Cylinder Head, Valves and Manifolds _Mounting cap ‘Screw (14) Dip entire cap screw in clean engine oil before instaling Fiywhoe! ou 4, Remove fuel injection nozzles. (See Fuel System in this section.) 5, Remove glow plugs. (See procedure in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section.) 6. Disassemble and inspect cylinder head and valves. (See Disassembly/ Assembly and Inspection/Replacement procedures.) IMPORTANT: Oil passage in gasket must be located over oil passage in cylinder block. Install gasket as shown. 7. Tighten mounting cap screws, in the sequence shown, in three stages of gradually-increasing torque. IMPORTANT: Cylinder head mounting cap screws must be checked for proper torque after 50 hours of engine operation. R220 Exhaust Manifold Side Fiywhee! Side Timing Gear Case Side Intake Manifold Side Torque Specifications - 3TN66: First ..ecceeeeeeeeeeeee LLNem (97 Ib-in,) Second ......++++0++++ 22 Nem (195 Ib-in.) Final ...ceeeeeeeeeeee4 34 Nem (25 Ib-ft) Torque Specifications - 3TNA72 (3009): First .0..06ee0eeeeeee5 19 Nem (168 Ib-in,) 38 Nem (28 Ib-ft) 61 Nem (45 Ib-ft) Second Final 1-22 amsPistons, Rods and Cylinder Block Inspection/Replacement 1. Inspect all parts for wear or damage. Replace as necessary, 2. Measure crankshaft connecting rod journal diameter. (See Crankshaft, Main Bearings and Flywheel in this section.) 3. Install connecting rod cap and bearing inserts on connecting rod. Install old connecting rod cap setews and tighten to 23 Nem (203 tb-in.). ‘4, Measure connecting rod bearing diameter. Connecting Rod Bearing LD. - 31N66: Standard . . 36.00 - 36.042 mm eee e eee eeeeeee eee e eee (L417 ~ 1419 in.) Wear Limit........... 37.07 mm (1.459 in.) = 0.16 mm (0.006 in.) Clearance. Connecting Rod Bearing ID. - 3TNA72 (3009): Standard . - 40.00 - 40.042 mm (1.575 - 1.577 in) Wear Limit.........-. 40.07 mm (1.578 in.) = 0.16 mm (0,006 in.) Clearance. If bearing diameter exceeds wear limit, replace bearing inserts. If bearing clearance (bearing LD. minus crankshaft joumal O.D.) exceeds specification, grind crankshaft connecting rod journals and install undersized bearing inserts, ‘or replace bearing inserts and crankshaft. 5, With rings installed on piston, measure piston ring groove clearance. Measure several places around each piston. 135960 Piston Ring Groove Clearance - 3TN66: First Compression Ring Standard .........+++++, 0.065 - 0.100 mm. = (0.0026 - 0.0039 in.) 0.20 mm (0.0079 in.) Wear Limi Second Compression Ring Standard ‘Wear Limit. 0.030 - 0.065 mm ss see es «(0.0012 - 0.0026 in.) = 0.20 mm (0.0079 in.) Oil Ring Standard .......66.+6++-0,020- 0.055 mm = (0.0008 - 0.0022 in.) 0.20 mm (0.0079 in.) Wear Limi 1:36 amsCrankshaft, Main Bearings and Flywheel | ” Ge ZO Main Bearing Gap — Is Main Bearing Cap Scrow (8) Dip in clean engine ol, 3TNG6: 54 Nem (40 Ib-f) 3TNA72 (3009):79 Nem (68 Ib-t) 9. Tighten main bearing cap screws to specifications. When tightening, start at center main bearing cap and work your way out, alternating to the ends. Turn crankshaft by hand. If it does not tum easily, disassemble the parts and find the cause. IMPORTANT: Connecting rod caps must be installed on the same connecting rods they ‘were removed from. Never reuse connecting rod cap replace with new. screws, 10.Match the connecting rod caps to the rods using alignment marks. Install caps. Crankshaft ‘Smooth Bearing Insert HRA 1LDip entire connecting rod cap screws in clean engine oil. Install new cap screws and tighten to 23 Nem (203 Ib-in.), 12.Install timing gear housing. (See Camshaft and Timing Gear Train in this section.) 13.Install crankcase extension housing, if equipped. (See procedure in this group.) 14.Install flywheel housing, if equipped. (See procedure in this group.) 15.Install rear oil seal. (See procedure in this group.) 1-48 amsCamshaft and Timing Gear Train CAMSHAFT Removal 1, Remove rocker arm assembly and push rods. (See Cylinder Head, Valves and Manifolds in this section.) 2. Remove timing gear cover. (See procedure in this group.) Check camshaft end play. (See Checks, Tests and Adjustments in this section.) 4. Check backlash of timing gears. (See Checks, Tests and Adjustments in this section.) NOTE: Ifa magnetic follower holder kit is not available, turn engine until oil pan is upward, to hold cam followers away from camshaft. 5. Hold cam followers away from camshaft using a magnetic follower holder kit such as D15001NU. NOTE: Due to the odd number of teeth on the idler gear; timing marks will only align periodically. 6, Rotate crankshaft and align timing marks, IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while removing camshaft. Machined surfaces can be damaged. 7. Remove two cap screws and camshaft. 8. Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) Mounting Cap Screws arene STN66, Later 3TINAT2 Mounting Cap Screws Camshaft Early 3TNATZ Installation + Apply clean engine oil on all parts during instailation. IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while installing camshaft. Machined surfaces can be damaged. 1. Rotate crankshaft to align timing marks. 2. Install camshaft. 3. Install and tighten mounting cap screws to 11 Nem (96 Ib-in.). 4, Install timing gear cover. (See procedure in this group.) 5. Install push rods and rocker arm assembly. (See Cylinder Head, Valves and Manifolds in this section.) 1-56 ams