NUMBER: 6 10–09 S.M. REF.: Listed in Table 1 ENGINE: EPA07 MBE 4000 DATE: July 2009 SUBJECT: PISTON INSTALLATION FOR EGR ENGINE ADDITIONS, REVISIONS, OR UPDATES Publication Number Platform Section Title Change Page Number(s) DDC-SVC-MAN-0026 EPA07 MBE 4000 Workshop Manual 1.19.2 Installation of Piston The piston installation procedure has been revised. 1–125 NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle. Table 1 INSTALLATION OF PISTON Installation steps are as follows: NOTICE: The carbon scraper ring has a smaller internal diameter than the piston skirt diameter; therefore, the piston installation and removal must be carried out with the carbon scraper ring uninstalled or removed. NOTE: Piston installation is performed with the engine facing upright – not turned on its side. 1. Position the connecting rod in the piston so that the longer end side is on the unit pump side (left side), and arrow on piston, if present, points toward the front of the engine. 2. Install the wrist pin in the piston. See Figure 1. 1. Piston Figure 1 2. Wrist Pin 3. Connecting Rod Wrist Pin [a] Lubricate the wrist pin with a light coating of clean engine oil. [b] Insert the wrist pin into the wrist pin bore. [c] Secure the wrist pin with the two snap rings. Orient the rings at a 12 o'clock and 6 o'clock position. 3. Install the piston rings on the piston (1). See Figure 2. Figure 2 Ring Gaps Offset 120 Degrees [a] Lubricate the piston with a light coating of clean engine oil. [b] Install each piston ring in the appropriate groove on the piston. 4. Offset the ring gaps alternately by 120 degrees. NOTICE: The half of the bearing shell installed in the connecting rod (rod half) has a specially-treated friction surface that allows it to bear higher loads. It cannot be interchanged (swapped) with the other half of the bearing shell installed in the bearing cap (cap half). 5. Install the rod half of the bearing shell in the connecting rod, as marked on removal. See Figure 3. 1. Connecting Rod 3. Bearing Cap 2. Bearing Shells Figure 3 Bearing Shells [a] Be sure that the locking lug in the bearing shell is fully seated in the groove of the rod. [b] Lubricate the bearing surface with a light coating of clean engine oil. 6. Lubricate the cylinder liners with a light coating of clean engine oil. NOTICE: Be careful not to scratch the crankshaft journals with the connecting rod. This can lead to premature wear of the crankshaft. 7. Clamp the ring compressor (J–45983) to compress the piston rings. 8. If reusing a cylinder liner, thoroughly clean the carbon scraper ring seat. 9. Install sleeve (J–47110) to the cylinder block. See Figure 4. Figure 4 Piston NOTE: If the replacement piston has a locating arrow, it must point toward the front of the engine. 10. Push the piston and connecting rod into cylinder liner. 11. Remove sleeve (J-47110) and wipe the carbon scraper ring seat clean. See Figure 5. 1. Cylinder Liner 3. Installed Piston 2. Carbon Scraper Ring 4. Installed Carbon Scraper Ring Figure 5 Carbon Scraper Ring 12. Install carbon scraper ring in the cylinder liner groove. 13. Check carbon scraper ring for correct fit after installation. 14. Install the cap half of the bearing shell in the bearing cap, as marked on removal. [a] Be sure that the locking lug in the bearing shell is fully seated in the groove of the cap. [b] Lubricate the bearing surface with a light coating of clean engine oil. 15. Measure the connecting rod bolts stretched length. Replace any bolts that exceed the maximum length of 68.5 mm (2.70 in.). Lubricate the stretch bolt threads with a light coating of engine oil. 16. Install the bearing cap on the connecting rod and hand-tighten the stretch bolts. Be sure that the marks on the cap and the rod match. 17. Tighten the M16 x 1.5 connecting rod stretch bolts alternately. Tighten each one in turn to the first stage and then go on to the next stage. Refer to the following table. Max. Shaft Length mm (in.) Tightening Stage Torque N·m (lb·ft) Stage 1 108 (80) Stage 2 Additional 90 degree rotation 68.5 (2.70) Table 2 Connecting Rod Stretch Bolts Tightening Stages 18. Check the connecting rod end play (axial play). 19. Rotate the crankshaft to make sure it turns freely. NOTE: If it is necessary to turn the crankshaft and the flywheel has been removed, install the flywheel guide pins in the crankshaft gear. 20. Using a dial gauge and holder, measure the piston protrusion relative to crankcase top dead center at all the pistons. See Figure 6. 1. Piston Figure 6 2. Cylinder Liner A. Protrusion = 0.244 to 0.715 mm (0.0096 to 0.0281 in.) Piston Protrusion at Top Dead Center 21. If piston protrusion is between 0.244 mm (0.0096 in.) minimum and 0.715 mm (0.0281 in.) maximum then continue to next step. If not within specification, check piston, piston pin, piston pin bushings, connecting rod and crankshaft. Refer to piston protrusion specifications, listed in the following table. [a] Inspect piston, piston pin bushings and piston pin for wear or damage. If damaged, repair as necessary. [b] Inspect connecting rod for bent rod, pin bushing wear or damage. If damaged, repair as necessary. [c] Inspect rod bearings for wear or damage. If damaged, repair as necessary. [d] Inspect crankshaft for damage to rod journal or for evidence of spun bearing. If damaged, repair as necessary. Table 3 Description Specification: mm (in.) Piston Protrusion (at TDC) 0.244 – 0.715 (0.0096 – 0.0281) Piston Protrusion Specifications 22. Remove the engine barring tool (J–46392). Refer to section “Engine Barring Tool Removal.” NOTICE: Be careful not to damage the oil spray nozzles. Damaged oil spray nozzles could result in a loss of oil pressure and cause engine damage. 23. Install the oil spray nozzles. Be sure they are seated and aligned correctly. Refer to section “Oil Spray Nozzle Installation.” 24. Install the oil pan. 25. Install each cylinder head, as removed. Refer to section “Cylinder Head Installation.” ADDITIONAL SERVICE INFORMATION Additional service information is available in Power Service Literature. Detroit Diesel®, DDC®, Series 60® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. © Copyright 2009 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.
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