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CATERPIILAR'
sENR5s45-03 1999 January

Sloc@ffiil@atnons
3064 and 3066 Engines For Gaterpllar b Built Machines
(Engine) 6LK1-Up (Engine) 7JK1-Up

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320i8, 32OE L, 32OB U, 32OB LU EXGAVATORS& 32OB LL FOREST HACI{INES Volume I (Engine, Electrical, Operation and tlaintenance) 4NRl-Up, SBRl-Up, 6GRl-Up' lDSl.Up' lESl.Up' 6LSl.Up' EESI-Up, gGSl-Up, 9JSl-Up' 4XWl-Up' SGWI.Up' 3tRl-UP' 4H Rl -Up, 9KR{ -Up' I GSI -U p' 2rII21.Up, 7ZZ1 -Up, 8G21.Up, AEDI-Up, BANI-Up, BBGI -Up

sENR9242-12 Contents for Service Manual SENR924O

separately. Manualfor product.Theitemslistedcan be ordered this Service Thisformliststhe complete Note as and in added, theywill be announced PREVIEW shouldbe ordered they or supplements Whenitemsare updated and for contents form REG1139F, current Manual microfiche, Contents Referto the Service available. become numbers thismanual. of Scction Title Form No, SENR23OO SENR9241 SENR7733 SENR9242 SENR3130 SENR,2ETO SENR5545 SENR5546 SENR5553 SENR9243 sENRil996 RENR1998 RENRlOOT SENR9258 RENR1O58 RENR3725 SENRiIET4 sEBU6975 SEBU7O79 XEBU2571

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Binder Label Binder Safety Manual Contents Service ications Torqr.re Specif Engine Index Tab 3066Engine ErgineSpecifications and Adjusting 3066Engine Testing Operations, Systems 3066Engine and Disassembly Assembly 3066Engine Supplement and Disassembly Assembly Elecfical Srsterns & Opeatos Station Index Tab Control and Engine PumpElectronic SystemsOperation System and Starting Charging SystemsOPeration System Electrical Schematc ForestMachines Electrical System; Schematic (6151-Up, 9JS1-Up) Electrical System(7721-UP Schematic BBGl-Up) 8GZ1-Up, taintenance lndex Tab and Operation Maintenance -Up, (6LS1 9JS1'Up) Machines Forest and Maintenance Operation -Up,BANI-UP, (721 -Up, 8GZ1 and Operation Maintenance BBGl-Up)

For information, see Engine, Electrical& Maintenance information. Systems This manualcontains Note: pageRENR2982. Contents

03/09/00

CATERPILIAR'

10056692

lmportantSafety Information
t r = M o s t c c i d e n tts a ti n v o l v p r o d u co p e r a t i o m,a i n t e n a n c e d r e p a i a r ec a u s e c ; ' . - ' = - . e an a h n A. t b b o b s e r v b a s i c a f e t yu l e s r p r e c a u t i o n sn a c c i d e nc a no f t e n e a v o i d e d y r e : : a ' - - = : : ' e r t i a l l y e r s o hazardous A mustbe alertto pote-: -=-=-:: - s situations occurs. person before accident an i p e r s o n h o u l d l s oh a v e h en e c e s s a r r a i n i n g , i l l s n dt o o l s o p e r f o r mh e s e- - : : - : : ' - . - ' y s sk a t t a t ty lmproperoperation, or and lubrication, maintenance repairof this productcan be dangerous could result in injury or death. Do not operateor performany lubrication, maintenance repairon this product unt,i you have or read and understoodthe operation,lubrication,maintenanceand repair information
':-=:: Safetyprecautions and warnings are providedin this manualand on the procjlc: w a r n i n g s r e n o t h e e d e d b o d i l yi n j u r y r d e a t hc o u l d o c c u rt o y o u o r t o o t h e ' p e ' s : - : a , o The hazardsare identified the "Safety AlertSymbol"and followedby a "Signa by "WARNING" shownbelow. ",:': as

-,

Themeaning thissafety is of alertsymbol as follows: Attention!BecomeAlert! Your Safetyis Involved. and can ce the explains hazard Themessage appears that under warning the
pictorially presented. lace s cby Operations that may cause productdamageare identified "NOTICE" t n i sp u b l i c a t i o n .
-':^l n

3\

Caterpillarcannot anticipateevery possiblecircumstancethat might involve a PGri: *a n^zerd. not The warningsin this publication and on the productare, therefore, all indusite. a tool, procedure,work methodor operatingtechniquethat is not specifically recomHlc Caterpillaris used, you must satisfy yourselfthat it is safe for you and for others-Yc- s h o u l d also ensurethat the product will not be damagedor be made unsafeby the oPerabor - orication, maintenance repair proceduresthat you choose. or
-th^+ ar t T h ei n f o r m a t i o n ,e c i f i c a t i o a n di l l u s t r a t i oi n sh i sp u b l i c a t i o n eo n t h e : a s s - ' - ' : ' sp ns, : :: ,:: ::':-=: : Thespecifications was was available thetimethatthe publication wntten. at - : : : - , :- l = S C a n a c i l, ns d m e a s u r e m e n t d , u s t m e n itls u s t r a t i o a n , o t h e r t e m s a nc h a n g e t a n r ' : - : asj - _ J t --:-- = - - ^g^u{l ^ .v ^ ano the to that affect service is given theproductObtain complete mos::-":-the -:

yclu orarr arry )ob. Caterpllar

dealers have the most current information avai a3:

=:'

T\OS\

M C c u r r e n p u b l i c a t i ofn r m n u m b e r s v a l l a b l e ,e e t h e S e r v i c e a n u a l o n t e r - : s ' . ' : ' : - : - = t s o a

JYT,

3 Tableof Contents

f v

Tableof Contents

i' .,'

v.

4 icationsSection Specif N o t e :T h e f r o n te n c c ' : - : ; - I --: l t h e f l y w h e ee " o o ' : - : : - ) - = -.Lfro the f lywhee : -- - -- : -:=' . c y l i n d eirs t h e f r o n : ,

Section Specifications
r01020901

- : cositeof
- : -

--=

- ^ ^{ +t ^ > uv u t L It v - /^ ,,i^,^,^/- : c vtvvru

N o .1

EngineDesign
SMCS Code: 1201

3066Engine

3064Engine

lllustration 2 Cylinderand valve location lllustration 1 Cylinderand valve location (A) Exhaustvalves.(B) lnlet valves.
900523889

)',t295223

(A) Exhaustvalves.(B) lnlet valves

Bore...,..... Stroke

. . . 1 0 2m m ( 4 . 0 2i n c h ) 1 3 0 m m ( 5 . 1 2i n c h ) . . . 4 . 3L ( 2 6 0i n ' ) . .l n - l i n e

Stroke
icnlanomant

'-

5 1 2i n c h ) a:-.390in')

arrangement Cylinder p V a l v e s e r c y l i n d e.r. . .

In-line . .......2 : 3-6-2-4 . . . . 1 71

Displacement................

H
ii I ll
ll

C y l i n d ea r r a n g e m e n t . . . . . . . . . . . . . . . . . r p V a l v e s e rc y l i n d e r Firing rder o rn Compressioatio

Firingorder .,,,,.......2 rato Compression .......13-4-2 ...)......17.1

Fuelinjection . . . .1 0 o r 1 6 c : ; - = = = : : - - ' = t o p c e n t e r timing Note:Referto the Engine -'-^'-.' -'-: -' p e r f o r m a n cs p e c i f i c a t r o ' e tnfo'-a::(Technical Marketing F u e lS e t t i n g n d R e l a t e c' ' - ^ ' - z ' a t h e c o r r e c tt i m i n g p e c ' : e . : - : s r M i n i m u mo m . . . . . . . . . . . . . . . is rotation ' :".:: The crankshaft end of the engine.Cranks-=: rotation - - : a:e for the ==':'to theTMI -' '-'-'to the : - ' : r o f i c h ef o r . . 9 0 0t 2 0 - -- -e flywheel - - -- erclockwise

injection Fuel top bfore center B or 20degrees timing


Note: Referto the Engine Inforfnation Platefor the performance specification number. Referto the TMI (Technical MarketingInformation) referto the or for Microfiche FuelSettingand RelatedInformation the correcttimlngspecifications, r M i n i m u mp m . , . . . , . . . . . . 900t 20
I

rotationis vrewedfrom the flvwheelr i The crankshaft ' '..*'-' end of the engine.Crankshaft ....Counterclockwise rotation

Note:The frontend of the e-; -= . , ::osite of - -' s de of the l t h e f l y w h e ee n d o f t h e e n E ' = s e n g i n e n d t h e r i g h t i d ec ' : - : : - , ' : - - :a r ev i e w e d a -= No. 1 l f r o mt h e f l y w h e ee n d o f t l ' e : - : cylinderis the frontcylinder

\t\

5 icationsSection Specif

i01029707

) v

FuelInjection Lines
SMCSCode:1252

valveholderto the Tightenthe delivery f o l l o w i n go r q u e . . . 3 9 t o 4 4 N m ( 2 9 t o 3 2 l b f t ) t (3) Boltfor lock plate Tightenthe bolt for the lock plateto the f o l l o w i n go r q u e . . . . . .3 t o 5 N m ( 2 7 t o 4 4 l b i n ) t . ( 4 ) Boltfor fuel line Tightenthe bolt for the fuel lineto the following 1 0t o 1 3 N ' m ( 7 t o 1 0 l b f t ) torque.

rsut
-t\

/5\

n l d l e rs u b s p r i n g u t nut Tightenthe idlersubspring to the following '12 to 16 N'm(9 to 12 lb ft) torque.

FJ

-//

/4'
(6)
9oo53o3o7

lrllar crhqnrinn

lllustration3

to Tightenthe idlersubspring the following . . . . . . .1 6 t o 2 0 N ' m ( 1 2 1 o1 5 l b f t ) torque. (7) Nut Tighten the nut to the followlng 3 t o 5 N ' m ( 2 7t o 4 4 l i n ) torque.
i01029643

( 1 ) F u e li n j e c t i o ln n e s i Tighten fuel injectlon the line nutsto the f o l l o w i ntg r q u e . o . . . . . . . 2N ' m ( 1 8 l b f t ) 5


\01029754

i v

Pump FuelIniection
SMCS Code: 1251,1290

FuelInjectionNozzles
SMCS Code:1254

lllustration5

g0O53O2B0

(1)Seal (2) Fuelinjection nozzle


lllustratlon4 soo53o354

(3) Retainer fuel injection nozzle for boltto the following Tightenthe retaining . . , . . . .2 . N ' m ( 1 6 l b f t ) .2 torque.

( 1 ) B o : s f o rf u e li n j e c t i o l i n e n line T grten the boltsfor the fuel injection to the ' o , o w i n go r q u e . . . . . 2t0 2 5 N ' m ( 1 5t o 1 B l b f t ) t o (2) De rvery valveholder

6 Section Specifications

t01024279

ValveMechanism
S M C SC o d e : 1 1 0 2

o--P

3>#\g

n\-P Y
lllustration6
900530283

( ) Body for fuel injectionnozzle (5) Shims i m I n c r e a s i ns h i m sb y O . 1 O m ( . O O an c h )c h a n g e s g 1375 kPa pressureby approximately injection in psi).Shimsare avatlable nine sizesfrom (2OO a m O . ' 1 0 m ( , O O i n c h )t o 0 . 5 8m m ( . 0 2 3i n c h ) . (6) Pressure spring (7) Pressure Pin (B) Gasket (9) Pln nozzle (10) Tip for fuel injection nozzle nut (11) Retaining for fuel injection the nut to the following Tighten + ......34 5 N m (25talbfI) torque. valvesteExhaust ( 4 ) Diameterof valve s:el n l e tv a l v es t e m , m .-- c 7.955 m : ' * : : 3 1 3 2i n c h ) . - - : o 7 9 4 0m m -: :3126inch)
!., ^ - r , 3 . 1 1 0n c h ) i
lllustration7
/ I \ Qnrinn I ga n nv it h l l L l r r nr rv lva r l ur tec.' -^'^:

900526366

l51 rurus

:es: Free length after' b M a x i m u m e n di n s 3 ' - :

-: '. 50to 55 lb) - -- (2.22inch) 2 degrees

0 ' - ( 1 7 3 , n " n '-, \ t

( 2 ) Valvestem seal (3) H e i g h t o t o p o f v a . : l , : :


'-l tO.30 mm : : : : . 0 1 2i n c h )

. s t e m. , , ; . . . . . . . . . . . .

' - . = ' ^ a u s tv a l v e a e M i n i m u m l l o w a b l c e - =-' = ' i : : - - - ( . 3 0 9 1n c h ) stem........... - alve ! f C l e a r a n c eo r i n t a k e ' = : : -- - - - , 0 0 3 3i n c h ) o g u i d e . . 0 . 0 5t5 0 . 0 8 5 ^ valve i f C l e a r a n c eo r e x h a u s , a . = : ' = -- - - : : 0 0 4 1i n c h ) g u i d e, .0 . 0 7 0t o 0 . 1 0 5 ' - - : . ; i d ef o r i n l e t : a e M a x i m u m l l o w a b l c l e e ' a '-a = - - ' - ( 0 0 5 9i n c h ) v a l v e. . . .

l,w

icationsSection Specif

lv

lvlax mum allowable for clearance guide for . . 0 . 2 0 0m m ( 0 0 7 9 i n c h ) e x ^ a . r sv a l v e . . . t I -.s Ce diameter valveguide of of L.- :e diameter guidefor inlet .a.: .. m . 1 3 . 0 2 5o 1 3 . 0 3 5 m t ( . 5 1 2 8o . 5 1 3 2 n c h ) i t l - . s r e d i a m e t eo f g u i d ef o r e x h a u s t r .z .= . 1 3 . 0 2 5o 1 3 . 0 3 5 m m t ( . 5 1 2 8o . 5 1 3 2 n c h ) i t -s :e diameter guidefor new inlet of .... m t 8 . 0 1 0 o 8 . 0 3 5 m ( . 3 1 5 4 o . 3 1 6 3i n c h ) t - : - = i a m e t eo f o u i d ef o r n e w e x h a u s t r . : . = 8 . 0 1 0t o 8 . 0 2 5m m ( . 3 1 5 4 o 3 1 5 9 i n c h ) t ^ . ' ' , - J m i n s i d ed i a m e t efro r o u i d ef o r i n l e t
....

( 1 1 ) V a l v e e a tb o r ef o r i n | e t . . 4 6 . 0 0t0 4 6 . 0 2 5 m m o s ( 1 . 8 1 1 t o 1 8 1 2 0i n c h ) 0 ('12)Valveseat bore for exhaust 39.000to 39.025mm ( 1 . 5 3 5 4o 1 . 5 3 6 4 n c h ) i t

tl

A. v O u w

ml m l ll rl

/ ? 1rO v
\.u

innh\

llv1,/

' . ' i ' - J m i n s i d ed i a m e t efro r o u i d ef o r e x h a u s t

. = .=
- - -occ nf lin

i 8 . 1 2r r m ( . 3 2 0 n c h )

lllustrationI

900527479

( 1 3 ) W d t h f v a l v es e a t . . . . . . . o

1 4 0 0 . 2 5m m ( . 0 5 5t . 0 1 0i n c h )

, : .: c thickness rnlet for and exhaust .: .:-i 2 1 3 m m ( , 0 8 4i n c h )

)L

',' - ---n allowable for valvelip thickness inlet . . 1 . 2 0m m ( . 0 4 7i n c h ) :-: :xlaust valves :- = ovalve ace.........,. f 30 degrees

permissible width of the valve Note:The maximum m s e a ti s 1 . B O m ( . 0 7 1i n c h ) . (14) Valveseat angle 30 degrees

(15) Dimension from top of closedvalveto face of


not

E x h a u svt a l v e . . . . .

. . . . . . 0 . 5t0 0 . 2 5m m ( . 0 2 0t . 0 1 0i n c h )

I n l e v a | v e . . . . 0 . 4t 0 0 . 2 5m m ( . 0 1 6t . 0 1 0i n c h ) t p e T N o t e : h e m a x i m u m e r m i s s i b ld e p t h i s 1 . 1 0m m ( . 0 4 3i n c h ) .

trusira: i-

900526884

(Br l=c:^ of bore in head for valveseat -se': , . 9 , 5 t 0 . 1m m ( . 3 7 4x . . 0 0 4i n c h ) ( 9 ) C ^ a ' : f e ro f i n l e t a l v e . . . v ......40 egrees d

of Note:Tne depth of the chamfer the inletvalveis 2 . 3 8 = C 1 0 m m ( . 0 9 4t . 0 0 4i n c h ) . ( 1 0 ) C ^ a m f e r f e x h a u sv a l v e o t ..45 degrees

lllustration 10

gOA52749A

(16) Pushrod

Note:Tne depth of the chamferof the exhaustvalve m i s 2 0 0 t 0 . ' 1 0 m ( . 0 7 9t . 0 0 4i n c h ) .

8 Specifications Section

in Use a dial indicator orderto check all pushrods runout. for Replacethe pushrodif the runoutexceedsthe following value. 0.40 mm ..... ( . 0 1 6i n c h )
t01023644

.,

ValveRockerArm
SMCS Code: 1123

lllustration12

900526256

( 3 ) A l i g nt h e o i l h o l e si n r o c < ? '= ' ^ : - s h i n g( A ) w i t ht h e o i l h o l e s n t h e ' c : - . ' . ' - ' , v h e n t h e i r o c k e r r m b u s h i n gs r e c : = : i a

tl

^"'-

lllustration 11

900526252

_3at*
vJ:-/-

-/"

(1) Rocker rm bushing a Bore in rockerarm bushingfor . . . . . . . 0 . 0 1 1o 2 0 . 0 9 4 m m shaft........... 2 t (.7878o .791 inch) t 1 (2) Rockerarm shaft Diameterof rockerarm shaft...
lllustration13

-/"

900526257
- ^r rnlrn^

1 9 . 9 6 6o 1 9 . 9 8 4 m m t ( 7861to .7868inch)

Position rockershaftbrac.e = the bolts. (4) Long bolt Tightenthe long bolt to i-e ': . . .1 5 - " torque. (5) Shortbolt Tightenthe shortbolt to :^e':

of Clearance rockerarm bushingfor i s h a f t . ,..... . . 0 . 0 2t7 0 . 1 2 8m m ( . 0 0 1 1o . 0 0 5 0 n c h ) o t Replace the rockerarm bushingif the repairlimit Replace of 0.15 mm (.006inch) has been reached. the rockerarm bushingand the rockerarm shaft tf

11

tBlbft)

I?:::3': "tit

has arm of therocker bushins been

torque.

..,.15 =

v 11 + A lh ft\

(6) Rocker shaftbracket

I icationsSection Specif

141025762

CylinderHead
SMCS Code: '1100

1 lllustratlon 4 Valvelash adjustment

900526261

Tur^ :^: crankshaft untilthe timingmark on the r c ' e ' - = - a ' : o u l l e yi s a l i g n e d i t ht h e p o i n t e o n t h e w : - - I :=ar houslngin orderto adjustthe valve as- :::^ the No, 1 inletvalveand the No 1 e / - . . : - . A v e n u s h r o d s u s tn o t b e i n t e n s i o n m
- --^.^^t,^. ^.^^

lllustraton 16

944527524

( 1 ) C y l i n d eh e a d r and Use a straightedge a feelergaugeto check head for warpage, the cylinder

i - : . : - : e x h a u sv a l v el a s h . . .0 . 2 5m m ( . 0 1 0i n c h ) t .
t01023202

) \,

ValveMechanism Cover
S M C SC o d e : 1 1 0 7

Resurface cylinder the head if the warpage ....0.20 m m amount exceedsthe following ( . 0 0 8i n c h )

ol "_:" " o n":3 "l' "lln :u'l": 3%li'?.'d#,? : r "n

of Gasketthickness cylinder h e a d . . . . . . . . . . . . 1t. 7 0 1 0m m ( . 0 7 0t . 0 0 4i n c h ) 0. . 0 T h i c k n e so f n e w h e a d . . . . . . . . . . . 9 5+00 , 1 0m m s (3.740t .004 inch) head.. 94.70mm thickness cvlinder of Minimum (3.728nch) i Note:The repairlimitof the contactsurfaceof the gasketand the repairlimitof the cylinderblock i s u r f a c e s 0 . 2 0m m ( . 0 0 8i n c h ) .

lluslra::-

900525829

(1) ,a,::over nul


the valve cover nuts to the followinq 3to5Nm(26to44 lbin) aBttagr .

15. 11-$

FoZ

5(!-Q)1s

lllustration 17 Numericalsequenceof bolts for 3064 Engne

10 icationsSection Specif

t\
o rC-Ot f9-O6 tt

lllustration18 Numericalsequenceof bolts for 3066 Engine

900527527

Put clean engrne on the threadsof the cylinder oil the boltsand tightenthe boltsin head bolts.lnstall to numerical sequence the following the appropriate t . . . . . . . . 1 1 85 N ' m ( 8 7 t 4 l b f t ) torque.
i01030322

lllustration 20

900530560

(6) Turbine shaft P l a c ea d i a l i n d l c a t o ' o -: - : shaft. Move the comPress:' in axialdirection orderto-= p l a y . . .0 . 0 5 7 o 0 . 1 0 3 . t rr-s: :: Note:The turbocharger m t h e t u r b o c h a r q e r u s tb e : - : : ' the end play is beyondt-? s:= :' :neturbine 1 ) r nt h e
-^^ ^t^,, E^ = ru Pray. Lrru

Turbocharger
,ri
i

SMCSGode:1052

. c . 0 0 4 1i n c h ) . =- . e m b J e d n d a - . : ' : l e a r a n c e si f
-: :^S,

0\

^-Y

19 lllustration

900530558

( 1 ) Compressor wheel (2) Turbine wheel


lllustration 21

(3)Turbinehousing
(4) Compressor housing (5) Cartridge housing of Note: Mark the orieniation the compressor housing, the cartridgehousingand the turbine housingbeforedisassembly.

(7) Lock plates Position lock platesa^c the ..,, torque. the following -=^ the boltsto -- \'m (15lb ft)

11 Specifications Section

i01029608

ExhaustManifold
SMCS Code: 1059

l',-s'.'a::^ 22 r-T -: -:-srng (3) and Cartridge (5) housing

900530562

!-'*"

:-rbine housing(3) with the cartridge -)

lllustration24

900530254

( 1 ) Nuts for turbocharger to Tighten the nutsfor the turbocharger the 41 N'm (30 lb t) torque. foilowing

( 2 ) Studsfor turbocharger

tt
I -s:'a:3,^
ri ^;-n,

to the studsfor the turbocharger the Tighten 12 N'm (9 lb ft) torque. followlng

(3) Studsfor exhaustmanifold


to manifold the studsfor the exhaust Tighten 12.5N'm (9 lb t) torque. th following
23 900530564

manifold (4) Nuts for exhaust to manifold the the nutsfor the exhaust Tighten 20 N'm (15 lb ft) torque. following

: : : . 5 P - 3 9 3 1A n t i - S e i zC o m p o u n do t h e t e the :--.:s of the clamp.Tighten clamp to the ': :,',.g torque. 4 t 1 N ' m( 3 5 t 9 l b i n ) Tac : a-: (8) lightlyaroundthe circumference. Tig^::- : amp (8) to the following . . 4 x 1 N ' m( 3 5 t 9 l b i n ) torc-?

te

Camshaft
SMCS Code: 1210

^f\,\ l )v ' \\ \
,\T,i

" f) ,v)

\iN
lllustration26
900527952

Note:
lllustraton25
900527937

(4) Camshaft lobe lift lobe l: camshaft Specified E x h a u sl to b e . . . . . . Inletlobe limitfor lobe liftfo' :'- =Service limitfor lobe liftfo' - =' Service t N o t e :R e p l a c e h e c a m s ' : the lobe lift is reached. (5) Camshaft iobe heigi:: - - - ( 2 8 9 1i n c h ) ^-(2633inch) . 6 . 8 4 4m m (.2695nch) i 6 . 1 8 9m m (.2437inch)

(1) Camshaft gear


permissible Maximum temperature the gear of for installation the camshaft . 315'C (600'F) on ... Note: Do not use a torch. journals (2) Diameters camshaft of
Table1

It,

Number Number of Journal of Journal for 3064 i for 3066 Engine Engine 1,2 1 , 2 ,3

' -: ::-. ce limit or f

Standard Diameter 53.94 to 53.96 mm (2.123to 2.124 inch) 52.94 to 52.96 mm (2.084to 2.085 inch)

53.90mm (2.122inch)

(6) Base circle

52.90 mm (2.083inch)

1. Measure camshafioc: -= the the 2. Measure base circie '--^:inStep2 the base circe :-=- . 3. Subtract - S t e p1 . T h e f r o mt h e l o b eh e i g h t n a : s ' - - - 'd i f f e r e n c ie t h e a c t u a c a - : - : s : : 3 l i f t( 4 ) .

(1)Theservice dimension the servce or limitis the maximum for that dimension is specified a part. limitis the minimum
Qptac th part i{ the se.vice limit is reached-

platebolt (3) Thrust Tighten boltto thefollowing the 1 8N ' m( 1 3l b t ) torque.

0b

v
Clearance between camshaft journalsand bushings

Standard Diameter

Repair Limit(1)

ooo,l3J0,3 "
.do7,""n1

,0.15 (.006 inch)

mm

(1)The reoairlimitis the maximum or dimension the repairlimts the minimumdimensionthat is specifiedfor a part. Repairthe part if the repairlimit is reached.

l L l u S l ' l r O2 7 n

900528061

and blocksin orderto Note:Jse a dial indicator Takeone half :::='- 1e the runoutof the camshaft. readingas the runout. :' -: r al indicator
- --^h^{+ - = 5r tdlt

' , ' r x . n u mp e r m i s s i b lre n o u f o r u t . . . . . 0 0 2 0 m m ( . 0 0 0 8i n c h ) :a-shaft if S 'a ghtenthe camshaft runoutis lessthan the ' : c w i n ga m o u n t . 0 0 5 0 m m ( . 0 0 2 0i n c h ) :=i ace the camshaft runoutis morethan the if ': :,,,,lng 0.050mm (.0020inch) amount.
29 lllustration
900529304

in (9) Install the dial indicator orderto determine gear end play i t0 E n d p | a y . . . . 0 . . 1 o 0 . 2 5m m ( 0 0 4 t o . O 1 0 n c h ) the thrustplateif the end play exceeds Replace i m f o l l o w i na m o u n t. ,. . . . . . . . 0 . 3 0m ( . 0 ' 1 2n c h ) g the

.t-

I)\1
ti\

4i

t . T h r u s p l a t e h i c k n e s s . . , . 4.. 8 5m m ( . 1 9 1i n c h ) t

(-\r
\

-]l_,o
900528067

lllustral,cr28
R, i:-cn:fi l_raarinn

with lhe bearing a dialindicator. Meas-'e camshaft journal in of lne Suc:rac: diameter thecamshaft
n r n e ' ' o o i v e l - r e a r i n o l e a r a n c e s .R e f e r t o T a b l e 2 . c
lllustration30

M
900529307
I

(10) Tappetbore diameter ..... Tappetbore diameter ..22.000Io 22.021mm ( . 8 6 6 1 o . 8 6 7 0i n c h ) t M a x i m u ma p p e tb o r ed i a m e t e.r. . . ...2 2 . 0 5 5m m t ( . 8 6 8 3i n c h ) ,
I

' r'{: Clearanceof tappet to b o r e . . .0 . 0 3 5t o 0 . 0 8 6m m ( . 0 0 . 1 t4 . 0 0 3 4 n c h ) o Note: Replacethe tappet if the clearanceis exceeoeo.
i01030986

NOTICE Beforeoperation, the pump n!s: :: :ubricated with clean engineoil and the pump -,si turn freely by hand or damageto partscan 5e :-= result. N o t e :T h e m i n i m u m c c e c : a 3 - : - : s s ! r e a t l o w a = i d l e i s 1 O O P a( 1 5 p s i ) . k ( 1 ) D r i v e n e a ra s s e m b l y g (2) Drivegear assembly
/"\ f.\l ^r rmn ^a.r

EngineOil PressureRelief Valve


SMCS Code: 1315

(4) ldler gear assembly The backlash betweer:-= amount.


t h e i c i l e ro c e r s t h e f O : , , , - :

: -^.: gear and - --:oO190mm - - : : . I 0 0 7 5i n c h )

N o t e :R e p l a c e h e g e a r s ' : - = : : - . : s ^ e x c e e d s t 0 . 3 5m m ( . 0 1 4i n c h ) (5) Spindle


lllustration31 Oil pressurereliefvalve
900530799

N o t e : h e o i l p u m p g e e re ' : - : : ' , : g e a r T ' ' . . 3imo gear is assembly are not servicea:= removed.

el

Removethe oil pressurereliefvalve from the cylinderblock.Checkthe valveand the valveseat Inspectthe spring for abnormal contactpatterns. the oil pressure for weakness damage.Replace or reliefvalve, if necessary. p e t R e l i ev a l v eo p e n i n g r e s s u r . . . . . . 3 4 3 2 0 k P a f (50 t 3 psi)
i01 30415 0

EngineOil Pump
Code:1304 SMCS

,
1r

!..
i

lllustration 33

900530644

.:
14 ll

(3) Olpumpgear Note:Do not usea torch,

lllustration32

900530573

15 icationsSection Specif

1v

Heat the oil pump gear to 180' to 220'C (356" to 428"F) and supportthe end of the drive gear snaftin orderto install oil pump gear. the Pressthe oil pump gear untilthe oil pump gear is f lushwith the end of the shaft.

lllustration35

900530702

(7) Cover Measure insidediameters the boresof the of the shaftsin the cover(7) and the oll pump housing(6). Measure boresof the shafts. the The clearance between the gear shaftsand the . o i l p u m p h o u s i n g n d c o v e r . . . 0 . 0 4t o 0 . 0 7m m a ( 002 to .003 lnch)
900530697

llirs:'aton34

-.r

the Note:Replacethe oil pump gear assembly, cover, the oil pump housingif the clearance or exceedsthe servicelimitof 0.15 mm (.006inch). Note:Replace the drivegear and drivengear as an assemory.

r e i n : , f n . n . l' n r , '- r - i

rJmp gear

'.ieasure difference the lengthof the in the o a s s e m b rfy r t h e o i l p u m p g e a r a n d t h e d e p t h - : ^ e o , rp u m p h o u s i n g . 0.020to -0.034 mm I earance ( 0008 to - 00'13 inch) if Note:Replace the oil pump gear assembly the crea'a.ceexceedsthe servicelimitof -0.150 mm ( - C C 5 9r c h ) . the Meas-'e the clearance between oil pump gears g w a n c : ^ e o r lp u m p h o u s i n g i t ha f e e l e r a u g e .
t^-.^^^^

to mm 0.050 0.098 (.0020 .0039 inch) to


lllustration36

Note: Rep\aoe the oil pump gear assembly if the clea'a^ce exceeds the servce limit of -0.150 mm

900530704

( - 0 C 5 9r n c h ) .

( B ) l d l e rg e a rb u s h i n g I n s i d e i a m e t eo f i d l e rg e a r d r 25.000to 25.021mm bushing (.9843to .9851inch) Maximum diameter idlergear bushingfor oil of pump...... i . . . . . . . . . 2 5 . 0m 9 ( . 9 8 6 6 n c h ) 5m

(9) Splndle Drameter spindle of 24.939to 24.960mm (.9818to .9827inch)

16 Specifications Section

Minimum diameter spindlefor oil of pump...,... . , . . . . . . . 2 4 . 9m 1 ( . 9 8 0 4 n c h ) 0m i


i01 31038 0

Openingpressure bypass . = = of

9 8 1t 98 kPa t+z t 14 psi)


l Aa

t\

i01030410

Engine Pressure Oil


SMCS Code:1924
Table3

Engine Pan Oil


SMCS Code:1302

Engine gil Psssrg(t)

Oil Pressure 1500rom at Oil Pressure iflls{e) t

196 to 392 kPa (28 to 57 psi) 98 kPa (1a psi)

(l) The oil temperature must be 60'to 70"C (140'to 158"F) (2) Engineidle is 900 r 20 rpm.

i01030990

Engine Bypass Oil Valve


SMCS Code: .1306
lllustration38
/r \ \ r./ ar;l \Jil ^^^ Pdr h^t+^ r uL)rJ

P"900530566

Tightenthe oil pan bc .-. torque. ( 2 ) O lp a n d r a i np l u g Tightenthe oil pan c'a - : -e foliowing 1 2 9 4 l b f t )
0 10 3 3 3 7 8

el

Temperature Regulator Water


SMCS Code: 1355

il' ii, 'l


I
1 90053080

5I - 8010 WaterTemperature

Regulator
e T h ew a t e rt e m p e r a t u rre g - : . : ' : ' : ' - : o o p e n a t thefollowingtempelatule - - , ( 1 6 0 '+ 4 ' F ) The valveliftsmorethan '1: -following ,., temperature, - -:r) at the 85"C(185"F) Note:The oil bypassvalveis mountedlnsidethe oil pan alongthe rail of the oil pan. ('1)Valveseat Check the valve and the valve seat for abnormal contact patterns. (2) Spring Inspectthe springfor weakness damage. or Freelengthof spring 83.5 mm (3.29inch)

5I - 8020 WaterTemperature

Regulator
T h ew a t e rt e m p e r a t u rre g - a : : - : ' : " : : c o p e n a t e . the following temperature. 32"C(180'F) The valve liftsmorethan 10 -followingtemperature - -^) at the 36'C (204'F)

06

17 icationsSection Specif

i 0 1 0 3111 1

WaterPump
SMCS Code: 1361

The pressfit betweenthe water pump shaftand the is rmpeller the following t a m o u n t... . .0 . 0 3 2t o 0 . 0 6 5m m ( . 0 0 1 3 o . 0 0 2 6i n c h )
tO1a2B288

CylinderBlock
SMCS Gode: .1201

41 lllustraton l l l L s : ' a t o3 9 n
900530877

900529444

( 1 ) C y l i n d eb l o c k r the Measure amountof the warpageof the and biockwith a straightedge feeler cylinder gauge.Maximum allowable . . . . . . .0.. 0 5m m ( . 0 0 2i n c h ) , clearance Repailimit...... r . . . . . . . . . 0 . m0 ( . 0 0 8i n c h ) 2 m

'

-oeller

and the waterpump shaft Tr: 'aces of the impeller a'e' -sn. ( 2 1F a n g e (3r -i'e to fromthe face of the impeller the distance pump housing the following is .',are' .. a'nount. 21.00lo 21.70mm (.826to .854 inch)

the Resurface top of the block if the repairIimitis reached.

42 lllustration 40 lllustraton
g00530BZB

900529446

(2) Cylinder sleeve

(4) V/a:e'pump shaft

T^e cress fit betweenthe water pump shaft and t a e ' a n g e i s t h ef o l l o w i n g .. ... 0.035to 0.065mm an:oint. ( . 0 0 1 4 o . 0 0 2 6i n c h ) t

18 icationsSection Specif

sleeve of Measure insidediameter the cylinder the Measure the to that is parallel the crankshaft. insidedrameter the cylindersleevethat ls in a of position the crankshaft. perpendicular Measure to the top, the middleand the bottomof the cylinder sleeve.Referto Table4 for tolerancesof the sleeves. cylinder
Table4

Q,(

Tolerances of Cylinder Sleeves


i--_!-_

standard Standard

n^--Repair

c^n,^^ Service

A""lirory
Inside Diameter

Limit{l)

Limit)
lllustration43
900529534

1 0 2 . 0 1t0 o 102.700 102.200 102.045 mm (4.0161 mm (4.0236 mm (4.0433 inch) inch) to 4.0175
inch)

(3) Cylinder sleeve l o ' S e r v i c ei m i t f c y i ; n c = : - : . 102.700mm i 4 0 4 3 3i n c h )


- - - ::U +h^ tl lU ^^",,i^^ Jl V IUV

Out of Round Taper

m 0.010 m
(.0004inch) 0 . 0 1 5m m (.0006inch)

N/A
N/A

N/A N/A -r a R e p l a c e l lc y l i n d e s l e e . = : = limit


-

(1)The repairlimitis the maximum or dimension the repairlimitls the mnimumdimensionthat is specifiedfor a part. Repaira part if the repairlimit is reached. (2) The service lmts the maximumdimensionor the service limit is the minimumdimensionthat s specifiedfor a part. Replacethe part if the servicelimit is reached.

\ -\z ,^: --'l -<t

-\// ,

ba

oversize Bore the cylinderto the specified the repair reaches if dimension the insidedtameter does not reachthe diameter limitbut the inside servicelimit.Referto Table5. Hone the sleeveto +0.25 mm (+ 010 inch) Hone the or +0.50 mm (+.020 inch) oversize. sleeveto an accuracywithin0.010to 0.045 mm ( . 0 0 0 4 o . 0 0 1 8i n c h ) . t that is necessary dimension the Determine oversize in orderto clean up the cylinderif any sleevehas unevenwear. that are in excessof sleeves all Replace cylinder the serviceIimit. Note: Refinishall sleevesto the same oversize dimensron. Use a ridge reamerin order to cut the ridge of the cylinderif the sleeveis in good Hone the cvlinderbore. condition.
Table5

--*$z
| :, I

?*

LI

lllustration44 Cylindersleeves

900529962

'iil

procec-': Use the following cylindersleeves.

- : l:- .f, repalr Ine

1l
I

^e 1 . S e t u p a b o r i n gm a c n : - - '= = , n d e r b l o c k . :enter of the A l i g nt h e b o r i n gm a c r , ^ e, ' , '.re lessworn of the cylinders e:. : bottom

m 2. Borethe sleeveuntiltne :- :" = = =s 0 . 5 0 m ( . 0 2 0i n c h ) .


o' 3. Removethe remainder :-: not to damagethe cyllnc:' : Alig^ a 4. Install new sleeve. block. of the cylinder

B ==.e, ecareful
= = .e w i t ht h e t o p

OversizeBore

CylinderBore Size

mm inch) 0250 (0100 J3273:5ilil iliil i:339?


0 . 5 0 0m m ( . 0 1 9 7i n c h ) i m 102.510 m (4.0358nch) 102.545mm (4.0372 inch)

5. The bore of the cylinder

mm ( to 102.000 102.035

. 10 1 7 1i n c h ) .

LI

19 icationsSection Specif

'-"'":l"i ':l: ."zu8ro l:: *o 068 eo mm


(3.5441to .5460nch) 3 i -- diameter the main bearing of . . . . . . . 9 0 . 1 5 0 ( 3 . 5 4 9 2n c h ) mm i r l.t of deck from centerline crankshaft of to t 3 0 7 . 0 0 0 . 0 5m m ( 1 20 B O . 0 0 2i n c h ) t reight from the centerline crankshaft of to 3 0 6 . 7 0 m ( 1 2 . 0 7 5n c h ) m i
i01023233

Put sealanton the contact surface betweenthe Put slingerand the crankshaft. clean engineoil on the surfaceof the rear sealassembly (6) Distance from rearsealassembly end of to 6.0 mm (.24 inch) crankshaft
r01022388

ConnectingRod Bearing Journal


SMCS Code: 1219;1225
Table6

Crankshaft Seals
1 S M C SC o d e :1 1 6 0 : 1 6 1

Connecting Rod Bearing Journal Originalsize journal(l) journal Undersize 0 . 2 5 m m ( . 0 1 0i n c h ) journal Undersize 0 . 5 0 m m ( . 0 2 0i n c h ) journal Undersize 0 . 7 5 m m ( . 0 3 0i n c h ) 59.945to 59.965mm (2.3600to 2.3608inch) 5 9 . 6 9 5t o 5 9 . 7 1 5m m (2.3502to 2.3510inch) 59.445 to 59.465 mm (2.3404to 2.3411 inch) 5 9 . 1 9 5o 5 9 . 2 1 5 m t m ( 2 . 3 3 0 5 o 2 . 3 3 1 3i n c h ) t

lc
; -Si'3i l' =.--45 -^^l

(1) Regrindthe connectingrod journalsto the next undersize dimension the repairlmitof 59.980mm (2.3614inch) is if exceeded.

betweena new bearingand a new The clearance j o u r n ails t h e f o l l o w i n g a l u e . . . . . . 0 3 5t o 0 . 1 0 0m m v 0 ( 0014 to .0039inch) if bearingis required the clearance An undersized rod the between connecting journaland the bearing is in excessof the servicelimitof 0 200 mm (.0079inch).lf the crankshaft worn excessively, or is bearing is an if the crankshaft uneven, undersized bearingis required, lf is required, an undersized listedin Table6. grindthe crankshaft a dimension to for tolerance rod bearing Note:The allowable journalsthat are out of round is 0.010 mm repairlimitis 0.030mm (.0004inch).The maximum , ( . 0 0 1 2 n c h ) .l f t h e r e p a i rl i m i ti s e x c e e d e dr e g r i n d i journals the specified the bearing to dimension.

900525904

f 2 =:='seaassembly
Nter --: .oar eeat assembly and the s l i n g e r a r e

<

-^a/

Note
:-:

-^e 'ear and the slrnger are seal assembly


=-^ iJ ^,,^i+ d ut ilt,

i-: =:2'

sealassembly

Note
r =:

--3 tear seal assembly shouldbe flushwith - :e' afterinstallation.


^ ' 5^ A ^ d+ t t t f l =

( 5 l:-:act surfacebetweenthe sltnqerand


-. _

t
:
t

20 Specifications Section
P u tt h e m a i n D e a '- : : = : :
nrlin|or horrinn iinhion hln hnJtc tho rrz D - ) =u-' I = ,- r-:

\01022652

MainBearing Journal
SMCSCode:1203
/?\

torque.
iel indininr
+h^ UtY -^ IIrd

-:J- :

- = following 'C1 t4lbft)

t .:{ln: I

i n d i c a t o r .u o r r a : : ' = : : S journa "a- " = crankshaft t h e m a i n b e a r i n g' . ' = .


UgOl ll IU UIVOI Ol Ug v :

f \r ^ ^ ^ , ,,^ fvfuclutv

-==

^ a dial '^e : ameter o -'re the


- ^ a l

Clearance betweer c'a'. :' 0earrng Note:Replace bear- : s :' ' the t o t h e n e x tu n d e ' s ' z e = 2 " c clearance exceeosO 2a -T a b l e f o r d i r r e i ^ s , o ra ' - - : = 7 s

'^aland main -:o011Bmm c 0047 inch) - l r Deaflng -:-r Referto


dt-. - a E aaal'^A^1+ Ut At lnJt tdtL

ot.

lllustration46

90052534i

journal (1) Crankshaft main bearing Measure the main bearingjournal. The diameter of journalis givenin Table the crankshaft main bearing 7.
Table7

N o t e :T h e a l l o w a b l eo i e ' a - : : - : ' - . ' c e a r i n g t i o r r n a lt s a ta r e o rr t o f . : , - : : - - - - n m h ( . 0 0 0 4 n c h ) T h em a x i r - - - = := ' - . s 0 0 3 0 m m i ( 0 0 1 2i n c h ) . f t h e r e p a ' - ' : : - : : J u , r g I t t u l j t h e b e a r i n go u r n a l so : ^ e s : - : . - - * ^ ^ i ^ ^ t


--.-^^ .^^,;^A :, iEI IJU I,

Main BearingJournal
Originalsize journal(t) journal Undersize 0 . 2 5 m m ( . 0 1 0i n c h ) 89.95 to 89.97 mm (3.541to 3.542 inch) 89.70 to 89.72 mm (3.531to 3.532 inch) 89.45 to 89.47 mm (3.521to 3.522 inch) journal Undersize 0.75 mm (.030 inch)
(1)

N o t e :T h e m a x l m u m e n ' : : s iournaiis -0.90 mm (- 03: crankshaft the cranxs?a-. if :this specification

, '-: crankshaft : = : a C et h e
: i . ' ,I ' n D e y O n O

89.20 to 89.22 mm ( 3 . 5 1 2 o 3 . 5 1 3i n c h ) t

Begrindthe main bearingjournalsto the next undersize dimensionif the repair limit of 89.85 mm (3.537 inch) is exceeded.

lllustration48 Typicalexample

900525380

(4) Crankshaft Supportthe crankshai - = -= - - . e e b l o c k s . M e a s u r eh e r u n o u t i - : - . - - = ' ^ e C e n t e f t d j o u r n a lM a x i m u m u n o - : . r . 0 . 0 2 0m m ( 0008 inch)


lllustration 47
900525373

Note:Replacethe cranksna . the reoairlimitof 0.050mn'

'-.- ;t exceeds

(2) Main bearingcap

ra

Note:The maximumrepairlimitis 0.300 mm (.01 8inch). 1 thrustplatesif the end play the standard Replace Threeoversize standardclearance. exceedsthe if as thrustplatesare available replacements the limit. Generally, end play stillexceedsthe maximum than to the rearjournalis likely be worn morerapidly the rearthrust replace the frontjournal.lf necessary, thrustplates. plate.Referto TableB for oversize
Table8 Dimensions for Grinding of Crankshaft Oversize Thrust Plates lllustration49
900525383

mainbearing (5) Widthof crankshaft

Oversize Thrust Plate

Oversize (front or rear)

Oversize (front or rear)

Tolerance
+0.039mm (+.0015 inch) +0.039mm (+.0015 inch) +0.039mm (+.0015 inch)

journal

m o3 . . . . . . . 3 3 . 0t0 0 3 . 0 3 9 m (1.2992 '1 inch) to .3007

3 3 . 3 0m m 3 3 . 1 5m m + 0 . 1 5m m i ( + . 0 0 6 n c h ) ( 1 . 3 0 5i n c h ) ( 1 . 3 1 1 n c h ) i

33.45mm 33.30mm mm +0.30 n 1 (+.012 inch) ( 1 . 31 i n c h ) ( 1 . 3 1 i7 c h )

I
lllustration50

ryfr
900525387

33.60mm 33.45 mm +0.45 mm inch) ( + . 0 1 8n c h ) ( 1 . 3 1 7n c h ) (1.323 i i

pulleyto nut the retaning of the crankshaft Tighten 4 g t h f o l l o w l n t o r q u e . . . . , . 9 0 + 5 N m ( 3 6 3t 4 l b f t )


tO1022446

ConnectingRod
S M C SG o d e : 1 2 1 8

(6) Put the main bearingand thrustplatesin the Put the blockand install crankshaft. clean engineoil on the bolt threadsTightenthe bolts 137 t 5 N'm torque. to the following ( 1 0 1t 4 l b f t )

lllustration 52

q00525099

( 1 ) M a t c n i nm a r k s g

51 lllustrahon

1 9005254 3

are Themarks usedto align the cap to the rod, connectrng

end olay.End the (7) lv'leas:re crankshaft I 0 . ' 1 0 0o 0 . 2 6 4m m ( 0 0 3 9t o . 0 1 0 4i n c h ) c a,

22 Specifications Section

(3) Connecting rod bolts

put Beforeassembly, c ea- =- I -= cil on the b o l tt h r e a d s n d a l l s u r l a : = - - : * a K e c o n t a c t a b e t w e e n h e b o l ta n d c o - - = - ' ' , - : l c a p s . t T i g h t e nh e c o n n e c : ' a ' - = - - ' : - - - e f o l l o w l n g t il:-: .--z6t4lbft) torque. ( 4 ) M e a s u r e h e b o r e sa ' e r : - : t rods and recordthe c -:-. : _ 1nna^trnn

t(

-- e bores.

lllustration 53

9 0 0 5 2 50 3 1

(A) The upper oil hole is 40 degreesabove the horizontal centerline. (B) The loweroil hole is 30 degreesbelowthe horizontal centerline, (C) The end of the pistonpin bearingis 30 degrees belowthe loweroil hole.
lllustration 55
9 0 0 5 2 59 4 1

(5) Connecting rod


'-: g eno play. U s e a f e e l e r a u g et o - : : : - : p l a y . . . 0 . 1 5t o 0 3 : - . , -: :o 014 inch) End

N o t e :R e p l a c e h e c o n n e : . I ' : : t -:e x c e e d s . 5 0m m ( A 2 i 0

an

ntq\/

'l I

\/

h(
\\

V/

/uI

Cl:---'
illu$raon 54

(2) Bore of piston pin bearing

34.020to 34.045mm (1.3394 '1.3404 inch) to

lllustration 56

900525201

(6) Piston (7) Markings piston on ' A s s e m b l eh e p i s t o na n d c c - - = : - = ' : d s . E n s u r e t :-: themarks o t h a tt h e m a r k i n g s n t h e p , s : : o o n t h e c o n n e c t i nrg d ( 1 )a t e . - - - = = : ' n es i d e .

The clearancebetweenthe piston pin bearing and the piston pin is 0.023to 0.054 mm (.0009to .0021inch). Note:A clearancefor the pistonpin to the pistonpin bearingover 0.010 mm (.0004inch) is excessive. Replacethe piston pin or replacethe bearingif the clearanceis excessive.

tC

23 ications Section Specif

Plstonprojection

. . 0 . 5 5 o 1 . 1 5m m t ( . 0 2 2 1 o . 0 4 5n c h ) i
\a1421241

Pistonand Rings
SMCS Code: 1214,1215

lllustraton57

90o525206

withthe marks(1) on (B) Install pistonassembly the . the connecting towardthe camshaft (8). rod

lllustration59

900524461

(1) Markings n piston o


58 lllustration
900525250

(9) Pistonprojection procedure measure the to Use the following block. lf helghtof each pistonabovethe cylinder range,inspect are clearances not in the acceptable for the components wear or damage. of the 1. Determine top centerposition the piston assemblY. with a dial indicator
on the top of 2- inetalt the dia.t indicator assembly the block. Set the needle of the dal indicator to

which are stampedon Each pistonhas markings are used to algn The markings top of the piston. side of the to the plstonassembly the camshaft cylinderblock, (2) Pistondiameter that are for Table9 givesthe dimensions prstons for Table9 also givesthe dimensions standard, pistons that are oversize. alongthe the pistondiameter Note:Measure perpendicular the pistonpin bore. of

zero. (9) 3. Measureprojection at three places on the top of the piston.Take an averageof the the in threemeasurements orderto determine from the projection. Subtractthe projection head gasketin of thickness the cylinder installed the between the orderto determine clearance head. top of the pistonand the cylinder read of thickness the cylinoer Installed . . 1 1 0 t 0 1 0 m n r ( . 0 7 0t . 0 0 4i n c h ) gasket

lza
ications Section Specif
ir^^^,,,^ +A^ -^ i-' : -: '

gear (5) Crankshaft Note:Ensure that the markson the timinggearsare in alignment.

faolor ac' r^a Qcj;' 'trflaraaar h v l. ' ' . " . - r .J rvrur vuqr v

- '- : ' , a f W i t h a ;^tenthe ,.r-:,.35N'm (26 rb ft)

lllustration 65 ldler gear (2)

900527864

lllustration 67
/?\ \/,/ r^^i!^ ilt>rLrg :i^-^+^' Ljrdr rErur ^. v C:. :_: : . _ _

j00527912

-c

and rotatethe idler gear Install dial indicator a (2) back and forthin orderto measurebacklash. exceedsthe Replacethe idlergear if the backlash servicelimit.Referto Table11.
Table11

/ Q\

lrilar

noe

r c h af t

\ v / , v ' v '

i t R e p l a c eh e b u s h i n g : ' : : : = - : - . a i d l e rg e a r b u s h i n g n d : - e : = -' -' : - 1 -?= . the servicelimit.Reterrc

- -t,.,^n tF.n - =ivvEvt I L t 9 ---{+ ^./^^^^^ : dtL E^ugvu)

( m t 0.03 o0.17 m (.001to .007inch) mm 0.05.to^0.20 [] lr,

0r028537

rtrtil?.,
. clearance

('br+ ncn)
m 0.100 m (.0039 inch)

0.35mm

Flywheel
S M C SC o d e : 1 1 5 6

i ii
I t

I
ili

(.ooo4 to ?:'-Y":il95j mm s"-1'-o!:llls .ooitincn L and Snan

to o.oog o.ogo

(1) Replacethe idler gear if the servicelimit is exceeded

, 1 i
lllustration 68
900529633

l'
lllustration66
9 0 0 5 2 7 90 1

(1) Flywheel
--^ | t^^ ^,.1:^l l P l a c et h e f l y w h e eo n a s - ' - = : : : '.iness of the n i n d i c a t oi r o r d e rt o m e a s - ' = ' - = f lywheel. ' ..0 15mm Standardat assemblyo' ..,', ==

(6) ldler gear bolt

/ OA
\.vvv

i nrn r \r / h v

27 icationsSection Specif

m R e p a i r i m i to f f l y w h e e l... . . . 0 . 5 0 m ( , 0 2 0l n c h ) l if the Note:Refrnish flywheel the repairlimitis exceeded

r01053076

BeltTensioner
SMCS Code: 1358

lllustration69

q00529634 lllustration70

q0054632 1

face with a (2) Measure runouton the flywheel the f M d i a li n d i c a t o r . a x i m u ma c e r u n o u t .. . 0 . 1 5m m ( . 0 0 6i n c h ) l R e p a i r i m i to f f a c e r u n o u t . . . . . 0 . 5 0m m ( . 0 2 0i n c h ) if the Note:Refinish flywheel the repairlimitis exceeoeo. o' temperature the ring gear Maxnrm permissible withoutusinga on for installatlon the flywheel ( . .. 150"C302'F) rorcn.,,..,.... on Note:The ring gear is pressed the flywheel. boltsto the following the Tighten flywheel 83 t 5 N'm (61 t 4 lb ft) torque o N u m b e r f t e e t ho f t h e f l y w h e erli n gg e a r . . . . .... . 1 2 7

(1) Bolt. Apply pressureto each belt midway betweenthe Adjust pulleysin orderto inspectthe belt tension. is if the bolt for the alternator the tension incorrect. the fan belttensionis approximately Proper .12.0 mm (.50 inch) . deflection. following

28 icationsSection Specif

i01031047

Belt Tensioner
SMCS Gode: 1358

Alternator
SMCS Code: 1405

o,o.,r.,f (

lllustration71

900530808

lllustration 72

900530887

(1) Bolt
Apply pressureto each belt midway betweenthe Adjust pulleysin orderto inspectthe belt tension. if ifre Oottfor the alternator the tensionis incorrect the is Properfan belt tension approximately . . . . . 1 2 0m m ( . 5 0i n c h ) d following eflection.

( 1 ) N u tf o r a l t e r n a t o r u l r e . ' P t T i g h t e nh e n u tf o rt t e z ' . ' ' . t f o l l o w i n go r q u e,., . Polarity Rotation Speedfor testing(rPm) :- ey to tne 'i2 t o 1 6 2N ' m l - t o 1 1 9l b f t ) - = ; a t i v eg r o u n d : :rer direction . 5000 rPm . 2 8 . 0t . 5 V 504

voltage Output o Rated utPut..

II

.a
-!

29 icationsSection Specif

1 00 3 1 3 7 8 1

Electric Motor Starting


SMCS Code: 1453

lllustration 73

900530889

(1)Terminnuts al
Tighten termrnal nutsto the following the torque. . . . . . . 1 1 1 N ' m( 9 7t 9 t b i n ) t The rotationis viewed from the drive end of the electncstarting motor.Rotation electricstarting of motor...,..... clockwise No load conditions S p e e d( r p m ) . . . Maximum current(draw) Voltage 3 3 0 0r p m m i n l m u m ...85 A ...............23\/

30 lndexSection

lndex
A Alternator .-'.'28 P a Piston nd Rings . . . . . . . . ' . . . 2.3' . .

B BefTensioner................ t 27,28

c
.'.'.'12 Camshaft 2. . . . . . . . . . . . . . . . . . . 1" ' C o n n e c t i nR o d . . . . . . . . . . . g ...'..19 Journal Rod Bearing Connecting . . . . . . . . . . . . . . . . .1.9 . " . . C r a n k s h a St e a l s. . . . . . . . . f '...'."17 C y l i n d e8 1 o c k . . . . . . . . . r . . . . . ' . .9' . C y l i n d eH e a d. . . . . . . . . r E M ElectriStarting otor......... c D Engine esign 3 0 6 4E n g i n e 3 0 6 6E n g i n e . V O Engine ilBypass alve ......" f n g i n eO i l P a n O engine il Pressure Valve Relief fngine Oil Pressure f n g i n eO i l P u m P E x h a u sM a n i f o l d t F Flywheel n F u e lI n j e c t i oL i n e s n F u e lI n j e c t i oN o z z l e s n F u e lI n j e c t i o P u m P '.."..26 ".'.......5 . " . . . " . . . . ' . . . ' . . . .5 ' . . . ........'.5 '."'.-....".29 .'-.....'.'.'...'.4 '..'.'.".'...'....4 '-.-.'."...'..'.'-4 .-........16 1. . . . . . . . . . . . . . 6. . 1 . . . . . . . .6 .-.'.'.'14 '.".""'...14 .'..'.'.....11 r V a l v eR o c k e A r m . . . . . . . . . . . . .'....',..",.....8

w
.......'.."'..'..17 . W a t eP u m p . . . . . . . . r 16 ' .'............... Regulator Temperature Water = .6 - 8 0 1 a t eT e m p e r a t u r::: - l a t o r . . . . ' . . .1 . . . W r 5I =e "" - 8 0 2 0W a t eT e m p e r a t u r= : - l a t o r . ' . . . . "1 6 r 5I
(

( G G e a r r o u pF r o n t ) . . . . . . . . I Information. Safety lmportant


M J M a i nB e a r i n g o u r n a | . . . . . . . . . . . .

.....................25

"--.-.--....'.2

20

tI