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ENGINE ASSEMBLY

Procedure:
Number Punching:

 Punch the Engine Number and model as per the

sequence. Fit Expansion plug and steel ball on IP face.

 Screw dummy plug on Sump face and torque to 45-50

Nm

 Fitment of PCN and torque tight to 17 Nm.

Fitment of Crankshaft:

 Ensure cleanliness of Cylinder block, Crank

shaft & bearing shells.

 Fill bearing shells in block & MB caps.

 Ensure oil groove coincidence, with oil hole on

cylinder Block.

 Fit Crank shaft in block.

 Fit bearing caps with bolts as per the SI.No.

Tightening of crankshaft:

 The bearing cap bolts in the crank shaft is fitted

with torque tight of 140±15’ Nm and 90±5 deg.


 Check free rotation & end float to be within

0.050 to 0.265 mm

Fitments:

 Fitment of dowel pins on front end & rear end of cylinder

block.

 Fitment of steel ball on front end of cylinder block.

 Fitment of Idler gear shaft with plate washer.

 Ensure oil hole direction towards oil pan side.

 Fitment of cam rear plate with O ring

Fitment of front-end plate :

 Fit gasket and Torque bolts to 19 - 26 Nm

Fitment of oil pump Sub Assembly :

 Torque bolts to 19-26 Nm as per sequence &

ensure free rotation of Oil pump

Fitment of camshaft Sub assy :

 Torque Thrust plate bolts 19 - 26 Nm. Match

number mark (1, 1) between Cam and Oil

pump gears.

Fitment of Idler gear:


 Application of oil on the bolt thread and face.

 Torque bolt to 100±10 Nm & 120±5 deg .

Alignment on timing marks on gears.

 Back lash 0.138 to 0.265mm

 End play 0.040/ 0.095 mm.

 Match number mark (1, 1) gears between

idler and crank and (2, 2) between OPD and

Idler.

Fitment of Flywheel housing:

 Torque M14 bolts 100 to 130 Nm & M8

bolts 19 to 26 Nm. Fitment of Rear oil

Seal & Check rear oil seal leak.

Fitment of Flywheel S/assy :

 Set the'0' mark on flywheel & Fit FW on

Crank shaft collar. Torque bolts to 100

±10 Nm & 60± 5Deg as per sequence.

 Fitment of FW, lock pin for Timing

Setting and Flip –up.

 Pre fitment of FIP support bracket.

 Fitment of oil separator hose.


 Ensure gear train matching. Fitment of

FIP Sub assembly. Fitment of TG case

cover S/assy Torque bolts to 19 - 26Nm.

Pre fit Starter motor stud.

 Ensure Dolley fitment before Torque

injection pump gear bolts to 30-35 Nm.

Remove spill cut tool & fit the TG Case

fitment the dummy plug in drive hsg.

 Fitment of bearing holder/ Front cover

Fitment Q of Number plate in EGR

Engines SM stud fitment.

Fitments:

 Fitment of Crank pulley Sub/assy with spacer and Nut Q

Torque nut to 480 - 570Nm A-P forrn).925 ± '125 NM

 Fitment of oil pipes to fuel pump & Stopper plate &

compressor. Torque Fip banjo bolt to 10 - 15Nm .Fitment of

Flywheel Brg . Fitment of Welch plug. Fitment of piston

assembly : Lubricate piston & liner bores Ensure Staggering

of piston rings at 120'. Position ‘O’ mark on piston towards

tappet chamber side. Fitment of oil strainer sub assembly


and Torque to 19-26-Nrn. Ensure matching marks on

connecting rod & cap.

 Fitment of Cylinder head S/assy Clean the Head face on the

block and Fit 2 dowels in cyl. block ,fit Cylinder head gasket

& fit 12 valve lifters. Fit Cylinder head sub assy using guide

rods Put all mtg bolts with two threads driven by hand

Check for 0 rings in gasket.

 CRS: Fill 70 ml oil in CRS pump and torque the screw to

10-15Nm. Apply grease on TG Case.

 Fitment of Push rods & Rocker assy : Fit Rocker assy.

Torque bolts to an 70 +2 NM & 180 + 2 Deg. Check free

rotation of collars. Tightening of modified Rocker shaft bolt

19-26Nm. Setting of injection timing marks on Flywheel &

on FIP flange for Inline pumps. Torque injection pump gear

bolts 30-35Nm.Fitment of Diesel filter'. and bracket and

torque bolts to 45-50Nm.Prefit fuel hoses. Fit 2 studs on

EMF. Fitment of EGR cooler with 19-26Nm .4D EMF pre

fit with 1 spacer and nut. Fitment of thermostat case S/assy :

Fitment of 2 '0' rings on timing gear A-A case. Apply grease

on thermostat S/Assy and connector stem(CRS) Fit

Thermostat Sub assy and Torque bolts to 19-26Nm Fitment

of Dipstick guide and gauge. Fitment of breather hose and


routing. Fit thermostat sensor. Torque Rocker addl. Bolts to

19-26Nm. Fitment of fuel return pipe with banjo. Pre fitment

of common rail and Harness mtg stud in IMF, RS FF

hose/Banjo Prefit Fitment of Exhaust manifold. Torque nuts

with spacers to 45-50Nm.Ensure proper seating of gasket.

Pre fitment of hot pipe. Fitment of turbo mtg stud in EMF.

 Sub assembly of Turbo charger. Fitment of Turbo Charger,

oil drain pin TC model. Pre fit TC adaptor. Ensure proper

seating of gasket Tightening TC adaptor to 19-26Nm and

tight EMF nuts to 45-50Nm.

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