Usage:
The former cylinder block and the service cylinder block assemblies for the engines in the list above, have been cancelled. These former cylinder blocks had a counterbore in the cylinder block, for the cylinder liner. The new cylinder blocks use a spacer plate and the lip of the cylinder liner sits on the cylinder block top deck. New service cylinder block groups and a cylinder block hardware kit are available to make a conversion to the spacer plate engine when replacement of the former cylinder block becomes necessary.
Installation Of 7N3803 Or 7N4011 Cylinder Block Group And 7N3802 Cylinder Block Hardware Kit
Install parts as given in the chart and diagrams that follow. Clean 4B3251 Studs (1) with 8M8060 Primer and put 7M7456, 8M8058 or 8M8059 Sealant on the threads before installation.
Expand (make larger as shown) the end of tubes (2) to make a tight fit in the block. Studs (4), (5), (6), (7) and (8) are to be installed on engines with cartridge type oil filter elements. Remove plug (9) for engines equipped with a compression release.
For installation of the remainder of the parts in the service group and hardware kit, see the topics, ENGINE ASSEMBLY and CYLINDER HEAD INSTALLATION.
Installation Of 7N4000 Or 7N4353 Cylinder Block Service Group And 7N3998 Cylinder Block Hardware Kit
(1) Install 4B3251 Studs (1). For engines that have a common lubrication system for the engine and starting engine, remove plug (2) from the starting engine mounting pad. A conversion to separate lubrication systems is the recommendation for these engines.
(2) Install the parts shown in the chart. Expand (make larger) the end of tubes (3), as shown, to make a tight fit in the cylinder block. Dowels (8) are used to hold the thick aluminum bearings. Cover (14) is not needed on engines that have a turbocharger, Remove plug (15) if the oil filter base has a quick lubrication valve for the turbocharger.
Engine Assembly
(1) Put an 8M5127 Seal in the top of the cylinder block in each lubrication supply passage for the rocker arms. Install the spacer plate gaskets, spacer plates and cylinder liners. Check cylinder liner projection, see the Service Manual Form No. SENR7003-02 for procedure.
(2) For installation of all other parts from the former cylinder block to the new cylinder block, such as crankshaft, connecting rods and pistons, flywheel, etc., except for cylinder head installation, see the Service Manual for the former engine. Manifold gaskets and studs are the same part numbers as those used with the former cylinder heads.
(3) Remove the valves, valve springs, precombustion chambers, etc., from the former cylinder heads and install them in the new cylinder heads. See the Service Manual for procedure.
Cylinder Head Installation
Install the new head gaskets and the 7N6243 Water Seals. Put a 6L7814 Seal on each 7B2420 Ferrule and install these seal assemblies, one in the top of each spacer plate, at the location of oil supply for lubrication of the rocker arms. Put 9M3710 Anti-Seize Compound on the head bolt threads. Install cylinder heads and head bolts. Tighten the bolts for the cylinder heads according to the sequence and torque shown.
NOTE: For those engines that have a compression release, install a new 7N3863 Push Rod for each intake valve.
a) Tighten bolts 1 thru 13 to ... 75 lb.ft.(100 N·m)
b) Tighten bolts A thru H to ... 210 lb.ft.(284 N·m)
c) Tighten bolts A thru H to ... 420 lb.ft.(565 N·m)
d) Tighten bolts 1 thru 13 to ... 150 lb.ft.(205 N·m)
e) Tighten bolts 14 thru 19 (hand torque only) to ... 75 ± 10 lb.ft.(100 ± 14 N·m)
f) Tighten bolts A thru H (hand torque only) to ... 420 lb.ft.(565 N·m)
g) Tighten bolts 1 thru 13 (hand torque only) to ... 150 lb.ft.(205 N·m)