i02242732
Cylinder Block
Illustration 45
g00924764
Cylinder block
Illustration 46
g00938203
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Specifications Section
Crankshaft
Illustration 47
g00992214
22
Specifications Section
Illustration 48
The 1104 engine crankshaft
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g01017233
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Specifications Section
Table 6
39.47 mm
(1.5539 inch)maximum
N/A
N/A
37.44 mm
(1.4740 inch)maximum
N/A
N/A
44.68 mm
(1.7591 inch)maximum
N/A
N/A
40.55 mm
(1.5965 inch)maximum
N/A
N/A
N/A
N/A
N/A
N/A
i01958114
Crankshaft Seals
Journal
(1)
Mounting
(2)
(3)
(4)
(5)
Mounting
Illustration 49
(1) Crankshaft
(2) Plastic sleeve
(3) Crankshaft seal
(4) Alignment tool
g00915078
24
Specifications Section
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i01958141
g00915076
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Specifications Section
i01958156
Connecting Rod
g00995584
Illustration 52
Alignment of the bearing shell
g00907738
31.62 to 31.88 mm
(1.245 to 1.255 inch)
31.55 to 31.88 mm
(1.2405 to 1.255 inch)
Thickness of Connecting
Rod Bearing at the
Center
1.835 to 1.842 mm
(0.0723 to 0.0725 inch)
Thickness of Connecting
Rod Bearing for the Cap
at the Center
1.835 to 1.842 mm
(0.0722 to 0.0725 inch)
Bearing Clearance
0.030 to 0.081 mm
(0.0012 to 0.0032 inch)
Table 9
26
Specifications Section
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Table 10
Color Code
Length (Y)
Red
165.728 to 165.761 mm
(6.5247 to 6.5260 inch)
Orange
165.682 to 165.715 mm
(6.5229 to 6.5242 inch)
White
165.637 to 165.670 mm
(6.5211 to 6.5224 inch)
Green
165.591 to 165.624 mm
(6.5193 to 6.5206 inch)
Purple
165.545 to 165.578 mm
(6.5175 to 6.5188 inch)
Blue
165.499 to 165.532 mm
(6.5157 to 6.4961 inch)
i01958185
Illustration 53
g00907744
g00888215
Illustration 54
g00915056
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Turbocharged
The shape of the top compression
ring ........................... Keystone with a barrel face
27
Specifications Section
i02242750
Piston
Note: An arrow which is marked on the piston crown
must be toward the front of the engine.
Illustration 56
g00942652
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Specifications Section
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Illustration 57
g01006929
Illustration 58
(1) Tighten the bolts that fasten the front cover to the
front housing to the following torque. ....... 22 Nm
(16 lb ft)
g00995663
Alignment
g00918672
Front cover
(2) Tighten the bolts that fasten the water pump to the
front housing to the following torque. ....... 22 Nm
(16 lb ft)
Note: Refer to Specifications, Water Pump for the
correct bolt tightening sequence for the water pump.
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29
Specifications Section
i01794692
g00918708
Illustration 60
Illustration 61
g00918756
30
Specifications Section
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i02253807
Flywheel
Illustration 62
g00584712
Standard flywheel
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Specifications Section
i02243052
Flywheel Housing
Four cylinder
i01958344
Fan Drive
Illustration 63
g00631781
(1) Bolt
Tighten the bolts for the cast iron flywheel
housing to the following torque:
Illustration 65
i02253806
Crankshaft Pulley
g00926178
Illustration 64
g00915497
A standard pulley
32
Specifications Section
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i01721280
V-Belt
Alternator
12 Volt and 24 Volt Alternator
Illustration 66
g00959541
A typical alternator
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Specifications Section
i01958653
Starter Motor
24 Volt Starter Motor
Illustration 67
The 24 volt starter motor which shows the electrical connections
g00974968
34
Specifications Section
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g00977365
Illustration 68
The 12 volt starter motor which shows the electrical connections
Illustration 70
g00884683
Illustration 69
Location of the coolant temperature sensor
g01131749
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Specifications Section
i02245818
Illustration 71
g01131721
Illustration 72
i02245819
Illustration 73
g01130928
g00884723
Illustration 74
g00884730
36
Specifications Section
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i02245820
i02245821
Speed/Timing Sensor
Illustration 77
Illustration 75
g01131036
g01131722
Illustration 78
Illustration 76
g00884683
g00884736
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Specifications Section
i02245822
i02253813
Glow Plugs
Illustration 81
Illustration 79
g00915868
(3) Tighten the bolts for the clips that hold the VLPM
to the following torque. ............. 22 Nm (16 lb ft)
i02246071
g00955714
Typical example
Illustration 80
g00915338
38
Index Section
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Index
A
Alternator ............................................................... 32
12 Volt and 24 Volt Alternator ............................ 32
V-Belt ................................................................. 32
B
Boost Pressure Sensor.......................................... 35
11
12
25
24
34
18
21
31
23
20
20
9
7
E
Electronic Control Module .....................................
Engine Design .......................................................
Four Cylinder Engine .........................................
Engine Lifting Bracket............................................
Engine Oil Bypass Valve .......................................
Installed in the Balancer.....................................
Installed in the Oil Pump ....................................
Engine Oil Filter .....................................................
Replaceable Element.........................................
Spin-on Oil Filter ................................................
Engine Oil Pan.......................................................
Front sealant ......................................................
Rear sealant.......................................................
The cast iron oil pan...........................................
Engine Oil Pressure...............................................
Engine Oil Pressure Sensor ..................................
Engine Oil Pump....................................................
Engines with Balancer Group ............................
Engines without Balancer Group .......................
Exhaust Manifold ...................................................
Four Cylinder Engine .........................................
30
31
31
28
4
4
4
5
6
C
Camshaft ...............................................................
Camshaft Bearings ................................................
Connecting Rod.....................................................
Connecting Rod Bearing Journal...........................
Coolant Temperature Sensor.................................
Crankcase Breather...............................................
Crankshaft ............................................................
Crankshaft Pulley ..................................................
Crankshaft Seals ...................................................
Cylinder Block........................................................
Four Cylinder Engine .........................................
Cylinder Head........................................................
Cylinder Head Valves ............................................
Flywheel ................................................................
Flywheel Housing ..................................................
Four cylinder ......................................................
Front Housing and Covers.....................................
Fuel Injection Lines................................................
Fuel Injection Pump...............................................
Bosch VP30 .......................................................
Fuel Injectors .........................................................
Fuel Transfer Pump...............................................
37
4
4
32
15
16
15
12
13
12
16
16
16
17
15
35
13
13
14
11
11
F
Fan Drive ............................................................... 31
Fan drive housing .............................................. 31
26
27
27
28
R
Rocker Shaft.......................................................... 6
S
Specifications Section ...........................................
Speed/Timing Sensor ............................................
Starter Motor..........................................................
12 Volt Starter Motor ..........................................
24 Volt Starter Motor ..........................................
4
36
33
34
33
SENR9976
T
Table of Contents................................................... 3
Turbocharger ......................................................... 10
Four Cylinder Engine ......................................... 10
V
Valve Mechanism Cover........................................ 7
Voltage Load Protection Module............................ 37
W
Water Pump........................................................... 19
Water Temperature Regulator and Housing .......... 18
Water Temperature Regulator............................ 19
39
Index Section
Printed in U.K.