003 -004 Overhead Set - JustAnswer

Overhead SetPage 1 of 16003-004 Overhead SetGeneral InformationWARNINGBatteries can emit explosive gases. Toreduce the possibility of personal injury,always ventilate the compartment beforeservicing the batteries. To reduce thepossibility of arcing, remove the negative () battery cable first and attach the negative(-) battery cable last.NOTE: Read the entire procedure foroverhead adjustment before attemptingto perform this operation.Valves and injectors must be correctlyadjusted for the engine to operateefficiently. Valve and injector adjustmentmust be performed using the values listedin this section.Table 1, CELECT Plus Valve andInjector Adjustment ValuesCELECT Plus Injector Adjustment:Bottom plunger, release, and bottomtiming plunger. Back out two flats(120 degrees).mminIntake Valve0.350.014Exhaust Valve0.680.027Engine /2010

Overhead SetPage 2 of 16The preferred method of performing normalvalve and step timing control (STC) injectoroverhead adjustment is to use the outer basecircle (OBC) method, where the crush of theinjector plunger to cup is set by tightening theinjector rocker lever adjusting screw to aprescribed torque. If the STC injectors havebeen removed for cleaning and calibration, orif new ReCon injectors are being installed,use the OBC overhead set procedure.Table 2, STC Valve and InjectorAdjustment ValuesSTC Injector Adjustment (OBC Method):Torque to 14 N m [125 in-lb].mminIntake Valve0.350.014Exhaust Valve0.680.027Engine brake0.580.023Preparatory Steps Disconnect the batteries. Refer toProcedure 013-009Remove the rocker lever covers.Refer to Procedure 003-011Remove the engine brakes, ifapplicable. Refer to Procedure xml/en/procedures/09/09-003-004-tr.html11/8/2010

Overhead SetPage 3 of 16AdjustCELECT or CELECT PlusAll overhead (valve and injector) adjustmentsmust be made when the engine is cold (anystabilized coolant temperature at 60 C [140 F] or below).NOTE: After an engine rebuild or anymajor repair where the injector settingmust be disturbed, set all the valvesand injectors.CELECT Plus injectors will provideacceptable engine performance with lash(OBC) anywhere from 0.51 to 2.04 mm[0.020 to 0.080 in]. The procedure forCELECT Plus injector reset will producelash between 0.51 and 0.74 mm [0.020and 0.029 in]. Under normal operation,there is never be a reason to adjustCELECT Plus injectors for excessivelash between scheduled maintenanceintervals.Tighten the rocker lever shaft capscrews.Torque Value: 156 n.m [115 ml/en/procedures/09/09-003-004-tr.html11/8/2010

Overhead SetPage 4 of 16Tighten the rocker lever housingcapscrews in the sequence shown (1through 6).Tighten the rocker lever housingcapscrews in the sequence shown (7 and8).1 Through 6115 n.m[85 ft-lb]7 and 847 n.m[35 ft-lb]Tighten the injector hold down capscrews.Torque Value: 41 n.m [30 ft-lb]WARNINGDo not pull or pry on the fan to manuallyrotate the engine. To do so can damagethe fan blades. Damaged fan blades cancause premature fan failures which canresult in serious personal injury or propertydamage.The valve set marks are located on theaccessory drive pulley. The marks align with apointer on the gear cover.Use the accessory drive shaft to rotate /2010

Overhead SetPage 5 of 16The crankshaft rotation is clockwise whenviewed from the front of the engine.The cylinders are numbered from the frontend of the engine.The engine firing order is 1-5-3-6-2-4.Each cylinder has three rocker levers. Therocker lever nearest to the center of thehousing is the intake lever.Exhaust rocker lever (1)Injector rocker lever (2)Intake rocker lever (3)The two levers closest to the center of eachrocker housing are the intake rocker levers.The two levers closest to the ends of therocker housing are the exhaust levers.The valves and the injectors on the samecylinder are adjusted at the same index markon the accessory drive pulley.One pair of valves and one injector areadjusted at each pulley index mark beforerotating the accessory drive to the next indexmark.Two crankshaft revolutions are required toadjust all of the valves and injectors.Table 3,CELECT Plus EnginesInjector /xml/en/procedures/09/09-003-004-tr.html11/8/2010

Overhead SetPage 6 of 16AdjustmentSequenceBar Engine inDirection ofRotationSetPulleyCylinderPositionInjector ValveStartA11Advance toB55Advance toC33Advance toA66Advance toB22Advance toC44Firing Order: 15-3-6-2-4Rotate the accessory drive in the direction ofengine rotation. The accessory drive willrotate clockwise , on a right hand engine,when looking at the front of the engine. Alignthe "A" or "1-6 VS" mark on the accessorydrive pulley with the pointer on the gear cover.Check the valve rocker levers on cylindernumber 1 to see if both valves are closed.Both valves are closed when both rockerlevers are loose and can be moved fromside to side. If both valves are not closed,rotate the accessory drive one completerevolution; and align the "A" mark with thepointer again.If the valve rocker lever adjusting screwshave been loosened and not yet adjusted,watch the valve push tubes as the ml/en/procedures/09/09-003-004-tr.html11/8/2010

Overhead SetPage 7 of 16rolls upon the "A" mark. Both valve pushtubes will have moved to the downward(valve closed) position if the engine is onthe correct stroke.WARNINGWhen using solvents, acids, or alkalinematerials for cleaning, follow themanufacturer's recommendations foruse. Wear goggles and protectiveclothing to reduce the possibility ofpersonal injury.WARNINGSome solvents are flammable and toxic.Read the manufacturer's instructionsbefore using.Clean the timing plunger to remove thevarnish from the top edge.Apply a non-chlorinated carburetor cleaner(Pyroil or equivalent) using a narrow boreorifice or extension tube of 2 mm [0.79 in]maximum outside diameter, into theinjector weep hole.If the entire overhead is to be reset, everyinjector is to be sprayed at this time.Loosen the injector adjusting screw lock nuton cylinder number 1. Bottom the injectortiming plunger by tightening and loosening theadjusting screw three or four times to removethe fuel.When removing the excess fuel, do not applycrush to the injector timing plunger by furthertightening the adjusting screw after en/procedures/09/09-003-004-tr.html11/8/2010

Overhead SetPage 8 of 16plunger is bottomed.CAUTIONDo not apply crush to the injector timingplunger by further tightening the adjustingscrew. Doing so will result in an incorrectinjector lash setting and can causeexcessive injection train wear.Tighten the adjusting screw on the injectorrocker lever until the timing plunger justtouches bottom.CAUTIONAfter bottoming the CELECT Plusinjector timing plunger, make certain toback out the adjusting screw two flats (120degrees) or damage to the injector willresult.Back out the adjusting screw on the injectorrocker lever two flats (120 degrees).Two flats will provide 0.56 mm [0.022 in] lash.The specification is 0.50 to 0.74 mm [0.020 to0.029 in] lash.Hold the adjusting screw and tighten thelock nut.Torque Value: 65 n.m [50 ml/en/procedures/09/09-003-004-tr.html11/8/2010

Overhead SetPage 9 of 16After setting the injector on a given cylinder,set the valves on the same cylinder.With the "A" set mark aligned with the pointeron the gear cover and both valves closed oncylinder number 1, loosen the lock nuts on theintake and the exhaust valve adjustingscrews.Select a feeler gauge for the correct valvelash specification.Valve Lash SpecificationsIntakeExhaust0.35 mm [0.014 in]0.68 mm [0.027 in]Insert the feeler gauge between the top ofthe crosshead and the rocker lever pad.Two different methods for establishingvalve lash clearance are described below.Either method can be used; however, thetorque wrench method has proven to bethe most consistent. Torque Wrench Method: Use theinch pound torque wrench, PartNumber 3376592, and tighten theadjusting screw.Torque Value: 0.68 n.m [6 in-lb] Feel Method: Tighten the adjustingscrew until a slight drag is felt on thefeeler ml/en/procedures/09/09-003-004-tr.html11/8/2010

Overhead SetPage 10 of 16Hold the adjusting screw in this position.The adjusting screw must not turn whenthe lock nut is tightened.Without TorqueWrench Adapter:68 n.m[50 ft-lb]With TorqueWrench Adapter,Part Number ST669:54 n.m[40 ft-lb]After tightening the lock nut to the correcttorque value, check to make sure thefeeler gauge will slide backward andforward between the crosshead and therocker lever with only a slight drag.If using the feel method, attempt to inserta feeler gauge that is 0.03 mm [0.001 in]thicker between the crosshead and therocker lever pad. The valve lash is notcorrect when a thicker feeler gauge will fit.After adjusting the injector on cylinder number1 and the valves on cylinder number 1, rotatethe accessory drive; and align the next valveset mark with the /xml/en/procedures/09/09-003-004-tr.html11/8/2010

Overhead SetPage 11 of 16Adjust the appropriate injector and valvesfollowing the Injector and ValveAdjustment Sequence in Table 4.Repeat the process to adjust all injectorsand valves correctly.Table 4,CELECT PlusEnginesInjector andValveAdjustmentSequenceSetBar EnginePulleyCylinderin DirectionPositionof RotationInjector ValveStartA11Advance toB55Advance toC33Advance toA66Advance toB22Advance toC44Firing ml11/8/2010

Overhead SetPage 12 of 16Loosen the lock nut on the injector adjustingscrew on the cylinder number 5.CAUTIONAn overtightened setting on the injectoradjusting screw will produce increasedstress on the injector train and thecamshaft injector lobes, which can result inengine damage.Use a dial type torque wrench to tighten theinjector rocker lever adjusting screw to thespecified torque. If the screw causeschattering during setting, repair the screw andlever as required.Hold the torque wrench in a position thatallows the direct view of the dial. This is tomake certain that the reading on the dial isaccurate.Torque Value: 14 n.m [125 ml/en/procedures/09/09-003-004-tr.html11/8/2010

Overhead SetPage 13 of 16Hold the adjusting screw in this position. Theadjusting screw must not turn when the locknut is tightened. Tighten the lock nut.Torque Value: 65 n.m [50 ft-lb]With the “B” mark aligned with the pointer onthe gear cover and both valves closed oncylinder number 5, loosen the locknuts on theintake and the exhaust valve adjustingscrews.Select a feeler gauge for the correct valvelash specification.Valve Lash SpecificationsmminIntake0.35 NOM [0.014]Exhaust0.68 NOM [0.027]Insert the feeler gauge between the top ofthe crosshead and the rocker lever nose.Two different methods for establishingvalve lash clearance are described below.Either method can be used: however, thetorque wrench method has proven to bethe most consistent.Torque Wrench ml/en/procedures/09/09-003-004-tr.html11/8/2010

Overhead Set Page 14 of 16Use the inch-pound torque wrench,Part Number 3376592, or equivalent,(normally used to set preload onSTC injectors), and tighten theadjusting screw.Torque Value: 0.56 to 0.68 n.m [5 to6 in-lb]Feel Method Hold the adjusting screw in thisposition. The adjusting screw mustnot turn when the locknut istightened. Tighten the locknut.With torque wrench adapter, Part Number3163196, or equivalent:Torque Value: 55 n.m [40 ft-lb]Without torque wrench adapter:Torque Value: 65 n.m [50 ft-lb]After tightening the locknut to the correcttorque value, check to make sure thefeeler gauge will slide backward andforward between the crosshead and therocker lever with only a slight drag.If using the feel method, attempt to inserta feeler gauge that is 0.03 mm [0.001 in]thicker between the crosshead and therocker lever pad. The valve lash is notcorrect when a thicker feeler gauge will /en/procedures/09/09-003-004-tr.html11/8/2010