Specification Manual

M11 Series Engines

Copyright© 1994 Bulletin No. 3666076-00

Cummins Engine Company, Inc. Printed 11/94
All Rights Reserved
 Foreword
This manual contains complete assembly and rebuild specifications for the M11 engine and all associated
components manufactured by Cummins Engine Company, Inc. This manual is intended as a quick reference guide
for an experienced technician who is fam iliar with our product. Various accessory and component suppliers can
be contacted directly for any information not covered in this manual.
A series of specific service manuals (Troubleshooting and Repair, Shop, Alternative Repair, and so on) are available
and can be ordered by filling out and mailing the Literature Order Form located at the end of this manual.
Reporting of errors, omissions, and recommendations for improving this publication by the user is encouraged.
Please use the postage paid, self-addressed Literature Survey Form at the end of this manual for communicating
your comments.
The specifications in this manual are based on the most current information at the time of publication. Cummins
Engine Company, Inc. reserves the right to initiate any changes at any time without obligation. If differences are
found between your engine and the information in this manual, contact a Cummins Authorized Repair Location,
a Cummins Division Office, or the factory.
The latest technology and the highest quality components are used to manufacture the products of Cummins
Engine Company, Inc. When replacement parts are needed, we recommend using only genuine Cummins or
ReCon exchange parts. These parts can be identified by the following trademarks:
 Table of Contents

Page

Capscrew Markings and Torques Value .................................................................................................... 51

Capscrew Markings and Torque Values Metric ....................................................................................... 51
Capscrew Markings and Torque Values - U.S Customary .................................................................... 52

Component Specifications and Torque V a lu e s ........................................................................................... 8

Air Equipment - Inspection Specifications ................................................................................................ 44
Air Intake System - Inspection Specifications........................................................................................... 44
Cam Follower Assembly - Rebuild Specifications ................................................................................... 35
Cooling System - Rebuild Specifications .................................................................................................. 39
Cooling System - Torque Values .............................................................................................................. 41
Cylinder Block - Rebuild Specifications .................................................................................................... 23
Cylinder Block - Torque Values ................................................................................................................. 31
Cylinder Head - Rebuild Specifications .................................................................................................... 31
Cylinder Head - Torque Values ................................................................................................................. 34
Drive Units - Rebuild Specifications ........................................................................................................ 42
Electrical Equipment - Inspection Specifications ..................................................................................... 45
Engine Assembly - Capscrew Torque Values ......................................................................................... 13
Engine Assembly - Specifications .............................................................................................................. 8
 Engine Testing - Test Specifications ........................................................................................................ 45
Exhaust System - Torque V a lu e s .............................................................................................................. 44
Fuel Pump - Torque Values ..................................................................................................................... 37
Fuel Pump - Rebuild Specifications .......................................................................................................... 36
Injectors - Rebuild Specifications ............................................................................................................ 38
Lubricating Oil System - Specifications .................................................................................................... 38
Lubricating Oil System - Torque Values .................................................................................................. 39
Mounting Adaptations - Rebuild Specifications ....................................................................................... 45
Rocker Lever Assembly - Rebuild Specifications ................................................................................... 34
Vehicle Braking - Rebuild Specifications .................................................................................................. 45

Drive Belt Tension ........................................................................................................................................ 47

Engine D ia g ra m ................................................................................................................................................ 2

Engine Id e n tific a tio n ........................................................................................................................................ 1

ECM Dataplate(s).......................................................................................................................................... 1
Engine D ataplate.......................................................................................................................................... 1

Engine S p e cifica tio n s ...................................................................................................................................... 4

Air Intake S ystem .......................................................................................................................................... 5
Batteries (Specific G ravity)........................................................................................................................... 6
Cooling System ............................................................................................................................................ 5
Electrical S y s te m .......................................................................................................................................... 6
Exhaust S ystem ............................................................................................................................................ 5
Fuel S ystem .................................................................................................................................................. 6
General Engine Data .................................................................................................................................... 4
Lubricating Oil S yste m ................................................................................................................................. 5

Fraction, Decimal, Millimeter C o n v e rs io n s ................................................................................................ 48

Injection Timing C o d e s .................................................................................................................................. 46

Newton-Meter to Food Pound Conversion Chart ..................................................................................... 50

Pipe Plug Torque Values ............................................................................................................................. 52

Specifications - General In fo rm a tio n ............................................................................................................ 3

Tap-Drill Chart - U.S. Customary & M e tric .................................................................................................. 53

Valve and Injector Adjustments* ................................................................................................................... 7

Injector Lash Recheck L im its ....................................................................................................................... 7
Jacobs Engine B ra k e .................................................................................................................................... 7
Valve and Injector Adjustment Sequence.................................................................................................... 7
Valves ........................................................................................................................................................... 7

Weight and Measures - Conversion Factors 49

 Engine Identification
M11 Page 1

Engine Identification
The model name provides the following data:
M 11-330 E

L Electronic Fuel System

Brake Horsepower
------------- Displacement (Liters)
------------------ Engine Model Designation

Engine Dataplate
The engine dataplate is located on the fuel pump side of
the rocker housing.
The engine dataplate provides model identification as
well as other important information about the engine.
Have the following engine data available when commu­
nicating with a Cummins Authorized Repair Location. The
information on the dataplate is mandatory when sourcing
service parts.
1. Engine Serial Number (E.S.N.)
2. Control Parts List (CPL)
3. Model
4. Horsepower and RPM Rating

ECM Dataplate(s)
On CELECT™ engines, there are two dataplates on the top
of the electronic control module (ECM). The dataplate on
the left contains the part number (P/N), serial number
(S/N) and the data code (D/C) of the ECM. The dataplate
on the right contains the engine serial number, fuel code,
and engine calibration information.
Engine Diagrams
Page 2 M11

Engine Diagrams
The following illustrations contain information about engine components, filter locations, drain points and access
locations for instrumentation and engine controls. The information and configuration of components shown in these
drawings are of a general nature. Some component locations will vary depending on applications and installations.
 Specifications - General Information
M11 Page 3

Specifications - General Information

The specifications in this manual are organized in the same sequence as the M11 Series Engine Shop Manual,
Bulletin No. 3666075. The minimum and maximum tolerance lim it specifications are listed in both metric and U.S.
Customary dimensions. The metric dimension is given first, followed by the U.S. Customary dimension in brackets;
for example: 0.50 mm [0.020 inch]. The assembly and rebuild specifications and torque values are provided to be
sure the parts are assembled correctly, fit properly, and are secured with the correct torque value.
Most of the capscrews used to assemble the M11 engine are metric. Some components, such as the air compressor
and the fuel pump, are installed using U.S. Customary capscrews. Capscrew torque values are listed in newton
meters and foot pounds, unless otherwise specified. If a torque value is not listed, use the standard torque value
for the capscrew. Refer to the Table of Contents, Capscrew Markings and Torque Values, in this manual.
Engine Specifications
Page 4 M11

Engine Specifications
Metric [U.S. Customary]
General Engine Data
Horsepower (Refer to the engine dataplate)
Engine speed @ Maximum Output:
• Governed Speed (RPM) - Automotive ................................................................................................................. 1800
• Governed Speed (RPM) - Vocational ................................................................................................................... 2000
• Advertised HP (RPM) .............................................................................................................................................. 1600
Bore and Stroke ........................................................................................... 125 mm [4.921 in] X 147 mm [5.787 in]
Displacement ................................................................................................................................ 10.8 liters [661 C.I.D.]
Firing Order ...................................................................................................................................................... 1-5-3-6-2-4
Engine Weight (with Standard Accessories):
• Dry Weight 940 Kg [2070 lb]
• Wet Weight 996 Kg [2193 lb]
Crankshaft Rotation - (viewed from the front of the engine) ........................................................................ Clockwise

Cylinder Location and Firing Order

Intake and Exhaust Valve Locations

 Engine Specifications
M11 Page 5

Engine Specifications (Continued)

Metric [U.S. Customary]
Air Intake System
Maximum Allowable Intake Restriction with Clean Air Filter Element:
• Heavy Duty Dry Type Cleaner ............................................. 254 mm H20 [10 in. H20]
Maximum Allowable Intake Restriction with Dirty Air Filter Element 635 mm H20 [25 in. H20]
Maximum Temperature Rise Between Ambient Air and Engine Air Inlet:
(Ambient Above 0°C [32°F]) 17°C [30°F]
Maximum Allowable Pressure Drop From Turbocharger to Intake Manifold: .................. 152 mm Hg [6 in Hg]
Maximum Allowable Pressure Drop Across Charge Air Cooler: ....................................... 152 mm Hg [6 in Hg]

Lubricating Oil System

Oil Pressure:
• Low Idle (Minimum Allowable) ..................................................................................................... 70 kPa [10 psi]
• At 1200 RPM or Torque Peak (Minumum Allowable) .......................................................... 207 kPa [30 psi]
Oil Capacity of Standard Engine:
• Combination Filter ....................................................................................................... 2.6 liters [0.7 U.S. gallon]
• Oil Pan (High-Low) ................................................................................... 34 to 26.5 liters [9 to 7 U.S. gallon]
Total System Capacity (Including Filter) .............................................................................. 39 liters [10.3 U.S. gallon]

Cooling System
Coolant Capacity (Engine Only) ........................................................................................ 9.5 liters [10 U.S. quarts]
Standard Modulating Thermostat Range: ................................................................... 82° to 93°C [180° to 200°F]
Minimum Coolant Cylinder Block Pressure (Pressure Cap Removed):
Closed Thermostat - 1800 RPM -NoLoad ................................................................................. 138 kPa [20 psi]
Maximum Cylinder Block Coolant Pressure (Pressure Cap Removed):
Closed Thermostat ................................................................................................................... 275 kPa [40 psi]
Maximum Allowable Operating Temperature ...................................................................................... 100°C [212°F]
Minimum Recommended Operating Temperature ............................................................................. 70°C [158°F]
Minimum Recommended Pressure Cap .............................................................................................. 50 kPa [7 psi]

Exhaust System
Maximum Allowable Back Pressure Created by Piping and Silencer:
• Hg ......................................................................................................................................................... 76 mm [3 inch]
• H20 ................................................................................................................................................ 1016 mm [40 inch]
Exhaust Pipe Size (Normally Acceptable Inside Diameter) .......................................................... 127mm [5 inch]
Engine Specifications
Page 6 M11

Metric [U.S. Customary]

Fuel System
For performance and fuel rate values, refer to the engine data sheet, or the fuel pump code for the particular model
involved.
Engine Idle Speed: .............................................................................................................................. 650 to 800 RPM
Maximum Allowable Fuel Inlet Restriction:
• With Clean Filter .................................................................................................................... 152 mm Hg [6 in Hg]
• With Dirty Filter ..................................................................................................................... 254 mm Hg [10 in Hg]
Maximum Allowable Drain Line Restriction: ......................................................................... 89 mm Hg [3.5 in Hg]
Minimum Fuel Pressure:
• During Cranking .......................................................................................................................... 172 kPa [25 psi]
• 1200 RPM .................................................................................................................................. 827 kPa [120 psi]
• Governed RPM ............................................................................................ 1034 to 1241 kPa [150 to 180 psi]
Minimum Cranking Speed: 150 RPM
Maximum Allowable Fuel Inlet Temperature ............................................................................................. 71°C [160°F]

Electrical System
Minimum Recommended Battery Capacity

System Voltage Ambient Temperatures

-18°C (0°F) 0°C (32°F)
Cold Reserve Cold Reserve
Cranking Capacity Cranking Capacity
Amperes Amperes Amperes Amperes
12 Volt 1800 640 1280 480
24 Volt 900 320 640 240

* The number of plates within a given battery size determines reserve capacity. Reserve capacity determines
the length of time which sustained cranking can occur.
** CCA ratings are based on two, 12 volt batteries in series.
A minimum of 6.5 volts at the three pin connector is required to power up the ECM on CELECT™ engines.

Batteries (Specific Gravity)

Specific Gravity
at 27°C [80°F1 State of Charge
1.260 to 1.280 100%
1.230 to 1.250 75%
1.200 to 1.220 50%
1.170 to 1.190 25%
1.110 to 1.130 Discharged
 Valve and Injector Adjustments*
M11 Page 7

Valve and Injector Adjustments*

Valves
Intake 0.35 mm [0.014 in]
E xh a u st 0.68 mm [0.027 in]
Recheck Limits
In ta k e ....................................................................................................................... 0.10 to 0.41 mm [0.004 to 0.016 in]
Exhaust 0.46 to 0.76 mm [0.018 to 0.030 in]
Adjusting Screw Locknut Torque (Valves and Injectors):
With Part No.ST-669 ............................................................................................................................. 47 N^m [35 ft-lb]
W ithout Part No. ST-669....................................................................................................................... 60 N^m [45 ft-lb]
Injector Lash Recheck Limits
MIN 0.51 mm [0.020 in]
MAX 2.04 mm [0.080 in]
Jacobs Engine Brake
Slave Piston Adjustment 0.38 mm [0.015 in]
Adjusting Screw Locknut Torque:
With Part No. S T -6 69 ............................................................................................................................. 47 N^m [35 ft-lb]
W ithout Part No.ST-669........................................................................................................................ 50 N^m [40 ft-lb]
* Adjustments must be made when the engine is cold (any stabalized coolant temperature at 60°C [140°F] or
below).
Valve and Injector Adjustment Sequence
Component Specifications and Torque Values
Page 8 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric_____________________ U .S .

Component Specifications and Torque Values

Engine Assembly - Specifications
C y lin d e r L in er P rotrusion 0.00 mm M IN 0.000 in
0.13 mm MAX 0.005 in
Note: Line r pro tru sio n is m ea sure d w ith Part No.
3823 49 5 C ylin e r Line r C lam p Set installed.

C y lin d e r L in er to B lo ck C lea ra n c e 0.25 mm M IN 0.010 in

C y lin d e r L in er O u t of Round 0.10 mm MAX 0.0 04 in

C ran ks h a ft End C lea ra n c e 0.10 mm M IN 0.0 04 in

0.56 mm MAX 0.022 in

H ig h Oil P ressure R e g u lato r R e tain e r Plug 8.03 mm MIN 0.316 in

8.53 mm M AX 0.336 in

M ain O il P ressure R e g u lato r S p rin g F ree 84.1 mm 3.31 in

Length

S p rin g Load at 4 8 .3 m m [1 .9 0 in] 91.1 N MIN 20 .5 0 lbf

94 .7 N M AX 21.30 lbf

M ain O il P ressure R e g u lato r R e tain e r Plug 11.1 mm MIN 0.4 4 in

13.4 mm M AX 0.53 in
 Component Specifications and Torque Values
M11 Page 9

C o m p o n e n t or A s se m b ly (P ro cedu re) R e f.N o ./S te p s M etric U .S.

SAE No.
F ly w h ee l H o u sing Bore I.D . 00 78 7 .7 mm M AX 31.01 in
0 64 8.0 mm M AX 25.51 in
1/2 58 4 .4 mm M AX 23.01 in
1 511.3 mm M AX 20 .13 in
2 44 7 .8 mm M AX 17.63 in
3 4 0 9 .7 mm M AX 16.13 in

SAE No.
F ly w h ee l H o u sing Bore A lig n m e n t TIR 00 0.31 mm M AX 0.012 in
0 0.25 mm M AX 0.010 in
1/2 0.25 mm M AX 0.010 in
1 0.20 mm M AX 0.008 in
2 0.20 mm M AX 0.008 in
3 0.20 mm M AX 0.008 in

SAE No.
F ly w h ee l H o u sing Face A lig n m e n t TIR 00 0.31 mm M AX 0.012 in
0 0.25 mm M AX 0.010 in
1/2 0.25 mm M AX 0.010 in
1 0.20 mm M AX 0.008 in
2 0.20 mm M AX 0.008 in
3 0.20 mm M AX 0.008 in

REPTO Id ler G ear B acklash 0.15 mm MIN 0.006 in

0.38 mm M AX 0.015 in

F ly w h ee l Bore R u n ou t TIR 0.1 2 7 mm M AX 0.0 050 in

R a d iu s (A)
mm in
F ly w h ee l Face R u n o u t TIR 203 8 0.2 03 mm M AX 0.008 in
254 10 0.2 5 4 mm M AX 0.010 in
305 12 0.3 05 mm M AX 0.012 in
356 14 0.3 56 mm M AX 0.014 in
406 16 0.4 06 mm M AX 0.016 in

O il C o n tro l Ring End Gap

T h e tw o -p ie ce oil ring m ust be in sta lle d w ith th e exp a n d e r g a p 180 d e gre es from the oil ring gap.
Component Specifications and Torque Values
Page 10 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

Piston Ring End Gap

T h e ring ga ps m ust not be a lig n e d w ith the piston pin bore. R o ta te th e rin g s to po sitio n th e gaps
as show n.

C o n n e c tin g Rod S ide C lea ra n c e 0.10 mm M IN 0.0 0 4 in

0.30 mm MAX 0.012 in
Note: T he rod m ust m ove fre e ly from side-to-side.

G ea r H o u sing Pro tru sio n (b elo w the 0.15 mm M AX 0.006 in

cy lin d e r b lo c k oil pan rail)

Lub ricatin g Oil Pum p G ea r End C lea ra n c e 0.0 6 4 mm M IN 0.0025 in

0.270 mm MAX 0.0106 in

H ydrau lic Pum p Drive S h a ft End C lea ra n c e 0.076 mm M IN 0.0030 in

0.6 35 mm MAX 0.0250 in

E n g in e T im in g
N ote: T he tim in g m arks on the ca m s h a ft id le r g e ar m ust align w ith the tim in g m arks on the
a cce sso ry d rive , c ra n ksh a ft and ca m s h a ft ge ars to m ake sure th e e n g in e tim in g is set correctly.
 Component Specifications and Torque Values
M11 Page 11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S .

Id ler G ea r End C lea ra n c e 0.30 mm MIN 0.012 in

0.53 mm M AX 0.021 in

Id ler G ea r B acklash 0.08 mm MIN 0.003 in

0.41 mm M AX 0.016 in

A c ce sso ry D rive G ear B acklash 0.08 mm MIN 0.003 in

0.41 mm M AX 0.016 in

C am F ollow er S id e C lea ra n c e B etw een

S u p p o rts 0.76 mm MIN 0.030 in

C y lin d e r Head C ap screw Free Length

Part No. 3045849 74.5 mm M AX 2.9 33 in
Part No. 3045850 139.5 mm M AX 5.492 in

S tatic In jec tio n T im in g

To v e rify th e co rre ct in je ctio n tim in g for a p a rtic u la r e n g in e refer to the e n g in e dataplate.

R efer to G ro u p 00, E ng in e Assem bly, In je ctio n T im in g for co m p le te in stru ction s.

V ib ra tio n D a m p er E c c e n tric ity TIR 0.28 mm M AX 0.011 in

Component Specifications and Torque Values
Page 12 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

V ib ra tio n D a m p er Face R u n o u t -
M ea su re m en t 0.28 mm MAX 0.011 in

R o cker Lever S id e C lea ra n c e 0.55 mm M IN 0.022 in

Jaco b s Brake Slave Piston C lea ra n c e 0.38 mm M IN 0.015 in

In je c to r A d ju s tm en t
1. B ottom p lu n g e r
2. Lo ose n a d ju s tin g scre w 2 flats and torqu e locknut.
Note: Do not use excess force w h e n bo tto m in g plunger.

Intake Valve C learan ce 0.36 mm MIN 0.014 in

E xh aust Valve C learan ce 0.69 mm MIN 0.0 27 in

A ir C o m p re ss o r to A c ce sso ry Drive
T im in g
Position the air co m p re sso r cra n ksh a ft tim in g m a rk at th e 12:00 o 'c lo c k position.
P osition the a cce sso ry drive sh a ft dow el pin at th e 2:0 0 o 'c lo c k position.

A lte rn a to r B elt Tension

R efer to th e belt te n sio n c h a rt in th is section.
 Component Specifications and Torque Values
M11 Page 13

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

Engine Assembly - Capscrew Torque Values

C y lin d e r L in e r C lam p in g P late Forcing
S crew 136 N^m 100 ft-lb

M ain B earin g 68 N^m 50 ft-lb

N ote: T ig h te n th e cap screw s in the 142 N^m 105 ft-lb
se q u e n ce show n. 210 N^m 155 ft-lb
Lo ose n A ll
68 N^m 50 ft-lb
142 N^m 105 ft-lb
210 N^m 155 ft-lb

V is c o s ity S en so r 24 N^m 18 ft-lb

M ain O il P ressure R e g u lato r R e tain e r Plug

R ear S u m p O il Pan 75 N^m 55 ft-lb
B lo ck M ou nted Front S u m p S u ctio n Tube 122 N^m 90 ft-lb

F ly w h ee l H o u sing A lig n m e n t P late 47 N^m 35 ft-lb

F ly w h ee l H o u sing 1 68 N^m 50 ft-lb

N ote: T ig h te n th e cap screw s in the 2 129 N^m 95 ft-lb
s e q u e n ce show n. 3 197 N^m 145 ft-lb

REPTO Id ler S h a ft C ap screw 102 N^m 75 ft-lb

Component Specifications and Torque Values
Page 14 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

C ran ks h a ft R ear Oil Seal 7 N^m 60 in-lb

N ote: T ig h te n in a star pattern. 20 N^m 180 in-lb

F ly w h ee l 183 N^m 135 ft-lb

N ote: T ig h te n th e cap screw s in a star
p attern.

C o n n e c tin g Rod 1 68 N^m 50 ft-lb

2 142 N^m 105 ft-lb
3 210 N^m 155 ft-lb
4 L o ose n A ll
5 68 N^m 50 ft-lb
6 142 N^m 105 ft-lb
7 210 N^m 155 ft-lb

Piston C oo lin g N ozzle 24 N^m 18 ft-lb

G ea r H o u sing 1 20 N^m 15 ft-lb

Note: T ig h te n th e cap screw s in se q u e n ce 2 68 N^m 50 ft-lb
show n

B lo ck M o un ted Front S u m p S u ction Tube

R e tain e r 61 N^m 45 ft-lb

L u b rica tin g Oil Pan 47 N^m 35 ft-lb

Note: T ig h te n the cap screw s in the
s e q u e n ce show n.
 Component Specifications and Torque Values
M11 Page 15

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S .

C a m s h a ft T h ru s t Plate 47 N^m 35 ft-lb

C a m s h a ft R ear C over Plate 47 N^m 35 ft-lb

L u b rica tin g Oil Pum p 41 N^m 30 ft-lb

H ydrau lic D riv e A d ap ter 47 N^m 35 ft-lb

H ydrau lic D riv e Cover Plate 27 N^m 20 ft-lb

A c ce sso ry D riv e A ssem b ly 47 N^m 35 ft-lb

Id ler G ea r C over R etainer: 61* N^m 4 5 * ft-lb

Plus 60 de gre es

C am F ollow er S u p p o rt S tu ds 34 N^m 25 ft-lb

N ote: Install th e cam fo llo w e r s u p p o rt studs
w ith tw o (M 10X1.5) nuts tig h te n e d together.
Rem ove th e nuts after th e stu d s are
tig h te n e d .
Component Specifications and Torque Values
Page 16 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

C am Follow er S u p p o rt Nuts 47 N^m 35 ft-lb

C y lin d e r Head 1 136 N^m 100 ft-lb

Note: T ig h te n th e c y lin d e r head cap screw s 2 217 N^m 160 ft-lb
in th e s e q u e n ce show n. 3 Rotate 90 D e g re e s
Note: Rotate at le ast one fla t, but not m ore
th a n two.

C y lin d e r Head (F uel Pum p Side) 47 N^m 35 ft-lb

T ig h te n th e cap screw s in the se q u e n ce
show n.

G ea r Cover
C a p scre w s 1 th ro u g h 22 20 N^m 15 ft-lb
C a p scre w s 23 th ro u g h 28 68 N^m 50 ft-lb

Note: T ig h te n th e cap screw s in the

s e q u e n ce show n.

A u to m atic B e lt Tensioner 43 N^m 32 ft-lb

F ro nt C ran ks h a ft O il Seal 7 N^m 60 in-lb

20 N^m 180 in-lb

V ib ra tio n D a m p e r and C ran kshaft Pulley 203 N^m 150 ft-lb

Note: T ig h te n th e cap screw s in a star
pattern.
 Component Specifications and Torque Values
M11 Page 17

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric_____________________ U .S .

A c ce sso ry D rive Oil Seal 1 7 N^m 60 in-lb

2 20 N^m 175 in-lb

A c ce sso ry D rive Pulley 542 N^m 400 ft-lb

R o cker Lever H ousing 47 N^m 35 ft-lb

Note: T ig h te n th e cap screw s in the
se q u e n ce show n.

Rocker Lever A s se m b ly 122 N^m 90 ft-lb

Jaco b s Brake Slave Piston

A d ju s tin g S rew Locknut:
• (W ith o u t Torque W rench A d a pter) 34 N^m 25 ft-lb
• (W ith ST-669 Torque W rench A dapter) 30 N^m 22 ft-lb
Component Specifications and Torque Values
Page 18 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

In je c to r Lever A d ju stin g S crew Locknut:

• (W ith o u t Torque W rench A d a pter) 61 N^m 45 ft-lb
• (W ith ST-669 Torque W rench A dapter) 47 N^m 35 ft-lb

Valve Lever A d ju stin g S crew

Locknut:
• (W ith o u t Torque W rench A d a p te r) 61 N^m 45 ft-lb
• (W ith ST-669 Torque W rench A d a pter) 47 N^m 35 ft-lb

Jaco b s Brake H o u sing S p a c e r 25 N^m 18 ft-lb

N ote: T ig h te n th e cap screw s in the
s e q u e n ce show n.

CELECT™ W irin g H arn ess B racket 41 N^m 30 ft-lb

In te rn al A c tu a to r H arn ess C lam ps 20 N^m 15 ft-lb

In te rn a l/E x te rn a l A c tu a to r Harness
C o n n e cto r 1 N^m 11 in-lb

CELECT™ S en sors
O il T em perature 34 N^m 25 ft-lb
O il P ressu re 30 N^m 22 ft-lb
E n g in e P osition 34 N^m 25 ft-lb
B o o s t P re ssu re 14 N^m 10 ft-lb
Intake M an ifold T em perature 14 N^m 10 ft-lb
 Component Specifications and Torque Values
M11 Page 19

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

R o cker Lever Cover 15 N^m 130 in-lb

Note: T ig h te n th e cap screw s in the
se q u e n ce show n.

A ir C o m p re ss o r C o o la n t In let Tube Fittin g

Locknut 47 N^m 35 ft-lb

A ir C o m p re ss o r C o o la n t In let Tube 40 N^m 30 ft-lb

S tartin g M o tor M o un tin g 90 N^m 140 ft-lb

A ir C o m p re ss o r M o un tin g 65 N^m 50 ft-lb

A ir C o m p re ss o r C o o la n t Hoses 40 N^m 30 ft-lb

A ir C o m p re ss o r A ir S u p p ly Tube 47 N^m 35 ft-lb

A ir C o m p re ss o r A ir Tube H ose C lam ps 5 N^m 40 in-lb
Component Specifications and Torque Values
Page 20 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric_____________________ U .S .

Fuel Pum p M o u n tin g 47 N^m 35 ft-lb

Fuel Pum p S u p p o rt Bracket

F uel pu m p h o u sin g m o u n tin g 47 N^m 35 ft-lb
C y lin d e r b lo c k m o u n tin g 47 N^m 35 ft-lb

E lectro n ic C o n tro l C o o lin g Plate 40 N^m 30 ft-lb

E lectro n ic C o n tro l M o du le 7 N^m 62 in-lb

 Component Specifications and Torque Values
M11 Page 21

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

Fan Hub S u p p o rt 75 N^m 55 ft-lb

Fan Hub 47 N^m 35 ft-lb

Fan Pulley and Fan 47 N^m 35 ft-lb

W a te r H e a d e r Plate 54 N^m 40 ft-lb

N ote: T ig h te n th e cap screw s in the
se q u e n ce show n.

W a te r Pum p M o un tin g 47 N^m 35 ft-lb

W a te r T ran sfer C o n n e ctio n 25 N^m 18 ft-lb

W a te r Pum p O il Seal 7 N^m 60 in-lb

N ote: T ig h te n the cap screw s in a star 20 N^m 180 in-lb
pattern

A lte rn a to r D riv e Pulley 75 N^m 55 ft-lb

Component Specifications and Torque Values
Page 22 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

L ub ricatin g Oil F ilter Head 47 N^m 35 ft-lb

Lub ricatin g Oil C o o le r M o un tin g 47 N^m 35 ft-lb

O il C o o le r T h e rm o s ta t S u p p o rt M oun tin g
Flang e 47 N^m 35 ft-lb

D ip stick Tube and H ousing 47 N^m 35 ft-lb

E x h a u s t M anifold 27 N^m 20 ft-lb

Note: T ig h te n the cap screw s in the 47 N^m 35 ft-lb
s e q u e n ce show n.

A ir Intake M anifold 47 N^m 35 ft-lb

N ote: T ig h te n th e cap screw s in the
s e q u e n ce show n.

Turbo ch arger - M o u n tin g Nuts 61 N^m 45 ft-lb

 Component Specifications and Torque Values
M11 Page 23

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

Turbo ch arger O il S u pp ly 20 N^m 15 ft-lb

Turbo ch ag er Oil Drain 27 N^m 20 ft-lb

T h e rm o s ta t H ousing 54 N^m 40 ft-lb

H o se C la m p s 3 N^m 30 in-lb

A lte rn a to r A d ju stin g S crew Locknuts 80 N^m 60 ft-lb

A lte rn a to r M o u n tin g B racket 47 N^m 35 ft-lb

Id ler P ulley S h a ft Locknut 190 N^m 140 ft-lb

Drain Plugs (C o o lant) 20 N^m 15 ft-lb

Drain Plug (L ub ricatin g O il Pan) 90 N^m 65 ft-lb

Cylinder Block - Rebuild Specifications

C y lin d e r B lo ck U p p er L in er B ore I.D . 145.900 mm M IN 5.7441 in
146.027 mm MAX 5.7491 in
Component Specifications and Torque Values
Page 24 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S .

C y lin d e r B lo ck L in er Seal S ea t B ore I.D. 138.063 mm MIN 5.4355 in

138.113 mm M AX 5.4375 in

M ain B earin g B ore I.D. 121.990 mm M IN 4 .8 028 in

122.015 mm M AX 4 .8 0 3 7 in

C y lin d e r B lo ck T h ru s t B e arin g S u rface

W id th 39 .95 mm M IN 1.573 in
4 0 .0 5 mm MAX 1.577 in

M ain O il P ressure R e g u lato r Valve Bore 2 2 .226 mm M IN 0.8750 in

I.D . 22.301 mm MAX 0.8780 in

H igh Oil P ressure R e lie f V alve S e a t Depth 62 .62 mm M IN 2.4 65 in

63 .62 mm MAX 2.5 05 in

Id ler G e a r Ring Dow el B ore I.D . 19.175 mm M IN 0.7549 in

19.215 mm MAX 0.7565 in

C a m s h a ft B u sh ing I.D . (Installed) 72.078 mm M IN 2 .8 3 7 7 in

7 2 .142 mm MAX 2 .8 402 in
N ote: If one of th e b u sh in g s exceeds th e sp e c ific a tio n s ,
all of th e b u sh in g s m u st be replaced.
 Component Specifications and Torque Values
M11 Page 25

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

C y lin d e r B lo ck C a m s h a ft B ore I.D . 7 6 .987 mm MIN 3.0310 in

77 .040 mm M AX 3.0331 in

C y lin d e r L in er I.D . 125.000 mm MIN 4.9213 in

125.095 mm M AX 4 .9 250 in

C y lin d e r L in er Top Press Fit O.D. 145.938 mm MIN 5.7 456 in

145.976 mm M ax 5.7471 in

C y lin d e r L in er Seal S ea t O.D. C 1 37.937 mm MIN 5.4 306 in

138.013 mm M AX 5.4 336 in

Id ler G ea r B ushing Bore I.D. 60 .045 mm MIN 2 .3 640 in

60.100 mm M AX 2.3661 in

Id ler G ea r S h a ft O.D. 59 .975 mm MIN 2.3612 in

60 .008 mm M AX 2 .3 625 in

Id ler G ea r S h a ft Ring Dow el Bore I.D . 19.245 mm MIN 0 .7 577 in

19.265 mm M AX 0.7 585 in
Component Specifications and Torque Values
Page 26 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

Id ler G ea r Ring Dow el O.D. 19.217 mm MIN 0.7566 in

19.243 mm M AX 0.7576 in

Id ler G ea r T h ru s t W a s h e r T h ick n e ss 2 .4 0 0 mm M IN 0.0945 in

2.470 mm MAX 0.0972 in

C ran ks h a ft R ear Oil Seal W e a r G roove 0.25 mm MAX 0.0098 in

C ran ks h a ft C o n n e ctin g Rod Jo u rn al O.D. 7 8 .950 mm M IN 3.1083 in

79.013 mm MAX 3.1107 in

C ran ks h a ft M ain B earin g Jo u rn al O.D. 114.015 mm M IN 4 .4 888 in

114.055 mm MAX 4 .4 903 in

C ran ks h a ft T h ru s t Face W id th 4 9 .975 mm MIN 1.9675 in

50.100 mm MAX 1.9724 in

C ran ks h a ft R ear Oil Seal F la n g e O.D. 164.965 mm M IN 6 .4 947 in

165.035 mm MAX 6 .4 974 in
 Component Specifications and Torque Values
M11 Page 27

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

C ran ks h a ft D a m p er P ilot O.D. 32.01 mm MIN 1.2602 in

32 .0 4 mm M AX 1.2614 in

M ain B earin g S h ell T h ic k n e s s (S tan d ard ) 3.8 95 mm M IN 0.1 533 in

3.9 4 4 mm MAX 0.1 553 in

N ote: For visu a l in sp e ctio n crite ria , refer to th e Parts R euse G uid eline s, B ulle tin No. 3810303.

C ran ks h a ft T h ru s t B e arin g T h ick n e ss 4.7 5 mm MIN 0.1870 in

4.8 9 mm M AX 0.1 925 in

C o n n e ctin g Rod B earin g T h ick n e ss 2.4 3 0 mm M IN 0 .0 957 in

(S tan d ard ) 2.4 7 3 mm MAX 0 .0 974 in

N ote: For visu a l in sp e ctio n crite ria , refer to th e Parts R euse G uid eline s, B ulle tin No. 3810303.

V ib ra tio n D a m p er T h ick n e ss
V ariatio n 0.25 mm MAX 0.010 in
T h ic k n e s s 45 .0 0 mm MAX 1.772 in

C ran ks h a ft G ea r B ore I.D . 85.910 mm M IN 3.3 823 in

85 .935 mm MAX 3.3 833 in

C ran ks h a ft G ea r Jo u rn al O.D. 85 .975 mm MIN 3.3 848 in

86 .000 mm M AX 3.3 858 in
Component Specifications and Torque Values
Page 28 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S .

C ran ks h a ft P ulley C ran ks h a ft Pilot Bore

I.D . 32 .05 mm MIN 1.2618 in
32.10 mm M AX 1.2638 in

C o n n e c tin g Rod C ap screw O.D. 12.600 mm MIN 0.4961 in

12.800 mm MAX 0.5039 in

C o n n e c tin g Rod Piston Pin B u sh ing I.D. 54 .054 mm MIN 2.1281 in

(In s talle d ) 54 .099 mm M AX 2 .1 299 in

C o n n e c tin g Rod B earin g B ore I.D. 83 .975 mm MIN 3.3061 in

84 .025 mm M AX 3.3080 in

C o n n e c tin g Rod - Length 217.975 mm MIN 3.5817 in

218.025 mm M AX .5836 in
C o n n e c tin g Rod - A lig n m e n t:
• (W ith B ushing) 0.10 mm M AX 0.0 04 in

C o n n e c tin g Rod - Twist:

• (W ith B ushing) 0.25 mm M AX 0.010 in

C a m s h a ft T h ru s t Plate C learan ce 0.1 80 mm MIN 0.0070 in

0.3 30 mm M AX 0.0130 in
 Component Specifications and Torque Values
M11 Page 29

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

C a m s h a ft B u sh ing Jo u rn al O.D. 71.987 mm MIN 2.8341 in

72.013 mm M AX 2 .8 352 in

C a m s h a ft G ea r M o u n tin g S u rface O .D . 4 6 .9 8 7 mm M IN 1.8499 in

47.013 mm MAX 1.8509 in

C a m s h a ft T h ru s t B earin g Jo u rn al O.D. 54 .800 mm MIN 2 .1 575 in

55 .200 mm M AX 2 .1 732 in

C a m s h a ft T h ru s t Plate I.D . 55 .60 mm MIN 2 .1 890 in

56.61 mm M AX 2 .2 2 8 7 in

C a m s h a ft T h ru s t Plate T h ick n e ss 8.9 60 mm MIN 0.3 528 in

9.0 40 mm M AX 0.3 559 in

C a m s h a ft G ea r B ore I.D . 46.912 mm M IN 1.8469 in

4 6 .938 mm MAX 1.8479 in

Piston S kirt O .D . (A) 124.939 mm M IN 4.9189 in

124.983 mm MAX 4 .9 206 in
Component Specifications and Torque Values
Page 30 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric_____________________ U .S .

Piston Ring G roove W id th

Use a new ring and a 0.15 mm [0.00 6 inch] fe e le r gauge. If th e fe e le r ga ug e en ters th e groove
w ith o u t re sista n ce the piston m ust be rep la ced.

Piston Pin B ore I.D .

• A rtic u la te d Crown 54 .040 mm MIN 2 .1 276 in
54 .055 mm M AX 2.1281 in

• A rtic u la te d S kirt 54.007 mm MIN 2 .1 263 in

54.015 mm M AX 2 .1 266 in

Piston Pin Len gth 101.700 mm MIN 4 .0 039 in

102.000 mm M AX 4.0 157 in
Piston Pin O.D. 5 3 .997 mm MIN 2 .1 259 in
54 .003 mm M AX 2.1261 in

Piston Ring Gap

Top 0.46 mm MIN 0.018 in
0.71 mm M AX 0.028 in
Inte rm e d ia te 0.76 mm MIN 0.030 in
1.14 mm M AX 0.045 in
Oil 0.25 mm MIN 0.010 in
0 .6 4 mm M AX 0.025 in

G ea r H o u sing B earin g Bore I.D .

H ydrau lic Drive 41 .967 mm MIN 1.6522 in
41.992 mm M AX 1.6532 in

W a te r Pum p Drive 36 .967 mm MIN 1.4553 in

36 .992 mm M AX 1.4564 in

A c ce sso ry Drive 45.100 mm MIN 1.7756 in

4 5 .125 mm M AX 1.7766 in

H ydrau lic Pum p N e ed le B e arin g Installed

Depth 0.25 mm MIN 0.010 in
0.76 mm M AX 0.030 in

W a te r Pum p N e ed le B earin g In s talle d

Depth
T h e be aring m ust be in sta lle d w ith th e pa rt n u m b e r sid e of the be a rin g a g a in s t the in sta lla tio n tool
to prevent be aring d a m ag e d u rin g in sta lla tion . Use be a rin g d rive r kit, Part No. 3824117, to install to
th e co rre ct s p e cifica tio n .
 Cylinder Block - Rebuild
M11 Page 31

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

Cylinder Block - Torque Values

M ain B e arin g Capscrew s 68 N^m 50 ft-lb
N ote: T ig h te n th e m ain be aring capscrew s 142 N^m 105 ft-lb
in th e se q u e n ce shown. 210 N^m 155 ft-lb
Loosen All
68 N^m 50 ft-lb
142 N^m 105 ft-lb
210 N^m 155 ft-lb

C o n n e ctin g Rod C apscrew s 68 N^m 50 ft-lb

142 N^m 105 ft-lb
210 N^m 155 ft-lb
Loosen A ll
68 N^m 50 ft-lb
142 N^m 105 ft-lb
210 N^m 155 ft-lb

C y lin d e r B lo ck Pipe Plugs

R efer to ‘ ‘ Pipe Plug Torque Value T able” at th e rear of th is se ctio n for to rq u e v a lu e of v a rio u s plug
sizes.

C am F o llo w er S tu ds 34 N^m 25 ft-lb

V is c o s ity S en so r 24 N^m 18 ft-lb

Cylinder Head - Rebuild Specifications

C y lin d e r Head F la tn e s s
A A and BB (C o rner to C orner) 0.200 M AX 0.008
CC (Across C o m b u stio n Face) 0.076 M AX 0.003
DD (Across Entire Head S urface) 0.127 M AX 0.005

N ote: D im e n sio n s CC and DD m ust be che cked from fro n t to rear of head.

C y lin d e r Head T h ic k n e s s 99 .24 mm MIN 3.907 in

100.25 mm M AX 3.9 47 in
Cylinder Block - Rebuild
Page 32 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

Valve S p rin g F ree H eight: A 103.300 mm N o m ina l 4 .0 669 in

Valve S p rin g W orking Height: B 71.48 mm N o m ina l 2.8142 in

Load fo r W orking H eig h t at 71 .4 8 mm

[2 .8 1 4 2 in]: C 1252 N M IN 281 lbf
1584 N MAX 356 lbf

Valve S te m O.D. 9.5 80 mm M IN 0.3772 in

9.6 33 mm MAX 0.3793 in

Valve H ead T h ic k n e s s at O.D. 3.15 mm MIN 0.1 24 in

3.62 mm M AX 0.143 in

Valve G u id e I.D . (Installed)

Used 9.670 mm MIN 0.3807 in
9.7 30 mm M AX 0.3831 in

N e w /R eb uilt 9.670 mm MIN 0.3807 in

9.6 95 mm M AX 0.3817 in

Valve G u id e H eig h t (In s talle d ) 27 .1 5 mm MIN 1.069 in

27 .6 5 mm M AX 1.089 in

Valve G u id e B ore I.D. 16.480 mm MIN 0.6488 in

16.500 mm MAX 0.6496 in
 Cylinder Block - Rebuild
M11 Page 33

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

Valve G u id e O .D . (Seal Area) 14.25 mm MIN 0.561 in

14.37 mm M AX 0.566 in

Valve G u id e O .D . (Base) 16.513 mm M IN 0.6501 in

16.526 mm MAX 0.6 506 in

Valve S e a t A re a W id th 1 1.63 mm M IN 0.0 64 in

2 .6 9 mm MAX 0.106 in

Valve S e a t to Valve G u id e C o n c e n tric ity 0.05 mm M AX 0.002 in

(Per 3 6 0 D egrees)

Valve R ecess in C y lin d e r Head 1 0.76 mm M IN 0.030 in

1.17 mm MAX 0.046 in

Valve H ead T h ic k n e s s (at. O .D .) 3.15 mm M IN 0.1 24 in

3.62 mm MAX 0.143 in

Valve In s ert B ore D epth (S tan d ard Insert) 9.40 mm M IN 0.370 in

9.50 mm MAX 0.3 74 in
Cylinder Block - Rebuild
Page 34 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S .

Valve In s ert B ore I.D . (S tan d ard Insert) 4 5 .920 mm MIN 1.8073 in
4 5 .935 mm M AX 1.8085 in
N ote: R efer to C y lin d e r H ead - O versize Valve
S eat Installatio n (2-05) for oversize valve in se rt dim en sion s.

In je c to r T ip Protrusion:
• (U sed Inje ctor Sleeve) 2.28 mm MIN 0.090 in
2.65 mm M AX 0.104 in

(N ew Inje ctor Sleeve) 2.28 mm MIN 0.090 in

2.5 4 mm M AX 0.100 in

C rossh ead S te m Pocket to Pad Face 12.05 mm MIN 0.4 74 in

12.55 mm M AX 0.4 94 in

Cylinder Head - Torque Values

C y lin d e r Head Pipe Plugs 10 N^m 8 ft-lb
N ote: T he pipe plug s (1) located in th e front
of th e c y lin d e r head m ust be in sta lle d be lo w
th e su rfa ce of th e c y lin d e r head.

Rocker Lever Assembly - Rebuild Specifications

R o cker Lever B ushing Bore I.D. 3 4 .887 mm M IN 1.3735 in
3 4 .990 mm MAX 1.3776 in

R o cker Lever B ore I.D . 3 6 .474 mm M IN 1.4359 in

3 6 .499 mm MAX 1.4370 in

R o cker Lever S h a ft O.D. 3 4 .837 mm MIN 1.3715 in

3 4 .864 mm MAX 1.3726 in
 Cylinder Block - Rebuild
M11 Page 35

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

Cam Follower Assembly - Rebuild Specifications

C am F ollow er R o lle r S id e C learan ce 0.19 mm MIN 0.007 in
0.65 mm M AX 0.026 in

C am F ollow er R o lle r to Pin C lea ra n c e 0.08 mm MIN 0.003 in

0.20 mm M AX 0.008 in

C am F ollow er S h a ft Jo u rn al O.D. 33.991 mm MIN 1.3382 in

34 .009 mm M AX 1.3389 in

C am F ollow er Lever S h a ft Bore I.D . 34 .086 mm MIN 1.3420 in

34.116 mm M AX 1.3431 in

C am F ollow er Lever R o ller Pin Bore I.D . 19.043 mm MIN 0 .7 497 in

19.055 mm M AX 0.7 502 in

C am F ollow er Lever R o ller Bore I.D . 19.151 mm MIN 0.7 540 in

19.177 mm M AX 0.7 550 in

C am F ollow er C row n ed R o lle r O .D. 41 .237 mm M IN 1.6235 in

4 1 .287 mm MAX 1.6255 in
Cylinder Block - Rebuild
Page 36 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

C am Follow er R o ller Pin (N ew ) O.D. 19.065 mm MIN 0.7506 in

19.073 mm M AX 0.7509 in

C am Follow er Lever S o cket B ore I.D. 19.024 mm M IN 0.7490 in

19.050 mm MAX 0.7500 in

C am Follow er Lever S o cket (N ew ) O.D. 19.062 mm M IN 0.7505 in

19.088 mm MAX 0.7515 in

Fuel Pump - Rebuild Specifications

G ea r Pum p S h a ft B earin g S u rfac e O.D. 12.695 mm MIN 0.4998 in

G ea r W id th 31.707 mm MIN 1.2483 in

G ea r Installed Depth 17.270 mm M IN 0.6799 in

17.533 mm MAX 0.6903 in
Note: Measure from the body end of the shaft.

B o d y G ear H o le Depth 31.704 mm MIN 1.2482 in

31.712 mm M AX 1.2485 in

B o d y S h aft B ore I.D . 12.733 mm MIN 0.5013 in

12.741 mm M AX 0.5016 in

B o d y R e g u lato r B ore I.D. 9.510 mm MIN 0 .3 744 in

9.5 20 mm M AX 0.3748 in
 Cylinder Block - Rebuild
M11 Page 37

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

S h a ft End C learan ce 0.0 23 mm MIN 0.0 009 in

0.0 38 mm M AX 0.0015 in

R e g u lato r S p rin g S p e c ific a tio n s

W ire Free
Part Dia. No. Load Length Length
No. m m [inch] Coils Kg [lb] m m [inch] m m [inch]
3 0 68 42 4 1.52 [.060] 5.25 4.0 [8.9] 16.0 [.631] 21.16 [.8337]

Fuel Pump - Torque Values

C over to B o d y Capscrew s 18 N^m 13 ft-lb

C h e c k Valve Elbow 6 N^m 50 in-lb

S u p p o rt to Pum 18 N^m 13 ft-lb

F ilte r Screen 18 N^m 13 ft-lb

D a m p er A ssem b ly 18 N^m 13 ft-lb

Fuel S h u to ff 3 N^m 30 in-lb

Cylinder Block - Rebuild
Page 38 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric_____________________ U .S.

Injectors - Rebuild Specifications

CELECT™ in je cto rs ca n n o t p re se n tly be rebuilt.

Lubricating Oil System - Specifications

O il Pan Capacity:
• A u to m o tive 26 .5 litres Low 7.0 gal.
34.0 litres High 9.0 gal.

L ub ricatin g Oil T h e rm o s ta t
• Initial O p e n in g Tem perature 106°C MIN 2 2 3 °F
108°C M AX 2 2 7 °F

• Fully O pen Tem perature 115°C M AX 2 4 0 °F

• M axim um O p e n in g D istance 6.35 mm M AX 0.2 50 in

L ub ricatin g Oil F ilter H e a d B ypass Valve

Spring:
• Free Length 37 .68 mm M IN 1.483 in
38 .52 mm MAX 1.517 in

Load at 29 .6 5 mm [1.16 7 inch] 110.1 N M IN 24.751 lbf

121.7 N MAX 2 7 .359 lbf

L ub ricatin g Oil Pum p S h a ft End C learan ce 0.0 6 4 mm M IN 0.0025 in

0.2 69 mm MAX 0.0106 in

L ub ricatin g Oil Pum p B o d y and Cover

S h a ft B ore I.D. 18.720 mm MIN 0.7370 in
18.746 mm M AX 0.7380 in

L ub ricatin g Oil Pum p G ea r S h aft O.D. 18.669 mm MIN 0.7350 in

18.681 mm MAX 0.7355 in
 Cylinder Block - Rebuild
M11 Page 39

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

Lub ricatin g Oil Pum p Drive G ea r Bore I.D. 18.600 mm MIN 0.7 323 in
18.625 mm M AX 0.7 333 in

Lub ricatin g Oil Pum p G ea r to B ody 9.50 mm MIN 0 .3 7 in

C lea ra n c e 12.00 mm M AX 0 .4 7 in

Lubricating Oil System - Torque Values

R ear C over Plate 20 N^m 18 ft-lb

Cooling System - Rebuild Specifications

W a te r Pum p B o d y B e arin g B ore I.D. 51.996 mm M IN 2.0471 in
52.011 mm MAX 2 .0 4 7 7 in

W a te r and O il S eal B ore I.D.

• W ater Seal Bore 1 36 .450 mm MIN 1.4350 in
36 .475 mm M AX 1.4360 in

O il Seal Bore 2 4 0 .975 mm MIN 1.6132 in

41.025 mm M AX 1.6152 in

W a te r Pum p Im p e lle r B ore I.D. 15.339 mm MIN 0.6 039 in

15.365 mm M AX 0.6 049 in

W a te r Pum p Drive G ea r B ore I.D. 33 .900 mm M IN 1.3346 in

33 .925 mm MAX 1.3356 in
Cylinder Block - Rebuild
Page 40 M11

C o m p o n e n t or A s se m b ly (P ro cedu re) N o ./S te p s M etric U .S.

W a te r Pum p S h a ft Jo u rn als O.D. 1 15.389 mm MIN 0.6059 in

15.402 mm M AX 0 .6 064 in

2 15.897 mm MIN 0.6259 in

15.910 mm M AX 0 .6 264 in

3 2 4 .999 mm MIN 0.9842 in

2 5 .009 mm M AX 0.9846 in

4 2 4 .999 mm MIN 0.9842 in

2 5 .009 mm M AX 0.9846 in
W a te r Pum p S h a ft Jo u rn als O .D . (C o n t’d.) 5 33.951 mm MIN 1.3366 in
33 .976 mm M AX 1.3376 in

6 2 9 .9 8 7 mm MIN 1.1806 in
30 .000 mm M AX 1.1811 in

7 2 7 .975 mm MIN 1.1014 in

2 8 .025 mm M AX 1.1033 in

8 2 7 .8 8 7 mm MIN 1.0979 in
2 7 .900 mm M AX 1.0984 in
W a te r Pum p Im p e lle r Hub To Body 13.52 mm MIN 0.532 in
S u rfac e D istance 13.72 mm M AX 0.540 in

Fan Hub S h a ft End C learance 0.076 mm MIN 0.0030 in

0.4 06 mm M AX 0.0160 in

Fan Hub S h a ft O.D. 3 4 .590 mm MIN 1.3760 in

3 4 .963 mm M AX 1.3765 in

34.912 mm MIN 1.3745 in

3 4 .925 mm M AX 1.3750 in

Fan Hub B earin g B ore I.D. 6 5 .038 mm MIN 2 .5 605 in

65.076 mm M AX 2 .5 620 in

Fan Hub F lan g e O .D . and I.D . 4 8 .975 mm MIN 1.9281 in

4 9 .000 mm M AX 1.9291 in

3 4 .849 mm MIN 1.3720 in

3 4 .875 mm M AX 1.3730 in
 Cylinder Block - Rebuild
M11 Page 41

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S .

Fan Hub Face to Face D istance 73 .4 mm MIN 2.8 90 in

74.0 mm M AX 2.913 in

Fan Id ler P ulley End C learan ce 0.05 mm MIN 0.002 in

0.25 mm M AX 0.010 in

Fan Id ler P ulley S h a ft O.D.

• O il Seal S urface 32 .975 mm MIN 1.2982 in
33 .000 mm M AX 1.2992 in

B ea rin g S urface 19.037 mm MIN 0.7 495 in

19.050 mm M AX 0.7 500 in

Fan Id ler P ulley B earin g Bore I.D . 45 .199 mm MIN 1.7795 in

4 5 .2 2 4 mm M AX 1.7805 in
N ote: T he fro n t and rear be a rin g bores
are the sam e in sid e diam eter.

Fan Id ler P ulley B ore O il Seal Installed

D epth 0.00 mm MIN 0.000 in
0.25 mm M AX 0.010 in
N ote: M ea sure de pth from th e m o u n tin g fla n g e
surface, as shown.

T h e rm o s ta t, C o o la n t - O peratin g
T em p eratu re
• Initial O p e n in g Tem perature 8 1 °C MIN 1 7 8 °F
8 3 °C M AX 1 8 2 °F

• Fully O pe n Tem perature 9 3 °C M AX 2 0 0 °F

• M axim um O p e n in g D istance 9.52 mm M AX 0.375 in

Cooling System - Torque Values

W a te r Pum p Cover 47 N^m 35 ft-lb
Cylinder Block - Rebuild
Page 42 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S.

Fan Hub R etainin g Capscrew 61 N^m 45 ft-lb

Fan Id ler P ulley A s se m b ly R etainin g

C apscrew 47 N^m 35 ft-lb

Drive Units - Rebuild Specifications

A c ce sso ry D rive S h aft End C lea ra n c e 0.10 mm MIN 0.0 04 in
0.30 mm M AX 0.012 in

A c ce sso ry D rive H o u sing B earin g Bore

I.D . 4 7 .676 mm M IN 1.8770 in
4 7 .775 mm M AX 1.8809 in

A c ce sso ry T h ru s t B e arin g T h ick n e ss 6.0 8 4 mm MIN 0.2395 in

6.312 mm M AX 0.2485 in

A c ce sso ry D rive S h aft Jo u rn al O.D. 1 3 4 .984 mm MIN 1.3773 in

3 5 .000 mm M AX 1.3779 in

2 4 4 .975 mm MIN 1.7706 in

4 5 .000 mm M AX 1.7716 in

3 4 7 .5 5 4 mm MIN 1.8722 in
47 .570 mm M AX 1.8728 in

4 2 5 .476 mm MIN 1.0030 in

2 5 .489 mm M AX 1.0035 in
A c ce sso ry D rive G ear Bore I.D . 4 7 .4 8 4 mm MIN 1.8694 in
4 7 .509 mm M AX 1.8704 in
 Cylinder Block - Rebuild
M11 Page 43

C o m p o n e n t or A s se m b ly (P ro cedu re) R e f.N o ./S te p s M etric U .S.

A c ce sso ry D rive S p lin ed C o u pling I.D. 25 .400 mm MIN 1.0000 in

2 5 .425 mm M AX 1.0010 in

A c ce sso ry D rive Hub C o u p lin g I.D . 2 5 .425 mm MIN 1.0010 in

2 5 .438 mm M AX 1.0015 in

A c ce sso ry D rive P ulley Bore I.D .: 35 .060 mm MIN 1.3803 in

35 .098 mm M AX 1.3818 in

D rive S h aft Installed H e ig h t 40.91 mm MIN 1.611 in

in th e Drive G ear 4 0 .9 7 mm M AX 1.613 in

H ydrau lic Pum p Drive S h a ft End C lea ra n c e 0.076 mm M IN 0.0 030 in

0.6 35 mm M AX 0.0 250 in
N ote: T he h yd ra u lic pu m p drive m ust be
m ou nted to the e n g in e to ch e c k the drive sh a ft end clearance.

H ydrau lic Pum p Drive S h a ft O.D. 3 4 .984 mm M IN 1.3773 in

35 .000 mm M AX 1.3780 in
N ote: M ea sure the drive sh a ft o u tsid e dia m e te r
in tw o p o sitio n s 90 de gre es a p a rt at points (1, 2 and 3).

H ydrau lic Pum p Drive G ea r B ore I.D . 34 .925 mm M IN 1.3750 in

34 .950 mm M AX 1.3760 in

H ydrau lic Pum p Drive R ear A d a p te r Bore

I.D . 4 1 .967 mm M IN 1.6522 in
41.992 mm M AX 1.6532 in
Cylinder Block - Rebuild
Page 44 M11

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric U .S .

H ydrau lic Pum p Drive S h a ft Installed

H e ig h t in th e Drive 18.50 mm MIN 0.728 in
G ear 19.50 mm M AX 0.768 in

H ydrau lic Pum p Drive R ear A d a p te r Bore

B e a rin g Depth 0.2 5 4 mm MIN 0.0100 in
0.7 62 mm MAX 0.0300 in

Air Intake System - Inspection Specifications

T u rb o ch arg er S h a ft A xial M o vem en t 0.0 38 mm M IN 0.0015 in
0.0 89 mm M AX 0.0035 in

C o m p re ss o r W h e e l Radial C learan ce 0.15 mm MIN 0.006 in

0 .6 4 mm M AX 0.025 in
N ote: S p e c ific a tio n s and in s tru c tio n s for re b u ild in g
th e tu rb o c h a rg e r are pro vid ed in the T urbo cha rger
C o m p o n e n t S ho p M an ua l, B ulle tin No. 3379461.

Exhaust System - Torque Values

E x h a u s t M anifold F la n g e To T urbo ch arger
M o u n tin g Stud Torque 65 N^m 50 ft-lb
N ote: A p p ly a coa t of an ti-seize c o m p o u n d
to th e threads. U se tw o m o u n tin g nuts locked
to g e th e r to tig h te n the studs.

Air Equipment - Inspection Specifications

S in g le C y lin d e r A ir C o m p ressor 0.05 mm MIN 0.002 in
C ran ks h a ft End C learance 0.15 mm M AX 0.006 in
N ote: S p e c ific a tio n s and in s tru c tio n s for re b u ild in g
th e sin g le c y lin d e r air co m p re sso r are pro vid ed in the
A ir E q u ip m e n t R ebuild M anual,
B u lle tin No. 3810457.

Two C y lin d e r A ir C o m p re ss o r C ran kshaft

End C learan ce 0.05 mm MIN 0.002 in
0.19 mm M AX 0.008 in
N ote: S p e c ific a tio n s and in s tru c tio n s for re b u ild in g
th e tw o c y lin d e r air co m p re sso r are pro vid ed in the
A ir E q u ip m e n t R ebuild M anual,
B u lle tin No. 3810347.
 Cylinder Block - Rebuild
M11 Page 45

C o m p o n e n t or A s se m b ly (P ro ce d u re ) R e f.N o ./S te p s M etric_____________________ U .S .

Electrical Equipment - Inspection Specifications

A lte rn a to r B racket (B us A p p lica tio n s) 210.7 mm MIN 8.30 in
Lower B racket Front to R ear M ou ntin g
S u rfa ce

A u to m atic T en sion er B racket Locator H ole

I.D . 4 .0 0 mm MIN 0.3 54 in
4.5 0 mm MAX 0.3 74 in

Engine Testing - Test Specifications

N ote: T he s p e c ific a tio n s and in s tru c tio n s for te stin g the e n g in e are pro vid ed in th is m anual. Refer
to E ngine Testing - G ro u p 14.

Mounting Adaptations - Rebuild Specifications

REPTO S h a ft End Play 0.00 mm M IN 0.000 in
0.03 mm MAX 0.001 in

REPTO R olling R esistan ce 0.6 N^m M IN 5 in-lb

1.1 N *m MAX 10 in-lb

REPTO O u tp u t F lan g e C ap screw 205 N^m 150 ft-lb

Vehicle Braking - Rebuild Specifications

N ote: T he sp e c ific a tio n s and in s tru c tio n s for re b u ild in g th e Ja co b s Brake are pro vid ed in the
J a co b s Brake Installatio n M anual. R efer to V e h icle B raking - G ro u p 20.
Injection Timing Codes
Page 46 M11

Injection Timing Codes

Note: Injection timing is measured at 5.161 mm [0.2032 inch] BTDC piston travel.

Reference Key Amount of

Timing Push Rod Travel Range Camshaft Key Configuration Offset
Code mm in Part No. mm [in]
CELECT™
HZ -5.92 to -6.02 -0.233 to -0.237 3009953 Straight Key 0.000 [0.0000]

Read the push rod travel gauge counterclockwise from

‘ ‘0 ’ ’. This travel represents the injection tim ing value. In
the example shown, the value is 1.98 mm [0.078 inch].
 Drive Belt Tension
M11 Page 47

Drive Belt Tension

SAE Belt Size Belt Tension Gauge Belt Tension Belt Tension Range
Part No. New Used*
Click-type Burroughs N lbf N lbf
.380 in. 3822524 620 140 270 to 490 60 to 110
.440 in. 3822524 620 140 270 to 490 60 to 110
1/2 in. 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in. 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in. 3822524 ST-1138 620 140 270 to 490 60 to 110
7/8 in. 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822525 ST-1293 710 160 290 to 580 65 to 130
8 rib 3822525 ST-1293 890 200 360 to 710 80 to 160
10 rib 3822525 3823138 1110 250 440 to 890 100 to 200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240

* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
FRACTION, DECIMAL, MILLIMETER CONVERSIONS
Page 48 M11

FRACTION, DECIMAL, MILLIMETER CONVERSIONS

8 16 32 64 8 16 32 64
THS. THS. NDS. THS. INCHES MM THS. THS. NDS. THS. INCHES MM
1 0.0156 0.397 33 0.5156 13.097
1 0.0313 0.794 17 0.5313 13.494
3 0.0469 1.191 35 0.5469 13.891
1 0.0625 1.588 9 0.5625 14.288
5 0.0781 1.984 37 0.5781 14.684
3 0.0938 2.381 19 0.5938 15.081
7 0.1094 2.778 39 0.6094 15.478
1 0.1250 3.175 5 0.6250 15.875
9 0.1406 3.572 41 0.6406 16.272
5 0.1563 3.969 21 0.6563 16.669
11 0.1719 4.366 43 0.6719 17.066
3 0.1875 4.763 11 0.6875 17.463
13 0.2031 5.159 45 0.7031 17.859
7 0.2188 5.556 23 0.7188 18.256
15 0.2344 5.953 47 0.7344 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17 0.2656 6.747 49 0.7656 19.447
9 0.2813 7.144 25 0.7813 19.844
19 0.2969 7.541 51 0.7969 20.241
5 0.3125 7.938 13 0.8125 20.638
21 0.3281 8.334 53 0.8281 21.034
11 0.3438 8.731 27 0.8438 21.431
23 0.3594 9.128 55 0.8594 21.828
3 0.3750 9.525 7 0.8750 22.225
25 0.3906 9.922 57 0.8906 22.622
13 0.4063 10.319 29 0.9063 23.019
27 0.4219 10.716 59 0.9219 23.416
7 0.4375 11.113 15 0.9375 23.813
29 0.4531 11.509 61 0.9531 24.209
15 0.4688 11.906 31 0.9688 24.606
31 0.4844 12.303 63 0.9844 25.003
1/2 0.5000 12.700 1 IN. 1.0000 25.400

CONVERSION FACTOR: 1 INCH = 25.4MM

 Weight and Measures - Conversion Factors
M11 Page 49

Weight and Measures - Conversion Factors

QUANTITY U.S. CUSTOMARY METRIC FROM U.S. FROM METRIC
CUSTOMARY TO U.S.
TO METRIC CUSTOMARY
MULTIPLY BY MULTIPLY BY
Unit Name Abbr. Unit Name Abbr.
Area sq. inch in2 sq. millimeters mm2 645.16 0.001550
sq. centimeters cm2 6.452 0.155
sq. foot ft2 sq. meter m2 0.0929 10.764
Fuel pounds per lb/hp-hr grams per g/kw-hr 608.277 0.001645
Consumption horsepower kilowatt hour
hour
Fuel miles per mpg kilometers per km/l 0.4251 2.352
Performance gallon liter
gallons per gpm liters per l/km 2.3527 0.4251
mile kilometer
Force pounds force lbf Newton N 4.4482 0.224809
Length inch in millimeters mm 25.40 0.039370
foot ft millimeters mm 304.801 0.00328
Power horsepower hp kilowatt kw 0.746 1.341
Pressure pounds force psi kilopascal kPa 6.8948 0.145037
per sq. inch
inches of in Hg kilopascal kPa 3.3769 0.29613
mercury
inches of in H2O kilopascal kPa 0.2488 4.019299
water
inches of in Hg millimeters mm Hg 25.40 0.039370
mercury of mercury
inches of in H2O millimeters mm H2O 25.40 0.039370
water of water
bars bars kilopascals kPa 100.001 0.00999
bars bars millimeters of mm Hg 750.06 0.001333
mercury
Temperature fahrenheit °F centigrade °C (°F-32) -1 .8 (1.8 x °C) +32
Torque pound force ft lb Newton-meter N^m 1.35582 0.737562
per foot
pound force in lb Newton-meter N^m 0.113 8.850756
per inch
Velocity miles/hour mph kilometers/hour kph 1.6093 0.6214
Volume: gallon (U.S.) gal. liter l 3.7853 0.264179
liquid gallon (Imp*) liter l 4.546 0.219976
gal.
displacement
cubic inch in3 liter l 0.01639 61.02545
cubic inch in3 cubic cm3 16.387 0.06102
centimeter
Weight (mass) pounds (avoir.) lb kilograms kg 0.4536 2.204623
Work British Thermal BTU joules j 1054.5 0.000948
Unit
British Thermal BTU kilowatt-hour kw-hr 0.000293 3414
Unit
horsepower hp-hr kilowatt-hour kw-hr 0.746 1.341
hours
Newton-Meter to Foot-Pound Conversion Chart
Page 50 M11

Newton-Meter to Foot-Pound Conversion Chart

N^m ft-lb N^m ft-lb N^m ft-lb
1 8.850756 in-lb 55 41 155 114

5 44 in-lb 60 44 160 118

6 53 in-lb 65 48 165 122
7 62 in-lb 70 52 170 125
8 71 in-lb 75 55 175 129
9 80 in-lb 80 59 180 133
10 89 in-lb 85 63 185 136
1 0.737562 ft-lb 90 66 190 140
12 9 95 70 195 144
14 10 100 74 200 148
15 11 105 77 205 151
16 12 110 81 210 155
18 13 115 85 215 159
20 15 120 89 220 162
25 18 125 92 225 165
30 22 130 96 230 170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184
NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.
 Capscrew Markings and Torque Values
M11 Page 51

Capscrew Markings and Torque Values

Caution: When replacing capscrews, always use a capscrew of the same measurement and strength as
the capscrew being replaced. Using the wrong capscrews can result in engine damage.
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the
surface of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew.
The following examples indicate how capscrews are identified:

Metric - M8-1.25 X 25 U.S. Customary [5/16 X 18 X 1-1/2]

M8 1.25 25 5/16 18 1-1/2
Major Distance Length Major Number Length
Thread Between in Thread Threads in
Diameter in Threads in Millimeters Diameter per Inch Inches
Millimeters Millimeters in Inches

NOTES:
1. Always use the torque values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other sections of this manual.
3. The torque values in the table are based on the use of lubricated threads.
4. When the ft-lb value is less than 10, give consideration to converting the ft-lb value to in-lb to obtain a better
torque with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-lb.

Capscrew Markings and Torque Values - Metric

Commercial Steel Class

8.8 10.9 12.9
Capscrew Head Markings

Body
Size Torque Torque Torque
Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm N^m ft-lb N^m ft-lb N^m ft-lb N^m ft-lb N^m ft-lb N^m ft-lb
6 9 5 7 4 12 9 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 25 18 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 60 45 30 25 70 50 30 25
12 80 60 55 40 105 75 55 40 125 95 55 40
14 125 90 90 65 165 122 90 65 195 145 90 65
16 180 130 140 100 240 175 140 100 290 210 140 100
18 230 170 180 135 320 240 180 135 400 290 180 135
Pipe Plug Torque Values
Page 52 M11

Capscrew Markings and Torque Values - U.S. Customary

SAE G rad e N u m b er 5 8
C ap screw H ead M arking s
T h e se are all SAE G rade 5 (3) line

©©S3
C apscrew Torque - G rad e 5 C apscrew C ap screw Torque - G rad e 8 C apscrew
crew B ody Size C ast Iron A lu m in u m C ast Iron A lu m in u m
N^m ft-lb N^m ft-lb N^m ft-lb N^m ft-lb
1/4 - 20 9 7 8 6 15 11 8 6
- 28 12 9 9 7 18 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
- 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
- 24 40 30 35 25 60 45 35 25
7/16 - 14 60 45 45 35 90 65 45 35
- 20 65 50 55 40 95 70 55 40
1/2 - 13 95 70 75 55 130 95 75 55
- 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
- 18 150 110 115 85 210 155 115 85
5/8 - 11 180 135 150 110 255 190 150 110
- 18 210 155 160 120 290 215 160 120
3/4 - 10 325 240 255 190 460 340 255 190
- 16 365 270 285 210 515 380 285 210
7/8 - 9 490 360 380 280 745 550 380 280
- 14 530 390 420 310 825 610 420 310
1 -8 720 530 570 420 1100 820 570 420
- 14 800 590 650 480 1200 890 650 480

Pipe Plug Torque Values

Size Torque Torque

In Cast Iron or
Thread Actual Thread O.D. In Aluminum Components Steel Components
in in N»m ft-lb N»m ft-lb
1/16 0.32 5 45 in-lb 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100
 Tap-Drill Chart - U.S. Customary & Metric
M11 Page 53

Tap-Drill Chart - U.S. Customary & Metric

NOTE ON SELECTING TAP-DRILL SIZES: The tap drill sizes shown on this card give the theoretical tap drill size for approxim ately 60%
and 75% of full thread depth. Generally, it is recom m ended that drill sizes be selected in the 60% range as these sizes w ill provide about
90% of the potential holding power. Drill sizes in the 75% range are recom m ended for shallow hole tapping (less than 1 1/2 tim es the hole
diam eter) in soft metals and mild steel.

Tap Size Drill Tap Size Drill Tap Size Drill Tap Size Drill
60% 75% Size 60% 75% Size 60 % 75% Size 60% 75% Size
48 4.40m m 7.50m m 13.25m m
1.95mm 12-24 16 19/64 5/8-11 17/32
5/64 4.50m m 7.60m m M 15x1.5 13.50m m
3-48 47 15 N M 15x1.5 13.75m m
2.00m m M 5.5x.9 4.60m m 7.70m m 5/8-11 35/64
M 2.5 x.45 2.05m m 12-24 12-28 14 M 9x1.25 7.75m m M 16x2 14.00m m
46 13 7.80m m 14.25m m
3-48 3056 45 4.70m m 7.90m m 5/8-18 9/16
2.10mm M 5.5 x.9 4.75m m 3/8-16 5/16 M 16x2 M 16x1.5 14.50m m
M 2.5x.45 M 2.6 x.45 2.15m m 12-28 3/16 M 9x1.25 M9x1 8.00m m 5/8-18 37/64
3-56 4-36 44 12 O 14.75m m
2.20m m 4.80m m 8.10m m M 16x1.5 15.00m m
M 2.6x.45 2.25m m 11 M9x1 8.20m m 19.32
4-36 4-40 43 4.90m m P 15.25m m
2.30m m 10 8.25m m 39/64
2.35m m 9 8.30m m M 17x1.5 15.50m m
4-40 4-48 42 M6x1 5.00m m 3/8-16 1/8-27NPT 21/64 M 17x1.5 M 18x2.5 15.75m m
3/32 8 8.40m m 5/8
M 3x.6 2.40m m 5.10m m 3/8-24 Q M 18x2.5 M 18x2 16.00m m
4-48 41 1/4-20 7 M 10x1.5 8.50m m M 18x2 16.25m m
2.45m m 13/64 8.60m m 3/4-10 41/64
40 6 R M 18x1.5 16.50m m
M 3x.6 M 3x.5 2.50m m M6x1 5.20m m 3/8-24 8.70m m 3/4-10 M 19x2.5 21/32
39 5 1/8-27NPT 11/32 M 18x1.5 16.75m m
5-40 38 M 6x.75 5.25m m M 10x1.25 8.75m m M 19x2.5 17.00m m
M 3x.5 2.60m m 5.30m m M 10x1.5 8.80m m 43/64
5-40 5-44 37 1/4-20 4 S 17.25m m
2.70m m M 6x.75 5.40m m 8.90m m 3/4-16 3/4-16 11/16
5-44 6-32 36 1/4-28 3 M 10x1.25 M10x1 9.00m m M 20x2.5 17.50m m
2.75m m 5.50m m T 17.75m m
7/64 7/32 9.10m m 45/64
35 5.60m m 23/64 M 20x2.5 M 20x2 18.00m m
2.80m m 1/4-28 2 M10x1 9.20m m M 20x2 18.25m m
34 5.70m m 9.30m m 23/32
6-32 6-40 33 5.75m m 7/16-14 U M 20x1.5 18.50m m
M 3.5x6 2.90m m 1 9.40m m 47/64
32 5.80m m M11x1.5 9.50m m M 20x1.5 18.75m m
M 3.5x6 3.00m m 5.90m m 3/8 19.00m m
6-40 31 A V 3/4
3.10m m 15/64 9.60m m 19.25m m
1/8 M7x1 6.00m m 9.70m m 7/8-9 49/64
3.20m m B 9.75m m M 22x2.5 19.50m m
M 4x.75 3.25m m 6.10m m M 11x1.5 9.80m m 7/8-9 25/32
30 C 7/16-14 W 19.75m m
M 4x.7 3.30m m M7x1 6.20m m 9.90m m M 22x2.5 M 22x2 20.00m m
M 4x.75 3.40m m D 7/16-20 25/64 7/8-14 51/64
M 4x.7 8-32 29 M 7x.75 6.25m m 10.00mm M 22x2 20.25m m
3.50m m 6.30m m 7/16-20 X M 22x1.5 20.50m m
8-36 28 E M 12x1.75 10.20mm 7/8-14 13/16
8-32 9/64 1/4 Y 20.75m m
3.60m m M 7x.75 6.40m m 13/32 M 22x1.5 M 24x3 21.00m m
8-36 27 6.50m m Z 53/64
3.70m m 5/16-18 F M 12x1.75 M 12x1.5 10.50mm 21/25m m
26 6.60m m 1/2-13 27/64 27/32
M 4.5 x.75 3.75m m G M 12x1.5 M 12x1.25 10.75mm M 24x3 21.50m m
10-24 25 6.70m m M 12x1.25 11.00mm 21.75m m
3.80m m 17/64 1/2-13 7/16 55/64
24 M 8x1.25 6.75m m 1/4-18NPT M 24x2 22.00m m
M 4.5x.75 3.90m m 5/16-18 H 11.25mm 1 -8 7/8
23 6.80m m 11.50mm M 24x2 22.25m m
5/32 6.90m m 29/64 M 24x1.5 22.50m m
10-24 22 5.16-24 I 11.75mm 1 -8 57/64
M5x1 4.00m m M 8x1.25 M8x1 7.00m m 11.50mm M 24x1.5 22.75m m
10-32 21 J 1/2-20 29/64 M 25x2 23.00m m
20 7.10m m 9/16-12 15/32 1 -12 29/32
M 5x.9 4.10m m 5/16-24 K M 14x2 12.00m M 25x2 23.25m m
M5x1 M 5x.8 4.20m m 9/32 12.25m m 1 x12 1 -14 59/64
10-32 19 M8x1 7.20m m 9/16-12 31/64 M 25x1.5 23.50m m
M 5x.9 4.25m m 7.25m m M 14x2 M 14x1.5 12.50m m M 20x1.5 23.75m m
M 5x.8 4.30m m 7.30m m 9/16-18 1/2 1 -14 15/16
18 L M 14x1.5 M 14x1.25 12.75m m
11/64 7.40m m M 14x1.25 13.00m m
17 M 9/16-18 33/64