torques motor 3066

CATERPIILAR' sENR5s45-03January 1999

Sloc@ffiil@atnons

3064 and 3066 Engines For Gaterp¡llarb Built Machines

6LK1-Up (Engine)7JK1-Up (Engine)

i

{j

, J

r

\-, Systems Operation

Systems OPerationSchemat¡cSchematic

Schematic

taintenance lndex TabOperation and MaintenanceOperation and MaintenanceOperation and Maintenance

Engine and Pump Electronic ControlSystemStarting and ChargingElectrical SystemElectrical System; Forest Machines(6151-Up, 9JS1-Up)Electrical System (7721 -UP8GZ1-Up, BBGl-Up)

Forest Machines (6LS1 -Up, 9JS1'Up)(721 -Up, 8GZ1 -Up, BANI -UP,BBGl-Up)

sENR9242-12

Contents forService Manual SENR924O

Form No,

SENR23OOSENR9241SENR7733SENR9242SENR3130SENR,2ETOSENR5545SENR5546SENR5553SENR9243sENRil996RENR1998

RENRlOOTSENR9258RENR1O58

RENR3725

SENRiIET4sEBU6975SEBU7O79XEBU2571

320i8, 32OE L, 32OB U, 32OB LU EXGAVATORS & 32OB LL FORESTHACI{INESVolume I (Engine, Electrical, Operation and tlaintenance)4NRl-Up, SBRl-Up, 6GRl-Up' lDSl.Up' lESl.Up' 6LSl.Up'EESI-Up, gGSl-Up, 9JSl-Up' 4XWl-Up' SGWI.Up' 3tRl-UP'4H Rl -Up, 9KR{ -Up' I GS I -U p' 2rII21.Up, 7ZZ1 -Up, 8G21.Up,AEDI-Up, BANI-Up, BBGI -Up

Note¡ This form lists the complete Service Manualfor this product. The items listed can be ordered separately.When items are updated or supplements added, they will be announced in PREVIEW and should be ordered as theybecome available. Refer to the Service Manual Contents microfiche, REG1139F, for current contents and formnumbers of this manual.

Scction Title

BinderBinder LabelSafetyService Manual ContentsTorq r.re Specif icationsEngine Index TabErgine Specifications 3066 EngineSystems Operations, Testing and Adjusting 3066 EngineDisassembly and Assembly 3066 EngineDisassembly and Assembly Supplement 3066 EngineElecfical S¡rsterns & Ope¡atoÉs Station Index Tab

Note: This manualcontains Engine, Electrical& Maintenance information. For Systems information, seeContents page RENR2982.

03/09/00 CATERPILIAR'

10056692

lmportant Safety InformationMost acc idents that involve product operat ion, maintenance and repai r are causec =; ' . - '=- .observe basic safety ru les or precaut ions. An acc ident can of ten be avoided by re: :a ' - - = : : 'er t ia l lyhazardous situations before an accident occurs. A person must be alert to pote-: ¿ -=-=-:: - sperson should a lso have the necessary t ra in ing, sk i l ls and too ls to per form these i - - : : - : : ' - . - 'y

lmproper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product unt,i you haveread and understood the operation, lubrication, maintenance and repair information

Safety precaut ions and warnings are provided in this manual and on the procj lc: ' : -=: :

warn ings are no t heeded, bod i l y in ju ry o r death cou ld occur to you or to o the 'pe 's : - :

The hazards are ident i f ied by the "Safety Alert Symbol" and fol lowed by a "Signa ", : ' :"WARNING" as shown below.

-,

The meaning of this safety alert symbol is as fol lows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can ce 3\pictor ial ly presented.

Operat ions that may cause product damage are ident i f ied by "NOTICE" lace s c-tn is pub l i ca t ion .

Caterpillar cannot anticipate every possible circumstance that might involve a PGri: *aThe warnings in this publication and on the product are, therefore, not all indusite. Éprocedure, work method or operating technique that is not specifically recomÍHlécCaterpillar is used, you must satisfy yourself that it is safe for you and for others- Yc-also ensure that the product will not be damaged or be made unsafe by the oPerabormaintenance or repair procedures that you choose.

- ' : ^ l n

n^zerd.a tool,

shou ld- or icat ion,

- - - t h ^ +

: : , : :- , : - l = S C a n- - - ^^ {^ .^= _ J g t u l v

-: T\OS\

J Y T ,

The in format ion, speci f icat ions, and i l lust rat ions in th is publ icat ion are on the:as s - ' - ' : '

was available at the t ime that the publication was wntten. The specif ications :: ' :-=: : :measurements, ad justments, i l lus t rat ions, and other i tems can change at anr ' : - : - : : :

affect the service that is given to the product Obtain the complete ano mos: :-":-- --:--

yclu orarr arry )ob. Caterpl lar dealers have the most current information avai a3: =: ' = .

cur ren t pub l i ca t ion fo rm numbers ava l lab le , see the Serv ice Manua l Conter - :s ' . ' : ' : - : -=

3Table of Contents

f v Table of Contents

i' .,'

v.

4Specif ications Section

Specifications Section

Engine DesignSMCS Code: 1201

3064 Engine

lllustration 1

Cylinder and valve location

(A) Exhaust valves. (B) lnlet valves.

900523889

B o r e . . . , . . . . . . . . 1 0 2 m m ( 4 . 0 2 i n c h )

St roke 130 mm (5 .12 inch)

D i s p l a c e m e n t . . . . . . . . . . . . . . . . . . . 4 . 3 L ( 2 6 0 i n ' )

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

V a l v e s p e r c y l i n d e r . , , , , . . . . . . . 2

F i r i n g o r d e r . . . . . . . 1 - 3 - 4 - 2

C o m p r e s s i o n r a t i o . . . ) . . . . . . 1 7 . 1

Fuel injectiontiming B or 20 degrees béfore top center

INote: Refer to the Engine Inforfnation Plate for theperformance specif icat ion number. Refer to the TMI(Technical Marketing Information) or refer to theFuel Setting and Related Information Microfiche forthe correct t imlng specif icat ions,

M i n i m u m r p m . , . . . , . . . . . . 9 0 0 t 2 0

The crankshaft rotation is vrewed from the flvwheelr iend of the engine. Crankshaft

' '..*'-'

rotat ion . . . . Counterclockwise

Note : The f ron t enc c ' : - : ; - I - :

the f l ywhee l e "o o ' : - : : - ) - =

-

froñ the f lywhee L- : -- - . - - -- :c y l i n d e r i s t h e f r o n : . , - : = '

3066 Engine

r01020901

\b- : cosi te of- - - ¡ ^ ^ { + t ^- > u v u t L I t v

- - / ^ , , i ^ , ^ , ^ / - ¡: : c v t ú v v r u- - =

N o . 1

lllustration 2

Cylinder and valve location

(A) Exhaust valves. (B) lnlet valves

) ' , t295223

Stroke ' -

ñ i c n l a n o m a n t

Cyl inder arrangement

Va lves per cy l inder . . . .

Fir ing order

Compression rat¡o

Fuel in ject iont i m i n g . . . . 1 0 o r 1 6 c : ; - = = = : : - - ' = t o p c e n t e r

Note: Refer to the Engine - ' -^ ' - . ' - - : a:e for theper fo rmance spec i f i ca t ro ' - ' - : - ' == ' : ' to the TMI(Technical Market ing tnfo'-a: :- - ' ' - ' - ' to theFue l Set t ing and Re la tec ' ' - ^ ' -z ' : - ' : ro f i che fo rt h e c o r r e c t t i m i n g s p e c ' : e . : - :

M i n i m u m r o m . . . . . . . . . . . . . . . . . 9 0 0 t 2 0

The crankshaft rotat ion is ' : " . : : - -- -e f lywheelend of the engine. Cranks-=:rotat ion - - -- erclockwise

Note: The front end of the e-; - = . , : :osi te ofthe f l ywhee l end o f the enE '=

- - - - ' s de o f the

e n g i n e a n d t h e r i g h t s i d e c ' : - : : - , ' : a r e v i e w e df rom the f l ywhee l end o f t l ' e : - : -= - - :

No. 1cyl inder is the front cyl inder

Hi i

I

l ll l

5 12 i nch ) ! \

a : - . 390 in ' )

I n - l i ne

. . . . . . . . 2

: 3 -6 -2 -4

. . . . 17 1

\ t \


lllustration 3 9oo53o3o7

(1 ) Fue l in jec t ion l ines

Tighten the fuel in ject lon l ine nuts to thef o l l o w i n g t o r q u e . . . . . . . . 2 5 N ' m ( 1 8 l b f t )

\01029754

SMCS Code: 1251,1290

lllustratlon 4 soo53o354

(1 ) Bo:s fo r fue l in jec t ion l ine

T grten the bolts for the fuel in ject ion l ine to the' o , o w i n g t o r q u e . . . . . 2 0 t o 2 5 N ' m ( 1 5 t o 1 B l b f t )

(2) De rvery valve holder

Tighten the del ivery valve holder to thefo l low ing to rque. . . .39 to 44 N m (29 to 32 lb f t )

(3) Bolt for lock plate

Tighten the bolt for the lock plate to thefo l low ing to rque. . . . . . . 3 to 5 N m (27 to 44 lb in )

Bolt for fuel l ine

Tighten the bolt for the fuel l ine to the fol lowingtorque. 10 to 13 N 'm (7 to 10 lb f t )

ld le r subspr ing nu t

Tighten the idler subspring nut to the fol lowingtorque. '12 to 16 N 'm (9 to 12 lb f t )

l r l l a r c r h q n r i n n

Tighten the idler subspring to the fol lowingt o r q u e . . . . . . . . 1 6 t o 2 0 N ' m ( 1 2 1 o 1 5 l b f t )

Nut

Tighten the nut to the fol lowlngtorque. 3 to 5 N 'm (27 to 44 ló in )

i01029643

SMCS Code:1254

lllustration 5

( 1 ) S e a l

(2) Fuel in ject ion nozzle

g0O53O2B0

i01029707

) v Fuel Injection LinesSMCS Code:1252

(4 )

/ 5 \

-t- \

ÉF J -//

rsut/4'

(6)

(7 )

¡i v Fuel Iniection Pump Fuel Injection Nozzles

(3) Retainer for fuel in ject ion nozzle

Tighten the retaining bolt to the fol lowingt o r q u e . . . , . . . . . . 2 2 N ' m ( 1 6 l b f t )

6Specifications Section

t01024279

LValve MechanismSMCS Code: 1102

q

6

73>#-o--P

Yn\-P\g

lllustration 6

( ) Body for fuel injection nozzle

(5) Shims

900530283

Inc reas ing sh ims by O.1O mm ( .OOa inch) changesinjection pressure by approximately 1375 kPa(2OO psi) . Shims are avat lable in nine sizes fromO. '10 mm ( ,OOa inch) to 0 .58 mm ( .023 inch) .

(6) Pressure spr ing

(7) Pressure Pin

(B) Gasket

(9) Pln

(10) Tip for fuel in ject ion nozzle

(11) Retaining nut for fuel in ject ion nozzle

Tighten the nut to the fol lowingt o r q u e . . . . . . . 3 4 + 5 N m ( 2 5 t a l b f I )

lllustration 7

/ I \ Q n r i n n

I a n n i h r r n r l a r t e c . ' - ^ ' ^ :L g l l v t l I u r r v v l

l ü 5 1 r u r u s

Free length after' :es:M a x i m u m b e n d i n s 3 ' - :

Valve stem seal

Diameter of valve s:e-

ln le t va lve s tem,: '

Exhaust valve ste-

900526366

- : ' . 5 0 t o 5 5 l b )- - - (2 .22 inch)

2 degrees

. - - c 7 . 9 5 5 m m* : : 3 1 3 2 i n c h )

. - - :o 7 940 mm- : : 3 1 2 6 i n c h )

(2)

(3)

(4 )

s tem . . , , ; . . . . . . . . . . . .-

! . , ^ - r , 3 . 1 1 0 i n c h )

Min imum a l lowab le c e - = '= ' ' - . = ' âus t va lves t e m . . . . . . . . . . .

- : : - - - ( . 3 0 9 1 i n c h )

C learance fo r in take !¿ '= : : - - a lveg u i d e . . 0 . 0 5 5 t o 0 . 0 8 5 - - - - - - , ¡ 0 0 3 3 i n c h )

C learance fo r exhaus i ,a .= : '= - ^ va lvegu ide , . 0 .070 to 0 .105 - - - - - : : 0041 inch)

Max imum a l lowab le c lee 'a - := ' - - : . ; ide fo r in le tva lve . . . . - ' a - - ' - ( 0059 inch)

' - (173,n"n ' , 0- \ t

H e i g h t t o t o p o f v a . : l , : : ' - - l t O . 3 0 m m: : : : . 0 1 2 i n c h )

l,w

7

Specif ications Section

lvlv lax mum al lowable clearance for guide forexâ . rs t va lve . . . . . 0 .200 mm ( 0079 inch)

I - .s Ce diameter of valve guide

L.- :e diameter of guide for in let. a . : . . . 1 3 . 0 2 5 t o 1 3 . 0 3 5 m m

( . 5 1 2 8 t o . 5 1 3 2 i n c h )

l - .s re d iameter o f gu ide fo r exhaust. z . = . 1 3 . 0 2 5 t o 1 3 . 0 3 5 m m

( . 5 1 2 8 t o . 5 1 3 2 i n c h )

-s :e diameter of guide for new inlet. . . . 8 . 0 1 0 t o 8 . 0 3 5 m m ( . 3 1 5 4 t o . 3 1 6 3 i n c h )

- : -= ñ iameter o f ou ide fo r new exhaust. : . = 8 .010 to 8 .025 mm ( .3154 to 3159 inch)

^ . ' ' , - Jm ins ide d iameter fo r ou ide fo r in le tA ñ O m m / ? 1 O i n n h \

. . . . u . v w l l l r l l \ . u r v l l ¡ v ¡ 1 , /

' . ' i ' - Jm ins ide d iameter fo r ou ide fo r exhaust. = . = 8.12 r rm ( .320 inch)

- - - o c c n f l i n

, : . : c thickness for rnlet and exhaust. : . : - i 2 1 3 m m ( , 0 8 4 i n c h )

' , ' - ---n al lowable valve l ip thickness for in let: - : : x laus t va lves . .1 .20 mm ( .047 inch)

- : - ¡ = o Í v a l v e f a c e . . . . . . . . . , . 3 0 d e g r e e s

t r ¡us i ra : i - s 900526884

(Br l=c:^ of bore in head for valve seat- s e ' : , . 9 , 5 t 0 . 1 m m ( . 3 7 4 x . . 0 0 4 i n c h )

(9 ) Câ ' : fe r o f in le t va lve . . . . . . . . .40 degrees

Note: Tne depth of the chamfer of the inlet valve is2 .38 = C 10 mm ( .094 t .004 inch) .

(10) Câmfer o f exhaust va lve . .45 degrees

Note: Tne depth of the chamfer of the exhaust valveis 2 00 t 0 . '10 mm ( .079 t .004 inch) .

(11) Va lve seat bore fo r in |e t . .46 .000 to 46 .025 mm( 1 . 8 1 1 0 t o 1 8 1 2 0 i n c h )

('12) Valve seat bore forexhaust 39.000 to 39.025 mm

(1.5354 to 1 .5364 inch)

lllustration I 900527479

(13) W¡dth o f va lve seat . . . . . . . 1 40 ¡ 0 .25 mm(.055 t .010 inch)

Note: The maximum permissible width of the valveseat i s 1 .BO mm ( .071 inch) .

(14) Valve seat angle 30 degrees

(15) Dimension from top of c losed valve to face ofn o t ñ

E x h a u s t v a l v e . . . . . . . . . . . 0 . 5 0 t 0 . 2 5 m m(.020 t .010 inch)

I n l e t v a | v e . . . . 0 . 4 0 t 0 . 2 5 m m ( . 0 1 6 t . 0 1 0 i n c h )

Note : The max imum permiss ib le depth is 1 .10 mm(.043 inch) .

l l lustrat ion 10

(16) Pushrod

)L

b

gOA52749A

tl


Use a dial indicator in order to check al lpushrods for runout. Replace the pushrod i f therunout exceeds the fol lowing value. . . . . . 0.40 mm

( . 0 1 6 i n c h )

t01023644

.,J

l l lustrat ion 12 900526256

(3 ) A l ign the o i l ho les in roc<? ' = ' ^ : -sh ing (A)w i t h t h e o i l h o l e s i n t h e ' c : - . ' . ' - ' , v h e n t h erocker a rm bush ing is rec ¿ := :

900526252

^"'- 4

tl

\- / "

_ 3 -

a t *

v - - / "J : - / -

l l lustrat ion 13

Posit ion the rocker shaft brac. e =bolts.

(4) Long bolt

Tighten the long bolt to i -e ' :

t o r q u e . . . . 1 5 - "

(5) Short bol t

Tighten the short bol t to :ê' :t o rque . . . , . 15 =

(6) Rocker shaft bracket

900526257

- - ñ ^ r r n l r n ^

1 1 t B l b f t )

v1 1 + A l h f t \

Valve Rocker ArmSMCS Code: 1123

l l lustrat ion 11

(1 ) Rocker a rm bush ing

Bore in rocker arm bushing fors h a f t . . . . . . . . . . . . . . . . . . 2 0 . 0 1 1 t o 2 0 . 0 9 4 m m

(.7878 to .791 1 inch)

(2) Rocker arm shaft

Diameter of rocker armshaf t . . . 19 .966 to 19 .984 mm

( 7861 to .7868 inch)

Clearance of rocker arm bushing fors h a f t . , . . . . . . . 0 . 0 2 7 t o 0 . 1 2 8 m m ( . 0 0 1 1 t o . 0 0 5 0 i n c h )

Replace the rocker arm bushing i f the repair l imitof 0.15 mm (.006 inch) has been reached. Replacethe rocker arm bushing and the rocker arm shaft tf

I?:::3': "tit of the rocker arm bushins has been

ISpecif ications Section

v

) \, Valve Mechanism CoverSMCS Code: 1107

l ¡ l u s l r a : : - - 5

( 1 ) , a , : : ove r nu l

l l l us t ra t lon 14

Valve lash adjustment

900526261

Tur^ :^: crankshaft unt i l the t iming mark on thec 'e ' -= - a ' : ou l ley i s a l igned w i th the po in te r on the: - - I :=ar houslng in order to adjust the valveas- : : :^ the No, 1 inlet valve and the No 1e / - . . : - .A ve nushrods must no t be in tens ion

- - - ^ . ^ ^ t , ^ . ^ . ^ ^

i - : . : - : e x h a u s t v a l v e l a s h . . . . 0 . 2 5 m m ( . 0 1 0 i n c h )

t01023202

900525829

the valve cover nuts to the followinq3 t o 5 N m ( 2 6 t o 4 4 l b i n )

Cylinder HeadSMCS Code: '1100

l l lustrat¡on 16

(1 ) Cy l inder head

Use a straightedge and a feeler gauge to checkthe cyl inder head for warpage,

ol "l' "_:" "l ln " :u'l : o " : n":3 3¿%li'?.'d#,? " n rResurface the cyl inder head i f the warpageexceeds the fol lowing amount . . . . 0 . 2 0 m m

(.008 inch)

Gasket thickness of cyl inderh e a d . . . . . . . . . . . . 1 . 7 0 t 0 . 1 0 m m ( . 0 7 0 t . 0 0 4 i n c h )

T h i c k n e s s o f n e w h e a d . . . . . . . . . . . 9 5 . 0 0 + 0 , 1 0 m m(3.740 t .004 inch)

Minimum thickness of cvl inder head . . 94.70 mm- (3 .728 inch)

Note: The repair l imit of the contact surface of thegasket and the repair l imit of the cyl inder blocksur face is 0 .20 mm ( .008 inch) .

l l lustrat ion 17

Numerical sequence of bolts for 3064 Eng¡ne

141025762

944527524

a B t t a g r

15. 11€-$ ¡úFoZ 5(!-Q)1s .¡

1 0Specif ications Section

t\

l l lustrat ion 18

Numerical sequence of bolts for 3066 Engine

900527527

Put clean engrne oi l on the threads of the cyl inderhead bolts. lnstal l the bolts and t ighten the bolts inthe appropriate numerical sequence to the fol lowingt o r q u e . . . . . . . . . 1 1 8 t 5 N ' m ( 8 7 t 4 l b f t )

i01030322

TurbochargerSMCS Gode: 1052

lllustration 20

(6) Turbine shaft

P lace a d ia l ind lca to 'o - : - :shaft. Move the comPress:'axial direct ion in orderto -=

p l a y . . . . 0 . 0 5 7 t o 0 . 1 0 3 - -

Note: The turbocharger rr-s: : :the tu rbocharqer must be : - : : 'the end play is beyond t-? s:=

900530560

: ' :ne tu rb ine1 ) r n t h e

- ^ ^ ^ t ^ , , E ñ ^= r u P r a y . L r r u

. c .0041 inch)

. = - . e m b J e d a n d- . : ' : l e a r a n c e s i f- : : ^ S ,

i,ri 0\

^-Y

900530558

( 1 )

(2)

(3)

(4)

(5)

lllustration 19

Compressor wheel

Turbine wheel

Turbine housing

Compressor housing

Cartr idge housing

Note: Mark the orieniation of the compressorhousing, the cartr idge housing and the turbinehousing before disassembly.

l l lustrat ion 21

(7) Lock plates

Posit ion the lock plates a^cthe fol lowing torque. . . , ,

-=^ the bolts to- - \ ' m ( 1 5 l b f t )

\

¡o rC-Ot f9-O6 tt¡


i01 029608t Exhaust ManifoldSMCS Code: 1059

l', -s'.'a::^ 22r-T -: - :-srng (3) and Cartr idge housing (5)

900530562

: - rbine housing (3) with the cartr idge- )

I -s:'a:3,^ 23 900530564

r i ^ ; - n ,

: : : . 5P-3931 Ant i -Se ize Compound to the:-- .¿:s of the clamp. Tighten the clamp to the' : : , ' , . g t o r q u e . 4 t 1 N ' m ( 3 5 t 9 l b i n )

Tac : a-: (8) l ight ly around the circumference.Tig^::- : amp (8) to the fol lowingt o r c - ? . . 4 x 1 N ' m ( 3 5 t 9 l b i n )

Nuts for turbocharger

Tighten the nuts for the turbocharger to thefoi lowing torque. 41 N'm (30 lb Í t )

Studs for turbocharger

Tighten the studs for the turbocharger to thefol lowlng torque. 12 N'm (9 lb f t )

Studs for exhaust manifold

Tighten the studs for the exhaust manifold tothé fol lowing torque. 12.5 N'm (9 lb Í t )

Nuts for exhaust manifold

Tighten the nuts for the exhaust manifold to thefol lowing torque. 20 N'm (15 lb f t )

ü!-'*"

900530254lllustration 24

( 1 )

(2)

tt(3)

(4)

te

CamshaftSMCS Code: 1210

LT

í^f\, )\ \ \ \ l v '

f) ,v) "

lllustrat¡on 25

(1) Camshaft gear

Maximum permissible temperature of the gearfor instal lat ion on the camshaft . . . . 315'C (600'F)

Note: Do not use a torch.

(2) Diameters of camshaft journals

Table 1

Numberof Journalfor 3064Engine

Numberof Journal

i for 3066Engine

StandardDiameter

53.94 to53.96 mm(2.123 to

2.124 inch)

900527937

53.90 mm(2.122 inch)

lllustration 26

Note:

(4) Camshaft lobe l i f t

Specif ied camshaft lobe l :

E x h a u s t l o b e . . . . . . . .In let lobe

Service l imit for lobe l i f t fo ' : ' - = -

Service l imit for lobe l i f t fo ' - = '

Note : Rep lace the cams '¿ : ' - :

the lobe l i f t is reached.

(5) Camshaft iobe heigi : :

(6) Base circ le

1. Measure the camshafi oc: -=

2. Measure the base circ ie €

3. Subtract the base circ e :-=- .f r o m t h e l o b e h e i g h t t n a : s ' - - -d i f fe rence is the ac tua ca- : - :

900527952

- - - ( 2891 inch)^ - ( 2 6 3 3 i n c h )

. 6 . 8 4 4 m m(.2695 inch)

6 . 1 8 9 m m(.2437 inch)

: : - . c e l i m i t f o r

' - - ^ : i n S t e p 2

- - S tep 1 . The' - : :3 l i f t (4 ) .

It,

1 , 2 1 , 2 , 3

52.94 to52.96 mm(2.084 to

2.085 inch)

(1) The service limit is the maximum dimension or the serv¡celimit is the minimum dimension that is specified for a part.Qéptacé thé part i{ the se.vice limit is reached-

(3) Thrust plate bolt

Tighten the bolt to the fol lowingtorque. 18 N'm (13 lb Í t )

52.90 mm(2.083 inch)

,\T,i\iN

0b

v StandardDiameter

Repair Limit(1)

Clearancebetweencamshaft

journals andbushings

(1) The reoair l imit is the maximum dimension or the repair l im¡t ¡sthe minimum dimension that is specified for a part. Repair thepart if the repair limit is reached.

o oo,l3J¡0,3 " ,0.15 mm.do7,""n1 (.006 inch)

l L l uS l ' á l rOn 27 900528061

Note: Jse a dial indicator and blocks in order to: : := '- 1e the runout of the camshaft . Take one half: ' - : r al indicator reading as the runout.

- - - - ^ h ^ { +- = 5 r t d l t

' , ' r x .num permiss ib le runout fo r:a -shaf t . . . . . 0 020 mm ( .0008 inch)

S 'a ghten the camshaft i f runout is less than the' : cw ing amount . 0 050 mm ( .0020 inch)

:=i ace the camshaft i f runout is more than the' : : , , , , lng amount. 0.050 mm (.0020 inch)

l l lustral,cr 28

¡ R , i : - c n : f i l _ r a a r i n n

900528067

Meas-'e lhe camshaft bearing with a dial indicator.Suc:rac: lne diameter of the camshaft journal innrne' 'o o ive l - rear ino c learances. Refer to Table 2.

l l lustrat ion 29

(9) Instal l the dialgear end play

900529304

indicator in order to determine

E n d p | a y . . . . 0 . . 1 0 t o 0 . 2 5 m m ( 0 0 4 t o . O 1 0 i n c h )

Replace the thrust plate i f the end play exceedst h e f o l l o w i n g a m o u n t , . . . . . . . . . 0 . 3 0 m m ( . 0 ' 1 2 i n c h )

T h r u s t p l a t e t h i c k n e s s . . , . . . , . 4 . 8 5 m m ( . 1 9 1 i n c h )

-]l_,o

Mlllustration 30 900529307

(10) Tappet bore diameter

Tappet bore diameter . . . . . . .22.000 Io 22.021 mm(.8661 to .8670 inch)

Max imum tappet bore d iameter . . . . . . .22 .055 mm(.8683 inch)

I

,I

. t - 4 i I

I ) \1t i \

(-\r

\

Clearance of tappet to ' r'{:

bore . . . 0 .035 to 0 .086 mm ( .00 .14 to .0034 ¡nch)

Note: Replace the tappet i f the clearance isexceeoeo.

i01030986

Engine Oil Pressure ReliefValveSMCS Code: 1315

NOTICEBefore operation, the pump n!s: :: :ubricated withclean engine oi l and the pump -,s i turn freely byhand or damage to parts can 5e :-= result .

Note : The min imum accec :a3 = - : - : ss ! re a t lowid le i s 1OO kPa (15 ps i ) .

(1 ) Dr iven gear assembly

(2) Drive gear assembly

/ " \ f . \ ¡ l ^ r r m n ^ a . r

(4) ld ler gear assembly

The backlash betweer :-= - : -^. : gear andt h e i c i l e r o c e r s t h e f O : , , , - :a m o u n t . - - - : o O 1 9 0 m m

- - : : . I 0075 inch)

Note : Rep lace the gears ' : -= : : - . : s^ exceeds0.35 mm ( .014 inch)

(5 ) Sp ind le

N o t e : T h e o i l p u m p g e e r e ' : - : : ' , : g e a rassembly are not servicea: = ' ' . . 3 imo gear isremoved.

lllustration 33

(3) O¡l pump gear

Note: Do not use a torch,

900530644

t I

lllustration 31

Oil pressure relief valve

900530799 el

,1 r

I

!..i.:

14l l

Remove the oil pressure relief valve from thecyl inder block. Check the valve and the valve seatfor abnormal contact patterns. Inspect the spr ingfor weakness or damage. Replace the oi l pressurerelief valve, if necessary.

Re l ie f va lve open ing pressure . . . . . .343 t 20 kPa(50 t 3 psi)

i01 030415

Engine Oil PumpSMCS Code: 1304

Illlustration 32 900530573


1v Heat the oi l pump gear to 180' to 220'C(356" to 428"F) and support the end of the drivegear snaft in order to instal l the oi l pump gear.Press the oi l pump gear unt i l the oi l pump gear isf lush with the end of the shaft .

l l i r s : ' a t ¡ on 34

i - . r r e i n ¡ f n r n i l n r, : , ' - . - . ' r Jmp gea r

900530697

' . ieasure the di f ference in the length of theassembry fo r the o i l pump gear and the depth- : ê o , r pump hous ing .I earance 0.020 to -0.034 mm

( 0008 to - 00'13 inch)

Note: Replace the oi l pump gear assembly i f thecrea'a.ce exceeds the service l imit of -0.150 mm(- CC59 rch) .

Meas- 'e the clearance between the oi l pump gearsanc :ê or l pump hous ing w i th a fee le r gauge.

t - ^ - . ^ ^ ^ ^ 0.050 to 0.098 mm(.0020 to .0039 inch)

Note: Rep\aoe the oi l pump gear assembly i f thec lea 'a^ce exceeds the serv ¡ce l im i t o f -0 .150 mm( - 0C59 rnch) .

Measure the inside diameters of the bores ofthe shafts in the cover (7) and the ol l pumphousing (6). Measure the bores of the shafts.The clearance between the gear shafts and theo i l pump hous ing and cover . . . . 0 .04 to 0 .07 mm

( 002 to .003 lnch)

Note: Replace the oi l pump gear assembly, thecover, or the oi l pump housing i f the clearanceexceeds the service l imit of 0.15 mm (.006 inch).

Note: Replace the dr ive gear and dr iven gear as anassemory.

lllustration 36

(B) ld le r gear bush ing

Ins ide d iameter o f id le r gear

900530704

bushing 25.000 to 25.021 mm(.9843 to .9851 inch)

Maximum diameter of id ler gear bushing for oi lp u m p . . . . . . . . . . . . . . . 2 5 . 0 5 9 m m ( . 9 8 6 6 i n c h )

(9 ) Sp lnd le

Drameter of spindle 24.939 to 24.960 mm(.9818 to .9827 inch)

lllustration 35

(7) Cover

900530702

I

I

1 6Specifications Section

Engine Oil PressureSMCS Code:1924

Table 3

Engine gil P¡sss¡r¡g(t)

Oil Pressure at 1500 rom

Minimum diameter of spindle for oi lp u m p . . . , . . . . , . . . . . . . 2 4 . 9 0 1 m m ( . 9 8 0 4 i n c h )

i01 031038

Opening pressure of bypass . = =

Engine Oil PanSMCS Code: 1302

9 8 1l A at + z

t 98 kPat 14 ps i )

i 01030410

196 to 392 kPa(28 to 57 psi)

Oil Pressure ¿t iflls{e) 98 kPa (1a psi)( l) The oi l temperature must be 60'to 70"C (140'to 158"F)(2) Engine idle is 900 r 20 rpm.

i01030990

Engine Oil Bypass ValveSMCS Code: .1306

90053080 1

Note: The oi l bypass valve is mounted lnside the oi lpan along the rai l of the oi l pan.

( '1) Valve seat

Check the valve and the valve seat for abnormalcontact patterns.

(2) Spring

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

P"-

lllustration 38

/ r \ a r ; l ^ ^ ^ h ^ t + ^\ r . / \ J i l P d r r u L ) r J

Tighten the oi l pan bc .- . -torque.

(2 ) O¡ l pan dra in p lug

Tighten the oi l pan c'a - :

900530566

-e fo l iow ing- 129 ¡ 4 lb f t )

01 033378

el

il'ii,' lI

60

Water Temperature RegulatorSMCS Code: 1355

5I - 8010 Water TemperatureRegulatorThe water tempera ture reg- : . : ' : ' : ' - : o open a tthe fo l low ing tempela tu le - - , (160 ' + 4 'F)

The valve l i f ts more than '1: -- - - : r) at thefol lowing temperature, , . , 85"C (185"F)

5I - 8020 Water TemperatureRegulatorThe water tempera ture reg- a : : - : ' : " : : c open a tthe fol lowing temperature. . 32"C (180'F)

The valve l i f ts more than 10 -- - -^) at thefollowing temperature 36'C (204'F)

t\


i 0 1 0 3 1 1 1 1

Water PumpSMCS Code: 1361

l l l Ls : 'a t ¡on 39

' -oe l le r

900530877

Tr: 'aces of the impel ler and the water pump shafta ' e ' - s n .

( 2 1 F a n g e

(3r - i 'e

distance from the face of the impel ler to the. ' ,are' pump housing is the fol lowinga'nount. . . 21.00 lo 21.70 mm (.826 to .854 inch)

The press fit between the water pump shaft and thermpel ler is the fol lowingamount . . . . . 0 .032 to 0 .065 mm ( .0013 to .0026 inch)

tO1a2B288

Ll l lustrat¡on 40

g00530BZB

(4) V/a:e' pump shaft

Tê cress fit between the water pump shaft andtae 'ange is the fo l low ingan:oint. . . . . . 0.035 to 0.065 mm

(.0014 to .0026 inch)

Cylinder BlockSMCS Gode: .1201

l l lustrat¡on 41

(1 ) Cy l inder b lock

900529444

Measure the amount of the warpage of thecyl inder biock with a straightedge and feelergauge. Maximum al lowablec learance . . . . . . . , . 0 .05 mm ( .002 inch)

R e p a i r l i m i t . . . . . . . . . . . . . . . 0 . 2 0 m m ( . 0 0 8 i n c h )

Resurface the top of the block i f the repair I imit isreached.

l l lustrat ion 42

(2) Cyl inder sleeve

900529446


Measure the inside diameter of the cyl inder sleevethat is paral lel to the crankshaft . Measure theinside drameter of the cyl inder sleeve that ls in aperpendicular posi t ion to the crankshaft . Measurethe top, the middle and the bottom of the cyl indersleeve. Refer to Table 4 for tolerances of thecyl inder sleeves.

Table 4

Q,(

InsideDiameter

Out ofRound

102.010 to102.045

mm (4.0161102.200

mm (4.0236inch)

102.700mm (4.0433

inch)

lllustration 43

(3) Cyl inder sleeve

Serv ice l im i t o f cy i ;nc= ' : - :

Rep lace a l l cy l inder s lee .= : - - =l im i t

900529534

. 102.700 mmi4 0433 inch)

- - - ¡ + h ^ ^ ^ " , , i ^ ^- : : U t l l U J ú l V I U V

to 4.0175inch)

0.010 mm N/A(.0004 inch)

Taper0 .015 mm

(.0006 inch)N/A N/A

(1) The repair l imit is the maximum dimension or the repair l imit lsthe m¡nimum dimension that is specified for a part. Repair apart if the repair limit is reached.

(2) The service l¡m¡t ¡s the maximum dimension or the servicelimit is the minimum dimension that ¡s specified for a part.Replace the part if the service limit is reached.

Bore the cyl inder to the specif ied oversizedimension i f the inside dtameter reaches the repairl imit but the inside diameter does not reach theservice limit. Refer to Table 5.

Hone the sleeve to +0.25 mm (+ 010 inch)or +0.50 mm (+.020 inch) oversize. Hone thesleeve to an accuracy within 0.010 to 0.045 mm(.0004 to .0018 inch) .

Determine the oversize dimension that is necessaryin order to clean up the cyl inder i f any sleeve hasuneven wear.

Replace al l cyl inder sleeves that are in excess ofthe service I imit .

Note: Refinish all sleeves to the same oversizedimensron. Use a r idge reamer in order to cutthe r idge of the cyl inder i f the sleeve is in goodcondit ion. Hone the cvl inder bore.

Table 5

lllustration 44

Cylinder sleeves

Use the fol lowing procec- ' : - :cyl inder sleeves.

1 . Set up a bor ing macn ̂e : -A l ign the bor ing macr ,ê , ' , -

bottom of the cyl inder s e:. :

2. Bore the sleeve unt i l tne :- :"( .020 inch) .

3. Remove the remainder o' : - :not to damage the cyl lnc: ' :

Instal l a new sleeve. Al igôf the cyl inder block.

The bore of the cyl inder102.000 to 102.035 mm (¿

N/A

\\-\z

,^¡: -\// ,--'l -<t ba

?*--*$z| : , I

LI

'iil1l

I

900529962

l : - . f , repal r Ine

= - , n d e r b l o c k .' -= : en te r o f t he

' - . r e l ess wo rn

=== s 0 .50 mm

==.e, Be carefu l

==. e w i th the top4.

5.

Tolerances of Cylinder Sleevesi - - _ ! - _

Standard n^--¡- c^n,¡^^standard Repair Service

A""lirory Limit{l) Limit€)

Oversize Bore i Cylinder Bore Size

0 250 mm ( 0100 inch) J3273:5ilil Íi:339? iliil

0.500 mm ( .0197 inch) 102.510 mm (4.0358 inch)102.545 mm (4.0372 inch)

.1 0171 inch) .

LI


'-"'":l"i l::

':l: ."zuü8ro *o eo 068 mm

(3 .5441to 3 .5460 inch)

-- diameter of the main bearing. . . . . . . 9 0 . 1 5 0 m m ( 3 . 5 4 9 2 i n c h )

r l . t of deck from center l ine of crankshaft to307.00 t 0 .05 mm (12 0BO t .002 inch)

reight f rom the center l ine of crankshaft to306.70 mm (12 .075 inch)

i01023233

Put sealant on the contact surface between thesl inger and the crankshaft . Put clean engine oi l onthe surface of the rear seal assembly

(6) Distance from rear seal assembly to end ofcrankshaft 6.0 mm (.24 inch)

r01022388

Connecting Rod BearingJournalSMCS Code: 1219;1225

Table 6

Connecting Rod Bearing Journal

Original size journal(l) 59.945 to 59.965 mm(2.3600 to 2.3608 inch)

Undersize journal0.25 mm ( .010 inch)

59.695 to 59.715 mm(2.3502 to 2.3510 inch)


59.445 to 59.465 mm(2.3404 to 2.3411 inch)

lcUndersize journal

0.75 mm ( .030 inch)59 .195 to 59 .215 mm

(2.3305 to 2.3313 inch)

(1) Regrind the connecting rod journals to the next undersizedimension i f the repair l¡mit of 59.980 mm (2.3614 inch) isexceeded.

The clearance between a new bearing and a newjourna l i s the fo l low ing va lue . . . . . . 0 .035 to 0 .100 mm

( 0014 to .0039 inch)

An undersized bearing is required i f the clearancebetween the connect ing rod journal and the bearingis in excess of the service l imit of 0 200 mm(.0079 inch). l f the crankshaft is worn excessively, ori f the crankshaft is uneven, an undersized bearingis required, l f an undersized bearing is required,gr ind the crankshaft to a dimension l isted in Table 6.

Note: The al lowable tolerance for rod bearingjournals that are out of round is 0.010 mm(.0004 inch). The maximum repair l imit is 0.030 mm(.0012 inch) . l f the repa i r l im i t i s exceeded, regr indthe bearing journals to the specif ied dimension.

< \ - ^ a /

i - : = : 2 '

Noter = :

t:

t

Crankshaft SealsS M C S C o d e : 1 1 6 0 : 1 1 6 1

; -S i '3 i l ' 45

- = . - - - - ^ ^ l

2 = := ' sea f assemb ly

Nóter - - : .oar eeat assembly and the

900525904

s l inger a re

Note -ê 'ear seal assembly and the slrnger are

- - ^ ^ , , ^ i +: - : = - i J d u t i l t ,

seal assembly

--3 tear seal assembly should be f lush with

- :e ' af ter instal lat ion.

l : - :act surface between the sl tnqer and- . ^ - ^ A ^ f +_ = ' 5 t t d l t

( 5


Main Bearing JournalSMCS Code: 1203

Put the main Dea ' - : : = : :n r ¡ l i n | o r h l n ¡ ¡ D - ) = u - =

h o r r i n n h n J t c , - r - : - ' I -

i i n h i o n t h o r r z - : -torque. - J- :

/ ? \ ñ i e l i n d i n ¡ i n r

f \ r ^ ^ ^ , , , ^ + h ^ - ^f v f u c l ¡ u t v U t Y I I r d - = =

i nd ica tor . Suor ra : : - '= : : -crankshaft journa "a- " =the main bear ing ' . '= .U g O l l l I U U I V O I O l U g v :

Clearance betweer c 'a ' . : '0earrng

Note: Replace the bear - : s : ' '

to the nex t unde 's 'ze c=2" -clearance exceeos O 2a --

Tab le 7 fo r d i r re i^s ,o rs a ' - - :=

Note : The a l lowab le to ie 'a - : : - :

i o r ¡ r n a l s t h a t a r e o r r t o f . : , - : :( .0004 inch) The max i r - - -= : =( 0 0 1 2 i n c h ) . l f t h e r e p a ' - ' :the bear ing journa ls to : ê s : - :

Note : The max lmum sen ' : :iournai is -0.90 mm (- 03:crankshaft i f the cranxs?a-. : -this specif icat ion

\01022652

lllustration 46

(1) Crankshaft main bearing journal

90052534i

Measure the main bearing journal. The diameter ofthe crankshaft main bearing journal is given in Table7 .

Table 7

Main Bearing Journal

Original size journal(t) 89.95 to 89.97 mm(3.541 to 3.542 inch)

I

Undersize journal0.75 mm (.030 inch)

89.20 to 89.22 mm(3.512 to 3.513 inch)

I

( 1 ) Begrind the main bearing journals to the next undersizedimension if the repair limit of 89.85 mm (3.537 inch) isexceeded.

lllustration 48

Typical example

(4) Crankshaft

Support the crankshai - = -=Measure the runout d i - : - . - -journa l . Max imum runo- :

Note: Replace the cranksna .the reoair l imit of 0.050 mn'

900525380

- - .ee b locks .= ' ê Cente f

. 0 . 0 2 0 m m( 0008 inch)

' - . - ¡ ; t exceedslllustration 47

(2) Main bearing cap

¿.:{ln: t I- = fol lowing' C 1 t 4 l b f t )

^ a d ia l' ^ e

: ameter oÍ- ' r e t h e

- ^ a lo t .

' â l and main- : o 0 1 1 B m mc 0047 inch)

- a a ¿ a a l ' ^ A ^ 1 +E U t A t l n J t t d t L

- l r Deaf lng- : - r R e f e r t o

d t - .

' - . ' c e a r i n g- - - - n m

' - . s 0 0 3 0 m m- - - . - ^ ^ . ^ ^ , ; ^ A: - : : J ü u , r ú g I t t u

. - - * ^ ñ ^ i ^ ^: , - i E I I J ¡ U ¡ I ,

, ' - : c rankshaf t: = : a C e t h e

: i . ' , I ' n DeyOnO


89.70 to 89.72 mm(3.531 to 3.532 inch)

89.45 to 89.47 mm(3.521 to 3.522 inch)

900525373 ra

I Note: The maximum repair l imit is 0.300 mm( . 0 1 1 8 i n c h ) .

Replace the standard thrust plates i f the end playexceeds the standard clearance. Three oversizethrust plates are avai lable as replacements i f theend play st i l l exceeds the maximum l imit . General ly,the rear journal is l ikely to be worn more rapidly thanthe front journal. l f necessary, replace the rear thrustplate. Refer to Table B for oversize thrust plates.

Table 8

Dimensions for Grinding of CrankshaftOversize Thrust Plates

lllustration 49

(5) Width of crankshaft main bearing

900525383 OversizeThrustPlate

Oversize(front

or rear)

Oversize(front Tolerance

or rear)

journal . . . . . . .33.000 to 33.039 mm(1.2992 to '1 .3007 inch) +0.15 mm 33.15 mm 33.30 mm

(+.006 inch) (1.305 inch) (1.311 inch)

+0.039 mm(+ .0015

inch)

+0.039 mm+0.30 mm

(+.012 inch)(+ .0015

inch)

33.30 mm 33.45 mm(1.31 1 inch) (1 .317 inch)

+0.45 mm 33.45 mm(+ .018 i nch ) (1 .317 i nch )

33.60 mm(1.323 inch)

+0.039 mm(+.0015

inch)

I Tighten the reta¡ning nut of the crankshaft pul ley tothé fo l low lng to rque. . . . , . 490 + 5 N m (363 t 4 lb f t )

tO1022446

900525387 Connecting RodSMCS Gode: 1218

lllustration 50

(6) Put the main bearing and thrust plates in theblock and instal l the crankshaft . Put cleanengine oi l on the bolt threads Tighten the boltsto the fol lowing torque. 137 t 5 N'm

( 1 0 1 t 4 l b f t )

q00525099

9005254 1 3

l l lustrat ion 52

(1) Matcning marks

The marks are used toconnectrng rod,t l l lustrahon 51

(7) lv ' leas:re the crankshaft end olay. Endc a , 0 . '100 Io 0 .264 mm ( 0039 to .0104 inch)

ryfr

al ign the cap to the

I 22Specifications Section

(3) Connect ing rod bolts

Before assembly, put c ea- =- I -= ci l on the

bo l t th reads and a l l sur la :=- - : *aKe contac tbe tween the bo l t and co- - = - ' ' , - : l caps .

T i g h t e n t h e c o n n e c : ' a ' - = - - ' : - - - e f o l l o w l n gt o r q u e . i l : - : . - - z 6 t 4 l b f t )

t(

(4 ) Measure the bores a ' e r : - : -rods and record the c - :- . : -

_ 1 n n a ^ t r n n-- e bores.

lllustration 53 9005251 03

(A) The upper oi l hole is 40 degrees above thehorizontal center l ine.

(B) The lower oi l hole is 30 degrees below thehorizontal centerline,

(C) The end of the piston pin bearing is 30 degreesbelow the lower oi l hole.

i l lu$raüon 54

(2) Bore of piston pinbearing 34.020 to 34.045 mm

(1.3394 to '1.3404 inch)

The clearance between the piston pin bearingand the piston pin is 0.023 to 0.054 mm(.0009 to .0021 inch).

Note: A clearance for the piston pin to the piston pinbearing over 0.010 mm (.0004 inch) is excessive.Replace the piston pin or replace the bearing if theclearance is excessive.

lllustration 55

(5) Connect ing rod

Use a fee le r gauge to - : : : -E n d p l a y . . . . 0 . 1 5 t o 0 3 : - -

9005251 94

: ' - : eno p lay ., - : : o 0 1 4 i n c h ) I

Note : Rep lace the conne: . - I

' : : : a n ñ n t q \ /

exceeds 0 .50 mm ( A2 i - : -

\ /

h(\ \ / u IV/

Cl:---'

'l

I -

lllustration 56

(6) Piston

(7) Markings on piston

900525201

Assemble the p is ton and cc- -= : ' - =

' :ds . Ensuretha t the mark ings on the p ,s : : - -

: - : the markso n t h e c o n n e c t i n g r o d ( 1 ) a t e . - - - = = : ' n e s i d e . tC


Plston projection . . 0 . 5 5 t o 1 . 1 5 m m(.0221o.045 inch)

\a1421241

Piston and RingsSMCS Code: 1214,1215

lllustrat¡on 57 90o525206

(B) Instal l the piston assembly with the marks (1) on. the connect ing rod toward the camshaft (8).

l l lustrat ion 58

(9) Piston projection

900525250

Use the fol lowing procedure to measure thehelght of each piston above the cyl inder block. l fc learances are not in the acceptable range, inspectthe components for wear or damage.

1. Determine the top center posi t ion of the piston

with a dial indicator assemblY.

2- inetal t the dia. t indicator assembly on the top of

t he b l ock . Se t t he need le o f t he d ¡a l i nd i ca to r t o

zero.

3. Measure projection (9) at three places onthe top of the piston. Take an average of thethree measurements in order to determine theprojection. Subtract the projection from theinstal led thickness of the cyl inder head gasket inorder to determine the clearance between thetop of the piston and the cyl inder head.

Instal led thickness of the cyl inoer readgasket . .110 t 0 10 mnr ( .070 t .004 inch)

Each piston has markings which are stamped ontop of the piston. The markings are used to al¡gnthe plston assembly to the camshaft s ide of thecyl inder block,

(2) Piston diameter

Table 9 gives the dimensions for prstons that arestandard, Table 9 also gives the dimensions forpistons that are oversize.

Note: Measure the piston diameter along theperpendicular of the piston pin bore.

900524461lllustration 59

(1 ) Mark ings on p is ton

lzaSpecif ications Section

(5) Crankshaft gear

Note: Ensure that the marks on the t iming gears arein a l ignment .

lllustration 65

ldler gear (2)

900527864

Instal l a dial indicator and rotate the idler gear(2) back and forth in order to measure backlash.Replace the idler gear i f the backlash exceeds theservice l imit . Refer to Table 11.

Table 11

0.100 mm(.0039 inch)

(1) Replace the idler gear if the service limit is exceeded

lllustration 66

(6) ld ler gear bolt

l l lustrat ion 67

/ ? \ r ^ ^ i ! ^ : i ^ - ^ + ^ ' ^ . C : . : : : . _ _\ / , / i l t > r L r g L j r d r r E r u r v _

/ Q \ l r i l a r n o e r c h a f t\ v / , v ' v '

R e p l a c e t h e b u s h i n g i : ' : : : = - : - .id le r gear bush ing and : -e : = - - : -1the service l imit . Reter rc

-?= . ' '

i r ^ ^ ^ , , , ^ + A ^

f a o l o r a c ' r ^ a Q c j ; ' - ^ i - : '

' t r f l a r a a a r h r l ' ' . " . - - - ' - -

r v r u r v u q r v v . . J - :

- ' : ' ,a f Wi th a- ; ^ ten the

, . r - : , . 3 5 N ' m(26 rb f t )

j00527912

- c

- - t , . , ^ ¡ n t F . n- = i v v E v t I L ¡ t 9- - - { + ^ . / ^ ^ ^ ^ ^: d t L E ^ u g v u )

(

0r 028537

FlywheelSMCS Code: 1156[]

lr,iiiI

It

ili

,1i

l'

l

t

lllustration 68

(1) Flywheel

P lace the f l ywhee l on a s - ' -= : : :i n d i c a t o r i n o r d e r t o m e a s - ' = ' - =f lywheel.

Standard at assembly o' ' .. , ', - ==

900529633

- - ^ | t ^ ^ ^ , . 1 : ^ l

' . i ness o f the

. . 0 1 5 m m/ ñ O A i n n h \\ . v v v Í r v r r /

i

0.03 to 0 .17 mm(.001 to

.007 inch)

0.05.to^0.20 mm 0.35 mm

ártrtil?., ('br+ ¡ncn)

. clearance o.oog to o.ogo?:'-Y":il95j mm (.ooo4 tos"-1'-o!:llls .ooit incn¡

and Snan L

90052791 0


Repa i r l im i t o f f l ywhee l . . . . . .0 .50 mm ( ,020 lnch)

Note: Refrnish the f lywheel i f the repair l imit isexceeded

lllustration 69 q00529634

(2) Measure the runout on the f lywheel face with ad ia l ind ica tor . Max imum face runout . . . 0 .15 mm

(.006 inch)

Repa i r l im i t o f face runout . . . . . . . 0 .50 mm ( .020 inch)

Note: Ref inish the f lywheel i f the repair l imit isexceeoeo.

Max nrm permissible temperature o' the r ing gearfor instal lat lon on the f lywheel without using ar o r c n . , , . . , . . . . . . . 1 5 0 " C ( 3 0 2 ' F )

Note: The r ing gear is pressed on the f lywheel.

Tighten the f lywheel bol ts to the fol lowingtorque 83 t 5 N'm (61 t 4 lb f t )

Number o f tee th o f the f l ywhee l r ing gear . . . . . . . . .127

Apply pressure to each belt midway between thepul leys in order to inspect the belt tension. Adjustthe bolt for the al ternator i f the tension is incorrect.

Proper fan belt tension is approximately thefol lowing def lect ion. . .12.0 mm (.50 inch)

r01053076

Belt TensionerSMCS Code: 1358

q005461 32lllustration 70

( 1 ) B o l t .


i 01031047 o,o.,r . , f (Belt TensionerSMCS Gode: 1358

AlternatorSMCS Code: 1405

900530808 lllustration 72

(1 ) Nut fo r a l te rna tor Pu l re . '

T igh ten the nu t fo r t te z ' . ' ' .fo l low ing to rque. , , .

Polarity

Rotat ion

Speed for test ing (rPm)

Output voltage

Rated outPut . .

900530887

: - ey to tne' i 2 t o 1 6 2 N ' ml - t o 1 1 9 l b f t )

- = ;a t i ve g round

: :rer direct ion

. 5000 rPm

.28.0 t .5 V

lllustration 71

(1) Bol t (

Apply pressure to each belt midway between thepul leys in order to inspect the belt tension. Adjustifre Oott for the alternator if the tension is incorrect

Proper fan belt tension is approximately thefo l low ing de f lec t ion . . . . . .120 mm ( .50 inch)

5 0 4

.aI I- !


101 031378

Electric Starting MotorSMCS Code: 1453

l l lustrat ion 73

(1) Terminal nuts

900530889

Tighten the termrnal nuts to the fol lowingt o r q u e . . . . . . . 1 1 t 1 N ' m ( 9 7 t 9 t b i n )

The rotation is viewed from the drive end of theelectnc start ing motor. Rotat ion of electr ic start ingm o t o r . . . , . . . . . c l o c k w i s e

No load condit ions

Speed ( rpm) . . . 3300 rpm min lmum

Maximum current (draw) . . . 85 A

V o l t a g e . . . . . . . . . . . . . . . 2 3 \ /

30lndex Section

lndex

A

Alternator .- ' . ' 28

M

Main Bear ing Journa | . . . . . . . . . . . .

B

Bef t Tensioner . . . . . . . . . . . . . . . . 27,28

c

Camshaft . ' . ' . ' 12Connect ing Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . " ' 21Connect ing Rod Bearing Journal . . . ' . . 19Crankshaf t Sea ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . " 19C y l i n d e r 8 1 o c k . . . . . . . . . ' . . . ' . " 1 7Cy l inder Head . . . . . . . . . . . . . . ' . . . ' 9

E

Elec t r i c S tar t ing Motor . . . . . . . . . ' . " ' . - . . . . " .29E n g i n e D e s i g n . ' - . . . . . ' . ' . ' . . . ' . 4

3 0 6 4 E n g i n e ' . . ' . ' . " . ' . . . ' . . . . 43066 Eng ine ' - . - . ' . " . . . ' . . ' . ' -4

Eng ine Oi l Bypass Va lve . . . . . . . " . - . . . . . . . .16f n g i n e O i l P a n . . . . . . . . . . . . . . . . 1 6eng ine Oi l Pressure . . . . . . . . 16fngine Oi l Pressure Rel ief Valve .- . ' . ' . '14f n g i n e O i l P u m P ' . " . " " ' . . . 1 4Exhaust Man i fo ld . ' . . ' . ' . . . . .11

F

Flywhee l ' . . " . .26Fue l In jec t ion L ines " . ' . . . . . . .5Fue l In jec t ion Nozz les . " . . . " . . . . ' . . . ' . . . . . ' . . 5Fue l In jec t ion PumP . . . . . . . . ' .5

G

Gear Group (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

I

lmportant Safety Information. "--.-.--. . . . ' .2

P

Pis ton and R ings . . . . . . . . ' . . . . . . ' 23

Va lve Rocker Arm . . . . . . . . . . . . . ' . . . . ' , . . " , . . . . . 8

w

Wate r Pump . . . . . . . . . . . . . . . . ' . . " ' . . ' . . 17Water Temperature Regulator ' . ' . . . . . . . . . . . . . . . 16

5I -801Ó Water Temperatur : = : : - la tor . . . . ' . . . . . . . 165I -8020 Water Temperature ==:- la tor . ' . . . . " " " 16

(

tIj

20

torques motor 3066

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