SENR5545-04 f

CATERPILLAR October 2001

3064 and 3 0 6 6 Engines for Caterpillar

sy Built Machines
6LK1-Up (Engine)
7JK1-Up (Engine)
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

WARNING

The meaning of this safety alert symbol is as follows:

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

WARNING
When replacement parts are required for this
product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 3
Table of Contents

Table of Contents
Specifications Section
Engine Design 4
Fuel Injection Lines 5
Fuel Injection Pump 5
Fuel Injection Nozzles 6
Lifter Group 6
Rocker Shaft 7
Valve Mechanism 8
Vafve Mechanism Cover 9
Cylinder Head 9
Turbocharger 10
Exhaust Manifold 11
Camshaft 12
Engine Oil Relief Valve 13
Engine Oil Pump 14
Engine Oil Pressure 15
Engine Oil Bypass Valve 15
Engine Oil Pan 16
Water Temperature Regulator 16
Water Pump 16
Cylinder Block 17
Crankshaft 18
Crankshaft Seals 20
Connecting Rod Bearing Journal 20
Main Bearing Journal 21
Connecting Rod 21
Piston and Rings 23
Gear Group (Front) 25
Flywheel 26
Crankshaft Pulley 27
Belt Tension Chart 27
Belt Tightener 28
Alternator and Regulator 28
Electric Starting Motor 29
Coolant Temperature Switch 29
Engine Oil Pressure Switch 29
Air Inlet Heater 29

Index Section
index 30
4
Specifications Section

Specifications Section The crankshaft rotation is viewed from the

flywheel end of the engine. Crankshaft
rotation Counterclockwise

Note: The front end of the engine is opposite of

Engine Design the flywheel end of the engine. The left side of the
engine and the right side of the engine are viewed
SMCSCode: 1201 from the flywheel end of the engine. The No. 1
cylinder is the front cylinder.
3064 Engine
3066 Engine

Illustration 1 g00523889
Cylinder and valve location Illustration 2 g00295223
(A) Exhaust valve Cylinder and valve location
(B) Inlet valve (A) Exhaust valve
(B) Inlet valve
Type Four cylinder and four stroke
Type Six cylinder and four stroke
Combustion system Direct injection
Combustion system Direct injection
Bore 102 mm (4.02 inch)
Bore 102 mm (4.02 inch)
Stroke 130 mm (5.12 inch)
Stroke 130 mm (5.12 inch)
Number of cylinders 4
Number of cylinders 6
Displacement 4.3 L (260 in3)
Displacement 6.4 L (390 in3)
Cylinder arrangement In-line
Cylinder arrangement In-line
Valves per cylinder 2
Valves per cylinder 2
Firing order 1 -3-4-2
Firing order 1-5-3-6-2-4
Compression ratio 17:1
Compression ratio 17:1
Note: Refer to the Engine Information Plate for the
performance specification number. Refer to the Note: Refer to the Engine Information Plate for the
Technical Marketing Information (TMI) or refer to the performance specification number. Refer to the
Fuel Setting and Related Information Microfiche for Technical Marketing Information (TMI) or refer to the
the correct timing specifications. Fuel Setting and Related Information Microfiche for
the correct timing specifications.
Minimum rpm 900 20
Minimum rpm 900 20
 5
Specifications Section

The crankshaft rotation is viewed from the

flywheel end of the engine. Crankshaft
rotation Counterclockwise Fuel Injection Pump
Note: The front end of the engine is opposite of SMCSCode: 1251; 1290
the flywheel end of the engine. The left side of the
engine and the right side of the engine are viewed
from the flywheel end of the engine. The No. 1
cylinder is the front cylinder.

Fuel Injection Lines

SMCSCode: 1252

Illustration 4

(1) Bolts for fuel injection line

Illustration 3 Tighten the bolts for the fuel injection line to the
following torque 20 to 25 N-m (15 to 18 lb ft)
(1) Fuel injection lines
(2) Delivery valve holder
Tighten the fuel injection line nuts to the
following torque 29 3 N-m (21 2 lb ft) Tighten the delivery valve holder to the following
torque 39 to 44 N-m (29 to 32 lb ft)

(3) Bolt for lock plate

Tighten the bolt for the lock plate to the following
torque 3 to 5 N-m (27 to 44 lb in)

(4) Bolt for fuel line

Tighten the bolt for the fuel line to the following
torque 10 to 13 N-m (7 to 10 lb ft)

(5) Idler subspring nut

Tighten the idler subspring nut to the following
torque 12 to 16 N-m (9 to 12 lb ft)

(6) Idler subspring

Tighten the idler subspring to the following
torque 16 to 20 N-m (12 to 15 lb ft)

(7) Nut
Tighten the nut to the following
torque 3 to 5 N-m (27 to 44 lb in)
6
Specifications Section

(6) Pressure spring

Fuel Injection Nozzles (7) Pressure pin
SMCSCode: 1254 (8) Gasket

(9) Pin

(10) Tip for fuel injection nozzle

(11) Retaining nut for fuel injection nozzle

Tighten the nut to the following
torque 34 + 5 N-m (25 4 lb ft)

Lifter Group
Illustration 5 g00530280 SMCSCode: 1209

(1) Seal
(2) Fuel injection nozzle

(3) Retainer for fuel injection nozzle

Tighten the retaining bolt to the following
torque 22 N.m (16 lb ft)

Illustration 7

(10) Tappet bore diameter

Tappet bore diameter 22.000 to 22.021 mm
(0.8661 to 0.8670 inch)
Maximum tappet bore diameter 22.055 mm
(0.8683 inch)
Clearance of tappet to bore.. 0.035 to 0.086 mm
(0.0014 to 0.0034 inch)

Note: Replace the tappet if the clearance is

exceeded.

Illustration 6

(4) Body for fuel injection nozzle

(5) Shims

Increasing shims by 0.10 mm (0.004 inch) changes

injection pressure by approximately 1375 kPa
(200 psi). Shims are available in nine sizes from
0.10 mm (0.004 inch) to 0.58 mm (0.023 inch).
 7
Specifications Section

Rocker Shaft
SHCS Code: 1102

Illustration 10

Position the rocker shaft brackets and mounting

bolts.

lflustration8 (4) Long bolt

(1) Rocker arm bushing Tighten the long bolt to the following
torque 15 + 3 N-m (11 2 lb ft)
Bore in rocker arm bushing for
shaft 20.011 to 20.094 mm (5) Short bolt
(0.7878 to 0.7911 inch)
Tighten the short bolt to the following
(2) Rocker arm shaft torque 15 3 N-m (11 2 lb ft)
Diameter of rocker arm (6) Rocker shaft bracket
shaft 19.966 to 19.984 mm
(0.7861 to 0.7868 inch)

Clearance of rocker arm bushing for

shaft 0.027 to 0.128 mm (0.0011 to 0.0050 inch)

Replace the rocker arm bushing if the repair limit of

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

Illustration 11
Valve lash adjustment

Turn the crankshaft until the timing mark on the

crankshaft pulley is aligned with the pointer on the
timing gear housing in order to adjust the valve lash.
Both the No. 1 inlet valve and the No. 1 exhaust
valve pushrods must not be in tension against the
rocker arms.

Inlet and exhaust valve lash .. 0.25 mm (0.010 inch)

(3) Align the oil holes in rocker arm bushing (A)

with the oil holes in the rocker arm when the
rocker arm bushing is replaced.
8
Specifications Section

Maximum allowable clearance for guide for inlet

valve 0.150 mm (0.0059 inch)
Valve Mechanism
Maximum allowable clearance for guide for
SMCS Code: 1102 exhaust valve 0.200 mm (0.0079 inch)

(5) Outside diameter of valve guide

Outside diameter of guide for inlet
valve 13.025 to 13.035 mm
(0.5128 to 0.5132 inch)
Outside diameter of guide for exhaust
valve 13.025 to 13.035 mm
(0.5128 to 0.5132 inch)
Inside diameter of guide for new inlet
valve 8.010 to 8.035 mm
(0.3154 to 0.3163 inch)
Inside diameter of guide for new exhaust
valve 8.010 to 8.025 mm
(0.3154 to 0.3159 inch)
Maximum inside diameter for guide for inlet
valve 8.09 mm (0.319 inch)
Maximum inside diameter for guide for exhaust
Illustration 12 valve 8.12 mm (0.320 inch)

(1) Spring (6) Thickness of lip

Length under test force .... 44.0 mm (1.73 inch) Valve lip thickness for inlet and exhaust
Test force 223 to 246 N (50 to 55 lb) valves 2.13 mm (0.084 inch)
Free length after test 56.4 mm (2.22 inch)
Maximum bend in spring 2 degrees Minimum allowable valve lip thickness for inlet
and exhaust valves 1.20 mm (0.047 inch)
(2) Valve stem seal
(7) Angle of valve face 30 degrees
(3) Height to top of valve guide .. 17.00 0.30 mm
(0.669 0.012 inch)

(4) Diameter of valve stem

Inlet valve stem 7.940 to 7.955 mm
(0.3126 to 0.3132 inch)
Exhaust valve stem 7.920 to 7.940 mm
(0.3118 to 0.3126 inch)
Minimum allowable diameter for inlet valve
stem 7.900 mm (0.3110 inch)
Minimum allowable diameter for exhaust valve
stem 7.850 mm (0.3091 inch)
Illustration 13
Clearance for intake valve stem in valve
guide 0.055 to 0.085 mm (8) Depth of bore in head for valve seat
(0.0022 to 0.0033 inch) insert 9.5 0.1 mm (0.374 0.004 inch)
Clearance for exhaust valve stem in valve (9) Chamfer of inlet valve 40 degrees
guide 0.070 to 0.105 mm
(0.0028 to 0.0041 inch) Note: The depth of the chamfer of the inlet valve is
2.38 0.10 mm (0.094 0.004 inch).
 Specifications Section

(10) Chamfer of exhaust valve 45 degrees (16) Pushrod

Note: The depth of the chamfer of the exhaust valve
is 2.00 0.10 mm (0.079 0.004 inch).
(11) Valve seat bore for inlet.. 46.000 to 46.025 mm
(1.8110 to 1.8120 inch)
Use a dial indicator in order to check all
pushrods for runout. Replace the pushrod if the
runout exceeds the following value 0.40 mm
(0.016 inch)

(12) Valve seat bore for

exhaust 39.000 to 39.025 mm Valve Mechanism Cover
(1.5354 to 1.5364 inch)
SMCSCode: 1107

Illustration 14
Illustration 16
(13) Width of valve seat 1.40 0.20 mm
(0.055 0.008 inch) (1) Valve cover nut

Note: The maximum permissible width of the valve Tighten the valve cover bolts to the following
seat is 1.80 mm (0.071 inch). torque 1 5 3 N - m ( 1 1 2 lb ft)

(14) Valve seat angle 30 degrees

(15) Dimension from top of closed valve to face of Cylinder Head

head
SMCSCode: 1100
Exhaust valve 0.50 0.25 mm
(0.020 0.010 inch)
Inlet valve 0.40 0.25 mm
(0.016 0.010 inch)

Note: The maximum permissible depth is 1.10 mm

(0.043 inch).

Illustration 17

(1) Cylinder head

Use a straightedge and a feeler gauge to check
the cylinder head for warpage.
Flatness of the cylinder head over total span
0.05 mm (0.002 inch)
Illustration 15
10
Specifications Section

Resurface the cylinder head if the warpage

exceeds the following amount 0.20 mm
(0.008 inch) Turbocharger
Gasket thickness of cylinder SMCS Code: 1052
head 1.70 0.10 mm (0.070 0.004 inch)
Thickness of new head 95.00 0.10 mm
(3.740 0.004 inch)
Minimum thickness of cylinder head .. 94.70 mm
(3.728 inch)

Note: The repair limit of the contact surface of the

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

Illustration 20 g00530558

(1) Compressor wheel

(2) Turbine wheel

(3) Turbine housing

(4) Compressor housing

(5) Cartridge housing

Illustration 18
Numerical sequence of bolts for 3064 Engine Note: Mark the orientation of the compressor
housing, the cartridge housing and the turbine
housing before disassembly.

Illustration 19
Numerical sequence of bolts for 3066 Engine

Put clean engine oil on the threads of the cylinder

head bolts. Install the bolts and tighten the bolts in
the appropriate numerical sequence to the following
torque 118 + 5 N.m (87 4 lb ft)

Illustration 21

(6) Turbine shaft

 11
Specifications Section

Place a dial indicator on the end of the turbine

shaft. Move the compressor wheel (1) in the
axial direction in order to measure end play. End
play .... 0.057 to 0.103 mm (.0022 to .0041 inch)

Note: The turbocharger must be disassembled and

the turbocharger must be checked for clearances if
the end play is beyond the specifications.

Illustration 24 g00530564

(8) Clamp
Apply 5P-3931 Anti-Seize Compound to the
threads of the clamp. Tighten the clamp to the
following torque 4 1 N-m (35 9 lb in)

Tap clamp (8) lightly around the circumference.

Illustration 22 900530561
Tighten clamp (8) to the following
torque 4 1 N-m (35 9 lb in)
(7) Lock plates
Position the lock plates and tighten the bolts to i01575653
the following torque 20 N-m (15 lb ft)
Exhaust Manifold
SMCS Code: 1059

Illustration 23 900530562
Turbine housing (3) and Cartridge housing (5)

Align the turbine housing (3) with the cartridge Illustration 25 900530254
housing (5).
(1) Nuts for turbocharger
Tighten the nuts for the turbocharger to the
following torque 41 N-m (30 lb ft)

(2) Studs for turbocharger

Tighten the studs for the turbocharger to the
following torque 12 N-m (9 lb ft)

(3) Studs for exhaust manifold

Tighten the studs for the exhaust manifold to the
following torque 12.5 N-m (9 lb ft)
12
Specifications Section

(4) Nuts for exhaust manifold

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

Camshaft
SMCSCode: 1210

Illustration 27 g00527952

(4) Camshaft lobe lift

Specified camshaft lobe lift (4)

Exhaust lobe 7.344 mm (0.2891 inch)
Inlet lobe 6.689 mm (0.2633 inch)

Service limit for lobe lift for exhaust 6.844 mm

(0.2695 inch)
Illustration 26

(1) Camshaft gear Service limit for lobe lift for inlet 6.189 mm
(0.2437 inch)
Maximum permissible temperature of the gear
for installation on the camshaft.... 315C (600F) Note: Replace the camshaft if the service limit for
the lobe lift is reached.
Note: Do not use a torch.
(5) Camshaft lobe height
(2) Diameters of camshaft journals
(6) Base circle
Table 1
Number Number To find the lobe lift, use the procedure that follows:
of Journal of Journal Standard Service
for 3064 for 3066 Diameter Limit(1) 1. Measure the camshaft lobe height (5).
Engine Engine
2. Measure the base circle (6).
53.94 to
53.96 mm 53.90 mm
1, 2 1, 2, 3 (2.122 inch)
3. Subtract the base circle that is found in Step 2
(2.123 to
2.124 inch) from the lobe height that is found in Step 1. The
difference is the actual camshaft lobe lift (4).
52.94 to
52.96 mm 52.90 mm
3 4
(2.084 to (2.083 inch)
2.085 inch)
(1) The service limit is the maximum dimension or the service limit
is the minimum dimension that is specified for a part. Replace
the part if the service limit is reached.

(3) Thrust plate bolt

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

Illustration 28
 13
Specifications Section

Note: Use a dial indicator and blocks in order to (9) Install the dial indicator in order to determine
determine the runout of the camshaft. Take one half gear end play.
of the dial indicator reading as the runout.
End play 0.10 to 0.25 mm
(7) Camshaft (0.004 to 0.010 inch)

Maximum permissible runout for Replace the thrust plate if the end play exceeds
camshaft 0.020 mm (0.0008 inch) the following amount 0.30 mm (0.012 inch)

Straighten the camshaft if runout is less than the Thrust plate thickness 4.85 mm (0.191 inch)
following amount 0.050 mm (0.0020 inch)
Replace the camshaft if runout is more than the
following amount 0.050 mm (0.0020 inch) Engine Oil Relief Valve
SMCS Code: 1315

Illustration 29

(8) Camshaft bearing Illustration 31

Engine oil relief valve
Measure the camshaft bearing with a dial indicator.
Subtract the diameter of the camshaft journal in Remove the oil pressure relief valve from the
order to give bearing clearances. Refer to Table 2. cylinder block. Check the valve and the valve seat
for abnormal contact patterns. Inspect the spring
Table 2
for weakness or damage. Replace the oil pressure
Standard relief valve, if necessary.
Repair Limit(1)
Diameter
Relief valve opening pressure 343 20 kPa
Clearance
0.04 to 0.09 mm
(50 3 psi)
between
0.15 mm Tighten the engine oil relief valve to the following
camshaft (0.002 to
(0.006 inch) torque 49 + 5 N-m (36 4 lb ft)
journals and 0.004 inch)
bushings
(1) The repair limit is the maximum dimension or the repair limit is
the minimum dimension that is specified for a part. Repair the
part if the repair limit is reached.

Illustration 30
14
Specifications Section

Engine Oil Pump

SMCS Code: 1304

Illustration 32

Illustration 33
NOTICE
Before operation, the pump must be lubricated with
(6) Housing for oil pump gear
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result. Measure the difference in the length
of the assembly for the oil pump gear
Note: The minimum acceptable oil pressure at low and the depth in the oil pump housing.
idle is 100 kPa(15 psi). Clearance 0.020 to 0.034 mm
(0.0008 to 0.0013 inch)
(1) Driven gear assembly
Note: Replace the oil pump gear assembly if the
(2) Drive gear assembly clearance exceeds the service limit of 0.150 mm
(0.0059 inch).
(3) Oil pump gear
Measure the clearance between the oil pump gears
Note: Do not use a torch. and the oil pump housing with a feeler gauge.
Clearance 0.050 to 0.098 mm
Heat the oil pump gear to 180 to 220C (0.0020 to 0.0039 inch)
(356 to 428F) and support the end of the drive
gear shaft in order to install the oil pump gear. Press Note: Replace the oil pump gear assembly if the
the oil pump gear until the oil pump gear is flush clearance exceeds the service limit of 0.150 mm
with the end of the shaft. (0.0059 inch).
(4) Idler gear assembly
The backlash between the oil pump
gear and the idler gear is the following
amount 0.100 to 0.190 mm
(0.0039 to 0.0075 inch)

Note: Replace the gears if the backlash exceeds

0.35 mm (0.014 inch).

(5) Spindle

Note: The oil pump gear and the drive gear

assembly are not serviceable if the oil pump gear
is removed.
 15
Specifications Section

(7) Cover (10) Bolts

Measure the inside diameters of the bores of Tighten the bolts (10) for the oil pump cover (7)
the shafts in the cover (7) and the oil pump to the following torque 35 6 N-m
housing (6). Measure the bores of the shafts. (26 4 lb ft)
The clearance between the gear shafts and the
oil pump housing and cover.... 0.04 to 0.07 mm
(0.002 to 0.003 inch)

Note: Replace the oil pump gear assembly, the

Engine Oil Pressure
cover, or the oil pump housing if the clearance SMCS Code: 1924
exceeds the service limit of 0.15 mm (0.006 inch).
Table 3
Note: Replace the drive gear and driven gear as
Engine Oil Pressure(1)
an assembly.
196 to 392 kPa
Oil Pressure at 1500 rpm
(28 to 57 psi)
Oil Pressure at idle(2) 98 kPa (14 psi)
(1)The oil temperature must be 60 to 70C (140 to 158F).
(2) Engine idle is 900 20 rpm.

Engine Oil Bypass Valve

SMCS Code: 1306-BV

Illustration 35

(8) Idler gear bushing

Inside diameter of idler gear
bushing 25.000 to 25.021 mm
(0.9843 to 0.9851 inch)
Maximum diameter of idler gear bushing for oil
pump 25.059 mm (0.9866 inch)

(9) Spindle
Diameter of spindle 24.939 to 24.960 mm
(0.9818 to 0.9827 inch)
Minimum diameter of spindle for oil
pump 24.901 mm (0.9804 inch)

Illustration 37

Note: The oil bypass valve is mounted inside the oil

pan along the rail of the oil pan.

(1) Valve seat

Check the valve and the valve seat for abnormal

contact patterns.

(2) Spring
Inspect the spring for weakness or damage.
Free length of spring 83.5 mm (3.29 inch)
Illustration 36
16
Specifications Section

Opening pressure of bypass valve .... 981 98 kPa

(142 14 psi)
Water Pump
Tighten the oil bypass valve to the following torque.
69 5 N-m (51 4 lb ft) SMCS Code: 1361

Engine Oil Pan

SMCSCode: 1302

2 Illustration 39
Illustration 38 g00530566

(1) Oil pan bolts (1) Impeller

Tighten the oil pan bolts to the following The faces of the impeller and the water pump shaft
torque 28 7 N-m (21 5 lb ft) are flush.
(2) Oil pan drain plug (2) Flange
Tighten the oil pan drain plug to the following
(3) The distance from the face of the impeller
torque 39 5 N-m (29 4 lb ft)
to the water pump housing is the following
amount 21.00 to 21.70 mm
(0.826 to 0.854 inch)

Water Temperature Regulator

SMCS Code: 1355

The water temperature regulator starts to open at

the following temperature. ... 71 2C (160 4F)

The optional water temperature regulator starts to

open at the following temperature 82C (180F)

The valve lifts more than 10 mm (0.4 inch) at the

following temperature 85C (185F)

The optional water temperature regulator lifts

more than 10 mm (0.4 inch) at the following Illustration 40
temperature 96C (204F)
(4) Water pump shaft
 17
Specifications Section

The press fit between the water pump Measure the inside diameter of the cylinder sleeve
shaft and the flange is the following that is parallel to the crankshaft. Measure the
amount 0.035 to 0.065 mm inside diameter of the cylinder liner that is in a
(0.0014 to 0.0026 inch) perpendicular position to the crankshaft. Measure
the top, the middle and the bottom of the cylinder
The press fit between the water pump liner. Refer to Table 4 for tolerances of the cylinder
shaft and the impeller is the following liner.
amount 0.032 to 0.065 mm
(0.0013 to 0.0026 inch) Table 4
Tolerances of Cylinder Sleeves
J01576112 Standard at Repair Service
Assembly Limit(1) Limit(2)
Cylinder Block
102.010 to
SMCSCode: 1201 102.045 102.200 102.700
Inside
mm mm (4.0236 mm (4.0433
Diameter
(4.0161 to inch) inch)
4.0175 inch)
0.010 mm
Out of
(0.0004 N/A N/A
Round
inch)
0.015 mm
Taper (0.0006 N/A N/A
inch)
(1) The repair limit is the maximum dimension or the repair limit
is the minimum dimension that is specified for a part. Repair a
part if the repair limit is reached.
(2) The service limit is the maximum dimension or the service limit
is the minimum dimension that is specified for a part. Replace
the part if the service limit is reached.
Illustration 41 ^00529444
Bore the cylinder to the specified oversize
(1) Cylinder block dimension if the inside diameter reaches the repair
limit but the inside diameter does not reach the
Measure the amount of the warpage of service limit. Refer to Table 5.
the cylinder block with a straightedge
and feeler gauge. Maximum allowable Hone the liner to +0.25 mm (+0.010 inch) or
clearance 0.05 mm (0.002 inch) +0.50 mm (+0.020 inch) oversize. Hone the
liner to an accuracy within 0.010 to 0.045 mm
Repair limit .0.20 mm (0.008 inch) (0.0004 to 0.0018 inch).
Resurface the top of the block if the repair limit is Determine the oversize dimension that is necessary
reached. in order to clean up the cylinder if any liner has
uneven wear.

Replace all cylinder liners that are in excess of the

service limit.

Note: Refinish all liners to the same oversize

dimension. Use a ridge reamer in order to cut the
ridge of the cylinder if the liner is in good condition.
Hone the cylinder bore.

Table 5
Oversize Bore Cylinder Bore Size
102.260 mm (4.0260 inch)
0.250 mm (0.0100 inch)
102.295 mm (4.0274 inch)
Illustration 42 900529446
102.510 mm (4.0358 inch)
0.500 mm (0.0197 inch)
(2) Cylinder liner 102.545 mm (4.0372 inch)
18
Specifications Section

New diameter for the main bearing

bores 90.020 to 90.068 mm
(3.5441 to 3.5460 inch)

Maximum diameter of the main bearing

bores 90.150 mm (3.5492 inch)

New height of deck from centerline of crankshaft to

deck 307.00 0.05 mm (12.086 0.002 inch)

Minimum height from the centerline of crankshaft to

deck 306.70 mm (12.075 inch)

i01573686
Illustration 43 g00529534
Crankshaft
(3) Cylinder liner
SMCSCode: 1202
Service limit of cylinder liner 102.700 mm
(4.0433 inch)

Replace all cylinder liners that exceed the service

limit.

Illustration 45 900525341

(1) Crankshaft main bearing journal

Measure the main bearing journal. The diameter

Illustration 44 g00529962 of the crankshaft main bearing journal is given in
Cylinder liner Table 6.
Table 6
Use the following procedure in order to repair the
cylinder liners. Main Bearing Journal
89.95 to 89.97 mm
1. Set up a boring machine on the cylinder block. Original size journal (1)
(3.541 to 3.542 inch)
Align the boring machine with the center of the
bottom of the cylinder liner with the less worn Undersize journal 89.70 to 89.72 mm
area. 0.25 mm (0.010 inch) (3.531 to 3.532 inch)
Undersize journal 89.45 to 89.47 mm
2. Bore the liner until the thickness is 0.50 mm 0.50 mm (0.020 inch) (3.521 to 3.522 inch)
(0.020 inch).
Undersize journal 89.20 to 89.22 mm
3. Remove the remainder of the liner. Be careful not 0.75 mm (0.030 inch) (3.512 to 3.513 inch)
to damage the cylinder block. (1) Regrind the main bearing journals to the next undersize
dimension if the repair limit of 89.85 mm (3.537 inch) is
4. Install a new liner. Align the liner with the top of exceeded.
the cylinder block.

5. The bore of the cylinder must be

102.000 to 102.035 mm (4.0157 to 4.0171 inch).
 19
Specifications Section

Illustration 46 Illustration 48

(2) Crankshaft (4) Crankshaft end play 0.100 to 0.264 mm

(0.0039 to 0.0104 inch)
Support the crankshaft in a set of vee blocks.
Measure the runout dimension at the center Note: The maximum repair limit is 0.300 mm
journal. Maximum runout 0.020 mm (0.0118 inch).
(0.0008 inch)
Replace the standard thrust plates if the end play
Note: The allowable tolerance for main bearing exceeds the standard clearance. Three oversize
journals that are out of round is 0.010 mm thrust plates are available as replacements if the
(0.0004 inch). The maximum repair limit is 0.030 mm end play still exceeds the maximum limit. Generally,
(0.0012 inch). If the repair limit is exceeded, regrind the rear journal is likely to be worn more rapidly than
the bearing journals to the specified dimension. the front journal. If necessary, replace the rear thrust
plate. Refer to Table 7 for oversize thrust plates.
Note: The maximum service limit for the crankshaft
journal is 0.90 mm (0.035 inch). Replace the Table 7
crankshaft if the crankshaft journal is worn beyond
Dimensions for Grinding of Crankshaft
this specification.
Oversize Thrust Plates
Note: Replace the crankshaft if the runout exceeds Oversize Oversize Oversize
the repair limit of 0.050 mm (0.0020 inch). Thrust (front or (front or Tolerance
Plate rear) rear)
+0.039 mm
+0.15 mm 33.15 mm 33.30 mm
(+0.0015
(+.006 inch) (1.305 inch) (1.311 inch)
inch)
+0.30 mm +0.039 mm
33.30 mm 33.45 mm
(+0.012 (+0.0015
(1.311 inch) (1.317 inch)
inch) inch)
+0.45 mm +0.039 mm
33.45 mm 33.60 mm
(+0.018 (+0.0015
(1.317 inch) (1.323 inch)
inch) inch)

Torque for the crankshaft pulley nut .... 490 5 N.m

(363 4 lb ft)
Illustration 47 The maximum temperature for installing the
crankshaft gear is the following value 100 C
(3) Width of crankshaft main bearing (212 F)
journal 33.000 to 33.039 mm
(1.2992 to 1.3007 inch)
20
Specifications Section

i01576124 i01576126

Crankshaft Seals Connecting Rod Bearing

SMCSCode: 1160; 1161 Journal
SMCSCode: 1202; 1219; 1225
Table 8
Connecting Rod Bearing Journal
59.945 to 59.965 mm
Original size journal(1)
(2.3600 to 2.3608 inch)
Undersize journal 59.695 to 59.715 mm
0.25 mm (0.010 inch) (2.3502 to 2.3510 inch)
Undersize journal 59.445 to 59.465 mm
0.50 mm (0.020 inch) (2.3404 to 2.3411 inch)
Undersize journal 59.195 to 59.215 mm
0.75 mm (0.030 inch) (2.3305 to 2.3313 inch)
(1) Regrind the connecting rod journals to the next undersize
dimension if the repair limit of 59.980 mm (2.3614 inch) is
exceeded.

The clearance between a new bearing and a new

journal is the following value 0.035 to 0.100 mm
(0.0014 to 0.0039 inch)
Illustration 49 g00525904
An undersized bearing is required if the clearance
(1) Front seal between the connecting rod journal and the bearing
is in excess of the service limit of 0.200 mm
(2) Rear seal assembly (0.0079 inch). If the crankshaft is worn excessively,
or if the crankshaft is uneven, an undersized bearing
Note: The rear seal assembly and the slinger are is required. If an undersized bearing is required,
installed as a unit. grind the crankshaft to a dimension listed in Table 8.

(3) Slinger Note: The allowable tolerance for rod bearing

journals that are out of round is 0.010 mm
Note: The rear seal assembly and the slinger are (0.0004 inch). The maximum repair limit is 0.030 mm
installed as a unit. (0.0012 inch). If the repair limit is exceeded, regrind
the bearing journals to the specified dimension.
(4) Rear seal assembly

Note: The rear seal assembly should be flush with

the slinger after installation.

(5) Contact surface between the slinger and

crankshaft

Put sealant on the contact surface between the

slinger and the crankshaft. Put clean engine oil on
the surface of the rear seal assembly.

(6) Distance from rear seal assembly to end of

crankshaft 6.0 mm (0.24 inch)
 21
Specifications Section

Main Bearing Journal

SMCSCode: 1202; 1203

(3) Bolts for the main bearing cap

Tighten the bolts for the bearing cap to the
Illustration 50 following torque 137 5 N-m (101 4 lb ft)

(1) Main bearing cap (4) Main bearing journal

Put the main bearing caps in position in the (5) Main bearing
cylinder block. Put clean engine oil on the main
bearing bolts. Install the main bearing bolts and
tighten the main bearing bolts to the following
torque 137 5 N-m (101 4 lb ft)
Connecting Rod
(2) Dial indicator SMCSCode: 1218
Measure the main bearing bores with a
dial indicator. Subtract the diameter of the
crankshaft journal from the inside diameter
of the main bearing in order to determine
the bearing clearance on the main journal.
Clearance between crankshaft journal and main
bearing 0.050 to 0.118 mm
(0.0020 to 0.0047 inch)

Note: Replace the bearings or refinish the crankshaft

to the next undersize bearing if the main bearing
clearance exceeds 0.20 mm (0.008 inch). Refer to
Table 50 for dimensions of undersize journals.

Note: The allowable tolerance for main bearing

Illustration 52
journals that are out of round is 0.010 mm
(0.0004 inch). The maximum repair limit is 0.030 mm
(1) Matching marks
(0.0012 inch). If the repair limit is exceeded, regrind
the bearing journals to the specified dimension.
The marks are used to align the cap to the
connecting rod.
22
Specifications Section

(3) Connecting rod bolts

Before assembly, put clean engine oil on the
bolt threads and all surfaces that make contact
between the bolt and connecting rod caps.
Tighten the connecting rod nuts to the following
torque 103 5 N-m (76 4 lb ft)

(4) Measure the bores of each of the connecting

rods and record the dimension of the bores.

Illustration 53

(A) The upper oil hole is 40 degrees above the

horizontal centerline.

(B) The lower oil hole is 30 degrees below the

horizontal centerline.

(C) The end of the piston pin bearing is 30 degrees

below the lower oil hole.
Illustration 55 g00525l94

(5) Connecting rod

Use a feeler gauge to measure the end play.
End play 0.15 to 0.35 mm
(0.006 to 0.014 inch)

Note: Replace the connecting rod if the end play

exceeds 0.50 mm (0.020 inch).

Illustration 54

(2) Bore of piston pin

bearing 34.020 to 34.045 mm
Illustration 56
(1.3394 to 1.3404 inch)
(6) Piston
The clearance between the piston pin bearing
and the piston pin is 0.023 to 0.054 mm
(7) Markings on piston
(0.0009 to 0.0021 inch).
Assemble the piston and connecting rods. Ensure
Note: A clearance for the piston pin to the piston pin
that the markings on the piston (7) and the marks
bearing over 0.010 mm (0.0004 inch) is excessive.
on the connecting rod (1) are on the same side.
Replace the piston pin or replace the bearing if the
clearance is excessive.
 23
Specifications Section

Piston and Rings

SMCSCode: 1214; 1215

Illustration 57

(8) Install the piston assembly with the marks (1) on

the connecting rod toward the camshaft (8).

Illustration 59

(1) Markings on piston

Each piston has markings which are stamped on

top of the piston. The markings are used to align
the piston assembly to the camshaft side of the
cylinder block.
Illustration 58

(2) Piston diameter

(9) Piston projection
Table 9 gives the dimensions for pistons that are
Use the following procedure to measure the
height of each piston above the cylinder block. If standard. Table 9 also gives the dimensions for
clearances are not in the acceptable range, inspect pistons that are oversize.
the components for wear or damage.
Note: Measure the piston diameter along the
1. Determine the top center position of the piston perpendicular of the piston pin bore.
with a dial indicator assembly.

2. Install the dial indicator assembly on the top of

the block. Set the needle of the dial indicator
to zero.

3. Measure projection (9) at three places on

the top of the piston. Take an average of the
three measurements in order to determine the
projection. Subtract the projection from the
installed thickness of the cylinder head gasket
in order to determine the clearance between the
top of the piston and the cylinder head.

Installed thickness of the cylinder head

gasket 1.70 0.10 mm (0.070 0.004 inch)

Piston projection 0.55 to 1.15 mm

(0.022 to 0.045 inch)
24
Specifications Section

Table 9
Dimensions for Piston Diameters
Standard at
Bore Size Service LimiK(1)
Assembly
101.915 to
101.945 mm 101.730 mm
Standard
(4.0124 to (4.0051 inch)
40136 inch)
102.165 to
Oversize
102.195 mm 101.980 mm
0.25 mm
(4.0222 to (4.0150 inch)
(0.010 inch)
4.0234 inch)
102.415 to
Oversize Illustration 61 g00524467
102.445 mm 102.230 mm
0.50 mm
(4.0321 to (4.0248 inch)
(0.020 inch)
4.0333 inch) (5) Identification mark on piston rings
(1) A piston which exceeds this limit must be replaced.
Install the piston rings with the identification mark
toward the top.

Note: Each piston ring is marked with an "R" or "T"

for an identification mark.

(6) Top piston ring

Piston ring end gap for a standard
bore 0.30 to 0.45 mm (0.012 to 0.018 inch)

Note: Replace the piston rings if the end gap

exceeds the maximum tolerance of 1.50 mm
(0.060 inch).

Illustration 60 (7) Intermediate piston ring

(3) Diameter of piston pin bore
(4) Diameter of piston pin 33.993 to 34.000 mm
(1.3383 to 1.3385 inch )
Measure the piston pin bore diameter. Subtract
the piston pin diameter from the bore diameter.
The clearance between the bore and piston
pin 0.002 to 0.019 mm (0.0001 to 0.0008 inch)
Note: The service limit for the clearance between
the piston pin and the piston pin bore is 0.050 mm
(0.0020 inch). Replace the piston if the clearance
has been exceeded.
Piston ring end gap for standard
bore 0.30 to 0.45 mm (0.012 to 0.018 inch)
Note: Replace the piston rings if the end gap
exceeds the maximum tolerance of 1.50 mm
(0.060 inch).
(8) Oil control piston ring
The position of the end gap of the oil control
ring is 180 degrees from the ends of the ring
expander.
Piston ring end gap for a standard
bore 0.30 to 0.50 mm (0.012 to 0.020 inch)
Note: Replace the piston rings if the end gap
exceeds the maximum tolerance of 1.50 mm
(0.060 inch).
 25
Specifications Section

Illustration 63 g00524492

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

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

compression ring)
Illustration 62
(C) End gap for oil control ring
(9) Side clearance of ring groove (X) Camshaft side of engine block
Install new piston rings in the ring grooves of the (Y) Side of engine with combustion chamber
piston. Measure the side clearance of the ring
groove with a straight edge and feeler gauge. Table
Position the piston rings according to Illustration 63.
10 groves acceptable 'Clearances of t i e ring groove.

Clearances of the Piston Rings

Gear Group (Front)
Side
Piston Width of Clearance Service SMCS Code: 1206
Rings Ring of Ring Limit (1)
Groove
0.080 to
No. 1 3.00 mm 0.200 mm
0.120 mm
Compression (0.118 (0.0080
(0.0031 to
Ring inch) inch)
0.0047 inch)
0.080 to
No. 2 2.00 mm 0.150 mm
0.120 mm
Compression (0.080 (0.0060
(0.0031 to
Ring inch) inch)
0.0050 inch)
0.025 to
4.00 mm 0.150 mm
Oil Control 0.065 mm
(0.157 (0.0060
Ring inch) (0.0010 to inch)
0.0026 inch)
(1) The piston must be replaced if the piston rings exceed these Illustration 64 g00527858
clearances.
(1) Fuel injection pump drive gear

(2) Idler gear

(3) Camshaft gear

(4) Nut for fuel injection pump drive gear

Tighten the nut to the following
torque 88 5 N.m (65 4 lb ft)
26
Specifications Section

(5) Crankshaft gear Measure the end play of the idler gear with a
feeler gauge. Refer to Table 11. Tighten the idler
Note: Ensure that the marks on the timing gears are gear bolt to the following torque 34 N-m
in alignment. (25 lb ft)

Illustration 65 g00527864 Illustration 67 900527912

Idler gear (2)
(7) Inside diameter of idler gear bushing
Install a dial indicator and rotate the idler gear
(2) back and forth in order to measure backlash. (8) Idler gear shaft
Replace the idler gear if the backlash exceeds the
service limit. Refer to Table 11. Replace the bushing if the clearance between the
idler gear bushing and the idler gear shaft exceeds
Table 11 the service limit. Refer to Table 11.
Standard at
Item Service Limit(1) Tighten the bolts for the timing gear cover to the
Assembly
following torque 35 + 6 N-m (26 4 lb ft)
0.03 to 0.17 mm
Backlash of idler 0.25 mm
(0.001 to (9) Front plate
gear (0.010 inch)
0.007 inch)
Tighten the bolt that holds the front plate to the
0.05 to 0.20 mm
End play of idler 0.35 mm following torque 35 5 N-m (26 4 lb ft)
(0.002 to
gear (0.014 inch)
0.008 inch)
Clearance i01576345
0.009 to 0.080
between idler 0.100 mm
gear bushing
mm (0.0004 to
0.0031 inch)
(0.0039 inch) Flywheel
and shaft
SMCSCode: 1156
(1) Replace the idler gear if the service limit is exceeded.

Illustration 68 g00529633
Illustration 66 900819139
(1) Flywheel
(6) Idler gear bolt
 27
Specifications Section

Place the flywheel on a surface plate. Use a

dial indicator in order to measure the flatness of
the flywheel. Crankshaft Pulley
Standard at assembly of flywheel 0.15 mm SMCSCode: 1205
(0.006 inch)
Repair limit of flywheel .... 0.50 mm (0.020 inch)

Note: Refinish the flywheel if the repair limit is

exceeded.

Illustration 70

Tighten the crankshaft pulley nut to the following

torque 490 10 N-m (361 7 lb ft)

i01449909

Belt Tension Chart

SMCS Code: 1357

Illustration 69 g00529634
Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.
(2) Measure the runout on the flywheel face with a
dial indicator. Maximum face runout.... 0.15 mm
(0.006 inch)

Repair limit of face runout 0.50 mm (0.020 inch)

Note: Refinish the flywheel if the repair limit is

exceeded.

Maximum permissible temperature of the ring gear

for installation on the flywheel without using a
torch 150 C (302 F)

Note: The ring gear is pressed on the flywheel.

Tighten the flywheel bolts to the following

torque 83 5 N-m (61 4 lb ft)

Number of teeth of the flywheel ring gear 127

28
Specifications Section

Table 12
Belt Tension Chart
Gauge Reading Borroughs Gauge Numbers
Size of Belt Width of Belt Number of the Selected
Initial Belt Tension(1) Used Belt Tension(2)
Gauge
3/8 10.72 mm (0.422 inch) 445 22 N (100 5 lb) 400 22 N (90 5 lb) BT-33-97
1/2 13.89 mm (0.547 Inch) 534 22 N (120 5 lb) 400 44 N (90 1 0 lb) BT-33-97
Measure the tension of the belt that is farthest from the engine.
(1) Initial Belt Tension refers to a new belt.
(2)Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.

i01574161 i01574185

Belt Tightener Alternator and Regulator

S M C S C o d e : 1358 S M C S C o d e : 1405; 1 4 1 0

Illustration 71 goossosos illustration 72 g00530887

(1) Bolt. (1) Nut for alternator pulley

Apply pressure to each belt midway between the Tighten the nut for the alternator pulley to the
pulleys in order to inspect the belt tension. Adjust following torque 132 to 162 N-m
the bolt for the alternator if the tension is incorrect. (97 to 119 lb ft)

The proper tension for the fan drive belt is Polarity negative ground
approximately the following deflection 12.0 mm
(0.50 inch) Rotation either direction

Speed for testing (rpm) 5000 rpm

Output voltage 28.0 .5 V

Rated output 50 A
 29
Specifications Section

Electric Starting Motor Coolant Temperature Switch

SMCSCode: 1453 SMCS Code: 1395; 1906

74
Engrie coolant temperature switch
Tighten the engine coolant temperature switch to
the foiowing torque. ... 7 to 12 N-m (62 to 106 lb in)

Illustration 73

(1) Terminal nuts Engine Oil Pressure Switch

Tighten the terminal nuts to the following SMCSCode: 1924
torque 11 + 1 N-m (97 + 9 lb in)

The rotation is viewed from the drive end of the

electric starting motor. Rotation of electric starting
motor clockwise

No load conditions
Speed (rpm) 3300 rpm minimum
Maximum current (draw) 85 A
Voltage 23 V

Engine oil pressure switch

Tighten the engine oil pressure switch to the

cylinder block to the following torque: .. 7 to 12 N-m
(62 to 106 lb in)

101578156

Air Inlet Heater

SMCS Code: 1090

Tighten the four bolts that secure the air inlet

heater to the inlet manifold to the following
torque 28 7 N-m (21 5 lb ft)
30
Index Section

Index
A L

Air Inlet Heater 29 Lifter Group 6

Alternator and Regulator 28

M
B
Main Bearing Journal 21
Belt Tension Chart 27
Belt Tightener 28
P

C Piston and Rings 23

Camshaft 12
Connecting Rod 21 R
Connecting Rod Bearing Journal 20
Coolant Temperature Switch 29 Rocker Shaft 7
Crankshaft 18
Crankshaft Pulley 27
Crankshaft Seals 20 S
Cylinder Block 17
Cylinder Head 9 Specifications Section 4

E T

Electric Starting Motor 29 Table of Contents 3

Engine Design 4 Turbocharger 10
3064 Engine 4
3066 Engine 4
Engine Oil Bypass Valve 15 V
Engine Oil Pan 16
Engine Oil Pressure 15 Valve Mechanism 8
Engine Oil Pressure Switch 29 Valve Mechanism Cover 9
Engine Oil Pump 14
Engine Oil Relief Valve 13
Exhaust Manifold 11 W

Water Pump 16
F Water Temperature Regulator 16

Flywheel 26
Fuel Injection Lines 5
Fuel Injection Nozzles 6
Fuel Injection Pump 5

Gear Group (Front) 25

Important Safety Information 2