Each cell has eight heat exchanger bundles in the default. The heat exchanger bundle consists of two-row staggered plat-finned flat tubes. Footprint Area: The plot area of the dry cooling system. That is a function of initial temperature difference between inlet steam and air and ambient pressure. Steam In: The total mass flow rate of the exhaust steam. That depends on the plant size and steam cycle heat rate.
Steam Temperature: The temperature of exhaust steam entering the air cooled condensers. That is empirically estimated in terms of the steam turbine back pressure.
Initial Temp. This variable significantly affects the performance and cost of the dry cooling system. The Capital Cost result screen displays tables for the direct and indirect capital costs related to the Air Cooled Condenser technology. Air-Cooled Condenser- Capital Cost Result Screen Capital costs are typically expressed in either constant or current dollars for a specified year, as shown on the bottom of the screen. Each result is described briefly below Direct Capital Costs Condenser Structure: This area deals with the cost of air cooled condenser equipments, erection and installation of the air cooled condensers at the site.
The cost of the ACC equipments is estimated as a function of initial temperature difference between inlet steam and air based on the cost data estimated by Electric Power Research Institute. Scream Duct Support: This area deals with the cost of steam duct support and column foundations.
Auxiliary Cooling: That deals with the cost of auxiliary cooling including separate fin-fan unit or others. Clearing System: That deals with the cost of clearing finned tube surfaces. That highly depends on the initial temperature difference between inlet steam and air. Disposal: Total cost to dispose the collected cleaning wastes.
Operating Labor: Operating labor cost is based on the operating labor rate, the number of personnel required to operate the plant per eighthour shift, and the average number of shifts per day over 40 hours per week and 52 weeks. The Total Cost result screen displays a table which totals the annual fixed, variable, operations and maintenance, and capital costs associated with the Air Cooled Condenser technology.
Air Cooled Condenser- Total Cost Result Screen Cost Component Total costs are typically expressed in either constant or current dollars for a specified year, as shown on the bottom of the screen.
Makeup Water System Results This screen is only available for pulverized coal power plants. Major outputs are briefly described below. Makeup Water Result Screen Plant Inlet: this variable presents the total amount of makeup water required by the plant for boiler, cooling system, bottom ash sluice, fly ash sluice, FGD, and carbon capture system if applicable.
Cooling Makeup: This variable presents the amount of makeup water for the cooling system. There is no makeup water required for oncethrough and air cooled condenser systems.
For the wet cooling tower, the makeup water is required to supplement the evaporation, blowdown and drift losses. Ash Sluice: This variable presents the amount of makeup water used for sluicing bottom ash that is collected at the bottom of the boiler.
In a wet sluicing system, bottom ash is sluiced with water and transported to a bottom ash pond where the ash settles in the pond.
There may no need of makeup water to sluice bottom ash as the blowdown from the wet tower and bottom ash pond overflow can be reused as sluice water. CE-ESP Sluice: This variable presents the amount of makeup water used for sluicing fly ash that is entrained in the flue gas and removed by air pollution control system equipment such as ESP. There may no need of makeup water to sluice fly ash as the blowdown from the wet tower and bottom ash pond overflow can be reused as sluice water.
FGD Makeup: The variable presents the amount of makeup water needed to replace the evaporated water in the reagent sluice circulation stream. CCS Makeup: The variable presents the amount of makeup water needed to replace the loss from contact cooler evaporation, dilute the makeup MEA, and supplement the reclaimer loss when amine-based capture system is used. Water Consumption Results This screen is only available for pulverized coal power plants. This screen summarizes water consumption across the entire plant.
Wet Tower Evap. CCS Evaporation: This variable presents the amount of evaporation loss in direct contact cooler when the amine-based capture system is loaded. Taxes Inputs Natural Gas Costs Gas Properties Input Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof.
The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. Purpose The product of this work is a desktop computer model that allows different technology options to be evaluated systematically at the level of an individual plant or facility.
The model takes into account not only avoided carbon emissions, but also the impacts on multi-pollutant emissions, plant-level resource requirements, costs capital, operating, and maintenance , and net plant efficiency. In addition, uncertainties and technological risks also can be explicitly characterized. The modeling framework is designed to support a variety of technology assessment and strategic planning activities by DOE and other organizations.
The model currently includes four types of fossil fuel power plants: a pulverized coal PC plant, a natural gas-fired combined cycle NGCC plant, a coal-based integrated gasification combined cycle IGCC plant, and an oxyfuel combustion plant. Each plant can be modeled with or without CO2 capture and storage.
The IECM-cs can thus be employed to quantify the costs and emission reduction benefits of CCS for a particular system or to identify the most cost-effective option for a given application. A Graphical User Interface GUI facilitates the configuration of the technologies, entry of data, and retrieval of results.
As many as one hundred input parameters can be assigned probability distributions. When input parameters are uncertain, an uncertainty distribution of results is returned. Such result distributions give the likelihood of a particular value, in contrast to conventional single-value estimates. The model can run using single deterministic values or uncertainty distributions. The conventional deterministic form using single values for all input parameters and results may be used, or probabilistic analyses may be run—for instance, to analyze advanced technology costs see Appendix A for more details.
This language provides the flexibility to configure many various power plant designs while also providing the power to conduct probabilistic analyses.
This format is a software industry standard and facilitates sharing and updating of information. The interface eliminates the need to master the underlying commands normally required for model operation.
Wise for Windows Installer was used to generate full installer programs. The Visual Basic runtime libraries provide the support needed to run the database file compactor program provided with the IECM. The taskbar, part of the Windows operating system, reduces the useable resolution of the screen if it is always visible. This may force the IECM interface to be scaled down slightly.
This is installed with the full installer for the IECM. NET 9. All Rights Reserved. Spread 6. Tab Pro 3. Graphics Server 6. Microsoft Visual Studio. NET 7. NET Framework 1. Wise for Windows Installer 6. Microsoft Data Access Components 2. Spread is a trademark of FarPoint Technologies, Inc. It provides detailed descriptions of plant configurations, parameter settings, and result screens. Technical Manuals The Technical manuals are detailed engineering descriptions of the technologies and costing assumptions used in the IECM.
This opens the help file to the table of contents. The IECM supports context-sensitive help and will open the help file to the topic associated with the item or screen you are viewing. Select Help Topics. If this method does not work, try one of the other options above.
This section addresses installation from a network drive or the worldwide web. This section also describes advanced features of the installation program and the files installed.
Local and Network Installation The Setup program can be run from a local hard drive or a network server. Installing from a network server simplifies the process of installing the entire package on a series of personal computers connected to the network. However, both methods require some familiarity with creating and finding folders and sub-directories on a network hard drive.
NOTE: You may also install the interface to a network server. All files will be loaded to the server except the shortcut in the start menu of the local personal computer. The interface will run from the server and all sessions will be saved to the network drive, meaning that others with access to the network drive may change or delete them.
Installation to a network server is not currently supported. On the personal computer, click the Start button. Choose Run… from the Start menu. The Installation Program will begin. Follow the instructions on the screen.
If you receive an error message while running Setup, restart your computer and run the installation program again. If Setup still returns an error message, call Technical Support. The media, documentation and various text files can be downloaded to your local computer or network hard drive.
Open a web browser program e. You will see the iecm— download page. A dialog box will appear. File download dialog box; save the program to disk 5. Click on the Save button. Choose a location to save the setup file and click the "Save" button.
File download progress indicator The download will begin. Once it is finished, you can proceed to install the IECM software. If you receive an error message while running the install program, restart your computer and run the installation program again. File download dialog box; run the program directly 4.
Click on the Run button. The installer program will download to a temporary location on your hard drive. Once it is finished, the installer program will automatically proceed to install the IECM software.
If it still returns an error message, contact Technical Support. Once the installer program is completed, it will be deleted from the temporary location on your hard drive. The software is divided into three categories. Program Files All applications and their support files specific to the IECM software itself are considered program files.
These can be installed into any directory during installation. The folder can be changed from the default location suggested during installation. It handles all database, uncertainty and model access. MDB: Microsoft Access 97 template database file.
It handles all uncertainty sampling. It contains all the technology performance and cost modules. EXE: Uninstaller program. This requires an installer log created during installation. These contain default data used in the interface program. The following files are installed by the installation program: Intdesc. It contains all the descriptions for the IECM interface screens.
It contains the model default coal information. All user data associated with sessions are stored here. These files are not created by the installation program; rather, they are created by the IECM Interface at runtime if they are not available.
This means that user data cannot be overwritten by the installation program. System Files Several files are installed into the windows system directory. These system files are common to many Windows applications. These system files are unique to the other IECM components listed above because they are hardwired into the system registry file. In order to maintain consistency with the operating system and stability with the IECM interface, these special system files must be stored in the windows system directory and installed with software installers directly from Microsoft.
ODBC is a programming interface that enables applications to access data in database management systems that use Structured Query Language SQL as a data access standard. Microsoft Visual Basic 4. Microsoft MFC 4. Combustion, postcombustion, and solids management controls must be configured by the user. The following sections describe each popup menu on the configuration screen. Pre-configuration settings can be selected using the Configuration menu at the top of the screen.
No Devices is the default. Combustion Controls These configuration options determine the type of furnace and any technologies for reducing NOx emissions. These options are selected from a pull-down menu in the Set Parameters menu Post-Combustion Controls These configuration options determine the presence and type of post-combustion emissions controls.
NOx Control: The default option is None. Although an SCR technology can be positioned at various points along the flue gas train, the IECM considers only the hot-side, high dust configuration. Particulates: The default option is None. This assures the removal of the carbon being injected immediately downstream of the air preheater. Multiple fabric filter types are provided. Fabric filter types are based on the bag cleaning techniques used. Various bag-cleaning techniques influence other process parameters.
The choice of the bag cleaning method is usually based on the type of coal used—and therefore the filterability of the ash—and your experience with filtering the particular kind of ash. The amount of filtered gas used is smaller than that used in Reverse Gas cleaning.
Wire support cages are used to prevent bag collapse during filtration and ash is collected outside of the bags. SO2 Control: The default option is None. Multiple reagent options are available under the SO2 Control tab in the Set Parameters section of the interface. The interfact places this technology before the particulate control technology in the plant design and diagrams.
Mercury: The default option is None. Other options are only available if a particulate control is configured. It is believed that some mercury is captured or trapped in ash and is removed with bottom ash and fly ash.
Carbon injection is provided as a technology to achieve higher removals by injecting fine particles of activated carbon into the flue gas after the air preheater. CO2 Capture: The default option is None. The following choices available are: None: for no CO2 capture. Other locations may be available in the future. Fly ash collected from a particulate removal system is typically combined with other solid waste streams if other waste streams exist.
The waste disposal option has little effect on the rest of the IECM. The choices are No Mixing: for no flyash mixing. This option disposes the flyash separately. Configuring the Combustion Turbine Plant The following configuration options are available when the Combustion Turbine is selected as the plant type from the New Session pull down menu. Configure Plant — Combustion Turbine input screen.
Only post-combustion controls can be configured by the user. The figure above shows the base configuration of the IGCC plant. Gasification, postcombustion, and solids management controls can be configured by the user. Base GE Quench is the default.
Gasification Options Gasifier: There is a pull down menu so that the user may select the gasifier type. Gas Cleanup: This menu will be used in the future to allow a user to select a suite of gas cleanup technologies. Particular devices for removing solids and sulfur while altering the syngas temperature are loaded with this menu.
CO2 Capture: The default is None. The user may select from the CO2 Capture pull down menu whether or not to capture CO2 and the method of capture. Solids Management Slag: Landfill is the default. This option is the only one currently available in the model. This option is grayed out in the pull down menu and may be available in a future release of the model.
These screens apply to the power plant as a whole, not to specific technologies. The screen displays the plant configuration settings on the left side of the page and a diagram of the configured plant on the right of the page.
No input parameters or results are displayed on this screen. The parameters available on this screen establish the plant availability, electrical requirements, and ambient conditions for the power plant. These parameters have a major impact on the performance and costs of each of the individual technologies. Capacity Factor: This is an annual average value, representing the percent of equivalent full load operation during a year.
The capacity factor is used to calculate annual average emissions and materials flows. The value does not include auxiliary power requirements. The model uses this information to calculate key mass flow rates.
The value here is shown for reference only. The value can be changed for a combustion plant by navigating to the Base Plant Performance Inputs page 95 screen. Net Electrical Output: This is the net plant capacity, which is the gross plant capacity minus the losses due to plant equipment and pollution equipment energy penalties. The value cannot be changed and is shown for reference only. Ambient Air Temperature: This is the inlet temperature of the ambient combustion air prior to entering the preheater.
The model presumes an annual average temperature. Inlet air temperature affects the boiler energy balance and efficiency. It provides a reference point for the calculation of pressure throughout the system.
Currently, the model cannot have temperatures below 77oF. Ambient Air Pressure: This is the absolute pressure of the air inlet stream to the boiler. The air pressure is used to convert flue gas molar flow rates to volume flow rates. This value is used in calculating the total water vapor content of the flue gas stream.
The value is referred to as the specific humidity ratio, expressed as a ratio of the water mass to the dry air mass. Combustion Overall Plant Constraints Inputs The Constraints input parameters define the emission constraints as they apply to the gases emitted from the power plant.
Overall Plant — Emission Constraints input screen. This screen accepts input for the allowable emission limits for sulfur dioxide, nitrogen oxides and particulate matter. Mercury and carbon dioxide are constrained by their removal efficiencies across the entire plant. SO2 emission limits are based on the NSPS limits that are a function of the sulfur content of the coal. The emission constraints determine the removal efficiencies of control systems for SO2, NOx, and particulate matter required to comply with the specified emission constraints.
As discussed later, however, user-specified values for control technology performance may cause the plant to over-comply or under-comply with the emission constraints specified in this screen. The calculated value is determined by the potential emission of the raw coal, minus the amount of sulfur retained in the ash streams.
The emission limit is dependent on the fuel type and is used to determine the removal efficiency of SOx control systems. The limit is a function of the coal rank and fuel type and is used to determine the removal efficiency of NOx control systems. The limit is a function of the fuel type and is used to determine the removal efficiency of particulate control systems.
Total Mercury Removal Constraint: The emission constraint of total after the economizer. Mercury removed in the furnace due to bottom ash removal is not considered in this constraint. The limit determines the removal efficiency of the particulate control systems.
Total CO2 Removal Constraint: The emission constraint applies to all the air emission sources in the power plant, primary or secondary. The default value is based on recent discussions and is not based on any currently enforced law. Combustion Overall Plant Financing Inputs Inputs for the financing costs of the base plant itself are entered on the Financing input screen. Overall Plant—Financing input screen. This screen describes the factors required to determine the carrying charge for all capital investments.
The carrying charge is defined as the revenue required for the capital investment. The total charge can also be expressed as a levelized cost factor or fixed charge factor.
The fixed charge factor is a function of many items. The fixed charge factor can be specified directly or calculated from the other input quantities below it on the financial input screen. Year Costs Reported: This is the year in which all costs are given or displayed, both in the input screens and the results. The cost year is reported on every input and result screen associated with costs throughout the interface. Constant or Current Dollars: Constant dollar analysis does not include the affect of inflation, although real escalation is included.
Current dollar analysis includes inflation and real escalation. This choice allows you to choose the mode of analysis for the entire IECM economics. The cost basis is reported on every input and result screen associated with costs throughout the interface. Discount Rate Before Taxes : This is also known as the cost of money. Discount rate before taxes is equal to the sum of return on debt plus return on equity, and is the time value of money used in before-tax present worth arithmetic i.
It determines the revenue required to finance the power plant based on the capital expenditures. Put another way, it is a levelized factor which accounts for the revenue per dollar of total plant cost that must be collected from customers in order to pay the carrying charges on that capital investment. One may specify a fixed charge factor, or fill in the following inputs and the model will calculate the FCF based on them: Inflation Rate: This is the rise in price levels caused by an increase in the available currency and credit without a proportionate increase in available goods or services.
It does not include real escalation. Plant or Project Book Life: This is the years of service expected from a capital investment. It is also the period over which an investment is recovered through book depreciation. Real Bond Interest Rate: This is a debt security associated with a loan or mortgage. It is the most secure form of security but the lowest in its return. Real Preferred Stock Return: This equity security is the second most speculative type and pays the second highest rate of return.
The holder of the stock is a part owner of the company. Real Common Stock Return: This is the most speculative type of equity security sold by a utility and pays the highest relative return. Percent Debt: This is the percent of the total capitalization that is associated with debt money. This includes loans and mortgage bonds. Percent Equity Preferred Stock : This is the percent of the total capitalization that is associated with the sale of preferred stock. Federal Tax Rate: This is the federal tax rate.
It is used to calculate the amount of taxes paid and deferred. When will it arrive? Zip Code: Update Delivery Dates. Made in USA. Capacity: 10 Round. Notify Me when available. Add product to Wish List. Beverage Dispenser Manuals.
Blender Manuals. Blower Manuals. Boiler Manuals. Bread Maker Manuals. Camper Manuals. Camping Equipment Manuals. Car Stereo System Manuals. Carpet Cleaner Manuals. Charcoal Grill Manuals. Clothes Dryer Manuals. Coffeemaker Manuals. Computer Hardware Manuals. Convection Oven Manuals. Replace the bearing if necessary. Use dial indicator, Part No.
If nicks or burrs cannot be removed with fine crocus cloth, the cap and bearings must be replaced. Measure the thrust bearing thickness and replace the bearings if they are not within specifications. Crankshaft Thrust Bearing Thickness mm in 4.
Compress the spring to Install the valve disc 4 , washer 3 and regulator spring 2. Use plug driver, Part No. Measure the retainer plug depth in the cylinder block.
Relief Valve Retainer Installed Depth mm in 8. Viscosity Sensor - Installation Install the viscosity sensor in the cylinder block. Regulator Spring Free Length mm in Use a spring compression tester to determine if the spring is defective.
Replace the spring with a new spring if it is defective. Warning: The regulator spring must be compressed to install the retainer plug 1. NOTE: A counterbore plunger and orifice is unique to engines with a viscosity sensor. Low oil pressure will result if a solid plunger is used with a viscosity sensor. Install the plunger 3 and spring 2. Install and tighten the retainer plug 1.
Flywheel Housing - Installation Measure the inside diameter of the housing bore to determine the SAE number and size of the housing being used.
Flywheel Housing Maximum Bore I. Section 0 - Engine Disassembly and Assembly - Group 00 M11 Rotate the engine on the rebuild stand to position the cylinder head mounting surface facing up. Install the flywheel housing over the guide pins. Install the ten capscrews M Remove the guide pins and install the remaining two capscrews M NOTE: This is not the final torque value. The flywheel housing bore must be aligned with the crankshaft. The capscrews will be tightened to the final torque value after the flywheel housing is aligned.
This component weighs 23 kg [50 lb] or more. Install the five of the seven long capscrews M Remove the two guide pins and install the two remaining M Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the four alignment plate capscrews and the alignment plate. ST, must be spaced out from the flywheel and longer mounting capscrews used. An alternative method is to use a magnetic base with the dial indicator gauge.
Use dial indicator gauge, Part No. ST, 2 to measure the bore alignment. Install the attachment and gauge as shown. Install the engine barring tool, Part No. Rotate the crankshaft one complete revolution degrees and record the TIR. If the maximum bore alignment does not meet the specifications, use a mallet to move the housing in the necessary direction.
NOTE: If the bore alignment is not within specifications and the bore is not round, the housing must be replaced. Flywheel Housing Face Alignment - Measurement Caution: If the tip of the gauge enters the capscrew holes, the gauge will be damaged. Position the contact tip of the gauge against the flywheel housing face. Push the crankshaft toward the front of the engine.
Rotate the crankshaft one complete revolution degrees while keeping the crankshaft end thrust pushed forward, and record the TIR. If the maximum face alignment does not meet the specifications, check for nicks, burrs and foreign material between the cylinder block mounting face and the flywheel housing mounting surface.
If none is found, the housing must be replaced. If it does not meet these specifications, the bore and face must be realigned. Measure the bore and face alignment again. NOTE: If the bore and face alignment does not meet the specification, loosen the housing capscrews, tighten the capscrews again, and measure the bore and face alignment again. Remove the barring tool and flywheel housing alignment measuring tool from the crankshaft.
Apply LubriplateW , or equivalent, on the outer races and the bearings. NOTE: The outer bearing races of new replacement gears are already pressed into the gear. Install the bearing and spacer into the idler gear. Use the manufactured sleeve to hold the bearing assembly together when installing the idler gear assembly. Apply a thin film of LubriplateW , or equivalent, into the idler shaft bore of the housing and on the idler shaft.
Install the idler gear assembly into the flywheel housing. Hold the idler gear and bearings in place and remove the plastic sleeve. Caution: Do not use a hammer when installing the idler shaft and capscrew, or the part can be damaged. Hold the gear assembly in place and insert the idler shaft through the housing and idler gear bearings. If the gear does not turn freely, it can indicate misalignment between the bore and the shaft. Remove the idler shaft and install it again. Apply LubriplateW under the head of the idler shaft capscrew.
Insert the capscrew through the idler shaft. Tighten the installation capscrew to draw the shaft into the bore. After the idler shaft has been seated, remove the capscrew. Apply pipe sealant, Part No. Apply LubriplateW under the head of the capscrew. Install the capscrew and tighten to its final torque value. NOTE: New cup plugs must be used. Do not use the cup plugs that were removed from the housing. Apply a film of cup plug sealant, Part No. Use driver, Part No. Make sure the crankshaft and crankshaft gear are clean.
Install the crankshaft gear on the guide pins. Use flat washers as a spacer and install the gear with two capscrews M Mount the gauge so the tip of the gauge is reading at the outmost edge of the output shaft.
The oil seal must be installed with the lip of the seal and the crankshaft clean and dry to provide a proper oil sealing surface. Use the installation sleeve provided with the seal to install the seal and gasket on the crankshaft. Install clamping ring using the 12 capscrews M Tighten in a star pattern. Torque Value:. Place a light film of oil or anti-freeze on the inside diameter of the dust seal. Install the dust seal on the crankshaft with the larger outside diameter facing toward the engine.
Push the dust seal back by hand on the crankshaft until the entire dust seal contacts the oil seal case. Flywheel - Installation Install one guide pin, Part No.
The crankshaft flange must be clean and free of damage. Install the flywheel on the guide pin. Caution: Capscrew length is critical. Capscrews of different length can result in loss of flywheel integrity that can cause engine damager and personal injury. Tighten the capscrews in a star pattern. ST, to check the flywheel bore 3 and face 4 runout. Install the attachment to the flywheel housing.
Install the gauge on the attachment. Install the contact tip of the indicator against the inside diameter of the flywheel bore. The maximum TIR must not exceed 0. Install the flywheel and tighten the capscrews to the correct torque value. Measure the bore runout again. Flywheel Face Runout - Measurement Install the contact tip of the indicator against the flywheel face as close as possible to the outside diameter to measure the face 4 runout. Push the flywheel forward to remove the crankshaft end thrust.
Rotate the crankshaft one complete revolution degrees while keeping the crankshaft end thrust pushed forward. The maximum TIR must not exceed the following specifications.
Piston and Connecting Rod - Assembly Articulated Piston The retainer snap ring must be seated completely in the piston pin groove to prevent engine damage during engine operation.
Install a new snap ring in one piston pin bore of each piston skirt. Position the skirt over the piston crown. NOTE: It is not necessary to heat the articulated pistons before assembly. The piston pin is slip fit. Caution: Do not use a hammer to install the piston pin. Align the pin bore of the rod with the pin bore of the piston skirt and crown, and install the piston pin.
The snap ring must be seated completely in the piston groove to prevent engine damage during engine operation.
Install a new snap ring in the piston pin bore. A cross sectional view of an oil control ring is shown. The two-piece oil control ring must be installed with the expander ring gap degrees from the gap of the oil ring.
Do not overlap the ends of the expander ring. ST, to install the rings on the piston. The top piston ring is a positive twist design that has a cutback notch on the top side of the ring. The intermediate ring is a negative twist design with a cutback notch on the bottom side and a two degree taper face.
It also has a black phosphate coating which helps to readily distinguish it from the top ring. Do not lubricate the back of the bearing shells. The operating clearance of the bearing will be reduced and the bearing can be damaged during engine operation.
If new bearings are not used, the used bearings must be installed on the same connecting rod from which they were removed. Install the upper bearing shell into the connecting rod. The tang of the bearing shell 1 must be in the slot of the rod 2. The end of the bearing shell must be even with the cap mounting surface. Use LubriplateW , or equivalent, to coat the bearing shell. Apply a heavy film of 15W oil to the cylinder liner bore. Remove the piston and ring assembly from the container and let the excess oil drain from the piston.
Rotate the rings to position the ring gaps as shown. NOTE: The ring gap of each ring must not be aligned with the piston pin or with any other ring gap. If the ring gaps are not aligned correctly, the rings will not seal properly. Install the connecting rod guide pins, Part No. Use piston ring compressor, Part No.
Rotate the crankshaft so the connecting rod journal of the connecting rod being installed is at bottom dead center. Insert the connecting rod through the cylinder liner until the ring compressor contacts the top of the liner. The piston, rings or cylinder liner can be damaged. Hold the ring compressor against the cylinder block. Push the piston through the ring compressor and into the cylinder liner. Push the piston until the top ring is completely inside the cylinder liner.
NOTE: If the piston does not move freely, remove the piston and inspect for broken or damaged rings. Use the nylon guide pins to align the connecting rod with the crankshaft while pushing the piston and rod assembly in place.
Remove the nylon guide pins. Install the bearing in the connecting rod cap. The tang of the bearing 2 must be in the slot of the cap 1. Use LubriplateW , or equivalent, to coat the inside diameter of the bearing shell. Use clean 15W oil to coat the connecting rod capscrews. The connecting rod and cap must have the same number, and must be installed in the proper cylinder. The connecting rod cap and rod number must be on the same side of the connecting rod to prevent engine damage during engine operation.
Install the connecting rod caps and capscrews. Section 0 - Engine Disassembly and Assembly - Group 00 M11 Complete the following steps to tighten the capscrews in alternating sequence: Torque Value:. Connecting Rod Side Clearance Measurement Use a feeler gauge to measure the connecting rod side clearance. Piston Cooling Nozzle - Installation The piston and connecting rod assemblies must be installed before the piston cooling nozzles are installed.
Rotate the crankshaft to position the connecting rod journal toward the exhaust side of the engine. Install the nozzles and the special capscrews.
The nozzle must be in alignment with the center of the notch in the piston skirt 1. NOTE: Rotate the crankshaft to be sure the pistons do not hit the nozzles. If the pistons hit the nozzles, the nozzles and engine will be damaged during engine operation. Gear Housing - Installation Caution: Avoid the use of excessive amounts of sealant which could result in blocked oil passages in the engine. Install a new o-ring, Part No. Be sure to keep sealant from the hole. NOTE: Sealant requires assembly in ten minutes or less.
It is best to apply the sealant and then immediately assemble the parts. Apply a bead of silicone sealant, Part No. Apply additional sealant in the area shown in the graphic. Install the gear housing and 10 capscrews M Install five capscrews M Remove the two guide pins and install the two remaining capscrews M Tighten the capscrews in the sequence shown.
Measure the gear housing protrusion below the oil pan rail. The maximum allowable protrusion is 0. If the protrusion is beyond the allowable limit, remove the housing and check the idler gear dowel pin O.
Lubricating Oil Pan - Installation Rotate the engine on the rebuild stand. If a front sump aluminum oil pan is used, install the spring clip on the oil transfer tube. Install a new o-ring s on the oil transfer tube. Use clean 15W oil to lubricate the o-rings. Install the oil transfer tube into the oil pan on rear sump oil pans.
On front sump aluminum oil pans, install the straight transfer tube into the cylinder block. On front sump oil pans with block mounted suction tube, install the suction into the cylinder block by hand. Install the retaining capscrew. Install and tighten the 32 capscrews M Camshaft and Gear Assembly - Installation Use LubriplateW , or equivalent, to coat the camshaft bushings and camshaft.
Install the camshaft installation pilot, Part No. Section 0 - Engine Disassembly and Assembly - Group 00 M11 Rotate the camshaft slowly as it is being installed into the cylinder block. Rotate the camshaft to align the holes in the camshaft gear with the thrust plate capscrew holes in the cylinder block. Align the capscrew holes in the thrust plate with the cylinder block capscrew holes. Install the two capscrews M Use a new gasket and install the camshaft rear cover plate.
Tighten the three capscrews M Use a dial indicator gauge and a magnetic base to measure the camshaft end clearance. Place the contact tip of the gauge against the face of the gear. Camshaft End Clearance mm in.
The o-rings will swell and the pump cannot be installed. Install two new o-rings on the oil pump body. Install the thickest o-ring into the groove nearest to the oil pump drive gear. Use clean 15W oil to lubricate the oil pump gears. Apply a film of LubriplateW to the oil pump bore in the cylinder block. NOTE: Be sure the threaded oil pump mounting holes in the cylinder block are clean and free of oil or dirt.
If they are not, use solvent to clean them before installing the oil pump. Caution: The dowel pin bore in the oil pump flange 1 must be aligned with the dowel pin 2 in the cylinder block to prevent damage to the oil pump flange during installation. Do not use the mounting capscrews to pull the oil pump into the bore. This can damage the mounting flange of the oil pump.
Install the oil pump by hand. Sealant, Part No. Caution: The shorter flange head capscrew must be used in the upper right hand mounting hole 1 to prevent the idler gear from contacting the head of the capscrew and causing damage to the lubricating oil pump.
Install the three capscrews and spacers. Use the short flange head capscrew in the upper right hand mounting hole 1. Use the longer flange head capscrews and spacers in the other two holes.
ST and a magnetic base, Part No. Place the contact tip of the gauge against the face of the oil pump drive gear. Hydraulic Pump Drive - Installation Use LubriplateW , or equivalent, to lubricate the front and rear needle bearings. Install the shaft and gear assembly so the internal splines of the shaft are facing away from the gear housing and toward the rear of the engine. Install a new o-ring on the hydraulic drive adapter. Lubricate the o-ring with clean 15W oil.
Lubricate the hydraulic drive adapter bore with clean 15W oil. Align the hydraulic drive adapter over the shaft and gear assembly. Start the three mounting capscrews M Use a rubber mallet to install the adapter. NOTE: Use care not to damage the o-ring during installation. Tighten the mounting capscrews. Use dial indicator assembly, Part No. ST, and a magnetic base, Part No.
Use a new gasket and install the hydraulic pump, if equipped, or the cover plate. Install the two mounting capscrews M Use a new gasket and install the accessory drive assembly. The capscrew located in the lower corner nearest the cylinder block 1 must be installed with a new copper sealing washer and sealant, Part No. Install the five capscrews M The camshaft idler gear assembly includes a wear plate 9. The marks on the idler gears should match the same mark on each of the other gears.
Use LubriplateW , or equivalent, to lubricate the wear plate, thrust bearing and idler gear. Install the camshaft idler gear wear plate 9.
Caution: The grooved side of the rear thrust bearing must be facing toward the gear to prevent damage to the gear and engine during engine operation. Install the idler gear shaft 8 and rear thrust bearing 7. Section 0 - Engine Disassembly and Assembly - Group 00 M11 Caution: The grooved side of the front thrust bearing must be facing toward the gear to prevent damage to the gear and engine during engine operation.
Align the timing marks and install the idler gear 6 , front thrust bearing 5 and gear retainer 4. Install the three retaining capscrews M Hydraulic Drive Idler - Installation Use LubriplateW , or equivalent, to lubricate the thrust bearing and idler gear. Caution: The grooved side of the front thrust bearing must be facing toward the gear to prevent damage to the gear and engine during engine operation. Install the idler gear 6 and front thrust bearing 5. Install the gear retainer 4.
Use LubriplateW , or equivalent, to lubricate the thrust bearings and idler gear shaft. Install the rear thrust bearing. Install the idler gear without the shaft. The shaft must pass through the gear and pilot into the rear thrust bearing. After installation, the shaft must protrude only slightly more than the thickness of the front thrust bearing. Excessive shaft protrusion beyond the thickness of the front thrust bearing indicates that the shaft is not properly piloted into the rear thrust bearing.
Install the shaft into the gear bore. Install the front thrust bearing. Install the gear retainer. Use a dial indicator gauge assembly, Part No. Place the contact tip of the gauge against the face of the idler gear.
Use the dial indicator gauge with the magnetic base to measure the idler gear backlash.
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