Manual Oficina c4.2 c6.4 Caterpilla

Tela anterior produtos: EXCAVATOR Modelo: 315D L EXCAVATOR CJN Configuração: 315D L Excavator CJN00001-UP (MACHINE) POWERED BY C4.2 Engine

Especificações C4.2 and C6.4 Engines for Caterpillar Built Machines Número de Mídia -KENR6740-04

Data de Publicação -01/04/2008

Data de Atualização -29/04/2008

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Engine Design SMCS - 1201 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1 (A) Exhaust valves

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(B) Inlet valves

Bore ... 102 mm (4.02 inch) Stroke ... 130 mm (5.12 inch) Displacement ... 4.2 L (256 cu in) Cylinder arrangement ... In-line Valves per cylinder ... 4 In order to check the engine valve lash setting, the engine must be cold and the engine must be stopped. Engine valve lash Inlet ... 0.25 mm (0.010 inch) Exhaust ... 0.40 mm (0.016 inch) Type of combustion ... Direct injection Firing order ... 1-3-4-2 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 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.

Direitos Autorais 1993 - 2017 Caterpillar Inc. Todos os Direitos Reservados. Rede Particular Para Licenciados SIS.

Wed Feb 8 14:18:46 UTC-0200 2017


Teste e Ajustes C4.2 and C6.4 Engine for Caterpillar Built Machines Número de Mídia -KENR6741-05



i02859277

Engine Valve Lash - Inspect/Adjust SMCS - 1102-025

Be sure the engine cannot be started while this maintenance is being performed. To prevent possible injury, do not use the starting motor to turn the flywheel. Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting engine valve lash clearance. The valve lash is measured between the top of the cap of the valve stem and the rocker arm. The valve lash is measured with a feeler gauge. Valve Lash Setting with Stopped Engine (Cold) Inlet ... 0.25 mm (0.010 inch) Exhaust ... 0.40 mm (0.016 inch)

Adjustment of the Height of the Valve Bridge

Illustration 1

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1. Push the rocker arm onto the bridge. 2. Loosen the adjustment screw (1) so that the nonadjustable side of the bridge is contacting the valve stem. 3. Tighten the adjustment screw (1) until the adjustment screw (1) contacts the stem. 4. Turn adjustment screw (1) an additional ten degrees. 5. Tighten locknut (2) to 4 ± 1 N·m (35 ± 9 lb in).

Valve Lash Check An adjustment is not necessary if the measurement of the valve lash is in the acceptable range in Table 2. 1. Put the No. 1 piston at top center. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston". Table 1 Inlet Valves

Exhaust Valves

0.25 mm (0.010 inch)

0.40 mm (0.016 inch)

TC Compression Stroke

1-2-4

1-3-5

TC Exhaust Stroke (1)

3-5-6

2-4-6

Valve Lash (Stopped Engine)

Firing Order (1)

360° from TC compression stroke

1-5-3-6-2-4 (2)

(2)

The No. 1 cylinder is at the front of the engine.

If the measurement is not within this range, an adjustment is necessary. Refer to "Valve Lash Adjustment" for the proper procedure.

Valve Lash Adjustment Use the following procedure to adjust the valve lash.

Illustration 2 Valve lash

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1. Ensure that the No. 1 piston is at the top center position on the compression stroke. Table 2 TC Compression Stroke Valve Lash

Inlet Valves

Exhaust Valves

0.25 mm (0.010 inch)

0.40 mm (0.016 inch)

1-2-4

1-3-5

Cylinders

2. Adjust the valve lash according to Table 3. 3. Loosen the adjustment locknut (3) . 4. Place the appropriate feeler gauge between rocker arm and the valve bridge. Then, turn the adjustment screw (4) in a clockwise direction. Slide the feeler gauge between the rocker arm and the valve bridge. Continue turning the adjustment screw (4) until a slight drag is felt on the feeler gauge. Remove the feeler gauge.

5. Tighten the adjustment locknut (3) to a torque of 4 ± 1 N·m (35 ± 9 lb in). Do not allow the adjustment screw (4) to turn while you are tightening the adjustment locknut (3) . Recheck the valve lash after tightening the adjustment locknut (3) . 6. Rotate the engine 360 degrees in the direction of the engine rotation. This will put the No. 6 piston at the top center position on the compression stroke. Table 3 TC Exhaust Stroke Valve Lash

Inlet Valves

Exhaust Valves

0.25 mm (0.010 inch)

0.40 mm (0.016 inch)

3-5-6

2-4-6

Cylinders

7. Adjust the valve lash according to Table 4. 8. Loosen the adjustment locknut (3) . 9. Place the appropriate feeler gauge between rocker arm and the valve bridge. Then, turn the adjustment screw (4) in a clockwise direction. Slide the feeler gauge between the rocker arm and the valve bridge. Continue turning the adjustment screw until a slight drag is felt on the feeler gauge. Remove the feeler gauge. 10. Tighten the adjustment locknut (3) to a torque of 4 ± 1 N·m (35 ± 9 lb in). Do not allow the adjustment screw (4) to turn while you are tightening the adjustment locknut (2) . Recheck the valve lash after tightening the adjustment locknut (3) . Adjusting the valve lash several times in a short period indicates wear in a different part of the engine. Find the problem and make any necessary repairs in order to prevent more damage to the engine. Rapid wear of the camshaft and tappets can occur if insufficient valve lash is not corrected. Insufficient valve lash can also be an indication of faulty valve seats. The following items are reasons for faulty seats of the valves: faulty fuel injection nozzles, restrictions to the air inlet, dirty air filters, incorrect fuel setting and overloading the engine. Broken valve stems, broken pushrods, or broken spring retainers can be caused by insufficient valve lash that is not corrected. A fast increase in valve lash can be an indication of any of the following items: z

Worn camshaft and tappets

z

Worn rocker arms

z

Bent pushrods

z

Loose adjustment screws for valve lash

z

Broken socket on the upper end of pushrod

Fuel in the lubrication oil may be a possible cause of rapid wear of the camshaft and the tappets. Dirty lubrication oil may also be a possible cause of rapid wear of the camshaft and tappets.


Wed Feb 8 15:43:35 UTC-0200 2017





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Camshaft SMCS - 1210 S/N - A6F1-UP S/N - A8F1-UP S/N - A9F1-UP S/N - BWW1-UP S/N - BYJ1-UP S/N - BYK1-UP S/N - BYM1-UP S/N - BZF1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - EAX1-UP S/N - FAL1-UP S/N - FMH1-UP S/N - GKS1-UP

S/N - HCW1-UP S/N - JBC1-UP S/N - JLG1-UP S/N - KBD1-UP S/N - KGF1-UP S/N - LFL1-UP S/N - MCH1-UP S/N - MDT1-UP S/N - NAS1-UP S/N - NCM1-UP S/N - PBD1-UP S/N - PBE1-UP S/N - PDP1-UP S/N - PHX1-UP S/N - RAC1-UP S/N - SBP1-UP S/N - SBZ1-UP S/N - SED1-UP S/N - TAE1-UP S/N - TGY1-UP S/N - WFD1-UP S/N - WGC1-UP S/N - XCK1-UP S/N - YDS1-UP S/N - YSD1-UP S/N - ZGB1-UP

Illustration 1

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(1) Maximum permissible temperature of the camshaft gear for installation on the camshaft ... 250 ° C (480 °F)

NOTICE Do not use a torch to heat the gear. A torch can unevenly heat the gear causing warpage. The hardness of the gear may also be changed with the use of a torch.

(A) Diameters of camshaft journals Table 1 Number of Journal 1, 2, 3 4 (1)

Standard Diameter

Service Limit (1)

53.94 to 53.96 mm (2.124 to 2.124 inch)

53.90 mm (2.122 inch)

52.94 to 52.96 mm (2.084 to 2.085 inch)

52.90 mm (2.083 inch)

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.

(2) Torque for two bolts ... 12 ± 2 N·m (105 ± 18 lb in)

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Illustration 3

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Note: Use a dial indicator and blocks in order to determine the runout of the camshaft. Take one half of the dial indicator reading as the runout. (3) Maximum permissible runout for camshaft ... 0.04 mm (0.002 inch)

Illustration 4

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(4) Measure the camshaft bearing with a dial indicator. Subtract the diameter of the camshaft journal in order to give bearing clearances. Refer to Table 4 for the clearance between the camshaft journals and the bushings.

Table 2 Standard Diameter

Repair Limit (1)

0.04 to 0.09 mm (0.002 to 0.004 inch)

0.15 mm (0.006 inch)

0.040 to 0.119 mm (0.0016 to 0.0047 inch)

0.15 mm (0.006 inch)

Number of Journal 1, 2, 3 4 (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.


Wed Feb 8 15:58:52 UTC-0200 2017





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Crankshaft SMCS - 1202 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1 (1) Crankshaft main bearing journal

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Illustration 2

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(2) Support the crankshaft in a set of vee blocks. Measure the runout dimension at the center journal. Maximum runout ... 0.07 ± 0.03 mm (0.003 ± 0.001 inch)

Illustration 3

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(3) Crankshaft end play ... 0.100 to 0.264 mm (0.0039 to 0.0104 inch) Note: The maximum repair limit is 0.300 mm (0.0118 inch). Replace the standard thrust plates if the end play exceeds the standard clearance. Three oversize thrust plates are available as replacements if the end play still exceeds the maximum limit. Generally, the rear journal is likely to be worn more rapidly than the front journal. If necessary, replace the rear thrust plate. Refer to Table 1 for oversize thrust plates. Table 1 Dimensions for Grinding of Crankshaft Oversize Thrust Plates Oversize Thrust Plate

Oversize (front or rear)


0.15 mm (0.006 inch)

33.15 mm (1.305 inch)

33.30 mm (1.311 inch)

0.039 mm (0.0015 inch)

0.30 mm (0.012 inch)

33.30 mm (1.311 inch)

33.45 mm (1.317 inch)

0.039 mm (0.0015 inch)

0.45 mm (0.018 inch)

33.45 mm (1.317 inch)

33.60 mm (1.323 inch)

0.039 mm (0.0015 inch)

Tolerance

Torque for the crankshaft pulley nut ... 706 ± 59 N·m (520 ± 44 lb ft) The maximum temperature for installing the crankshaft gear is the following value. ... 250 °C (482 ° F)


Wed Feb 8 14:35:49 UTC-0200 2017





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Fuel Injection Nozzles SMCS - 1254 S/N - A6F1-UP S/N - A8F1-UP S/N - A9F1-UP S/N - BWW1-UP S/N - BYJ1-UP S/N - BYK1-UP S/N - BYM1-UP S/N - BZF1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - EAX1-UP S/N - FAL1-UP S/N - FMH1-UP S/N - GKS1-UP


Illustration 1 (2) Clamp

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(3) O-ring seal

(1) Torque for the bolt ... 29 ± 3 N·m (21 ± 2 lb ft)


Wed Feb 8 14:24:56 UTC-0200 2017





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Cylinder Block SMCS - 1201 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1

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(1) Torque for four bolts ... 108 ± 5 N·m (80 ± 4 lb ft) (2) Torque for the bolt ... 58 ± 6 N·m (43 ± 4 lb ft)

Illustration 2

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(3) Measure the amount of the warpage of the cylinder block with a straightedge and feeler gauge. Maximum allowable clearance ... 0.05 mm (0.002 inch)

Repair limit ... 0.20 mm (0.008 inch) Resurface the top of the block if the repair limit is reached.

Illustration 3

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(4) Measure the inside diameter of the cylinder sleeve that is parallel to the crankshaft. Measure the inside diameter of the cylinder liner that is in a perpendicular position to the crankshaft. Measure the top, the middle and the bottom of the cylinder liner. Refer to Table 2 for tolerances of the cylinder liner. Table 1 Tolerances of Cylinder Sleeves Standard at Assembly Inside Diameter

0.010 mm (0.0004 inch)

(1) (2)

Service Limit (2)

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

Out of Round

Taper

Repair Limit (1)

0.015 mm (0.0006 inch)

N/A

N/A

N/A

N/A

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. 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.

Bore the cylinder to the specified oversize dimension if the inside diameter reaches the repair limit but the inside diameter does not reach the service limit. Refer to Table 3.

Hone the liner to +0.25 mm (+0.010 inch) or +0.50 mm (+0.020 inch) oversize. Hone the liner to an accuracy within 0.010 to 0.045 mm (0.0004 to 0.0018 inch). Determine the oversize dimension that is necessary 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 2 Oversize Bore

Cylinder Bore Size 102.260 mm (4.0260 inch)

0.250 mm (0.0098 inch) 102.295 mm (4.0274 inch) 102.510 mm (4.0358 inch) 0.500 mm (0.0197 inch) 102.545 mm (4.0372 inch)

Illustration 4

(5) Service limit of cylinder liner ... 102.700 mm (4.0433 inch) Note: Replace all cylinder liners that exceed the service limit. Use the following procedure in order to replace the cylinder liners.

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1. 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 least worn area. 2. Bore the liner until the thickness is 0.50 mm (0.020 inch). 3. Remove the remainder of the liner. Be careful not to damage the cylinder block. 4. Install a new liner. Align the liner with the top of the cylinder block. 5. The bore of the cylinder must be 102.000 to 102.035 mm (4.0157 to 4.0171 inch). Diameter for the main bearing bores ... 95.000 mm (3.7402 inch) Maximum diameter of the main bearing bores ... 95.022 mm (3.7410 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)


Wed Feb 8 14:35:07 UTC-0200 2017





i02982121

Fuel Injection Pump SMCS - 1251; 1290 S/N - A6F1-UP S/N - A8F1-UP S/N - A9F1-UP S/N - BWW1-UP S/N - BYJ1-UP S/N - BYK1-UP S/N - BYM1-UP S/N - BZF1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - EAX1-UP S/N - FAL1-UP S/N - FMH1-UP S/N - GKS1-UP


Illustration 1

(1) Torque for solenoid valve group ... 70 ± 5 N·m (50 ± 4 lb ft) (2) Torque for two plugs ... 60 ± 6 N·m (44 ± 4 lb ft) (3) Torque for plug ... 24 ± 2 N·m (18 ± 1 lb ft) (4) Lubricate three seals with clean engine oil before assembly.

g01527228

Illustration 2

(5) Torque for two plugs ... 40 ± 3 N·m (30 ± 2 lb ft) (6) Torque for bolt ... 12 ± 3 N·m (105 ± 27 lb in) (7) Torque for bolt ... 9 ± 1 N·m (80 ± 9 lb in) (8) Torque for five bolts ... 30 ± 2 N·m (22 ± 1 lb ft)

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Illustration 3

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(9) Torque for connector ... 25.0 ± 2.5 N·m (18 ± 2 lb ft) (10) Torque for connector ... 25.0 ± 2.5 N·m (18 ± 2 lb ft) (11) Torque for connector ... 25.0 ± 2.5 N·m (18 ± 2 lb ft) (12) Torque for connector ... 25.0 ± 2.5 N·m (18 ± 2 lb ft)


Wed Feb 8 14:21:39 UTC-0200 2017





i02830711

Engine Oil Pump SMCS - 1304 S/N - A6F1-UP S/N - A8F1-UP S/N - A9F1-UP S/N - BWW1-UP S/N - BYJ1-UP S/N - BYK1-UP S/N - BYM1-UP S/N - BZF1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - EAX1-UP S/N - FAL1-UP S/N - FMH1-UP S/N - GKS1-UP


Illustration 1 (1) Driven gear assembly

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(2) Drive gear assembly (5) Spindle

NOTICE Before operation, the pump must be lubricated with clean engine oil and the pump must turn freely by hand or damage to parts can be the result.

Note: The minimum acceptable oil pressure at low idle is 98 kPa (14 psi). Heat the oil pump gear (3) to 180 to 220 °C (356 to 428 °F) and support the end of the drive gear shaft in order to install the oil pump gear. Press the oil pump gear until the oil pump gear is flush with the end of the shaft.


The backlash between the oil pump gear (3) and the idler gear (4) is the following. ... 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).

Note: The oil pump gear and the drive gear assembly are not serviceable if the oil pump gear is removed.

Illustration 2

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(6) Housing for oil pump gear Maximum distance between the oil pump gear assembly and the oil pump housing Distance above the housing ... 0.020 mm (0.0008 inch) Distance below the housing ... 0.034 mm (0.0013 inch) Note: The service limit of the oil pump gear assembly is 0.150 mm (0.0059 inch) below the oil pump housing. Note: Measure the clearance between the oil pump gears and the oil pump housing with a feeler gauge. Clearance between the oil pump gears and the oil pump housing ... 0.050 to 0.098 mm (0.0020 to 0.0039 inch) Note: The service limit of the oil pump gear assembly is 0.10 mm (0.004 inch).

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Inside diameter of idler gear bushing ... 25.000 to 25.021 mm (0.9842 to 0.9851 inch) Maximum diameter of idler gear bushing for oil pump ... 25.059 mm (0.9866 inch) (B) 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 5

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(9) Torque for bolts ... 35 ± 6 N·m (26 ± 4 lb ft)


Wed Feb 8 14:30:56 UTC-0200 2017





i02970181

Cylinder Head SMCS - 1100 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZF1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1

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(1) Dimension for the 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) Resurface the cylinder head if the warpage exceeds the following value. ... 0.20 mm (0.008 inch) Gasket thickness of cylinder head ... 1.70 ± 0.05 mm (0.067 ± 0.002 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 2

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Note: Put clean engine oil on the threads of the cylinder head bolts. Tighten the bolt 1 through bolt 17 in the numerical sequence that is shown in Illustration 2 to 137 ± 5 N·m (100 ± 4 lb ft).


Wed Feb 8 16:00:10 UTC-0200 2017





i02970181

Cylinder Head SMCS - 1100 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZF1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1

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(1) Dimension for the 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) Resurface the cylinder head if the warpage exceeds the following value. ... 0.20 mm (0.008 inch) Gasket thickness of cylinder head ... 1.70 ± 0.05 mm (0.067 ± 0.002 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 2

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Note: Put clean engine oil on the threads of the cylinder head bolts. Tighten the bolt 1 through bolt 17 in the numerical sequence that is shown in Illustration 2 to 137 ± 5 N·m (100 ± 4 lb ft).


Wed Feb 8 14:29:12 UTC-0200 2017





i02972801

Engine Oil Pan SMCS - 1302 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1

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(1) Torque for 28 bolts ... 18 ± 2 N·m (13 ± 1 lb ft)


Wed Feb 8 14:32:51 UTC-0200 2017





i02970240

Exhaust Manifold SMCS - 1059 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1

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(1) Torque for nine nuts ... 18 ± 2 N·m (13 ± 1 lb ft)


Wed Feb 8 14:29:52 UTC-0200 2017





i02980079

Crankshaft SMCS - 1202 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1 (1) Crankshaft main bearing journal

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Illustration 2

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(2) Support the crankshaft in a set of vee blocks. Measure the runout dimension at the center journal. Maximum runout ... 0.07 ± 0.03 mm (0.003 ± 0.001 inch)

Illustration 3

g01356072

(3) Crankshaft end play ... 0.100 to 0.264 mm (0.0039 to 0.0104 inch) Note: The maximum repair limit is 0.300 mm (0.0118 inch). Replace the standard thrust plates if the end play exceeds the standard clearance. Three oversize thrust plates are available as replacements if the end play still exceeds the maximum limit. Generally, the rear journal is likely to be worn more rapidly than the front journal. If necessary, replace the rear thrust plate. Refer to Table 1 for oversize thrust plates. Table 1 Dimensions for Grinding of Crankshaft Oversize Thrust Plates Oversize Thrust Plate



0.15 mm (0.006 inch)

33.15 mm (1.305 inch)

33.30 mm (1.311 inch)

0.039 mm (0.0015 inch)

0.30 mm (0.012 inch)

33.30 mm (1.311 inch)

33.45 mm (1.317 inch)

0.039 mm (0.0015 inch)

0.45 mm (0.018 inch)

33.45 mm (1.317 inch)

33.60 mm (1.323 inch)

0.039 mm (0.0015 inch)

Tolerance

Torque for the crankshaft pulley nut ... 706 ± 59 N·m (520 ± 44 lb ft) The maximum temperature for installing the crankshaft gear is the following value. ... 250 °C (482 ° F)


Wed Feb 8 16:04:41 UTC-0200 2017





i02759135

Connecting Rod Bearing Journal SMCS - 1202; 1219; 1225 S/N - A6F1-UP S/N - A8F1-UP S/N - A9F1-UP S/N - BWW1-UP S/N - BYJ1-UP S/N - BYK1-UP S/N - BYM1-UP S/N - BZF1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - EAX1-UP S/N - FAL1-UP S/N - FMH1-UP S/N - GKS1-UP

S/N - HCW1-UP S/N - JBC1-UP S/N - JLG1-UP S/N - KBD1-UP S/N - KGF1-UP S/N - LFL1-UP S/N - MCH1-UP S/N - MDT1-UP S/N - NAS1-UP S/N - NCM1-UP S/N - PBD1-UP S/N - PBE1-UP S/N - PDP1-UP S/N - PHX1-UP S/N - RAC1-UP S/N - SBP1-UP S/N - SBZ1-UP S/N - SED1-UP S/N - TAE1-UP S/N - TGY1-UP S/N - WFD1-UP S/N - WGC1-UP S/N - XCK1-UP S/N - YDS1-UP S/N - YSD1-UP S/N - ZGB1-UP Table 1

Connecting Rod Bearing Journal Original size journal

64.945 to 64.965 mm (2.5569 to 2.5577 inch)

Undersize journal 0.25 mm (0.010 inch)

64.695 to 64.715 mm (2.5470 to 2.5478 inch)


64.445 to 64.465 mm (2.5372 to 2.5380 inch)


64.195 to 64.215 mm (2.5274 to 2.5281 inch)

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) An undersized bearing is required if the clearance between the connecting rod journal and the bearing is in excess of the service limit of 0.200 mm (0.0079 inch). If the crankshaft is worn excessively, or if the crankshaft is uneven, an undersized bearing is required. If an undersized bearing is required, grind the crankshaft to a dimension listed in Table 2. Note: The allowable tolerance for rod bearing journals that are out of round is 0.010 mm (0.0004 inch). The maximum repair limit is 0.030 mm (0.0012 inch). If the repair limit is exceeded, regrind the bearing journals to the specified dimension.


Wed Feb 8 14:36:38 UTC-0200 2017





i02978141

Connecting Rod SMCS - 1218

Illustration 1

g01411338

(1) Matching marks that are used to align the cap to the connecting rod

Illustration 2

g01411339

(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 3

g01505976

(D) Bore of piston pin bearing ... 34.020 to 34.045 mm (1.3394 to 1.3404 inch) The clearance between the piston pin bearing and the piston pin is 0.023 to 0.054 mm (0.0009 to 0.0021 inch).

Note: A clearance for the piston pin to the piston pin bearing over 0.080 mm (0.0031 inch) is excessive. Replace the piston pin or replace the bearing if the clearance is excessive. Note: Before assembly, put clean engine oil on the bolt threads and all surfaces that make contact between the bolt and connecting rod caps. (2) Torque for nuts ... 103 ± 5 N·m (75 ± 4 lb ft) Note: Measure the bores of each of the connecting rods and record the dimension of the bores. (E) Bore in connecting rod ... 64.000 mm to 64.019 mm (2.5197 inch to 2.5204 inch)

Illustration 4

g01373137

(3) Use a feeler gauge to measure the end play. End play of the connecting rod should be within 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 5

g01373146

Assemble the piston (4) and connecting rods. Ensure that the markings (5) on the piston and the marks (1) on the connecting rod are on the same side.

Illustration 6

g01373153

Install the piston assembly with the marks (1) on the connecting rod toward the camshaft (6) .

Illustration 7 (F) Piston projection

g01411344

Use the following procedure to measure the height of each piston above the cylinder block. If clearances are not in the acceptable range, inspect the components for wear or damage. 1. Determine the top center position of the piston 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 (F) 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 (0.067 ± 0.004 inch) Piston projection ... 0.55 to 1.15 mm (0.022 to 0.045 inch)


Wed Feb 8 14:38:31 UTC-0200 2017





i02876647

Main Bearing Journal SMCS - 1202; 1203 S/N - A6F1-UP S/N - A8F1-UP S/N - A9F1-UP S/N - BWW1-UP S/N - BYJ1-UP S/N - BYK1-UP S/N - BYM1-UP S/N - BZF1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - EAX1-UP S/N - FAL1-UP S/N - FMH1-UP S/N - GKS1-UP


Illustration 1 (1) Main bearing cap

g01358113

(2) Dial indicator

Procedure to measure the bore of main bearing journal 1. Put the main bearing caps in position in the cylinder block. Apply clean engine oil on the main bearing bolts. Install the main bearing bolts and tighten the main bearing bolts to a torque of 137 ± 5 N·m (100 ± 4 lb ft). 2. 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 the crankshaft journal and the main bearing is 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). Note: The allowable tolerance for main bearing journals that are out of round is 0.010 mm (0.0004 inch). The maximum repair limit is 0.030 mm (0.0012 inch). If the repair limit is exceeded, regrind the bearing journals to the specified dimension.

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4 2 $

! " # $ % & ' ' ' 13( ) * N+ ,

100 ) . $ # " % T2 # $ ! 1

Thickness for Crankshaft Main Bearing Size of Crankshaft Main Bearing Journal = 16 14 2 $ & 1> ! 7

4 2 $

Bearing Thickness 2' . ( ( % 2' . 90 , ,

0' 09( * % 0' 0980 1 4 3 /

U4 0 ! & 1 > ! 0' 010 1 4 3 /

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T/ ! 0 1 2 , ! % ! " % / ! 3 2 4 5 & / 2 " % , 2 1 4 # ! 2 1 4 6 7 T2 # $ ! 2 Main Bearing Journal

4 2 $ 1 & 6 1 8 ! 4 1 4 T2 # $ ! 3'

= 16 14 2 $ & 1> ! 7 U4 0 ! & 1 > ! 7 0' 2* , ,

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89' 20 % 89' 22 , ,

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4 2 $

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4 0 ! & 1 > ! 0 1 , ! 4 & 1 4 1 " % / ! ! < 2 1 $ 1 , 1 % " 89' 8* , ,

3' * 3( 1 4 3 / 1 &

Wed Feb 8 14:37:31 UTC-0200 2017





i02970360

Rocker Shaft SMCS - 1102 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1

g01411580

(1) Bore in rocker arm bushing for shaft ... 24.949 to 24.975 mm (0.9822 to 0.9833 inch) (2) Diameter of rocker arm shaft ... 24.915 to 24.928 mm (0.9809 to 0.9814 inch) Clearance of rocker arm bushing and shaft Minimum ... 0.021 mm (0.0008 inch) Maximum ... 0.060 mm (0.0024 inch)

Illustration 2

g01411576

(3) Align the oil holes in rocker arm bushing (4) with the oil holes in the rocker arm when the rocker arm bushing is replaced.

Illustration 3

(5) Torque for four bolts ... 18 ± 2 N·m (13 ± 1 lb ft) (6) Torque for four bolts ... 18 ± 2 N·m (13 ± 1 lb ft) (7) Torque for bolt ... 74 ± 5 N·m (55 ± 4 lb ft)

g01526063

Illustration 4 Valve lash adjustment

g01411582

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 valve lash ... 0.25 mm (0.010 inch) Exhaust valve lash ... 0.40 mm (0.016 inch)


Wed Feb 8 14:26:02 UTC-0200 2017





i02972601

Camshaft SMCS - 1210 S/N - A6F1-UP S/N - A8F1-UP S/N - A9F1-UP S/N - BWW1-UP S/N - BYJ1-UP S/N - BYK1-UP S/N - BYM1-UP S/N - BZF1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - EAX1-UP S/N - FAL1-UP S/N - FMH1-UP S/N - GKS1-UP


Illustration 1

g01411978

(1) Maximum permissible temperature of the camshaft gear for installation on the camshaft ... 250 ° C (480 °F)


(A) Diameters of camshaft journals Table 1 Number of Journal 1, 2, 3 4 (1)

Standard Diameter

Service Limit (1)

53.94 to 53.96 mm (2.124 to 2.124 inch)

53.90 mm (2.122 inch)

52.94 to 52.96 mm (2.084 to 2.085 inch)

52.90 mm (2.083 inch)

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.

(2) Torque for two bolts ... 12 ± 2 N·m (105 ± 18 lb in)

: ) & * " # 2

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Note: R % * ' ' * . * " & < " ' " . " & + " " & * ' ( -

Illustration 3

g01357419

Note: Use a dial indicator and blocks in order to determine the runout of the camshaft. Take one half of the dial indicator reading as the runout. (3) Maximum permissible runout for camshaft ... 0.04 mm (0.002 inch)

Illustration 4

g01357422

(4) Measure the camshaft bearing with a dial indicator. Subtract the diameter of the camshaft journal in order to give bearing clearances. Refer to Table 4 for the clearance between the camshaft journals and the bushings.

Table 2 Standard Diameter

Repair Limit (1)

0.04 to 0.09 mm (0.002 to 0.004 inch)

0.15 mm (0.006 inch)

0.040 to 0.119 mm (0.0016 to 0.0047 inch)

0.15 mm (0.006 inch)

Number of Journal 1, 2, 3 4 (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.


Wed Feb 8 14:30:28 UTC-0200 2017





i02970360

Rocker Shaft SMCS - 1102 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1

g01411580

(1) Bore in rocker arm bushing for shaft ... 24.949 to 24.975 mm (0.9822 to 0.9833 inch) (2) Diameter of rocker arm shaft ... 24.915 to 24.928 mm (0.9809 to 0.9814 inch) Clearance of rocker arm bushing and shaft Minimum ... 0.021 mm (0.0008 inch) Maximum ... 0.060 mm (0.0024 inch)

Illustration 2

g01411576

(3) Align the oil holes in rocker arm bushing (4) with the oil holes in the rocker arm when the rocker arm bushing is replaced.

Illustration 3

(5) Torque for four bolts ... 18 ± 2 N·m (13 ± 1 lb ft) (6) Torque for four bolts ... 18 ± 2 N·m (13 ± 1 lb ft) (7) Torque for bolt ... 74 ± 5 N·m (55 ± 4 lb ft)

g01526063

Illustration 4 Valve lash adjustment

g01411582

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 valve lash ... 0.25 mm (0.010 inch) Exhaust valve lash ... 0.40 mm (0.016 inch)


Wed Feb 8 16:01:13 UTC-0200 2017





i02978141

Connecting Rod SMCS - 1218

Illustration 1

g01411338

(1) Matching marks that are used to align the cap to the connecting rod

Illustration 2

g01411339

(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 3

g01505976

(D) Bore of piston pin bearing ... 34.020 to 34.045 mm (1.3394 to 1.3404 inch) The clearance between the piston pin bearing and the piston pin is 0.023 to 0.054 mm (0.0009 to 0.0021 inch).

Note: A clearance for the piston pin to the piston pin bearing over 0.080 mm (0.0031 inch) is excessive. Replace the piston pin or replace the bearing if the clearance is excessive. Note: Before assembly, put clean engine oil on the bolt threads and all surfaces that make contact between the bolt and connecting rod caps. (2) Torque for nuts ... 103 ± 5 N·m (75 ± 4 lb ft) Note: Measure the bores of each of the connecting rods and record the dimension of the bores. (E) Bore in connecting rod ... 64.000 mm to 64.019 mm (2.5197 inch to 2.5204 inch)

Illustration 4

g01373137

(3) Use a feeler gauge to measure the end play. End play of the connecting rod should be within 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 5

g01373146

Assemble the piston (4) and connecting rods. Ensure that the markings (5) on the piston and the marks (1) on the connecting rod are on the same side.

Illustration 6

g01373153

Install the piston assembly with the marks (1) on the connecting rod toward the camshaft (6) .

Illustration 7 (F) Piston projection

g01411344

Use the following procedure to measure the height of each piston above the cylinder block. If clearances are not in the acceptable range, inspect the components for wear or damage. 1. Determine the top center position of the piston 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 (F) 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 (0.067 ± 0.004 inch) Piston projection ... 0.55 to 1.15 mm (0.022 to 0.045 inch)


Wed Feb 8 16:08:10 UTC-0200 2017





i02759135

Connecting Rod Bearing Journal SMCS - 1202; 1219; 1225 S/N - A6F1-UP S/N - A8F1-UP S/N - A9F1-UP S/N - BWW1-UP S/N - BYJ1-UP S/N - BYK1-UP S/N - BYM1-UP S/N - BZF1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - EAX1-UP S/N - FAL1-UP S/N - FMH1-UP S/N - GKS1-UP

S/N - HCW1-UP S/N - JBC1-UP S/N - JLG1-UP S/N - KBD1-UP S/N - KGF1-UP S/N - LFL1-UP S/N - MCH1-UP S/N - MDT1-UP S/N - NAS1-UP S/N - NCM1-UP S/N - PBD1-UP S/N - PBE1-UP S/N - PDP1-UP S/N - PHX1-UP S/N - RAC1-UP S/N - SBP1-UP S/N - SBZ1-UP S/N - SED1-UP S/N - TAE1-UP S/N - TGY1-UP S/N - WFD1-UP S/N - WGC1-UP S/N - XCK1-UP S/N - YDS1-UP S/N - YSD1-UP S/N - ZGB1-UP Table 1

Connecting Rod Bearing Journal Original size journal

64.945 to 64.965 mm (2.5569 to 2.5577 inch)


64.695 to 64.715 mm (2.5470 to 2.5478 inch)


64.445 to 64.465 mm (2.5372 to 2.5380 inch)


64.195 to 64.215 mm (2.5274 to 2.5281 inch)

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) An undersized bearing is required if the clearance between the connecting rod journal and the bearing is in excess of the service limit of 0.200 mm (0.0079 inch). If the crankshaft is worn excessively, or if the crankshaft is uneven, an undersized bearing is required. If an undersized bearing is required, grind the crankshaft to a dimension listed in Table 2. Note: The allowable tolerance for rod bearing journals that are out of round is 0.010 mm (0.0004 inch). The maximum repair limit is 0.030 mm (0.0012 inch). If the repair limit is exceeded, regrind the bearing journals to the specified dimension.


Wed Feb 8 16:05:41 UTC-0200 2017





i02980088

Cylinder Block SMCS - 1201 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1

g01507813

(1) Torque for four bolts ... 108 ± 5 N·m (80 ± 4 lb ft) (2) Torque for the bolt ... 58 ± 6 N·m (43 ± 4 lb ft)

Illustration 2

g01507808

(3) Measure the amount of the warpage of the cylinder block with a straightedge and feeler gauge. Maximum allowable clearance ... 0.05 mm (0.002 inch)

Repair limit ... 0.20 mm (0.008 inch) Resurface the top of the block if the repair limit is reached.

Illustration 3

g01507814

(4) Measure the inside diameter of the cylinder sleeve that is parallel to the crankshaft. Measure the inside diameter of the cylinder liner that is in a perpendicular position to the crankshaft. Measure the top, the middle and the bottom of the cylinder liner. Refer to Table 2 for tolerances of the cylinder liner. Table 1 Tolerances of Cylinder Sleeves Standard at Assembly Inside Diameter

0.010 mm (0.0004 inch)

(1) (2)

Service Limit (2)

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

Out of Round

Taper

Repair Limit (1)

0.015 mm (0.0006 inch)

N/A

N/A

N/A

N/A

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. 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.

Bore the cylinder to the specified oversize dimension if the inside diameter reaches the repair limit but the inside diameter does not reach the service limit. Refer to Table 3.

Hone the liner to +0.25 mm (+0.010 inch) or +0.50 mm (+0.020 inch) oversize. Hone the liner to an accuracy within 0.010 to 0.045 mm (0.0004 to 0.0018 inch). Determine the oversize dimension that is necessary 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 2 Oversize Bore

Cylinder Bore Size 102.260 mm (4.0260 inch)

0.250 mm (0.0098 inch) 102.295 mm (4.0274 inch) 102.510 mm (4.0358 inch) 0.500 mm (0.0197 inch) 102.545 mm (4.0372 inch)

Illustration 4

(5) Service limit of cylinder liner ... 102.700 mm (4.0433 inch) Note: Replace all cylinder liners that exceed the service limit. Use the following procedure in order to replace the cylinder liners.

g01507815

1. 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 least worn area. 2. Bore the liner until the thickness is 0.50 mm (0.020 inch). 3. Remove the remainder of the liner. Be careful not to damage the cylinder block. 4. Install a new liner. Align the liner with the top of the cylinder block. 5. The bore of the cylinder must be 102.000 to 102.035 mm (4.0157 to 4.0171 inch). Diameter for the main bearing bores ... 95.000 mm (3.7402 inch) Maximum diameter of the main bearing bores ... 95.022 mm (3.7410 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)


Wed Feb 8 16:03:58 UTC-0200 2017





i02876647

Main Bearing Journal SMCS - 1202; 1203 S/N - A6F1-UP S/N - A8F1-UP S/N - A9F1-UP S/N - BWW1-UP S/N - BYJ1-UP S/N - BYK1-UP S/N - BYM1-UP S/N - BZF1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - EAX1-UP S/N - FAL1-UP S/N - FMH1-UP S/N - GKS1-UP



g01358113

(2) Dial indicator

Procedure to measure the bore of main bearing journal 1. Put the main bearing caps in position in the cylinder block. Apply clean engine oil on the main bearing bolts. Install the main bearing bolts and tighten the main bearing bolts to a torque of 137 ± 5 N·m (100 ± 4 lb ft). 2. 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 the crankshaft journal and the main bearing is 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). Note: The allowable tolerance for main bearing journals that are out of round is 0.010 mm (0.0004 inch). The maximum repair limit is 0.030 mm (0.0012 inch). If the repair limit is exceeded, regrind the bearing journals to the specified dimension.


g01358114

(3) Bolts (4) Main bearing (5) Main bearing journal

(3) Torque for bolts ... 137 ± 5 N·m (100 ± 4 lb ft) Table 1 T ! " # C# $ $ ! % M$ B $ # & S ' " ! C# $ $ ! % M$ B $ # & J " ( # $ ) Original size journal

B $ # & T 2.477 to 2.490 mm (0.0975 to 0.0980 inch)

Undersize 0.25 mm (0.010 inch)

2.602 to 2.615 mm (0.1024 to 0.1030 inch)


2.727 to 2.740 mm (0.1074 to 0.1079 inch)


2.852 to 2.865 mm (0.1123 to 0.1128 inch)

The diameter of the crankshaft main bearing journal is given in Table 3. Table 2 M$ B $ # & J " ( # $ )

Original size journal (1)

89.95 to 89.97 mm (3.541 to 3.542 inch)


89.70 to 89.72 mm (3.531 to 3.532 inch)


89.45 to 89.47 mm (3.521 to 3.522 inch)

Undersize journal 0.75 mm (0.030 inch) (1)

89.20 to 89.22 mm (3.512 to 3.513 inch)

Regrind the main bearing journals to the next undersize dimension if the repair limit of 89.85 mm (3.537 inch) is exceeded.


Wed Feb 8 16:07:13 UTC-0200 2017





i02978080

Piston and Rings SMCS - 1214; 1215 S/N - A6F1-UP S/N - A8F1-UP S/N - A9F1-UP S/N - BWW1-UP S/N - BYJ1-UP S/N - BYK1-UP S/N - BYM1-UP S/N - BZF1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - EAX1-UP S/N - FAL1-UP S/N - FMH1-UP S/N - GKS1-UP


Illustration 1 (A) Piston diameter

g01411623

Each piston has markings (1) 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. Table 2 gives the dimensions for pistons that are standard. Table 2 also gives the dimensions for pistons that are oversize. Note: Measure the piston diameter along the perpendicular of the piston pin bore. Table 1 Dimensions for Piston Diameters Bore Size Standard Oversize 0.25 mm (0.010 inch)

Standard at Assembly 101.915 to 101.945 mm (4.0124 to 4.0136 inch)

102.165 to 102.195 mm (4.0222 to 4.0234 inch)

Service Limit (1) 101.730 mm (4.0051 inch) 101.980 mm (4.0150 inch)

8 6 !% 9 5 ' 55 5 ' 5 25 & . / 1

15 2' 415 " 15 2' 445 & . /

4' 5 ( 21 " 4' 5 ( ( (

15 2' 2( 5 4' 5 248 & . /

A$ % " & 4 / . / 7 . 2 % / % 3 0 % 1 ! $ 3 . 2 '

;330 % ! " & 2 B D ! " # $ % " & $ & 1 " !

C D ! " # $ % " & $ & ' ' ' ( ( ' 991 " ( ( ' 99*

< 5 1411629

1' ( ( 82 " 1' ( ( 85 & . /

M % 0 ! / $ % " & $ & 1 " ! 2 ! ' S0 1 ! . / $ % " & $ & 2 ! # ! " / 1 " ! 2 ! ' T/ . 3 ! & . 1 4 & / 1 " ! & 2 $ % " & $ & ' ' ' 5 ' 5 5 5 " 5 ' 5 21 5 ' 5 5 5 2 " 5 ' 5 5 5 8 & . / Note: T/ % ! 6 . 3 # " ! / . 3 ! & . 1 4 & / $ % " & $ & & 2 / $ % " & $ & 1 " ! % 5 ' 5 55 5 ' 5 5 25 & . / ' R $ 3 . / $ % " & # / . 3 ! & . / % 1 & 7 . 2 2 '

Illustration 3

g01526449

(2) 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. (3) When the top piston ring is installed in a cylinder liner with a bore of 102 mm (4.0 inch), the clearance between the ends of the top piston ring is the following distance. ... 0.30 to 0.45 mm (0.012 to 0.018 inch) Note: Replace the top piston rings if the end gap exceeds the maximum tolerance of 1.50 mm (0.060 inch). (4) When the intermediate piston ring is installed in a cylinder liner with a bore size of 102 mm (4.0 inch), the clearance between the ends of the intermediate piston ring is the following distance. ... 0.30 to 0.45 mm (0.012 to 0.018 inch) Note: Replace the intermediate piston rings if the end gap exceeds the maximum tolerance of 1.50 mm (0.060 inch). Note: The position of the end gap of the oil control ring is 180 degrees from the ends of the ring expander. (5) When the oil control piston ring is installed in a cylinder liner with a bore of 102 mm (4.0 inch), the clearance between the ends of the oil control piston ring is the following distance. ... 0.30 to 0.50 mm (0.012 to 0.020 inch)

Note: Replace the oil control piston rings if the end gap exceeds the maximum tolerance of 1.50 mm (0.060 inch).

Illustration 4

g01411650

Note: Install new piston rings in the ring grooves of the piston. Measure the side clearance of the ring groove (D) with a straight edge and feeler gauge. Table 3 gives acceptable clearances of the ring groove. Table 2 Clearances of the Piston Rings Piston Rings No. 1 Compression Ring No. 2 Compression Ring

Oil Control Ring (2)

Width of Ring

Side Clearance of Ring Groove

3.00 mm (0.118 inch)

0.080 to 0.120 mm (0.0031 to 0.0047 inch)

0.200 mm (0.0079 inch)

2.00 mm (0.079 inch)

0.080 to 0.120 mm (0.0031 to 0.0047 inch)

0.150 mm (0.0060 inch)

4.00 mm (0.157 inch)

0.025 to 0.065 mm (0.0010 to 0.0026 inch)

0.150 mm (0.0060 inch)

The piston must be replaced if the piston rings exceed these clearances.

Service Limit (2)

Illustration 5 (6) Camshaft side of engine block

g01526453

(7) End gap for no. 1 ring (top compression ring) (8) End gap for no. 2 ring (intermediate compression ring) (9) End gap for oil control ring

Note: Position the piston rings according to Illustration 5.


Wed Feb 8 16:09:09 UTC-0200 2017





i02967360

Cylinder Head Valves SMCS - 1105

Illustration 1

(A) Diameter of the valve head Inlet ... 34.5 mm (1.36 inch) Exhaust ... 27.5 mm (1.08 inch) (B) Diameter of the valve stem Inlet valve ... 6.6 mm (0.26 inch) Exhaust valve ... 6.6 mm (0.26 inch) (C) Length of the valve

g01491353

Inlet valve ... 144.0 mm (5.67 inch) Exhaust valve ... 144.0 mm (5.67 inch)

Illustration 2

g01491360

(D) Width of the valve seat Inlet ... 1.0 mm (0.039 inch) Exhaust ... 1.2 mm (0.047 inch) (E) Angle of valve seat face Inlet ... 30 degrees Exhaust ... 45 degrees


Wed Feb 8 16:02:44 UTC-0200 2017





i02707320

Piston Ring Groove - Inspect SMCS - 1214-040 Table 1 Required Tools Part Number

Part Name

Qty

8H-8581

Feeler Gauge

1

Inspect the Piston and the Piston Rings 1. Check the piston for wear and other damage. 2. Check that the piston rings are free to move in the grooves and that the rings are not broken.

Inspect the Clearance of the Piston Ring 1. Remove the piston rings and clean the grooves and the piston rings.

Illustration 1 (1) Feeler gauge

g01284934

(2) Piston ring (3) Piston grooves

2. Fit new piston rings (2) in the piston grooves (3) . 3. Check the clearance for the piston ring by placing the 8H-8581 Feeler Gauge (1) between piston groove (3) and the top of piston ring (2) . Refer to Specifications, "Piston and Rings" for the dimensions. Note: Some pistons have a tapered top groove and the piston ring is wedged. The clearance for the top piston ring cannot be checked by the above method when this occurs.

Inspect the Piston Ring End Gap

/ llustration 2 ' 1( & iston ring

g01* 582* 5

' 2( C% linder ring ridge ' * ( Feeler gauge

1. Clean all carbon from the top of the c% linder bores. 2. & lace each piston ring ' 1( in the c% linder bore ) ust below the c% linder ring ridge ' 2( . * . + se the 8H-8581 Feeler Gauge ' * ( to measure piston ring end gap. Refer to , pecifications. & iston and Rings. for the dimensions. Note: The coil spring must be removed from the oil control ring before the gap of the oil control ring is measured.


Wed Feb 8 15:48:33 UTC-0200 2017





i02877995

Engine Oil Pump - Inspect SMCS - 1304-040 If any part of the oil pump is worn enough in order to affect performance of the oil pump, the oil pump must be replaced. Perform the following procedures in order to inspect the oil pump. Refer to Specifications, "Engine Oil Pump" for clearances and torques. 1. Remove the cover for the engine oil pump. Refer to the Disassembly and Assembly, "Engine Oil Pump - Remove". 2. Clean all of the parts. Look for cracks in the metal or other damage.

Illustration 1 Engine oil pump

g01432433

(1) Driven gear assembly (2) Drive gear assembly (3) Oil pump gear (4) Idler gear assembly (5) Spindle

NOTICE Before operation, the pump must be lubricated with clean engine oil and the pump must turn freely by hand or damage to parts can be the result.

Note: The minimum acceptable oil pressure at low idle is 48 kPa (7 psi). Measure the backlash between the oil pump gear and the idler gear. Note: Replace the gears if the backlash exceeds 0.35 mm (0.014 inch). Note: The oil pump gear and the drive gear assembly are not serviceable if the oil pump gear is removed.

Illustration 2 (3) Oil pump gear

g01432436

Note: Do not use a torch. Heat the oil pump gear to 180 °C to 220 °C (356 °F to 428 °F) and support the end of the drive gear shaft in order to install the oil pump gear. Press the oil pump gear until the oil pump gear is flush with the end of the shaft.

Illustration 3 (6) Housing for oil pump gear

g01432439

Measure the difference in the length of the assembly for the oil pump gear. Measure the depth in the oil pump housing. Note: Replace the oil pump gear assembly if the clearance exceeds the service limit of 0.150 mm (0.0059 inch). Measure the clearance between the oil pump gears and the oil pump housing with a feeler gauge. Note: Replace the oil pump gear assembly if the clearance exceeds the service limit of 0.100 mm (0.0039 inch).

Illustration 4 (6) Housing for oil pump gear

g01432441

(7) Cover

Measure the inside diameters of the bores of the shafts in the cover (7) and the oil pump housing (6) . Measure the bores of the shafts. Note: Replace the oil pump gear assembly, the cover, or the oil pump housing if the clearance exceeds the service limit of 0.150 mm (0.0059 inch). Note: Replace the drive gear and driven gear as an assembly.

Illustration 5 (5) Spindle

g01432444

(8) Idler gear bushing

Measure the inside diameter of the idler gear bushing. Measure the diameter of the spindle. Clean the surface of the oil pump cover (7) . Install the cover to the oil pump housing (6) . Install bolts for the oil pump cover.


Wed Feb 8 15:46:09 UTC-0200 2017





i02725180

Cylinder Head - Inspect SMCS - 1100-040 Table 1 Required Tools Part Number

Part Name

Quantity

8S - 6691

Cylinder Head Repair Stand

1

1U - 7234

Feeler Gauge

1

Illustration 1 Bolt tightening sequence

g01355662

1. Remove the cylinder head bolts in the reverse sequence that is shown in Illustration 1. 2. Clean the cylinder head thoroughly. Make sure that the contact surfaces of the cylinder head and the cylinder block are clean, smooth and flat. 3. Inspect the bottom surface of the cylinder head for pitting, corrosion, and cracks. Inspect the area around the valve seat inserts and the holes for the fuel injection nozzles.

Illustration 2 (1) Cylinder head

g00876690

(2) Cylinder head repair stand

4. Put the cylinder head (1) on the 8S-6691 Cylinder Head Stand Set (2) .

Illustration 3

g01367177

5. Measure the flatness of the cylinder head with a straight edge (1) and with a feeler gauge (2) .


Wed Feb 8 15:51:28 UTC-0200 2017





i01309662

Cylinder Block - Inspect SMCS - 1201-040 Table 1 Required Tools Part Number

Part Name

Qty

1P-3537

Dial Bore Gauge Group

1

Illustration 1

g00285686

Inspect the top of the cylinder block for cracks and warpage. Refer to the Specifications Module, "Cylinder Block" topic for the tolerances. Inspect each cylinder bore. There should be no scoring, rust or corrosion. Use a 1P-3537 Dial Bore

Gauge Group in order to measure each cylinder bore. Each cylinder bore should be measured at the top, middle and bottom. Refer to Special Instruction, GMG00981 for the instructions that are needed to use the dial bore gauge. If the cylinder bores are out of the service limit, the cylinder block must be bored oversize. Refer to the Specifications Module, "Cylinder Block" topic for the tolerances.


Wed Feb 8 15:50:34 UTC-0200 2017





i02878004

Engine Oil Cooler - Inspect SMCS - 1378-040

Illustration 1 (1) Element

g01432449

(2) Gaskets (3) Oil cooler cover

Check the element (1) for cracks or other defects. If the element is damaged replace the element. Replace all gaskets (2) and check the oil cooler cover (3) for cracks. If the oil cooler cover is damaged, replace the cover.


Wed Feb 8 15:47:38 UTC-0200 2017





i02725199

Flywheel - Inspect SMCS - 1156-040

Face Runout (Axial Eccentricity) of the Flywheel Table 1 Required Tools Part Number

Part Name

Qty

8T-5096

Dial Indicator Gp

1

Illustration 1 Checking face runout of the flywheel

g00295955

1. Refer to Illustration 1 and install the dial indicator. Always put a force on the crankshaft in the same direction before the dial indicator is read. This will remove any crankshaft end clearance. 2. Set the dial indicator to read 0.0 mm (0.00 inch). 3. Turn the flywheel at intervals of 25 mm (1.00 inch) along the outer circumference of the flywheel face, and record measurements at each point. 4. The difference between two consecutive measurements must not be more than 0.03 mm (0.001 inch), which is the maximum permissible flywheel face runout.

Flywheel Runout Note: The flywheel housing must be removed in order to perform this runout check.

Illu s tration 2 C h eck ing f ly w h eel ru nou t

g 002 95956

1. R ef er to Illu s tration 2 and ins tall th e dial indicator. 2 . S et th e dial indicator to read 0. 00 m m

( 0. 000 inch ) .

3 . Tu rn th e f ly w h eel at interv als of 90 deg rees and read th e dial indicator. 4. C alcu late th e dif f erence betw een th e low es t m eas u rem ent and th e h ig h es t m eas u rem ent of th e f ou r locations . Th is dif f erence m u s t not be g reater th an 0. 50 m m ( 0. 0197 inch ) . Th is dim ens ion is th e m ax im u m perm is s ible dis tance f or th e ou ts ide diam eter ru nou t of th e f ly w h eel.


Wed Feb 8 15:53:04 UTC-0200 2017





i02965663

Fuel Injection Lines SMCS - 1252 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

Illustration 1

(1) Torque for five bolts ... 17 ± 2 N·m (150 ± 18 lb in) (2) Torque for two bolts ... 9 ± 1 N·m (80 ± 9 lb in) (3) Torque for three bolts ... 34 ± 4 N·m (300 ± 35 lb in) (4) Torque for four bolts ... 15 ± 2 N·m (130 ± 18 lb in) (5) Torque for four bolts ... 17 ± 2 N·m (150 ± 18 lb in)

g01488042


Wed Feb 8 14:20:32 UTC-0200 2017





i03062703

Finding Top Center Position for No. 1 Piston SMCS - 1105-531 Note: Refer to the Disassembly and Assembly for your machine for the removal of components. 1. Remove the valve mechanism cover. Rotate the crankshaft in the normal direction of the engine rotation until the inlet valve of the rear cylinder has just opened and the exhaust valve of the rear cylinder has not completely closed.

Illustration 1 Typical example

g00565561

2. Align the TC mark on the crankshaft pulley with the pointer on the timing case.


Wed Feb 8 15:35:21 UTC-0200 2017





i02966780

Valve Mechanism Cover SMCS - 1107 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1

g01490773

(1) Torque for 19 bolts ... 17 ± 2 N·m (150 ± 18 lb in) (2) Torque for 12 bolts ... 18 ± 2 N·m (160 ± 18 lb in) (3) Torque for six bolts ... 8.8 ± 1.0 N·m (80 ± 9 lb in)


Wed Feb 8 14:27:47 UTC-0200 2017





i02878012

Piston Height - Inspect SMCS - 1214-040 If the height of the piston above the cylinder block is not within the tolerance that is given in the Specifications Module, "Piston and Rings", the piston and the bearing for the piston pin must be replaced. If any of the following components are replaced or remachined, the piston height above the cylinder block must be measured: z

Crankshaft

z

Cylinder head

z

Connecting rod

z

Bearing for the piston pin

z

Piston

The correct piston height must be maintained in order to ensure that the engine conforms to the standards for emissions. Note: The top of the piston should not be machined. If the original piston is installed, be sure that the original piston is assembled to the correct connecting rod and installed in the original cylinder.

Illustration 1 8T-0455 Liner Projection Tool Group

g01432459

(1) 1P-2403 Dial indicator (2) 1P-2402 Gauge body (3) 1P-5507 Gauge block

1. Use the 8T-0455 Liner Projection Tool Group in order to measure the piston height above the cylinder block. Use the gauge block (3) to zero the dial indicator (1) on the face of the cylinder block. 2. Position the gauge block (3) on the cylinder block. Rotate the crankshaft until the piston is at the approximate top center. Ensure that the flame ring of the cylinder liner does not interfere with the gauge block or the dial indicator.

Illustration 2 Measurement of the piston height

g01432465

(1) 1P-2403 Dial indicator (2) 1P-2402 Gauge body

3. Position the gauge body (2) and dial indicator (1) in order to measure the piston height above the cylinder block. Slowly rotate the crankshaft in order to determine when the piston is at the highest position. Record this dimension. Compare this dimension with the dimensions that are given in Specifications, "Piston and Rings".


Wed Feb 8 15:52:15 UTC-0200 2017





i02978080

Piston and Rings SMCS - 1214; 1215 S/N - A6F1-UP S/N - A8F1-UP S/N - A9F1-UP S/N - BWW1-UP S/N - BYJ1-UP S/N - BYK1-UP S/N - BYM1-UP S/N - BZF1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - EAX1-UP S/N - FAL1-UP S/N - FMH1-UP S/N - GKS1-UP


Illustration 1 (A) Piston diameter

g01411623

Each piston has markings (1) 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. Table 2 gives the dimensions for pistons that are standard. Table 2 also gives the dimensions for pistons that are oversize. Note: Measure the piston diameter along the perpendicular of the piston pin bore. Table 1 Dimensions for Piston Diameters Bore Size Standard Oversize 0.25 mm (0.010 inch)

Standard at Assembly 101.915 to 101.945 mm (4.0124 to 4.0136 inch)

102.165 to 102.195 mm (4.0222 to 4.0234 inch)

Service Limit (1) 101.730 mm (4.0051 inch) 101.980 mm (4.0150 inch)

8 6 !% 9 5 ' 55 5 ' 5 25 & . / 1

15 2' 415 " 15 2' 445 & . /

4' 5 ( 21 " 4' 5 ( ( (

15 2' 2( 5 4' 5 248 & . /

A$ % " & 4 / . / 7 . 2 % / % 3 0 % 1 ! $ 3 . 2 '

;330 % ! " & 2 B D ! " # $ % " & $ & 1 " !

C D ! " # $ % " & $ & ' ' ' ( ( ' 991 " ( ( ' 99*

< 5 1411629

1' ( ( 82 " 1' ( ( 85 & . /

M % 0 ! / $ % " & $ & 1 " ! 2 ! ' S0 1 ! . / $ % " & $ & 2 ! # ! " / 1 " ! 2 ! ' T/ . 3 ! & . 1 4 & / 1 " ! & 2 $ % " & $ & ' ' ' 5 ' 5 5 5 " 5 ' 5 21 5 ' 5 5 5 2 " 5 ' 5 5 5 8 & . / Note: T/ % ! 6 . 3 # " ! / . 3 ! & . 1 4 & / $ % " & $ & & 2 / $ % " & $ & 1 " ! % 5 ' 5 55 5 ' 5 5 25 & . / ' R $ 3 . / $ % " & # / . 3 ! & . / % 1 & 7 . 2 2 '

Illustration 3

g01526449

(2) 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. (3) When the top piston ring is installed in a cylinder liner with a bore of 102 mm (4.0 inch), the clearance between the ends of the top piston ring is the following distance. ... 0.30 to 0.45 mm (0.012 to 0.018 inch) Note: Replace the top piston rings if the end gap exceeds the maximum tolerance of 1.50 mm (0.060 inch). (4) When the intermediate piston ring is installed in a cylinder liner with a bore size of 102 mm (4.0 inch), the clearance between the ends of the intermediate piston ring is the following distance. ... 0.30 to 0.45 mm (0.012 to 0.018 inch) Note: Replace the intermediate piston rings if the end gap exceeds the maximum tolerance of 1.50 mm (0.060 inch). Note: The position of the end gap of the oil control ring is 180 degrees from the ends of the ring expander. (5) When the oil control piston ring is installed in a cylinder liner with a bore of 102 mm (4.0 inch), the clearance between the ends of the oil control piston ring is the following distance. ... 0.30 to 0.50 mm (0.012 to 0.020 inch)

Note: Replace the oil control piston rings if the end gap exceeds the maximum tolerance of 1.50 mm (0.060 inch).

Illustration 4

g01411650

Note: Install new piston rings in the ring grooves of the piston. Measure the side clearance of the ring groove (D) with a straight edge and feeler gauge. Table 3 gives acceptable clearances of the ring groove. Table 2 Clearances of the Piston Rings Piston Rings No. 1 Compression Ring No. 2 Compression Ring

Oil Control Ring (2)

Width of Ring

Side Clearance of Ring Groove

3.00 mm (0.118 inch)

0.080 to 0.120 mm (0.0031 to 0.0047 inch)

0.200 mm (0.0079 inch)

2.00 mm (0.079 inch)

0.080 to 0.120 mm (0.0031 to 0.0047 inch)

0.150 mm (0.0060 inch)

4.00 mm (0.157 inch)

0.025 to 0.065 mm (0.0010 to 0.0026 inch)

0.150 mm (0.0060 inch)

The piston must be replaced if the piston rings exceed these clearances.

Service Limit (2)

Illustration 5 (6) Camshaft side of engine block

g01526453

(7) End gap for no. 1 ring (top compression ring) (8) End gap for no. 2 ring (intermediate compression ring) (9) End gap for oil control ring

Note: Position the piston rings according to Illustration 5.


Wed Feb 8 14:39:23 UTC-0200 2017





i02986420

Crankshaft Pulley SMCS - 1205 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1

g01513051

(1) Torque for the crankshaft pulley nut ... 706 ± 59 N·m (520 ± 45 lb ft)


Wed Feb 8 14:41:44 UTC-0200 2017





i02976008

Fan Drive SMCS - 1359 S/N - BYK1-UP S/N - CJN1-UP S/N - DAY1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - NCM1-UP S/N - TGY1-UP

Illustration 1

g01504021

(1) Torque for four bolts. ... 58 ± 6 N·m (43 ± 4 lb ft)


Wed Feb 8 14:42:24 UTC-0200 2017





i02974181

Engine Oil Pressure Sensor SMCS - 1924

Illustration 1

g01502573

(1) Final installation torque for the pressure sensor group ... 10 ± 2 N·m (90 ± 18 lb in) Operating temperature ... -40 to 125 °C (-40 to 257 °F) Operating voltage ... 5.0 ± 0.5 VDC


Wed Feb 8 14:50:03 UTC-0200 2017





i02974301

Boost Pressure Sensor SMCS - 1917

Illustration 1

g01502191

(1) Final installation torque for the pressure sensor group ... 12 N·m (105 lb in) Operating temperature ... −40 to 125 °C (−40 to 257 °F) Operating voltage ... 5.00 ± 0.25 VDC


Wed Feb 8 14:52:46 UTC-0200 2017





i02973716

Fuel Pressure Sensor SMCS - 1718

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. Refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" before adjustments and repairs are performed. Note: Refer to Systems Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. Ensure that all adjustments and repairs are performed by personnel that have had the correct training.

Illustration 1

g01502187

(1) Final installation torque for the pressure sensor group ... 34 ± 6 N·m (25 ± 4 lb ft) Operating voltage ... 5.00 ± 0.25 VDC Operating temperature ... -40 to 125 °C (-40 to 257 °F)


Wed Feb 8 14:47:41 UTC-0200 2017





i02974360

Speed/Timing Sensor SMCS - 1907; 1912

Illustration 1

g01502615

(1) Final installation torque for the speed sensor group ... 18 N·m (13 lb ft) Operating temperature ... -40 to 125 °C (-40 to 257 °F) Operating voltage ... 4 to 24 VDC


Wed Feb 8 14:53:49 UTC-0200 2017





i02974322


(1) Final installation torque for the pressure sensor group ... 34 ± 6 N·m (25 ± 4 lb ft) Operating temperature ... −40 to 125 °C (−40 to 257 °F)

Operating voltage ... 5.00 ± 0.25 VDC


Wed Feb 8 14:51:51 UTC-0200 2017





i02974280


Illustration 1

g01502573

(1) Final installation torque for the pressure sensor group ... 10 ± 2 N·m (90 ± 18 lb in) Operating temperature ... -40 to 125 °C (-40 to 257 °F) Operating voltage ... 5.0 ± 0.5 VDC


Wed Feb 8 14:51:17 UTC-0200 2017





i02974120


Illustration 1

g01502573

(1) Final installation torque for the pressure sensor group ... 10 ± 2 N·m (90 ± 18 lb in) Operating voltage ... 5.0 ± 0.5 VDC Operating temperature ... -40 to 125 °C (-40 to 257 °F)


Wed Feb 8 14:46:33 UTC-0200 2017





i02973719


Illustration 1

g01502191

(1) Final installation torque for the pressure sensor group ... 12 N·m (105 lb in) Operating voltage ... 5.00 ± 0.25 VDC Operating temperature ... −40 to 125 °C (−40 to 257 °F)


Wed Feb 8 14:45:30 UTC-0200 2017





i02974240


(1) Final installation torque for the pressure sensor group ... 34 ± 6 N·m (25 ± 4 lb ft) Operating voltage ... 5.00 ± 0.25 VDC

Operating temperature ... −40 to 125 °C (−40 to 257 °F)


Wed Feb 8 14:48:26 UTC-0200 2017





i02974220


Illustration 1

g01502191

(1) Final installation torque for the pressure sensor group ... 12 N·m (105 lb in) Operating temperature ... −40 to 125 °C (−40 to 257 °F) Operating voltage ... 5.00 ± 0.25 VDC


Wed Feb 8 14:49:22 UTC-0200 2017





i02973696

Coolant Temperature Sensor SMCS - 1906

Illustration 1

g01502163

(1) Final installation torque for the temperature sensor group ... 20 ± 3 N·m (15 ± 2 lb ft) Output type ... Passive Operating temperature ... -40 to 150 °C (-40 to 302 °F)


Wed Feb 8 14:43:14 UTC-0200 2017





i02973696

Coolant Temperature Sensor SMCS - 1906

Illustration 1

g01502163



Wed Feb 8 16:25:47 UTC-0200 2017





i02973702

Fuel Temperature Sensor SMCS - 1922

Illustration 1

g01502163



Wed Feb 8 14:44:40 UTC-0200 2017





i02867135

Fuel Injection Timing - Check SMCS - 1251-036

Illustration 1 (1) Fuel injection pump drive gear

g01428333

(2) Idler gear (3) Camshaft gear (4) Crankshaft gear

1. Set the number one piston at the top center on the compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for the No. 1 Piston" for the correct procedure. 2. Align the marks of each gear to the idler gear.


Wed Feb 8 15:41:31 UTC-0200 2017





i02966780

Valve Mechanism Cover SMCS - 1107 S/N - BYJ1-UP S/N - BYK1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - FMH1-UP S/N - HCW1-UP S/N - JBC1-UP S/N - KBD1-UP S/N - NCM1-UP S/N - PDP1-UP S/N - SBP1-UP S/N - TGY1-UP

Illustration 1

g01490773

(1) Torque for 19 bolts ... 17 ± 2 N·m (150 ± 18 lb in) (2) Torque for 12 bolts ... 18 ± 2 N·m (160 ± 18 lb in) (3) Torque for six bolts ... 8.8 ± 1.0 N·m (80 ± 9 lb in)


Wed Feb 8 16:01:52 UTC-0200 2017





i02725129

Engine Oil Pressure - Test SMCS - 1304-081 Table 1 Tools Needed Part Number

Part Name

Qty

1U-5470

Engine Pressure Group

1

An oil pressure gauge that has a defect can indicate low oil pressure. The 1U-5470 Engine Pressure Group can be used to check engine oil pressure.

Illustration 1 1U-5470 Engine Pressure Group

g00296486

The 1U-5470 Engine Pressure Group has a gauge that measures the oil pressure in the engine. Refer to Special Instruction, SEHS8907 for more information on using the 1U-5470 Engine Pressure Group. The information is included in the tool group. 1. Ensure that the engine is filled to the correct oil level. 2. Connect the 1U-5470 Engine Pressure Group to the sender for the engine oil or the sensor for the engine oil. 3. Operate the engine. Allow the engine to obtain normal operating temperature. 4. Keep the oil temperature constant with the engine at the rated rpm. Read the pressure gauge. 5. Refer to Table 2 in order to determine if the engine oil pressure is in tolerance. Table 2 Oil Pressure (1) Oil Pressure at 1500 rpm Oil Pressure at Idle (2)

145 kPa (21 psi) 48 kPa (7 psi)

(1)

The oil temperature must be 60° to 70°C (140° to 158°F).

(2)

Idle rpm is 900 ± 20 rpm.

Find the cause of the problem and correct the problem if the results of the test do not fall within the pressure range in Table 2. Engine failure or a reduction in engine life can be the result if engine operation is continued with oil pressure outside this range. Note: A record of engine oil pressure at regular intervals can be used as an indication of possible problems of the engine. A record of engine oil pressure at regular intervals can also be used as an indication of possible damage to the engine. The engine should be inspected and the problem should be corrected if there is a sudden increase or a sudden decrease of 70 kPa (10 psi) in oil pressure.


Wed Feb 8 15:45:20 UTC-0200 2017





i02976074

Gear Group (Front) SMCS - 1206

Illustration 1 (1) Fuel injection pump drive gear (2) Idler gear (3) Camshaft gear (5) Crankshaft gear

(4) Torque for nut ... 90 ± 6 N·m (65 ± 4 lb ft)

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Illustration 2

g01412610

Note: Ensure that the marks on the timing gears are in alignment. Install a dial indicator and rotate the idler gear (2) back and forth in order to measure backlash. Replace the idler gear if the backlash exceeds the service limit. Refer to Table 2. Table 1 Item

Service Limit (1)

Backlash of idler gear

0.03 to 0.17 mm (0.001 to 0.007 inch)

0.25 mm (0.010 inch)

End play of idler gear

0.05 to 0.20 mm (0.002 to 0.008 inch)

0.35 mm (0.014 inch)

0.019 to 0.100 mm (0.0007 to 0.0039 inch)

0.120 mm (0.0047 inch)

Clearance between idler gear bushing and shaft (1)

Standard at Assembly

Replace the idler gear if the service limit is exceeded.

Illustration 3

g01412611

Note: Measure the end play of the idler gear with a feeler gauge. Refer to Table 2. (6) Torque for bolt ... 34 ± 5 N·m (25 ± 4 lb ft) (7) Torque for bolts that holds the front plate ... 29 to 41 N·m (21 to 30 lb ft)

Illustration 4 (A) Inside diameter of idler gear bushing

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(8) Idler gear shaft

Replace the bushing if the clearance between the idler gear bushing and the idler gear shaft exceeds

the service limit. Refer to Table 2. Torque for bolts of the timing gear cover ... 29 to 41 N·m (21 to 30 lb ft)


Wed Feb 8 14:40:18 UTC-0200 2017





i02972680

Engine Oil Bypass Valve SMCS - 1306-BV

(1) Torque for nut ... 44 ± 5 N·m (32 ± 4 lb ft) (2) Torque for relief valve assembly ... 49 ± 5 N·m (36 ± 4 lb ft)

The valve opens at the following pressure. ... 350 ± 50 kPa (51 ± 7 psi)


Wed Feb 8 14:31:55 UTC-0200 2017





i02972952

Water Temperature Regulator SMCS - 1355

Illustration 1

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Start to open temperature of the water temperature regulator ... 71 ± 2 °C (160 ± 4 °F) The valve lifts more than 10 mm (0.4 inch) at the following temperature. ... 85 °C (185 °F)

Direitos Autorais 1993 - 2017 Caterpillar Inc. Todos os Direitos Reservados.

Wed Feb 8 14:34:30 UTC-0200 2017

Rede Particular Para Licenciados SIS.





i02967360

Cylinder Head Valves SMCS - 1105

Illustration 1

(A) Diameter of the valve head Inlet ... 34.5 mm (1.36 inch) Exhaust ... 27.5 mm (1.08 inch) (B) Diameter of the valve stem Inlet valve ... 6.6 mm (0.26 inch) Exhaust valve ... 6.6 mm (0.26 inch) (C) Length of the valve

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Inlet valve ... 144.0 mm (5.67 inch) Exhaust valve ... 144.0 mm (5.67 inch)

Illustration 2

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(D) Width of the valve seat Inlet ... 1.0 mm (0.039 inch) Exhaust ... 1.2 mm (0.047 inch) (E) Angle of valve seat face Inlet ... 30 degrees Exhaust ... 45 degrees


Wed Feb 8 14:28:29 UTC-0200 2017





i02978042

Flywheel SMCS - 1156 S/N - A6F1-UP S/N - A8F1-UP S/N - A9F1-UP S/N - BWW1-UP S/N - BYJ1-UP S/N - BYK1-UP S/N - BYM1-UP S/N - BZF1-UP S/N - BZH1-UP S/N - CJN1-UP S/N - CLA1-UP S/N - DAY1-UP S/N - DDW1-UP S/N - EAW1-UP S/N - EAX1-UP S/N - FAL1-UP S/N - FMH1-UP S/N - GKS1-UP


Illustration 1

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(1) Place the flywheel on a surface plate in order to measure the flatness of the flywheel. Use a dial indicator to measure the flatness of the flywheel. Standard at assembly of flywheel ... 0.15 mm (0.006 inch) Repair limit of flywheel ... 0.50 mm (0.020 inch) Note: Refinish the flywheel if the repair limit is exceeded.

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Wed Feb 8 14:40:58 UTC-0200 2017

Manual Oficina c4.2 c6.4 Caterpilla

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