torques motor 3066

CATERPIILAR'

sENR5s45-03 January 99

Sloc@ffiil@atnons 3066 Engines For Gaterp¡llar 3064 Built Machines 6LK1-UpEngine) 7JK1-UpEngine)

sENR9242-12 EXGAVATORS& 32OB LL FOREST 320i8, 32OE L, 32OB U, 32OB LU EXGAVATORS& HACI{INES Contents for Volume I (Engine, Electrical, Operation and tlaintenance) Service Manual SENR924O 4NRl-Up, SBRl-Up, 6GRl-Up' lDSl.Up' lESl.Up' 6LSl.Up' EESI-Up, gGSl-Up, 9JSl-Up' 4XWl-Up' SGWI.Up' 3tRl-UP' 4H Rl -Up, 9KR{ -Up' I G -U p' 2rII21.Up, 7ZZ1 Up 8G21.Up, AEDI-Up, BANI-Up, BBGI Up Manualforhi product.Th tems isted an be ordered eparately. This orm ists he complete erviceManualforhi Note¡ dded,he willbe will beannounced PREVIEW nd should e ordered s they temsareupdated r supplements dded,he When temsare C ontents icrofiche, EG1139F,or current ontents nd or ServiceManualContents R efer o the ServiceManual vailable.Refero numbers f hismanual. hismanual. Scction

\-,

Title

Binder Binder abel Safety C ontents ServiceManualContents Torq .re pecifcations Engine Index Tab 3066Engine ErgineSpecifications Ergine Specifications 3066Engine SystemsOperations, SystemsOperations,esting nd Adjusting 3066Engine 3066Engine 3066Engine Assembly Disassemblynd DisassemblyndAssembly Engine 3066Engine 3066 upplement nd Assembly Disassembly ndAssembly Elecfical S¡rsterns & Ope¡atoÉs Station Index Tab Electronic ontrol nd PumpElectronic Engine ndPump SystemsOperation SystemsOperation System nd Charging Starting ndCharging SystemsOPeration SystemsOPeration Electrical ystem Schemat¡c ForestMachines Electrical ystem;ForestMachines Schematic (6151-Up,JS1-Up) J S1-Up) 7721 UP Electrical ystem Schematic 8GZ1-Up,BGl-Up) 8GZ1-Up,BGl-Up) taintenance lndex Ta Operation nd Maintenance Forest achines6LS1Up 9JS1'Up) Operation nd Maintenance (721 -Up, GZ Up BANI UP Operation nd Maintenance BBGl-Up)

Form No, SENR23OO SENR9241 SENR7733 SENR9242 SENR3130 SENR,2ETO SENR5545 SENR5546 SENR5553 SENR9243 sENRil996 RENR1998 RENRlOOT SENR9258 RENR1O58 RENR3725 SENRiIET4 sEBU6975 SEBU7O79 XEBU2571

nformation,ee ee nformation. orSystems Systemsnformation, Thismanualcontains Thismanualcontains ngine, lectrical& aintenancenformation.or Note: ag RENR2982. Contents

03/09/00

CATERPILIAR'

10056692

lmportantSafety nformation Most ccidents nvolve roduct peration,aintenance epair recausec ;'. -'=-. observeasic afetyules precautions.accident often e avoided y re::a' =::'ertially hazardousituationsefore n accident ccurs. personmustbe alert o pote-: -=-=-:: person hould :-: :'-.-'y necessaryraining,k ills nd ools performhese lmproperoperation,ubrication,m aintenance r repairof this productcan be dangerous nd could result n injuryor death. Do not operate perform ny lubrication,m aintenance r repair this product unt,i yo have readand understood he operation, ubrication,maintenance nd repair nformation Safety recautions nd warnings re provided this manualand on the procjlc: ':-=:: warnings h e e d e d , o d i l y n j u r y r d e a t h o u l do c c u r o or to othe'pe's:-: hazards re dentified y the "Safety lertSymbol" WARNING" shownbelow.

meaning f thissafety lert ymbols

followed

"Signa

",:':

ollows:

Attention!BecomeAlert! YourSafety s Involved. message

appears nder hewarning xplains

ictorially resented. Operations t n i sp u b l i c a t i o n .

cause productdamage

dentified

hazard nd can "NOTICE"

s

-':^l

Caterpillar annot anticipateevery possiblecircumstance ha might involve PGri: *a n^zerd. The warnings n this publication on th productare, herefore, ot all indusite. a tool, procedure,w ork methodor operating echnique hat is not specifically ecomÍHléc Caterpillar s used yo must satisfy yourself hat it is safe for yo an for others-Yc s h o u l d also ensure hat the product will not be damagedor be made unsafeby th oPerabor - orication, maintenance repair procedures ha yo choose. th^+ The nformation, pecifications, llustrations publication on he:as s - -':' availablet the ime hat he publication wntten. specifications:':-=:-::: ,: l=S llustrations, othertems change t anr':-: measurements, djustments, --:-^^{^.^ = _ Jgtul v productObtain complete mos: -":--=: given affect service -: yclu orarr arry )ob. Caterpllar dealers have the most current information avai a3:

current ublication

numbers vallable,

l onter-:s'.':':-:-= S e r v i c eM a n u a C

T\OS\

JYT,

-,

Tableof Contents

Tableof Contents

i' .,'

v.

SpecifcationsSection

Specifications ection r01020901

EngineDesign

N o t e : h e r o n t n c c ' :-: ;lywheel o' :-: :froñ the ywhee - : -ron:, -:=' c y l i n d e rs

cosite

:

¡^ ^{ +t > uv ut LI /^ ,,i^,^,^/-¡ : c vtúvvru

3066Engine

SMCSCode: 1201

3064Engine

900523889

lllustration Cylinderand valve ocation (A Exhaust alves. B) lnlet valves.

Bore...,.....

...102

(5.12 nch)

Stroke Displacement................

...4.3 (260

C y l i n d e rr r a n g e m e n t . . . . . . . . . . . . . . . . . Valves

4.02nch)

cylinder

Firing rder C o m p r e s s i o na t i o

Fuelnjection timing

.. n-line .,,,,.......2

.......1- -4-2 ...)......17.1

degreeséforeop center

Note:Refer o the Engine nforfnation late or the performance pecificationumber.R efer o the TMI (TechnicalM arketing nformation) refer o the FuelSettingan Related nformationMicroficheor the correct imlngspecifications, M i n i m u mp m . , . . . , . . . . . . The crankshaft otation s vrewed rom he flvwheelr '..*'-' end of the engine.Crankshaft ....Counterclockwise rotation

lllustration Cylinderan valve ocation (A Exhaustvalves. B) lnletvalves

nch)

Stroke

a:-.390in')

ñicnlanomant

In-line

Cylinder rrangement Valves

)',t295223

. .......2

cylinder

: 3-6-2-4

Firing rder

.. 17

Compression at¡o Fuel njection .... timing

c:;-=== :--'= topcenter

or the Engine -'-^'-.' Note:Refer o = = ' : ' t o p e r f o r m a n c ep e c i f i c a t r o ' '-'-'to (Technical arketingnfo'-a::':rofiche ' ^ ' z ' F u e lS e t t i n g R e l a t e c c o r r e c ti m i n g p e c ' : e . M i n i m u mo m . . . . . . . . . . . . . . . The crankshaftotations ' :".:: end of the engine.C ranks-=: rotation

..900 20 flywheel - - -- erclockwise

Note:The frontend of the e-; = . , ::osite of - -' s d e o f enE'= lywheel nd ight ide ':-: :-,': are iewed engine nd No. 1 from he l y w h e e l n d o f t l ' e : - : rontcylinder cylinder

SpecifcationsSection i01029707

Fuel njection ines

Tighten he delivery alveholder o the 44 N m f o l l o w i n go r q u e . . o3

b ft)

Bolt or lockplate

SMCSCode:1252

Tighten bolt or the ock plate o the 44 lb in) f o l l o w i n go r q u e . . . . . .. t o 5 N m Bolt or fuel Tighten he bolt or the uel ine o the ollowing 10 o 13 N'm 0 torque.

rsut -t-

-//

ldler ubspring

/4'

lllustration

Tighten he dlersubspring torque.

o the ollowing 12 b t)

lrllar crhqnrinn

9oo53o3o7

Tighten he dlersubspringo the ollowing . . . . . . . 6 2 0 N ' m 1 2 1 o1 5 b t ) torque.

F u e l n j e c t i o ni n e s Tighten he uel njectlon nuts f o l l o w i n go r q u e . .......25

Fuel niectionPump

b

Tighten he torque.

o the followlng 3 t 5 N'm

\01029754

Fuel njectionNozzles

SMCSCode: 1251,1290

44ló i01029643

SMCS Code:1254

lllustration

g0O53O2B0

Seal Fuel njection ozzle lllustratlon

soo53o354

Bo:s or uel njection grten he bolts uel njectionine o the ' o , o w i n gto r q u e . . . . . 2 0 2 5 N ' m 1B b t) rvery alveholder

Retaineror uel njection ozzle Tighten heretaining olt o the ollowing ..,...... torque.

Specifications ection

ValveMechanism

t01024279

SMCSC o d e : 1 1 0 2

3>#o--P n\-P

\g 900530283

lllustration

Body or fuel njection ozzle Shims I n c r e a s i n gh i m s O.1O (.OOan c h ) h a n g e s injection ressureby approximately 37 kP (2OO si).Shims avatlablen ninesizes (.023 nch). O . ' 1 0 (,OOan c h ) o 0 . 5 8 Pressure pring

900526366

lllustration / I \ Qnrinn I a n lnv it hl

Free engthafter' es s3'-: Maximum Valvestem seal

(B Gasket

H e i g h to t o p

(11) Retaining Tighten torque.

-l tO.30 : .012 nch)

va.:

Diameter valves:e-

njection ozzle or uel njection ozzle ollowing ......34

o5 (2.22inch) 2 degrees

lü51 rurus

(7 Pressure

(10) Tip or

(173,n"n',

r r nr rv lval r t e c . ' - ^ ' ^ :

albfI)

l n l e t a l v e tem,

7.955 : 3132 nch)

Exhaust alveste-

7 940 :3126inch) ^ - r , 3 . 1 1 0in c h )

s t e m. , , ; . . . . . . . . . . . . Minimum llowable stem........... Clearance ntake guide..0.055 0.085

='='

='^aust alve ( . 3 0 9 1n c h ) alve - --- ,¡ 0033 nch)

valve Clearance exhausi .= :'=- - -: : 0041 nch) guide 0.070 0.105 M a x i m u m l l o w a b l el e e ' a - : = : . ; i d e o r n l e t 0059 nch) valve

SpecifcationsSection lvlax allowable learance guide 0079 nch) e x ^ a . r s ta l v e . . . 0.200 Ce diameter valveguide :e diameter guide or nlet .a.: .. .13.025 13.035 m ( . 5 1 2 8 . 5 1 3 2n c h ) l-.s .z .= ....

( 1 1 ) V a l v e e a tb o r e o r n | e t . . 4 6 . 0 0 0 4 6 . 0 2 5 ( 1 . 8 1 1 0o 1 8 1 2 0 n c h ) ('12)Valveseat bore or exhaust

39.000 o 39.025 ( 1 . 5 3 5 4 1 . 5 3 6 4n c h )

diameter guide exhaust . 13.025 13.035 m (.5128 .5132nch) diameter f guide or new nlet . 3 1 5 4o . 3 1 6 3 n c h ) 8.010o8.035

ñiameter f ouide exhaust (.3154o 3159 nch) : = 8.010 o 8.025 ^.'', inside iameter ouide or nlet ....

'.'i'

A u . vñwO lm l lm rll

innh\

ll¡v¡1,/

inside iameter ouide orexhaust

8.12 rm .320nch)

-occ

( 1 3 )W¡dth f v a l v e e a t . . . . . . .

nf lin

c thicknessor rnlet nd exhaust .: .:-i 2 13mm(,084 nch) ',' - ---n allowable alve ip hicknessor inlet (.047 nch) ..1.20 :-: :xlaust valves ¡ = oÍvalveace.........,.

lllustration

30degrees

900527479

1 ¡ 0.25 (.055 .010 nch)

Note:The maximum ermissible idthof the valve s e a t 1.BO m ( . 0 7 1 n c h ) . (14) Valve eatangle

30 degrees

(15) Dimensionrom op of closedvalve face of notñ

E x h a u s ta l v e . . . . . Inlet a|ve....0.400.25

......0.50 0.25 (.020 .010 nch) (.016 .010 nch)

m a x i m u m e r m i s s i b l ee p t h s 1 . 1 0 Note: (.043 nch).

900526884

tr¡usira: -

l=c:^ of bore n head orvalveseat -se': , (.374 ..004 nch) .9,5 0.1 C^a':fer

inlet alve...

......40 egrees

Note: depthof the chamfer f the nlet alve s 2 . 3 8= C 1 0 m m ( . 0 9 4 . 0 0 4 n c h ) . (10) C^amfer f exhaust alve

..45 degrees

Note:Tn depth of the chamferof the exhaust alve t 0.'10 (.079 .004 nch).

lllustration 0

(16)Pushrod

gOA52749A

Specifications ection a dial ndicator order o check pushrods or runout.R eplace pushrod f the runout xceeds he ollowing alue. .... (.016 nch)

ValveRocker

t01023644

SMCSCode: 1123

900526256

lllustration 2

A l i g n h e o i l h o l e s n r o c < ? '= ' ^ : - s h i n g w i t h h e h o l e sn h e ' c : - . ' . ' - ' , v h e n rocker bushing ¿:=: ^"'-

tl

900526252

lllustration 1

Rocker rmbushing Bore n rockerarm bushing or . . . . . . .0 . 0 1 1 2 0 . 0 9 4 m shaft........... ( . 7 8 7 8o . 7 9 1 i n c h ) (2 Rockerar

shaft

Diameter f rocker rm shaft...

19.966 19.984 7861 o .7868 nch)

Clearance rockerarm bushing ( . 0 0 1 1 . 0 0 5 0n c h ) s h a f t . , .. . . . 0 . 0 2 7o 0 . 1 2 8 Replace rockerarm bushing f repair imit (.006 nch) of 0.15 been eached.R eplace th rockerar bushingand the rockerarm shaft

I?:::3': "tit

J:-/-

of he ocker rmbushinsasbeen

900526257

lllustration 3

Positionhe rocker haftbrac.e = bolts.

ñ^r rnlrn^

Long bolt Tighten torque.

bolt

tBlbft)

Shortbolt Tighten

torque.

shortbolt o :^e':

..,.15

(6 Rocker haftbracket

11 + A lh ft\

SpecifcationsSection 141025762

CylinderHead

SMCS Code: 1100

900526261

lllustratlon Valve as adjustment

Tur^ ^: crankshaft ntil he timingmarkon the c'e'-=- oulley aligned ith pointer :=ar houslng order o adjust he valve :::^ the No, 1 inlet alveand the o e / - . . : - . Av e n u s h r o d s be in tension - --^.^^t,^.

^.^^

e x h a u s ta l v e a s h . . .0 . 2 5

(.010 nch)

ValveMechanism over

t01023202

SMCSC o d e :1 1 0 7

944527524

lllustrat¡on 6

Cylinder a straightedge d feelergauge o check the cylinder ead or warpage,

ol"l' _:" n :u'l n":33¿%li'?.'d#,?

Resurfacehe cylinder ead f the warpage ....0.20 m exceeds he ollowing mount (.008 nch)

Gasket hickness f cylinder (.070 .004 nch) h e a d . . . . . . . . . . . . 1 . 700. 1 0 Thickness

h e a d . . . . . . . . . . . 9 5 . 000, 1 0 (3.740 .004 nch)

Minimumhickness f cvlinder ead .94.70 ( 3 . 7 2 8n c h ) repair imitof the contact urface f the Note: gasket repair imit cylinder lock ( . 0 0 8 nch). s u r f a c es 0 . 2 0

900525829

l¡luslra::-

,a,::over the valve cover nuts o the followinq 3to5Nm(26to44 lbin)

aBttagr 15. 11€-$

¡úFoZ 5(!-Q)1s

lllustration 7 Numerical equenceof bolts or 3064 Eng¡ne

.¡

SpecifcationsSection

¡o rC-Ot f9-O6 lllustration 8 Numerical equenceof bolts or 3066 Engine

tt¡

900527527

cleanengrne il on the hreads f the cylinder tighten he bolts headbolts. nstallhe bolts the appropriate umerical equenceo the following 4lb ft) . . . . . . . . 1 1 85 N ' m torque.

Turbocharger ,ri

i01030322

900530560

lllustration 20

Turbine haft :' :ne urbine n

Place dial ndlcato'oshaft.Move he comPress:' axialdirection orderto play.... .057o0.103

SMCSGode:1052

Note:The urbochargerr-s: :: :-::' the urbocharqer the end play s beyond

^ t ^ , , LE rñr ^u Pray.

.0041nch) . = .embJednd -.:':learances -:

:^S,

^-Y

lllustration

900530558

Compressorw heel Turbinewheel Turbine ousing (4 Compressor ousing Cartridge ousing Note: Mark the orieniation f the compressor housing, he cartridge ousing nd the turbine housing efore isassembly.

lllustration 1

(7 Lock plates plates Position followingorque.

the bolts

Specif cations Section i01 29608

ExhaustManifold SMCSCode: 1059

l' s'.'a::^ 22 r- -: -:-srng (3 an Cartridge ousing

:-rbinehousing

900530562 ü!-'*"

with he cartridge lllustration24

900530254

Nuts or urbocharger Tighten he nuts or he urbochargero the foilowingorque. Studs or urbocharger Tighten he studs or he urbocharger 12 N'm followlngorque. Studs or exhaustm anifold

-s:'a:3,^ 23

900530564

^;-n,

5 P - 3 9 3 1A n t i - S e i z eo m p o u n do the :--.¿:s of the clamp.Tighten clamp t 1 N'm :,',.g torque. ightly round he circumference. Tac : a-: o the ollowing Tig^::- : amp lb n) 1 N'm torc-?

he exhaustm anifold Tighten studs 12.5 followingorque. Nuts or exhaustm anifold Tighten nuts or he exhaustm anifold b ft) followingorque.

Camshaft SMCSCode: 1210

í^f\, ) \\ \\l v'

f) ,v)

,\T,i

\iN

900527952

lllustration26

Note: 900527937

lllustrat¡on25

Camshaftobe ift Specified amshaft

Camshaft Maximum ermissibleemperaturef the gear for nstallationn the camshaft 315'C (600'F) Note:Do not use a torch. Diameters f camshaftournals

E x h a u s to b e . . . . . . Inlet obe Serviceimit or obe ift

2891 nch) ^-(2633inch) :'- =

Serviceimit or obe ift o'

Table

Number Number of Journal of Journal for 3064 i for 3066 Engine Engine

N o t e :R e p l a c eh e c a m s ' ¿ : obe ift s reached.

Standard Diameter 53.94 to 53.96mm 53.90mm (2.123 (2.122nch) 2.124 nch) 52.94 to 52.96 52.90 (2.083 nch) (2.084 2.085 nch)

(1 Th serviceimit s the maximumimension the serv¡ce limit s the minimum imensionha specifiedor part. Qéptacé

thé

part

i{ the

se.vice

limit

is reached-

Thrust late Tighten bolt o the ollowing torque.

b

Camshaft

.6.844 ( . 2 6 9 5n c h ) 6.189 (.2437 nch) ::-. ce limitor

heigi::

Basecircle 1. Measure he camshafi Measurehe basecircie '--^:inStep2 Subtract basecirc :-=Step1 . T h e s'--eight from he difference actuaca-:-: lift

Standard Diameter Clearance between camshaft journalsan bushings

Repair Limit(1)

oo,l3J¡0,3 .do7,""n1

,0.15 (.006nch)

(1 The reoair imit s the maximum imension r the repair im¡t s the minimumdimension hat is specified or part. Repair he part f the repair imit s reached.

900528061

lLluSl'álrOn

Note: :::='-

a dial ndicator nd blocks n order o one half runout f the camshaft. indicator eading the runout.

r

--^h^{+ - = 5r tdlt

' , ' r x . n u mp e r m i s s i b l eu n o u t ... .0 0 2 0 :a-shaft

(.0008nch)

ghten he camshaft runout s ess (.0020nch) 0 050 c w i n ga m o u n t . the camshaft runout s more han (.0020 nch) 0.050 :,,,,lng mount.

900529304

lllustration

Install he dial indicatorn order o determine play gear p | a y . . . . 0 . . 1o0 0 . 2 5

( 0 0 4 o . O 1 0n c h )

hrustplate f the end playexceeds Replace o l l o w i n gm o u n t ,. . . . . . . . 0 . 3 0 ( . 0 ' 1 2n c h ) (.191nch) T h r u s t l a t e h i c k n e s s . . , . .4.. 8 5

i

(-\r

-]l_,o 900528067

lllustral,cr ¡R,

i:-cn:fi

l_raarinn

Meas-'e camshaftearing a dial ndicator. camshafto urnal Suc:rac: diameter nrne'

oive l-rearino learances.Refer o Table

900529307

lllustration30

(10) Tappet orediameter Tappet

diameter.....22.000 o 22.021 (.8661 .8670 nch)

M a x i m u ma p p e t

d i a m e t e r. . . . .2 2 . 0 5 5 (.8683nch)

Clearance f tappet b o r e . . .0 . 0 3 5 o 0 . 0 8 6

r'{: ( . 0 0 . 1 4o . 0 0 3 4 n c h )

Note:Replace he tappet the clearance s exceeoeo. i01030986

Engine Valve

PressureRelief

NOTICE Beforeoperation,he pump n!s: :: :ubricated th cleanengineoil and the pump -,si turn reely handor damage partscan 5e :-= result. N o t e : h em i n i m u m c c e c : a 3 - : - : s s ! r e psi). idle s 1OO P Driven

assembly

Drivegear assembly

SMCSCode: 1315 /"\

f.\¡l ^r rmn

^a.r

ldlergearassembly backlash etweer -= - : -^.: gear

t h e i c i l e ro c e r s t h e

amount.

:,,,

- --:oO190mm - - ::. I 0075 nch)

N o t e :R e p l a c e g e a r s : - = : : - . : s ^ e x c e e d s (.014 nch) 0.35 Spindle lllustration31 Oi pressure eliefvalve

900530799

Remove he oil pressure eliefvalve from the cylinder lock.Check he valveand the valveseat abnormal ontactpatterns. nspect he spring for weakness r damage.Replace he oil pressure reliefvalve, f necessary.

N o t e : h e p u m pg e e r assembly re not servicea: ' removed.

,: gear . . 3imo gear

R e l i e f a l v e p e n i n g r e s s u r e. . . . . 3 4 3 2 0 k P a psi)

Engine

Pump

01 30415

SMCS ode: 30

1r

!..

lllustration 3

.:

pumpgear

14

Note:Do no sea torch, lllustration32

900530573

900530644

SpecifcationsSection Heat he oil pump gear to 180' to 220'C (356" o 428"F) nd support he end of the drive gear snaft order o install he oil pump gear. Press he oil pump gear until he oil pump gear f ushwith end of the shaft.

lllustration35

900530702

Cover Measure nsidediameters f the bores the shafts the cover and the oll pump housing Measurehe boresof the shafts. The clearance etween he gear shafts nd p u m ph o u s i n g c o v e r . . . . . 0 4 o 0 . 0 7 002 o .003 nch) 900530697

llirs:'at¡on 34 r e i n :¡ , f n- r. n i l rnJr m p

gear

'.ieasurethe difference engthof the p u m pg e a ra n d h ed e p t h assembry : ^ e o , rp u m ph o u s i n g . 0.020 o -0.034 I earance 00'13 nch) 0008

Note:Replace he oil pump gear assembly, cover, r the oil pump housing the clearance (.006 nch). exceeds he serviceimitof 0.15 Note:Replace he drivegearand drivengear assemory.

Note:Replace he oil pump gear assembly crea'a.ceexceeds he service imit -0.150 CC59 c h ) . Meas-'e he clearance etween he oil pump gears feeler auge. a n c : ^ e o r lp u m p h o u s i n g t- ^-.^^^^

0.050 o 0.098 (.0020 .0039nch)

th Note: Rep\aoe the oil pump gear assembly -0.150 clea'a^ce exceeds the serv¡ce limit

0C59 nch).

lllustration36

900530704

d l e rg e a rb u s h i n g Inside iameter idler bushing

25.000 o 25.021 (.9843 .9851 nch)

Maximum iameter f idlergear bushing pump...... . . . . . . . . . 2 5 . 0 5 9 ( . 9 8 6 6n c h ) Splndle Drameter f spindle

24.939 o 24.960 (.9818 .9827 nch)

SpecificationsSection Minimum iameter f spindle or pump...,... . , . . . . . . . 2 4 . 9 0 1 ( . 9 8 0 4n c h )

Engine

01 31038

Pressure

SMCS Code:1924

Openingpressure bypass = =

l

t 98 kPa psi) t i01030410

Engine SMCSCode:1302

Table

Engine gi P¡sss¡r¡g(t)

Oi Pressuret 1500 om

19 o 392 kPa (2 to 57 psi)

Oi Pressure iflls{e)

98 kPa (1 psi)

(l The oil emperature us be 60'to 70"C (140'to 158"F) (2 Engine dle s 900 r 20 rpm.

Engine

BypassValve

i01030990

SMCS Code: .1306

900530566

lllustration38 /r \ r.

ar;l ^^^ \ J i l Pd

h^t+^ uL)rJ

Tighten he oil torque.

bc .-. -

d r a i np l u g Tighten

foliowing 4 lb ft) 01 33378

WaterT emperatureegulator SMCSCode: 1355

il' ii,

8010 WaterTemperature

Regulator 90053080

Note: oil bypassvalve s mounted nside along he railof the oil pan. ('1)Valve eat Check he valve and the valve seat or abnormal contact patterns.

water emperature t h e f o l l o w i n g t e m p e l a tu l e valve iftsmore followingemperature,

:':'-: o open - - , ( 1 6 0 '+ 4 ' F ) -:r) at the 85"C 185"F)

8020 WaterTemperature

Regulator

Spring

water emperature a::- :':": :c open the ollowingemperature. 32"C 180'F)

Inspect he spring or weakness r damage. Free engthof spring (3.29 nch) 83.5

valve iftsmore han 10 following emperature

at the 36'C (204'F)

SpecifcationsSection

WaterPump

i01031

Th press it between he waterpump shaftan th ollowing rmpeller (.0013 .0026 nch) amount. 0.032 o 0.065

SMCSCode: 1361

CylinderBlock

tO1a2B288

SMCS Gode: .1201

lllustrat¡on 900530877

lllLs:'at¡on

-oeller 'aces -sn.

mpeller nd he waterpump shaft

ange -i'e of the mpellero the distance rom he housings the ollowing .',are' (.826 .854 nch) a'nount.. 21.00 o 21.70

Cylinder lock Measurehe amount f the warpage f the eeler cylinder iockwith straightedge gauge.Maximum llowable (.002 nch) .......,. clearance R e p a i ri m i t . . . . . .

g00530BZB

V/a:e'pump shaft T^ cress it between he water pump shaft nd ange is the ollowing 0.035 o 0.065 an:oint. (.0014 .0026nch)

.........0.20 (.008 nch)

Resurfacehe op of the block f the repair imit s reached.

lllustration lllustrat¡on

900529444

Cylinder leeve

900529446

SpecifcationsSection nsidediameter f the cylinder leeve Measure parallel the crankshaft. easure he that s in a insidedrameter f the cylinder leeve perpendicularosition o the crankshaft. easure op, he middleand the bottom f the cylinder sleeve.Refer o Table4 for tolerances f the cylinder leeves. Table

Tolerances of Cylinder Sleeves

i--_!-_

tandard Standard

n^--¡Repair

Limit{l)

A""lirory Inside Diameter

c^n,¡^^ Service

Limit€)

102.010 102.700 102.200 102.045 4.0161 mm 4.0236 mm (4.0433 inch) inch) 4.0175 inch)

0.010

Out of Round

(.0004 nch)

Taper

0.015 (.0006 nch)

N/A N/A

N/A N/A

Cylinder leeve

Replace cylinder lee.=: limit

--'l

'iil

1l

Replace cylinder leeves service imit.

s necessary

n excess

Note:Refinish ll sleeves o the sameoversize dimensron. se ridge reamer n order ridge the cylinder f the sleeve s i good condition. one he cvlinder ore. Table

OversizeBore

CylinderBore Size

250mm0100nch)J3273:5ilili:339? liil 0.500

(.0197 nch)

102.510 (4.0358nch) 102.545mm (4.0372 nch)

102.700mm 0433 nch) -¡ ::U

-

,^¡: -