10

Specifications Section

Resurface the cylinder head if the warpage

exceeds the following amount 0.20 mm
(0.008 inch) Turbocharger
Gasket thickness of cylinder SMCS Code: 1052
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: The repair limit of the contact surface of the

gasket and the repair limit of the cylinder block
surface is 0.20 mm (0.008 inch).

Illustration 20 g00530558

(1) Compressor wheel

(2) Turbine wheel

(3) Turbine housing

(4) Compressor housing

(5) Cartridge housing

Illustration 18
Numerical sequence of bolts for 3064 Engine Note: Mark the orientation of the compressor
housing, the cartridge housing and the turbine
housing before disassembly.

Illustration 19
Numerical sequence of bolts for 3066 Engine

Put clean engine oil on the threads of the cylinder

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

Illustration 21

(6) Turbine shaft

 21
Specifications Section

Main Bearing Journal

SMCSCode: 1202; 1203

(3) Bolts for the main bearing cap

Tighten the bolts for the bearing cap to the
Illustration 50 following torque 137 ± 5 N-m (101 ± 4 lb ft)

(1) Main bearing cap (4) Main bearing journal

Put the main bearing caps in position in the (5) Main bearing
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)
Connecting Rod
(2) Dial indicator SMCSCode: 1218
Measure the main bearing bores with a
dial indicator. Subtract the diameter of the
crankshaft journal from the inside diameter
of the main bearing in order to determine
the bearing clearance on the main journal.
Clearance between crankshaft journal and main
bearing 0.050 to 0.118 mm
(0.0020 to 0.0047 inch)

Note: Replace the bearings or refinish the crankshaft

to the next undersize bearing if the main bearing
clearance exceeds 0.20 mm (0.008 inch). Refer to
Table 50 for dimensions of undersize journals.

Note: The allowable tolerance for main bearing

Illustration 52
journals that are out of round is 0.010 mm
(0.0004 inch). The maximum repair limit is 0.030 mm
(1) Matching marks
(0.0012 inch). If the repair limit is exceeded, regrind
the bearing journals to the specified dimension.
The marks are used to align the cap to the
connecting rod.
22
Specifications Section

(3) Connecting rod bolts

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

(4) Measure the bores of each of the connecting

rods and record the dimension of the bores.

Illustration 53

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

horizontal centerline.

(B) The lower oil hole is 30 degrees below the

horizontal centerline.

(C) The end of the piston pin bearing is 30 degrees

below the lower oil hole.
Illustration 55 g00525l94

(5) Connecting rod

Use a feeler gauge to measure the end play.
End play 0.15 to 0.35 mm
(0.006 to 0.014 inch)

Note: Replace the connecting rod if the end play

exceeds 0.50 mm (0.020 inch).

Illustration 54

(2) Bore of piston pin

bearing 34.020 to 34.045 mm
Illustration 56
(1.3394 to 1.3404 inch)
(6) Piston
The clearance between the piston pin bearing
and the piston pin is 0.023 to 0.054 mm
(7) Markings on piston
(0.0009 to 0.0021 inch).
Assemble the piston and connecting rods. Ensure
Note: A clearance for the piston pin to the piston pin
that the markings on the piston (7) and the marks
bearing over 0.010 mm (0.0004 inch) is excessive.
on the connecting rod (1) are on the same side.
Replace the piston pin or replace the bearing if the
clearance is excessive.
 25
Specifications Section

Illustration 63 g00524492

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

(B) End gap for No. 2 ring (intermediate

compression ring)
Illustration 62
(C) End gap for oil control ring
(9) Side clearance of ring groove (X) Camshaft side of engine block
Install new piston rings in the ring grooves of the (Y) Side of engine with combustion chamber
piston. Measure the side clearance of the ring
groove with a straight edge and feeler gauge. Table
Position the piston rings according to Illustration 63.
10 groves acceptable 'Clearances of t i e ring groove.

Clearances of the Piston Rings

Gear Group (Front)
Side
Piston Width of Clearance Service SMCS Code: 1206
Rings Ring of Ring Limit (1)
Groove
0.080 to
No. 1 3.00 mm 0.200 mm
0.120 mm
Compression (0.118 (0.0080
(0.0031 to
Ring inch) inch)
0.0047 inch)
0.080 to
No. 2 2.00 mm 0.150 mm
0.120 mm
Compression (0.080 (0.0060
(0.0031 to
Ring inch) inch)
0.0050 inch)
0.025 to
4.00 mm 0.150 mm
Oil Control 0.065 mm
(0.157 (0.0060
Ring inch) (0.0010 to inch)
0.0026 inch)
(1) The piston must be replaced if the piston rings exceed these Illustration 64 g00527858
clearances.
(1) Fuel injection pump drive gear

(2) Idler gear

(3) Camshaft gear

(4) Nut for fuel injection pump drive gear

Tighten the nut to the following
torque 88 ± 5 N.m (65 ± 4 lb ft)