Engine 3066 - 3064 - Specifications

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CATERPILLAR

SENR5545-04 f

October 2001

3064 and 3066 Engines for Caterpillar

sy

Built Machines

6LK1-Up (Engine) 6LK1-Up (Engine) 7JK1-Up (Engine) 7JK1-Up (Engine)

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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 Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have 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.

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. 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.

Caterpill

Caterpillar cannot anticipate every ar cannot anticipate every possible circumstance that might involve possible circumstance that might involve a potential hazara potential hazard. Thed. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, 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, 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 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 product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

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 When replacement parts are required for this product Caterpillar recommends using Caterpil product Caterpillar recommends using Caterpil lar replacement parts or parts with equivalent lar replacement parts or parts with equivalent specifications including, but not limited to, phys specifications including, but not limited to, phys ical dimensions, type, strength and material. ical dimensions, type, strength and material. Failure to heed this warning can lead to prema Failure to heed this warning can lead to prema ture failures, product damage, personal injury or ture failures, product damage, personal injury or death.

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3 Table of Contents

Specifications Section

Engine Design 4

Fuel Injection Lines 5

Fuel Injection Pump 5

Fuel Injection Nozzles 6

Lifter Group 6

Rocker Shaft 7

Valve Mechanism 8

Vafve Mechanism Cover 9

Cylinder Head 9

Turbocharger 10

Exhaust Manifold 11

Camshaft 12

Engine Oil Relief Valve 13

Engine Oil Pump 14

Engine Oil Pressure 15

Engine Oil Bypass Valve 15

Engine Oil Pan 16

Water Temperature Regulator 16

Water Pump 16

Cylinder Block 17

Crankshaft 18

Crankshaft Seals 20

Connecting Rod Bearing Journal 20

Main Bearing Journal 21

Connecting Rod 21

Piston and Rings 23

Gear Group (Front) 25

Flywheel 26

Crankshaft Pulley 27

Belt Tension Chart 27

Belt Tightener 28

Alternator and Regulator 28

Electric Starting Motor 29

Coolant Temperature Switch 29

Engine Oil Pressure Switch 29

Air Inlet Heater 29

Index Section

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4 Specifications Section

Specifications Section

Engine Design

SMCSCode: SMCSCode: 1201

3064 Engine

Illustration 1 g00523889

Cylinder and valve location (A) Exhaust valve (B) Inlet valve

Type Four cylinder and four stroke

Combustion system Direct injection

Bore 102 mm (4.02 inch)

Stroke 130 mm (5.12 inch)

Number of cylinders 4

Displacement 4.3 L (260 in3)

Cylinder arrangement In-line

Valves per cylinder 2

Firing order 1 - 3 - 4 - 2

Compression ratio 17:1

Note:

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 900 ± 20

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

3066 Engine

Cylinder and valve location (A) Exhaust valve (B) Inlet valve

Type Six cylinder and four stroke

Combustion system Direct injection

Bore 102 mm (4.02 inch)

Stroke 130 mm (5.12 inch)

Number of cylinders 6

Displacement 6.4 L (390 in3₎

Cylinder arrangement In-line

Valves per cylinder 2

Firing order 1 - 5 - 3 - 6 - 2 - 4

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.

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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 Lines

SMCSCode:

SMCSCode: 1252

Illustration 3

(1) Fuel injection lines

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

Fuel Injection Pump

SMCSCode:

SMCSCode: 1251; 1290

Illustration 4

(1) Bolts for fuel injection line

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

(5) Idler subspring nut

Tighten the idler subspring nut to the following

(6) Idler subspring

Tighten the idler subspring to the following

(7) Nut

Tighten the nut to the following

(6)

6

Specifications Section

Fuel Injection Nozzles

SMCSCode:

SMCSCode: 1254

(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 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).

(6) Pressure spring (7) Pressure pin (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

SMCSCode: SMCSCode: 1209 Illustration 7

(10) Tappet bore diameter

Tappet bore diameter 22.000 to 22.021 mm (0.8661 to 0.8670 inch) Maximum tappe t 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.

(7)

Rocker Shaft

SHCS Code: 1102 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) 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 10

Position the rocker shaft brackets and mounting bolts.

(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

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 val ve lash. Both the No. 1 inlet valve and the No. 1 exhaust valve pushrods must not be in tension against the rocker arms.

(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)

Valve Mechanism

SMCS Code: SMCS Code: 1102 Illustration 12 (1) Spring

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

(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)

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)

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)

(6) Thickness of lip

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

Illustration 13

(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).

(9)

(10) Chamfer of exhaust valve 45 degrees

Note:

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:

SMCSCode: 1107

Illustration 14

(13) Width of valve seat 1.40 ±0 .2 0 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 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) Note: The maximum permissible depth is 1.10 mm (0.043 inch).

Illustration 16

(1) Valve cover nut

Tighten the valve cover bolts to the following

torque 15 ±3 N -m (1 1 ± 2 lb ft)

Cylinder Head

SMCSCode: SMCSCode: 1100 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)

10

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 95.00 ± 0.10 mm (3.740 ± 0.004 inch) Minimum thickness of cylinder head .. 94.70 mm

(3.728 inch) Note:

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 18 Illustration 18

Numerical sequence of bolts for 3064 Engine Numerical sequence of bolts for 3064 Engine

Turbocharger

SMCS Code: SMCS Code: 1052 Illustration 20 Illustration 20 g00530558 (1) Compressor wheel (2) Turbine wheel (3) Turbine housing (4) Compressor housing (5) Cartridge housing Note:

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

Numerical sequence of bolts for 3066 Engine 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)

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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 22 900530561

(7) Lock plates

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

Turbine housing (3) and Cartridge housing (5)

Align the turbine housing (3) with the cartridge housing (5).

(8) Clamp

Apply 5P- 393 1 Anti-Seize Compound to the threads of the clamp. Tighten the clamp to the following torque 4 ± 1 N-m (35 ± 9 lb in) Tap clamp (8) lightly around the circumference. Tighten clamp (8) to the following

torque 4 ± 1 N-m (35 ± 9 lb in) i01575653 i01575653

Exhaust Manifold

SMCS Code: SMCS Code: 1059 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

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12

Specifications Section 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: SMCSCode: 1210 Illustration 26 (1) Camshaft gear

Maximum permissible temperature of the gear for installation on the camshaft.... 315°C (600°F) Note:

Note: Do not use a torch. (2) Diameters of camshaft journals

Table 1 Number Number of Journal of Journal for 3064 for 3064 Engine Engine 1, 2 1, 2 3 3 Number Number of Journal of Journal for 3066 for 3066 Engine Engine 1, 2, 3 1, 2, 3 4 4 Standard Standard Diameter Diameter 53.94 to 53.96 mm (2.123 to 2.124 inch) 52.94 to 52.96 mm (2.084 to 2.085 inch) Service Service Limit Limit(1)(1) 53.90 mm (2.122 inch) 52.90 mm (2.083 inch)

(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)

(4) Camshaft lobe lift Specified camshaft lobe lift (4)

Exhaust lobe 7.344 mm (0.2891 inch)

Inlet lobe 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) Note:

Note: Replace the camshaft if the service limit for the lobe lift is reached.

(5) Camshaft lobe height (6) Base circle

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

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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. (7) Camshaft

Maximum permissible runout for

camshaft 0.020 mm (0.0008 inch)

Straighten the camshaft if runout is less than the following amount 0.050 mm (0.0020 inch) Replace the camshaft if runout is more than the following amount 0.050 mm (0.0020 inch)

Illustration 29

(8) Camshaft bearing

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 Clearance between camshaft journals and bushings Standard Standard Diameter Diameter 0.04 to 0.09 mm (0.002 to 0.004 inch) Repair Limit Repair Limit(1)(1) 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.

(9) Install the dial indicator in order to determine gear end play.

End play 0.10 to 0.25 mm

(0.004 to 0.010 inch) Replace the thrust plate if the end play exceeds the following amount 0.30 mm (0.012 inch) Thrust plate thickness 4.85 mm (0.191 inch)

Engine Oil Relief Valve

SMCS Code: SMCS Code: 1315

Illustration 31 Engine oil relief valve

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 343 ± 20 kPa (50 ± 3 psi) Tighten the engine oil relief valve to the following

torque 49 + 5 N-m (36 ± 4 lb ft)

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14

Engine Oil Pump

SMCS Code:

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 220°C (356° to 428°F) 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:

Note: Replace the oil pump gear assembly if the clearance exceeds the service limit of 0.150 mm (0.0059 inch).

(15)

(7) Cover

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.

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)

(10) Bolts

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: SMCS Code: 1924

Table 3

Engine Oil Pressure Engine Oil Pressure

(1) (1)

Oil Pressure at 1500 rpm

Oil Pressure at idle(2)

196 to 392 kPa (28 to 57 psi) 98 kPa (14 psi)

(1)The oil temperatu re must be 60°to 70°C (140°to 158°F). (2) Engine idle is 900 ± 20 rpm.

Engine Oil Bypass Valve

SMCS Code: SMCS Code: 1306-BV

Illustration 37

Illustration 36

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

Inspect the spring for weakness or damage. Free length of spring 83.5 mm (3.29 inch)

(16)

16

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)

Engine Oil Pan

SMCSCode:

SMCSCode: 1302

2

Illu stra tion 38 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)

Water Temperature Regulator

SMCS Code:

SMCS Code: 1355

The water temperature regulator starts to open at the following temperature. ... 71° ± 2°C (160° ± 4°F) The optional water temperature regulator starts to open at the following temperature 82°C (180°F) The valve lifts more than 10 mm (0.4 inch) at the

following temperature 85°C (185°F)

The optional water temperature regulator lifts more than 10 mm (0.4 inch) at the following

temperature 96°C (204°F)

Water Pump

SMCS Code: SMCS Code: 1361 Illustration 39 (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

(0.826 to 0.854 inch)

Illustration 40

(17)

The press fit between the water pump shaft and the flange is the following

(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) J01576112

Cylinder Block

SMCSCode: SMCSCode: 1201 Illustration 41 ^005294 44 (1) Cylinder block

Measure the amount of the warpage of the cylinder block with a straightedge and feeler gauge. Maximum allowable

cleara nce 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.

(2) Cylinder liner

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 Tolerances of Cylinder Sleeves

Inside Diameter Out of Round Taper Standard at Standard at Assembly Assembly 102.010 to 102.045 mm (4.0161 to 4.0175 inch) 0.010 mm (0.0004 inch) 0.015 mm (0.0006 inch) Repair Repair Limit Limit(1)(1) 102.200 mm (4.0236 inch) N/A N/A Service Service Limit Limit(2)(2) 102.700 mm (4.0433 inch) N/A N/A

(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.

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

Oversize Bore Oversize Bore 0.250 mm (0.0100 inch) 0.500 mm (0.0197 inch)

Cylinder Bore Size Cylinder Bore Size 102.260 mm (4.0260 inch) 102.295 mm (4.0274 inch) 102.510 mm (4.0358 inch) 102.545 mm (4.0372 inch)

(18)

18

(3) Cylinder liner

Service limit of cylinder liner 102.700 mm (4.0433 inch) Replace all cylinder liners that exceed the service limit.

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.

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 i01573686

Crankshaft

SMCSCode: SMCSCode: 1202 Illustration 45 900525341

(1) Crankshaft main bearing journal

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

Table 6

Main Bearing Journal Main Bearing Journal Original size journal (1)

Undersize journal 0.25 mm (0.010 inch) Undersize journal 0.50 mm (0.020 inch) Undersize journal 0.75 mm (0.030 inch) 89.95 to 89.97 mm (3.541 to 3.542 inch) 89.70 to 89.72 mm (3.531 to 3.532 inch) 89.45 to 89.47 mm (3.521 to 3.522 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.

5. The bore of the cylinder must be

(19)

(2) Crankshaft

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).

Illustration 47

(3) Width of crankshaft main bearing

journal 33.000 to 33.039 mm

(1.2992 to 1.3007 inch)

(4) Crankshaft end play 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 Dimensions for Grinding of Crankshaft

Oversize Thrust Plates Oversize Thrust Plates Oversize Oversize Thrust Thrust Plate Plate +0.15 mm (+.006 inch) +0.30 mm (+0.012 inch) +0.45 mm (+0.018 inch) Oversize Oversize (front or (front or rear) rear) 33.15 mm (1.305 inch) 33.30 mm (1.311 inch) 33.45 mm (1.317 inch) Oversize Oversize (front or (front or rear) rear) 33.30 mm (1.311 inch) 33.45 mm (1.317 inch) 33.60 mm (1.323 inch) Tolerance Tolerance +0.039 mm (+0.0015 inch) +0.039 mm (+0.0015 inch) +0.039 mm (+0.0015 inch)

Torque for the crankshaft pulley nut .... 490 ± 5 N.m (363 ± 4 lb ft) The maximum temperature for installing the crankshaft gear is the following value 100 °C

(20)

20 Specifications Section i01576124

Crankshaft Seals

SMCSCode: SMCSCode: 1160; 1161 Illustration 49 g00525904 (1) Front seal (2) Rear seal assembly Note:

Note: The rear seal assembly and the slinger are installed as a unit.

(3) Slinger Note:

Note: The rear seal assembly and the slinger are installed as a unit.

(4) Rear seal assembly Note:

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)

i01576126

Connecting Rod Bearing

Journal

SMCSCode:

SMCSCode: 1202; 1219; 1225

Table 8

Connecting Rod Bearing Journal Connecting Rod Bearing Journal

Original size journal(1)

Undersize journal 0.25 mm (0.010 inch) Undersize journal 0.50 mm (0.020 inch) Undersize journal 0.75 mm (0.030 inch) 59.945 to 59.965 mm (2.3600 to 2.3608 inch) 59.695 to 59.715 mm (2.3502 to 2.3510 inch) 59.445 to 59.465 mm (2.3404 to 2.3411 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) 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:

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)

Main Bearing Journal

SMCSCode:

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

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 li mit is exceeded , regrind the bearing journals to the specified dimension.

(3) Bolts for the main bearing cap

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: SMCSCode: 1218 Illustration 52 (1) Matching marks

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

(22)

22

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 54

(2) Bore of piston pin

bearing _{(1.3394 to 1.3404 inch)}34.020 to 34.045 mm 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:

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.

(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 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:

Note: Replace the connecting rod if the end play exceeds 0.50 mm (0.020 inch).

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)

Illustration 57

(8) Install the piston assembly with the marks (1) on the connecting rod toward the camshaft (8).

Illustration 58

(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 and Rings

SMCSCode:

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.

(2) Piston diameter

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.

Piston projection 0.55 to 1.15 mm

(24)

24

Table 9

Dimensions for Piston Diameters Dimensions for Piston Diameters Bore Size Bore Size Standard Oversize 0.25 mm (0.010 inch) Oversize 0.50 mm (0.020 inch) Standard at Standard at Assembly Assembly 101.915 to 101.945 mm (4.0124 to 40136 inch) 102.165 to 102.195 mm (4.0222 to 4.0234 inch) 102.415 to 102.445 mm (4.0321 to 4.0333 inch) Serv

Service Limiice LimiKK(1)

101.730 mm (4.0051 inch) 101.980 mm (4.0150 inch) 102.230 mm (4.0248 inch)

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

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.

(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

Piston ring end gap for standard

(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

(25)

Illustration 62

(9) Side clearance of ring groove

Install new piston rings in the ring grooves of the piston. Measure the side clearance of the ring groove with a straight edge a nd feeler gauge. Table 10 groves acceptable 'Clearances of t i e ring groove.

Clearances

Clearances of the Piston Rings of the Piston Rings

Piston

Piston_Rings_Rings

No. 1 Compression Ring No. 2 Compression Ring Oil Control Ring Width of

Width of_Ring_Ring

3.00 mm (0.118 inch) 2.00 mm (0.080 inch) 4.00 mm (0.157 inch) Side Side Clearance

Clearance_{of Ring}_{of Ring}

Groove Groove 0.080 to 0.120 mm (0.0031 to 0.0047 inch) 0.080 to 0.120 mm (0.0031 to 0.0050 inch) 0.025 to 0.065 mm (0.0010 to 0.0026 inch) Service Service Limit(1) 0.200 mm (0.0080 inch) 0.150 mm (0.0060 inch) 0.150 mm (0.0060 inch)

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

(A) End gap for No. 1 ring (top compression ring) (B) End gap for No. 2 ring (intermediate

compression ring) (C) End gap for oil control ring (X) Camshaft side of engine block (Y) Side of engine with combustion chamber Position the piston rings according to Illustration 63.

Gea

Gear

r Gro

Group (Front)

up (Front)

SMCS Code:

SMCS Code: 1206

(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

(26)

26

(5) Crankshaft gear

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

Idler gear (2)

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.

Table 11

Item Item Backlash of idler

gear End play of idler

gear Clearance between idler gear bushing and shaft Standard at Standard at Assembly Assembly 0.03 to 0.17 mm (0.001 to 0.007 inch) 0.05 to 0.20 mm (0.002 to 0.008 inch) 0.009 to 0.080 mm (0.0004 to 0.0031 inch) Service Limit Service Limit(1)(1) 0.25 mm (0.010 inch) 0.35 mm (0.014 inch) 0.100 mm (0.0039 inch)

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

(6) Idler gear bolt

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)

(7) Inside diameter of idler gear bushing (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 i01576345

Flywheel

SMCSCode: SMCSCode: 1156 Illustration 68 g00529633 (1) Flywheel

(27)

Place the flywheel on a surface plate. Use a dial indicator in order to measure the flatness of the flywheel.

Standard at assembly of flywheel 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.

(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

Crankshaft Pulley

SMCSCode:

SMCSCode: 1205

Illustration 70

Tighten the crankshaft pulley nut to the following

torque 490 ± 10 N-m (361± 7 lb ft)

i01449909

Bel

Belt Tension

t Tension Chart

Chart

SMCS Code:

SMCS Code: 1357

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

(28)

28 Specifications Section Table 12 Size of Belt Size of Belt 3/8 3/8 1/2 1/2

Belt Tension Chart Belt Tension Chart

Width of Belt Width of Belt 10.72 mm (0.422 inch) 13.89 mm (0.547 Inch) Gauge Reading Gauge Reading Initial Belt Tension

Initial Belt Tension(1)(1)

445 ± 22 ± 22 NN (100 ±5 lb) ±5 lb)

534 ± 22 N ± 22 N (120 ±5 lb) ±5 lb)

Used Belt Tension

Used Belt Tension(2)(2)

400 ± 22 N (90 ± 5 lb) ± 22 N (90 ± 5 lb)

400 ± 44 N (90 ±1 ± 44 N (90 ±1 0 lb0 lb))

Borroughs Gauge Numbers Borroughs Gauge Numbers Number of the Selected Number of the Selected

Gauge Gauge BT-33-97 BT-33-97 Measure the tension of the belt that is farthest from the engine. 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

Belt Tighten

Tightener

er

Alternator

Alternator and

and Regu

Regulato

latorr

SMCS Code:

SMCS Code: 1358 SMCS SMCS Code:Code: 1405; 1410

Illustration 71 goossosos illustration 72 g00530887

(1) Bolt. (1) Nut for alternator pulley

Apply pressure to each belt midway between the Tighten the nut for the alternator pulley to the

pulleys in order to inspect the belt tension. Adjust following torque 132 to 162 N-m

the bolt for the alternator if the tension is incorrect. (97 to 119 lb ft)

The proper tension for the fan drive belt is Polarity negative ground

approximately the following deflection 12.0 mm

(0.50 inch) Rotation either direction

Speed for testing (rpm) 5000 rpm

Output voltage 28.0 ± .5 V

(29)

Electric Starting Motor

SMCSCode:

SMCSCode: 1453

Coolant

Coolant Temperatu

Temperature

re Switch

SMCS Code:

SMCS Code: 1395; 1906

Illustration 73

(1) Terminal nuts

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

74 74 Engrie

Engrie coolancoolant temperatut temperaturere switch

Tighten the engine coolant temperature switch to the foiowing torque. ... 7 to 12 N-m (62 to 106 lb in)

Engin

Engine

e Oil

Oil Pressure Switch

SMCSCode: SMCSCode: 1924

Engine oil pressure pressure switch

Tighten

Tighten the engine oil pressure switch to the cylinder

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

101578156 101578156

Ai

Airr Inlet Heater

SMCS Code:

SMCS Code: 1090

Tighten the four bolts that secure the air inlet heater to the inlet manifold to the following

(30)

30 Index Section

Index

L Lifter Group 6 M

Main Bearing Journal 21

P

Piston and Rings 23

R Rocker Shaft 7 S Specifications Section 4 T Table of Contents 3 Turbocharger 10 V Valve Mechanism 8

Valve Mechanism Cover 9

W

Water Pump 16

Water Temperature Regulator 16

A A

Air Inlet Heater 29

Alternator and Regulator 28

B

Belt Tension Chart 27

Belt Tightener 28

C

Camshaft 12

Connecting Rod 21

Connecting Rod Bearing Journal 20

Coolant Temperature Switch 29

Crankshaft 18 Crankshaft Pulley 27 Crankshaft Seals 20 Cylinder Block 17 Cylinder Head 9 E

Electric Starting Motor 29

Engine Design 4

3064 Engine 4

3066 Engine 4

Engine Oil Bypass Valve 15

Engine Oil Pan 16

Engine Oil Pressure 15

Engine Oil Pressure Switch 29

Engine Oil Pump 14

Engine Oil Relief Valve 13

Exhaust Manifold 11

F

Flywheel 26

Fuel Injection Lines 5

Fuel Injection Nozzles 6

Fuel Injection Pump 5

G

Gear Group (Front) 25

I