Engine 3066 - 3064 - Specifications

CATERPILLAR

3064 and 3066 Engines for Caterpillar sy Built Machines 6LK1-Up (Engine) 7JK1-Up (Engine)

SENR5545-04 October 2001

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Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

WARNING The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazar d. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available atadjustments, the time thatillustrations, the publication was written. Thechange specifications, torques, pressures, measurements, and other items can at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

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

3 Table of Contents

Table of Contents Specifications Section Engine Design Fuel Injection Lines Fuel Injection Pump Fuel Injection Nozzles Lifter Group Rocker Shaft Valve Mechanism Vafve Mechanism Cover Cylinder Head Turbocharger Exhaust Manifold Camshaft Engine Oil Relief Valve Engine Oil Pump Engine Oil Pressure Engine Oil Bypass Valve Engine Oil Pan Water Temperature Regulator Water Pump Cylinder Block Crankshaft Crankshaft Seals Connecting Rod Bearing Journal Main Bearing Journal Connecting Rod Piston and Rings Gear Group (Front) Flywheel Crankshaft Pulley Belt Tension Chart Belt Tightener Alternator and Regulator Electric Starting Motor Coolant Temperature Switch Engine Oil Pressure Switch Air Inlet Heater

4 5 5 6 6 7 8 9 9 10 11 12 13 14 15 15 16 16 16 17 18 20 20 21 21 23 25 26 27 27 28 28 29 29 29 29

Index Section index

30

4 Specifications Section

Specifications Section

The crankshaft rotation is viewed from the flywheel end of the engine. Crankshaft rotation Counterclockwise

Engine Design

Note: The front end of the engine is opposite of the flywheel end of the engine. The left side of the engine and the right side of the engine are viewed from the flywheel end of the engine. The No. 1 cylinder is the front cylinder.

SMCSCode: 1201

3064 Engine

Illustration 1

3066 Engine

g00523889

Cylinder and valve location

Illustration 2

(A) Exhaust valve

Cylinder and valve location

(B) Inlet valve

(A) Exhaust valve

Type Combustion system

Four cylinder and four stroke Direct injection

Bore

102 mm (4.02 inch)

Stroke

130 mm (5.12 inch)

Number of cylinders Displacement Cylinder arrangement Valves per cylinder Firing order Compression ratio

4 4.3 L (260 in3) In-line 2 1 -3-4-2 17:1

Note: Refer to the Engine Information Plate for the performance specification number. Refer to the Technical Marketing Information (TMI) or refer to the Fuel Setting and Related Information Microfiche for the correct timing specifications. Minimum rpm

900 ± 20

g00295223

(B) Inlet valve

Type Combustion system

Six cylinder and four stroke Direct injection

Bore

102 mm (4.02 inch)

Stroke

130 mm (5.12 inch)

Number of cylinders Displacement Cylinder arrangement Valves per cylinder Firing order Compression ratio

6 6.4 L (390 in3) In-line 2 1-5-3-6-2-4 17:1

Note: Refer to the Engine Information Plate for the performance specification number. Refer to the Technical Marketing Information (TMI) or refer to the Fuel Setting and Related Information Microfiche for the correct timing specifications. Minimum rpm

900 ± 20

5 Specifications Section

The crankshaft rotation is viewed from the flywheel end of the engine. Crankshaft rotation Counterclockwise Note: The front end of the engine is opposite of the flywheel end of the engine. The left side of the engine and the right side of the engine are viewed from the flywheel end of the engine. The No. 1 cylinder is the front cylinder.

Fuel Injection Pump SMCSCode: 1251; 1290

Fuel Injection Lines SMCSCode: 1252

Illustration 4

(1) Bolts for fuel injection line Illustration 3

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

Tighten the bolts for the fuel injection line to the following torque 20 to 25 N-m (15 to 18 lb ft) (2) Delivery valve holder Tighten the delivery valve holder to the following torque 39 to 44 N-m (29 to 32 lb ft) (3) Bolt for lock plate Tighten the bolt for the lock plate to the following torque 3 to 5 N-m (27 to 44 lb in) (4) Bolt for fuel line Tighten the bolt for the fuel line to the following torque 10 to 13 N-m (7 to 10 lb ft) (5) Idler subspring nut Tighten the idler subspring nut to the following torque 12 to 16 N-m (9 to 12 lb ft) (6) Idler subspring Tighten the idler subspring to the following torque

16 to 20 N-m (12 to 15 lb ft)

(7) Nut Tighten the nut to the following torque 3 to 5 N-m (27 to 44 lb in)

6 Specifications Section

(6) Pressure spring

Fuel Injection Nozzles

(7) Pressure pin

SMCSCode: 1254

(8) Gasket (9) Pin (10) Tip for fuel injection nozzle (11) Retaining nut for fuel injection nozzle Tighten the nut to the following torque 34 + 5 N-m (25 ± 4 lb ft)

Lifter Group Illustration 5

g00530280

SMCSCode: 1209

(1) Seal

(2) Fuel injection nozzle (3) Retainer for fuel injection nozzle Tighten the retaining bolt to the following torque 22 N.m (16 lb ft)

Illustration 7

(10) Tappet bore diameter Tappet bore diameter

22.000 to 22.021 mm (0.8661 to 0.8670 inch)

Maximum tappet bore diameter

22.055 mm (0.8683 inch)

Clearance of tappet to bore .. 0.035 to 0.086 mm (0.0014 to 0.0034 inch) Note: Replace the tappet if the clearance is exceeded. Illustration 6

(4) Body for fuel injection nozzle (5) Shims Increasing shims by 0.10 mm (0.004 inch) changes injection pressure by approximately 1375 kPa (200 psi). Shims are available in nine sizes from 0.10 mm (0.004 inch) to 0.58 mm (0.023 inch).

7 Specifications Section

Rocker Shaft SHCS Code: 1102

Illustration 10

Position the rocker shaft brackets and mounting bolts. lflustration8

(1) Rocker arm bushing Bore in rocker arm bushing for shaft 20.011 to 20.094 mm (0.7878 to 0.7911 inch) (2) Rocker arm shaft Diameter of rocker arm shaft 19.966 to 19.984 mm (0.7861 to 0.7868 inch)

(4) Long bolt Tighten the long bolt to the following torque 15 + 3 N-m (11 ±2 lb ft) (5) Short bolt Tighten the short bolt to the following torque 15 ± 3 N-m (11 ± 2 lb ft) (6) Rocker shaft bracket

Clearance of rocker arm bushing for shaft

0.027 to 0.128 mm (0.0011 to 0.0050 inch)

Replace the rocker arm bushing if the repair limit of 0.15 mm (.006 inch) has been reached. Replace the rocker arm bushing and the rocker arm shaft if ttie repair limit of the rocker arm bushing has been exceeded.

Illustration 11 Valve lash adjustment

Turn the crankshaft until the timing mark on the crankshaft pulley is aligned with the pointer on the timing gear housing in order to adjust the val ve lash. Both the No. 1 inlet valve and the No. 1 exhaust valve pushrods must not be in tension against the rocker arms. Inlet and exhaust valve lash .. 0.25 mm (0.010 inch) (3) Align the oil holes in rocker arm bushing (A) with the oil holes in the rocker arm when the rocker arm bushing is replaced.

8 Specifications Section

Valve Mechanism SMCS Code: 1102

Maximum allowable clearance for guide for inlet valve 0.150 mm (0.0059 inch) Maximum allowable clearance for guide for exhaust valve 0.200 mm (0.0079 inch) (5) Outside diameter of valve guide Outside diameter of guide for inlet valve 13.025 to 13.035 mm (0.5128 to 0.5132 inch) Outside diameter of guide for exhaust valve 13.025 to 13.035 mm (0.5128 to 0.5132 inch) Inside diameter of guide for new inlet valve 8.010 to 8.035 mm (0.3154 to 0.3163 inch) Inside diameter of guide for new exhaust valve 8.010 to 8.025 mm (0.3154 to 0.3159 inch) Maximum inside diameter for guide for inlet valve 8.09 mm (0.319 inch) Maximum inside diameter for guide for exhaust valve 8.12 mm (0.320 inch)

Illustration 12

(1) Spring

(6) Thickness of lip

Length under test force .... 44.0 mm (1.73 inch) Test force 223 to 246 N (50 to 55 lb) Free length after test 56.4 mm (2.22 inch) Maximum bend in spring 2 degrees

Valve lip thickness for inlet and exhaust valves 2.13 mm (0.084 inch) Minimum allowable valve lip thickness for inlet and exhaust valves (7) Angle of valve face

(2) Valve stem seal

1.20 mm (0.047 inch) 30 degrees

(3) Height to top of valve guide .. 17.00 ± 0.30 mm (0.669 ± 0.012 inch) (4) Diameter of valve stem Inlet valve stem

7.940 to 7.955 mm (0.3126 to 0.3132 inch)

Exhaust valve stem

7.920 to 7.940 mm (0.3118 to 0.3126 inch)

Minimum allowable diameter for inlet valve stem 7.900 mm (0.3110 inch) Minimum allowable diameter for exhaust valve stem 7.850 mm (0.3091 inch) Illustration 13

Clearance for intake valve stem in valve guide 0.055 to 0.085 mm (0.0022 to 0.0033 inch) Clearance for exhaust valve stem in valve guide 0.070 to 0.105 mm (0.0028 to 0.0041 inch)

(8) Depth of bore in head for valve seat insert

9.5 ± 0.1 mm (0.374 ± 0.004 inch)

(9) Chamfer of inlet valve

40 degrees

Note: The depth of the chamfer of the inlet valve is 2.38 ± 0.10 mm (0.094 ± 0.004 inch).

Specifications Section

(10) Chamfer of exhaust valve

45 degrees

Note: The depth of the chamfer of the exhaust valve is 2.00 ± 0.10 mm (0.079 ± 0.004 inch). (11) Valve seat bore for inlet.. 46.000 to 46.025 mm (1.8110 to 1.8120 inch) (12) Valve seat bore for exhaust

39.000 to 39.025 mm (1.5354 to 1.5364 inch)

(16) Pushrod Use a dial indicator in order to check all pushrods for runout. Replace the pushrod if the runout exceeds the following value 0.40 mm (0.016 inch)

Valve Mechanism Cover SMCSCode: 1107

Illustration 14 Illustration 16

(13) Width of valve seat

1.40 ±0 .2 0 mm (0.055 ± 0.008 inch)

Note: The maximum permissible width of the valve seat is 1.80 mm (0.071 inch). (14) Valve seat angle

(1) Valve cover nut Tighten the valve cover bolts to the following torque 15 ±3 N -m (1 1 ± 2 lb ft)

30 degrees

(15) Dimension from top of closed valve to face of head Exhaust valve

0.50 ± 0.25 mm (0.020 ± 0.010 inch)

Inlet valve

0.40 ± 0.25 mm (0.016 ± 0.010 inch)

Cylinder Head SMCSCode: 1100

Note: The maximum permissible depth is 1.10 mm (0.043 inch).

Illustration 17

(1) Cylinder head Use a straightedge and a feeler gauge to check the cylinder head for warpage. Illustration 15

Flatness of the cylinder head over total span 0.05 mm (0.002 inch)

10 Specifications Section

Resurface the cylinder head if the warpage exceeds the following amount 0.20 mm (0.008 inch) Gasket thickness of cylinder head 1.70 ± 0.10 mm (0.070 ± 0.004 inch) Thickness of new head

Turbocharger SMCS Code: 1052

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

Illustration 20

g00530558

(1) Compressor wheel (2) Turbine wheel (3) Turbine housing (4) Compressor housing Illustration 18 Numerical sequence of bolts for 3064 Engine

(5) Cartridge housing 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

11 Specifications Section

Place a dial indicator on the end of the turbine shaft. Move the compressor wheel (1) in the axial direction in order to measure end play. End play .... 0.057 to 0.103 mm (.0022 to .0041 inch) Note: The turbocharger must be disassembled and the turbocharger must be checked for clearances if the end play is beyond the specifications.

Illustration 24

g00530564

(8) Clamp Apply 5P- 393 1 Anti-Seize Compound to the threads of the clamp. Tighten the clamp to the following torque 4 ± 1 N-m (35 ± 9 lb in) Illustration 22

9 00530561

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

Tap clamp (8) lightly around the circumference. Tighten clamp (8) to the following torque 4 ± 1 N-m (35 ± 9 lb in) i01575653

Exhaust Manifold SMCS Code: 1059

Illustration 23

9 00530562

Turbine housing (3) and Cartridge housing (5)

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

Illustration 25

9 00530254

(1) Nuts for turbocharger Tighten the nuts for the turbocharger to the following torque 41 N-m (30 lb ft) (2) Studs for turbocharger Tighten the studs for the turbocharger to the following torque 12 N-m (9 lb ft) (3) Studs for exhaust manifold Tighten the studs for the exhaust manifold to the following torque 12.5 N-m (9 lb ft)

12

Specifications Section

(4) Nuts for exhaust manifold Tighten the nuts for the exhaust manifold to the following torque 18 + 4 N-m (13 ± 3 lb ft)

Camshaft SMCSCode: 1210

Illustration 27

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

7.344 mm (0.2891 inch) 6.689 mm (0.2633 inch)

Service limit for lobe lift for exhaust

6.844 mm (0.2695 inch)

Service limit for lobe lift for inlet

6.189 mm (0.2437 inch)

Illustration 26

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

Note: Do not use a torch.

Note: Replace the camshaft if the service limit for the lobe lift is reached. (5) Camshaft lobe height

(2) Diameters of camshaft journals

(6) Base circle

Table 1

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

Number of Journal for 3064 Engine

Number of Journal for 3066 Engine

Standard Diameter

1, 2

1, 2, 3

53.94 to 53.96 mm (2.123 to 2.124 inch)

53.90 mm (2.122 inch)

3

4

52.94 to 52.96 mm (2.084 to 2.085 inch)

52.90 mm (2.083 inch)

Service Limit(1)

1. Measure the camshaft lobe height (5). 2. Measure the base circle (6). 3. Subtract the base circle that is found in Step 2 from the lobe height that is found in Step 1. The difference is the actual camshaft lobe lift (4).

(1) The service limit is the maximum dimension or the service limit is the minimum dimension that is specified for a part. Replace the part if the service limit is reached.

(3) Thrust plate bolt Tighten the bolt to the following torque 11 ± 2 N-m (8 ± 1 lb ft)

Illustration 28

13 Specifications Section

Note: Use a dial indicator and blocks in order to determine the runout of the camshaft. Take one half of the dial indicator reading as the runout.

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

(7) Camshaft

0.10 to 0.25 mm (0.004 to 0.010 inch)

Maximum permissible runout for camshaft 0.020 mm (0.0008 inch)

Replace the thrust plate if the end play exceeds the following amount 0.30 mm (0.012 inch)

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

Thrust plate thickness

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

4.85 mm (0.191 inch)

Engine Oil Relief Valve SMCS Code: 1315

Illustration 29

(8) Camshaft bearing

Illustration 31

Measure the camshaft bearing with a dial indicator. Subtract the diameter of the camshaft journal in order to give bearing clearances. Refer to Table 2. Table 2

Standard Diameter Clearance between camshaft journals and bushings

(1) Repair Limit

Remove block. the oilCheck pressure fromvalve the seat cylinder the relief valvevalve and the for abnormal contact patterns. Inspect the spring for weakness or damage. Replace the oil pressure relief valve, if necessary. Relief valve opening pressure

0.04 to 0.09 mm (0.002 to 0.004 inch)

0.15 mm (0.006 inch)

(1) The repair limit is the maximum dimension or the repair limit is the minimum dimension that is specified for a part. Repair the part if the repair limit is reached.

Illustration 30

Engine oil relief valve

343 ± 20 kPa (50 ± 3 psi) Tighten the engine oil relief valve to the following torque 49 + 5 N-m (36 ± 4 lb ft)

14 Specifications Section

Engine Oil Pump SMCS Code: 1304

Illustration 32

NOTICE Before operation, the pump must be lubricated with clean engine oil and the pump must turn freely by hand or damage to parts can be the result. Note: The minimum acceptable oil pressure at low idle is 100 kPa(15 psi). (1) Driven gear assembly (2) Drive gear assembly

Illustration 33

(6) Housing for oil pump gear Measure the difference in the length of the assembly for the oil pump gear and the depth in the oil pump housing. Clearance 0.020 to 0.034 mm (0.0008 to 0.0013 inch) Note: Replace the oil pump gear assembly if the clearance exceeds the service limit of 0.150 mm (0.0059 inch).

(3) Oil pump gear Note: Do not use a torch. Heat the oil pump gear to 180° to 220°C (356° to 428°F) and support the end of the drive gear shaft in order to install the oil pump gear. Press the oil pump gear until the oil pump gear is flush with the end of the shaft. (4) Idler gear assembly The backlash between the oil pump gear and the idler gear is the following amount 0.100 to 0.190 mm (0.0039 to 0.0075 inch) Note: Replace the gears if the backlash exceeds 0.35 mm (0.014 inch). (5) Spindle Note: The oil pump gear and the drive gear assembly are not serviceable if the oil pump gear is removed.

Measure the clearance between the oil pump gears and the oil pump housing with a feeler gauge. Clearance

0.050 to 0.098 mm (0.0020 to 0.0039 inch)

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

15 Specifications Section

(7) Cover

(10) Bolts

Measure the inside diameters of the bores of the shafts in the cover (7) and the oil pump housing (6). Measure the bores of the shafts. The clearance between the gear shafts and the oil pump housing and cover.... 0.04 to 0.07 mm (0.002 to 0.003 inch) Note: Replace the oil pump gear assembly, the cover, or the oil pump housing if the clearance exceeds the service limit of 0.15 mm (0.006 inch). Note: Replace the drive gear and driven gear as an assembly.

Tighten the bolts (10) for the oil pump cover (7) to the following torque 35 ± 6 N-m (26 ± 4 lb ft)

Engine Oil Pressure SMCS Code: 1924 Table 3 (1)

Engine Oil Pressure 196 to 392 kPa Oil Pressure at 1500 rpm (28 to 57 psi) Oil Pressure at idle(2)

98 kPa (14 psi)

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

Engine Oil Bypass Valve SMCS Code: 1306-BV

Illustration 35

(8) Idler gear bushing Inside diameter of idler gear bushing 25.000 to 25.021 mm (0.9843 to 0.9851 inch) Maximum diameter of idler gear bushing for oil pump 25.059 mm (0.9866 inch) (9) Spindle Diameter of spindle

24.939 to 24.960 mm (0.9818 to 0.9827 inch)

Minimum diameter of spindle for oil pump 24.901 mm (0.9804 inch) Illustration 37

Note: The oil bypass valve is mounted inside the oil pan along the rail of the oil pan. (1) Valve seat Check the valve and the valve seat for abnormal contact patterns. (2) Spring

Illustration 36

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

16 Specifications Section

Opening pressure of bypass valve .... 981 ± 98 kPa (142 ± 14 psi) Tighten the oil bypass valve to the following torque. 69 ± 5 N-m (51 ± 4 lb ft)

Water Pump SMCS Code: 1361

Engine Oil Pan SMCSCode: 1302

2 Illu stra tion 38

Illustration 39 g00530566

(1) Oil pan bolts Tighten the oil pan bolts to the following torque 28 ± 7 N-m (21 ±5 lb ft) (2) Oil pan drain plug Tighten the oil pan drain plug to the following torque 39 ± 5 N-m (29 ± 4 lb ft)

(1) Impeller The faces of the impeller and the water pump shaft are flush. (2) Flange (3) The distance from the face of the impeller to the water pump housing is the following amount 21.00 to 21.70 mm (0.826 to 0.854 inch)

Water Temperature Regulator SMCS Code: 1355 The water temperature regulator starts to open at the following temperature. ... 71° ± 2°C (160° ± 4°F) The optional water temperature regulator starts to open at the following temperature 82°C (180°F) The valve lifts more than 10 mm (0.4 inch) at the following temperature 85°C (185°F) The optional water temperature regulator lifts more than 10 mm (0.4 inch) at the following temperature 96°C (204°F)

Illustration 40

(4) Water pump shaft

17 Specifications Section

The press fit between the water pump shaft and the flange is the following amount 0.035 to 0.065 mm (0.0014 to 0.0026 inch) The press fit between the water pump shaft and the impeller is the following amount 0.032 to 0.065 mm (0.0013 to 0.0026 inch)

Measure the inside diameter of the cylinder sleeve that is parallel to the crankshaft. Measure the inside diameter of the cylinder liner that is in a perpendicular position to the crankshaft. Measure the top, the middle and the bottom of the cylinder liner. Refer to Table 4 for tolerances of the cylinder liner. Table 4

Tolerances of Cylinder Sleeves J01576112

Standard at Assembly

Repair Limit(1)

Service Limit(2)

Inside Diameter

102.010 to 102.045 mm (4.0161 to 4.0175 inch)

102.200 mm (4.0236 inch)

102.700 mm (4.0433 inch)

Out of Round

0.010 mm (0.0004 inch)

N/A

N/A

Taper

0.015 mm (0.0006 inch)

N/A

N/A

Cylinder Block SMCSCode: 1201

(1) The repair limit is the maximum dimension or the repair limit is the minimum dimension that is specified for a part. Repair a part if the repair limit is reached. (2) The service limit is the maximum dimension or the service limit is the minimum dimension that is specified for a part. Replace the part if the service limit is reached. Illustration 41

^005294 44

Bore the cylinder to the specified oversize dimension if the inside diameter reaches the repair limit but the inside diameter does not reach the

(1) Cylinder block Measure the amount of the warpage of the cylinder block with a straightedge and feeler gauge. Maximum allowable clearance 0.05 mm (0.002 inch) Repair limit

.0.20 mm (0.008 inch)

Resurface the top of the block if the repair limit is reached.

service limit. Refer to Table 5. Hone the liner to +0.25 mm (+0.010 inch) or +0.50 mm (+0.020 inch) oversize. Hone the liner to an accuracy within 0.010 to 0.045 mm (0.0004 to 0.0018 inch). Determine the oversize dimension that is necessary in order to clean up the cylinder if any liner has uneven wear. Replace all cylinder liners that are in excess of the service limit. Note: Refinish all liners to the same oversize dimension. Use a ridge reamer in order to cut the ridge of the cylinder if the liner is in good condition. Hone the cylinder bore. Table 5

Illustration 42

(2) Cylinder liner

9

Oversize Bore

Cylinder Bore Size

0.250 mm (0.0100 inch)

102.260 mm (4.0260 inch) 102.295 mm (4.0274 inch)

0.500 mm (0.0197 inch)

102.510 mm (4.0358 inch) 102.545 mm (4.0372 inch)

00529446

18 Specifications Section

New diameter for the main bearing bores 90.020 to 90.068 mm (3.5441 to 3.5460 inch) Maximum diameter of the main bearing bores 90.150 mm (3.5492 inch) New height of deck from centerline of crankshaft to deck 307.00 ± 0.05 mm (12.086 ± 0.002 inch) Minimum height from the centerline of crankshaft to deck 306.70 mm (12.075 inch) i01573686

Illustration 43

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(3) Cylinder liner Service limit of cylinder liner

Crankshaft SMCSCode: 1202

102.700 mm (4.0433 inch)

Replace all cylinder liners that exceed the service limit.

Illustration 45

9

00525341

(1) Crankshaft main bearing journal Illustration 44

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Cylinder liner

Use the following procedure in order to repair the cylinder liners. 1. Set up a boring machine on the cylinder block. Align the boring machine with the center of the bottom of the cylinder liner with the less worn area. 2. Bore the liner until the thickness is 0.50 mm (0.020 inch). 3. Remove the remainder of the liner. Be careful not to damage the cylinder block. 4. Install a new liner. Align the liner with the top of the cylinder block. 5. The bore of the cylinder must be 102.000 to 102.035 mm (4.0157 to 4.0171 inch).

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

Main Bearing Journal Original size journal (1)

89.95 to 89.97 mm (3.541 to 3.542 inch)

Undersize journal 0.25 mm (0.010 inch)

89.70 to 89.72 mm (3.531 to 3.532 inch)

Undersize journal 0.50 mm (0.020 inch)

89.45 to 89.47 mm (3.521 to 3.522 inch)

Undersize journal 0.75 mm (0.030 inch)

89.20 to 89.22 mm (3.512 to 3.513 inch)

(1) Regrind the main bearing journals to the next undersize dimension if the repair limit of 89.85 mm (3.537 inch) is exceeded.

19 Specifications Section

Illustration 46

Illustration 48

(2) Crankshaft

(4) Crankshaft end play

Support the crankshaft in a set of vee blocks. Measure the runout dimension at the center journal. Maximum runout 0.020 mm (0.0008 inch) Note: The allowable tolerance for main bearing journals that are out of round is 0.010 mm (0.0004 inch). The maximum repair limit is 0.030 mm (0.0012 inch). If the repair limit is exceeded, regrind the bearing journals to the specified dimension. Note: The maximum service limit for the crankshaft journal is 0.90 mm (0.035 inch). Replace the crankshaft if the crankshaft journal is worn beyond this specification. Note: Replace the crankshaft if the runout exceeds the repair limit of 0.050 mm (0.0020 inch).

0.100 to 0.264 mm (0.0039 to 0.0104 inch)

Note: The maximum repair limit is 0.300 mm (0.0118 inch). Replace the standard thrust plates if the end play exceeds the standard clearance. Three oversize thrust plates are available as replacements if the end play still exceeds the maximum limit. Generally, the rear journal is likely to be worn more rapidly than the front journal. If necessary, replace the rear thrust plate. Refer to Table 7 for oversize thrust plates. Table 7

Dimensions for Grinding of Crankshaft Oversize Thrust Plates Oversize Thrust Plate

Oversize (front or rear)

Oversize (front or rear)

Tolerance

+0.15 mm (+.006 inch)

33.15 mm (1.305 inch)

33.30 mm (1.311 inch)

+0.039 mm (+0.0015 inch)

+0.30 mm (+0.012 inch)

33.30 mm (1.311 inch)

33.45 mm (1.317 inch)

+0.039 mm (+0.0015 inch)

+0.45 mm (+0.018 inch)

33.45 mm (1.317 inch)

33.60 mm (1.323 inch)

+0.039 mm (+0.0015 inch)

Torque for the crankshaft pulley nut .... 490 ± 5 N.m (363 ± 4 lb ft) Illustration 47

(3) Width of crankshaft main bearing journal 33.000 to 33.039 mm (1.2992 to 1.3007 inch)

The maximum temperature for installing the crankshaft gear is the following value 100 °C (212 °F)

20 Specifications Section

i01576124

Crankshaft Seals

i01576126

Connecting Rod Bearing Journal

SMCSCode: 1160; 1161

SMCSCode: 1202; 1219; 1225 Table 8

Connecting Rod Bearing Journal Original size journal(1)

59.945 to 59.965 mm (2.3600 to 2.3608 inch)

Undersize journal 0.25 mm (0.010 inch)

59.695 to 59.715 mm (2.3502 to 2.3510 inch)

Undersize journal 0.50 mm (0.020 inch)

59.445 to 59.465 mm (2.3404 to 2.3411 inch)

Undersize journal 0.75 mm (0.030 inch)

59.195 to 59.215 mm (2.3305 to 2.3313 inch)

(1) Regrind the connecting rod journals to the next undersize dimension if the repair limit of 59.980 mm (2.3614 inch) is exceeded.

The clearance between a new bearing and a new journal is the following value 0.035 to 0.100 mm (0.0014 to 0.0039 inch) Illustration 49

g00525904

(1) Front seal (2) Rear seal assembly Note: The rear seal assembly and the slinger are installed as a unit. (3) Slinger Note: The rear seal assembly and the slinger are installed as a unit. (4) Rear seal assembly Note: The rear seal assembly should be flush with the slinger after installation. (5) Contact surface between the slinger and crankshaft Put sealant on the contact surface between the slinger and the crankshaft. Put clean engine oil on the surface of the rear seal assembly. (6) Distance from rear seal assembly to end of crankshaft 6.0 mm (0.24 inch)

An undersized bearing is required if the clearance between the connecting rod journal and the bearing is in excess of the service limit of 0.200 mm (0.0079 inch). If the crankshaft is worn excessively, or if the crankshaft is uneven, an undersized bearing is required. If an undersized bearing is required, grind the crankshaft to a dimension listed in Table 8. Note: The allowable tolerance for rod bearing journals that are out of round is 0.010 mm (0.0004 inch). The maximum repair limit is 0.030 mm (0.0012 inch). If the repair limit is exceeded, regrind the bearing journals to the specified dimension.

21 Specifications Section

Main Bearing Journal SMCSCode: 1202; 1203

(3) Bolts for the main bearing cap Illustration 50

(1) Main bearing cap Put the main bearing caps in position in the cylinder block. Put clean engine oil on the main bearing bolts. Install the main bearing bolts and tighten the main bearing bolts to the following torque 137 ± 5 N-m (101 ± 4 lb ft) (2) Dial indicator

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

Connecting Rod SMCSCode: 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 journals that are out of round is 0.010 mm (0.0004 inch). The maximum repair limit is 0.030 mm (0.0012 inch). If the repair li mit is exceeded , regrind the bearing journals to the specified dimension.

Illustration 52

(1) Matching marks 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 feeler gauge to measure 0.15 the end play.mm End a play to 0.35 (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

34.020toto1.3404 34.045 inch) mm (1.3394

The clearance between the piston pin bearing and the piston pin is 0.023 to 0.054 mm (0.0009 to 0.0021 inch). Note: A clearance for the piston pin to the piston pin bearing over 0.010 mm (0.0004 inch) is excessive. Replace the piston pin or replace the bearing if the clearance is excessive.

Illustration 56

(6) Piston (7) Markings on piston Assemble the piston and connecting rods. Ensure that the markings on the piston (7) and the marks on the connecting rod (1) are on the same side.

23 Specifications Section

Piston and Rings SMCSCode: 1214; 1215

Illustration 57

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

Illustration 59

(1) Markings on piston Each piston has markings which are stamped on top of the piston. The markings are used to align the piston assembly to the camshaft side of the cylinder block. Illustration 58

(2) Piston diameter

(9) Piston projection Use the following procedure to measure the height of each piston above the cylinder block. If clearances are not in the acceptable range, inspect the components for wear or damage. 1. Determine the top center position of the piston with a dial indicator assembly. 2. Install the dial indicator assembly on the top of the block. Set the needle of the dial indicator to zero. 3. Measure projection (9) at three places on the top of the piston. Take an average of the three measurements in order to determine the projection. Subtract the projection from the installed thickness of the cylinder head gasket in order to determine the clearance between the top of the piston and the cylinder head. Installed thickness of the cylinder head gasket 1.70 ± 0.10 mm (0.070 ± 0.004 inch) Piston projection

0.55 to 1.15 mm (0.022 to 0.045 inch)

Table 9 gives the dimensions for pistons that are standard. Table 9 also gives the dimensions for pistons that are oversize. Note: Measure the piston diameter along the perpendicular of the piston pin bore.

24 Specifications Section

Table 9

Dimensions for Piston Diameters Bore Size

Standard at Assembly

(1) Serv ice LimiK

Standard

101.915 to 101.945 mm (4.0124 to 40136 inch)

101.730 mm (4.0051 inch)

Oversize 0.25 mm (0.010 inch)

102.165 to 102.195 mm (4.0222 to 4.0234 inch)

101.980 mm (4.0150 inch)

Oversize 0.50 mm (0.020 inch)

102.415 to 102.445 mm (4.0321 to 4.0333 inch)

102.230 mm (4.0248 inch)

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

Illustration 61

g00524467

(5) Identification mark on piston rings Install the piston rings with the identification mark toward the top. Note: Each piston ring is marked with an "R" or "T" for an identification mark. (6) Top piston ring Piston ring end gap for a standard bore 0.30 to 0.45 mm (0.012 to 0.018 inch) Note: Replace the piston rings if the end gap exceeds the maximum tolerance of 1.50 mm (0.060 inch). (7) Intermediate piston ring

Illustration 60

(3) Diameter of piston pin bore (4) Diameter of piston pin

33.993 to 34.000 mm (1.3383 to 1.3385 inch )

Measure the piston pin bore diameter. Subtract the piston pin diameter from the bore diameter. The clearance between the bore and piston pin 0.002 to 0.019 mm (0.0001 to 0.0008 inch) Note: The service limit for the clearance between the piston pin and the piston pin bore is 0.050 mm (0.0020 inch). Replace the piston if the clearance has been exceeded.

Piston ring end gap for standard bore 0.30 to 0.45 mm (0.012 to 0.018 inch) Note: Replace the piston rings if the end gap exceeds the maximum tolerance of 1.50 mm (0.060 inch). (8) Oil control piston ring The position of the end gap of the oil control ring is 180 degrees from the ends of the ring expander. Piston ring end gap for a standard bore 0.30 to 0.50 mm (0.012 to 0.020 inch) Note: Replace the piston rings if the end gap exceeds the maximum tolerance of 1.50 mm (0.060 inch).

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

Clearancesof the Piston Rings

Gear Group (Front)

Side Piston Rings

Width of Ring

No. 1 Compression Ring

(Y) Side of engine with combustion chamber Position the piston rings according to Illustration 63.

Clearance of Ring Groove

Service (1) Limit

3.00 mm (0.118 inch)

0.080 to 0.120 mm (0.0031 to 0.0047 inch)

0.200 mm (0.0080 inch)

No. 2 Compression Ring

2.00 mm (0.080 inch)

0.080 to 0.120 mm (0.0031 to 0.0050 inch)

0.150 mm (0.0060 inch)

Oil Control Ring

4.00 mm (0.157 inch)

0.025 to 0.065 mm (0.0010 to 0.0026 inch)

0.150 mm (0.0060 inch)

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

SMCS Code: 1206

Illustration 64

g00527858

(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)

26 Specifications Section

(5) Crankshaft gear Note: Ensure that the marks on the timing gears are in alignment.

Illustration 65

g00527864

Idler gear (2)

Table 11

Item

Standard at Assembly

(1) Service Limit

Backlash of idler gear

0.03 to 0.17 mm (0.001 to 0.007 inch)

0.25 mm (0.010 inch)

End play of idler gear

0.05 to 0.20 mm (0.002 to 0.008 inch)

0.35 mm (0.014 inch)

Clearance between idler gear bushing and shaft

0.009 to 0.080 mm (0.0004 to 0.0031 inch)

0.100 mm (0.0039 inch)

9 00527912

(8) Idler gear shaft Replace the bushing if the clearance between the idler gear bushing and the idler gear shaft exceeds the service limit. Refer to Table 11. Tighten the bolts for the timing gear cover to the following torque 35 + 6 N-m (26 ± 4 lb ft) (9) Front plate Tighten bolt that holds the5 front plate± to theft) followingthe torque 35 ± N-m (26 4 lb i01576345

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

(6) Idler gear bolt

Illustration 67

(7) Inside diameter of idler gear bushing

Install a dial indicator and rotate the idler gear (2) back and forth in order to measure backlash. Replace the idler gear if the backlash exceeds the service limit. Refer to Table 11.

Illustration 66

Measure the end play of the idler gear with a feeler gauge. Refer to Table 11 . Tighten the idler gear bolt to the following torque 34 N-m (25 lb ft)

9 00819139

Flywheel SMCSCode: 1156

Illustration 68

(1) Flywheel

g00529633

27 Specifications Section

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

Crankshaft Pulley

Standard at assembly of flywheel

SMCSCode: 1205

0.15 mm (0.006 inch)

Repair limit of flywheel .... 0.50 mm (0.020 inch) Note: Refinish the flywheel if the repair limit is exceeded.

Illustration 70

Tighten the crankshaft pulley nut to the following torque 490 ± 10 N-m (361± 7 lb ft) i01449909

Belt Tension Chart SMCS Code: 1357 Illustration 69

g00529634

(2) Measure the runout on the flywheel face with a dial indicator. Maximum face runout.... 0.15 mm (0.006 inch) Repair limit of face runout

0.50 mm (0.020 inch)

Note: Refinish the flywheel if the repair limit is exceeded. Maximum permissible temperature of the ring gear for installation on the flywheel without using a torch 150° C (302° F) Note: The ring gear is pressed on the flywheel. Tighten the flywheel bolts to the following torque 83 ± 5 N-m (61 ± 4 lb ft) Number of teeth of the flywheel ring gear

127

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

28 Specifications Section

Table 12

Belt Tension Chart Gauge Reading Width of Belt

Size of Belt

(1) Initial Belt Tension

Borroughs Gauge Numbers

(2) Used Belt Tension

Number of the Selected Gauge

3/8

10.72 mm (0.422 inch)

445 ± 22 N (100 ±5 lb)

400 ± 22 N (90 ± 5 lb)

BT-33-97

1/2

13.89 mm (0.547 Inch)

534 ± 22 N (120 ±5 lb)

400 ± 44 N (90 ±1 0 lb)

BT-33-97

Measure the tension of the belt that is farthest from the engine. (1) Initial Belt Tension refers to a new belt. (2)Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.

i01574161

Belt Tightener SMCS Code:

Illustration 71

1358

i01574185

Alternator and Regulator SMCS

Code:

goossosos

(1) Bolt.

1405; 1410

illustration 72

g00530887

(1) Nut for alternator pulley

Apply pressure to each belt midway between the pulleys in order to inspect the belt tension. Adjust the bolt for the alternator if the tension is incorrect. The proper tension for the fan drive belt is approximately the following deflection 12.0 mm (0.50 inch)

Tighten the nut for the alternator pulley to the following torque 132 to 162 N-m (97 to 119 lb ft) Polarity Rotation Speed for testing (rpm) Output voltage Rated output

negative ground either direction 5000 rpm 28.0 ± .5 V 50 A

29 Specifications Section

Electric Starting Motor

Coolant Temperature Switch

SMCSCode: 1453

SMCS Code: 1395; 1906

74 Engrie coolant temperature switch

Tighten the engine coolant temperature switch to the foiowing torque. ... 7 to 12 N-m (62 to 106 lb in) Illustration 73

Engine Oil Pressure Switch

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

SMCSCode: 1924

The rotation is viewed from the drive end of the electric starting motor starting motor. Rotation of electric clockwise No load conditions Speed (rpm)

3300 rpm minimum

Maximum current (draw)

85 A

Voltage

23 V

Engine oil pressureswitch

Tighten the engine oil pressure switch to the cylinder block to the following torque: .. 7 to 12 N-m (62 to 106 lb in) 101578156

Air Inlet Heater SMCS Code: 1090 Tighten the four bolts that secure the air inlet heater to the inlet manifold to the following torque 28 ± 7 N-m (21 ± 5 lb ft)

30 Index Section

Index L

A Air Inlet Heater Alternator and Regulator

29 28

Lifter Group

6

M B Main Bearing Journal Belt Tension Chart Belt Tightener

21

27 28 P Piston and Rings

C

Camshaft Connecting Rod Connecting Rod Bearing Journal Coolant Temperature Switch Crankshaft Crankshaft Pulley Crankshaft Seals Cylinder Block Cylinder Head

12 21 20 29 18 27 20 17 9

29 4 4 4 15 16 15 29 14 13 11

26 5 6 5

G Gear Group (Front)

25

I Important Safety Information

Rocker Shaft

7

S Specifications Section

Table of Contents Turbocharger

4

2

3 10

V Valve Mechanism Valve Mechanism Cover

8 9

W Water Pump Water Temperature Regulator

F Flywheel Fuel Injection Lines Fuel Injection Nozzles Fuel Injection Pump

R

T

E Electric Starting Motor Engine Design 3064 Engine 3066 Engine Engine Oil Bypass Valve Engine Oil Pan Engine Oil Pressure Engine Oil Pressure Switch Engine Oil Pump Engine Oil Relief Valve Exhaust Manifold

23

16 16