r

CATERPIILAR' sENR5s45-03
January1999

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

{
j
,J
 320i8, 32OE L, 32OB U, 32OB LU EXGAVATORS& 32OB LL FOREST sENR9242-12
HACI{INES
Volume I (Engine, Electrical, Operation and tlaintenance) Contents for
4NRl-Up, SBRl-Up, 6GRl-Up' lDSl.Up' lESl.Up' 6LSl.Up' Service Manual SENR924O
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
Note¡ Thisformliststhe completeServiceManualforthisproduct.Theitemslistedcan be orderedseparately.
Whenitemsare updatedor supplements added,theywill be announcedin PREVIEW and shouldbe orderedas they
becomeavailable.Refer to the Manual
Service Contents REG1139F,
microfiche, for currentcontentsand form
numbersof thismanual.

Scction Title Form No,

Binder SENR23OO
BinderLabel SENR9241
Safety SENR7733
ServiceManualContents SENR9242
Torqr.reSpecifications SENR3130
Engine Index Tab SENR,2ETO
ErgineSpecifications 3066Engine SENR5545
SystemsOperations, Testingand Adjusting 3066Engine SENR5546
Disassembly andAssembly 3066Engine SENR5553
Disassembly and Assembly Supplement 3066 Engine SENR9243
Elecfical S¡rsterns & Ope¡atoÉs Station Index Tab sENRil996
SystemsOperation Engineand PumpElectronic Control RENR1998
\-,
System
SystemsOPeration Startingand Charging RENRlOOT
Schemat¡c ElectricalSystem SENR9258
Schematic ElectricalSystem;ForestMachines RENR1O58
(6151-Up, 9JS1-Up)
Schematic Electrical
System (7721-UP RENR3725
8GZ1-Up, BBGl-Up)
taintenance lndex Tab SENRiIET4
Operationand Maintenance sEBU6975
Operationand Maintenance ForestMachines (6LS1-Up,9JS1'Up) SEBU7O79
Operationand Maintenance (721 -Up, 8GZ1-Up, BANI-UP, XEBU2571
BBGl-Up)

Note: Engine,Electrical&
This manualcontains Maintenance For Systemsinformation,
information. see
page
Contents RENR2982.

03/09/00 CATERPILIAR'
 10056692

lmportantSafety Information -,
M o s ta c c i d e n ttsh a ti n v o l v pe r o d u cot p e r a t i o mn ,a i n t e n a n caen d r e p a i a r r ec a u s e c= ; ' . - ' = - .
o b s e r vbe a s i cs a f e t yr u l e so r p r e c a u t i o nAsn. a c c i d e nct a no f t e nb e a v o i d e db y r e : : a ' - - = : : ' e r t i a l l y
hazardous situations beforean accidentoccurs.A personmustbe alertto pote-:¿ -=-=-:: - s
t h e s ei - - : : - : : ' - . - ' y
p e r s o ns h o u l da l s oh a v et h en e c e s s a rt rya i n i n gs ,k i l l sa n dt o o l st o p e r f o r m

lmproperoperation,lubrication,maintenanceor repairof this productcan be dangerousand

could result in injury or death.
Do not operateor performany lubrication,maintenanceor repairon this product unt,i you have
read and understoodthe operation,lubrication,maintenanceand repair information

Safetyprecautionsand warningsare providedin this manualand on the procjlc: ':-=::

, o d i l yi n j u r yo 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 : - :
w a r n i n g sa r e n o t h e e d e d b

The hazardsare identifiedby the "SafetyAlertSymbol"and followedby a "Signa

"WARNING" as shownbelow. ",:':

Themeaning
of thissafetyalertsymbolis as follows:
Attention!BecomeAlert! Your Safetyis Involved.

thatappearsunderthe warningexplainsthe hazardand can ce

Themessage
pictoriallypresented. 3\
Operationsthat may cause productdamageare identifiedby "NOTICE"lace s c- -':^l n
t n i sp u b l i c a t i o n .

Caterpillarcannot anticipateevery possiblecircumstancethat might involve a PGri: *a n^zerd.

The warningsin this publicationand on the productare, therefore,not all indusite. É a tool,
procedure,work methodor operatingtechniquethat is not specifically recomÍHléc
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,
maintenanceor repair proceduresthat you choose.
-':' - --
, i l l u s t r a t i oi n st h i sp u b l i c a t i oanr eo n t h e : a s s - '
T h ei n f o r m a t i osnp,e c i f i c a t i o an ns d th^+

::':-=: : : , : :
was available at thetimethatthe publication waswntten.Thespecifications : :
- : : : - , :- l = S C a n
m e a s u r e m e nat d s ,j u s t m e n itlsl u, s t r a t i o a
nn s ,do t h e ri t e m sc a nc h a n g ea t a n r ' : - : --:-- =- -_ - ^J g^t u{l ^ .v ^
affecttheservicethatis givento theproductObtainthe complete ano mos::-":-- -:
=:' = . T\OS\
yclu orarr arry )ob. Caterpllar dealers have the most current information avai a3:
currenp
t u b l i c a t i ofno r m n u m b e r sa v a l l a b l es,e e t h e S e r v i c eM a n u a lC o n t e r - : s ' . ' : ' : - : - = JYT,
 3
Tableof Contents

Tableof Contents
f v

i' .,'

v.
 4
SpecificationsSection

Section
Specifications N o t e :T h e f r o n te n c c ' : - : ; - I --: - : cositeof
t h e f l y w h e eel " o o ' : - : : - ) - =
- -
-
-
- ¡^
> uv
^{ +t ^
u t L It v
- /^ ,,i^,^,^/-¡
b \
: : c vtúvvru
-.- --=
r01020901 froñ the f lywheeL- : -- - -- : N o .1
c y l i n d eirs t h e f r o n :. , - : = '
EngineDesign
SMCS Code: 1201 3066Engine

3064Engine

)',t295223
lllustration 2
Cylinderand valve location
900523889 (A) Exhaustvalves.(B) lnlet valves
lllustration 1
Cylinderand valve location
(A) Exhaustvalves.(B) lnlet valves.
'- 5 1 2i n c h )
Stroke
Bore...,..... . . . 1 0 2m m ( 4 . 0 2i n c h ) ! \
ñicnlanomant a:-.390in')
Stroke 1 3 0 m m ( 5 . 1 2i n c h )
Cylinderarrangement In-line
Displacement................ . . . 4 . 3L ( 2 6 0i n ' )
V a l v e sp e r c y l i n d e.r. . . . .......2
H C y l i n d ear r r a n g e m e n t . . . . . . . . . . . . . . . . . . .l n - l i n e
Firingorder : 3-6-2-4
V a l v e sp e r c y l i n d e r .,,,,.......2
ii Compressionrat¡o . . . . 1 71
I F i r i n go r d e r .......13
- -4-2
ll Fuelinjection
ll C o m p r e s s i or a
ntio ...)......17.1 timing . . . .1 0 o r 1 6 c : ; - = = = : : - - ' = t o p c e n t e r

Fuelinjection Note:Referto the Engine -'-^'-.' - - : a:e for the

topcenter -'-: -' ==':'to theTMI
timing béfore
B or 20degrees p e r f o r m a n csep e c i f i c a t r o '
I (TechnicalMarketingtnfo'-a::- -' '-'-'to the
Note: Referto the Engine InforfnationPlatefor the F u e lS e t t i n ga n d R e l a t e c' ' - ^ ' - z ' : - ' : r o f i c h ef o r
performance specification
number.Referto the TMI t h e c o r r e c tt i m i n gs p e c ' : e . : - :
(TechnicalMarketingInformation)or referto the
FuelSettingand RelatedInformationMicrofichefor rom...............
Minimum . . 9 0 0t 2 0
the correcttimlngspecifications,
The crankshaftrotationis ' :".:: - -- -e flywheel
rpm.,...,......
Minimum 900t 20 end of the engine.Cranks-=:
rotation - - -- erclockwise
The crankshaftrotationis vrewedfrom the flvwheelr
' '..*'-'i
end of the engine.Crankshaft -
Note:The frontend of the e-; -=- . , ::osite of
rotation ....Counterclockwise t h e f l y w h e eel n d o f t h e e n E ' = - -' s de of the
e n g i n ea n d t h e r i g h ts i d ec ' : - : : - , ' : - - :a r ev i e w e d
-=
\t\
f r o mt h e f l y w h e eel n d o f t l ' e : - : No. 1
cylinderis the frontcylinder
 5
SpecificationsSection

i01029707 Tightenthe deliveryvalveholderto the

t o r q u e . . . 3 9 t o 4 4 N m ( 2 9t o 3 2 l b f t )
following
) v FuelInjectionLines
(3) Boltfor lock plate
SMCSCode:1252
Tightenthe bolt for the lock plateto the
t o r q u e . . . . . .3. t o 5 N m ( 2 7 t o 4 4 l b i n )
following

( 4 ) Boltfor fuel line

Tightenthe bolt for the fuel lineto the following
torque. 1 0t o 1 3 N ' m ( 7 t o 1 0 l b f t )

rsut /5\ l d l e rs u b s p r i n gn u t

-t-
É
FJ
\

-//
/4' (6)
Tightenthe idlersubspringnut to the following
torque.
lrllar crhqnrinn
'12
to 16 N'm(9 to 12 lb ft)

9oo53o3o7
Tightenthe idlersubspringto the following
lllustration3
torque. . . . . . . .1 6 t o 2 0 N ' m ( 1 2 1 o1 5 l b f t )
( 1 ) F u e li n j e c t i o lni n e s (7) Nut
Tightenthe fuel injectlonline nutsto the Tightenthe nut to the followlng
f o l l o w i ntgo r q u e . 5 ' m( 1 8l b f t )
. . . . . . . 2N torque. 3 t o 5 N ' m ( 2 7t o 4 4 l ó i n )

\01029754 i01029643

FuelIniectionPump FuelInjectionNozzles
¡i v SMCS Code: 1251,1290 SMCS Code:1254

g0O53O2B0
lllustration5

(1)Seal

(2) Fuelinjectionnozzle

soo53o354 (3) Retainerfor fuel injectionnozzle

lllustratlon4
Tightenthe retainingboltto the following
( 1 ) B o : s f o r f u e l i n j e c t i o lni n e torque. . . , . . . .2. .2 N ' m ( 1 6 l b f t )
T grten the boltsfor the fuel injectionlineto the
' o , o w i n gt o r q u e . . . . . 2t0o 2 5 N ' m ( 1 5t o 1 B l b f t )

(2) De rveryvalveholder
6
SpecificationsSection

t01024279

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

3>#- 7

o--P
n\-P Y
\g

900530283
lllustration6

( ) Body for fuel injectionnozzle

(5) Shims 900526366

lllustration7

I n c r e a s i nsgh i m sb y O . 1 Om m ( . O O ai n c h )c h a n g e s
/ I \ Qnrinn
injection pressure by approximately 1375 kPa
(2OOpsi).Shimsare avatlablein nine sizesfrom IL gal n n ih ru rr nr rv lval r tec.'
-^'^: 0 '-, \ t
'- (173,n"n
-: '. 50to 55 lb)
lvtl I

O.'10 m m ( , O O ian c h )t o 0 . 5 8m m ( . 0 2 3i n c h ) . lü51 rurus

Free length after':es: - -- (2.22inch)
(6) Pressurespring M a x i m u mb e n d i n s 3 ' - : 2 degrees

(7) PressurePin ( 2 ) Valvestem seal

(B) Gasket '-
(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 )
(9) Pln
( 4 ) Diameterof valve s:e-
(10) Tip for fuel injectionnozzle
l n l e tv a l v es t e m , . - - c 7 . 9 5 5m m
(11) Retainingnut for fuel injectionnozzle : ' * : : 3 1 3 2i n c h )

Tightenthe nut to the following Exhaustvalveste- . - - : o 7 9 4 0m m

-:
torque. . . . . . . 3 4+ 5 N m ( 2 5 t a l b f I ) :3126inch)

- ^ - r , 3 . 1 1 0i n c h )
s t e m. . , , ; . . . . . . . . . . . . !.,
' - . = ' ^ a u s tv a l v e
M i n i m u ma l l o w a b l ce e - =-' = '
stem........... : : - - - ( . 3 0 9 1i n c h )
- alve
Clearance f o r i n t a k e! ¿ ' = : : -
g u i d e . . 0 . 0 5t5o 0 . 0 8 5 - - - - - - , ¡ 0 0 3 3i n c h )
^ valve
Clearance f o r e x h a u s ,i a . = : ' = -
g u i d e, .0 . 0 7 0t o 0 . 1 0 5 - - - - - : : 0 0 4 1i n c h )

M a x i m u ma l l o w a b l cel e e ' a '-a: =

v a l v e. . . . -
' - - : . ; i d ef o r i n l e t
- - ' - ( 0 0 5 9i n c h )
l,w
 7

SpecificationsSection

lvlaxmum allowableclearancefor guide for ( 1 1 ) V a l v es e a tb o r ef o r i n | e t . . 4 6 . 0 0t0o 4 6 . 0 2 5m m

lv e x ^ a . r svt a l v e . . . . . 0 . 2 0 0m m ( 0 0 7 9 i n c h ) ( 1 . 8 1 1 t0o 1 8 1 2 0i n c h )

I -.s Ce diameterof valveguide ('12)Valveseat bore for tl

exhaust 39.000to 39.025mm
L.- :e diameterof guidefor inlet ( 1 . 5 3 5 4t o 1 . 5 3 6 4i n c h )
.a.: .. . 1 3 . 0 2 5t o 1 3 . 0 3 5m m
( . 5 1 2 8t o . 5 1 3 2i n c h )

l - . s r e d i a m e t eor f g u i d ef o r e x h a u s t
.z .= . 1 3 . 0 2 5t o 1 3 . 0 3 5m m
( . 5 1 2 8t o . 5 1 3 2i n c h )
-s :e diameterof guidefor new inlet
.... 8 . 0 1 0t o 8 . 0 3 5m m ( . 3 1 5 4t o . 3 1 6 3i n c h )
- : - = ñ i a m e t eor f o u i d ef o r n e w e x h a u s t
. : . = 8 . 0 1 0t o 8 . 0 2 5m m ( . 3 1 5 4t o 3 1 5 9 i n c h )
^ . ' ' , - 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
.... A. vñw O
u lm
l lm
rll / ? 1rO
v
innh\
ll¡v¡1,/
\.u

' . ' 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

lllustrationI 900527479
. = .= 8 . 1 2r r m ( . 3 2 0i n c h )
- - -occ nf lin
( 1 3 ) W ¡ d t ho f v a l v es e a t . . . . . . . 1 4 0 ¡ 0 . 2 5m m
( . 0 5 5t . 0 1 0i n c h )
, : .: c thicknessfor rnletand exhaust
.: .:-i 2 1 3 m m ( , 0 8 4i n c h ) Note:The maximumpermissible width of the valve
s e a ti s 1 . B Om m ( . 0 7 1i n c h ) .
',' - ---n allowablevalvelip thicknessfor inlet
. . 1 . 2 0m m ( . 0 4 7i n c h ) 30 degrees
)L -
:-: :xlaust valves (14) Valveseat angle
: - ¡ = o Í v a l v ef a c e . . . . . . . . . , . 30 degrees (15) Dimensionfrom top of closedvalveto face of
notñ

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 vt a | v e . . . . 0 . 4t 0 0 . 2 5m m ( . 0 1 6t . 0 1 0i n c h )

N o t e :T h e m a x i m u mp e r m i s s i b ldee p t h i s 1 . 1 0m m
( . 0 4 3i n c h ) .

tr¡usira: i- s 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 tv a l v e . . . . . . . . . 4 0d e g r e e s

Note:Tne depth of the chamferof the inletvalveis

2 . 3 8 = C 1 0 m m ( . 0 9 4t . 0 0 4i n c h ) . lllustration10
gOA52749A

( 1 0 ) C ^ a m f e ro f e x h a u svt a l v e ..45 degrees

(16) Pushrod
b Note:Tne depth of the chamferof the exhaustvalve
i s 2 0 0 t 0 . ' 1 0m m ( . 0 7 9t . 0 0 4i n c h ) .
8
SpecificationsSection

Use a dial indicatorin orderto check all

pushrodsfor runout.Replacethe pushrodif the
runoutexceedsthe followingvalue......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 si n t h e ' c : - . ' . ' - ' , v h e n t h e
r o c k e ra r m b u s h i n gi s r e c ¿ : = :

4
^"'-
tl
\
-/"
lllustration11 900526252 _3-

( 1 ) R o c k e ra r m b u s h i n g at*

Bore in rockerarm bushingfor v- -/"

shaft........... . . . . . .2.0 . 0 1 1t o 2 0 . 0 9 4m m J:-/-
( . 7 8 7 8t o . 7 9 11 i n c h )

(2) Rockerarm shaft

Diameterof rockerarm lllustration13 900526257
shaft... 1 9 . 9 6 6t o 1 9 . 9 8 4m m
- -
( 7861to .7868inch) Positionthe rockershaftbrac.e = ñ^r rnlrn^

bolts.
Clearanceof rockerarm bushingfor
s h a f t . ,..... . . 0 . 0 2t7o 0 . 1 2 8m m ( . 0 0 1 1t o . 0 0 5 0i n c h ) (4) Long bolt

Replacethe rockerarm bushingif the repairlimit Tightenthe long bolt to i-e ':
of 0.15 mm (.006inch) has been reached.Replace torque. . . .1 5 - " 11
tBlbft)
the rockerarm bushingand the rockerarm shaft tf
hasbeen
of therockerarmbushins (5) Shortbolt
I?:::3': "tit Tightenthe shortbolt to :^e': v
torque. . . , . 1 5= 11 + A lh ft\

(6) Rockershaftbracket
 I
SpecificationsSection

141025762

v CylinderHead
'1100
SMCS Code:

14
lllustratlon 900526261

Valvelash adjustment

Tur^ :^: crankshaftuntilthe timingmark on the

c ' e ' - = - a ' : o u l l e yi s a l i g n e dw i t ht h e p o i n t e o
r n the
944527524
: - - I :=ar houslngin orderto adjustthe valve lllustrat¡on16
as- :::^ the No, 1 inletvalveand the No 1
e / - . . : - . A v e n u s h r o d sm u s t n o t b e i n t e n s i o n ( 1 ) C y l i n d e hr e a d
- --^.^^t,^. ^.^^
Use a straightedge and a feelergaugeto check
the cylinderhead for warpage,
i - : . : - : e x h a u svt a l v el a s h. . . .0 . 2 5m m ( . 0 1 0i n c h )
ol"l'"_:" o n":3
: ": 3¿%li'?.'d#,?
"lln" :u'l
"nr
t01023202
Resurfacethe cylinderhead if the warpage
) \, ValveMechanismCover exceedsthe followingamount ....0.20 mm
( . 0 0 8i n c h )
S M C SC o d e : 1 1 0 7
Gasketthicknessof cylinder
h e a d . . . . . . . . . . . . 1t. 700. 1 0m m ( . 0 7 0t . 0 0 4i n c h )
T h i c k n e sosf n e w h e a d . . . . . . . . . . . 9 5+. 000, 1 0m m
(3.740t .004 inch)
head.. 94.70mm
Minimumthicknessof cvlinder
-
( 3 . 7 2 8i n c h )

Note:The repairlimitof the contactsurfaceof the

gasketand the repairlimitof the cylinderblock
s u r f a c ei s 0 . 2 0m m ( . 0 0 8i n c h ) .

- 900525829
l¡luslra::- 5

(1) ,a,::over nul

aBttagr
the valve cover nuts to the followinq
3to5Nm(26to44 lbin)
.¡
15. 11€-$ ¡úFoZ 5(!-Q)1s

lllustration17
Numericalsequenceof bolts for 3064 Eng¡ne
 10
SpecificationsSection

t\
tt¡
¡o rC-Ot f9-O6

lllustration18 900527527

Numericalsequenceof bolts for 3066 Engine

Put clean engrneoil on the threadsof the cylinder

head bolts.lnstallthe boltsand tightenthe boltsin
the appropriatenumericalsequenceto the following
torque. . . . . . . . . 1 1t 85 N ' m ( 8 7 t 4 l b f t ) lllustration 20 900530560

i01030322 (6) Turbineshaft

Turbocharger P l a c ea d i a l i n d l c a t o ' o -: - :
shaft. Move the comPress:'
:' :neturbine
1 ) r nt h e
i SMCSGode:1052 axialdirectionin orderto-= -^^ ^t^,, Eñ^
= ru Pray. Lrru

,ri p l a y . . .0. . 0 5 7t o 0 . 1 0 3- - . c . 0 0 4 1i n c h )

Note:The turbocharger rr-s: :: . =- . e m b J e d and

0\
t h e t u r b o c h a r q emr u s tb e : - : : ' - . : ' : l e a r a n c e si f
the end play is beyondt-? s:= -: :^S,

^-Y

900530558
lllustration19

( 1 ) Compressorwheel
(2) Turbinewheel
lllustration21
(3)Turbinehousing
(7) Lock plates
(4) Compressorhousing -=^ the boltsto
Positionthe lock platesa^c
the followingtorque...,, -- \'m (15lb ft)
(5) Cartridgehousing

Note: Mark the orieniationof the compressor

housing,the cartridgehousingand the turbine
housingbeforedisassembly.
\
 11
Specifications Section

t ExhaustManifold
i01029608

SMCS Code: 1059

l',-s'.'a::^ 22 900530562

r-T -: -:-srng (3) and Cartridgehousing(5)

ü!-'*"

:-rbine housing(3) with the cartridge

-) 900530254
lllustration24

( 1 ) Nuts for turbocharger

to the
Tightenthe nutsfor the turbocharger
foilowingtorque. 41 N'm (30 lb Ít)

( 2 ) Studsfor turbocharger
to the
Tightenthe studsfor the turbocharger

tt followlngtorque.

(3) Studsfor exhaustmanifold

12 N'm (9 lb ft)

Tightenthe studsfor the exhaustmanifoldto

thé followingtorque. 12.5N'm (9 lb Ít)
900530564
I -s:'a:3,^ 23
(4) Nuts for exhaustmanifold
^;-n,
ri
Tightenthe nutsfor the exhaustmanifoldto the
: : : . 5 P - 3 9 3 1A n t i - S e i zCe o m p o u n dt o t h e followingtorque. 20 N'm (15 lb ft)
:--.¿:s of the clamp.Tightenthe 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
torc-? . . 4 x 1 N ' m( 3 5 t 9 l b i n )

te
Camshaft T L
SMCS Code: 1210

í^f\,
\\ \\l
)v '
,\T,i f) ,v)"
\iN
lllustration26 900527952

Note:

(4) Camshaftlobe lift

lllustrat¡on25 900527937

Specifiedcamshaftlobe l:
(1) Camshaft
gear
E x h a u sl to b e . . . . . . - - - ( 2 8 9 1i n c h )
Maximumpermissible temperature of the gear Inletlobe ^-(2633inch)
on the camshaft.... 315'C (600'F)
for installation
Servicelimitfor lobe liftfo' :'- =- . 6 . 8 4 4m m
Note: Do not use a torch. ( . 2 6 9 5i n c h )

(2) Diametersof camshaftjournals Servicelimitfor lobe liftfo' - ='

Table1
6 . 1 8 9m m
(.2437inch) It,
' - : : : - . c e l i m i tf o r
Number Number N o t e :R e p l a c et h e c a m s ' ¿ :
of Journal of Journal Standard the lobe lift is reached.
for 3064 i for 3066 Diameter
Engine Engine (5) Camshaftiobe heigi::
53.94 to
53.96 mm 53.90mm (6) Base circle
1,2 1 , 2 ,3 (2.123to (2.122inch)
2.124 inch)
52.94 to
52.96 mm 52.90 mm
1. Measurethe camshafioc: -=
(2.084to (2.083inch)
2.085 inch) 2. Measurethe base circie €
(1)Theservicelimitis the maximumdimension or the serv¡ce '--^:inStep2
for a part.
3. Subtractthe base circe :-=- .
that is specified
limitis the minimumdimension - 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 ' - - - -
Qéptacé thé part i{ the se.vice limit is reached-
'-
d i f f e r e n c ies t h e a c t u a c a - : - : : : 3 l i f t( 4 ) .
(3) Thrustplatebolt
Tightentheboltto thefollowing
torque. 1 8N ' m( 1 3l b Í t )

0b
v Standard
Repair Limit(1)
Diameter
Clearance
between ooo,l3J¡0,3 mm
camshaft " ,0.15
(.006
inch)
journalsand .do7,""n1
bushings
(1)The reoairlimitis the maximumdimensionor the repairlim¡t¡s
the minimumdimensionthat is specifiedfor a part. Repairthe
part if the repairlimit is reached.

l L l u S l ' á l r O 2n 7 900528061

Note:Jse a dial indicatorand blocksin orderto

:::='- 1e the runoutof the camshaft.Takeone half
:' -: r al indicatorreadingas the runout.
- - --^h^{+
- = 5r tdlt

' , ' r x . n u mp e r m i s s i b lreu n o u ft o r

:a-shaft . . . . . 0 0 2 0 m m ( . 0 0 0 8i n c h )
S 'a ghtenthe camshaftif 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 ) 900529304
lllustration29
:=i ace the camshaftif runoutis morethan the
': :,,,,lngamount. (9) Installthe dial indicatorin orderto determine
0.050mm (.0020inch) gear end play
E n d p | a y . . . . 0 . . 1t o0 0 . 2 5m m ( 0 0 4 t o . O 1 0i n c h )
Replacethe thrustplateif the end play exceeds
t h e f o l l o w i nagm o u n t. ,. . . . . . . . 0 . 3m0m ( . 0 ' 1 2
inch)
.t- 4i I . .. 8 5m m ( . 1 9 1i n c h )
T h r u s pt l a t et h i c k n e s s . . , . 4
I)\1
ti\
(-\r
\
-]l_,o

lllustral,cr28
¡R, i:-cn:fi

Meas-'elhe camshaft
l_raarinn

bearingwitha dialindicator.
of thecamshaft
Suc:rac:lne diameter journalin
900528067

n r n e ' ' o o i v e l - r e a r i n oc l e a r a n c e s .R e f e r t o T a b l e 2 .
M 900529307
lllustration30

(10) Tappetbore diameter

Tappetbore diameter.......22.000Io 22.021mm
( . 8 6 6 1t o . 8 6 7 0i n c h )

M a x i m u mt a p p e tb o r ed i a m e t e.r. . . ...2 2 . 0 5 5m m
( . 8 6 8 3i n c h )
I

,
I
 Clearanceof tappet to ' r'{:
b o r e . . .0 . 0 3 5t o 0 . 0 8 6m m ( . 0 0 . 1 t4o . 0 0 3 4¡ n c h )

Note: Replacethe tappet if the clearanceis

NOTICE
Beforeoperation,the pump n!s: :: :ubricatedwith
clean engineoil and the pump -,si turn freely by
t I
exceeoeo. hand or damageto partscan 5e :-= result.

i01030986 N o t e :T h e m i n i m u ma c c e c : a 3= - : - : s s ! r e a t l o w
i d l e i s 1 O Ok P a( 1 5 p s i ) .
EngineOil PressureRelief
Valve ( 1 ) D r i v e ng e a ra s s e m b l y

SMCS Code: 1315 (2) Drivegear assembly

/"\ f.\¡l ^r rmn ^a.r

(4) ldler gear assembly

The backlashbetweer:-= - : -^.: gear and
t h e i c i l e ro c e r s t h e f O : , , , - :
amount. - --:oO190mm
- - : : . I 0 0 7 5i n c h )

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

(5) Spindle

N o t e :T h e o i l p u m p g e e r e ' : - : : ' , : g e a r

el
lllustration31 900530799
' ' . . 3imo gear is
Oil pressurereliefvalve
assemblyare not servicea:=
removed.
Removethe oil pressurereliefvalve from the
cylinderblock.Checkthe valveand the valveseat
for abnormalcontactpatterns.Inspectthe spring
for weaknessor damage.Replacethe oil pressure
reliefvalve, if necessary.
R e l i evf a l v eo p e n i n gp r e s s u r .e. . . . . 3 4 3t 2 0 k P a
(50 t 3 psi)

i 0 10 3 0 4 1 5

EngineOil Pump
SMCSCode:1304

,
1r

!..
i
lllustration33 900530644

.: (3) O¡lpumpgear
14
ll

Note:Do not usea torch,

900530573
I
lllustration32
 15
SpecificationsSection

Heat the oil pump gear to 180' to 220'C

1v (356" to 428"F)and supportthe end of the drive
gear snaftin orderto installthe oil pump gear.
Pressthe oil pump gear untilthe oil pump gear is
f lushwith the end of the shaft.

lllustration35 900530702

(7) Cover
Measurethe insidediametersof the boresof
the shaftsin the cover(7) and the oll pump
housing(6). Measurethe boresof the shafts.
The clearancebetweenthe gear shaftsand the
o i l p u m p h o u s i n ga n d c o v e r . . . 0. . 0 4t o 0 . 0 7m m
( 002 to .003 lnch)

Note:Replacethe oil pump gear assembly,the

900530697
llirs:'at¡on34 cover,or the oil pump housingif the clearance
exceedsthe servicelimitof 0.15 mm (.006inch).

I
i -.r r e i n, :¡ , f' n
- .r n- .i l' n r
rJmp gear
'.ieasurethe differencein the lengthof the Note:Replacethe drivegear and drivengear as an
assemory.
a s s e m b rfyo 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 .
I earance 0.020to -0.034 mm
( 0008 to - 00'13inch)

Note:Replacethe oil pump gear assemblyif the

crea'a.ceexceedsthe servicelimitof -0.150 mm
( - C C 5 9r c h ) .

Meas-'e the clearancebetweenthe oil pump gears

a n c : ^ e o r lp u m p h o u s i n gw i t ha f e e l e rg a u g e .
t- ^-.^^^^
0.050to 0.098mm
(.0020to .0039inch)

Note: Rep\aoe the oil pump gear assembly if the 900530704

clea'a^ce exceeds the serv¡ce limit of -0.150 mm lllustration36
( - 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 ed i a m e t eor f i d l e rg e a r
bushing 25.000to 25.021mm
(.9843to .9851inch)

Maximumdiameterof idlergear bushingfor oil

pump...... . . . . . . . . . 2 5 . 0m
59m ( . 9 8 6 6i n c h )

I (9) Splndle
Drameterof spindle 24.939to 24.960mm
(.9818to .9827inch)
 16
SpecificationsSection

Minimumdiameterof spindlefor oil

pump...,... . , . . . . . . . 2 4 . 9m
01m ( . 9 8 0 4i n c h )
Openingpressureof bypass . = = 9 8 1t 98 kPa
t+z t 14 psi)
l Aa

t\
i 0 10 3 1 0 3 8 i01030410

EngineOil Pressure EngineOil Pan

SMCS Code:1924 SMCSCode:1302
Table3

Engine gil P¡sss¡r¡g(t)

196 to 392 kPa
Oil Pressure
at 1500rom (28 to 57 psi)
Oil Pressure¿t iflls{e) 98 kPa (1a psi)
(l) The oil temperaturemust be 60'to 70"C (140'to 158"F)
(2) Engineidle is 900 r 20 rpm.

i01030990

EngineOil BypassValve P"-

.1306
SMCS Code: lllustration38 900530566

/r \ ar;l ^^^ h^t+^

\ r./ \Jil Pdr r uL)rJ

Tightenthe oil pan bc .-. -

torque.

( 2 ) O ¡ lp a n d r a i np l u g el
Tightenthe oil pan c'a - : -e foliowing
-
1 2 9¡ 4 l b f t )

0 10 3 3 3 7 8

WaterTemperature
Regulator
SMCS Code: 1355

il' 5I - 8010 WaterTemperature

ii,
'l Regulator
I T h ew a t e rt e m p e r a t u rree g - : . : ' : ' : ' - : o o p e n a t
900530801
thefollowingtempelatule - - , ( 1 6 0 '+ 4 ' F )
Note:The oil bypassvalveis mountedlnsidethe oil
The valveliftsmorethan '1: -- - -:r) at the
pan alongthe rail of the oil pan.
followingtemperature,
,., 85"C(185"F)
('1)Valveseat
5I - 8020 WaterTemperature
Check the valve and the valve seat for abnormal
contact patterns.
Regulator
T h ew a t e rt e m p e r a t u rree g - a : : - : ' : " : : c o p e n a t
(2) Spring the followingtemperature. . 32"C(180'F)
Inspectthe springfor weaknessor damage.
Freelengthof spring 83.5 mm (3.29inch)
The valve liftsmorethan 10 --
followingtemperature
- -^) at the
36'C (204'F)
06
 17
SpecificationsSection

i 0 1 0 31111 The pressfit betweenthe water pump shaftand the

rmpelleris the following
WaterPump a m o u n t... . .0 . 0 3 2t o 0 . 0 6 5m m ( . 0 0 1 3t o . 0 0 2 6i n c h )
SMCS Code: 1361
tO1a2B288

CylinderBlock
.1201
SMCS Gode:

900529444
lllustrat¡on41

900530877 ( 1 ) C y l i n d e br l o c k
l l l L s : ' a t ¡ o3
n9

' -oeller Measurethe amountof the warpageof the

cylinderbiockwith a straightedge and feeler
Tr: 'aces of the impellerand the waterpump shaft gauge.Maximumallowable
. . . . . . .0, .. 0 5m m ( . 0 0 2i n c h )
a'e' -sn. clearance
R e p a i lri m i t . . . . . . 2 0m ( . 0 0 8i n c h )
.........0.m
( 2 1F a n g e
-i'e Resurfacethe top of the block if the repairIimitis
(3r distancefromthe face of the impellerto the reached.
.',are'pump housingis the following
a'nount... 21.00lo 21.70mm (.826to .854 inch)

900529446
lllustration42
g00530BZB
lllustrat¡on40 (2) Cylindersleeve
(4) V/a:e'pump shaft

L 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
an:oint. .. ... 0.035to 0.065mm
( . 0 0 1 4t o . 0 0 2 6i n c h )
 18
SpecificationsSection

Measurethe insidediameterof the cylindersleeve

that is parallelto the crankshaft.Measurethe
insidedrameterof the cylindersleevethat ls in a
Q,(
perpendicular positionto the crankshaft.
Measure
the top, the middleand the bottomof the cylinder
sleeve.Referto Table4 for tolerancesof the
cylindersleeves.
Table4
Tolerances of Cylinder Sleeves
i--_!-_
standard
Standard n^--¡- c^n,¡^^
Service
Repair
Limit{l) Limit€)
A""lirory
1 0 2 . 0 1t0o 900529534
102.200 102.700 lllustration43
102.045
Inside
mm (4.0161 mm (4.0236 mm (4.0433
Diameter inch) (3) Cylindersleeve
to 4.0175 inch)
inch)
S e r v i c el i m i to f c y i ; n c = :' - : . 102.700mm
Out of 0 . 0 1 0m m N/A N/A i 4 0 4 3 3i n c h )
Round (.0004inch)
-- - - -¡ +h^ ^^",,i^^
0 . 0 1 5m m R e p l a c ea l l c y l i n d e sr l e e . = : = - ::U tl lU Júl V IUV
Taper N/A N/A limit
(.0006inch)
(1)The repairlimitis the maximumdimensionor the repairlimitls
the m¡nimumdimensionthat is specifiedfor a part. Repaira \
part if the repairlimit is reached.
(2) The service l¡m¡t¡s the maximumdimensionor the service -\z\
limit is the minimumdimensionthat ¡s specifiedfor a part. ,^¡: -\// ,
--'l -<t
Replacethe part if the servicelimit is reached.

Bore the cylinderto the specifiedoversize

--*$z
?*
ba
LI
dimensionif the insidedtameterreachesthe repair | :, I

limitbut the insidediameterdoes not reachthe

servicelimit.Referto Table5.

Hone the sleeveto +0.25 mm (+ 010 inch)

or +0.50 mm (+.020 inch) oversize.Hone the
sleeveto an accuracywithin0.010to 0.045 mm
900529962
( . 0 0 0 4t o . 0 0 1 8i n c h ) . lllustration44
Cylindersleeves
Determinethe oversizedimensionthat is necessary
in orderto clean up the cylinderif any sleevehas - : l:- .f, repalr Ine
Use the followingprocec-':
'iil unevenwear. cylindersleeves.
1l
I Replaceall cylindersleevesthat are in excessof
^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 .
the serviceIimit. A l i g nt h e b o r i n gm a c r , ^ e, ' , '-
:enter of the
bottom of the cylinder s e:. : .re lessworn
Note: Refinishall sleevesto the same oversize
dimensron. Use a ridge reamerin order to cut
the ridge of the cylinderif the sleeveis in good 2. Borethe sleeveuntiltne :- :" = = =s 0 . 5 0m m
condition.Hone the cvlinderbore. ( . 0 2 0i n c h ) .
Table5 3. Removethe remaindero' :-: = = . e ,B e c a r e f u l
OversizeBore i CylinderBore Size not to damagethe cyllnc:' :

(0100
0250mm inch)J3273:5ilil iliil
Íi:339? 4. Installa new sleeve.Alig^ = = .e w i t ht h e t o p
of the cylinderblock.
0 . 5 0 0m m ( . 0 1 9 7i n c h )
1 0 2 . 5 1 0m m ( 4 . 0 3 5 8i n c h )
102.545mm (4.0372 inch) 5. The bore of the cylinder
. 10 1 7 1i n c h ) .
LI
102.000to 102.035mm (¿
 19
SpecificationsSection

'-"'":l"i ':l: ."zuü8ro Put sealanton the contact surface betweenthe

l:: *oeo068
mm slingerand the crankshaft.Put clean engineoil on
( 3 . 5 4 4 1 t o3 . 5 4 6 0i n c h ) the surfaceof the rear sealassembly

-- diameterof the main bearing (6) Distancefrom rearsealassemblyto end of

m0m ( 3 . 5 4 9 2i n c h )
.......90.15 crankshaft 6.0 mm (.24 inch)

r l.t of deck from centerline of crankshaftto

r01022388
3 0 7 . 0 0t 0 . 0 5m m ( 1 20 B Ot . 0 0 2i n c h )

reight from the centerline of crankshaftto

ConnectingRod Bearing
3 0 6 . 7 0m m ( 1 2 . 0 7 5i n c h ) Journal
SMCS Code: 1219;1225
i01023233
Table6
CrankshaftSeals
Connecting Rod Bearing Journal
S M C SC o d e :1 1 6 0 :1 1 6 1 59.945to 59.965mm
Originalsize journal(l) (2.3600to 2.3608inch)
Undersizejournal 5 9 . 6 9 5t o 5 9 . 7 1 5m m
0 . 2 5 m m ( . 0 1 0i n c h ) (2.3502to 2.3510inch)

Undersizejournal 59.445 to 59.465 mm

0 . 5 0 m m ( . 0 2 0i n c h ) (2.3404to 2.3411 inch)
Undersizejournal 5 9 . 1 9 5t o 5 9 . 2 1 5m m
0 . 7 5 m m ( . 0 3 0i n c h ) ( 2 . 3 3 0 5t o 2 . 3 3 1 3i n c h )
(1) Regrindthe connectingrod journalsto the next undersize

lc dimensionif the repairl¡mitof 59.980mm (2.3614inch) is

exceeded.

The clearancebetweena new bearingand a new

j o u r n ails t h e f o l l o w i n g
v a l u e . . . . .0 . 0 3 5t o 0 . 1 0 0m m
( 0014 to .0039inch)

An undersizedbearingis requiredif the clearance

betweenthe connectingrod journaland the bearing
is in excessof the servicelimitof 0 200 mm
(.0079inch).lf the crankshaftis worn excessively,or
if the crankshaftis uneven,an undersizedbearing
; -Si'3i l' 45 900525904 is required,lf an undersizedbearingis required,
grindthe crankshaft to a dimensionlistedin Table6.
- =.--- -^^l

Note:The allowabletolerancefor rod bearing

2 =:='seaa
f ssembly journalsthat are out of round is 0.010 mm
(.0004inch).The maximumrepairlimitis 0.030mm
--: ( . 0 0 1 2i 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
Nóter .oar eeat assembly and the s l i n g e r a r e
the bearingjournalsto the specifieddimension.
< \ -^a/

-^e 'ear
Note seal assemblyand the slrngerare
- -^ ^,,^i+
:-: =- iJ d ut ilt,

i-: =:2' sealassembly

--3
Note tear seal assemblyshouldbe flushwith
r =:
- :e' afterinstallation.

( 5 l:-:act surfacebetweenthe sltnqerand

-. ^ -
_ = ' 5 ^t A ^t d
f+
lt

t
:
t
 20
Specifications
Section

P u tt h e m a i n D e a '- : : = : :
MainBearingJournal
\01022652
nr¡lin|or
horrinn
hln¡¡
hnJtc
D

,- r-:
- ) =u-
-' I -
=
t I
¿.:{ln:
- = following
iinhion tho rrz -:-
SMCSCode:1203 - 'C1
torque. J- : t4lbft)
/?\ ñiel indin¡inr

f \r ^ ^ ^ ,
fvfucl¡utv
,,^ +h^
UtY
-^
IIrd -==
^ a dial
i n d i c a t o rS. u o r r a : :- ' = : : - '^e
crankshaftjourna "a- " = : ameteroÍ
t h e m a i n b e a r i n g' . ' = . -'re the
- ^ a l
UgOl ll IU UIVOI Ol Ug v : ot.

Clearancebetweer c'a'. :' '^aland main

0earrng -:o011Bmm
c 0047 inch)

Note:Replacethe bear- : s :' ' - a

E
a¿aal'^A^1+
Ut At lnJt tdtL

t o t h e n e x t u n d e ' s ' z ec = 2 " - - l r Deaflng

clearanceexceeosO 2a -- -:-r Referto
lllustration46 90052534i
T a b l e7 f o r d i r r e i ^ s , o ras' - - : = dt-.

main bearingjournal
(1) Crankshaft N o t e :T h e a l l o w a b l et o i e ' a - : : - : ' - . ' c e a r i n g
i o r ¡ r n a lt sh a ta r e o rr t o f . : , - : : - - - - n m
Measurethe main bearingjournal.The diameterof ( . 0 0 0 4i n c h ) T h e m a x i r - - - = : = ' - . s 0 0 3 0 m m
the crankshaftmain bearingjournalis givenin Table ( 0 0 1 2i n c h ) .l f t h e r e p a ' - ' : : - : : J ü u , r ú g I t t u
- --.-^^ .^^,;^A

7. t h e b e a r i n gj o u r n a l st o : ^ e s : - : . - - * ^ ñ ^ i ^ ^ :, - iEI IJ¡U¡ I,

, '-: crankshaft
Table7
N o t e :T h e m a x l m u ms e n ' : :
Main BearingJournal

Originalsize journal(t)
89.95 to 89.97 mm
iournaiis -0.90 mm (- 03:
crankshaftif the cranxs?a-.:-
this specification
:
: = : a C et h e
i . ' ,I ' n D e y O n O I
(3.541to 3.542 inch)
Undersizejournal 89.70 to 89.72 mm
0 . 2 5 m m ( . 0 1 0i n c h ) (3.531to 3.532 inch)
89.45 to 89.47 mm
(3.521to 3.522 inch)
Undersizejournal 89.20 to 89.22 mm
0.75 mm (.030 inch) ( 3 . 5 1 2t o 3 . 5 1 3i n c h )
(1) Begrindthe main bearingjournalsto the next undersize
I dimensionif the repair limit of 89.85 mm (3.537 inch) is
exceeded.

lllustration48 900525380
Typicalexample

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

lllustration 47

(2) Main bearingcap

900525373
Note:Replacethe cranksna.
the reoairlimitof 0.050mn'
'-.- ¡;t exceeds

ra
 Note:The maximumrepairlimitis 0.300 mm

I ( . 0 11 8 i n c h ) .

Replacethe standardthrustplatesif the end play

exceedsthe standardclearance.Threeoversize
thrustplatesare availableas replacements if the
end play stillexceedsthe maximumlimit.Generally,
the rearjournalis likelyto be worn morerapidlythan
the frontjournal.lf necessary, replacethe rearthrust
plate.Referto TableB for oversizethrustplates.

Table8
Dimensions for Grinding of Crankshaft
Oversize Thrust Plates

lllustration49 900525383 Oversize Oversize Oversize

Thrust (front (front Tolerance
Plate or rear) or rear)
(5) Widthof crankshaftmainbearing
journal mm
. . . . . . . 3 3 . 0t0o03 3 . 0 3 9 +0.039mm
(1.2992 '1 + 0 . 1 5m m 3 3 . 1 5m m 3 3 . 3 0m m
to .3007inch) ( + . 0 0 6i n c h ) ( 1 . 3 0 5i n c h ) ( 1 . 3 1 1i n c h )
(+.0015
inch)
+0.039mm
+0.30mm 33.30mm 33.45mm (+.0015
(+.012inch) ( 1 . 311 i n c h ) ( 1 . 3 1 i7n c h ) inch)

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

Tightenthe reta¡ningnut of the crankshaftpulleyto

inch)
+0.039mm
(+.0015
inch)

t h é f o l l o w l n tgo r q u e . . . . ,4. 9 0 + 5 N m ( 3 6 3t 4 l b f t )

tO1022446

lllustration50
900525387 ConnectingRod
S M C SG o d e : 1 2 1 8
(6) Put the main bearingand thrustplatesin the
blockand installthe crankshaft.Put clean
engineoil on the bolt threadsTightenthe bolts
to the followingtorque. 137 t 5 N'm
( 1 0 1t 4 l b f t )

q00525099
lllustration52

( 1 ) M a t c n i nm
g arks

900525413
Themarksare usedto align the cap to the

t rod,
lllustrahon51 connectrng
the crankshaftend olay.End
(7) lv'leas:re
c a, 0 . ' 1 0 0I o 0 . 2 6 4m m ( 0 0 3 9t o . 0 1 0 4i n c h )
I 22
Specifications
Section

(3) Connectingrod bolts

Beforeassembly,put c ea- =- I -= cil on the
b o l t t h r e a d sa n d a l l s u r l a : = - - : * a K e c o n t a c t
t(
b e t w e e nt h e b o l ta n d c o - - = - ' ' , - : l c a p s .
T i g h t e nt h e c o n n e c : ' a ' - = - - ' : - - - e f o l l o w l n g
torque. il:-: .--z6t4lbft)

( 4 ) M e a s u r et h e b o r e sa ' e r : - : - _ 1nna^trnn

rods and recordthe c -:-. : - -- e bores.

lllustration 53 9 0 0 5 2 50
13

(A) The upper oil hole is 40 degreesabove the

horizontalcenterline.

(B) The loweroil hole is 30 degreesbelowthe

horizontalcenterline,

(C) The end of the pistonpin bearingis 30 degrees

belowthe loweroil hole.
lllustration 55 9 0 0 5 2 59
14

(5) Connectingrod
U s e a f e e l e rg a u g et o - : : : - :
End p l a y . . . .
0 . 1 5t o 0 3 : - - ,
'-:
eno play.
-: :o 014 inch) I
N o t e :R e p l a c et h e c o n n e : .- I ' : : : anñ ntq\/

e x c e e d s0 . 5 0m m ( A 2 i - : -

'l
I -

\/

h(
\\ /uI
V/

illu$raüon 54
Cl:---'
(2) Bore of piston pin 900525201
lllustration 56
bearing 34.020to 34.045mm
(1.3394to '1.3404inch)
(6) Piston
The clearancebetweenthe piston pin bearing (7) Markingson piston
and the piston pin is 0.023to 0.054 mm
(.0009to .0021inch). -
A s s e m b l et h e p i s t o na n d c c - - = : -' = ' : d s . E n s u r e
t h a tt h e m a r k i n g so n t h e p , s : : - :-: themarks
Note:A clearancefor the pistonpin to the pistonpin
bearingover 0.010 mm (.0004inch) is excessive.
Replacethe piston pin or replacethe bearingif the
clearanceis excessive.
o n t h e c o n n e c t i nrgo d ( 1 )a t e . - - - = = : ' n es i d e .
tC
 23
icationsSection
Specif

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

\a1421241

Pistonand Rings
SMCS Code: 1214,1215

lllustrat¡on57 90o525206

(B) Installthe pistonassemblywiththe marks(1) on

. the connectingrod towardthe camshaft(8).

900524461
lllustration59

( 1 ) M a r k i n g so n p i s t o n

lllustration58
900525250
(9) Pistonprojection
Use the followingprocedureto measurethe
helghtof each pistonabovethe cylinderblock. lf
clearancesare not in the acceptablerange,inspect
the componentsfor wear or damage.
1. Determinethe top centerpositionof the piston
with a dial indicatorassemblY.
2- inetalt the dia.t indicator assembly on the top of
the block. Set the needle of the d¡al indicator to
zero.
Each pistonhas markingswhich are stampedon
top of the piston.The markingsare used to al¡gn
the plstonassemblyto the camshaftside of the
cylinderblock,
(2) Pistondiameter
Table9 givesthe dimensionsfor prstonsthat are
standard,Table9 also givesthe dimensionsfor
pistonsthat are oversize.
Note:Measurethe pistondiameteralongthe
of the pistonpin bore.
perpendicular

3. Measureprojection(9) at three places on

the top of the piston.Take an averageof the
threemeasurements in orderto determinethe
projection.Subtractthe projectionfrom the
installedthicknessof the cylinderhead gasketin
orderto determinethe clearancebetweenthe
top of the pistonand the cylinderhead.

Installedthicknessof the cylinoerread

gasket . . 1 1 0 t 0 1 0 m n r ( . 0 7 0t . 0 0 4i n c h )
lza
SpecificationsSection

ir^^^,,,^ +A^ - '- : ' , a f W i t ha

(5) Crankshaftgear '
-^
faolor ac' r^a
'trflaraaar
Qcj;' i-
-'
:
--
;^tenthe
Note:Ensurethat the markson the timinggearsare h
rvrur vuqr vv.r l ' ' . ". .J- - - : ,.r-:,.35N'm
in alignment. (26 rb ft)

900527864 j00527912
lllustration 65 lllustration67
ldler gear (2) /?\ r^^i!^ :i^-^+^' ^. -c
ilt>rLrg Ljrdr rErur v C:. :_: : . _ _
\/,/

Installa dial indicatorand rotatethe idler gear

/ Q\ lrilar noe r c h af t
(2) back and forthin orderto measurebacklash. \ v / , v ' v '

Replacethe idlergear if the backlashexceedsthe - -t,.,^¡n

servicelimit.Referto Table11. R e p l a c et h e b u s h i n gi : ' : : : = - : - . - =ivvEvt
tF.n
I L ¡t 9
---{+
: =- -:-1
i d l e rg e a r b u s h i n ga n d : - e-?= :
^./^^^^^
dtL E^ugvu)
' '
Table11 the servicelimit.Reterrc .

0 . 0 3t o 0 . 1 7m m
(.001to
.007inch) 0r028537

mm
0.05.to^0.20 0.35mm Flywheel
ártrtil?., ('br+
¡ncn)
[] S M C SC o d e : 1 1 5 6
lr,
iii . clearance o.oogto o.ogo 0 . 1 0 0m m
?:'-Y":il95j mm(.ooo4
to (.0039inch)
I
s"-1'-o!:llls .ooitincn¡
I
t
ili
and Snan L
(1) Replacethe idler gear if the servicelimit is exceeded t

,
1
i
900529633
lllustration 68

l' (1) Flywheel

--^ | t^^ ^,.1:^l
P l a c et h e f l y w h e eol n a s - ' - = : : :
lllustration66

(6) ldler gear bolt

9 0 0 5 2 7 901
i n d i c a t oi rn o r d e rt o m e a s - ' = ' - =
f lywheel.
Standardat assemblyo' ..,', ==
' -
'.iness of the

..0 15mm
i
/ ñOA iÍ nrnv rh \r /
\.vvv

l
 27
SpecificationsSection

R e p a i rl i m i to f f l y w h e e l... . . . 0 . 5 0m m ( , 0 2 0l n c h ) r01053076

the flywheelif the repairlimitis

Note:Refrnish BeltTensioner
exceeded
SMCS Code: 1358

q00529634
lllustration69 q005463
12
lllustration70
(2) Measurethe runouton the flywheelface with a
(1) Bolt.
d i a li n d i c a t o rM. a x i m u mf a c e r u n o u t .. . 0 . 1 5m m
( . 0 0 6i n c h )
Apply pressureto each belt midway betweenthe
pulleysin orderto inspectthe belt tension.Adjust
R e p a i rl 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 )
the bolt for the alternatorif the tensionis incorrect.
Note:Refinishthe flywheelif the repairlimitis the
Properfan belttensionis approximately
.12.0
exceeoeo. . mm (.50 inch)
followingdeflection.
Maxnrm permissibletemperature o' the ring gear
on the flywheelwithoutusinga
for installatlon
rorcn.,,..,.... . . . 1 5 0 " C( 3 0 2 ' F )

Note:The ring gear is pressedon the flywheel.

Tightenthe flywheelboltsto the following

torque 83 t 5 N'm (61 t 4 lb ft)

N u m b e ro 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
28
SpecificationsSection

i01031047 o,o.,r.,f (
Belt Tensioner Alternator
SMCS Gode: 1358 SMCS Code: 1405

900530808 900530887
lllustration71 lllustration 72

(1) Bolt ( 1 ) N u t f o r a l t e r n a t oPr u l r e . '

(
T i g h t e nt h e n u t f o r t t e z ' . ' ' . :- ey to tne
Apply pressureto each belt midway betweenthe 'i2
following t o r q u e,., . t o 1 6 2N ' m
pulleysin orderto inspectthe belt tension.Adjust l - t o 1 1 9l b f t )
ifre Oottfor the alternatorif the tensionis incorrect
- = ; a t i v eg r o u n d
the Polarity
Properfan belt tensionis approximately
deflection.
following . . . . . 1 2 0m m ( . 5 0i n c h ) : :rer direction
Rotation

Speedfor testing(rPm) . 5000 rPm

Outputvoltage . 2 8 . 0t . 5 V

R a t e do u t P u t . . 504

.a
II
-!
 29
SpecificationsSection

1 0 01 3 1 3 7 8

ElectricStartingMotor
SMCS Code: 1453

lllustration73 900530889

(1)Terminn
aul ts
Tightenthe termrnalnutsto the following
torque. . . . . . . 1 1t 1 N ' m ( 9 7 t 9 t b i n )

The rotationis viewed from the drive end of the

electncstartingmotor.Rotationof electricstarting
motor...,..... clockwise

No load conditions
S p e e d( r p m ) . . . 3 3 0 0r p m m i n l m u m
Maximumcurrent(draw) ...85 A
Voltage ...............23\/
 30
lndexSection

lndex
A P

Alternator .-'.'28 P i s t o na n d R i n g s ........'...2

. .3. '

B
BefT
t ensioner................ 27,28

c
Camshaft .'.'.'12
C o n n e c t i nRg od........... . . . . . . . . . . . . . . . . .2. 1. " '
Connecting Rod Bearing Journal ...'.. 19
C r a n k s h aS f t e a l s. . . . . . . . . . . . . . . . . . . . . . . . . .1. .9. . "
C y l i n d e8r 1 o c k . . . . . . . . . '...'."17
r e a d. . . . . . . . .
C y l i n d eH . . . . . ' . .9. '

E r rm ............
V a l v eR o c k e A .'....',..",.....8

ElectriS c t a r t i n gM o t o r . . . . . . . . . '."'.-....".29
E n g i n eD e s i g n .'-.....'.'.'...'.4 w
3 0 6 4E n g i n e '..'.'.".'...'....4
'-.-.'."...'..'.'-4 W a t ePr u m p. . . . . . . . . .......'.."'..'..17 (
3 0 6 6E n g i n e 16
.-........16 WaterTemperature Regulator ' .'...............
E n g i n eO i l B y p a s sV a l v e. . . . . . . " = : : - l a t o r . . . . ' . . .1. .6. .
. . . . . . . . . . . .1. 6. . . 5I - 8 0 1 ÓW a t eT r emperatur:
f n g i n eO i l P a n = = : - l a t o r . ' . . . . "1" 6"
. . . . . . .1. 6 5I - 8 0 2 0W a t e Tr e m p e r a t u r e
e n g i n eO i l P r e s s u r e
fngine Oil PressureReliefValve .-.'.'.'14
f n g i n eO i l P u m P '.".""'...14
E x h a u sMt anifold .'..'.'.....11

Flywheel '.."..26
F u e lI n j e c t i oLni n e s ".'.......5
F u e lI n j e c t i oNn ozzles . " . . . " . . . . ' . . . ' . . . .5. ' . .
F u e lI n j e c t i o P
n umP ........'.5

G e a rG r o u p( F r o n t ) . . . . . . . . .....................25

I
SafetyInformation.
lmportant "--.-.--....'.2

M a i nB e a r i n gJ o u r n a | . . . . . . . . . . . . 20 tI
j