Motor 3066

Fuel Priming Pump - Remove and Install

SMCS - 1258-010

Removal Procedure

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing,

adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any

compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to

collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Ver imagen

Illustration 1 g00606436

Remove banjo bolt (1) and washers (2) (not shown) from the fuel priming pump in order to remove fuel outlet line (3)

.

Note: Cap all openings or plug all openings immediately in order to prevent contamination of the fuel system.

Loosen hose clamp (4) in order to remove fuel supply line (5) .


Ver imagen


Remove nuts (6) that secure the fuel priming pump to the fuel injection pump.

Note: Fuel will drain from the fuel priming pump during removal. Collect the fuel in a suitable container for storage or

for disposal.

Remove fuel priming pump (7) and the O-ring (8) (not shown).


Installation Procedure

Ver imagen


Note: Check the O-ring (8) (not shown) for wear or damage. Replace a worn O-ring or a damaged O-ring with a new

replacement part.

Place the O-ring (8) (not shown) and place the fuel priming pump (7) in position on the fuel injection pump.

Install nuts (6) that secure the fuel priming pump to the fuel injection pump.

Ver imagen


Connect fuel supply line (5) and hose clamp (4) to the fuel priming pump.

Tighten the hose clamps.

Note: Check the washers (2) (not shown) for wear or damage. Replace a worn washer or a damaged washer with a

new replacement part.

Secure the fuel outlet line (3) and the washers (2) (not shown) to the fuel priming pump with banjo bolt (1) .

Tighten banjo bolt (1) to a torque of 20 to 25 N�m (15 to 18 lb ft).

Fuel Filter Base - Remove and Install

SMCS - 1262-010

Table 1

Required Tools

Tool Part Number Part Description Qty

A 185-3630 Strap Wrench Assembly 1

NOTICE



NOTICE







Ver imagen


Use Tool (A) to remove fuel filter (3) from fuel filter base (2) .

Note: It is not necessary to remove the fuel filter in order to remove the fuel filter base.

Remove banjo bolts (1) and copper washers in order to disconnect the fuel lines (4) from the fuel filter base (2).


Ver imagen

--------------------------------------------------------------------------------


Remove two bolts (5) and the washers that secure the fuel filter base (2) to the air inlet manifold. Remove the fuel

filter base (2) from the fuel filter bracket.


NOTICE



Ver imagen


Place the fuel filter base (2) in position on the fuel filter bracket. Install the washers and two bolts (5) that secure the

fuel filter base tothe fuel filter bracket.

Ver imagen


Install the banjo bolts (1) and install new copper washers in order to connect the fuel lines (4) to the fuel filter base

(2) .

If the fuel filter was removed, install the fuel filter (3) to the fuel filter base (2). Tighten the fuel filter by hand

according to the instructions that are shown on the fuel filter. Do not overtighten the fuel filter.

Fuel Injection Lines - Remove and Install

SMCS - 1252-010

Removal Procedure

Start By:

Remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install".

NOTICE



NOTICE







Ver imagen

--------------------------------------------------------------------------------


The 3066 Engine is shown.

Remove the bolts (1), the washers, and the clamps (2), which secure the fuel lines to the inlet manifold (3) .

--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Disconnect the fuel injection lines (4) from the fuel injection nozzles (5) .


--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Fuel injection pump for a 3066 Engine

Disconnect the end of the fuel injection lines (4) from the fuel injection pump (6) .


Remove the fuel injection lines (4) from the engine.

--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Loosen the acorn nuts (7), which secure the fuel return line to the fuel injection nozzles.

Remove one bolt (8) and the washer from the clamp that secures the fuel return line to the intake manifold.

Note: The clamp will remain with the fuel return line, when the fuel return line is removed from the engine.

Disconnect fitting (9). Remove fuel return line (10) from the engine.



--------------------------------------------------------------------------------

NOTICE



Ver imagen

--------------------------------------------------------------------------------


Place the fuel return line (10) in position on the engine. Connect fitting (9) of the fuel return line to the fuel injection

pump.

Install the washer and bolt (8) through the clamp in order to secure the fuel return line to the inlet manifold.

Install the fuel return line (10) to the fuel injection nozzles. Secure the fuel return line to the fuel injection nozzle with

acorn nuts (7) .

--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Fuel injection pump for a 3066 Engine

Place the fuel injection lines (4) on the engine.

Connect the fuel injection lines (4) to the fuel injection pump (6) .

Connect the fuel injection lines (4) to the fuel injection nozzles (5) .

Note: The fuel lines (4) should be connected at the fuel injection nozzle (5) and at the fuel injection pump (6) before

tightening the nuts for the fuel injection line.

Tighten the nuts for the fuel injection line to a torque of 25 N�m (18 lb ft).

--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Fuel lines for a 3066 Engine

Install the clamps (2), the washers, and the bolts (1), which secure the fuel lines to the inlet manifold (3) .

End By: Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install".

Fuel Injection Nozzles - RemoveSMCS - 1254-011

Table 1

Required Tools


A 1U-7600 Slide Hammer Puller 1

B 9U-6278 Adapter 1

Start By:

Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".

NOTICE



Ver imagen


Remove bolt (1) and the washer that secures the clamp (2) to the cylinder head assembly.

Remove the clamp (2) that secures the fuel injection nozzle (3) in position in the cylinder head assembly.

Note: Put caps or plugs on all openings immediately in order to prevent contamination in the fuel system.

Note: Mark the clamp for later installation.

Install Tool (B) (not shown) to the fuel injection nozzle.

Note: Tool (B) is installed at the connection (4) for the fuel injection lines.

Connect Tool (A) (not shown) to Tool (B) in order to carefully remove fuel injection nozzle (3) .

Note: Align the centerline of Tool (A) with the extended centerline of fuel injection nozzle (3). This procedure will help

prevent distortion of the fuel injection nozzle which can cause the fuel injection nozzle to bend or break.

Remove the seat washer from the fuel injection nozzle.

Fuel Injection Nozzles - Install

SMCS - 1254-012


NOTICE



Ver imagen

--------------------------------------------------------------------------------


Install a new seat washer (5) .

Install fuel injection nozzle (3).

Install clamp (2), the washer, and bolt (1) that secures the fuel injection nozzle to the cylinder head assembly.

Tighten bolt (1), that secures the fuel injection nozzle, to a torque of 22 N�m (16 lb ft).

End By: Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".

Fuel Shutoff Solenoid - Remove and Install

SMCS - 1259-010

Removal Procedure

Ver imagen


Disconnect two wire leads (1). Mark the wires for later installation.

Disconnect actuator lever (2) from the governor lever.

Remove two bolts (3) and washers that secure the fuel shutoff solenoid to the bracket.

Remove shutoff solenoid (4) from the bracket.


Ver imagen


Place the shutoff solenoid (4) in position on the bracket.

Install the two washers and bolts (3) that secure the fuel shutoff solenoid to the bracket.

Connect actuator lever (2) to the governor lever.

Connect two wire leads (1) to the fuel shutoff solenoid. Ensure that the wires are properly connected.

Fuel Injection Pump - Remove

SMCS - 1251-011

Table 1

Required Tools


A 9U-6124 Universal Metric Socket Set 1

B 9U-6128 Universal Metric Socket (1) 1

Start By:

Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".

NOTICE



NOTICE







Ensure that the engine is the top center position on number one piston. Refer to Testing and Adjusting, "Finding Center

Position for No. 1 Piston".

Ver imagen


Remove bolts (1) and washers that secure the cover (2) to the engine front housing.

Remove the access cover. Note the timing marks on the fuel injection pump drive gear and the idler gear for later

installation.

Ver imagen

--------------------------------------------------------------------------------


Scribe a line across the front plate (3) and the mounting flange for the fuel injection pump (4). This ensures proper

alignment for the installation of fuel injection pump (8) .

Loosen fitting (5) for oil line (6) .

Remove oil line (6) from nipple (7) (not shown).

Note: Put caps or plugs on all openings immediately in order to prevent contamination.

Use a lifting sling and a hoist in order to secure the fuel injection pump. The weight of the fuel injection pump is 13 kg

(29 lb).

Note: Use Tool (B) to remove the bolts and the washers that mount the fuel injection pump (8) .

Remove bolt (9) and the washer from the cylinder block.

Remove four bolts (10) and the washers that secure the fuel injection pump to the front housing.

--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Remove the fuel injection pump (8). The gear and the mounting flange will remain with the fuel injection pump.

Note: The fuel injection pump must be mounted to the engine in order to loosen the nut for the drive gear.

Note: Do not rotate the engine after the fuel injection pump is removed.

Ensure that the old gasket material is removed from all mating surfaces of the pump mounting flange and the face of

the fuel injection pump flange.

Fuel Injection Pump - Install

SMCS - 1251-012

Table 1

Required Tools

Tool Part number Part Description Qty

A 9U-6124 Universal Metric Socket Set 1

B 9U-6128 Universal Metric Socket (1) 1

( 1 ) Part of the Universal Metric Socket Set

NOTICE



Note: If the nut for the fuel injection pump drive gear is removed, you must tighten the nut for the fuel injection pump

drive gear to 88 ± 5 N�m (65 ± 4 lb ft).

Ver imagen


Use a lifting sling and a hoist in order to secure the fuel injection pump (8). The weight of the fuel injection pump is 13

kg (29 lb).

Install a new gasket and install fuel injection pump (8) .

Ensure that the engine is in the top center position on No. 1 piston. Refer to Testing and Adjusting, "Finding Top Center

Position for No. 1 Piston".

Ensure that the mark on the front plate (3) and the mark on the fuel injection pump flange (4) are aligned.

Refer to Testing and Adjusting, "Fuel Injection Timing-Check" for more information on fuel injection pump timing.

Note: Use Tool (B) to install the bolts and washers that secure the fuel injection pump to the cylinder block.

Install the washers and bolts (9) that secure the fuel injection pump to the engine cylinder block.

Remove the sling from the fuel injection pump.

Connect oil line (6) to nipple (7) (not shown).

Tighten fitting (5) for oil line (6) .

Turbocharger - Remove

SMCS - 1052-011

Removal Procedure

NOTICE



NOTICE







Ver imagen


Loosen the hose clamp (1) on hose (2) .

Remove hose (2) from the turbocharger (3) .

Ver imagen

--------------------------------------------------------------------------------


Disconnect oil supply line (4) from the cylinder block.

Loosen two clamps (5) on hose (7) .

Slide hose (7) off fitting (8) onto oil return line (6) .

Ver imagen


Remove eight nuts (9) from the studs on the exhaust manifold.

Note: The four studs have two nuts for a total of eight nuts.

Remove turbocharger (3), oil supply line (4), and oil return line (6) as an unit.

Remove metal gasket (10) (not shown). Check the gasket for wear or damage. Replace the gasket, if necessary.

Turbocharger - Disassemble

SMCS - 1052-015

Disassembly Procedure

Start By:

Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".

--------------------------------------------------------------------------------

NOTICE



--------------------------------------------------------------------------------

--------------------------------------------------------------------------------

NOTICE







Place an index mark on all of the components. The marks will help to align the components during the assembly

procedure.

Ver imagen


Remove two bolts (1) from the oil return line. Remove bolt (2) from the oil supply line.

Remove oil return line (3) from the cartridge.

Remove oil supply line (4) from the cartridge.

Ver imagen


Remove gasket (5) from the cartridge.

Remove gasket (6) from the turbine housing.

Ver imagen


Remove the bolt and nut (7) from clamp (8). Remove clamp (8) that secures the turbine housing (9) to the cartridge

(10) .

Separate turbine housing (9) from the cartridge (10) .

Ver imagen

--------------------------------------------------------------------------------


Ver imagen


Remove snap ring (11) from compressor housing (12) .

Separate compressor housing (12) from the cartridge (10) .

Electric Starting Motor - Remove and Install

SMCS - 1453-010

Removal Procedure

Disconnect batteries before performance of any service work.

NOTICE



Put identification marks on the wires for the electric starting motor. Disconnect the wires from the terminals of the

electric starting motor.

Ver imagen


Remove two bolts (1) and the washers that secure electric starting motor (4) to the flywheel housing.

Remove electric starting motor (4) from the flywheel housing.

Note: Check the condition of the O-ring (2) (not shown). If the O-ring is damaged, use a new part for replacement .


--------------------------------------------------------------------------------

NOTICE



Ver imagen

--------------------------------------------------------------------------------


Note: Apply glycerine to the O-ring before installation of the starter.

Put the O-ring (2) (not shown) and electric starting motor (4) in position on the flywheel housing. Install two bolts (1)

that secure electric starting motor (4) to the flywheel housing.

Connect the wires to the terminals (3) of electric starting motor (4) .

Note: Tighten starter terminals (3) to a torque of 11 ± 1 N�m (8 ± 1 lb ft).

Alternator - Remove and Install

SMCS - 1405-010

Removal Procedure

Start By:

Remove the V-belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".

Disconnect batteries before performance of any service work.

NOTICE



Ver imagen


Ver imagen


Put identification marks on the wires for the alternator. Disconnect wires (1) from the alternator.

Remove bolt (6) and the washer from alternator (4) .

Remove bolt (7) and the washer from the cylinder block. Remove the belt tensioner (5) from the engine.

Remove bolt (2) and the washer from the alternator support. Remove bolt (3) (not shown) and the washer from the

alternator support.

Remove alternator (4) from the engine.


NOTICE



Ver imagen


Ver imagen


Put alternator (4) in position. Install bolt (2) and the washer into the alternator support. Install bolt (3) and the washer

into the alternator support. The bolts are installed finger tight into the alternator.

Note: If the alternator pulley (8) is removed, tighten the alternator pulley nut (9) to a torque of 147 ± 15 N�m (108.5

± 10.5 lb ft).

Place the belt tensioner (5) in position on the engine. Install bolt (7) and the washer into the cylinder block in order to

secure the belt tensioner.

Install bolt (6) and the washer into the alternator.

Reconnect wires (1) to the alternator.

End By: Install the V-belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".

V-Belts - Remove and Install

SMCS - 1357-010

Removal Procedure

NOTICE



Ver imagen


Loosen bolts (2) and (5) on alternator (4) .

Loosen bolt (3) on the alternator bracket (1) .

Push alternator (4) toward the engine and remove two V-belts (6) from the engine.


NOTICE



Ver imagen


Check the condition of V-belts (6). If the V-belts are worn or damaged, use new V-belts for replacement.

Note: Always replace the V-belts in sets of two.

Install two V-belts (6). Move alternator (4) away from the engine and tighten bolt (3) in order to apply tension to V-

belts (6).

Tighten bolts (2) and (5) on alternator (4).

Reference: Refer to the Specifications Module, "Belt Tension Chart" for the correct tension of the V-belts.

Engine Oil Pressure Switch - Remove and Install

SMCS - 1924

Removal Procedure

NOTICE



NOTICE







Note: Disconnect all electrical connections to the engine oil pressure switch before proceeding. Mark all connections for

later installation.

--------------------------------------------------------------------------------

Ver imagen


Remove engine oil pressure switch (1) from the cylinder block.


NOTICE



Ver imagen


Install engine oil pressure switch (1) in the cylinder block.

Tighten engine oil pressure switch (1) to a torque of 7 to 12 N�m (62 to 106 lb in).

Note: Reconnect all electrical connections to the engine oil pressure switch before you operate the engine.

Coolant Temperature Switch - Remove and Install

SMCS - 1906-010

Removal Procedure

Personal injury can result from hot coolant, steam and alkali.

At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine

contain hot coolant or steam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system

pressure cap is cool enough to touch with your bare hand.

Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.

Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

NOTICE









Drain the level of coolant from the radiator below the coolant temperature switch. Drain the coolant into a suitable

container for storage or disposal.

Disconnect the electrical connection to the coolant temperature switch.

Ver imagen


Remove coolant temperature switch (1) from the elbow.


NOTICE



Apply a thin coat of 5P-3413 Pipe Sealant to coolant temperature switch (1) .

Ver imagen


Install coolant temperature switch (1). Tighten coolant temperature switch (1) to a torque of 7 to 12 N�m (62 to 106 lb

in).

Reconnect the electrical connection to the coolant temperature switch.

Fill the cooling system with coolant to the correct level. Refer to the Operation and Maintenance Manual, "Refill

Capacities" topic for more information.

Bearing Clearance - Check

SMCS - 1203-535; 1219-535

Measurement ProcedureTable 1

Required Tools


A

198-9142 Plastic Gauge (Green)0.025 to 0.076 mm (0.001 to 0.003 inch)

1

198-9143 Plastic Gauge (Red)0.051 to 0.152 mm (0.002 to 0.006 inch)

1

198-9144 Plastic Gauge (Blue)0.102 to 0.229 mm (0.004 to 0.009 inch)

1

198-9145 Plastic Gauge (Yellow)0.230 to 0.510 mm (0.009 to 0.020 inch)

1

Note: Plastic gauge may not be necessary when the engine is in the chassis.

NOTICEKeep all parts clean from contaminants.


Note: Caterpillar does not recommend the checking of the actual bearing clearances particularly on smallengines. This is because of the possibility of obtaining inaccurate results and the possibility of damaging thebearing or the journal surfaces. Each Caterpillar engine bearing is quality checked for specific wall thickness.

Note: The measurements should be within specifications and the correct bearings should be used. If thecrankshaft journals and the bores for the block and the rods were measured during disassembly, no furtherchecks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is anacceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10mm (0.004 inch).

NOTICE

Lead wire, shim stock or a dial bore gauge can damage the bearingsurfaces.

The technician must be very careful to use Tooling (A) correctly. The following points must be remembered:

• Ensure that the backs of the bearings and the bores are clean and dry.

• Ensure that the bearing locking tabs are properly seated in the tab grooves.

• The crankshaft must be free of oil at the contact points of Tooling (A) .

1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.

Note: Do not allow Tooling (A) to extend over the edge of the bearing.

1. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impactwrench. Be careful not to dislodge the bearing when the cap is installed.

Note: Do not turn the crankshaft when Tooling (A) is installed.

1. Carefully remove the cap, but do not remove Tooling (A) . Measure the width of Tooling (A) whileTooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.

Illustration 1g01152855

Typical Example

1. Remove all of Tooling (A) before you install the bearing cap.

Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts ofTooling (A) are not the same width. Measure the major width in order to ensure that the parts are withinthe specification range. Refer to Specifications Manual, "Connecting Rod Bearing Journal" andSpecifications Manual, "Main Bearing Journal" for the correct clearances.

Crankshaft Gear - Remove and Install

SMCS - 1204-010-GE

Removal ProcedureTable 1

Required Tools


A

1P-0820 Hydraulic Puller 1

9U-6600 Hand Hydraulic Pump 1

0S-2398 Step Plate 1

3H-0468 Puller Plate 4

8B-7549 Puller Leg 2

1B-4207 Full Nut 2

8B-7551 Bearing Puller 1

Start By:

A. Remove the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove".

Use Tool (A) to remove crankshaft gear (1) from crankshaft (2) .

Note: Do not remove the gear by tapping with a hammer.

Note: Be careful not to damage the finished surfaces on the crankshaft.

Check the key on the crankshaft. If the key is damaged, use a new part for replacement.


NOTICE



Always wear protective gloves when handling parts that have been heated.

Use an oven and heat the crankshaft gear to a temperature of about 100 °C (212 °F). The crankshaft gear is heated in

order to ease installation of the crankshaft gear.

Wear eye protection in order to prevent possible personal injury while performing the following steps.


Install the crankshaft gear on the end of the crankshaft. Ensure that the key in the crankshaft is aligned with the

keyway in the gear. Tap lightly with a copper hammer until the crankshaft gear is seated. Ensure that the crankshaft

gear is seated against the shoulder on the crankshaft.

Note: Ensure that the timing marks of the crankshaft gear are on the front.

End By: Install the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Install

Crankshaft - Install

SMCS - 1202-012

Table 1

Required Tools


A 6V-9120 Socket (1) 1

B 8T-5096 Dial Indicator 1

NOTICE



Ver imagen


If the thrust washers were removed, then install a thrust washer (11) on the rear face of the crankshaft with the oil

groove toward the outside.

Place the upper halves of crankshaft main bearings (10) in the cylinder block. Place the lower halves of the crankshaft

main bearings in crankshaft main bearing caps. Install the bearings with the main bearing tabs in the correct position.

Lubricate the bearings with clean engine oil.

--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Lubricate the crankshaft journals with clean engine oil. Fasten a suitable lifting device and straps to crankshaft (9). The

weight of the crankshaft for the 3064 engine is 84 kg (185 lb). The weight of the crankshaft for the 3066 engine is 99

kg (220 lb). Position crankshaft (9) onto the upper halves of the crankshaft main bearings.


--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Install main bearings into main bearing caps (8). Install the bearings with the main bearing tabs in the correct

position. Lubricate the bearings with clean engine oil.

Place the thrust washers on the rear main bearing cap. Install the rear main bearing cap and two seals on the rear

journal of the cylinder block.

Install crankshaft main bearing caps (8). Put clean engine oil on the threads of the main bearing cap bolts. Install main

bearing cap bolts (7). Tighten the bolts evenly to a torque of 137 ± 5 N�m (101 ± 4 lb ft).

Note: Ensure that the crankshaft main bearing caps are installed in the original locations.

Cut off the excess length on the two seals on the rear journal of the cylinder block.

--------------------------------------------------------------------------------

Ver imagen


Check the end play of the crankshaft with Tool (B). The end play must be 0.100 to 0.264 mm (0.0039 to 0.0104 inch).

Refer to the Testing and Adjusting Module, "Basic Block" for more information on crankshaft end play.

Ver imagen


Apply a light coat of clean engine oil to the connecting rod bearing surfaces and to the connecting rod journals. Install

the connecting rods onto the connecting rod journals.

Install the lower half of the connecting bearings into the corresponding connecting rod caps and install connecting rod

caps (6) .

Note: Align the tabs on the back of the connecting rod bearings with the tab grooves in the connecting rod caps.

Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install".

--------------------------------------------------------------------------------

Ver imagen


Check for free crankshaft rotation by rotating the crankshaft for two complete revolutions. Use Tool (A) on crankshaft

pulley nut (4) in order to rotate the crankshaft.

Ver imagen


Install O-ring seal (3) on oil supply tube (2) .

Ver imagen


Position oil supply tube (2). Install two bolts (1) in order to secure the oil supply tube to the cylinder block.

End By:

Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".

Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".

Install the crankshaft rear seal, if the crankshaft wear sleeve was removed. Refer to Disassembly and Assembly,

"Crankshaft Rear Seal - Install".

Crankshaft - Remove

SMCS - 1202-011

Table 1

Required Tools


A 6V-9120 Socket (1) 1

( 1 ) Tool (A) is a 46 mm socket.

Start By:

Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove".

Remove the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remove".

Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".

Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

NOTICE



Ver imagen


Remove two bolts (1) from oil supply tube (2). Remove oil supply tube (2) from the engine cylinder block.

Ver imagen


Check condition of the O-ring seal (3) on the oil supply tube (2). If the O-ring is damaged, use a new part for

replacement.

Ver imagen


Install nut (4) and the washer onto the crankshaft. Use Tool (A) to turn the crankshaft.

Ver imagen


Remove nuts and bolts (5) that secure connecting rod caps (6) to the connecting rods. Remove connecting rod caps

(6) from the connecting rods.

Note: Be careful not to damage the bearings. Mark each connecting rod cap and the bearing in order to ensure

installation in the original location.

Carefully push the connecting rods and the pistons into the top of bores.

Ver imagen

--------------------------------------------------------------------------------


Remove bolts (7) that secure crankshaft main bearing caps (8) in position in the engine cylinder block. Remove

crankshaft main bearing caps (8) from the engine.

Note: Be careful not to damage the bearings. Mark each crankshaft main bearing cap and the bearing in order to

ensure installation in the original location.

--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Fasten a suitable lifting device and straps to crankshaft (9). Remove the crankshaft. The weight of the crankshaft for

the 3064 engine is 84 kg (185 lb). The weight of the crankshaft for the 3066 engine is 99 kg (220 lb).


--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Remove the upper halves of crankshaft main bearings (10). If necessary, remove thrust washers (11) .

--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


If necessary, use a hammer and a chisel to remove the wear sleeve (12) for the crankshaft rear seal. Hold the chisel at

right angles to the surface of the wear sleeve. Tap the wear sleeve in three places. You can remove the wear sleeve

once the tension is released.

Note: When you are removing the wear sleeve, take extreme care not to damage the crankshaft.

Note: Take extreme care not to damage the wear sleeve, if it is not necessary to remove the wear sleeve.

Crankshaft Main Bearings - Install

SMCS - 1203-012


NOTICE



Ver imagen


Install the upper halves of the crankshaft main bearings (1) in the main bearing housing of the cylinder block.

Note: Ensure that the main bearing tab fits in the tab groove of the bearing housing of the cylinder block.

Install thrust washers (2) into the cylinder block and the rear main cap.

Note: Install the thrust washers with the oil grooves toward the outside.

Ver imagen


Install the lower halves of the crankshaft main bearings (4) into the crankshaft main bearing caps (3) .

Note: Ensure that the main bearing tab fits in the tab groove of the crankshaft main bearing cap.

End By: Install the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Install".

Crankshaft Main Bearings - Remove

SMCS - 1203-011

Removal Procedure

Start By:

Remove the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove".

NOTICE



------------------------------------------------------------------------

Ver imagen


Remove the main bearings (1) (upper shell) from the main bearing housing of the engine cylinder block. The 3066

Engine has seven main bearings while the 3064 Engine has five main bearings.

Remove thrust washers (2) from the cylinder block and from the rear main cap.

Ver imagen


Remove the lower halves of the crankshaft main bearings (4) from the main bearing cap (3) .

Note: Be careful not to damage the bearings. Mark each main bearing in order to ensure installation in the original

location.

Note: Check the condition of the crankshaft main bearings. Refer to the Guideline For Reusable Parts, SEBF8009, "Main

and Connecting Rod Bearings" or refer to the Special Publication, SEBD0531, "Engine Bearings and Crankshafts".

Note: Refer to the Specifications Module, "Main Bearing Journal" for more information on crankshaft main bearings and

the main bearing journals.

Connecting Rod Bearings - Install

SMCS - 1219-012

Table 1

Required Tools


A 6V-9120 Socket (1) 1

NOTICE



NOTICE

When the connecting rod caps are installed, ensure that the identification marks are aligned.

Note: Refer to Specifications, "Connecting Rod Bearing Journal" for information on bearing clearance checks.

--------------------------------------------------------------------------------

Ver imagen


Clean the bearing surface of connecting rod (5) and connecting rod cap (2). Ensure that the number on connecting rod

cap (2) matches the number on connecting rod (5) .

Clean upper connecting rod bearing (4) and lubricate the bearing face with clean engine oil.

Clean lower connecting rod bearing (3) and lubricate the bearing face with clean engine oil.

Note: Align the tabs on the back of the connecting rod bearings with the tab grooves in the connecting rod.

Use Tool (A) to rotate the crankshaft until two of the connecting rod journals are at the bottom center. Install upper

connecting rod bearing (4) in connecting rod (5) .

Pull connecting rod (5) into position against the crankshaft.

Install lower connecting rod bearing (3) in connecting rod cap (2) .

Put clean engine oil on the connecting rod bolts.

Ver imagen


Install two nuts (1) on connecting rod cap (2). Tighten the connecting rod nuts to a torque of 103 ± 5 N�m (76 ± 4 lb

ft).

Repeat Steps 1 through 8 for the installation of the remaining connecting rod bearings.

End By:

Install the oil supply tube. Refer to Disassembly and Assembly, "Crankshaft - Install".


Connecting Rod Bearings - Remove

SMCS - 1219-011

Start By:


Remove the oil supply tube. Refer to Disassembly and Assembly, "Crankshaft - Remove".

Table 1

Required Tools


A 6V-9120 Socket (1) 1

NOTICE



Ver imagen


Use Tool (A) to rotate the crankshaft until two of the pistons are at the bottom center. Remove connecting rod nuts (1)

from the connecting rod. Remove connecting rod cap (2) for one connecting rod.

Remove the lower half of the connecting rod bearing from connecting rod cap (2) .

Remove the upper half of the connecting rod bearing from the connecting rod. Push the connecting rod away from the

crankshaft, if necessary.

Note: Use tape or rubber tubing on connecting rod bolts to protect the crankshaft journals. The sharp edges of the

connecting rod bolts could damage the crankshaft journals.

Note: Ensure that identification marks are on the connecting rod, the connecting rod cap and the connecting rod

bearing. The identification marks must be on the bearing tab side for installation purposes.

Repeat Steps 1 through 3 for the remaining connecting rod bearings.

Exhaust Manifold - Remove and Install

SMCS - 1059-010

Removal Procedure

Start By:

Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".

NOTICE



Ver imagen


Remove the nuts (1) and washers that secure the exhaust manifold to the cylinder head assembly. The 3066 Engine

has twelve nuts and washers while the 3064 Engine has eight nuts and washers.

Remove exhaust manifold (2) from the cylinder head assembly.

Remove exhaust manifold gasket (3) that is located between exhaust manifold (2) and the cylinder head assembly.

Note: The 3066 Engine has two exhaust manifold gaskets, while the 3064 Engine has one exhaust manifold gasket.


NOTICE



Ver imagen


Install exhaust manifold gasket (3) between exhaust manifold (2) and the cylinder head assembly.

Note: The 3066 Engine has two exhaust manifold gaskets, while the 3064 Engine has one exhaust manifold gasket.

Place exhaust manifold (2) in position on the cylinder head.

Install the nuts (1) and the washers that secure the exhaust manifold to the cylinder head assembly. The 3066 Engine

has twelve nuts and washers while the 3064 Engine has eight nuts and washers.

Tighten exhaust manifold nuts (1) to a torque of 18 ± 4 N�m (13 ± 3 lb ft).

End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".

Air Inlet Heater - Remove and Install

SMCS - 1090-010

Removal Procedure

NOTICE



Ver imagen


Loosen hose clamp (1) that secures air inlet hose (2) to air inlet elbow (4) .

Disconnect air inlet hose (2) from air inlet elbow (4) .

Remove four bolts (3) and washers that secure the following items to the air inlet manifold: air inlet elbow (4), gasket

(5), air inlet heater (6) and gasket (7) .

Ver imagen


Remove the following items from the air inlet manifold: air inlet elbow (4), gasket (5), air inlet heater (6) and gasket

(7) .

Note: Check the condition of the gaskets that are used between the elbow and the air inlet heater. Check the gaskets

between the air inlet heater and the air inlet manifold. If the gaskets are damaged in any way, replace the gaskets.


NOTICE



Ver imagen


Note: Check condition of the gaskets for the air inlet elbow and the air inlet heater. If the gaskets are damaged, use a

new part for replacement. The wire mesh gasket (7) is installed between the air inlet manifold and the air inlet heater.

Place the following items in position on the air inlet manifold: gasket (7), the air inlet heater (6), gasket (5) and the air

inlet elbow (4) .

--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Install four bolts (3) that secure the following items to the air inlet manifold: gasket (7), the air inlet heater (6), gasket

(5) and the air inlet elbow (4)

Tighten bolts (3) to a torque of 28 ± 7 N�m (21 ± 5 lb ft).

Connect air inlet hose (2) to air inlet elbow (4) .

Tighten hose clamp (1) that secures the air inlet hose to the air inlet elbow.

Inlet Manifold - Remove

SMCS - 1058-011

Removal Procedure

Start By:

Remove fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install".

Remove fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".

Remove the air inlet heater. Refer to Disassembly and Assembly, "Air Inlet Heater - Remove and Install".

NOTICE



Ver imagen


Loosen clamp (1) on hose assembly (3) .

Remove two bolts (2) that secure the hose assembly to the engine.

Slide the hose assembly (3) from the retaining ring (4) .

Remove the bolts and washers (5) that secure the air inlet manifold to the cylinder heads. The 3066 Engine has eleven

bolts and washers while the 3064 Engine has eight bolts and washers.

Note: One bolt has previously been removed in order to remove the fuel return line.

Remove one bolt (6) and the washer that secures the lifting bracket (7) to the cylinder block.

Remove inlet manifold (8) and remove the lifting bracket (7) .

Remove gaskets (9) (not shown). Check the gaskets for wear or damage. Replace the gaskets, if the gasket is worn or

damaged.

Note: The 3064 Engine has one gasket, while the 3066 Engine has two gaskets

Inlet Manifold - Remove

SMCS - 1058-011

Removal Procedure

Start By:

Remove fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install".

Remove fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".

Remove the air inlet heater. Refer to Disassembly and Assembly, "Air Inlet Heater - Remove and Install".

NOTICE



Ver imagen


Loosen clamp (1) on hose assembly (3) .

Remove two bolts (2) that secure the hose assembly to the engine.

Slide the hose assembly (3) from the retaining ring (4) .

Remove the bolts and washers (5) that secure the air inlet manifold to the cylinder heads. The 3066 Engine has eleven

bolts and washers while the 3064 Engine has eight bolts and washers.

Note: One bolt has previously been removed in order to remove the fuel return line.

Remove one bolt (6) and the washer that secures the lifting bracket (7) to the cylinder block.

Remove inlet manifold (8) and remove the lifting bracket (7) .

Remove gaskets (9) (not shown). Check the gaskets for wear or damage. Replace the gaskets, if the gasket is worn or

damaged.

Note: The 3064 Engine has one gasket, while the 3066 Engine has two gaskets.

Inlet Manifold - Install

SMCS - 1058-012


NOTICE



Ver imagen


Note: Check condition of the inlet manifold gasket. If the gasket is damaged, use a new part for replacement.

Place the following items in position on the engine: gasket (9) (not shown), air inlet manifold (8) and lifting bracket (7)

.

Install the washer and one bolt (6) onto lifting bracket (7) .

Install the washers and bolts (5) that secure the inlet manifold to the cylinder head. The 3066 Engine has eleven

washers and bolts while the 3064 Engine has eight washers and bolts.

Slide the hose assembly (3) through the retaining ring (4) .

Install washers and two bolts (2) that secure the hose assembly to the engine.

Tighten the hose clamps (1) on the hose assembly (3) .

End By:

Install the air inlet heater. Refer to Disassembly and Assembly, "Air Inlet Heater - Remove and Install".

Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".

Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install".

Inlet and Exhaust Valve Springs - Remove and Install

SMCS - 1108-010

Table 1

Required Tools


A 5S-1322 Valve Keeper Installer 1

B 9U-6145 Air Connector (1) 1

C 9U-6144 Adapter 1

7F-4292 Valve Spring Compressor 1

6V-5223 Bolt 1

8T-4121 Washer 1

6V-5218 Bolt 1

D 8S-2263 Spring Tester 1

Start By:

Remove the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod -

Remove".

Remove the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles - Remove".

NOTICE







NOTICE



Note: The following procedure is for the removal of the inlet valve springs and the exhaust valve springs without

removing the cylinder head.

Ver imagen


Install Tool (B). Attach an air hose to Tool (B) in order to force air pressure into the cylinder. This will hold the valves in

position while the inlet and exhaust valve springs are removed and installed.

Note: Maintain air pressure in each cylinder until both of the valve springs are removed and installed.

Use Tool (C) to compress the valve spring (1) .

Note: Compress the valve spring evenly in order to avoid damage to the valve stem.

Use the magnetic end of Tool (A) to remove cap (2) (not shown) and valve keepers (3) (not shown) from the inlet and

exhaust valves.

Slowly release the tension on Tool (C) .

Remove the retainer and spring (1) from the cylinder head assembly.

Note: Repeat Steps 1 through 5 in order to remove the remaining valve spring of the same cylinder.

Ver imagen


Check the valve spring force with Tool (D). Refer to Specifications, "Valve Mechanism" for information on the valve

springs.

Install the valve springs. Refer to the following installation procedure.

Perform Steps 1 through 7 for the removal and installation of the remaining inlet and exhaust valve springs.


Table 2

Required Tools


A 5S-1322 Valve Keeper Installer 1

B 9U-6145 Air Connector 1

C

9U-6144 Adapter 1

7F-4292 Valve Spring Compressor 1

6V-5223 Bolt 1

8T-4121 Washer 1

6V-5218 Bolt 1

NOTICE



Ver imagen


Keep an air hose connected to Tool (B) in order to force air pressure into the cylinder. This will hold the valves in

position while the inlet and exhaust valve springs are removed and installed.

Position valve spring (1) and the retainer over the valve stem.

Use Tool (C) to compress valve spring (1) .

Note: Compress the valve spring evenly in order to avoid damage to the valve stem.

Place the valve keepers (3) (not shown) in position on the inlet and exhaust valves.

Note: Tool (A) may be used to install valve keepers.

The valve keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve

keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the

valve keepers and valve springs during the installation of the valves.

Install cap (2) (not shown) on the inlet and exhaust valves and slowly release the tension on Tool (C). Tap the top of

valve with a soft faced hammer in order to ensure that the valve keepers are properly installed.

Note: Repeat Steps 1 through 5 in order to install the remaining valve spring of the same cylinder.

Remove air hose and Tool (B) .

Perform Steps 1 through 6 for the installation of the remaining inlet and exhaust valve springs.

End By:

Install the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles - Install".

Install the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod -

Install".

Inlet and Exhaust Valves - Remove and Install

SMCS - 1105-010

Table 1

Required Tools


A 8S-6691 Cylinder Head Repair Stand 1

B 1P-3527 Valve Spring Compressor 1

C 5S-1322 Valve Keeper Installer 1

D 8S-2263 Spring Tester 1

Start By:

Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove".

NOTICE



Ver imagen


Ver imagen


Support cylinder head assembly (1) on Tool (A) .

Use tool (B) to compress valve spring (2) .

Use the magnetic end of tool (C) (not shown) to remove cap (4) and valve keepers (3). Slowly release the pressure on

tool (B) and remove tool (B) .

Remove retainer (5) and remove spring (2) .

Ver imagen


Check the valve spring force with Tool (D). Refer to Specifications, "Valve Mechanism" for information on the valve

springs.

Remove exhaust valve (6) and inlet valve (7) through the bottom of the cylinder head assembly (1). Put identification

marks on the valves for installation purposes.

Perform the following procedure, if the valves need to be refaced:

Set the machine that will reface the valves at an angle of 30 degrees.

The valve has a stellite facing. This facing will be gone, if the margin of the valve exceeds the service limit.

Replace the valve, if the margin exceeds the service limit after refacing.

Grind the valve seat in order to reface the valve seat, if necessary.

Replace the valve seat, if the width exceeds the repair limit as a result of wear or grinding.

Perform Steps 2 through 7 for the remaining inlet valves and exhaust valves in the cylinder head assembly.

Table 2

Required Tools


A 8S-6691 Cylinder Head Repair Stand 1

B 1P-3527 Valve Spring Compressor 1

C 5S-1322 Valve Keeper Installer 1

NOTICE



Ver imagen


Ver imagen


Support cylinder head assembly on Tool (A). Lubricate the inlet and exhaust valves with clean engine oil. Install the

inlet and exhaust valves through the bottom of the cylinder head.

Note: Ensure that the inlet and exhaust valves are installed in the original location in the cylinder head.

Install spring (2) and retainer (5) .

Use Tool (B) to compress spring (2). Install valve keepers (3) and cap (4) on the valve stem with Tool (C) .

The valve keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve

keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the

valve keepers and valve springs during the installation of the valves.

Carefully remove Tool (B). Tap the top of exhaust valve (6) or inlet valve (7) with a soft faced hammer in order to

ensure that the valve keepers are properly installed.

Repeat Steps 2 through 4 for the installation of the remaining inlet and exhaust valves.

End By: Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

Inlet and Exhaust Valve Guides - Remove and Install

SMCS - 1104-010

Removal Procedure

Table 1

Required Tools


A 4C-6366 Valve Guide Driver 1

Start By:

Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and

Install".

NOTICE



Ver imagen


Use Tool (A) to remove the inlet and exhaust valve guides (2) from the cylinder head (1) .

Repeat Step 1 in order to remove the remaining inlet and exhaust valve guides.


Table 2

Required Tools


A 4C-6366 Valve Guide Driver 1

B 4C-6370 Valve Guide Collar 1

NOTICE



Ver imagen


Put clean engine oil on the outside diameter of the valve guide. Install valve guide (2) with Tool (A) and Tool (B). The

valve guide is driven from the top of the cylinder head.

Ver imagen


Typical Example

The counterbore in Tool (B) installs the valve guide to the correct height. Height (X) from the top of the valve guide to

the cylinder head must be 17.00 ± 0.30 mm (0.699 ± 0.012 inch). For more information on the inlet and exhaust

valve guides, refer to Specifications, "Valve Mechanism".

Note: In order to help prevent damage to the valve guides, Tool (B) must be used during installation.

Ver imagen


View (X) shows that the contact between the valve and the valve seat is good. View (Y) shows that the contact

between the valve and the valve seat is poor.

Perform the following procedure after the valve guide has been inspected or the valve guide has been replaced:

Check the valve face.

Press the valve that is coated with red lead against the seat without rotating the valve.

After refacing or replacement of the valve or valve seat, be sure to lap the valve into the valve seat.

Repeat Steps 1 through 3 for the remaining inlet and exhaust valve guides.

End By: Install the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove

and Install".

Inlet and Exhaust Valve Seat Inserts - Remove and Install

SMCS - 1103-010

Table 1

Required Tools


A

166-7441 Valve Seat Extractor Tool Group 1

6V-4194 Valve Seat Extractor (1) 1

6V-4196 Valve Seat Extractor (1) 1

( 1 ) This is a component of the Valve Seat Extractor Tool Group.

Start By:


Install".

NOTICE



Ver imagen


A 3066 cylinder head is shown.

Use the valve seat grinder of Tool (A) in order to notch the valve seat.

Ver imagen



Use the valve seat extractor of Tool (A) to remove the inlet and exhaust valve seats.

Clean the valve seat in the cylinder head. Remove any rough areas from the valve seat in the cylinder head.

Repeat Steps 1 through 3 for the remaining inlet valve seat inserts and exhaust valve seat inserts.


Table 2

Required Tools


B 9U-6176 Valve Seat Driver 1

C 9U-6177 Valve Seat Driver Adapter 1

NOTICE



Ver imagen



Lower the temperature of the new inlet valve seat inserts. Use Tool (B) to install the new inlet valve seat insert (1) in

the cylinder head.

Note: The temperature of the valve seat insert is lowered in order to ease the installation of the valve seat insert.

Ver imagen


Lower the temperature of the new exhaust valve seat inserts. Use Tool (B) and (C) to install the new exhaust valve

seat insert (2) in the cylinder head.

Note: The temperature of the valve seat insert is lowered in order to ease the installation of the valve seat insert.

Repeat Step 1 and 2 for the remaining inlet valve seat inserts and exhaust valve seat inserts.


and Install".

Inlet and Exhaust Valve Seals - Remove and Install

SMCS - 1104-010-SA

Table 1

Required Tools


A 5P-1720 Seal Pick 1

Start By:


Install".

NOTICE



Ver imagen


Ver imagen

--------------------------------------------------------------------------------


Use Tool (A) to remove valve stem seal (1) from the inlet and exhaust valve guide.

Illustration 1 shows the removal of the valve stem seal, when the valve guide (2) is removed from cylinder head (4) .

Illustration 2 shows the removal of the valve stem seal, while the valve guide (2) is installed in cylinder head (4) .


Table 2 Required Tools



Table 2

Required Tools



NOTICE



Note: Do not apply any oil or sealant to the mating surface of the valve seal that comes into contact with the valve

guide. When the valve seal is installed, coat the surface of the valve stem with engine oil in order to ensure initial

lubrication of the seal lip.

--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Ver imagen

--------------------------------------------------------------------------------


Place the new valve stem seal in position on the valve guide.

Use Tool (A) to assist in installing the new valve stem seal.

Illustration 3 shows the installation of the valve stem seal, when the valve guide (2) is removed from the cylinder head

(4) .

Illustration 4 shows the installation of the valve stem seal, while the valve guide (2) is installed in the cylinder head (4)

.

Note: After the valve stem seal is installed on the valve guide, ensure that the seal is properly installed in the groove

of the valve guide.


and Install".

Cylinder Head - RemoveSMCS - 1100-011

Removal Procedure

Table 1

Required Tools


A 138-7573 Link Bracket 2

Start By:

Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".

Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".

Remove the inlet manifold. Refer to Disassembly and Assembly, "Inlet Manifold - Remove".

Remove the water temperature regulator. Refer to Disassembly and Assembly, "Water Temperature Regulator- Remove

and Install".

NOTICE



NOTICE







Note: The 3064 Engine has one cylinder head, while the 3066 Engine has two cylinder heads.

Ver imagen


Torque sequence for the cylinder head bolts ( 3066 Engine)

Ver imagen



Ver imagen


Gradually remove the cylinder head bolts (1) from the cylinder head. The 3066 Engine has thirteen cylinder head bolts

while the 3064 Engine has seventeen cylinder head bolts. Remove the bolts in reverse order of the torque sequence.

Note: Do not use a pry bar to separate the cylinder head from the engine block.

Ver imagen


Typical example

Install Tooling (A), chains and a suitable lifting device to cylinder head (2) .

Remove the cylinder head (2) from the cylinder block. The weight of the cylinder head assembly for the 3066 Engine is

32 kg (70 lb). The weight of the cylinder head assembly for the 3064 Engine is 45 kg (100 lb).

Note: Place the cylinder head on a surface that will not damage the face of the cylinder head.

Ver imagen


Note: When the gasket is removed from the cylinder block, be careful not to damage the mounting face of the cylinder

block.

Remove the cylinder head gasket (3) from the cylinder block.

Repeat Step 1 through Step 4 for the other cylinder head ( 3066 Engine).

Cylinder Head - Install

SMCS - 1100-012


Table 1

Required Tools



NOTICE



Note: The 3064 Engine has one cylinder head, while the 3066 Engine has two cylinder heads.

Ver imagen

--------------------------------------------------------------------------------


Clean the surfaces of the cylinder head and the cylinder block that are in contact with each other. Ensure that the

surfaces are clean and dry. Install a new, dry cylinder head gasket (3) on the cylinder block.

Note: Do not use any sealant or gasket adhesive on the cylinder head gasket .

--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Typical example

Install Tooling (A) , chains, and a suitable lifting device to the cylinder head.

Install the cylinder head in position on the cylinder block. The weight of the cylinder head assembly for the 3066

Engine is approximately 32 kg (70 lb). The weight of the cylinder head assembly for the 3064 Engine is approximately

45 kg (100 lb).

Remove Tooling (A) .

--------------------------------------------------------------------------------

Ver imagen

--------------------------------------------------------------------------------


Put clean engine oil on the threads of the cylinder head bolts. Install thirteen cylinder head bolts (1) into cylinder head

(2) ( 3066 Engine). Install seventeen cylinder head bolts (1) into cylinder head (2) ( 3064 Engine).

Ver imagen



Ver imagen



Tighten the cylinder head bolts in the appropriate numerical sequence to torque of118 ± 5 N�m (87 ± 4 lb ft).

Repeat step 9 through step 6 for the other cylinder head ( 3066 Engine).

After assembly, run the engine to operating temperature.

Stop the engine and allow the engine to cool.

Tighten the cylinder head bolts again in the appropriate numerical sequence to a torque of 118 ± 5 N�m (87 ± 4 lb ft).

End By:

Install the water temperature regulator. Refer to Disassembly and Assembly, "Water Temperature Regulator - Remove

and Install".

Install the inlet manifold. Refer to Disassembly and Assembly, "Inlet Manifold - Install".

Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".

Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".

Pistons and Connecting Rods - Install

SMCS - 1225-012

Installation ProcedureTable 1

Required Tools


A 1U-6684 Piston Ring Compressor 1

B 6V-9120 Socket (1) 1

( 1 ) Tool (B) is a 46 mm socket.

NOTICE



Note: Refer to Disassembly and Assembly, "Connecting Rod Bearings - Install" for the inspection procedure of the

connecting rod bearings and the crankshaft connecting rod journals.

Put clean engine oil on the crankshaft journals and on the inside of the cylinder bores. Put clean engine oil on the

piston rings and the connecting rod bearings.

Use Tooling (B) to rotate the crankshaft until the bearing journals are at the bottom center. The bearing journals that

are at the bottom center are for the piston installation.

Ver imagen


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

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

(C) End gap for oil control ring

(X) Camshaft side of engine block

(Y) Side of engine with combustion chamber

Move the piston rings on the pistons until the ring openings are separated by approximately 120 degrees.

Ver imagen


Put the piston in the cylinder liner. Align the identification marks on the top of the piston to the camshaft side of the

cylinder block. Put Tooling (A) in position on the cylinder block and compress the piston rings.

Align the piston and connecting rod with the crankshaft. Use a soft faced hammer to tap the piston into the cylinder

bore until Tool (A) comes off the piston.

Note: Ensure that Tooling (A) is installed correctly in order to allow the piston and the connecting rod to easily slip into

the cylinder block.

Note: Use tape or rubber tubing on connecting rod bolts to protect the crankshaft journals. The sharp edges of the

connecting rod bolts could damage the surface of the connecting rod journal.

Before the connecting rod contacts the crankshaft, install the rod bearing upper half in the respective connecting rod.

Make sure that the bearing tab properly engages with the slot in the connecting rod.

Place clean engine oil on the surface of the upper half of the connecting rod bearing. Guide the connecting rod into

position on the crankshaft.

Install the lower half of the connecting rod bearing in the correspondingly marked connecting rod cap. Put clean engine

oil on the surface of the lower half of the connecting rod bearing and on the connecting rod bolts.

--------------------------------------------------------------------------------

Ver imagen

Install connecting rod cap (2) and connecting rod nuts (1) . Tighten both of the nuts to a torque of 103 ± 5 N�m (76 ±

4 lb ft).

Repeat Steps 1 through 9 for the remainder of the piston and connecting rods.

End By:

Install the oil supply tube. Refer to Disassembly and Assembly, "Crankshaft - Install".


Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

Pistons and Connecting Rods - Assemble

SMCS - 1225-016

Assembly ProcedureTable 1

Required Tools


A 1P-1857 Retaining Ring Pliers 1

B 1U-6683 Ring Expander 1

C 1P-0510 Driver Group 1



Ver imagen


Piston and Connecting Rod Assembly

Ver imagen


If necessary, use Tool (C) and a suitable press to install piston pin bearing (8) into connecting rod (3) .

Note: Align the oil holes in the piston pin bearing and the connecting rod when the piston pin bearing is installed.

Note: If the clearance between piston pin (2) and piston pin bearing (8) is over 0.0001 mm (0.0008 inch), replace the

piston pin or the piston pin bearing with a new part.

Clean the piston ring grooves of the used pistons with an acceptable tool or 4C-8648 Cleaner. Clean excess carbon

from piston (4) .

Ver imagen


Install connecting rod (3) into piston (4). Ensure that the identification marks on the connecting rod are on the same

side as the marks on the top of the piston.

Lubricate piston pin (2) with clean engine oil and install piston pin (2) through the piston and connecting rod. Use Tool

(A) to install two retaining rings (1) on the end of piston pin (2). Locate the ends of retaining rings (1) toward the

bottom of piston (4) .

Note: Ensure that the piston pin turns freely in the piston pin bearing.

Ver imagen


Ver imagen


Ver imagen


(X) Ends of spring for the oil control piston ring

(Y) Oil ring end gap

Install the oil control piston ring on the piston with Tool (B) .

Note: The ends of spring (9) of the oil control piston ring should be assembled 180 degrees from the oil ring end gap.

Ver imagen


Note: Each piston ring (5) should be installed with the side marked "R or T" (11) toward the top of the piston.

Use Tool (B) to install the intermediate piston ring onto the piston.

Use Tool (B) to install the top piston ring onto the piston.

Note: The gaps in the intermediate piston ring and the top piston ring should be separated by 120 degrees.

Note: Check the clearance of the piston ring end gap for all the rings. Refer to Specifications, "Piston and Rings".

End By: Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods -

Install

Pistons and Connecting Rods - Disassemble

SMCS - 1225-015

Disassembly ProcedureTable 1

Required Tools


A 1P-1857 Retaining Ring Pliers 1

B 1U-6683 Ring Expander 1

C 1P-0510 Driver Group 1

Start By:

Remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods -

Remove".

NOTICE



Ver imagen


Use Tool (A) to remove two retaining rings (1) from piston (4) .

Remove piston pin (2) and connecting rod (3) from piston (4) .

Note: Check the condition of the following parts: retaining rings (1), piston pin (2) and piston (4). If these items are

worn or damaged, use new parts for replacement.

Ver imagen


Ver imagen


Ver imagen


Remove piston rings (5) from pistons (4) with tool (B) .

Note: Check the condition of the piston rings. If the piston rings are worn or damaged, use new parts for replacement.

Ver imagen


Remove connecting rod bearing (6) and two bolts (7) from connecting rod (3) .

Note: Check the condition of the following items: connecting rod bearing (6), connecting rod bolt (7), piston pin

bushing (8) and connecting rod (3). If the items are worn or damaged, use new parts for replacement.

Ver imagen


Use Tool (C) and a suitable press to remove piston pin bushing (8) from connecting rod (3) .

Ver imagen


Piston and Connecting Rod Assembly

(1) Retaining rings

(2) Piston pin

(3) Connecting rod

(4) Piston

(5) Piston rings

(6) Connecting rod bearing

(7) Connecting rod bolts

(8) Piston pin bushing

Cylinder Liner - Install

SMCS - 1216-012


Required Tools


A

9U-6142 Puller Plate 1

1P-2392 Puller Plate 1

6V-2183 Forcing Screw 1

1P-0820 Hydraulic Puller 1

1D-5119 Nut 1

5H-1504 Hard Washer 1




(1) Forcing Screw

(2) Hydraulic Puller

(3) Cylinder liner

(4) Puller Plate

(5) Nut

(6) Cylinder block

(7) Puller Plate

Use Tool (A) to install cylinder liner (3) .

Press cylinder liner (3) into the cylinder block (6) within 0.3 to 0.5 mm (0.012 to 0.020 inch) of the top of the cylinder

block. Then make the cylinder liner (3) flush with the top of the cylinder block.

Bore the cylinder liner and hone the cylinder liner to 102.017 ± 0.017 mm (4.02 ± 0.0007 inch).

Refinish the rest of the cylinder liners to the same size.

Note: For more information on the assembly specifications for the cylinder liner, refer to Specifications Module,

"Cylinder block".

End By:

Install the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Install".

Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Piston and Connecting Rods - Install".

Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

Cylinder Liner - Remove

SMCS - 1216-011

Removal Procedure

Start By:

Remove the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove".

Remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods -

Remove".

NOTICE



Wear eye protection in order to prevent possible personal injury while performing the following steps.

Note: Before you proceed with the removal of the cylinder liner, check the cylinder liners for the following items: wear,

damage and rusting.

Note: If the liner is found in good condition and the liner wear is less than the repair limit, then perform the following

tasks: replace the piston rings, and ream the "ridge" at the top of the liner. Hone the bore, if necessary.

Ver imagen

Use the following procedure in order to remove the cylinder liners from the engine cylinder block.

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.

Bore the liner until the thickness of the liner is 0.50 mm (0.020 inch).

Ver imagen


Ver imagen


Break the cylinder liner in order to remove the remainder of the cylinder liner. Be careful not to damage the cylinder

block.

Engine Oil Pan - Remove and Install

SMCS - 1302-010

Removal Procedure------ WARNING! ------

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.



NOTICECare must be taken to ensure that fluids are contained duringperformance of inspection, maintenance, testing, adjusting and repairof the product. Be prepared to collect the fluid with suitable containersbefore opening any compartment or disassembling any componentcontaining fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and ShopProducts Guide" for tools and supplies suitable to collect and containfluids on Caterpillar products.


Remove oil pan drain plug (1). Drain the engine oil into a suitable container.

1. Install oil pan drain plug (1). Tighten the oil pan drain plug to a torque of 39 ± 5 N·m (29 ± 4 lb ft).

1. Remove bolts (2) and washers that secure the oil pan to the engine cylinder block. The 3066 Engine has38 bolts and washers while the 3064 Engine has 30 bolts and washers. Remove engine oil pan (4) andgasket (3) from the engine cylinder block.

Note: A liquid gasket may be factory installed in place of an oil pan gasket.

Installation procedure



Clean engine oil pan (4) .

Note: Ensure that the engine oil pan and all of the mating surfaces are free of oil and gasket material.

1. Install gasket (3), engine oil pan (4), bolts (2) and the washers. Tighten the bolts to a torque of 28 ± 7N·m (21 ± 5 lb ft).

Note: 8T-9022 Silicone Gasket may be used instead of gasket (3). Both contact surfaces must becompletely free of oil. Apply gasket material on the cylinder block on the inside of the bolt hole patternin a continuous bead in order to help prevent an oil leak.

1. Fill the crankcase with engine oil to the correct level. Refer to the proper Operation and MaintenanceManual for the correct engine oil and the correct filling procedure.

Camshaft Bearings - Install

SMCS - 1211-012


Required Tools


A 8S-2241 Camshaft Bearing Tool Group 1

8H-0684 Ratchet Wrench 1

NOTICE



Ver imagen


Ver imagen


Use Tool (A) in order to install the camshaft bearings into the cylinder block. Ensure that the oil hole of the camshaft

bearings are in alignment with the oil ports in the engine block.

Note: Refer to the instructions of the 8S-2241 Camshaft Bearing Tool Group for the proper procedure.

Ver imagen


Install plug (1) into the cylinder block. Use 8T-9013 Silicone Sealant .

End By:

Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".

Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".

Camshaft Bearings - Remove

SMCS - 1211-011


Required Tools


A 8S-2241 Camshaft Bearing Tool Group 1

8H-0684 Ratchet Wrench 1

Start By:

Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".

Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".

NOTICE



Ver imagen


Remove plug (1) from the cylinder block.

Ver imagen


Ver imagen


Use Tool (A) in order to remove the camshaft bearings from the cylinder block.

Note: Refer to the instructions of the 8S-2241 Camshaft Bearing Tool Group for the proper procedure.

Camshaft Gear - Remove and Install

SMCS - 1210-010-GE

Removal Procedure

Table 1

Required Tools


A 1P-2321 Combination Puller 1

9S-9153 Puller Jaws 3

Start By:


--------------------------------------------------------------------------------

NOTICE



Ver imagen


Use tool (A) to remove camshaft gear (1) from camshaft (3) .

Remove thrust plate (2) from camshaft (3) .

Note: It is not necessary to remove the camshaft gear unless the gear (1) or the thrust plate (2) is damaged.

Note: Check the slot in the camshaft for the woodruff key for wear or damage.

Note: Check the thrust plate (2) for wear or damage.


NOTICE



Ver imagen


Note: During installation, ensure that camshaft (3) is clean and lubricate all of the components with clean engine oil.

Install the thrust plate (2) on the camshaft (3) .


Heat camshaft gear (1) in an oven to a temperature of about 100 °C (212 °F) and install camshaft gear (1) onto

camshaft (3) .

Note: The camshaft gear is heated in order to ease the installation of the camshaft gear.

Note: Ensure that the timing marks of the camshaft gear are on the front.

End By: Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".

Camshaft - Install

SMCS - 1210-012


Note: In this installation procedure, the engine needs to remain in the upside-down position in order to keep the lifters

in position while the camshaft is installed.

NOTICE



Note: During installation, ensure that the camshaft is clean and lubricate all of the components with clean engine oil.

Install the valve lifters. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".

Ver imagen


Note: During installation, ensure that the marks on the timing gears are in alignment. Align fuel injection drive gear

(A) with the "33" mark with the "3" mark on idler gear (B). Make an alignment of the "2" mark on camshaft gear (C)

with the "22" mark on idler gear (B). Align the "1" mark on crankshaft gear (D) with the "11" mark on idler gear (B).

The No. 1 cylinder is at the top center position when these marks are in alignment.

Carefully install the camshaft assembly into the original location in the cylinder block.

Note: Caution must be used when the camshaft is installed in order to not damage the camshaft lobe or the camshaft

bearings.

Ver imagen


Position camshaft gear (2) so that the gear's slots align from the top to the bottom. Install two bolts (1) and the

washers that hold thrust plate (3). Tighten bolts (1) to a torque of 11 ± 2 N�m (8 ± 1 lb ft).

End By:

Install the oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

Install the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod -

Install".

Install the timing gear cover. Refer to Disassembly and Assembly, "Housing (Front) - Install".

Camshaft - RemoveSMCS - 1210-011

Removal ProcedureStart By:

Remove the front housing. Refer to Disassembly and Assembly, " Housing (Front) - Remove".

Remove the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod -

Remove".

Remove the oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

Note: In this removal procedure, the engine needs to be placed in the upside-down position. This will allow the lifters

to remain in position after the camshaft is removed.

NOTICE



NOTICE







Ver imagen


Note: Ensure that the marks on the timing gears are in alignment. Align fuel injection drive gear (A) with the "33"

mark with the "3" mark on idler gear (B). Make an alignment of the "2" mark on camshaft gear (C) with the "22" mark

on idler gear (B). Align the "1" mark on crankshaft gear (D) with the "11" mark on idler gear (B). The No. 1 cylinder is

at the top center position when these marks are in alignment.

Rotate the engine at 180 degrees in order to place the engine in the upside-down position. This will ease the removal

of the camshaft.

Ver imagen


NOTICE

Do not damage the lobes or the bearings when the camshaft is removed or installed.

Position camshaft gear (2) so that the gear's slots align from the top to the bottom. Remove two bolts (1) and the

washers that hold thrust plate (3) (not shown).

Carefully remove the camshaft, the thrust plate and the camshaft gear as an assembly.

Remove the valve lifters. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".

Lifter Group - Remove and Install

SMCS - 1209-010

Removal Procedure

Start By:


NOTICE



Ver imagen

--------------------------------------------------------------------------------


Ver imagen


Use a magnet to remove valve lifter (1) from the engine cylinder block, as shown. Put identification marks on the valve

lifters for installation purposes.

Repeat Step 1 for the remainder of the valve lifters.

Ver imagen


View (X) shows a good contact pattern. Views (Y) and (Z) show bad contact patterns.

Note: Check the valve lifters for wear.

Note: Refer to Specifications, "Camshaft" for more information on valve lifters.


NOTICE



Ver imagen


Put 8T-2998 Lubricant on valve lifter (1) prior to installation. Install valve lifter (1) in the original location in the engine

cylinder block.

Repeat Step 1 for the remainder of the valve lifters.

End By: Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".

Rocker Shaft and Pushrod - Install

SMCS - 1102-012; 1208-012


NOTICE



Ver imagen


Install valve caps (7) on the end of the valve stem.

Install pushrods (5) in the cylinder head assembly (6) .

Note: Ensure that the pushrods are installed in the original location. Also, ensure that the pushrods are seated in the

valve lifters correctly.

Ver imagen


Place the rocker shaft assembly (4) in position on the cylinder head.

Install six long bolts (3) for the rocker shaft bracket and tighten the bolts to a torque of 15 ± 3 N�m (11 ± 2 lb ft).

Install six short bolts (2) and the washers. Tighten the short bolts to a torque of 15 ± 3 N�m (11 ± 2 lb ft).

Note: Perform Steps 1 through 5 for the other head assembly on the 3066 Engine.

Adjust the inlet valve lash and the exhaust valve lash to 0.25 mm (0.010 inch). Refer to Testing and Adjusting, "Air

Inlet and Exhaust System" for more information on setting the valve lash. Tighten adjusting screws (1) .

End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove

and Install".

Rocker Shaft - Assemble

SMCS - 1102-016

Table 1

Required Tools


A 1P-0510 Driver Group 1

NOTICE



Ver imagen


Ver imagen


Use Tool (A) to install bushing (7) into rocker arm (6), if the bushing was removed.

Refer to Specifications, "Rocker Shaft" for more information.

Ver imagen


Install spacer (4) and clip (3) onto one end of shaft assembly (5) .

Slide components onto shaft (5) in the correct order. Refer to Illustration 1 in order to install the components correctly.

The shaft assembly includes the following components:

Bolt (1)

Oil tube (2)

Clip (3)

Spacer (4)

Shaft assembly (5)

Rocker arm (6)

Bushing (7)

Rocker shaft bracket (8)

Spring (9)

Install spacer (4) and clip (3) onto the other end of shaft assembly (5) .

Install bolt (1) and oil supply tube (2) into the end of shaft assembly (5) .

End By: Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod -

Install".

Rocker Shaft - Disassemble

SMCS - 1102-015

Disassembly ProcedureTable 1

Required Tools



Start By:

Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".



Mark the location and the position of each component for later assembly.

Ver imagen


Ver imagen


Remove bolt (1) and oil supply tube (2) from the end of shaft assembly (5) .

Remove clip (3) and remove spacer (4) from shaft assembly (5) .

Note: Check the spacer for wear. Replace the spacer, if necessary.

Slide components to the left and off the end of shaft assembly (5) .

The shaft assembly includes the following components:

Bolt (1)

Oil tube (2)

Clip (3)

Spacer (4)

Shaft assembly (5)

Rocker arm (6)

Bushing (7)

Rocker shaft bracket (8)

Spring (9)

Remove clip (3) and remove spacer (4) from the other end of shaft assembly (5) .

Note: Check the spacer for wear. Replace the spacer, if necessary.

Ver imagen


Inspect bushing (7) for wear or damage. Use Tool (A) to remove the bushing from rocker arm (6), if necessary.

Refer to Specifications, "Rocker Shaft" for more information.

Rocker Shaft and Pushrod - Remove

SMCS - 1102-011; 1208-011

Removal Procedure

Start By:

Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and

Install".

NOTICE



Ver imagen


Loosen adjusting screws (1) on each the rocker arms about one rotation.

Loosen six short bolts (2) and the washers on the rocker shaft brackets.

Loosen six long bolts (3) for the rocker shaft bracket.

Remove six bolts (3) from the rocker shaft brackets.

Remove six short bolts (2) and the washers from the rocker shaft brackets.

Remove the rocker shaft assembly (4) from the cylinder head.

Note: Perform Steps 1 through 6 for the other rocker shaft assembly on the 3066 Engine.

Note: Check the contact surface of the adjusting screw (1) for wear from the pushrods and check for threads that are

stripped.

Ver imagen


Put identification marks on pushrods (5) in order to identify the location of the pushrods in the engine. Remove six

pushrods (5) from each head assembly (6) ( 3066 Engine) or remove eight pushrods (5) from head assembly (6)

( 3064 Engine).

Note: Check pushrods for worn ends and check for distortion. If necessary, replace any pushrods that are worn or

distorted.

Remove valve caps (7) from the valve stem. This will prevent the valve cap from becoming lost.

Note: Check the contact surface of the valve caps for wear and check for oil passages that are clogged.

Valve Mechanism Cover - Remove and Install

SMCS - 1107-010

Removal ProcedureKeep all parts clean from contaminants.


Ver imagen


Loosen hose clamp (2) and remove hose (1) from the air inlet manifold (3) and the turbocharger (7) .

Loosen hose clamps (4) and disconnect hose (5) from the breather (6) .

Remove bolts (8) and the washers from valve mechanism cover (9) .

Note: The 3064 Engine has four bolts and washers while the 3066 Engine has six bolts and washers. Earlier models of

the 3064 and 3066 Engines used acorn nuts and washers in place of bolts.

Remove valve mechanism cover (9) .

Note: The 3064 Engine has one valve mechanism cover while the 3066 Engine has two valve mechanism covers.


NOTICE



Ver imagen


Check the condition of the gasket on valve mechanism cover (9). If the gasket is worn or damaged, use a new part for

replacement.

Install valve mechanism cover (9). Install the washers and bolts (8) .

Note: The 3064 Engine has four bolts and washers while the 3066 Engine has six bolts and washers.

Note: The 3064 Engine has one valve mechanism cover while the 3066 Engine has two valve mechanism covers.

Earlier models of the 3064 and 3066 Engines used acorn nuts and washers in place of bolts.

Torque bolts (8) to 15 ± 3 N�m (11 ± 2 lb ft).

Install hose (5) onto the breather (6). Tighten two hose clamps (4) that secure the hose.

Install hose (1) and tighten hose clamp (2) that secures the hose to the air inlet manifold (3) and to the turbocharger

(7) .

Crankcase Breather - Remove and InstallSMCS - 1317-010

Removal Procedure



NOTICE

Care must be taken to ensure that fluids are contained duringperformance of inspection, maintenance, testing, adjusting and repairof the product. Be prepared to collect the fluid with suitable containersbefore opening any compartment or disassembling any componentcontaining fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and ShopProducts Guide" for tools and supplies suitable to collect and containfluids on Caterpillar products.


Loosen hose clamps (2) on hose (1). Remove the hose from the breather assembly (3) .

Remove breather assembly (3) from valve mechanism cover (4) .

Installation

NOTICE



Ver imagen


Install new breather assembly (3).

Install hose (1) on the breather assembly (3) and tighten the hose clamp (2) .

Front Plate - Install

SMCS - 1163-012


NOTICE



Ver imagen


Place gasket (3) (not shown) in position on the engine.

Note: Ensure that all mating surfaces are clear of old gaskets.

Place front plate (2) in position on the engine.

Install one bolt (1) and the washer in order to secure front plate (2) to the engine. Tighten the bolt to a torque of 35 ±

5 N�m (26 ± 4 lb ft).

End By:

Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".

Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".

Install the idler gear. Refer to Disassembly and Assembly, "Gear Group (Front) - Install".

Front Plate - Remove

SMCS - 1163-011

Removal Procedure

Start By:

Remove the idler gear. Refer to Disassembly and Assembly, "Gear Group (Front) - Remove".


Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove".

NOTICE



Ver imagen


Remove one bolt (1) and the washer from the front plate (2) .

Remove front plate (2) from the engine.

Remove gasket (3) (not shown) from the engine or from the front plate (2) .

Note: Ensure that all mating surfaces are clear of old gaskets.

Note: Check the cylinder block for the following conditions: scale buildup, corrosion and other damage.

Housing (Front) - Install

SMCS - 1151-012


Required Tools




Alignment marks for timing gears

Check the alignment of the timing gears.

Note: Ensure that the marks on the timing gears are in alignment. Align the fuel injection drive gear with the "33"

mark with the "3" mark on idler gear. Make an alignment of the "2" mark on the camshaft gear with the "22" mark on

the idler gear. Align the "1" mark on the crankshaft gear with the "11" mark on the idler gear. The No. 1 cylinder is at

the top center position when the timing marks are in alignment.

Note: When the marks are aligned, the piston in No. 1 cylinder is at the top center position on the compression stroke.

Note: Refer to Specifications, "Gear Group (Front)" for specifications on the assembly of the timing gears.

--------------------------------------------------------------------------------

Ver imagen


Ensure that the old gasket material (9) is removed from the mating surface of front housing (4) and the timing gear

plate. Install a new gasket.

If the crankshaft front seal (10) (not shown) was removed, use Tool (A) to install a new crankshaft front seal.

----------------------------------------------------------------------------

Ver imagen


Before installation of the front housing, check the gasket (7) (not shown) for the oil pan for damage. Replace the

gasket, if necessary. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for replacement of the

gasket for the engine oil pan.

Use two technicians to install the front housing onto the front plate and the cylinder block. The weight of the front

housing is 20 kg (45 lb).

Install two bolts (6) in order to fasten front housing (4) onto the cylinder block and the front plate (8) .

Ver imagen


Install the washers and six bolts (5) (not shown) in order to secure front housing (4) onto engine oil pan.

Install bolts (3) and washers that secure the front housing (4) to the front plate and the cylinder block.

Ver imagen


Connect hose (2) to the front housing.

Install the hose clamp (1) in order to secure the hose to the front housing.

End By:

Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".

Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".

Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".

Install the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and Install".

Flywheel - Remove

SMCS - 1156-011


Required Tools



B Forcing screws M16 X 2 2



Remove twelve bolts (1) and washers from the adapter (2) .

Remove the adapter (2) from the flywheel housing.

Ver imagen


Remove four socket head bolts (3) from the inner ring (4) .

Remove the inner ring (4) from the flywheel.

Ver imagen


Remove six bolts (5) that secure flywheel (6) to the crankshaft. Check all bolts for stripped threads. Replace the bolts,

if necessary.

Ver imagen


Install Tool (A), a strap, and a suitable lifting device onto the flywheel (6).

Use Tool (B) in order to remove the flywheel and ring gear out of the housing. The weight of the flywheel is 50 kg (110

lb).

Perform the following procedure in order to remove the flywheel ring gear.

Ver imagen

-


Place the flywheel and ring gear assembly on a suitable support.

Note: Check the flywheel ring gear for the following conditions:cracks, damaged dowel holes, worn ring gear and

damaged ring gear.

Note: Identify the orientation of the old ring gear on the flywheel for proper positioning, when the new ring gear is

installed.


Heat ring gear (7) uniformly.

Remove the ring gear (7) by tapping the ring gear all the way around the flywheel (6) .

Reposition the flywheel in order to remove the ring gear.

Water Temperature Regulator - Remove and InstallSMCS - 1355-010

Removal Procedure

At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personal injury.

Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with the bare

hand.

Remove the filler cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.

NOTICE



NOTICE







Drain the coolant level below the water temperature regulator.

Ver imagen

--------------------------------------------------------------------------------


Loosen hose clamp (1) and disconnect hose (2) from cover (4) of the water temperature regulator.

Remove two bolts (3) and the washers from cover (4) of the water temperature regulator.

Separate cover (4) from elbow (5) .

Remove bolts (6). Separate elbow (5) from the water outlet manifold.

Remove water temperature regulator (8) (not shown) from cover (4) .

Remove gasket (7) (not shown) and gasket (9) (not shown) from the mounting surfaces of cover (4) and elbow (5) .

Use the following procedure in order to test the water temperature regulator:

Put the water temperature regulator in a tub of water. Heat the water in order to test the water temperature regulator

for thermostatic action.

Note: Stir the water in the tub in order to maintain even temperature during the test.

When the valve of the water temperature regulator lifts more than 10 mm (0.4 inch), measure the water temperature.

Note: The opening temperature for the water temperature regulator is 71° ± 2°C (160° ± 3.6°F).

If the valve fails to operate properly, replace the water temperature regulator.


NOTICE



Clean all of the mounting surfaces for the gaskets and remove all gasket material.

NOTICE

If the water temperature regulator is installed incorrectly, it will cause the engine to overheat.

Ver imagen


Install water temperature regulator (8) (not shown) into elbow (5) .

Note: When the water temperature regulator is installed, ensure that the hole for the air vent is up.

Install gasket (7) (not shown) and gasket (9) (not shown).

Note: Check the condition of the gaskets. If the gaskets are worn or damaged, use 8T-9013 Silicone Sealant for

replacement.

Install the bolts (6) in order to secure elbow (5) to the water outlet manifold.

Install cover (4) for the water regulator housing.

Install the washers and two bolts (3) in order to secure cover (4) of the water regulator housing.

Reconnect hose (2) and tighten hose clamp (1) onto cover (4) of the water regulator housing.

Fill the cooling system to the correct level. Refer to the Operation and Maintenance Manual for the correct fluid and the

correct filling procedure.

Water Pump - Install

SMCS - 1361-012


NOTICE



Ver imagen


Replace O-ring (4) (not shown) with a new part. Apply glycerine to the O-ring before the installation of the water pump

(3) and water pump pulley (2) .

Install the water pump (3) and water pump pulley (2) as a unit onto the engine.

Note: When the water pump is installed, ensure that the grease fitting is up. Also, ensure that the weep hole is down.

Install bolts (1) in order to secure water pump (3) to the cylinder block.

Fill the cooling system to the correct level. Refer to the appropriate Operation and Maintenance Manual for the correct

fluid and the correct filling procedure.

End By: Install V-belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".

Water Pump - Assemble

SMCS - 1361-016

Assembly ProcedureTable 1

Required Tools



B 1P-1861 Retaining Ring Pliers 1

Note: Refer to Specifications, "Water Pump" for specifications that are required during assembly.

--------------------------------------------------------------------------------

Ver imagen


Install seal (14), if the seal was removed during the disassembly procedures.

The following components are installed on shaft (9) :

Washer (13)

Bearing (12)

Spacer (11)

Bearing (10)

Note: Check two bearings (10) and (12) for correct rotation.

Ver imagen


Use a press and Tool (A) to install shaft assembly (5) into the water pump housing.

Use a press and Tool (A) to install impeller (8) onto shaft assembly (5) .

Ver imagen


Use Tool (B) to install retaining ring (4) into the water pump housing.

Use a press and Tool (A) to install flange (3) onto shaft assembly (5) .

Ver imagen


Install water pump pulley (2) onto the flange.

Install four bolts (1) in order to secure water pump pulley (2) to the flange.

End By: Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".

Engine Oil Pump - Install

SMCS - 1304-012


Required Tools



Use Tool (A) to install the front oil seal (8) (not shown).

Ver imagen


Lower the temperature of the spindle (10). Install spindle (10) and idler gear (11) as an assembly in the front housing.

Note: The temperature of the spindle is lowered in order to ease the installation of the spindle in the front housing.

Ver imagen


Install set screw (9) in the front housing.

Ver imagen


Lower the temperature of the drive gear assembly. Install drive gear (7) in the front housing.

Note: The temperature of the drive gear assembly is lowered in order to ease the installation of the drive gear

assembly in the front housing.

Ver imagen



Heat the oil pump gear up to 180 to 220 °C (356 to 428 °F). Support end (X) of the shaft (7) (drive gear). Install oil

pump gear (6) onto the shaft. The end of the gear (Z) should be flush with the end of the shaft (Y) .

Ver imagen


Install driven gear (4) into the front housing (slip fit).

Ver imagen


Place gasket (3) and cover (2) in position on the front housing.

Note: Ensure that the old gasket material is removed from the mating surfaces.

Install the washer and bolt (1) that secures the cover to the front housing. Tighten bolt (1) to a torque of 34 ± 5 N�m

(25 ± 4 lb ft).

Refer to the Specifications Module, "Engine Oil Pump" for more information on the engine oil pump.

End By: Install the front housing. Refer to Disassembly and Assembly, " Housing (Front) - Install".

Engine Oil Bypass Valve - Remove and Install

SMCS - 1306-010-BV

Removal ProcedureStart By:


NOTICE



Ver imagen


Ver imagen


Remove threaded plug (1) for the engine oil bypass valve from the cylinder block (2) .

Remove shim (3) from the cylinder block (2) .

Remove spring (4) from the cylinder block (2) .

Remove spring seat (5) from the cylinder block (2) .

Note: Check the spring seat (5) and the valve seat for an abnormal contact pattern. Inspect the spring (4) for

weakness or damage. If necessary, replace the engine oil bypass valve with a new part.

Note: Check the cylinder block (2) for oil passages that are clogged.


NOTICE



Ver imagen


Ver imagen


Install spring seat (5) (not shown) and spring (4) in the cylinder block (2) .

Install shim (3) and threaded plug (1) in the cylinder block (2) .

Tighten the threaded plug (1) to a torque of 69 ± 5 N�m (51 ± 4 lb ft).

Note: Test the opening pressure for the engine oil relief valve. The opening pressure for the relief valve is 981 ± 98

kPa (142 ± 14 psi). Make adjustments by shimming, if necessary.

For information on testing the engine oil relief valve, refer to Testing and Adjusting, "Lubrication System".

For more information, refer to Specifications, "Engine Oil Bypass Valve".

End By: Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".

Engine Oil Cooler - Install

SMCS - 1378-012


NOTICE



Ver imagen


Install engine oil cooler (5) and new gasket (6) (not shown). Ensure that all mating surfaces are clean. Install bolts (4)

and washers in order to secure the engine oil cooler to the engine cylinder block. The 3066 Engine has 24 bolts and

washers while the 3064 Engine has 16 bolts and washers.

Ver imagen


Install oil tube assembly (dipstick) (2) into the cylinder block.

Note: Apply clean engine oil to the O-ring seal (3) (not shown) before installation.

Install bolt (1) and the washer into the cylinder head.

End By: Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".