Motor Caterpillar

GAIERPII.TAB'

Specifications 34OOE and 3456 Engines

Built Machines

AEfl-Up

9

for Gaterpillar

4nhbtErbow.....,............ ...............,,.......... Eú.rct Mánirotd ._........,,..............

EnSiñe Oil

Pán

19

.....

$hÉPup','''.'''.''''''''''..'.'''''-..'-

cdn€cting Ród Beann! Jouhát

r&ñ

B.árino

Jdmd

..

35

Specif ications Sect¡on

3456

Eng¡ne Des¡gn 3406E

(AIdd. (É)

Éd

Bft

1B)

e&r

(c)

d €4 rs.lF)

bi

!*

Filhd6

d

dd¡e

d4tu

cr ¡@ ¡uñbei GIFDú€d e¡d (D)

...........-........................... 137.0 mm (5.40 rnch)

strcke .................................... 165.0 mm (6.50 inoh)

Dbpráenénl -................................. 143

L (3e0

rn)

Cy¡nder Aftnq€ment .......,.... ...... ln-ñne sü rylinde¡ Valv€s

ps cy¡ind*

.........-......... ..,

lnlel varve hsh ......... .............. 0.3! mm (0.01s ¡nch) Exhaúst %lve

l6h .......,,.,...,,. 0.76

mm (0.030irch)

Finns order (injeclion sequene) ..

cÉnlchan bialion

lrm

lhe iyrheel

I

5

Fuel Transfer Pump Type

I

¡FisftfoFhú..1hú1tsñP

tol

tE h01s to t¡e ing iotque. ..........._........._...._ 30 r 5 N ó (22 14 b n) lEñtan

Type 2 (2i P.$su€ eoulalinq

ú|re

(2) P''ersuE resubiilns wNé

Electronic Un¡t In¡ector Mechan¡sm

fshlen lhe nús lo rhe rollowitrs

torqoe. ...........-.............3015N m (22 r 4lbfr)

Fuel Filter Base

l fshc¡ lhe Ép nut3 io $é tunówi¡o Irqué. ......... 2 sr 0.25 N m (2212|b in)

ü,

\2) fighign Úlé ádjosrinO screw rooloul lo lhe fon@insrrque. ........1ml 10 N.m(74 17 rbñ) (3) Adjusr ü'e unir anj€.{tr héiqht ro the forr@ine diremó¡. ...... 7a.0 ! 0.2 mm {3.07 ! 0.01 incrr)

\4) unit injecbr clmp Bráinhq bon

f ) fté *rin! srud is lhé

fghián üé únit injectw damp ÉrÁ¡ning bdr tó

3ú'ráe o¡ rhé básé b mé énd of $e fóllwins dimension. ... 24.6 ! 1.3 mm (0.e7

r

5s

o.o5 inch)

!

10 N.m (40.6 ¿ 7.4 lb ñ).

L@sén

(2) Appry 1 s5 - 0695 ThÉad Lock Compound on rhe lapeEd end of rhe srud io rhe lollowing

tlé éiáinifE b.lt

fghisn $é éiainiñs

d¡ménsro.. ........................... 7.7 mm (o.30 inch) (5) ']lghr€n rhé stud io

Ílé d¡rwiño

túque. ......,.,, ....,......

70 1 15 N m (50

t

11 lb

,t)

(6) (7) OÉng

**

unül

$e

bolt is ñnc€r

boft asain ro 55

r l0

Nm

I

B€loB insbnáion ot Íle un[ ir]edor tubri€té thé wls silh á so/50 mixru€ ol dsn

iop reú o{ing €ng¡né oir and

3f-2993Lubn@nr

Valve Mechan¡sm

: R.lér to fsrins and Adtúsrño, .Etecroric Unil hr€dor . adju{ lol flé 6recr prc _

¡ot

dr€ r¿sh on tñ6

€re.troic unir

iDaciof

Electronic Un¡t ln¡ector Rocker Arm

(1) Válw ró.ker ám a*mbry

(l) 8oE¡nlheoc*ersmbéadnqrdthercckorám r

0.015 mn (1.s774r0.0006 rn¿h) Mdimuñ di'mensim fof dM pans .40.193mm O.$24 inch)

.......... 40.065

TrE

rl€r

€üE Éé

añ

beainq musl nd

ór he

m.br áñ

de¡d bMnd

(2) Adj$ihq screw ¡ochd

fghrén the.djlsiiñs sEw tocknút to üle fón4in! lorqué. ...........30! 7 N m (22 f5 tbfr)

xor.: rflhe eisine É.cuipped w¡th á ónoGsion bEk6 tle mouniino botts for thé domores;¡on br¿ké red66 bons l3). Rér€¡ lo s¡eciriÉróns ¡cd¡pEes'ón &¿ke".

Tqff€n rh€ botb ro lhe lbntuins

bque.

........_ .109rlsNm(30!f

Oiamder or á

ñw

bn)

Ecksr am

shai1.....-...

...............,,,.... ¿0.00o1o.olo mm

Bm

kr,er ¿m

añ

in a n€w

shán

11s743r000ü in.hr rorthe,ockr ' .. ..... ..40ir6s!o0r5mm (r.5774 r 0.00m nór ú€srino

Mdlmum d m6N,on rd Ébd. ñ"--a"; ámbeanngtorlheook€rámshafi .. 40.193mm

(1 s324 inoh)

hlá Elves ......... ..,................,.

0.38 ! 0.03 hm '10.01510.003 ind,l

(0.030

* 0.003 irch)

Cylinder Head

o

o

o

ó

t

a¿)oO@(D

o

o

@

@

@

o

óóóóóó

"r

áÉ 21s mm (3.5 inoh) The bo[s ihal are ñadied rhe bolls áé 194 mm rong. Th6 Bmainde. ol

a

appry 6v -4a76 Lubfiéff b rh6 boll lhcads and bolh sid6 ot Íle Mshec. fohteñ thé bolE ¡n fl€

¡ ¡

l.

!

2.

ln á numeri@l sequetue,

tqhle¡ bolts 1 lh@ugh

Torlue for bohs ,...... 270

r

ln á

¡n a

5 N m (200 1 11 rb

f)

c

!

ñuné'tÉl @uen@, liqhlen bolis 1 thouch

torque lor bolls .......450i

3.

r

l5N ñ

(330

t

11

lbñ)

numedclsequérG. áq6iñ ligh¡án bólt3 I

Torqua lor borrs

......450+ 15N ñ

(330

r

11

lbñ)

(A) Cylinder H€d Tltichess

of a lw .rrifde he¡d.,,,,. 120.0010 15mm (4.72.11 0.006incn) Tht

*n*

M¡ñjmun Úl¡.h* of. used ryl¡ndér héád .........-......-............. 11e.50 mm (a 70s inch)

l

I

Noré: The frabess or rhe cyiinder head should b€

wn náror¿lot0 13mm(.005¡nó).also,rheiar.ss ofihe ryfnder h€.d sh@rd b€ wilñ¡n. mdjmum of 0 05 mm I 002 inch) ror ary 150 ñm (s.e iñcl') stán.

I

I

11

9C)';

\Q\

NOftcE

C.rddr b.¡'inss musl b. iñst¡ued

,úI

inl! $en corécr

FailuE io do so w¡l resuh in €nodne dañaqe

€r) fIr¡ereroreruháñbofe

ffin

ot beain! joht

t¡-...--.................

..

20'15'ábdého'izni.r

t ¡./

ol rlie rha deóih o! 'n{ana¡on h'ralrb€ ;;ry iñlD.'tant

comPression Brake (F EduiPPed)

'gs (30

*ñshañ be¿ d ns5 ) t 0 50 ñm (0 75 ! 0 02 inoh c ... ... 19'12 oo'? .. .... ..... iá-1'.'d¡;' i9:9 ' ""n P......1 .,.... F... ........ ;;;;ió;;.i1,'s'g'o'.'?i^"r' i'¡ *o oz 1 ......... .... 0, i$ "¡ 9?

r¡stárlat'on

3

de Prh

lor

3it'.-os*¡li:9:i:$ll* iá6.i;;;;; "n üój;;';;; '9 ilt

l'- - ,il)iiói

i¡ga¿"ooz'o

1\ 1( ::ilIJr.T"Jtr f t':"$ilT'"" (2) 1. rishbn tuo @nler bolls

"

54Ññ(401bli)

T'stfen moúnüns

dld

nul (5).

Toqu. ior mourfing stud nút .....

Tofqué

rr

oule¡ b.ris

rghián ¡^o enrer

....

b TsÍng ánd Adjüs1ine, :aláre pisloñ adjust for $€ omple¡e Fó.edufe for .djusrñq rhe srávé piion ra3h. Nor€: R.rer

g

Lásh -

N.m (¿0 tb ñ)

.. 54 N.m (40

tb

f)

botrs (2) aqain.

(3) Fmár idrque for srav€ pislcnr ádtwlins $rew l@rnd ......... ........ ............. 34 N.m (25 tb lr) (4) Fináliorcué ro¡ soteno¡d vátk

.

(e.22 b n)

To.!u€loreniérbols,........... 109Nñ(30lbn) Iohlen the mounÍng slud nul

(5) aga¡n.

Torqoélormoundnssludnul... 10sN.ñ(30tbñ)

rshlen 1so dlBr b.[s

f

)

as€in.

Torlúeroroulerbois............. 109N.m(30|bft)

Pnofb

.

NOTICE

ad¡usrins rh. l.eh s.fins ror the.ngtno cmpre.sio¡ br.ke, ¿héck tho ido¡tlric.tlon pl8b

thr

¡5 or lh. coñPession br.k .r.r ro d€rémi¡e thc mod.t th.r i. insral€d on yoúr ensiné. You mu.t h.w rhis nod.¡ numh€r .ñd thc ensin6's €..lal nlnbs pGfir ¡n od.r to dé¡em¡¡€ rh. l.Éh settins tor your .ng¡n..

(6) Fna rofque fof

of thá mouffino stud

'nr,ándion htlU'ecvlind€rhe¿d ......... 33Nmt65.0tbñ)

Turbocharger Pá¡l Num6.É AE Forlh€ Fott.wtnqtlustáiio.s: 2221753, 2221751, Zn4t56. 2221757. ánd

123-0460, 132-3163, 14,r.m16. 143-2016. 151-3026. 1s4-36t7, 1s5¡301, 155-79s3, t6¡37t0, 165-7311,

r39.9172, 19l. 009s, 19r-2S2s, 19

l.--

roÍshlen

,f]ghlen

cramps (1)onlhe tuóocharsér, usá thá

lhe clamp lo the fo lNins .................. 14 r 1 N m (10.31

brqúe.

2. Genuy lap rhe clamp

w rh a sofr taced

o 7 lb

fi)

To r ohren

dámps

I )d

dré

ródharsei

use the

hañmer

3. Aqain liqhrán [re cláñP.

nghEn Ihe crámp !o lhe lollowinq lorque ... .......... .. 1a¡ 1 N.m (10.3 r0.7 rbtt)

I ¡ghls

rhe daDp io Úle lorr ino tófque........................ 1411 N m l0 310.7 rb fr)

2. Gently bp n'e danp *iú' a $fr la@d hammer ope ñing p€ssúr€ or lhe wasl€saG

....

133kPa (20 psi)

3

i4tfs fE d.fp. rEften n€ crep b t€ tuleins

3. again

i

ro l¡shlen rbe clamp (6) on rhe úóocharler, 0se the

ro t¡shten lhe clamp (3)on ihe turb¡charce4 use lhe

nqhrón lhe cámp nur ro the fonowinq

... l3Nm(133lbn)

Loosen rbe c amp nur to rhé iollówing

Loos€n rhecramp io lñe ionow¡ng tolque. ..6 N m (53 1 rb n)

¡qhten the clamp nut lo rhe lollow ns rorque....................135r1 N.m(ss10.7rblt)

Tishleñ rhé dlañp ro rhe rol ow ns

6Nm(531bin)

Tshren rhe bolls (4 ror lhé coñp.essór c!áñp asséñby i óppñiié pans. fghlér rhé bó b ióf rhé @mpfessof c ¿mp ¿ssemb y lo rhe fonNins lorque

175i r N.m (12.s01070rbft).

Appy5P-3931 Anr seizecomp! .B used io mounl ihe lu¡boch.4er ¡qhlen l¡e nuls rorhelorow¡ns tofqueT0 I 15 N m (51.6 I 11 0 rbñ). Parl ñ umb.rs Ar. For Th. Followa¡ s lllust¡at¡on: 62-7603. 1 6¿4693. 1 6¿4490, 164-9¡1s6, 1 69-1675, 1694271, 173-002, 139-S2f 0, 139-9211, 1A9-9212, 1

190.6210, r90-621r, 190€2r2. rS0-6213, 190-6215, 1

l33lblt)

91

-2926,

19

2-207 7, 19 4 -1 115, 19 4 -111 1, 196 -21 7 5,

lo4ue

...

.. .... 13.sl r

N m (e

¡ghlen the boli to [ie róliowins rcfqoe. ................ 13 5 r 1 N m

(9

s10.7

b ñ)

9!

b fi)

0.7

Paft Nunb.6 aé For Thé Forrowins frusrá¡ion: r 5s-79s2, r 64-9490, r 6+9¡93, 1 64-9496, r 39-921 0¡ r64.94S0, r39-9210, 139,9211, 13 1904210, 190-6211, 1905212, r90{2r3, and

v

ndé onñdad3 ruffiqenú aud4áb

To lrshren rhé

d¿ñp {r0t on

lhe lonowiño pmceduE

Irr€

fy¡ié$npbdallúeoqa6'waú9a6

tuÉo.ha@i

u*

d

ro llshFn Ihe cramp (13)

'le

tu'boch¿f!É4 use

rgh¡ánü\eclamptotheloltowins!órque... 1aN.m (133

rrqhcnrh€clan!btl.fon inqtoEue... 13N.ú

Loo*n the d.mp

Locenlhecrampror¡€folt inotofque...6N.m

b0

ró lhe tottoving

tolqo.. .. 6 N.n (53.1lb ln)

fghlen rh6 daúp to the tdtowfiq rorqoé. ............,......... 13.5 r 1N.m (9.9

r

0.7 tbfr)

o3.3

tb

f)

(53.1tbin)

¡ghrd rré .

bfque

amp io

....

...

[ie rolwing 13511N.ñ(S9r07rbii)

I11) wasteqáie Opm¡ñg

plsuE

of trlé w6resEte ....... 156

kpa

(23 Ps)

Tjgn¡€ñ

[le

cramp

(t2l b the fotrd'ng t3.5r tN.m 199r0

7

tbñ)

Pa¡t Numb€É are Fd nE Folldi¡. fitudÉrio¡: 162-7303, 190520s, t90á206, t90-si0?, t9o-6203,

openins pbssuÉ ollh6 Mr¿sate ....... 135 kfh (24 p€0

TiqhGn thé ctamp to

rolque

..........

rie

13

folsh!

51

1 N.m (9

910.7lbfrJ

¡{umb.B Arc For Th. Foltowtno tuslr¡üoni 1¡134321.1¡l,l-¡ar6.drc.¡?rá P¿d

Pll

To

Numt)Ñ A@ For Th¿

tqhián th8 damp (16) on the tur¡ocnaEol lso

. 13Nñ (l3.3lb rl)

r'shlenrhecramprórhélollowingtoque

Les.n

mE dámp t('

üe tollNins lorqué.

.. 6 N m (53 1 lb iñ)

IOhten thé cLmp io Ihé tunowing rolque. ..................,..... 1311N m (9.6

To tighrén rhe Boll (17) on rhe

fgtfen

r0.7|bñ)

1uóel'arge¡.

ú*

f33

lo lh€

follNinglolque.

nghián ü€ b.ll lo the tollwins rorque.,.......-...............

13i1

N

Trghla ülé @ñÉcser clañp plálé b.ll3 09) h oppo€ilé palE. ligtfen t¡e @mp'esr dláñp plate b¡lts ló lhé folleing L.que. ... l7-5 ! 1 N.m

f2.s 10.7D

üre

the boll io rhe ¡onú¡ng roqué. .... 13 N m

Les6¡ lhs bó[

IEhián rh6 tuóine clámp plale bofs (13) to trré follMinOlorAue.-. 15310.6Nn(11.6r0.4bn)

lbn)

...... 6 N m

(s3.1rbin)

h (9.6.0.7|bft)

n)

- 3 931 Arls.iza C¡mpound lo üle n uls ihal áe use¡ lo ñounl tte iúóochargei liqht$ lha nds tó lhá lclldlnq to¡que ?0 t 15 N m (515 i 1l.0 lb fr).

Apply 5P

Air lnlet Elbow

oo oo oo

o(D oG)

Apply

(1) LuMere üt€ bore riohty üith ¡¡srrl ing th. o{ins s€ts.

Exhaust Manifold

5F -

@

3931 Anli-seize Compound to the

tlcáds of fts studs Ílat éngag. Ístfen lhe 3tuds ¡n tE cytind€r lollowing

(d)

iorqué

.

........ 35

I

the tocknuts. héad ro rhe . 4 tb ñ)

s N.ñ {26

Appry énq¡né órr to the Gmaté ends of lhé manÍólds bélG assenbly Apdy 2P,2333 H¡oh TempeEtu6 &aler b $e mare énds ot th6 mántrolds b€fo6 asffibly. R€more €x@ss s€lerlrom iñé Asehbted

Íqtfen he l¡ál

i3

roc¡úLts in

tle numánetsedu.nd

r.rk;ho 33r5Nñ(2S!4ióñ)

shtun rn ll usr¿ron 4t ro rhe

ioqué,............

Exhaust Manifold Shield

O) rshlen the nuls ió ü€ tun ino ro¡que. ............,............25i 7 N.m 03tr5 tbfr)

spéciñéd

robé

Iñ

r r

J¡

Err,áusrbbé........-....... 3.5rs mm(0.3352rnch) l¡lél lobé ...... .... ......... s.,431mm(0.3713inch) hiecltr bóe...,......,....., 10.451 ñm (0.4115 inch)

Camshaft Type

éñshafi

I Io

frnd rh6 robé riñ, usé rñé

i,

MeasuE

€ruhaít

pmedu€ rhá

ror

M:

lobe heighl {7),

2. M€éuÉ bas. crrcb (3). 3. Subtáor ü'e base @.le neasuEmenl (siép 2) from lhe ensháfr hó€ heighl (Slep 1). The

diffee¡e

¡s rhé

.cruár robé r¡ft

Máxlmm pemissible diñersce benrÉn ¡he actual bbe fin {Siep 3) ánd ür€ 3pédñéd lobé l¡lt ol a n€w 013 mm (0.005 iñch)

o@shaft

[or.: LLbdd€

th8 Émshaft lóbés with á 50/50 mirlure ol aT 2993 Lubri€nt áñd cr@n engh. or¡.

Diamers of Í'e b€arinq loumá|s .. 3¡.35i0.02mm{3.341.0-001 in.h)

bá.nr$

rh créán ord: Lubñér€ t'e msháfr o pnd lo inslallins lhe @nshafr.

engine

fshlen tE bohs lhal taslen $le órer io lhe cyr¡nd€rh€.dbtñáfon ingtoqué. .. t3r3N

n

2 ¡b

ff)

f0 t

Z_\

21

fype 2 Io find lhe lob.

L

rrfr, use th€

pb@dué $át

fóIm:

Máásue €nBhán t¡be heiqhr (7).

2. M*3ur6 báse cn b (3). 3. sdbract lhe b*é cale meásu€m¿ñr rsiéb 2) rion rh€ Éñshantob. hé'shrlsleD i). ihs diñéBnce is me sduár rób. riñ Máxiñum lemiss¡bté dtfieren@ bet*€éi ü¡e actuat lobe liñ (Scp 3) ánd rhe speoiti€d tobé rifr of a new @nsháñ.....-......,,,.......-.......-.. 0.13 mo (0.005 hch)

xotc Lubri€16 I¡6 €mshait n

¡ue

tob€s eith á 50/s0

ol 3T- 2993 Lubdcúr and ct€án éng¡ñe o¡

.

ñ Diamebr or the beadns

joumáb.. 343510.02

mm(3.341

r

0.001 in.rr)

Nor€: Lub.i@1. rhé kmshafi b€ánnds w rh .re¡n enqine

o

pde to insr¡r ns rh6

eroi¿ir

lighl€n rñe botts thát hsrén rhe 6wr lo ihe ctllhdgrheadtoth€fóI@insrorqué. .. 13.3N.m

0012 br)

Sleciñ€d €nshañ ¡o6é tin Exhsusr rob.................. 3.515 ñú lnl€r robe........_............. s.702 hm

l¡jeclorlobe...........,,. 10.451 mm

fype 2

Engine Oil F¡lter Base Type

f

(1) Apply 9¡l 3263 ThHd Look Compound on tle r¿percd end of üle stud io rh. lorlovÍno drnénsion. ...... 1o.5 ! 1 .5 nm (0¿1 r 0.06 ¡not¡)

I€hl€nlhestudlDÚletol

ing iúrqu6. ..

66I7

N

ñ

(50i5rbn)

t) t6t fo@ .., 55.25 ññ (2,175 inch) ........--.......... ... ?6 1 5 N (17.0 ! l.1 lb) Fe bngrh ¿fler test .......... 93.7 mn (3.69 irch) ou6ide diamecr .--............. 20.6 mm (0.31inch) Th6 iirt.¡.nd thé @or.f bypass larves úrrr ópén wit) rhé lórrejng pG$B Léngih under Tesl

fo@

dlie6ce,,,,.,,,.......-.... 255120 kPái37l 3psi) Í2) s-lud appyss-3263 Thresd Lod( comoound d úe lapeEd qd ot rhe srúd ró ¡h6 forrMiis d¡m€ns¡d. ...........--.............,, 3.0 mm (0.32 inch) ]lohrán rhe shrd ro nle fdlowing tórqle.,,....,,.,...,..-,.....30. 14N m (601 10 lbfrl

L€nglh lnd€r 16r

rúe

.., 55,25 mm (2.175 inch)

N f7 t 1,30 tb) Gr .......... s3.7 mm {3.69 inch) ::úsidedisrei6................ 20.6mn (0.31 inch) 4,-. fihd úd iñá er€. bypass qtves ,:rr ¡!éñ $tl me ftlwins pt€sr6

Fe

.......76r5.3

lensih añe.

25s

tr!.n tlE

prug

r

20 kPa {37

io fle foúrfjis

113. .....-...............100r 15 N.n (74

i

}

3 psD

11 lb

ñ)

Eng¡ne Oil Coole¡ Bypass Valve

Engine Oil Pump Type

Léngh ú¡dérléstfor@... 55.25 mm (2.175 inch) réstrorce ...................7615 N (17.0 t 1.l3lb) Ffee renqlh ale¡1esr.......... 93 7mñ {3.6s inch) Oulsided¡ámét.r................ 20.6ññ {0,31 inch) Th€ fllér añd lhé cader bypass vatvs

willops wid1 lhe follodinq lGsuG direre¡@ ................. zss120kPa(37r3ps0

I

NOTICE Belore operaton, th€ púmp nur be lub Ér€d

lith

cleán onginéóir andrhepumpmusttumffeetybyhand of dañaqe to oans eñ be rhé ésuh.

(1) D¡amáéf of shafrs......_....... 22.217 (0.374?

t

t

o_a05

ññ

0.0002 irch)

D¡áméráf of boes in

shafrs

cd€r fór r 0.003 ñn (0.3763

22.253

1 0.0003 iddh)

(2) L€ndhoroea6,......_._......... 7s37510.025ñm (31250 t 0.0010 inch) D€prh ol

bo6

ror

Léngrh uñder

F€e

ensÍh

!ea6

............ 79.502 + 0020mm (3.1300

i

0.0003 indh)

lsrfoG..... ri7 9mn (4 3.4 hch) 150!3Nml 0r3tbfrr

áfi€rr8sr 152 9mm fo 02in.h) . .. .... 27 ñm {1 063 inohj

ours d€ d,amerer

Type 2

(@ l.sr¿Í me béadñOs s lheb@inge:€ év.n wiü flé oúside ol üe puñp body. (A) Pc¡r oñ or b€ádnq joinl from th6 eniérriie tlrcugh beains bocs ........ 30! l5 d€qrees

NOTICE

B€¡r€ opeélion, thé pump nusl ba tubri€ted wh .réánssineo¡¿ndÍEpumpmu6lrumrreetybyhañd o' d¿m.sé ¡r Fds can bo üP 6u r

T6t

d

Rotátror

lést srand with sAE 10W oit a! 4s

llm

the dñre €nd

"c

.

Puñpspe€d..................................2550RpM Oulrüt ......... ..........., ..... 193 Umtr (51 US gpm)

Oiámérér or lhe ddvé shafr

(néw).....................

..

Dameler of ddve

(n4)

...... 20.32010.005mm (0.3000 + 0 0002 inch)

shatr

r a :'

'.-'.'--.-----'.- (0

22.211

374t r

t

a.oa'

úñ

0 ooo2 inch)

Bóre in bed nss ror dnre sh¿fr (new)................................. 22.25310.003ñm (0.3763 t 0.0003 inoh)

(néw)..............:.............. .. 20.361 ¡0.00shm (0.3016r0.0003inch) (3)

Dameteroridlérshafi

(ns)..

B.E in beann$ fof

tdtér shañ

(new).................

L€ngd¡

20.320r0.00smm

(03000r00002n.h)

.....20.36110.003mm (0.3016100003inch)

Diaméta¡ófidreIshafr(n Bo/é in

beáin6 lo, dbr

) . 22.217 lo.aosññ (0 374710.0002 incht

sh6ñ

(new) ........................,,..... 22.25310003mm (0.3763

r

0.0003 inch)

ofsea6 (new) ........ s7.153r0.025mm

(2 2503 ! 0.0010 inch) Deplhof b.€srorgéars..... 57.235r0.020mm (2.2s531 0.0003 inó)

Test on t€.r

rañd wiÍl saE low

.i ii ¡c ".

Rolaton iiom $é drive end ..... counrérc

Pum! rpñ

..

ód.li*

................ ............... 2550 lpm

FIM speciñeuons lor row pessuE ouhul ..,.............. .......... 272 L,tnin (72 uS spm) PHsure ............ ............. ........ 310 kPa (a5 psi) Flry 3p€c¡ficáions tor hish pBssuÉ ourput................ ..... 1¡r4Llm¡n(33usqpm) PressuÉ .................................. 560 kpa (31 ps¡)

ol ddve shafr (n€w).....:............................ 22 217 Diameler

(0 3747 drive sh¿fr

r

I 0.005 mm 0.0002 ncht

BoE in beñnos rtr ínwl...........,....,,.................. 22253 r 0 003 mm (0.3763 ! 0.0m3 inú)

t:) Diamereroridbshañ(new).. 22 217i0.00sñm

(037¡7r00002inch) BoÉ in b€arinst rrr idler shán ('e*)-.. -'..---.----. 22.2531 0.003 mn (0.3763

r

0.0003 inch)

(€) Lonslh

(n

órq€6ln*)........

. 79.375 r 0.02s mn (3.t25o!0001Oimh)

).....,..............................

79502I0.020ñú

(3.1300i0.0003inch)

Terfo@... .. ..439!24Nl11o.0rsslbr Lonoür unds les¡ fo@ .117.s;m1464 n¿ñi Fée rens{¡ áfi6f resr .... rs29mm(6.02'n.ht oursided'¿m¿rer ............. 27mn(1.063inchj

@ffedine o4 ) Posiriú of benns lolnr lon lñ@sh be¿nnq bó6 ..............''e30 r l5 des€s

fype 2

Nolé: rñstáfi rh6 béarings so t¡al lhe beaifos áf6 úih lhe olsid€ of lhe pump body.

fiush

Engine Oil Pan Type {

f'ghén oB oa p4 bdls lo üe loaue. ...---...---......-.......-47 1 9

fshlÉ

tré ptug r. ilF fo¡lwins .....701 l0N m (5217 lb fr)

9S-32$ úEd L@k Compóund 10 th€ lrcads ol.ll piF p&gp d Úle oil pan. fghlen áÍ ot nt€ ¡tp€ plugs lo tle rolNinq App¡y

fghr€n rhe oil p¿n bolts io lh€ iorqué ...... ... ... .47r9

rorqué. ......-................-- a1

¡

11N-m (60

t S lbl)

Typé 3 Lub cáE the plug liqhüy s'l¡ énghé of. Íohlen lhe plus lo lhe lóllúlng rorque..................... 95rlsNm(70r11lbñ)

Igh¡án the bdb io *E fo¡lowjns lqque, ....,......-............. 55 1 10 N,m (41 (2) Pipá plus

i

7 lb

ii)

Apply 5P- 3413 Pipe Seál€nt to rhé rhreáds ór rhe

liqhren lhe óvér bdüs io ]johién rhe dE¡n pruq ro t€ forówhq roque......................, 70!10Nm(5017tbñ)

lighten ih€

Ioqu€.

Crankcase Breather appry á r¡glf

hN

....,,.

*l

tle

dáñpé lo lhe fot ówing ..........__913 N m (30r27 tbin)

ololy@nn io lhe

*át bo€i

Water Temperature Regulalor

l-'

----r

(2) woter iempetué reouraior

Water L¡nes

cómplelelyopenFmpáduÉ 92'ct193"F)

¿isl¡nÉ...... Min¡muñ oreninq

................. 92.C093.F) dislán€ .. (o.41 inoh)

2A

Water Pump

f,shrs fr6 bol thá tollding

hotds ihe lmpéler to

úE

rdqué .. .. 39 r 3 N ñ {29 t 2 tb ff)

*t

(2) rha shafr diám.ií ar rhe €rhon asmbly e€ár aBa E th€ lonNino

dn€n50n..,, ................. 191010.01m {0.7520

tt*

E .ear s*mbty odo úe

unür lhé

shion.ry ñp

¡s tut y

I

@lr

*iád

in

0.0004 inch)

pufiD sh€fr

tE NmD

(a) oirs@r

stsih

lnsláü Úlá or wái¿r purp dnre

s€r

lrl.

prtmary tip io@rd fte Press oit @t ¡nto ih€

'l.

Cylinder Block

'-'.

tl I

L. |.,. L.l

Appry 7r¡- 7456 Compound to rré dowet

befo6

Thó dorerénsds sbov6 flé iop $tá@ ór rhe crÍnder block by rhe ronrynq d slanúo. ....... 13 5t0 5 mm {0.73r002 inch)

rshlen $é ptug b the loll ing ldque- ............. .....70110 N.m (52 iT tblr)

dséts éirend p$¡ tha €nd or lhe cyt'nder brdr by i¡e forld'no dirú@. ... tg.t r0 5mm T1€

(0.7s

fhickiess ofrh€ 3páérptale .. 3.53510.025 ñn (0.3330! 0.0010 inch) Thrckness of the !5skét tEt is ph6d bel$€en ül. sp¿car prale and ¡h€ cyti.der blo¿r. 0.233r0 032 mm (0.0094 i 0 0013mch)

cynnder riner prcjecllor abow lhe sDae¡ prare....................._.....,......... 0.025 ro 0.152 mm (0.0010 to 0.0060 inch)

dMréxrends abdé rhé 14 sutaé rtu cylinder b¡o.r by rhe roÍoüns ditan@ ........ t6o+o5 nm (0 63 r 0 02,ncn) Th€ of

Apply 7rr- 7456

Cmpdnd

io

ra ddel betoE

rhá d@teñends.bM thé bp $laú6 óf rhe cyindor btoc* by $e rolw ns disEnce. ..... 20 0r 0 5mm (0 79i 002 inchl

r

0,02 inch)

Nol€: Thé tótár iá1ns or tle lóp MEol suda@ of Ih€ cylinder bloc* musl be wihiñ 0 10 mm t0.0o4 mch). Th¿ fldnéte mur aLs¡ewfh¡n

00s

rn

(s) ede

¡0 002 rncn) for anv

in

tle

"".

mm

99 in.h)

16

oylind€r bló.k for the main beanigs

Ma¡nbéannq€rridrh.. W_ri*l or

1t.s

. 215.90010.025mm (3.5000t00410¡nch)

ih. drinder block lór lhe main beadno ..:................. 2r5.s0010013ññ 13

50oo

r

o ooo5

'nch)

(11) Main b€arins Qp bofts of lheprus..........

2.012.0 mm

(0.03

i

0.03 ¡nch)

6' ruh bÉii! 6p bts

r4!*m !di!¡h! dd

use rhe fonowlng prc@duÉ in

l.

údd

lo üstfer lhé

Appt cléan ensine oil ló thé th€áds ol the bohs

2. nshbn he bo[s fiÉt

on

tl.

beá¡in!

üb

side

I

)

'roñueforb.lts.......260i14Nml90!10|bñ) 3. liqhlen lhe holls Tofqué rof

bo[s

Pd a malk

o

on

Íle opp6ie

....... 260

!

14

(2

).

N.ñ (190

r

s¡dé

10 lb fr)

eadh bolt ánd eadr @P.

d

the opposile sidé (3) ftom

lt'e

Úlé Érledine ol thé cÉnlshafi beánnq borc iD Úle róp of lhe tylinde' block

rshlen rhé bolls

N4

Aislé(a).....-................ 120!5d€s@s(2rat5)

(3) D'mension rroñ

(16.75ú !0.006inoh) .......... 425 02 ññ l1a.rc3inoh)

...42s.45r0.15 mñ

nohGn lhe b.lrs óñ rñ€ be.nno iab gde (41 ol lhe rom rhe ma'r l. Elé ro¡'ownq €rue.

éi

ansre (a)...,.,................

120i5d6sێs (2nals)

(12) N€w dhensión íiom üle @nt8rhé ófrhe dfánkshan befins bore to lné bonóñ of the

cyli¡derblockpánEft ....... 16510r0.10hm (6.s00

I

15) Prús fshren lhé

prus b ihe tonowing. rolqu€.........,.................3517N.m

0.004 inch)

Cylinder Liner 3406E

Apply 5P 3413 Pipe Seáránt on rhe drreads orüle pipe plugs bef@ ¡n.lánáióñ in the cylinder block.

To p'evenr dáñáqe to $e pislon .oor,ns rers du ng storcé, rhe pison @ol'nslÓ¡t ñust be

fghten tlá bóris rhai ho¡d the pEion cootiñq jels ro rh6 bnryins lorqu€. ..40r 3 N.n (30 i6 tbñ) Mininum pemisrbl€ clea¡ane betw3añ ú'e p,eron, 116 p Erón @oths let, ánd rhé .. . 0.63 mm (0 025 in.ht

@nksháñ

The follow ns deps

ac

ror

háta

no rhe cyinder I n€r

l.

appt 5P-3975 Rubbq Lobn€ñr ón th€ sutácós of fré cyrinder liner boc. appty 5P 397s Rubbéf Lrbrjcanton rh. tubb€r sats on thé tN¿rFd of

2.

Pur rhe

3.

rñslafl finer bánd (3) ¡n me srcore ondér the tiner

¡. rnúr

fÍer band.ompterety

rhe riner

'n

ceán snqine o¡

h thé b.G mrFdErári beroc

ü16

(1) 806 in nw lin€. .....-.....,.,.. 137.135 I 0.025 mm (s.4010i 0.0010 inch) (2) Thicknéss orfangé on r¡ñe¡ ,.. 3.390 (0.3s00

r

l

0.020 nm 0.0oo8 inch)

The minimúm rhic*n$ of rh8 pan lhal eñ b€ used agáin Érhérorrwins ............. 3.370 mn (0.3492 inoh)

varúé..

Ndé: Rerer

1o

Guid€llné For Reusablo Párts, ne6 lor moÉ

SEBF3063, 'Cvlhdér L

also, Érer lo rad nq ¿nd adrúins, 'c,'ntomdion nder Line¡ . Proj€dion for úF prc(éduE fof insp€crng ¡h€ orolecüon or the cü'nd€r ineE

3456

The

forr

ina steps

a€

lhe cvllnder linef

fof

'nslallúg b sFcl¿l hrn rhc turnder bloc{. Reléf REHso272 for noÉ inlbmalión

Inrrudon,

Rubbár Lubd€nlú lhe crl rder bor€ suraces and on Ú16 rubber seá13 l@s Paá ol lhe crlinder liner

r- A¡orv 5P 397s

bÉi llF m üs

z

Pút rhe ñlld band @ñpLelelv in dean €nsii é .¡r

3. lmláll fler bánd (3) in the sodé undef rhé linér

4. hshll

th6 liner n thé bo€ imtud¡álelv bero€ lhe

(r) Ns cJ'nder

nerbore

r3s.635r 0025 mm

154S94

r

0 0010 iñch)

\2')

Minimuñ €ómmended lh¡doess or lne ovlind€r

Lhériianqe..............,,

...

3370mm(03492inch)

Nor.: Refe¡ {o Guideline ior Reusable P¿rs,

Crankshaft Seals Durjns imianafion, rhe *atdnvet shoutd nor úilád üe s¿t wirh'n lhe tunN no

d'ámérer

......... ..

... r77304025ñm {700010.010in(ht Ale¡ imlan¿don lhé láe ór he seátt waar sl*v¿ shdrd be w tlin t'le tuneins dimonsion fiom thó f€áf rá@ of rE énkshafr. ............ 1 .5 r 0.5 mñ

ñ

6ha

lhe láÉ or seár'e 'nslárárion, 3hourd be kith n ¡há lonMins dimeñiof f.om rhe @rraceotlhecránksh¿n .... 5.4+0.0 0.6mm

añ€r

(02s

+000 003mchl s.a

Atter insiall¿rion rhe rad ói rh. *er nn ñ, Ét bá paÉnd w h rhe Eáf fáe or h€ cEn|sñáf1 úúrin rhe lollw¡ng roreÉñce. ............

{r

Vibration Damper

x6re

Rerer ro sp*árrishorion, sMHs35o3, 'spe.tal Handr¡ng rni'@lion and tmlá¡ztion nslruclions for cBnkshafr sé.t Gbops lhar Háv. HydódFañic G@Ns h ihe seatins LD.for lne 6f€ct pmcedurc oñ the tñsbl¿lion of ¡h€ irod ¿nd

No¡.: Do not sepaÉle lhé sd fiom lhe ste.v€. ff lñ. *al is seeaEt€d noñ ihe sred€. slé seát nusi

NOTICE

Dufiñs insra áton, rhe seardfivéf shoutd nol ontacl t'e sea¡ sithrn rhe fonM'nd

...........

1t.s0 r-o 2s

mm

17.00orooro,n¿hr

Añer nstanáüón rhe tac ot lhé se¿r's wer sl€€vá should be frush ülh lhe front faÉ or r¡e cÉnkshañ wih he f.¡tdtno

........ -o13do 13mñ l-0.005 ¡o 0.00s inchr

Añar ms1¡l arion rh€ r¡ont É.e or ih. s €sin! shóuld be wi¡h n thá t¡ttNLno dimssron rrom he tom ¡ae or

*l

ihe

@nkshan,.....................s.23+000-0.60mm (0.203 + 0.000.0024 After insiandon. úe Ée ofihé *¿t s es'nd 'n.hr ñnsi b€ paf¿nerwih me fód race ot [¡e r¿ñks-háfi wilhin r¡e tollúhg roleEnce.

Thdouoh|yinspectülev|'eusdá re.káse or for rsns of ¿ d6niád ld;maoedt-c*e Eilher or rh6* @ñditio¡s en Gus lhó f,¡taht lo ñake @nl¿ct wilh tl6 €* This can áffed lh6 v¡s-

appry4c 5593 arfisoze compound lo rhe

botrs.

Connecting Rod Bear¡ng Journal

f

sMcScod.:

I

'l

ffid.,&;-

To..ds-.rú*s..TP,sir-i-i;t (5 f3s ¡ 0.0005 ii.h) h úE sod( lÉhoB-

1202: 12191 1225

Refef io Guideliñe Fof Reüsable Pátu, SEBFP,009, "Mai¡ a¡d conn€ciins Rdd Béánnss'úd Guld8line -CEnkshaft For R€lsbre Pañs, SEBF3041,

roor5b¡

r5.ts4 ¡o.ooo5 rmhr

I

C.nnect¡ng Rod R€id to Sr@l l¡6tudDn, sMHs7l66, 'Usins dE sP-2o5O cffino Rod CheÜñO FnuÉ

g"ffi:}ffi :'3[",fl :fi rÉ""lfi¿:'""" Parrr s€BF3oer, -sártEge ot Non séml€d

oeaÉne belw*ñ lhé n4

Lumal. .........

1_

beafing ánd lhe

0 062 nñ k,0 1€0 mm (0 0024 mch ro o 0063ln.h)

M&ñuñ oémissible d€áEn@ ber*en ¡n6 beadns ¿n¿ t¡. ¡.'lm¿r..... .... ... .. o.2omm (0003 ln.h)

-------------::-l

l--ffi-1-' I ; I \\4-r I

Ma¡n Bear¡ng Journal Rerer lo Gú¡d€line For Reúsablé PalE, sEBFsooS,

üáin and coñmcling Rod Bsfiñ$ and Guideline Fú R.@ble P€rs, sEBF3Ml, 'CÉnksh.n

I

\T'fV \

i /[["

t/" M

| _,/ !2 \=

cr*Énce berv@n

lhe

r

beding and

t'e

0091mmloO.l6órm

Mdimum pfrÉsrble de@né b€ide€n ule and

¡hel(unal

\ -,. b- r!

..... .. 025mm10.01' ;¡)

;ll

lrr Bo'e'n

l\

_Jl

I

6nnec0no rcd tor Íré psion prn 59640r0.013mm

'

(2.34¡0

i

O,OO05 ¡nch)

I¡é 6medlq ód must be h€iEd fo. ihe insbnáidnoldÉp¡fupinbeadngDonotusea

ansre(A) ....................e0r5dba€¿.{1/4tum)

Nor€:

t¡e @nkshgfr @nneclinq rcd

únedi's úd

musr be hsled from 175 rd 260 'C (3,r7 b 463 'F) lor the insianátun of rhe Fn b€.ring. Mdiñom d sbnce ror 35 0mm (3.35 inch)

(2) rh€

rilo

(3) PÉton p¡n bedinq bofé ......... 55.035!0.003mm (21657 r 0.0003 in.i') Thooúqhly lub'iÉL4 mé pisrón ptñ u(h dean engine oil Díor io asmblv of ü'e piro¡ and lhe .dneclinq

(4) The beinna ioinr mur be wirhin

t

5 deo@es

"Pislons' ánd Gu¡dénne rór Réusabré SEBF3051,

"Pilon Pi¡s and Relain¡nq

inch)

(6) Etch rhe cylinds ¡u nber on t'e mnneoli ns rod and ihe 6p an lh s l@lion Maí( rhe @nnecl¡ng rcd and üle €p wilñ a ¡umber i lhrcugh 6. Malk Iñ6 nuñb66 ón rhé sañé sidé or ihé conne.l¡nq rod as rhe beains lab slob.

use thé

3406E

al

(5) Dki?ne beMq r},e oentec of beadnqs.............................. 261.62¿0.05mm

f0.30010.0m

Pislon and Rinqs

3

lóllNins prcedufe in ofder lo I qhten lhe

tubn€ie the out6r soffáe ol lhe piston and rhe pdton f¡nqs wú crsn ensin€ oitbef@ indanaüóñ in rhe cytinds btock. ThorouqhLy

listáll lhe

rwad l@ldumfghbn¡gmeúdbf@me¡]Ed€phd6 1- LúbfiÉre lhe boll threads ánd rñe sear no ráes the @ps wilh 4c- 5s9s Antl-sé?e compound.

z

ot

lqhlen n'e @nnec$na rcd bolts Toque fof bons ............,.9013 N.n

(65r6lbñ)

3. Pd a már* on 8ách bon ánd údh Ép.

¿ rqhren

eaoh bolt

fom lhe

ro¡l

lo anqle lA).

iop

ng w'lh rhé side marked'UP-1'

rhe rop óf lhe

p

sion.

yvhen lhe piston dng is rndáned in a cytinder t¡rcr lhát has á boÉ size ot 137.16 mm (5.400 tnch), lhé creaE¡e belween tle €nds ól lh€ pi$n nns

isrherolowing vá|oe. ................ 055r 0.'15ñm 10 022 1 0.006 inch)

lñsrárr lhe

t{h lhe side ña.ked Úré1@ of rhe oÉion.

inremédiále dñc

UP2 io@d

when lhe DBlon dno E inráLl8d n a cvrndd ljner

h*

boc siz€ ol 137 16 mm (s.400 iich), ll¿ cleaÉ¡cé béMen lhé dds or lhs p¡glo nnq 1030r0190mm is [lé roll@inq várue l0 042510 0o7s ircn) har

á

sde orrhe ollcontrolfing should b6 as*mbr¿d 1s0 ddE* fom lhe nng end sap w dlh .r rhe dód€ in á n pislon lor lhe oil Mrdmo.:. -....... ......... 321 r00tmñ {0 126410 0004 Th6 sDnno

'nch)

ino

1137 r 0.013 mm10.1235t 00005 inch)

cr6aE*. b€ts*n

lhá

srcd. dd lhe is dl 00s010 020 ññ ''''' (0 0020 r 0 0003 i^ch)

nDdgdy lubÉE

Úle od€r sulfa@ sid' .lean €ng'ne rir4 'n¡gs tlE qlinder b¡otk. 'nsEllaüd 'ñ

¿nd dÉ

(r)

F¡isroi'

own aslmbt

M,rimum oamEs'bL€ deáEncé b€hden ñ. dmdd ¿nd the oiló rc|nnsáñer '' 0 15 úm 10 006 inch)

Whs th. o¡l @nlrol nno is imlalled ii a drndef I nd tlal h¿s á boÉ siz 0l 137 16 ñm ,i¿nñ ñó, ú. derañcá berween ihe ;ds of ¡h€ osron nnq 6 rhé tunoün!

v'iue

.....

¡.57i0.1emn(0022100$rnd'l

For éach o.o3 úñ 10.001 inch) ¡n@M h lhe cvxnder lir€r boE 5¿€, ü€ de¿Én@ betoéén ü;á áds or rhá plslon rin! lncreas6 bv 0 03 mñ

Nd¿: Dorúed w n the qaps ol rhé nñss appó¡mácry 120 desl€g ffom each Ólhér Thá ñnos should b¿

lhorcoghly tubn€b llé pidor ph wilh clean éng¡ne oil Pdor lo

on

.

55

á*ñbly

M7 rO.OO3 ñm (2.1672r0 0@3 inchl

h ilr€ pisbn ák'.1 for lhé piels oin 55.0r9t 0 004 mm{2166l r 0 CO02 indr)

Bof€

D¿m.lgofl¡€new9is|0n p

n

55.000

!

0.005 mm 12 1654 1 0 0002 ¡ncn)

113rOrO15mñ L.nolhofrhaodonp'n...... (4 45?

lvw

!

0 005

ind')

2

R€ler !o Guld.Iine tof Rd*ble PafE, SEBF3049 ?'dóns and Gu'd€xne for R.usble Párrg, sFFFAosl -Pidon P'É and Réts'n'nq Riñs'

lnstd tlÉ iop nng *iÚl m€ stde marx€d rhe b0 ot tte Pi$on.

"UPrr

trrárd

wB ÜE r*iú¡ .ins É instáI€d ¡n á ovlindar l¡ner tlai hs . bde .¿€ ot 137 16 rñ (5'100 iñdh) beüEn tlé €nds ot rhé p¡3ton nnq Úle d6.E É

lle foüoriis Etue.

.... ..... 045!010mn

(0.01310.004inch)

hstar üE hEffisát dns wilh ttré sade nadcd 'uP,z btm¡d üe rop ól1há pision. ws tlE Fidn 'i4 i!; 'ñsned in a cvl'nd4 linef M Éálul 9zór 137.r6 mm {54m,ncn), tné dá¿É bd,¡é¡ tle ends orti€ pislon ñnq ÉdEtuadE rdE ........ ..033r015mn (0 033 I 0 006 h¿n)

TIE sp.liq

dÉ.

ot the oil cóñlrol dng should b6

er$léd l3o dégÉ lom lhe nng énd gap wdth d ¡é ql@ r ns p'don for tle oil 403'001nm dúElt¡E - 'n (0.lss100004inch)

0E lw oil @ñtbl 333 1 O01 Fm (0 1567

Itl-bÉ.a ¡g

-----...

Clá'E befiE, dtdriE...--,

iñ€

1 0.0004 inch)

grwe

and Úlé new oil 0.05 r 002mm l0 0020 0.0003 inch)

.......

I

[ráximum p€m¡sibre deaEn@ ber*€en [i€ gr6ve ad the ol @nircl ñn9 alter use... ...................... ..... 0.15mm(0.006inch)

(3) Top pision fñs ¡nsiarr thé lop fins wirh thé side malked 'uP-1' lNard the iop of tlé pirón. whaf rhé pision nng b ¡n$áned in ¿ cytinde¡ t¡nef lhat h6 a borc size or 139.66 mm (5.4S3 inch), rhe deaÉn€ béhr*n rhe ends ol lh€ p¡slón rjia

vlhen th€ oir ónbor ññs is insr¿rLed in a cylind€rlin*lhál has a bore size of137.16 mñ (5400 inch),Ih€ce.Ene bstu€er lhe ends ol th€ pision dno is rhe fbn@inq

É lh€ ronMins va ue. ............... 0.50

válué.... 0.55!015mm(0.022t00059hch)

(0.020

For €ach 0.03 ññ (0.001 inch) n@se in the cyliide. ¡ner bore si¿q lhe dea€n@ bete.6n lhe €nds oflhe p¡ston nng i¡masés by 0.03 ññ

ensiñé óir pfiof

b

¡

! 0.10 mm 0.004 inoh)

ln.ian $e ñremediate rins witr rh€ srdé márxéd 'UP'2'roward tle lop of lho prslóñ. wh€ñ lhé pÉron ¡jns is insráIen iñ á cyrlnd€r rhsr t'al has a borc size ol 139.66 mm (s.493 idrh), tle .lea€ne bétw*n trl6 ends or rhe p sron íns is thé lórleirg varue. ............... 0.3310.15 mm (0.m3 l 0.003 ¡nch)

Nole: The dngs should b€ p*¡Íon€d wilh ülé gaps or lhé dngs ápporimátély 120 dégre6 nóm éách other

fhobughry robñel8 ih€ pisidn pin w

.

crean

assembry

cM

Bore in lh. psion béring ror rhe pislon pin... s5.047 r 0.003 mm (2.1672¿0.0003 inch)

fté

Bore ¡ lhe pislon skñ for lhe p¡ston p¡n .. 55.01s10.004mm(2.1361¡0.0002inch)

@¡fdnns...........................4.033!0.013mm

spnns ends ot the o¡r 6ntror dng shóú d be €ssembled 130 d€sreés 16ñ $e nna end qaD. widrh ol rhe gbde h . néw pisr¡n ror Íle oil (0.r533 1 0.000s ¡nch)

pin... 55.000!0.005 mm (2.16910.0002inch) Leñgth

ollh.

ing....

p¡slon pin ..........113.20 i0.15mm (4.457 I 0.006 inch)

3.930

!0.010 mn (0.1567r0.0004

¡nch)

cLeaEn@ bel*€en rhe gbow áñd the nry oit @¡nrcl ¡ins ........ . .................. 0053t 0.023 mn (0.0021 r 0.0000 inch)

3456

Mdiñun pemissibrecr€afándebéh'*n *'e srcove and lhé ó 6naolnns añs

Reler ro cu¡deriñé fór Réusabte Pads. SEBF3049. "P¡sions" and Guideüne for Reusable Pá,ts, sEBF305l,'Pisbn Pins and R€ráinho Rinqs".

......... . 0.15mm(0.006 iich)

wheñ rhe oil @¡rd nng is insEled n a cylinder iner rhár has a blc gze of 139.66 mñ (5.4s3 ¡nch), t¡e deaEnÉ bélweéñ the ends ofrhe ldon ¡ng is rhe bno{ng (0.0177 + 0.0059 tnch) For each 0.03 mm (0.001 inchi increás in Ílé cylinder liner boé size, lhe oleaEné bé¡¿een rhe

€¡ds of tlé pision nnq ¡n@ses by 0.03 mm

Not€: Th€ dñss shourd be

pc'i

s trom earh

'¡t'óroushly lubnele lhe ouls suÍacé and lhe piston r ngs wlll dean eng ne insr.rraton h thé dyrinder brock

Thoróoohly

lubi€ie

ol olhsr

óñed wiih rhe q€p3

the p¡sion pin wiih dean

é¡sine o¡l píor lo á.sémbly.

Bofé in rhe piron qoM b¿áfing for ire p slon pin ................. .................. s5 0355 !0.m55 mm

{2.166710.0002

rndh1

ir rhe pislon ski¡l fd thé piston pin... s5 020I0.00s ññ (2.1661.0.0002 ¡nch) Boré

ol lhe new !¡slon prn.. 55.000r0.00sñm(2.165.410.0002inch) D¡amerer

. 14

r13.201015mn 457 r 0.006

rrf€d ro.k c¿mpoú¡¿ to rh€ ffirioru dt te á¡ (2) p'ior b indállaüón. apdy 155-06S5

s.:i's dÉ

(3)

'nch)

Hous¡ng (Front)

u*

thé

fdrdiE Flaáft a oder ro üshlén tlé *, ,E Plrlle b dE cylinder b ook.

bdrs ülát

1.

U* httd b* b tqhrF

trré b.hÉ.

fEñ¡a o: b.lE io 0E lollo*inq .....55r5Nml4Ot4lbfr) dcE.... 2, Ue h¿id

b.t

b tghien t'e b.lls

ágáin.

TdíEr üE bG b lÉ lo¡b{ing lolq@ .,.-....--.......-.-..... 5s r s N m (40 }

4 lb

f)

Nor.: aldv aT-9{t22 s¡ó¡e Gasket in order i0 fin üe sp€É drrE drE frg jo¡nl of lhe f¡onr plate, oil Fn q4r¡Gr, ad qftrq t¡od(

Front Hous¡ng and Covers

Tqhleñ lhé ttuds ¡har

idw'ns b'que

aon rhe blod\ ¡o the ! 10 N m 175 t 7 lb fi)

... .. 102

Gear Group

(Front)

,

fohren iñ6 bdú had s@G ontv ¿ñer ¡lhldn'no ¡he oúH bol¡e ánd nurs ln 6 ¡uturical seqwne, tightán {.e buron h€ád s¡)¡@ lo thelollM¡ng rofqúe. .........13 4 3 N.m

(f0r2rbfr)

apply 155 0695 ThEad tock lhEds ol fl. úd thai ens.s. Agply 95-3263 Thcád Lock ComDound lve bolE ror rhé srub +er

b

rhe

fshren rh. ñ€ bohs lor ihe stub sh¿l ¡n lhe folldinq sqúd@. s@ rrrusrrarion e¡ for ¡lE nunbüro of úE 1.3,4.5 2.1.2.3.4.s.

Apply

95

3263 ThFad

b.l

compound to the

oiing *al on lhe oúG¡dé ol *áins dab *i[l a 50/50 mi{lure of 3T'2993 Lubfi€nl ad dú éngine oil Applv 95 - 3263 Th€d Lod( cdpound ló lhé th€e bolb rú lñe €rdÉn sÍng Plate. foht€¡ rñe the éreháñ wlinq p át ! boills ro rh6 dt*n€ blqE. see llu#lion 39....... ...............-... 1213N m(9i2lbñ) Lrohtv lÚbn@le thé

rrhhn rhe r.ur bóh8 rhal fasreñ th6 clustef dár b fié 3lub shalt io lhe lol owiñq

ü¡qre.

...............

30t7Nm(22i5 blt)

lrre @mshañ

Tlehl6n ule dlq¡d b.is in Ú'e rollN¡ng +ouen.¿ sé lüstr.ton 90 fof lhe numbe¡n q ........... 1.4.2,5 3,6, r.4 ófiié borr.

fomen*le*€F€hafrqealbo[910lhe roiNiq lacÉ. .. 2.or40 N m (ln 1 30 |b fl l uÉ PrtE stñ $e oir qrevé t(Mrd Thread Loc( cdmúd to oE oÉ b.lrs lhal hsren lh€ LnEt.n

lhe@rh@ Ardy9s.3263 ¿¿N,isu. id6 9.¡r

lo

t'e sr,¡ s¡aí

fstller tE oE bdrs ror lhé ádluslable idr.r € b üÉ $b shañ lo lhé iclloMnq

r-i ..3or7Nmr22islbfir á ¡ rot¡ *,¿ ¡¡i,"tns, "e"". e.,P (Frorq rr iB b.cldash ádjút¡nent -

Ire-

t'elEr dE €mh.ñ gear aid lhe 0.21610.114 ñm ádiusr¿tle'ddes .. Bác¡d6h

100035r00u5inch)

AFdy 9s-326É lrE-ad Lock Compound

*

b.¡l ¡l TEhlen tE $áñ ro üF (6) air

fE áds lq

m

the slub

10

lhe

.háil.

hoü and five nuc tor lhe s¡lb ............ 55 r 10 N m

badríq tr.que.

dlpre* qd

(41r7rbñ)

f'r €quipeed)

@"o

A¡,pt 9S-3263

oo

Atply 9s-326ts Tn:F¡d Ldk compound 10 lhe ül@ b.rs rEl iaá€n Úle idler sear io tha Errb

oe

ItF¡i

Lúk

Compound to lh€

-d fE sUds ror rhé stúb sháft f-tu tu dE bdr ánd ff\€ ¡uc for lhe stub s5 1 10 N m sfi-aff b iE ¡adÍg L.que (4r r 7rbñ) ore boü

üE bdE üar fasbn lhe tE s&b shán to üe fol owinq 'dr€r .30I7Nm(22*5lbil) brqG..---.. rEhEn ÍE

@'

g4r *iln tu há

(41 Al'sn rhe lrm'ng mari óñ [ie émshañ üls im nq m¿Á ón the fronl housng Ño. 1 pislon is al rop 6nie.

(3) G€r

ro

b.tE ñ¡l

(9) a¡lqn ÜE

F¿Ecl

PumP drivé

únE É* d tle

the ri¡ig nst o

@nkshafi séár wlh tlE ús:tá gáár

Flywheel Housing Tighren rhé b.rr rór 1¡e oit

follówlnq

lump lóque. .........55 1 10

3406E

Flywheel

lloi.:

Oudng ássembly, anspoct thé rottM]ns

compó¡eñls tor a¡y foEigi mate'ias: th6 frdt ráce of rhe iyrhéer housins, lle rro sidés of lhe

fryrheel ho$¡ng gasker, and lhé €ár f¡@ ot lhe cylindd brd.r( These 6mponénrs nust b€ fr* of lhé toneins subGtanes oit, tuet, w¿l€. a¿sker ádhesive asñblv conDounds. and antoher

rorcrsn máiénar. Appty á iñ¿n ¿mou oisr-90p2 Silimne G€ské¡ h ór¿er lo llrthe ápáce be{rm $e cylinds bl@[, lhe flyvheet hous'no, and úe of Dan berorc he oÍ oán a¿sier and flé or oin

'nsbniñq

xore

Do nol h6át ihé dns

q€r

w¡rh á tofch,

Apply €ng¡ne oir to f¡e lhÉads ol the bdts.

TEhre¡ Ílá bórts ro üle fott ing iorqlo. .....,,............270r40 N.m (200 r30 tbñ)

To ¡ghrén

t.

$e nrahéet housins botrs,

ú*

ln á núned@tsequéne. tishle¡ bo[

fo¡que lor bofts ......... 100

2. h

¿

I

1t\muqh9.

20 N m (74 1 15 tb tr)

nuñen€¡ sau€ñce, riqhren botr

Toquo rorbdÍs.............40

the

t

10

rh'@qh

r0 N.m (30

17b

lñ a nunsicar séqúenoe, aqain rsht€ñ bott lhrcugh bort L

n)

1

135120Nm(l00r1slbfr)

¿

,r, ln a rúmé'l@r sequsn@. &ari ¡d¡len boll

bo[ 10

ln á num€d€lsequ€n@, ága¡n liqhlen

Torqúé iorbohs.............5str r0 Ñm

To$uéfo.bolb ........... 55r l0N m(4017lbfi)

(40l

'9.. ¡9

ro

o

o

1'?

o5

o

o

@

o

@

t)

rqht6n lhe Pluo to lhe lolldins ssi 14 N m (414 roE@ ...... .

¡ú:

ou¡i.o ¿semb¡y' hsped ü6 fond¡ng ffióonsc r.f anv foféEn mar€náls: lhe ftonl b;or ú. ñw¡e€r hesino. ri¡e ¡"¡ sdes or ft6 ñwheel hou;hs $s[€¡, and lñ€ reaf fác. of ihe .;[nd.. block. These úmoon€nc musr bé É or ie rdlNinq $b3lános oll tuer Él6i s*r€l

zl,^'

fób'on m¿bdá1. AaDlv . small ámoun' of 3r_ s022 sil;né Gasl€t h order io fll üe epae b6l*€€n the cdinder bloc{, dr€ n$heel hdsing ánd he oil pan Mó€ insbl||m lhe o I Fn aáskál ánd [lé oil psn

To

Ígtfen Ílé ítyvrheel housino boltr' u$ lhé

l.

ln a

nuMi@lssquene,

ghten boh

TótquelorbolE...,... 1m l20 ln a numeñ€l

h

a

ñúre

N m (74

sq@@. ligftei

fofqueforbolls....,,.......40+

1[rrcush9-

r

15 !b

boh 10 üróugh

10 N m

(30r7 lbfr)

@l ssauence, asáin tshisñ bolt

forque lor botts

...

ñ)

1

l3S+20Nm(100t15lbn)

a I'

Nor.: Dufno

asñbrx

inspecl

ÍE ldnMins

6ñpónenb ltr¿ny foÉ'qn ruián¿b rhe rronl r¿cé ór rhe nr'heet houdiq rhe úo sdes ot the f,yúeerhoushs oásrér and rhe Earláca orrhe cylnd.f brock. rhese conponenlg musr bé nee oi fré iollNins subshnÉs: of¡ luél wáel saske¡ ¿dhesire asse mbly r mp.und s, and.ny dhsr ibÉian ñ¿ténár ADDrv ¿ snal amountorsT s022 srrlcóñe Gaskel in o.der ró iI rhé spae be¡4€en th€ úylindárbr4r $e ñrrheer housinq, ánd iha ótp¿n

3456

ro lighren l¡e ¡lnhÉlhoG¡ng b.rt6, use üle

l.

h

¿

ñuñefi€l*quenÉ, fghlen

Torqué lor borts ........

2.

Ln

[rfoush

I

100120 N m (74115 rbñ)

z numefi€l seq ue¡@, i¡ghtan boft 10 {hrcush

Tofqú€

3. ln

bort 1

i'f

bdrb .....

a nuned@l

.

.

40 1 10 N.m (30

I

s€quen6, aga ¡ rigtfen botr

7 tb ñ) 1

foqúef¡rbóls...... 135120N.ñl0ai15tbñ) 21, ln á

¡um€dca séquéne, asain tghl€n botr 10

Torqueforbolts............s5 1 10

Nm

(4017 tbfr)

Nor.: Dunng **ñbty, inspe.l thé ró tdins mmpotunrs for any loreiqn máreda s: rhe fáce of the ll,lh€.r hoúsins, rhe lwo sidos or rré flywheel housing gaskeL and lhe bár fáce or the cyihdér bbcr. These compdénls musl be free of Me tunowins subsránG oit, tuet, sats, oastel

fdr

*sMbry (mpNnds, and antot¡e¡ fo€'qn m¿ten¿l AoDrv a sm¿n ámud or 3r . so22 sr rconé Gaskel ¡n ofdér b ñn dre sp.ce b.twéén rhe adhesive.

cylinde¡ bl@k, $6 fiwheel housins, ánd $é oit oan beloB i¡starÍng the oit pán gásket ánd l¡le o¡r páñ.

To iight€ñ rhe frynh€ét hoús¡ñg

l.

n á numed@t

bo[s, us. thé

s6quéne. tighten bot I rhmush 9.

rorquelorbons.........100120 2.

rn ¿

numei6l $quenG,

N m (74

riorrl€n ¡otr

i

1s tb fr)

r0 urrcuoh

Iolqúéforbolrs...........40rl0N.m(30i7tbñ) 3, ln a ¡um€rica sequ6nc6, aoaiñ üshlen bon TEtfen lhe lh€é bohs ror tle @wr to the

tollw¡ngtorqoe....,,.l15.20Nñ(35r15tbñ)

Tofque for bofts

ln á

..

135120N.ñ(100115tbñ)

núñai€r sequ€n*,

To¡lue

1

ágaiñ tqhlen b.tr 10

¡orbóls.. ......55i 10N ñ

(40

!7 tbf)

Belt Tension chart Not : Dó ñor u* the bell len6h¡ chá¡Ls iansioM i¡él áE apring lo€dod

for bell¡ wilh

for oAYco €uF[ád B.rb

ont

)

Mounting Gp-Fan Dr¡ve

Alternator and Regulator 114-2401 Alternator Gp

trn ,Et

ll$

!

E .....................2516Nn(13r4|bfi)

Eng¡ne Support (Front) Nolo: L@d t'e batrery wit' a €'¡.n pile aC a91 Ba{ery LÉd Téler in dd€¡ to get lle maximum

)-

l

P.r.i'v................................. ........ Nesárive Gfound

Miniñum

ouFn

út rld

Írb!€

lftnr

al 2000 rpm

........ ......

T'grnú rE b.ü

o

üE gound tem¡na io lhe

to[orn'gtdqÉ........6.2]06N ñ(5s1slbin) ].ishbn lhe elght bolls lo lhe roque. ......... . 135 r 20

fshien üe nú on lhe output

sháfr or ihé €lienalor Io rhe follow¡ng to4ú€- ... 102r7Nm

(75¿5tbtt)

,

fghGn rhe nd on rh€ pos(ive teminat lo lhe forlowino rofq¡e. .... .7.110.3 N.m (5 1 0.6 lb fr)

Voltase sefiing................. ....-..... No

adj¡.t¡€nt

P€m¡sibrgvorra!€ fánoe....,......,.... 27to29v

liqhien lhe not oñ rhe posit¡ve lém{náIs th€ forro*rngtofqúe. ...... 13.21 2.4 N m f13r 2lbfi)

fshGn üle nut or 1¡e oúpur shañ o,

rhé

áll€má¡crtoú'ero(winqioeu€...i27110Nm

(94i7lbñ)

Tiohten lhe nú on th€ qrcund lém¡na tó rhé

ror*inslorqoe........4.4r1.0N.m(3ererbin)

169-3345 Allernator Gp vohase s¡ins .......................... No adjusLft nt Pemissible vorras6 En$ .................. 27 tó 29 v

Electr¡c Starting Motor Type

I

ilA á!".s Noré: L¿ad the bate¡y wirh a eÉon p¡t. 4c- 491 Baüery L@d T6le. i¡ .rne¡ l(l gé11he naximum

1

P.|arily . .,,. ............ ......-....... ........ Néqáive c@nd Rota ón ................................................. CtoclMts Minlmom lull loád

drenr

Minimum tull load

orenr .t

ar 5000 ¡pm ......... 50 1500

Am

......... 3o

oú&utvóftágé ...,,,,.................................. 23

I

Anp Añp 1.0 V

tle electic aiáñho úo¡dr is üewed from rh. ddv€ énd, rhe moror @lales iñ tho ionúing When

No ro¿d

trdriom d x"c

(77"F)

.............. .... 76,131 1633 Dm corenr dr.w ....... ............. ... 67.5 r7.s amp vollagé.................................................23V Speed....

rhe not on the banery lem¡na io lhe t) nghlen tollowins brqúé. ..... 30.5a3.5 N m (22 ¡ 3 rbñ)

t2)

rght !ñ thé ñot on thá gbúnd l€m¡nal lo lhe tolowinqiorlue.....30.5r3.5N m€2r3lbn)

(3) rshl€n th€ ñut on the gmund l€minal io lhe tol ow¡nq iorque. ... 22s 1 0.25 N m (20 1 2 lb in)

d

'fishl€n ltu nut rotowins ro!ué.

lñe swiich leminal lo rhe

... 2.25 1 0.2s N m (20 1 2 lb ¡n)

ihe (22 brqu€. ......30.513.5 N m r 3!b followi¡s

(s) fshr€n rhé nol on rhe moror teminal

1o

f)

(3) fght€n rh. nul on lhe morú rÉne bminal to ilre róllówin! lorlue. .....313 N m {71127 bin)

whén m. €bcrric sNañjng morof is vised rrcm lhe dive end, tÉ mobr robres in t'e loll@ing dnedion. ....................................... ......... Clockwise No load condirions

Sp€€d ............. .......... ........ 5500 lpm minimum .... 140 AnP mdlhúm

9x-gsrl Slarlins ororsol€noidAsséñbly cúr€ntmñ.úñ

on á125'c (77'F)

. ............56.5i4.s4mp tlold-inw¡dingsa120V. ......... ..... 14.6Amp Purl n windinss ar 20v

Type 2

d 25'c O7'F)

Vohase (r

) r€ht€n il'6 n', for ówing

.... .-....-....--.-.........-- .-.24y on lhé

brqué

(2) fsht€n iné

¡d

...

sóoñd tehin¿l to th8

30.5 1 3 5 N.m (22

!

3 tb fr)

on rhe bahé'y rem nar to rhe

follNingro'que... ..30.5t3.5Nñ(2213|bñ)

(3) rshle¡ l,'e not on llié sbúnd teminal to t'e fónMiñ! idrque. .. 2.2510.25 N m (20! 2 lbin) (4) fg'rlen lhe nut on il'é sw .h teminar to tle irnNingrórqué ... 2.2510.25 N m (20! 2 lb ¡n)

(5) rsrrlen rhe nur on üé ñotd reminar ro rhe i'nMiñq róqué ... . 30.5 r 3 5 N m (22 r 3 tb ft) (6) Iishlen r'e ñú on rhé moro' ú.ame reminar lo the

turNiñsrorque ... 305!3.5N.m(22r3rbfr)

cúféff

doñsumpüon ar 25"c (77.F)

Pulliln *ind¡.gÉ at

24V .. ........ ........ 51 Añp ........-...... ...... 7 Amp

Coolant Temperature Séñsor

Fuel Pressure Sensor

dtf,: #il fqhlen lhé lotque...... hshren trle

*ntr

a$embly ro the rólldlñg

ssor .s*mbly .

{2) Pr0o w lr

edcr a. wker

t514rbñ)

Engine O¡l Pressure Sensor Fuel Temperature sensor

I'lrlld *|Ú .süy

lo lhe ibnding

rdqúe......-..............-.......... 1012N.m (€3 1 13 rbin)

rght€n rhé s6mor assembly !o brqué......--...................20r5

Atmospheric Pressure Sensor )

]lohbn ulle sénsor asembty b lhe b r.wha roque ........ _. _. 1012 N.m (s3113tb ln)

lnlet Atr Temperature Sensor Type

Type 2

IEhten rh€

qsor asnbty

¡c rhe

fond,nc

....... .. ..20rsN.m(t5!4rbn)

Speed and Tim¡ng Sensor

I

'-\e.'

(1) Pluo wirh eok€t A, ed(ét

l-Bhten Ihé se¡sor a*ñbrv r. r.rcue. .... ...................... 1dr 3

B,

ad tutet

C.

P'n cleán énsine ot on rh€ crim 3ea . pur 4p -s5e7 compoúnd t¡e th€áds ¡ohién ilp tunborassembty b lh6 fonNino ioque _ 40i 5N.m

anii*éi}

d

(30

.4

r! íi)

lndex Ens'ne SuPPod lFront)

ExháústMánito|d

- .. ..-- ... 11¿.2401 Aléma@rGP 16e.334s além¿ror Gp

arLnrdErbow-

-

Armospheñc Pf€ssu'e

.... ..

Exhaust Manlóld shi6ld

1!

"

"

49

1! Jr

Sen$f

Housin9......

.........

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