Vous êtes sur la page 1sur 30

CATERPILLAR

SENR5545-04
October 2001

3064 and 3 0 6 6 Engines for Caterpillar


sy Built Machines
6LK1-Up (Engine)
7JK1-Up (Engine)

Important Safety Information


Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

WARNING
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

WARNING
When replacement parts are required for this
product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.

3
Table of Contents

Table of Contents
Specifications Section
Engine Design
Fuel Injection Lines
Fuel Injection Pump
Fuel Injection Nozzles
Lifter Group
Rocker Shaft
Valve Mechanism
Vafve Mechanism Cover
Cylinder Head
Turbocharger
Exhaust Manifold
Camshaft
Engine Oil Relief Valve
Engine Oil Pump
Engine Oil Pressure
Engine Oil Bypass Valve
Engine Oil Pan
Water Temperature Regulator
Water Pump
Cylinder Block
Crankshaft
Crankshaft Seals
Connecting Rod Bearing Journal
Main Bearing Journal
Connecting Rod
Piston and Rings
Gear Group (Front)
Flywheel
Crankshaft Pulley
Belt Tension Chart
Belt Tightener
Alternator and Regulator
Electric Starting Motor
Coolant Temperature Switch
Engine Oil Pressure Switch
Air Inlet Heater

4
5
5
6
6
7
8
9
9
10
11
12
13
14
15
15
16
16
16
17
18
20
20
21
21
23
25
26
27
27
28
28
29
29
29
29

Index Section
index

30

4
Specifications Section

Specifications Section

The crankshaft rotation is viewed from the


flywheel end of the engine. Crankshaft
rotation
Counterclockwise

Engine Design

Note: The front end of the engine is opposite of


the flywheel end of the engine. The left side of the
engine and the right side of the engine are viewed
from the flywheel end of the engine. The No. 1
cylinder is the front cylinder.

SMCSCode: 1201

3064 Engine
3066 Engine

Illustration 1

g00523889

Cylinder and valve location

Illustration 2

(A) Exhaust valve

Cylinder and valve location

(B) Inlet valve

(A) Exhaust valve

g00295223

(B) Inlet valve

Type
Combustion system

Four cylinder and four stroke


Direct injection

Bore

102 mm (4.02 inch)

Stroke

130 mm (5.12 inch)

Number of cylinders
Displacement
Cylinder arrangement

Type
Combustion system

102 mm (4.02 inch)

Stroke

130 mm (5.12 inch)

4
4.3 L (260 in3)
In-line

Number of cylinders
Displacement

In-line
2
1-5-3-6-2-4

17:1

Note: Refer to the Engine Information Plate for the


performance specification number. Refer to the
Technical Marketing Information (TMI) or refer to the
Fuel Setting and Related Information Microfiche for
the correct timing specifications.
Minimum rpm

6.4 L (390 in3)

1 -3-4-2
Firing order

Compression ratio

2
Valves per cylinder

Firing order

Direct injection

Bore

Cylinder arrangement
Valves per cylinder

Six cylinder and four stroke

Compression ratio

17:1

Note: Refer to the Engine Information Plate for the


performance specification number. Refer to the
Technical Marketing Information (TMI) or refer to the
Fuel Setting and Related Information Microfiche for
the correct timing specifications.

900 20
Minimum rpm

900 20

5
Specifications Section

The crankshaft rotation is viewed from the


flywheel end of the engine. Crankshaft
rotation
Counterclockwise
Note: The front end of the engine is opposite of
the flywheel end of the engine. The left side of the
engine and the right side of the engine are viewed
from the flywheel end of the engine. The No. 1
cylinder is the front cylinder.

Fuel Injection Pump


SMCSCode: 1251; 1290

Fuel Injection Lines


SMCSCode: 1252

Illustration 4

(1) Bolts for fuel injection line


Illustration 3

(1) Fuel injection lines


Tighten the fuel injection line nuts to the
following torque
29 3 N-m (21 2 lb ft)

Tighten the bolts for the fuel injection line to the


following torque
20 to 25 N-m (15 to 18 lb ft)
(2) Delivery valve holder
Tighten the delivery valve holder to the following
torque
39 to 44 N-m (29 to 32 lb ft)
(3) Bolt for lock plate
Tighten the bolt for the lock plate to the following
torque
3 to 5 N-m (27 to 44 lb in)
(4) Bolt for fuel line
Tighten the bolt for the fuel line to the following
torque
10 to 13 N-m (7 to 10 lb ft)
(5) Idler subspring nut
Tighten the idler subspring nut to the following
torque
12 to 16 N-m (9 to 12 lb ft)
(6) Idler subspring
Tighten the idler subspring to the following
torque
16 to 20 N-m (12 to 15 lb ft)
(7) Nut
Tighten the nut to the following
torque
3 to 5 N-m (27 to 44 lb in)

6
Specifications Section

(6) Pressure spring

Fuel Injection Nozzles

(7) Pressure pin

SMCSCode: 1254

(8) Gasket
(9) Pin
(10) Tip for fuel injection nozzle
(11) Retaining nut for fuel injection nozzle
Tighten the nut to the following
torque
34 + 5 N-m (25 4 lb ft)

Lifter Group
Illustration 5

g00530280

SMCSCode: 1209

(1) Seal
(2) Fuel injection nozzle
(3) Retainer for fuel injection nozzle
Tighten the retaining bolt to the following
torque
22 N.m (16 lb ft)

Illustration 7

(10) Tappet bore diameter


Tappet bore diameter

22.000 to 22.021 mm
(0.8661 to 0.8670 inch)

Maximum tappet bore diameter

22.055 mm
(0.8683 inch)

Clearance of tappet to bore.. 0.035 to 0.086 mm


(0.0014 to 0.0034 inch)
Note: Replace the tappet if the clearance is
exceeded.
Illustration 6

(4) Body for fuel injection nozzle


(5) Shims
Increasing shims by 0.10 mm (0.004 inch) changes
injection pressure by approximately 1375 kPa
(200 psi). Shims are available in nine sizes from
0.10 mm (0.004 inch) to 0.58 mm (0.023 inch).

7
Specifications Section

Rocker Shaft
SHCS Code: 1102

Illustration 10

Position the rocker shaft brackets and mounting


bolts.
lflustration8

(1) Rocker arm bushing


Bore in rocker arm bushing for
shaft
20.011 to 20.094 mm
(0.7878 to 0.7911 inch)
(2) Rocker arm shaft
Diameter of rocker arm
shaft
19.966 to 19.984 mm
(0.7861 to 0.7868 inch)

(4) Long bolt


Tighten the long bolt to the following
torque
15 + 3 N-m (11 2 lb ft)
(5) Short bolt
Tighten the short bolt to the following
torque
15 3 N-m (11 2 lb ft)
(6) Rocker shaft bracket

Clearance of rocker arm bushing for


shaft
0.027 to 0.128 mm (0.0011 to 0.0050 inch)
Replace the rocker arm bushing if the repair limit of
0.15 mm (.006 inch) has been reached. Replace
the rocker arm bushing and the rocker arm shaft if
ttie repair limit of the rocker arm bushing has been
exceeded.

Illustration 11
Valve lash adjustment

Turn the crankshaft until the timing mark on the


crankshaft pulley is aligned with the pointer on the
timing gear housing in order to adjust the valve lash.
Both the No. 1 inlet valve and the No. 1 exhaust
valve pushrods must not be in tension against the
rocker arms.
Inlet and exhaust valve lash .. 0.25 mm (0.010 inch)
(3) Align the oil holes in rocker arm bushing (A)
with the oil holes in the rocker arm when the
rocker arm bushing is replaced.

8
Specifications Section

Valve Mechanism
SMCS Code: 1102

Maximum allowable clearance for guide for inlet


valve
0.150 mm (0.0059 inch)
Maximum allowable clearance for guide for
exhaust valve
0.200 mm (0.0079 inch)
(5) Outside diameter of valve guide
Outside diameter of guide for inlet
valve
13.025 to 13.035 mm
(0.5128 to 0.5132 inch)
Outside diameter of guide for exhaust
valve
13.025 to 13.035 mm
(0.5128 to 0.5132 inch)
Inside diameter of guide for new inlet
valve
8.010 to 8.035 mm
(0.3154 to 0.3163 inch)
Inside diameter of guide for new exhaust
valve
8.010 to 8.025 mm
(0.3154 to 0.3159 inch)
Maximum inside diameter for guide for inlet
valve
8.09 mm (0.319 inch)
Maximum inside diameter for guide for exhaust
valve
8.12 mm (0.320 inch)

Illustration 12

(1) Spring

(6) Thickness of lip

Length under test force .... 44.0 mm (1.73 inch)


Test force
223 to 246 N (50 to 55 lb)
Free length after test
56.4 mm (2.22 inch)
Maximum bend in spring
2 degrees
(2) Valve stem seal

Valve lip thickness for inlet and exhaust


valves
2.13 mm (0.084 inch)
Minimum allowable valve lip thickness for inlet
and exhaust valves
1.20 mm (0.047 inch)
(7) Angle of valve face

30 degrees

(3) Height to top of valve guide .. 17.00 0.30 mm


(0.669 0.012 inch)
(4) Diameter of valve stem
Inlet valve stem

7.940 to 7.955 mm
(0.3126 to 0.3132 inch)

Exhaust valve stem

7.920 to 7.940 mm
(0.3118 to 0.3126 inch)

Minimum allowable diameter for inlet valve


stem
7.900 mm (0.3110 inch)
Minimum allowable diameter for exhaust valve
stem
7.850 mm (0.3091 inch)
Illustration 13

Clearance for intake valve stem in valve


guide
0.055 to 0.085 mm
(0.0022 to 0.0033 inch)
Clearance for exhaust valve stem in valve
guide
0.070 to 0.105 mm
(0.0028 to 0.0041 inch)

(8) Depth of bore in head for valve seat


insert
9.5 0.1 mm (0.374 0.004 inch)
(9) Chamfer of inlet valve

40 degrees

Note: The depth of the chamfer of the inlet valve is


2.38 0.10 mm (0.094 0.004 inch).

Specifications Section

(10) Chamfer of exhaust valve

45 degrees

Note: The depth of the chamfer of the exhaust valve


is 2.00 0.10 mm (0.079 0.004 inch).
(11) Valve seat bore for inlet.. 46.000 to 46.025 mm
(1.8110 to 1.8120 inch)
(12) Valve seat bore for
exhaust

39.000 to 39.025 mm
(1.5354 to 1.5364 inch)

(16) Pushrod
Use a dial indicator in order to check all
pushrods for runout. Replace the pushrod if the
runout exceeds the following value
0.40 mm
(0.016 inch)

Valve Mechanism Cover


SMCSCode: 1107

Illustration 14
Illustration 16

(13) Width of valve seat

1.40 0.20 mm
(0.055 0.008 inch)

Note: The maximum permissible width of the valve


seat is 1.80 mm (0.071 inch).
(14) Valve seat angle

(1) Valve cover nut


Tighten the valve cover bolts to the following
torque
1 5 3 N - m ( 1 1 2 lb ft)

30 degrees

(15) Dimension from top of closed valve to face of


head
Exhaust valve

0.50 0.25 mm
(0.020 0.010 inch)

Inlet valve

0.40 0.25 mm
(0.016 0.010 inch)

Cylinder Head
SMCSCode: 1100

Note: The maximum permissible depth is 1.10 mm


(0.043 inch).

Illustration 17

(1) Cylinder head

Illustration 15

Use a straightedge and a feeler gauge to check


the cylinder head for warpage.
Flatness of the cylinder head over total span
0.05 mm (0.002 inch)

10
Specifications Section

Resurface the cylinder head if the warpage


exceeds the following amount
0.20 mm
(0.008 inch)
Gasket thickness of cylinder
head
1.70 0.10 mm (0.070 0.004 inch)
Thickness of new head

Turbocharger
SMCS Code: 1052

95.00 0.10 mm
(3.740 0.004 inch)

Minimum thickness of cylinder head .. 94.70 mm


(3.728 inch)
Note: The repair limit of the contact surface of the
gasket and the repair limit of the cylinder block
surface is 0.20 mm (0.008 inch).

Illustration 20

g00530558

(1) Compressor wheel


(2) Turbine wheel
(3) Turbine housing
(4) Compressor housing
Illustration 18
Numerical sequence of bolts for 3064 Engine

(5) Cartridge housing


Note: Mark the orientation of the compressor
housing, the cartridge housing and the turbine
housing before disassembly.

Illustration 19
Numerical sequence of bolts for 3066 Engine

Put clean engine oil on the threads of the cylinder


head bolts. Install the bolts and tighten the bolts in
the appropriate numerical sequence to the following
torque
118 + 5 N.m (87 4 lb ft)
Illustration 21

(6) Turbine shaft

11
Specifications Section

Place a dial indicator on the end of the turbine


shaft. Move the compressor wheel (1) in the
axial direction in order to measure end play. End
play .... 0.057 to 0.103 mm (.0022 to .0041 inch)
Note: The turbocharger must be disassembled and
the turbocharger must be checked for clearances if
the end play is beyond the specifications.

Illustration 24

g00530564

(8) Clamp
Apply 5P-3931 Anti-Seize Compound to the
threads of the clamp. Tighten the clamp to the
following torque
4 1 N-m (35 9 lb in)
Illustration 22

900530561

(7) Lock plates


Position the lock plates and tighten the bolts to
the following torque
20 N-m (15 lb ft)

Tap clamp (8) lightly around the circumference.


Tighten clamp (8) to the following
torque
4 1 N-m (35 9 lb in)
i01575653

Exhaust Manifold
SMCS Code: 1059

Illustration 23

900530562

Turbine housing (3) and Cartridge housing (5)

Align the turbine housing (3) with the cartridge


housing (5).

Illustration 25

900530254

(1) Nuts for turbocharger


Tighten the nuts for the turbocharger to the
following torque
41 N-m (30 lb ft)
(2) Studs for turbocharger
Tighten the studs for the turbocharger to the
following torque
12 N-m (9 lb ft)
(3) Studs for exhaust manifold
Tighten the studs for the exhaust manifold to the
following torque
12.5 N-m (9 lb ft)

12
Specifications Section

(4) Nuts for exhaust manifold


Tighten the nuts for the exhaust manifold to the
following torque
18 + 4 N-m (13 3 lb ft)

Camshaft
SMCSCode: 1210

Illustration 27

g00527952

(4) Camshaft lobe lift


Specified camshaft lobe lift (4)
Exhaust lobe
Inlet lobe

7.344 mm (0.2891 inch)


6.689 mm (0.2633 inch)

Service limit for lobe lift for exhaust

6.844 mm
(0.2695 inch)

Service limit for lobe lift for inlet

6.189 mm
(0.2437 inch)

Illustration 26

(1) Camshaft gear


Maximum permissible temperature of the gear
for installation on the camshaft.... 315C (600F)
Note: Do not use a torch.

Note: Replace the camshaft if the service limit for


the lobe lift is reached.
(5) Camshaft lobe height

(2) Diameters of camshaft journals

(6) Base circle

Table 1

Number
of Journal
for 3064
Engine

1, 2

To find the lobe lift, use the procedure that follows:

Number
of Journal
for 3066
Engine

Standard
Diameter

1, 2, 3

53.94 to
53.96 mm
(2.123 to
2.124 inch)

53.90 mm
(2.122 inch)

52.94 to
52.96 mm
(2.084 to
2.085 inch)

52.90 mm
(2.083 inch)

Service
Limit(1)

1. Measure the camshaft lobe height (5).


2. Measure the base circle (6).
3. Subtract the base circle that is found in Step 2
from the lobe height that is found in Step 1. The
difference is the actual camshaft lobe lift (4).

(1) The service limit is the maximum dimension or the service limit
is the minimum dimension that is specified for a part. Replace
the part if the service limit is reached.

(3) Thrust plate bolt


Tighten the bolt to the following
torque
11 2 N-m (8 1 lb ft)

Illustration 28

13
Specifications Section

Note: Use a dial indicator and blocks in order to


determine the runout of the camshaft. Take one half
of the dial indicator reading as the runout.

(9) Install the dial indicator in order to determine


gear end play.
End play

(7) Camshaft

0.10 to 0.25 mm
(0.004 to 0.010 inch)

Maximum permissible runout for


camshaft
0.020 mm (0.0008 inch)

Replace the thrust plate if the end play exceeds


the following amount
0.30 mm (0.012 inch)

Straighten the camshaft if runout is less than the


following amount
0.050 mm (0.0020 inch)

Thrust plate thickness

Replace the camshaft if runout is more than the


following amount
0.050 mm (0.0020 inch)

4.85 mm (0.191 inch)

Engine Oil Relief Valve


SMCS Code: 1315

Illustration 29

(8) Camshaft bearing

Illustration 31

Measure the camshaft bearing with a dial indicator.


Subtract the diameter of the camshaft journal in
order to give bearing clearances. Refer to Table 2.
Table 2

Standard
Diameter
Clearance
between
camshaft
journals and
bushings

Repair Limit(1)

Remove the oil pressure relief valve from the


cylinder block. Check the valve and the valve seat
for abnormal contact patterns. Inspect the spring
for weakness or damage. Replace the oil pressure
relief valve, if necessary.
Relief valve opening pressure

0.04 to 0.09 mm
(0.002 to
0.004 inch)

0.15 mm
(0.006 inch)

(1) The repair limit is the maximum dimension or the repair limit is
the minimum dimension that is specified for a part. Repair the
part if the repair limit is reached.

Illustration 30

Engine oil relief valve

343 20 kPa
(50 3 psi)
Tighten the engine oil relief valve to the following
torque
49 + 5 N-m (36 4 lb ft)

14
Specifications Section

Engine Oil Pump


SMCS Code: 1304

Illustration 32

NOTICE
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result.
Note: The minimum acceptable oil pressure at low
idle is 100 kPa(15 psi).
(1) Driven gear assembly
(2) Drive gear assembly
(3) Oil pump gear
Note: Do not use a torch.
Heat the oil pump gear to 180 to 220C
(356 to 428F) and support the end of the drive
gear shaft in order to install the oil pump gear. Press
the oil pump gear until the oil pump gear is flush
with the end of the shaft.
(4) Idler gear assembly
The backlash between the oil pump
gear and the idler gear is the following
amount
0.100 to 0.190 mm
(0.0039 to 0.0075 inch)
Note: Replace the gears if the backlash exceeds
0.35 mm (0.014 inch).
(5) Spindle
Note: The oil pump gear and the drive gear
assembly are not serviceable if the oil pump gear
is removed.

Illustration 33

(6) Housing for oil pump gear


Measure the difference in the length
of the assembly for the oil pump gear
and the depth in the oil pump housing.
Clearance
0.020 to 0.034 mm
(0.0008 to 0.0013 inch)
Note: Replace the oil pump gear assembly if the
clearance exceeds the service limit of 0.150 mm
(0.0059 inch).
Measure the clearance between the oil pump gears
and the oil pump housing with a feeler gauge.
Clearance

0.050 to 0.098 mm
(0.0020 to 0.0039 inch)

Note: Replace the oil pump gear assembly if the


clearance exceeds the service limit of 0.150 mm
(0.0059 inch).

15
Specifications Section

(7) Cover

(10) Bolts

Measure the inside diameters of the bores of


the shafts in the cover (7) and the oil pump
housing (6). Measure the bores of the shafts.
The clearance between the gear shafts and the
oil pump housing and cover.... 0.04 to 0.07 mm
(0.002 to 0.003 inch)
Note: Replace the oil pump gear assembly, the
cover, or the oil pump housing if the clearance
exceeds the service limit of 0.15 mm (0.006 inch).
Note: Replace the drive gear and driven gear as
an assembly.

Tighten the bolts (10) for the oil pump cover (7)
to the following torque
35 6 N-m
(26 4 lb ft)

Engine Oil Pressure


SMCS Code: 1924
Table 3

Engine Oil Pressure(1)


Oil Pressure at 1500 rpm

196 to 392 kPa


(28 to 57 psi)

Oil Pressure at idle(2)

98 kPa (14 psi)

(1)The oil temperature must be 60 to 70C (140 to 158F).


(2) Engine idle is 900 20 rpm.

Engine Oil Bypass Valve


SMCS Code: 1306-BV

Illustration 35

(8) Idler gear bushing


Inside diameter of idler gear
bushing
25.000 to 25.021 mm
(0.9843 to 0.9851 inch)
Maximum diameter of idler gear bushing for oil
pump
25.059 mm (0.9866 inch)
(9) Spindle
Diameter of spindle

24.939 to 24.960 mm
(0.9818 to 0.9827 inch)

Minimum diameter of spindle for oil


pump
24.901 mm (0.9804 inch)
Illustration 37

Note: The oil bypass valve is mounted inside the oil


pan along the rail of the oil pan.
(1) Valve seat
Check the valve and the valve seat for abnormal
contact patterns.
(2) Spring

Illustration 36

Inspect the spring for weakness or damage.


Free length of spring
83.5 mm (3.29 inch)

16
Specifications Section

Opening pressure of bypass valve .... 981 98 kPa


(142 14 psi)
Tighten the oil bypass valve to the following torque.
69 5 N-m (51 4 lb ft)

Water Pump
SMCS Code: 1361

Engine Oil Pan


SMCSCode: 1302

2
Illustration 38

Illustration 39
g00530566

(1) Oil pan bolts


Tighten the oil pan bolts to the following
torque
28 7 N-m (21 5 lb ft)
(2) Oil pan drain plug
Tighten the oil pan drain plug to the following
torque
39 5 N-m (29 4 lb ft)

(1) Impeller
The faces of the impeller and the water pump shaft
are flush.
(2) Flange
(3) The distance from the face of the impeller
to the water pump housing is the following
amount
21.00 to 21.70 mm
(0.826 to 0.854 inch)

Water Temperature Regulator


SMCS Code: 1355
The water temperature regulator starts to open at
the following temperature. ... 71 2C (160 4F)
The optional water temperature regulator starts to
open at the following temperature
82C (180F)
The valve lifts more than 10 mm (0.4 inch) at the
following temperature
85C (185F)
The optional water temperature regulator lifts
more than 10 mm (0.4 inch) at the following
temperature
96C (204F)

Illustration 40

(4) Water pump shaft

17
Specifications Section

The press fit between the water pump


shaft and the flange is the following
amount
0.035 to 0.065 mm
(0.0014 to 0.0026 inch)
The press fit between the water pump
shaft and the impeller is the following
amount
0.032 to 0.065 mm
(0.0013 to 0.0026 inch)

Measure the inside diameter of the cylinder sleeve


that is parallel to the crankshaft. Measure the
inside diameter of the cylinder liner that is in a
perpendicular position to the crankshaft. Measure
the top, the middle and the bottom of the cylinder
liner. Refer to Table 4 for tolerances of the cylinder
liner.
Table 4
Tolerances of Cylinder Sleeves

J01576112

Standard at
Assembly

Repair
Limit(1)

Service
Limit(2)

Inside
Diameter

102.010 to
102.045
mm
(4.0161 to
4.0175 inch)

102.200
mm (4.0236
inch)

102.700
mm (4.0433
inch)

Out of
Round

0.010 mm
(0.0004
inch)

N/A

N/A

Taper

0.015 mm
(0.0006
inch)

N/A

N/A

Cylinder Block
SMCSCode: 1201

(1) The repair limit is the maximum dimension or the repair limit
is the minimum dimension that is specified for a part. Repair a
part if the repair limit is reached.
(2) The service limit is the maximum dimension or the service limit
is the minimum dimension that is specified for a part. Replace
the part if the service limit is reached.
Illustration 41

^00529444

(1) Cylinder block


Measure the amount of the warpage of
the cylinder block with a straightedge
and feeler gauge. Maximum allowable
clearance
0.05 mm (0.002 inch)
Repair limit

.0.20 mm (0.008 inch)

Resurface the top of the block if the repair limit is


reached.

Bore the cylinder to the specified oversize


dimension if the inside diameter reaches the repair
limit but the inside diameter does not reach the
service limit. Refer to Table 5.
Hone the liner to +0.25 mm (+0.010 inch) or
+0.50 mm (+0.020 inch) oversize. Hone the
liner to an accuracy within 0.010 to 0.045 mm
(0.0004 to 0.0018 inch).
Determine the oversize dimension that is necessary
in order to clean up the cylinder if any liner has
uneven wear.
Replace all cylinder liners that are in excess of the
service limit.
Note: Refinish all liners to the same oversize
dimension. Use a ridge reamer in order to cut the
ridge of the cylinder if the liner is in good condition.
Hone the cylinder bore.
Table 5

Illustration 42

(2) Cylinder liner

Oversize Bore

Cylinder Bore Size

0.250 mm (0.0100 inch)

102.260 mm (4.0260 inch)


102.295 mm (4.0274 inch)

0.500 mm (0.0197 inch)

102.510 mm (4.0358 inch)


102.545 mm (4.0372 inch)

900529446

18
Specifications Section

New diameter for the main bearing


bores
90.020 to 90.068 mm
(3.5441 to 3.5460 inch)
Maximum diameter of the main bearing
bores
90.150 mm (3.5492 inch)
New height of deck from centerline of crankshaft to
deck
307.00 0.05 mm (12.086 0.002 inch)
Minimum height from the centerline of crankshaft to
deck
306.70 mm (12.075 inch)
i01573686
Illustration 43

g00529534

(3) Cylinder liner


Service limit of cylinder liner

Crankshaft
SMCSCode: 1202

102.700 mm
(4.0433 inch)

Replace all cylinder liners that exceed the service


limit.

900525341

Illustration 45

(1) Crankshaft main bearing journal


Illustration 44

g00529962

Cylinder liner

Use the following procedure in order to repair the


cylinder liners.
1. Set up a boring machine on the cylinder block.
Align the boring machine with the center of the
bottom of the cylinder liner with the less worn
area.
2. Bore the liner until the thickness is 0.50 mm
(0.020 inch).
3. Remove the remainder of the liner. Be careful not
to damage the cylinder block.
4. Install a new liner. Align the liner with the top of
the cylinder block.
5. The bore of the cylinder must be
102.000 to 102.035 mm (4.0157 to 4.0171 inch).

Measure the main bearing journal. The diameter


of the crankshaft main bearing journal is given in
Table 6.
Table 6

Main Bearing Journal


Original size journal (1)

89.95 to 89.97 mm
(3.541 to 3.542 inch)

Undersize journal
0.25 mm (0.010 inch)

89.70 to 89.72 mm
(3.531 to 3.532 inch)

Undersize journal
0.50 mm (0.020 inch)

89.45 to 89.47 mm
(3.521 to 3.522 inch)

Undersize journal
0.75 mm (0.030 inch)

89.20 to 89.22 mm
(3.512 to 3.513 inch)

(1) Regrind the main bearing journals to the next undersize


dimension if the repair limit of 89.85 mm (3.537 inch) is
exceeded.

19
Specifications Section

Illustration 46

Illustration 48

(2) Crankshaft

(4) Crankshaft end play

Support the crankshaft in a set of vee blocks.


Measure the runout dimension at the center
journal. Maximum runout
0.020 mm
(0.0008 inch)
Note: The allowable tolerance for main bearing
journals that are out of round is 0.010 mm
(0.0004 inch). The maximum repair limit is 0.030 mm
(0.0012 inch). If the repair limit is exceeded, regrind
the bearing journals to the specified dimension.
Note: The maximum service limit for the crankshaft
journal is 0.90 mm (0.035 inch). Replace the
crankshaft if the crankshaft journal is worn beyond
this specification.
Note: Replace the crankshaft if the runout exceeds
the repair limit of 0.050 mm (0.0020 inch).

0.100 to 0.264 mm
(0.0039 to 0.0104 inch)

Note: The maximum repair limit is 0.300 mm


(0.0118 inch).
Replace the standard thrust plates if the end play
exceeds the standard clearance. Three oversize
thrust plates are available as replacements if the
end play still exceeds the maximum limit. Generally,
the rear journal is likely to be worn more rapidly than
the front journal. If necessary, replace the rear thrust
plate. Refer to Table 7 for oversize thrust plates.
Table 7

Dimensions for Grinding of Crankshaft


Oversize Thrust Plates
Oversize
Thrust
Plate

Oversize
(front or
rear)

Oversize
(front or
rear)

Tolerance

+0.15 mm
(+.006 inch)

33.15 mm
(1.305 inch)

33.30 mm
(1.311 inch)

+0.039 mm
(+0.0015
inch)

+0.30 mm
(+0.012
inch)

33.30 mm
(1.311 inch)

33.45 mm
(1.317 inch)

+0.039 mm
(+0.0015
inch)

+0.45 mm
(+0.018
inch)

33.45 mm
(1.317 inch)

33.60 mm
(1.323 inch)

+0.039 mm
(+0.0015
inch)

Torque for the crankshaft pulley nut .... 490 5 N.m


(363 4 lb ft)
Illustration 47

(3) Width of crankshaft main bearing


journal
33.000 to 33.039 mm

(1.2992 to 1.3007 inch)

The maximum temperature for installing the


crankshaft gear is the following value
100 C
(212 F)

20
Specifications Section

i01576124

Crankshaft Seals

i01576126

Connecting Rod Bearing


Journal

SMCSCode: 1160; 1161

SMCSCode: 1202; 1219; 1225


Table 8

Connecting Rod Bearing Journal


Original size journal(1)

59.945 to 59.965 mm
(2.3600 to 2.3608 inch)

Undersize journal
0.25 mm (0.010 inch)

59.695 to 59.715 mm
(2.3502 to 2.3510 inch)

Undersize journal
0.50 mm (0.020 inch)

59.445 to 59.465 mm
(2.3404 to 2.3411 inch)

Undersize journal
0.75 mm (0.030 inch)

59.195 to 59.215 mm
(2.3305 to 2.3313 inch)

(1) Regrind the connecting rod journals to the next undersize


dimension if the repair limit of 59.980 mm (2.3614 inch) is
exceeded.

The clearance between a new bearing and a new


journal is the following value
0.035 to 0.100 mm
(0.0014 to 0.0039 inch)
Illustration 49

g00525904

(1) Front seal


(2) Rear seal assembly
Note: The rear seal assembly and the slinger are
installed as a unit.
(3) Slinger
Note: The rear seal assembly and the slinger are
installed as a unit.
(4) Rear seal assembly
Note: The rear seal assembly should be flush with
the slinger after installation.
(5) Contact surface between the slinger and
crankshaft
Put sealant on the contact surface between the
slinger and the crankshaft. Put clean engine oil on
the surface of the rear seal assembly.
(6) Distance from rear seal assembly to end of
crankshaft
6.0 mm (0.24 inch)

An undersized bearing is required if the clearance


between the connecting rod journal and the bearing
is in excess of the service limit of 0.200 mm
(0.0079 inch). If the crankshaft is worn excessively,
or if the crankshaft is uneven, an undersized bearing
is required. If an undersized bearing is required,
grind the crankshaft to a dimension listed in Table 8.
Note: The allowable tolerance for rod bearing
journals that are out of round is 0.010 mm
(0.0004 inch). The maximum repair limit is 0.030 mm
(0.0012 inch). If the repair limit is exceeded, regrind
the bearing journals to the specified dimension.

21
Specifications Section

Main Bearing Journal


SMCSCode: 1202; 1203

(3) Bolts for the main bearing cap


Illustration 50

(1) Main bearing cap


Put the main bearing caps in position in the
cylinder block. Put clean engine oil on the main
bearing bolts. Install the main bearing bolts and
tighten the main bearing bolts to the following
torque
137 5 N-m (101 4 lb ft)

(2) Dial indicator

Tighten the bolts for the bearing cap to the


following torque
137 5 N-m (101 4 lb ft)
(4) Main bearing journal
(5) Main bearing

Connecting Rod
SMCSCode: 1218

Measure the main bearing bores with a


dial indicator. Subtract the diameter of the
crankshaft journal from the inside diameter
of the main bearing in order to determine
the bearing clearance on the main journal.
Clearance between crankshaft journal and main
bearing
0.050 to 0.118 mm
(0.0020 to 0.0047 inch)
Note: Replace the bearings or refinish the crankshaft
to the next undersize bearing if the main bearing
clearance exceeds 0.20 mm (0.008 inch). Refer to
Table 50 for dimensions of undersize journals.
Note: The allowable tolerance for main bearing
journals that are out of round is 0.010 mm
(0.0004 inch). The maximum repair limit is 0.030 mm
(0.0012 inch). If the repair limit is exceeded, regrind
the bearing journals to the specified dimension.

Illustration 52

(1) Matching marks


The marks are used to align the cap to the
connecting rod.

22
Specifications Section

(3) Connecting rod bolts


Before assembly, put clean engine oil on the
bolt threads and all surfaces that make contact
between the bolt and connecting rod caps.
Tighten the connecting rod nuts to the following
torque
103 5 N-m (76 4 lb ft)
(4) Measure the bores of each of the connecting
rods and record the dimension of the bores.

Illustration 53

(A) The upper oil hole is 40 degrees above the


horizontal centerline.
(B) The lower oil hole is 30 degrees below the
horizontal centerline.
(C) The end of the piston pin bearing is 30 degrees
below the lower oil hole.
Illustration 55

g00525l94

(5) Connecting rod


Use a feeler gauge to measure the end play.
End play
0.15 to 0.35 mm
(0.006 to 0.014 inch)
Note: Replace the connecting rod if the end play
exceeds 0.50 mm (0.020 inch).

Illustration 54

(2) Bore of piston pin


bearing

34.020 to 34.045 mm
(1.3394 to 1.3404 inch)

The clearance between the piston pin bearing


and the piston pin is 0.023 to 0.054 mm
(0.0009 to 0.0021 inch).
Note: A clearance for the piston pin to the piston pin
bearing over 0.010 mm (0.0004 inch) is excessive.
Replace the piston pin or replace the bearing if the
clearance is excessive.

Illustration 56

(6) Piston
(7) Markings on piston
Assemble the piston and connecting rods. Ensure
that the markings on the piston (7) and the marks
on the connecting rod (1) are on the same side.

23
Specifications Section

Piston and Rings


SMCSCode: 1214; 1215

Illustration 57

(8) Install the piston assembly with the marks (1) on


the connecting rod toward the camshaft (8).

Illustration 59

(1) Markings on piston


Each piston has markings which are stamped on
top of the piston. The markings are used to align
the piston assembly to the camshaft side of the
cylinder block.

Illustration 58

(2) Piston diameter

(9) Piston projection


Use the following procedure to measure the
height of each piston above the cylinder block. If
clearances are not in the acceptable range, inspect
the components for wear or damage.
1. Determine the top center position of the piston
with a dial indicator assembly.
2. Install the dial indicator assembly on the top of
the block. Set the needle of the dial indicator
to zero.
3. Measure projection (9) at three places on
the top of the piston. Take an average of the
three measurements in order to determine the
projection. Subtract the projection from the
installed thickness of the cylinder head gasket
in order to determine the clearance between the
top of the piston and the cylinder head.
Installed thickness of the cylinder head
gasket
1.70 0.10 mm (0.070 0.004 inch)
Piston projection

0.55 to 1.15 mm
(0.022 to 0.045 inch)

Table 9 gives the dimensions for pistons that are


standard. Table 9 also gives the dimensions for
pistons that are oversize.
Note: Measure the piston diameter along the
perpendicular of the piston pin bore.

24
Specifications Section

Table 9

Dimensions for Piston Diameters


Bore Size

Standard at
Assembly

Service LimiK(1)

Standard

101.915 to
101.945 mm
(4.0124 to
40136 inch)

101.730 mm
(4.0051 inch)

Oversize
0.25 mm
(0.010 inch)

102.165 to
102.195 mm
(4.0222 to
4.0234 inch)

101.980 mm
(4.0150 inch)

Oversize
0.50 mm
(0.020 inch)

102.415 to
102.445 mm
(4.0321 to
4.0333 inch)

102.230 mm
(4.0248 inch)

(1) A piston which exceeds this limit must be replaced.

Illustration 61

g00524467

(5) Identification mark on piston rings


Install the piston rings with the identification mark
toward the top.
Note: Each piston ring is marked with an "R" or "T"
for an identification mark.
(6) Top piston ring
Piston ring end gap for a standard
bore
0.30 to 0.45 mm (0.012 to 0.018 inch)
Note: Replace the piston rings if the end gap
exceeds the maximum tolerance of 1.50 mm
(0.060 inch).
(7) Intermediate piston ring

Illustration 60

(3) Diameter of piston pin bore


(4) Diameter of piston pin

33.993 to 34.000 mm
(1.3383 to 1.3385 inch )

Measure the piston pin bore diameter. Subtract


the piston pin diameter from the bore diameter.
The clearance between the bore and piston
pin
0.002 to 0.019 mm (0.0001 to 0.0008 inch)
Note: The service limit for the clearance between
the piston pin and the piston pin bore is 0.050 mm
(0.0020 inch). Replace the piston if the clearance
has been exceeded.

Piston ring end gap for standard


bore
0.30 to 0.45 mm (0.012 to 0.018 inch)
Note: Replace the piston rings if the end gap
exceeds the maximum tolerance of 1.50 mm
(0.060 inch).
(8) Oil control piston ring
The position of the end gap of the oil control
ring is 180 degrees from the ends of the ring
expander.
Piston ring end gap for a standard
bore
0.30 to 0.50 mm (0.012 to 0.020 inch)
Note: Replace the piston rings if the end gap
exceeds the maximum tolerance of 1.50 mm
(0.060 inch).

25
Specifications Section

Illustration 63

g00524492

(A) End gap for No. 1 ring (top compression ring)


(B) End gap for No. 2 ring (intermediate
compression ring)
Illustration 62

(C) End gap for oil control ring

(9) Side clearance of ring groove

(X) Camshaft side of engine block

Install new piston rings in the ring grooves of the


piston. Measure the side clearance of the ring
groove with a straight edge and feeler gauge. Table
10 groves acceptable 'Clearances of t i e ring groove.

(Y) Side of engine with combustion chamber

Clearances of the Piston Rings

Position the piston rings according to Illustration 63.

Gear Group (Front)

Piston
Rings

Width of
Ring

Side
Clearance
of Ring
Groove

No. 1
Compression
Ring

3.00 mm
(0.118
inch)

0.080 to
0.120 mm
(0.0031 to
0.0047 inch)

0.200 mm
(0.0080
inch)

No. 2
Compression
Ring

2.00 mm
(0.080
inch)

0.080 to
0.120 mm
(0.0031 to
0.0050 inch)

0.150 mm
(0.0060
inch)

Oil Control
Ring

4.00 mm
(0.157
inch)

0.025 to
0.065 mm
(0.0010 to
0.0026 inch)

0.150 mm
(0.0060
inch)

Service
Limit (1)

(1) The piston must be replaced if the piston rings exceed these
clearances.

SMCS Code: 1206

Illustration 64

g00527858

(1) Fuel injection pump drive gear


(2) Idler gear
(3) Camshaft gear
(4) Nut for fuel injection pump drive gear
Tighten the nut to the following
torque
88 5 N.m (65 4 lb ft)

26
Specifications Section

(5) Crankshaft gear


Note: Ensure that the marks on the timing gears are
in alignment.

Illustration 65

g00527864

Idler gear (2)

Table 11

Item

Standard at
Assembly

Service Limit(1)

Backlash of idler
gear

0.03 to 0.17 mm
(0.001 to
0.007 inch)

0.25 mm
(0.010 inch)

End play of idler


gear

0.05 to 0.20 mm
(0.002 to
0.008 inch)

0.35 mm
(0.014 inch)

Clearance
between idler
gear bushing
and shaft

0.009 to 0.080
mm (0.0004 to
0.0031 inch)

0.100 mm
(0.0039 inch)

900527912

(8) Idler gear shaft


Replace the bushing if the clearance between the
idler gear bushing and the idler gear shaft exceeds
the service limit. Refer to Table 11.
Tighten the bolts for the timing gear cover to the
following torque
35 + 6 N-m (26 4 lb ft)
(9) Front plate
Tighten the bolt that holds the front plate to the
following torque
35 5 N-m (26 4 lb ft)
i01576345

(1) Replace the idler gear if the service limit is exceeded.

(6) Idler gear bolt

Illustration 67

(7) Inside diameter of idler gear bushing

Install a dial indicator and rotate the idler gear


(2) back and forth in order to measure backlash.
Replace the idler gear if the backlash exceeds the
service limit. Refer to Table 11.

Illustration 66

Measure the end play of the idler gear with a


feeler gauge. Refer to Table 11. Tighten the idler
gear bolt to the following torque
34 N-m
(25 lb ft)

900819139

Flywheel
SMCSCode: 1156

Illustration 68

(1) Flywheel

g00529633

27
Specifications Section

Place the flywheel on a surface plate. Use a


dial indicator in order to measure the flatness of
the flywheel.

Crankshaft Pulley

Standard at assembly of flywheel

SMCSCode: 1205

0.15 mm
(0.006 inch)

Repair limit of flywheel .... 0.50 mm (0.020 inch)


Note: Refinish the flywheel if the repair limit is
exceeded.

Illustration 70

Tighten the crankshaft pulley nut to the following


torque
490 10 N-m (361 7 lb ft)
i01449909

Belt Tension Chart


SMCS Code: 1357
Illustration 69

g00529634

(2) Measure the runout on the flywheel face with a


dial indicator. Maximum face runout.... 0.15 mm
(0.006 inch)
Repair limit of face runout

0.50 mm (0.020 inch)

Note: Refinish the flywheel if the repair limit is


exceeded.
Maximum permissible temperature of the ring gear
for installation on the flywheel without using a
torch
150 C (302 F)
Note: The ring gear is pressed on the flywheel.
Tighten the flywheel bolts to the following
torque
83 5 N-m (61 4 lb ft)
Number of teeth of the flywheel ring gear

127

Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.

28
Specifications Section

Table 12

Belt Tension Chart


Gauge Reading
Size of Belt

Width of Belt

3/8
1/2

Borroughs Gauge Numbers

Initial Belt Tension(1)

Used Belt Tension(2)

Number of the Selected


Gauge

10.72 mm (0.422 inch)

445 22 N (100 5 lb)

400 22 N (90 5 lb)

BT-33-97

13.89 mm (0.547 Inch)

534 22 N (120 5 lb)

400 44 N (90 1 0 lb)

BT-33-97

Measure the tension of the belt that is farthest from the engine.
(1) Initial Belt Tension refers to a new belt.
(2)Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.

i01574161

i01574185

Belt Tightener

Alternator and Regulator

S M C S C o d e : 1358

S M C S C o d e : 1405; 1 4 1 0

Illustration 71

goossosos

(1) Bolt.

illustration 72

g00530887

(1) Nut for alternator pulley

Apply pressure to each belt midway between the


pulleys in order to inspect the belt tension. Adjust
the bolt for the alternator if the tension is incorrect.
The proper tension for the fan drive belt is
approximately the following deflection
12.0 mm
(0.50 inch)

Tighten the nut for the alternator pulley to the


following torque
132 to 162 N-m
(97 to 119 lb ft)
Polarity
Rotation
Speed for testing (rpm)
Output voltage
Rated output

negative ground
either direction
5000 rpm
28.0 .5 V
50 A

29
Specifications Section

Electric Starting Motor

Coolant Temperature Switch

SMCSCode: 1453

SMCS Code: 1395; 1906

74
Engrie coolant temperature switch

Tighten the engine coolant temperature switch to


the foiowing torque. ... 7 to 12 N-m (62 to 106 lb in)
Illustration 73

Engine Oil Pressure Switch

(1) Terminal nuts


Tighten the terminal nuts to the following
torque
11 + 1 N-m (97 + 9 lb in)

SMCSCode: 1924

The rotation is viewed from the drive end of the


electric starting motor. Rotation of electric starting
motor
clockwise
No load conditions
Speed (rpm)

3300 rpm minimum

Maximum current (draw)

85 A

Voltage

23 V

Engine oil pressure switch

Tighten the engine oil pressure switch to the


cylinder block to the following torque: .. 7 to 12 N-m
(62 to 106 lb in)
101578156

Air Inlet Heater


SMCS Code: 1090
Tighten the four bolts that secure the air inlet
heater to the inlet manifold to the following
torque
28 7 N-m (21 5 lb ft)

30
Index Section

Index
L

A
Air Inlet Heater
Alternator and Regulator

29
28

Lifter Group

M
B
Main Bearing Journal
Belt Tension Chart
Belt Tightener

21

27
28
P
Piston and Rings

C
Camshaft
Connecting Rod
Connecting Rod Bearing Journal
Coolant Temperature Switch
Crankshaft
Crankshaft Pulley
Crankshaft Seals
Cylinder Block
Cylinder Head

12
21
20
29
18
27
20
17
9

29
4
4
4
15
16
15
29
14
13
11

26
5
6
5

G
Gear Group (Front)

25

I
Important Safety Information

Rocker Shaft

S
Specifications Section

Table of Contents
Turbocharger

3
10

V
Valve Mechanism
Valve Mechanism Cover

8
9

W
Water Pump
Water Temperature Regulator

F
Flywheel
Fuel Injection Lines
Fuel Injection Nozzles
Fuel Injection Pump

E
Electric Starting Motor
Engine Design
3064 Engine
3066 Engine
Engine Oil Bypass Valve
Engine Oil Pan
Engine Oil Pressure
Engine Oil Pressure Switch
Engine Oil Pump
Engine Oil Relief Valve
Exhaust Manifold

23

16
16