GAIERPII.TAB'

Specifications34OOE and 3456 Engines for GaterpillarBuilt Machines

AEfl-Up

9

4nhbtErbow.....,............ ...............,,..........Eú.rct Mánirotd ._........,,..............

cdn€cting Ród Beann! Jouhát

EnSiñe Oil Pán .....

$hÉPup','''.'''.''''''''''..'.'''''-..'-

19

r&ñ B.árino Jdmd . .

35

Specif ications Sect¡on

Eng¡ne Des¡gn

3406E

3456 I

(AIdd. 1B) e&r (c) bi !* d dd¡e (D) cr ¡@ ¡uñbei(É) Éd d €4 rs.lF) Filhd6 d4tu GIFDú€d e¡d

Bft ...........-........................... 137.0 mm (5.40 rnch)

strcke .................................... 165.0 mm (6.50 inoh)

Dbpráenénl -................................. 143 L (3e0 rn)

Cy¡nder Aftnq€ment .......,.... ...... ln-ñne sü rylinde¡

Valv€s ps cy¡ind* .........-......... ..,

lnlel varve hsh ......... .............. 0.3! mm (0.01s ¡nch)

Exhaúst %lve l6h .......,,.,...,,. 0.76 mm (0.030irch)

Finns order (injeclion sequene) ..

cÉnlchan bialion lrm lhe iyrheel

5

Fuel Transfer Pump

Type I

¡FisftfoFhú..1hú1tsñP

lEñtan tE h01s to t¡e tol ingiotque. ..........._........._...._ 30 r 5 N ó (22 14 b n)

Type 2

(2i P.$su€ eoulalinq ú|re

(2) P''ersuE resubiilns wNé

fshlen lhe nús lo rhe rollowitrstorqoe. ...........-.............3015N m (22 r 4lbfr)

Fuel Filter Base

Electronic Un¡t In¡ectorMechan¡sm

fshc¡ lhe Ép nut3 io $é tunówi¡oIrqué. ......... 2 sr 0.25 N m (2212|b in)

(3)

fighign Úlé ádjosrinO screw rooloul lo lhefon@insrrque. ........1ml 10 N.m(74 17 rbñ)

Adjusr ü'e unir anj€.{tr héiqht ro the forr@inediremó¡. ...... 7a.0 ! 0.2 mm {3.07 ! 0.01 incrr)

unit injecbr clmp Bráinhq bon

fghián üé únit injectw damp ÉrÁ¡ning bdr tó5s ! 10 N.m (40.6 ¿ 7.4 lb ñ).

L@sén tlé éiáinifE b.lt unül $e bolt is ñnc€r

fghisn $é éiainiñs boft asain ro 55 r l0 N m

OÉng **

lü,

\2)

f ) fté *rin! 3ú'ráe o¡ rhé básé b mé énd of $esrud is lhé fóllwins dimension. ... 24.6 ! 1.3 mm

(0.e7 r o.o5 inch)

(2) Appry 1 s5 - 0695 ThÉad Lock Compound onrhe lapeEd end of rhe srud io rhe lollowingd¡ménsro.. ........................... 7.7 mm (o.30 inch)

']lghr€n rhé stud io Ílé d¡rwiñotúque. ......,.,, ....,...... 70 1 15 N m (50 t 11 lb ,t)

\4)

(5)

(6)

(7)

I

B€loB insbnáion ot Íle un[ ir]edor tubri€té théiop reú o{ing wls silh á so/50 mixru€ ol dsn€ng¡né oir and 3f-2993Lubn@nr

¡ot : R.lér to fsrins and Adtúsrño, .Etecroric Unilhr€dor . adju{ lol flé 6recr prcdr€ r¿sh on tñ6 €re.troic unir iDaciof _

Electronic Un¡t ln¡ector RockerArm

(l) 8oE¡nlheoc*ersmbéadnqrdthercckorám

.......... 40.065 r 0.015 mn(1.s774r0.0006 rn¿h)

Mdimuñ di'mensim fof dM pans .40.193mmO.$24 inch)

TrE rl€r añ beainq musl nd de¡d bMnd€üE Éé ór he m.br áñ

Valve Mechan¡sm

(1) Válw ró.ker ám a*mbry

(2) Adj$ihq screw ¡ochdfghrén the.djlsiiñs sEw tocknút to ülefón4in! lorqué. ...........30! 7 N m (22 f5 tbfr)

xor.: rflhe eisine É.cuipped w¡th á ónoGsionbEk6 tle mouniino botts for thé domores;¡onbr¿ké red66 bons l3). Rér€¡ lo s¡eciriÉróns¡cd¡pEes'ón &¿ke".

Tqff€n rh€ botb ro lhe lbntuinsbque. ........_ .109rlsNm(30!f bn)

Oiamder or á ñw Ecksr amshai1.....-... ...............,,,.... ¿0.00o1o.olo mm

11s743r000ü in.hrBm in a n€w kr,er ¿m ú€srino rorthe,ockr 'añ shán .. ..... ..40ir6s!o0r5mm

(r.5774 r 0.00m nórMdlmum d m6N,on rd Ébd. ñ"-- -a";ámbeanngtorlheook€rámshafi .. 40.193mm

(1 s324 inoh)

hlá Elves ......... ..,................,. 0.38 ! 0.03 hm'10.01510.003 ind,l

(0.030 * 0.003 irch)

Cylinder Head

oto

@

@o

oa¿)oO@(D

óóóóóó

@ó o o

The bo[s ihal are ñadied "r áÉ 21s mm (3.5 inoh)rong. Th6 Bmainde. ol rhe bolls áé 194 mm

appry 6v -4a76 Lubfiéff b rh6 boll lhcads andbolh sid6 ot Íle Mshec. fohteñ thé bolE ¡n fl€

l. ln á numeri@l sequetue, tqhle¡ bolts 1 lh@ugh

Torlue for bohs ,...... 270 r r 5 N m (200 1 11 rb f)

2. ln á ñuné'tÉl @uen@, liqhlen bolis 1 thouch

torque lor bolls .......450i l5N ñ (330 t 11 lbñ)

3. ¡n a numedclsequérG. áq6iñ ligh¡án bólt3 I

Torqua lor borrs ......450+ 15N ñ (330 r 11 lbñ)

Noré: The frabess or rhe cyiinder head should b€wn náror¿lot0 13mm(.005¡nó).also,rheiar.ssofihe ryfnder h€.d sh@rd b€ wilñ¡n. mdjmum of0 05 mm I 002 inch) ror ary 150 ñm (s.e iñcl') stán.

(A) Cylinder H€d Tltichess

Tht *n* of a lw .rrifde

a

¡¡

!

c!

l

I

I

I

he¡d.,,,,. 120.0010 15mm (4.72.11 0.006incn)M¡ñjmun Úl¡.h* of. used ryl¡ndérhéád .........-......-............. 11e.50 mm (a 70s inch)

11

NOftcEC.rddr b.¡'inss musl b. iñst¡ued inl! $en corécr,úI FailuE io do so w¡l resuh in €nodne dañaqe

€r) fIr¡ereroreruháñbofe

ffin ot beain! johtt¡-...--................. .. 20'15'ábdého'izni.r

9C)';

\Q\

t

¡./

rha deóih o! 'n{ana¡on

ol rlie

;;ry iñlD.'tant h'ralrb€ 'gs

comPression Brake(F EduiPPed)

r¡stárlat'on de Prh lor *ñshañ be¿ d ns5 (30 )

3 .. .... ..... iá-1'.'d¡;' i9:9 ' oo'? ""n

P......1 .,.... 3it'.-os*¡li:9:i:$ll*F... ........ ;;;;ió;;.i1,'s'g'o'.'?i^"r'1 ......... .... iá6.i;;;;; i'¡

"¡ *o oz "nüój;;';;; i$ 0, '9 9? ilt

c ... ... 19'12 t 0 50 ñm (0 75 ! 0 02 inoh

l'- - ,il)iiói i¡ga¿"ooz'o

1\

1(

::ilIJr.T"Jtr f t':"$ilT'""1. rishbn tuo @nler bolls (2)

" 54Ññ(401bli)

T'stfen moúnüns dld nul (5).

Toqu. ior mourfing stud nút ..... g N.m (¿0 tb ñ)

Tofqué rr oule¡ b.ris .... .. 54 N.m (40 tb f)rghián ¡^o enrer botrs (2) aqain.

To.!u€loreniérbols,........... 109Nñ(30lbn)

Iohlen the mounÍng slud nul (5) aga¡n.

Torqoélormoundnssludnul... 10sN.ñ(30tbñ)

rshlen 1so dlBr b.[s f ) as€in.

Torlúeroroulerbois............. 109N.m(30|bft)

. NOTICEPnofb ad¡usrins rh. l.eh s.fins ror the.ngtnocmpre.sio¡ br.ke, ¿héck tho ido¡tlric.tlon pl8bthr ¡5 or lh. coñPession br.k.r.r ro d€rémi¡e thc mod.t th.r i. insral€d onyoúr ensiné. You mu.t h.w rhis nod.¡ numh€r.ñd thc ensin6's €..lal nlnbs pGfir ¡n od.r todé¡em¡¡€ rh. l.Éh settins tor your .ng¡n..

Nor€: R.rer b TsÍng ánd Adjüs1ine, :aláre pisloñLásh - adjust for $€ omple¡e Fó.edufe for.djusrñq rhe srávé piion ra3h.

(3) Fmár idrque for srav€ pislcnr ádtwlins $rewl@rnd ......... ........ ............. 34 N.m (25 tb lr)

(4) Fináliorcué ro¡ soteno¡d vátk .(e.22 b n)

(6) Fna rofque fof 'nr,ándion

of thá mouffino studhtlU'ecvlind€rhe¿d ......... 33Nmt65.0tbñ)

Turbocharger

Pá¡l Num6.É AE Forlh€ Fott.wtnqtlustáiio.s:2221753, 2221751, Zn4t56. 2221757. ánd

l.--

123-0460, 132-3163, 14,r.m16. 143-2016. 151-3026.1s4-36t7, 1s5¡301, 155-79s3, t6¡37t0, 165-7311,

r39.9172, 19l. 009s, 19r-2S2s, 19

3

roÍshlen cramps (1)onlhe tuóocharsér, usá thá

,f]ghlen lhe clamp lo the fo lNins

brqúe. .................. 14 r 1 N m (10.31 o 7 lb fi)

2. Genuy lap rhe clamp w rh a sofr taced hañmer

3. Aqain liqhrán [re cláñP.

nghEn Ihe crámp !o lhe lollowinqlorque ... .......... .. 1a¡ 1 N.m (10.3 r0.7 rbtt)

ope ñing p€ssúr€ or lhe wasl€saG .... 133kPa(20 psi)

To r ohren dámps I ) d dré ródharsei use the

¡ghls rhe daDp io Úle lorr inotófque........................ 1411 N m l0 310.7 rb fr)

2. Gently bp n'e danp *iú' a $fr la@d hammer

3. again i4tfs fE d.fp.rEften n€ crep b t€ tuleins

I

i

ro l¡shlen rbe clamp (6) on rhe úóocharler, 0se the

nqhrón lhe cámp nur ro the fonowinq... l3Nm(133lbn)

ro t¡shten lhe clamp (3)on ihe turb¡charce4 use lhe

l33lblt)

vLoos€n rhecramp io lñe ionow¡ng tolque. ..6 N m

(53 1 rb n)

Tishleñ rhé dlañp ro rhe rol ow nslo4ue ... .. .... 13.sl r N m (e s10.7 b ñ)

¡ghlen the boli to [ie róliowinsrcfqoe. ................ 13 5 r 1 N m (9 9! 0.7 b fi)

Paft Nunb.6 aé For Thé Forrowins frusrá¡ion:r 5s-79s2, r 64-9490, r 6+9¡93, 1 64-9496, r 39-921 0¡r64.94S0, r39-9210, 139,9211, 131904210, 190-6211, 1905212, r90{2r3, and

Loosen rbe c amp nur to rhé iollówing6Nm(531bin)

¡qhten the clamp nut lo rhe lollow nsrorque....................135r1 N.m(ss10.7rblt)

Tshren rhe bolls (4 ror lhé coñp.essór c!áñpasséñby i óppñiié pans. fghlér rhé bó b ióf rhé@mpfessof c ¿mp ¿ssemb y lo rhe fonNins lorque175i r N.m (12.s01070rbft).

Appy5P-3931 Anr seizecomp!.B used io mounl ihe lu¡boch.4er ¡qhlen l¡e nulsrorhelorow¡ns tofqueT0 I 15 N m (51.6 I 11 0 rbñ).

Parl ñ umb.rs Ar. For Th. Followa¡ s lllust¡at¡on:

1 62-7603. 1 6¿4693. 1 6¿4490, 164-9¡1s6, 1 69-1675,1694271, 173-002, 139-S2f 0, 139-9211, 1A9-9212,

190.6210, r90-621r, 190€2r2. rS0-6213, 190-6215,1 91 -2926, 19 2-207 7, 19 4 -1 115, 19 4 -111 1, 196 -21 7 5,

ndé onñdad3 ruffiqenú aud4áb

To lrshren rhé d¿ñp {r0t on Irr€ tuÉo.ha@i u*lhe lonowiño pmceduE

rgh¡ánü\eclamptotheloltowins!órque... 1aN.m(133 b0

Loo*n the d.mp ró lhe tottoving tolqo.. .. 6 N.n(53.1lb ln)

fghlen rh6 daúp to the tdtowfiqrorqoé. ............,......... 13.5 r 1N.m (9.9 r 0.7 tbfr)

I11) wasteqáie

Opm¡ñg plsuE of trlé w6resEte ....... 156 kpa(23 Ps)

Tjgn¡€ñ [le cramp (t2l b the fotrd'ngt3.5r tN.m 199r0 7 tbñ)

Pa¡t Numb€É are Fd nE Folldi¡. fitudÉrio¡:162-7303, 190520s, t90á206, t90-si0?, t9o-6203,

fy¡ié$npbdallúeoqa6'waú9a6

ro llshFn Ihe cramp (13) d 'le

tu'boch¿f!É4 use

rrqhcnrh€clan!btl.fon inqtoEue... 13N.úo3.3 tb f)

Locenlhecrampror¡€folt inotofque...6N.m(53.1tbin)

¡ghrd rré . amp io [ie rolwingbfque .... ... 13511N.ñ(S9r07rbii)

openins pbssuÉ ollh6 Mr¿sate ....... 135 kfh(24 p€0

TiqhGn thé ctamp to rie folsh!rolque .......... 13 51 1 N.m (9 910.7lbfrJ

P¿d ¡{umb.B Arc For Th. Foltowtno tuslr¡üoni1¡134321.1¡l,l-¡ar6.drc.¡?rá -

Pll Numt)Ñ A@ For Th¿

To tqhián th8 damp (16) on the tur¡ocnaEol lso

r'shlenrhecramprórhélollowingtoque . 13Nñ(l3.3lb rl)

Les.n mE dámp t(' üe tollNins lorqué. .. 6 N m(53 1 lb iñ)

IOhten thé cLmp io Ihé tunowingrolque. ..................,..... 1311N m (9.6 r0.7|bñ)

To tighrén rhe Boll (17) on rhe 1uóel'arge¡. ú* üre

fgtfen the boll io rhe ¡onú¡ng roqué. .... 13 N mf33 lbn)

Les6¡ lhs bó[ lo lh€ follNinglolque. ...... 6 N m(s3.1rbin)

nghián ü€ b.ll lo the tollwinsrorque.,.......-............... 13i1 N h (9.6.0.7|bft)

IEhián rh6 tuóine clámp plale bofs (13) to trréfollMinOlorAue.-. 15310.6Nn(11.6r0.4bn)

Trghla ülé @ñÉcser clañp plálé b.ll3 09)h oppo€ilé palE. ligtfen t¡e @mp'esr dláñpplate b¡lts ló lhé folleing L.que. ... l7-5 ! 1 N.m

f2.s 10.7D n)

Apply 5P - 3 931 Arls.iza C¡mpound lo üle n uls ihaláe use¡ lo ñounl tte iúóochargei liqht$ lha ndstó lhá lclldlnq to¡que ?0 t 15 N m (515 i 1l.0 lb fr).

Air lnlet Elbow

(1) LuMere üt€ bore riohty üith¡¡srrl ing th. o{ins s€ts.

Exhaust Manifold

Apply 5F - 3931 Anli-seize Compound to thetlcáds of fts studs Ílat éngag. the tocknuts.Ístfen lhe 3tuds ¡n tE cytind€r héad ro rhelollowing iorqué . ........ 35 I s N.ñ {26 . 4 tb ñ)

Appry énq¡né órr to the Gmaté ends of lhé manÍóldsbélG assenbly Apdy 2P,2333 H¡oh TempeEtu6&aler b $e mare énds ot th6 mántrolds b€fo6asffibly. R€more €x@ss s€lerlrom iñé Asehbted

Íqtfen he roc¡úLts in tle numánetsedu.ndl¡ál i3 shtun rn ll usr¿ron 4t ro rhe r.rk;hoioqué,............ 33r5Nñ(2S!4ióñ)

Exhaust Manifold Shield

O) rshlen the nuls ió ü€ tun inoro¡que. ............,............25i 7 N.m 03tr5 tbfr)

oo@ (d)

oooG)

ooo(D

spéciñéd éñshafi robé Iñ r r J¡Err,áusrbbé........-....... 3.5rs mm(0.3352rnch)l¡lél lobé ...... .... ......... s.,431mm(0.3713inch)hiecltr bóe...,......,....., 10.451 ñm (0.4115 inch)

Io frnd rh6 robé riñ, usé rñé pmedu€ rhá ror M:i, MeasuE €ruhaít lobe heighl {7),

2. M€éuÉ bas. crrcb (3).

3. Subtáor ü'e base @.le neasuEmenl (siép2) from lhe ensháfr hó€ heighl (Slep 1). Thediffee¡e ¡s rhé .cruár robé r¡ft

Máxlmm pemissible diñersce benrÉn ¡he actualbbe fin {Siep 3) ánd ür€ 3pédñéd lobé l¡lt ol a n€wo@shaft 013 mm (0.005 iñch)

fshlen tE bohs lhal taslen $le órer io lhecyr¡nd€rh€.dbtñáfon ingtoqué. .. t3r3N n

f0 t 2 ¡b ff)

Camshaft

Type I

[or.: LLbdd€ th8 Émshaft lóbés with á 50/50mirlure ol aT 2993 Lubri€nt áñd cr@n engh. or¡.

Diamers of Í'e b€arinqloumá|s .. 3¡.35i0.02mm{3.341.0-001 in.h)

ord: Lubñér€ t'e msháfr bá.nr$ rh créánengine o pnd lo inslallins lhe @nshafr.

Z_\

21

fype 2

Io find lhe lob. rrfr, use th€ pb@dué $át fóIm:L Máásue €nBhán t¡be heiqhr (7).

2. M*3ur6 báse cn b (3).

3. sdbract lhe b*é cale meásu€m¿ñr rsiéb2) rion rh€ Éñshantob. hé'shrlsleD i). ihsdiñéBnce is me sduár rób. riñ

Máxiñum lemiss¡bté dtfieren@ bet*€éi ü¡e actuatlobe liñ (Scp 3) ánd rhe speoiti€d tobé rifr of a new@nsháñ.....-......,,,.......-.......-.. 0.13 mo (0.005 hch)

xotc Lubri€16 I¡6 €mshait tob€s eith á 50/s0n ¡ue ol 3T- 2993 Lubdcúr and ct€án éng¡ñe o¡ .

Diamebr or the beadnsjoumáb.. 343510.02 mm(3.341 r 0.001 in.rr)

Nor€: Lub.i@1. rhé kmshafi b€ánnds w rh .re¡nenqine o pde to insr¡r ns rh6 eroi¿ir lighl€n rñe botts thát hsrén rhe 6wr lo ihe

ctllhdgrheadtoth€fóI@insrorqué. .. 13.3N.m0012 br)

ñ

Sleciñ€d €nshañ ¡o6é tinExhsusr rob.................. 3.515 ñúlnl€r robe........_............. s.702 hml¡jeclorlobe...........,,. 10.451 mm

fype 2Engine Oil F¡lter Base

Type f

(1) Apply 9¡l 3263 ThHd Look Compound ontle r¿percd end of üle stud io rh. lorlovÍnodrnénsion. ...... 1o.5 ! 1 .5 nm (0¿1 r 0.06 ¡not¡)

I€hl€nlhestudlDÚletol ing iúrqu6. .. 66I7 N ñ(50i5rbn)

Léngih under t6t fo@ .., 55.25 ññ (2,175 inch)Tesl fo@ ........--.......... ... ?6 1 5 N (17.0 ! l.1 lb)Fe bngrh ¿fler test .......... 93.7 mn (3.69 irch)ou6ide diamecr .--............. 20.6 mm (0.31inch)Th6 iirt.¡.nd thé @or.f bypass larvesúrrr ópén wit) rhé lórrejng pG$Bdlie6ce,,,,.,,,.......-.... 255120 kPái37l 3psi)

s-lud

appyss-3263 Thresd Lod( comoound dúe lapeEd qd ot rhe srúd ró ¡h6 forrMiisd¡m€ns¡d. ...........--.............,, 3.0 mm (0.32 inch)]lohrán rhe shrd ro nle fdlowingtórqle.,,....,,.,...,..-,.....30. 14N m (601 10 lbfrl

t)

Í2)

L€nglh lnd€r 16r rúe .., 55,25 mm (2.175 inch).......76r5.3 N f7 t 1,30 tb)

Fe lensih añe. Gr .......... s3.7 mm {3.69 inch)::úsidedisrei6................ 20.6mn (0.31 inch)4,-. fihd úd iñá er€. bypass qtves,:rr ¡!éñ $tl me ftlwins pt€sr6

25s r 20 kPa {37 } 3 psD

tr!.n tlE prug io fle foúrfjis113. .....-...............100r 15 N.n (74 i 11 lb ñ)

Eng¡ne Oil Coole¡Valve

Bypass Engine Oil Pump

Type I

Léngh ú¡dérléstfor@... 55.25 mm (2.175 inch)réstrorce ...................7615 N (17.0 t 1.l3lb)Ffee renqlh ale¡1esr.......... 93 7mñ {3.6s inch)Oulsided¡ámét.r................ 20.6ññ {0,31 inch)Th€ fllér añd lhé cader bypass vatvswillops wid1 lhe follodinq lGsuGdirere¡@ ................. zss120kPa(37r3ps0

NOTICEBelore operaton, th€ púmp nur be lub Ér€d lithcleán onginéóir andrhepumpmusttumffeetybyhandof dañaqe to oans eñ be rhé ésuh.

(1) D¡amáéf of shafrs......_....... 22.217 t o_a05 ññ(0.374? t 0.0002 irch)

D¡áméráf of boes in cd€r fórshafrs 22.253 r 0.003 ñn (0.3763 1 0.0003 iddh)

(2) L€ndhoroea6,......_._......... 7s37510.025ñm(31250 t 0.0010 inch)

D€prh ol bo6 ror !ea6 ............ 79.502 + 0020mm(3.1300 i 0.0003 indh)

Léngrh uñder lsrfoG..... ri7 9mn (4 3.4 hch)150!3Nml 0r3tbfrr

F€e ensÍh áfi€rr8sr 152 9mm fo 02in.h)ours d€ d,amerer . .. .... 27 ñm {1 063 inohj

l.sr¿Í me béadñOs s lheb@inge:€ év.n wiüflé oúside ol üe puñp body.

(A) Pc¡r oñ or b€ádnq joinl from th6 eniérriietlrcugh beains bocs ........ 30! l5 d€qrees

Type 2

NOTICEB€¡r€ opeélion, thé pump nusl ba tubri€ted wh.réánssineo¡¿ndÍEpumpmu6lrumrreetybyhañdo' d¿m.sé ¡r Fds can bo üP 6u r

T6t d lést srand with sAE 10W oit a! 4s "c

Rotátror llm the dñre €nd .Puñpspe€d..................................2550RpMOulrüt ......... ..........., ..... 193 Umtr (51 US gpm)

(@

Oiámérér or lhe ddvé shafr(néw)..................... .. ...... 20.32010.005mm

(0.3000 + 0 0002 inch)

(néw)..............:.............. .. 20.361 ¡0.00shm(0.3016r0.0003inch)

Dameteroridlérshafi (ns).. 20.320r0.00smm(03000r00002n.h)

B.E in beann$ fof tdtér shañ(new)................. .....20.36110.003mm

(0.3016100003inch)

L€ngd¡ ofsea6 (new) ........ s7.153r0.025mm(2 2503 ! 0.0010 inch)

Deplhof b.€srorgéars..... 57.235r0.020mm(2.2s531 0.0003 inó)

Test on t€.r rañd wiÍl saE low .i ii ¡c ".Rolaton iiom $é drive end ..... counrérc ód.li*Pum! rpñ .. ................ ............... 2550 lpm

FIM speciñeuons lor row pessuEouhul ..,.............. .......... 272 L,tnin (72 uS spm)PHsure ............ ............. ........ 310 kPa (a5 psi)

Flry 3p€c¡ficáions tor hish pBssuÉourput................ ..... 1¡r4Llm¡n(33usqpm)PressuÉ .................................. 560 kpa (31 ps¡)

Diameler ol ddve shafr(n€w).....:............................ 22 217 I 0.005 mm

(0 3747 r 0.0002 nchtBoE in beñnos rtr drive sh¿frínwl...........,....,,.................. 22253 r 0 003 mm

(€)

(0.3763 ! 0.0m3 inú)

Diamereroridbshañ(new).. 22 217i0.00sñm(037¡7r00002inch)

BoÉ in b€arinst rrr idler shán('e*)-.. -'..---.----. 22.2531 0.003 mn(0.3763 r 0.0003 inch)

Lonslh órq€6ln*)........ . 79.375 r 0.02s mn(3.t25o!0001Oimh)

(n ).....,.............................. 79502I0.020ñú(3.1300i0.0003inch)

Dameler of ddve shatr r a :'(n4) '.-'.'--.-----'.- 22.211 t a.oa' úñ

(0 374t r 0 ooo2 inch)Bóre in bed nss ror dnre sh¿fr(new)................................. 22.25310.003ñm

(0.3763 t 0.0003 inoh)

Diaméta¡ófidreIshafr(n ) . 22.217 lo.aosññ(0 374710.0002 incht

Bo/é in beáin6 lo, dbr sh6ñ(new) ........................,,..... 22.25310003mm

(0.3763 r 0.0003 inch)

(3)

Terfo@... .. ..439!24Nl11o.0rsslbrLonoür unds les¡ fo@ .117.s;m1464 n¿ñiFée rens{¡ áfi6f resr .... rs29mm(6.02'n.htoursided'¿m¿rer ............. 27mn(1.063inchj

t:)

o4 ) Posiriú of benns lolnr lon ''e

@ffedinelñ@sh be¿nnq bó6 .............. 30 r l5 des€s

Nolé: rñstáfi rh6 béarings so t¡al lhe beaifos áf6fiush úih lhe olsid€ of lhe pump body.

Engine Oil Pan

Type {

fype 2

fshlÉ tré ptug r. ilF fo¡lwins.....701 l0N m (5217 lb fr)

App¡y 9S-32$ úEd L@k Compóund 10 th€lrcads ol.ll piF p&gp d Úle oil pan.

fghlen áÍ ot nt€ ¡tp€ plugs lo tle rolNinqrorqué. ......-................-- a1 ¡ 11N-m (60 t S lbl)

Typé 3

Igh¡án the bdb io *E fo¡lowjnslqque, ....,......-............. 55 1 10 N,m (41 i 7 lb ii)

(2) Pipá plus

f'ghén oB oa p4 bdls lo üeloaue. ...---...---......-.......-47 1 9

fghr€n rhe oil p¿n bolts io lh€iorqué ...... ... ... .47r9

Lub cáE the plug liqhüy s'l¡ énghé of.Íohlen lhe plus lo lhe lóllúlngrorque..................... 95rlsNm(70r11lbñ)

Apply 5P- 3413 Pipe Seál€nt to rhé rhreáds ór rhe

]johién rhe dE¡n pruq ro t€ forówhqroque......................, 70!10Nm(5017tbñ)

Crankcase Breather

l-' ----r

liqhren lhe óvér bdüs io tle

lighten ih€ hN dáñpé lo lhe fot ówingIoqu€. ....,,. ..........__913 N m (30r27 tbin)

appry á r¡glf *l ololy@nn io lhe *át bo€i

Water Temperature Regulalor

Water L¡nes

(2) woter iempetué reouraior

cómplelelyopenFmpáduÉ 92'ct193"F)

¿isl¡nÉ...... ................. 92.C093.F)Min¡muñ oreninq dislán€ ..

(o.41 inoh)

2A

Water Pump

f,shrs fr6 bol thá hotds ihe lmpéler to úEtollding rdqué .. .. 39 r 3 N ñ {29 t 2 tb ff)

(2) rha shafr diám.ií ar rhe €rhon *tasmbly e€ár aBa E th€ lonNinodn€n50n..,, ................. 191010.01m

{0.7520 I 0.0004 inch)

tt* E .ear s*mbty odo úe @lr pufiD sh€frunür lhé shion.ry ñp ¡s tut y *iád in tE NmD

(a) oirs@r

lnsláü Úlá or stsih lrl. prtmary tip io@rd ftewái¿r purp dnre s€r Press

'l. oit @t ¡nto ih€

Cylinder Block

'-'.

I

tlL.

|.,.L.l

Appry 7r¡- 7456 Compound to rré dowet befo6

Thó dorerénsds sbov6 flé iop $tá@ór rhe crÍnder block by rhe ronrynqd slanúo. ....... 13 5t0 5 mm {0.73r002 inch)

fhickiess ofrh€ 3páérptale .. 3.53510.025 ñn(0.3330! 0.0010 inch)

Thrckness of the !5skét tEt is ph6dbel$€en ül. sp¿car prale and ¡h€ cyti.derblo¿r. 0.233r0 032 mm (0.0094 i 0 0013mch)

cynnder riner prcjecllor abow lhe sDae¡prare....................._.....,......... 0.025 ro 0.152 mm

(0.0010 to 0.0060 inch)

Th€ dMréxrends abdé rhé 14 sutaéof rtu cylinder b¡o.r by rhe roÍoünsditan@ ........ t6o+o5 nm (0 63 r 0 02,ncn)

Apply 7rr- 7456 Cmpdnd io ra ddel betoE

rhá d@teñends.bM thé bp $laú6óf rhe cyindor btoc* by $e rolw nsdisEnce. ..... 20 0r 0 5mm (0 79i 002 inchl

rshlen $é ptug b the loll ingldque- ............. .....70110 N.m (52 iT tblr)

T1€ dséts éirend p$¡ tha €nd or lhe cyt'nderbrdr by i¡e forld'no dirú@. ... tg.t r0 5mm

(0.7s r 0,02 inch)

of lheprus.......... 2.012.0 mm(0.03 i 0.03 ¡nch)

Nol€: Thé tótár iá1ns or tle lóp MEol suda@of Ih€ cylinder bloc* musl be wihiñ 0 10 mmt0.0o4 mch). Th¿ fldnéte mur aLs¡ewfh¡n00s rn ¡0 002 rncn) for anv 1t.s mm 16 99 in.h)

(s) ede in tle oylind€r bló.k for the main beanigs

Ma¡nbéannq€rridrh.. . 215.90010.025mm(3.5000t00410¡nch)

W_ri*l or ih. drinder block lór lhe main beadno

"". ..:................. 2r5.s0010013ññ13 50oo r o ooo5

'nch)

(11) Main b€arins Qp bofts

r4!*m !di!¡h! dd 6' ruh bÉii! 6p bts

use rhe fonowlng prc@duÉ in údd lo üstfer lhé

l. Appt cléan ensine oil ló thé th€áds ol the bohs

2. nshbn he bo[s fiÉt on tl. beá¡in! üb side I )

'roñueforb.lts.......260i14Nml90!10|bñ)

3. liqhlen lhe holls on Íle opp6ie s¡dé (2 ).

(3) D'mension rroñ Úlé Érledine ol thé cÉnlshafibeánnq borc iD Úle róp of lhe tylinde' block

N4 ...42s.45r0.15 mñ (16.75ú !0.006inoh).......... 425 02 ññ l1a.rc3inoh)

Tofqué rof bo[s ....... 260 ! 14 N.ñ (190 r 10 lb fr)

Pd a malk o eadh bolt ánd eadr @P.

rshlen rhé bolls d the opposile sidé (3) ftom lt'e

Aislé(a).....-................ 120!5d€s@s(2rat5)

nohGn lhe b.lrs óñ rñ€ be.nno iab gde (41 ol lheéi rom rhe ma'r l. Elé ro¡'ownq €rue.

ansre (a)...,.,................ 120i5d6sێs (2nals)

(12) N€w dhensión íiom üle @nt8rhé ófrhedfánkshan befins bore to lné bonóñ of thecyli¡derblockpánEft ....... 16510r0.10hm

(6.s00 I 0.004 inch)

15) Prús

fshren lhé prus b ihe tonowing.rolqu€.........,.................3517N.m

Cylinder Liner

3406E

Apply 5P 3413 Pipe Seáránt on rhe drreads orülepipe plugs bef@ ¡n.lánáióñ in the cylinder block.

To p'evenr dáñáqe to $e pislon .oor,ns rersdu ng storcé, rhe pison @ol'nslÓ¡t ñust be

fghten tlá bóris rhai ho¡d the pEion cootiñq jelsro rh6 bnryins lorqu€. ..40r 3 N.n (30 i6 tbñ)

Mininum pemisrbl€ clea¡ane betw3añú'e p,eron, 116 p Erón @oths let, ánd rhé@nksháñ .. . 0.63 mm (0 025 in.ht

The follow ns deps ac ror háta no rhe cyinder I n€r

l. appt 5P-3975 Rubbq Lobn€ñr ón th€ sutácósof fré cyrinder liner boc. appty 5P 397s RubbéfLrbrjcanton rh. tubb€r sats on thé tN¿rFd of

2. Pur rhe fÍer band.ompterety 'n

ceán snqine o¡

3. rñslafl finer bánd (3) ¡n me srcore ondér the tiner

¡. rnúr rhe riner h thé b.G mrFdErári beroc ü16

(1) 806 in nw lin€. .....-.....,.,.. 137.135 I 0.025 mm(s.4010i 0.0010 inch)

(2) Thicknéss orfangé on r¡ñe¡ ,.. 3.390 l 0.020 nm(0.3s00 r 0.0oo8 inch)

The minimúm rhic*n$ of rh8 pan lhal eñ b€ usedagáin Érhérorrwins varúé.. ............. 3.370 mn

(0.3492 inoh)

Ndé: Rerer 1o Guid€llné For Reusablo Párts,SEBF3063, 'Cvlhdér L ne6 lor moÉ

'ntomdionalso, Érer lo rad nq ¿nd adrúins, 'c, nder Line¡. Proj€dion for úF prc(éduE fof insp€crng ¡h€orolecüon or the cü'nd€r ineE

3456

The forr ina steps a€ fof 'nslallúg

lhe cvllnder linefhrn rhc turnder bloc{. Reléf b sFcl¿l Inrrudon,REHso272 for noÉ inlbmalión

r- A¡orv 5P 397s Rubbár Lubd€nlú lhe crl rderbÉi llF bor€ suraces and on Ú16 rubber seá13

m üs l@s Paá ol lhe crlinder liner

z Pút rhe ñlld band @ñpLelelv in dean €nsii é .¡r

3. lmláll fler bánd (3) in the sodé undef rhé linér

4. hshll th6 liner n thé bo€ imtud¡álelv bero€ lhe

Ns cJ'nder nerbore r3s.635r 0025 mm154S94 r 0 0010 iñch)

(r)

\2')

Minimuñ €ómmended lh¡doess or lne ovlind€rLhériianqe..............,, ... 3370mm(03492inch)

Nor.: Refe¡ {o Guideline ior Reusable P¿rs,

Crankshaft Seals

úúrin rhe lollw¡ng roreÉñce. ............{r

Vibration Damper

Durjns imianafion, rhe *atdnvet shoutdnor úilád üe s¿t wirh'n lhe tunN nod'ámérer ......... .. ... r77304025ñm

{700010.010in(htAle¡ imlan¿don lhé láe ór he seátt waar sl*v¿shdrd be w tlin t'le tuneins dimonsion fiom thóf€áf rá@ of rE énkshafr. ............ 1 .5 r 0.5 mñ

añ€r 'nslárárion,

lhe láÉ or ñ seár'e 6ha3hourd be kith n ¡há lonMins dimeñiof f.om rhe@rraceotlhecránksh¿n .... 5.4+0.0 0.6mm

(02s +000 003mchlAtter insiall¿rion rhe rad ói rh. *er s.a nn ñ, Étbá paÉnd w h rhe Eáf fáe or h€ cEn|sñáf1

x6re Rerer ro sp*árrishorion, sMHs35o3,'spe.tal Handr¡ng rni'@lion and tmlá¡ztionnslruclions for cBnkshafr sé.t Gbops lhar Háv.HydódFañic G@Ns h ihe seatins LD.for lne6f€ct pmcedurc oñ the tñsbl¿lion of ¡h€ irod ¿nd

No¡.: Do not sepaÉle lhé sd fiom lhe ste.v€. fflñ. *al is seeaEt€d noñ ihe sred€. slé seát nusi

Dufiñs insra áton, rhe seardfivéf shoutdnol ontacl t'e sea¡ sithrn rhe fonM'nd

........... 1t.s0 r-o 2s mm17.00orooro,n¿hr

Añer nstanáüón rhe tac ot lhé se¿r'swer sl€€vá should be frush ülh lhe frontfaÉ or r¡e cÉnkshañ wih he f.¡tdtno

........ -o13do 13mñl-0.005 ¡o 0.00s inchr

Añar ms1¡l arion rh€ r¡ont É.e or ih.*l s €sin! shóuld be wi¡h n thá t¡ttNLnodimssron rrom he tom ¡ae or ihe -@nkshan,.....................s.23+000-0.60mm

(0.203 + 0.000.0024 'n.hrAfter insiandon. úe Ée ofihé *¿t s es'nd ñnsi

b€ paf¿nerwih me fód race ot [¡e r¿ñks-háfi

NOTICEThdouoh|yinspectülev|'eusdáre.káse or for rsns of ¿ d6niád ld;maoedt-c*eEilher or rh6* @ñditio¡s en Gus lhó f,¡taht loñake @nl¿ct wilh tl6 €* This can áffed lh6 v¡s-

appry4c 5593 arfisoze compound lo rhe botrs.

wilhin r¡e tollúhg roleEnce.

f ffid.,&;- 'lTo..ds-.rú*s..TP,sir-i-i;t

h úE sod( (5 f3s ¡ 0.0005 ii.h)lÉhoB-I roor5b¡ r5.ts4 ¡o.ooo5 rmhr I

C.nnect¡ng Rod

R€id to Sr@l l¡6tudDn, sMHs7l66, 'UsinsdE sP-2o5O cffino Rod CheÜñO FnuÉg"ffi:}ffi :'3[",fl :fi rÉ""lfi¿:'"""Parrr s€BF3oer, -sártEge ot Non séml€d

1_ -------------::-l

l--ffi-1-'I ; I \\4-rI I \T'fV \

i /[["| _,/ !2 \=t/"M\ -,. l\ _Jl I;ll

Connecting Rod Bear¡ngJournalsMcScod.: 1202: 12191 1225

Refef io Guideliñe Fof Reüsable Pátu, SEBFP,009,"Mai¡ a¡d conn€ciins Rdd Béánnss'úd Guld8lineFor R€lsbre Pañs, SEBF3041, -CEnkshaft

oeaÉne belw*ñ lhé n4 beafing ánd lheLumal. ......... 0 062 nñ k,0 1€0 mm

(0 0024 mch ro o 0063ln.h)

M&ñuñ oémissible d€áEn@ ber*en ¡n6 beadns¿n¿ t¡. ¡.'lm¿r..... .... ... .. o.2omm (0003 ln.h)

Ma¡n Bear¡ng Journal

Rerer lo Gú¡d€line For Reúsablé PalE, sEBFsooS,üáin and coñmcling Rod Bsfiñ$ and GuidelineFú R.@ble P€rs, sEBF3Ml, 'CÉnksh.n

cr*Énce berv@n lhe r beding and t'e0091mmloO.l6órm

Mdimum pfrÉsrble de@né b€ide€n ule b- r!and ¡hel(unal ..... .. 025mm10.01' ;¡) lrr Bo'e'n 6nnec0no rcd tor Íré psion prn

59640r0.013mm' (2.34¡0 i O,OO05 ¡nch)

Nor€: I¡é 6medlq ód must be h€iEd fo. iheinsbnáidnoldÉp¡fupinbeadngDonotusea

(2) rh€ únedi's úd musr be hsled from175 rd 260 'C (3,r7 b 463 'F) lor the insianátunof rhe rilo Fn b€.ring. Mdiñom d sbnce ror

35 0mm (3.35 inch)

(3) PÉton p¡n bedinq bofé......... 55.035!0.003mm

(21657 r 0.0003 in.i')

Thooúqhly lub'iÉL4 mé pisrón ptñ u(h dean engineoil Díor io asmblv of ü'e piro¡ and lhe .dneclinq

(4) The beinna ioinr mur be wirhin t 5 deo@es al

(5) Dki?ne beMq r},e oentec ofbeadnqs.............................. 261.62¿0.05mm

f0.30010.0m inch)

(6) Etch rhe cylinds ¡u nber on t'e mnneoli ns rodand ihe 6p an lh s l@lion Maí( rhe @nnecl¡ngrcd and üle €p wilñ a ¡umber i lhrcugh 6. MalkIñ6 nuñb66 ón rhé sañé sidé or ihé conne.l¡nqrod as rhe beains lab slob.

use thé lóllNins prcedufe in ofder lo I qhten lhe

l@ldumfghbn¡gmeúdbf@me¡]Ed€phd6

1- LúbfiÉre lhe boll threads ánd rñe sear no ráes otthe @ps wilh 4c- 5s9s Antl-sé?e compound.

z lqhlen n'e @nnec$na rcd bolts

ansre(A) ....................e0r5dba€¿.{1/4tum)

Pislon and Rinqs

t¡e @nkshgfr @nneclinq rcd

3406E

"Pislons' ánd Gu¡dénne rór RéusabréSEBF3051, "Pilon Pi¡s and Relain¡nq

3

ThorouqhLy tubn€ie the out6r soffáe ol lhe pistonand rhe pdton f¡nqs wú crsn ensin€ oitbef@indanaüóñ in rhe cytinds btock.

listáll lhe iop ng w'lh rhé side marked'UP-1'rwad rhe rop óf lhe p sion.yvhen lhe piston dng is rndáned in a cytinder t¡rcrlhát has á boÉ size ot 137.16 mm (5.400 tnch),lhé creaE¡e belween tle €nds ól lh€ pi$n nnsisrherolowing vá|oe. ................ 055r 0.'15ñm

10 022 1 0.006 inch)

Toque fof bons ............,.9013 N.n (65r6lbñ)

3. Pd a már* on 8ách bon ánd údh Ép.

¿ rqhren eaoh bolt fom lhe ro¡l lo anqle lA).

lñsrárr lhe inremédiále dñc t{h lhe side ña.kedUP2 io@d Úré1@ of rhe oÉion.

when lhe DBlon dno E inráLl8d n a cvrndd ljnerhar h* á boc siz€ ol 137 16 mm (s.400 iich),ll¿ cleaÉ¡cé béMen lhé dds or lhs p¡glo nnqis [lé roll@inq várue 1030r0190mm

l0 042510 0o7s ircn)

Th6 sDnno sde orrhe ollcontrolfing should b6as*mbr¿d 1s0 ddE* fom lhe nng end sapw dlh .r rhe dód€ in á n pislon lor lhe oilMrdmo.:. -....... ......... 321 r00tmñ

{0 126410 0004 'nch)

ino 1137 r 0.013 mm10.1235t 00005 inch)

cr6aE*. b€ts*n lhá srcd. dd lhe is dl''''' 00s010 020 ññ(0 0020 r 0 0003 i^ch)

M,rimum oamEs'bL€ deáEncé b€hdenñ. dmdd ¿nd the oiló rc|nnsáñer

'' 0 15 úm 10 006 inch)

Whs th. o¡l @nlrol nno is imlalled ii adrndef I nd tlal h¿s á boÉ siz 0l 137 16 ñm,i¿nñ ñó, ú. derañcá berween ihe;ds of ¡h€ osron nnq 6 rhé tunoün!v'iue ..... ¡.57i0.1emn(0022100$rnd'l

For éach o.o3 úñ 10.001 inch) ¡n@M h lhecvxnder lir€r boE 5¿€, ü€ de¿Én@ betoéénü;á áds or rhá plslon rin! lncreas6 bv 0 03 mñ

Nd¿: Thá ñnos should b¿ Dorúed w n the qaps olrhé nñss appó¡mácry 120 desl€g ffom each Ólhér

lhorcoghly tubn€b llé pidor ph wilh cleanéng¡ne oil Pdor lo á*ñbly

on . 55 M7 rO.OO3 ñm (2.1672r0 0@3 inchl

Bof€ h ilr€ pisbn ák'.1 for lhé pielsoin 55.0r9t 0 004 mm{2166l r 0 CO02 indr)

D¿m.lgofl¡€new9is|0np n 55.000 ! 0.005 mm 12 1654 1 0 0002 ¡ncn)

L.nolhofrhaodonp'n...... 113rOrO15mñ- (4 45? ! 0 005 ind')

lvw 2

R€ler !o Guld.Iine tof Rd*ble PafE, SEBF3049?'dóns and Gu'd€xne for R.usble Párrg,sFFFAosl -Pidon P'É and Réts'n'nq Riñs'

nDdgdy lubÉE Úle od€r sulfa@¿nd dÉ rir4

'n¡gs sid' .lean €ng'ne

'nsEllaüd 'ñ tlE qlinder b¡otk.

(r) F¡isroi' own aslmbt

lnstd tlÉ iop nng *iÚl m€ stde marx€d "UPrrtrrárd rhe b0 ot tte Pi$on.wB ÜE r*iú¡ .ins É instáI€d ¡n á ovlindar l¡nertlai hs . bde .¿€ ot 137 16 rñ (5'100 iñdh)Úle d6.E beüEn tlé €nds ot rhé p¡3ton nnqÉ lle foüoriis Etue. .... ..... 045!010mn

(0.01310.004inch)

hstar üE hEffisát dns wilh ttré sade nadcd'uP,z btm¡d üe rop ól1há pision.

ws tlE Fidn 'i4 i!; 'ñsned

in a cvl'nd4 linefM Éálul 9zór 137.r6 mm {54m,ncn),tné dá¿É bd,¡é¡ tle ends orti€ pislon ñnqÉdEtuadE rdE ........ ..033r015mn

(0 033 I 0 006 h¿n)

TIE sp.liq dÉ. ot the oil cóñlrol dng should b6er$léd l3o dégÉ lom lhe nng énd gap

wdth d ¡é ql@ 'n

r ns p'don for tle oildúElt¡E - 403'001nm

(0.lss100004inch)

Itl-bÉ.a 0E lw oil @ñtbl¡g -----... 333 1 O01 Fm (0 1567 1 0.0004 inch)

Clá'E befiE, iñ€ grwe and Úlé new oildtdriE...--, ....... 0.05 r 002mm

l0 0020 I 0.0003 inch)

[ráximum p€m¡sibre deaEn@ ber*€en[i€ gr6ve ad the ol @nircl ñn9 alteruse... ...................... ..... 0.15mm(0.006inch)

vlhen th€ oir ónbor ññs is insr¿rLed in acylind€rlin*lhál has a bore size of137.16 mñ(5400 inch),Ih€ce.Ene bstu€er lheends ol th€ pision dno is rhe fbn@inqválué.... 0.55!015mm(0.022t00059hch)

For €ach 0.03 ññ (0.001 inch) n@se in thecyliide. ¡ner bore si¿q lhe dea€n@ bete.6nlhe €nds oflhe p¡ston nng i¡masés by 0.03 ññ

Nole: The dngs should b€ p*¡Íon€d wilh ülé gaps orlhé dngs ápporimátély 120 dégre6 nóm éách other

fhobughry robñel8 ih€ pisidn pin w ¡ creanensiñé óir pfiof b assembry

Bore in lh. psion cM béring ror rhe pislonpin... s5.047 r 0.003 mm (2.1672¿0.0003 inch)

Bore ¡ lhe pislon skñ for lhe p¡stonp¡n .. 55.01s10.004mm(2.1361¡0.0002inch)

pin... 55.000!0.005 mm (2.16910.0002inch)

Leñgth ollh. p¡slon pin ..........113.20 i0.15mm(4.457 I 0.006 inch)

3456

Reler ro cu¡deriñé fór Réusabte Pads. SEBF3049."P¡sions" and Guideüne for Reusable Pá,ts,sEBF305l,'Pisbn Pins and R€ráinho Rinqs".

(3) Top pision fñs

¡nsiarr thé lop fins wirh thé side malked 'uP-1'lNard the iop of tlé pirón.whaf rhé pision nng b ¡n$áned in ¿ cytinde¡ t¡neflhat h6 a borc size or 139.66 mm (5.4S3 inch),rhe deaÉn€ béhr*n rhe ends ol lh€ p¡slón rjiaÉ lh€ ronMins va ue. ............... 0.50 ! 0.10 mm

(0.020 . 0.004 inoh)

ln.ian $e ñremediate rins witr rh€ srdé márxéd'UP'2'roward tle lop of lho prslóñ.

wh€ñ lhé pÉron ¡jns is insráIen iñ á cyrlnd€r rhsrt'al has a borc size ol 139.66 mm (s.493 idrh),tle .lea€ne bétw*n trl6 ends or rhe p sron ínsis thé lórleirg varue. ............... 0.3310.15 mm

(0.m3 l 0.003 ¡nch)

fté spnns ends ot the o¡r 6ntror dng shóú d be€ssembled 130 d€sreés 16ñ $e nna end qaD.

widrh ol rhe gbde h . néw pisr¡n ror Íle oil@¡fdnns...........................4.033!0.013mm

(0.r533 1 0.000s ¡nch)

ing.... 3.930 !0.010 mn (0.1567r0.0004 ¡nch)

cLeaEn@ bel*€en rhe gbow áñd the nry oit@¡nrcl ¡ins ........ . .................. 0053t 0.023 mn

(0.0021 r 0.0000 inch)

Mdiñun pemissibrecr€afándebéh'*n*'e srcove and lhé ó 6naolnns añs

......... . 0.15mm(0.006 iich)

wheñ rhe oil @¡rd nng is insEled n acylinder iner rhár has a blc gze of 139.66 mñ(5.4s3 ¡nch), t¡e deaEnÉ bélweéñ theends ofrhe ldon ¡ng is rhe bno{ng

(0.0177 + 0.0059 tnch)

For each 0.03 mm (0.001 inchi increás in Ílécylinder liner boé size, lhe oleaEné bé¡¿eenrhe €¡ds of tlé pision nnq ¡n@ses by 0.03 mm

Not€: Th€ dñss shourd be pc'i óñed wiih rhe q€p3 ols trom earh olhsr

Thoróoohly lubi€ie the p¡sion pin wiih deané¡sine o¡l píor lo á.sémbly.Bofé in rhe piron qoM b¿áfing for ire p slonpin ................. .................. s5 0355 !0.m55 mm

{2.166710.0002 rndh1

Boré ir rhe pislon ski¡l fd thé pistonpin... s5 020I0.00s ññ (2.1661.0.0002 ¡nch)

'¡t'óroushly lubnele lhe ouls suÍacéand lhe piston r ngs wlll dean eng neinsr.rraton h thé dyrinder brock

Hous¡ng (Front)

D¡amerer ol lhe new !¡slonprn.. 55.000r0.00sñm(2.165.410.0002inch)

. r13.201015mn14 457 r 0.006

'nch)

apdy 155-06S5 rrf€d ro.k c¿mpoú¡¿ to rh€ffirioru dt te á¡ (2) p'ior b indállaüón.

(3) s.:i's dÉ

u* thé fdrdiE Flaáft a oder ro üshlén tlébdrs ülát *, ,E Plrlle b dE cylinder b ook.

1. U* httd b* b tqhrF trré b.hÉ.

fEñ¡a o: b.lE io 0E lollo*inqdcE.... .....55r5Nml4Ot4lbfr)

2, Ue h¿id b.t b tghien t'e b.lls ágáin.

TdíEr üE bG b lÉ lo¡b{inglolq@ .,.-....--.......-.-..... 5s r s N m (40 } 4 lb f)

Nor.: aldv aT-9{t22 s¡ó¡e Gasket in order i0 finüe sp€É drrE drE frg jo¡nl of lhe f¡onr plate, oilFn q4r¡Gr, ad qftrq t¡od(

Front Hous¡ng and Covers

Tqhleñ lhé ttuds ¡har aon rhe blod\ ¡o theidw'ns b'que ... .. 102 ! 10 N m 175 t 7 lb fi)

Gear Group (Front) ,

fohren iñ6 bdú had s@G ontv ¿ñer¡lhldn'no ¡he oúH bol¡e ánd nurs

ln 6 ¡uturical seqwne, tightán {.e buron h€áds¡)¡@ lo thelollM¡ng rofqúe. .........13 4 3 N.m

(f0r2rbfr)

apply 155 0695 ThEad tocklhEds ol fl. úd thai ens.s.

Agply 95-3263 Thcád Lock ComDound b rhelve bolE ror rhé srub +erfshren rh. ñ€ bohs lor ihe stubsh¿l ¡n lhe folldinq sqúd@. s@rrrusrrarion e¡ for ¡lE nunbüro of úE

1.3,4.5 2.1.2.3.4.s.

Apply 95 3263 ThFad b.l compound to the

rrhhn rhe r.ur bóh8 rhal fasreñ th6 clustefdár b fié 3lub shalt io lhe lol owiñqü¡qre. ............... 30t7Nm(22i5 blt)

Lrohtv lÚbn@le thé oiing *al on lhe oúG¡dé ollrre @mshañ *áins dab *i[l a 50/50 mi{lure of3T'2993 Lubfi€nl ad dú éngine oil Applv95 - 3263 Th€d Lod( cdpound ló lhé th€ebolb rú lñe €rdÉn sÍng Plate.foht€¡ rñe the éreháñ wlinq p át !boills ro rh6 dt*n€ blqE. see llu#lion39....... ...............-... 1213N m(9i2lbñ)Tlehl6n ule dlq¡d b.is in Ú'e rollN¡ng+ouen.¿ sé lüstr.ton 90 fof lhe numbe¡n q

ófiié borr. ........... 1.4.2,5 3,6, r.4fomen*le*€F€hafrqealbo[910lheroiNiq lacÉ. .. 2.or40 N m (ln 1 30 |b fl l

LnEt.n uÉ PrtE stñ $e oir qrevé t(Mrdlhe@rh@ Ardy9s.3263 Thread Loc(cdmúd to oE oÉ b.lrs lhal hsren lh€¿¿N,isu. id6 9.¡r lo t'e sr,¡ s¡aífstller tE oE bdrs ror lhé ádluslableidr.r € b üÉ $b shañ lo lhé iclloMnqr-i ..3or7Nmr22islbfirá ¡ rot¡ *,¿ ¡¡i,"tns, "e"". e.,P(Frorq - Ire- rr iB b.cldash ádjút¡nent

Bác¡d6h t'elEr dE €mh.ñ gear aid lheádiusr¿tle'ddes .. 0.21610.114 ñm

100035r00u5inch)

AFdy 9s-326É lrE-ad Lock Compound 10 lhe* b.¡l ¡l fE áds lq the slub .háil.TEhlen tE m hoü and five nuc tor lhe s¡lb$áñ ro üF badríq tr.que. ............ 55 r 10 N m

(41r7rbñ)

(6) air dlpre* qd f'r €quipeed)

A¡,pt 9S-3263 ItF¡i Lúk Compound to lh€ore boü -d fE sUds ror rhé stúb sháft

f-tu tu dE bdr ánd ff\€ ¡uc for lhe stubsfi-aff b iE ¡adÍg L.que s5 1 10 N m

(4r r 7rbñ)

Atply 9s-326ts Tn:F¡d Ldk compound 10 lheül@ b.rs rEl iaá€n Úle idler sear io tha Errb

rEhEn ÍE üE bdE üar fasbn lhe

'dr€r @' ro tE s&b shán to üe fol owinq

brqG..---.. .30I7Nm(22*5lbil)

(3) G€r b.tE ñ¡l F¿Ecl PumP drivé

(9) a¡lqn ÜE únE É* d tle @nkshafi séár wlhthe ri¡ig nst o tlE ús:tá gáár

(41 Al'sn rhe lrm'ng mari óñ [ie émshañ g4r *ilnüls im nq m¿Á ón the fronl housng tu háÑo. 1 pislon is al rop 6nie.

@"ooeoo

Tighren rhé b.rr rór 1¡e oit lumpfollówlnq lóque. .........55 1 10

Flywheel

Flywheel Housing

3406E

xore Do nol h6át ihé dns q€r w¡rh á tofch,

Apply €ng¡ne oir to f¡e lhÉads ol the bdts.TEhre¡ Ílá bórts ro üle fott ingiorqlo. .....,,............270r40 N.m (200 r30 tbñ)

lloi.: Oudng ássembly, anspoct thé rottM]nscompó¡eñls tor a¡y foEigi mate'ias: th6 frdtráce of rhe iyrhéer housins, lle rro sidés of lhefryrheel ho$¡ng gasker, and lhé €ár f¡@ ot lhecylindd brd.r( These 6mponénrs nust b€ fr* oflhé toneins subGtanes oit, tuet, w¿l€. a¿skerádhesive asñblv conDounds. and antoherrorcrsn máiénar. Appty á iñ¿n ¿mou oisr-90p2Silimne G€ské¡ h ór¿er lo llrthe ápáce be{rm $ecylinds bl@[, lhe flyvheet hous'no, and úe of Danberorc

'nsbniñq he oÍ oán a¿sier and flé or oin

To ¡ghrén $e nrahéet housins botrs, ú* the

t. ln á núned@tsequéne. tishle¡ bo[ 1t\muqh9.

fo¡que lor bofts ......... 100 I 20 N m (74 1 15 tb tr)

2. h ¿ nuñen€¡ sau€ñce, riqhren botr 10 rh'@qh

Toquo rorbdÍs.............40 t r0 N.m (30 17b n)

lñ a nunsicar séqúenoe, aqain rsht€ñ bott 1lhrcugh bort L

135120Nm(l00r1slbfr)

¿ ln á num€d€lsequ€n@, ága¡n liqhlen bo[ 10

To$uéfo.bolb ........... 55r l0N m(4017lbfi)

1'? o

t)

,r, ln a rúmé'l@r sequsn@. &ari ¡d¡len boll

Torqúé iorbohs.............5str r0 Ñm (40l

rqht6n lhe Pluo to lhe lolldinsroE@ ...... . ssi 14 N m (414

'9..

o5

¡ú: ou¡i.o ¿semb¡y' hsped ü6 fond¡ngffióonsc r.f anv foféEn mar€náls: lhe ftonlb;or ú. ñw¡e€r hesino. ri¡e ¡"¡ sdes or ft6ñwheel hou;hs $s[€¡, and lñ€ reaf fác. of ihe.;[nd.. block. These úmoon€nc musr bé É or

ie rdlNinq $b3lános oll tuer Él6i s*r€l

fób'on m¿bdá1. AaDlv . small ámoun' of 3r_ s022sil;né Gasl€t h order io fll üe epae b6l*€€n thecdinder bloc{, dr€ n$heel hdsing ánd he oil pan

Mó€ insbl||m lhe o I Fn aáskál ánd [lé oil psn

To Ígtfen Ílé ítyvrheel housino boltr' u$ lhé

l. ln a nuMi@lssquene, ghten boh 1[rrcush9-

TótquelorbolE...,... 1m l20 N m (74 r 15 !b ñ)

ln a numeñ€l sq@@. ligftei boh 10 üróugh

fofqueforbolls....,,.......40+ 10 N m (30r7 lbfr)

h a ñúre @l ssauence, asáin tshisñ bolt 1

forque lor botts ... l3S+20Nm(100t15lbn)

roooo

¡9o

@

@

zl,^'

Nor.: Dufno asñbrx inspecl ÍE ldnMinsa 6ñpónenb ltr¿ny foÉ'qn ruián¿b rhe rronlI r¿cé ór rhe nr'heet houdiq rhe úo sdes ot the' f,yúeerhoushs oásrér and rhe Earláca orrhe

cylnd.f brock. rhese conponenlg musr bé nee oifré iollNins subshnÉs: of¡ luél wáel saske¡¿dhesire asse mbly r mp.und s, and.ny dhsribÉian ñ¿ténár ADDrv ¿ snal amountorsT s022srrlcóñe Gaskel in o.der ró iI rhé spae be¡4€en th€úylindárbr4r $e ñrrheer housinq, ánd iha ótp¿n

ro lighren l¡e ¡lnhÉlhoG¡ng b.rt6, use üle

l. h ¿ ñuñefi€l*quenÉ, fghlen bort 1 [rfoush ITorqué lor borts ........ 100120 N m (74115 rbñ)

2. Ln z numefi€l seq ue¡@, i¡ghtan boft 10 {hrcush

Tofqú€ i'f bdrb ..... . . 40 1 10 N.m (30 I 7 tb ñ)

3. ln a nuned@l s€quen6, aga ¡ rigtfen botr 1

foqúef¡rbóls...... 135120N.ñl0ai15tbñ)

21, ln á ¡um€dca séquéne, asain tghl€n botr 10

Torqueforbolts............s5 1 10 N m (4017 tbfr)

Nor.: Dunng **ñbty, inspe.l thé ró tdinsmmpotunrs for any loreiqn máreda s: rhe fdrfáce of the ll,lh€.r hoúsins, rhe lwo sidos or rréflywheel housing gaskeL and lhe bár fáce or thecyihdér bbcr. These compdénls musl be free ofMe tunowins subsránG oit, tuet, sats, oasteladhesive. *sMbry (mpNnds, and antot¡e¡fo€'qn m¿ten¿l AoDrv a sm¿n ámud or 3r . so22sr rconé Gaskel ¡n ofdér b ñn dre sp.ce b.twéén rhecylinde¡ bl@k, $6 fiwheel housins, ánd $é oit oanbeloB i¡starÍng the oit pán gásket ánd l¡le o¡r páñ.

To iight€ñ rhe frynh€ét hoús¡ñg bo[s, us. thé

l. n á numed@t s6quéne. tighten bot I rhmush 9.

rorquelorbons.........100120 N m (74 i 1s tb fr)

2. rn ¿ numei6l $quenG, riorrl€n ¡otr r0 urrcuoh

Iolqúéforbolrs...........40rl0N.m(30i7tbñ)

3, ln a ¡um€rica sequ6nc6, aoaiñ üshlen bon 1

Tofque for bofts .. 135120N.ñ(100115tbñ)

ln á núñai€r sequ€n*, ágaiñ tqhlen b.tr 10

To¡lue ¡orbóls.. ......55i 10N ñ (40 !7 tbf)

3456

TEtfen lhe lh€é bohs ror tle @wr to thetollw¡ngtorqoe....,,.l15.20Nñ(35r15tbñ)

Belt Tension chart

Not : Dó ñor u* the bell len6h¡ chá¡Ls for bell¡ wilhiansioM i¡él áE apring lo€dod

)

for oAYco €uF[ád B.rb ont

Eng¡ne Support

Alternator and Regulator

114-2401 Alternator Gp

Nolo: L@d t'e batrery wit' a €'¡.n pile aC a91 lBa{ery LÉd Téler in dd€¡ to get lle maximum

P.r.i'v................................. ........ Nesárive Gfound

Miniñum út rld lftnr al 2000 rpm

ouFn Írb!€ ........ ......

T'grnú rE b.ü o üE gound tem¡na io lheto[orn'gtdqÉ........6.2]06N ñ(5s1slbin)

Mounting Gp-Fan Dr¡ve

trn

,Etll$

!E

.....................2516Nn(13r4|bfi)

].ishbn lhe elght bolls lo lheroque. ......... . 135 r 20

(Front)

)-

,

fshien üe nú on lhe output sháfr or ihé€lienalor Io rhe follow¡ng to4ú€- ... 102r7Nm

(75¿5tbtt)

fghGn rhe nd on rh€ pos(ive teminat lo lheforlowino rofq¡e. .... .7.110.3 N.m (5 1 0.6 lb fr)

Voltase sefiing................. ....-..... No adj¡.t¡€ntP€m¡sibrgvorra!€ fánoe....,......,.... 27to29v

169-3345 Allernator Gp

liqhien lhe not oñ rhe posit¡ve lém{náIs th€forro*rngtofqúe. ...... 13.21 2.4 N m f13r 2lbfi)

fshGn üle nut or 1¡e oúpur shañ o, rhéáll€má¡crtoú'ero(winqioeu€...i27110Nm

(94i7lbñ)

Tiohten lhe nú on th€ qrcund lém¡na tó rhéror*inslorqoe........4.4r1.0N.m(3ererbin)

vohase s¡ins .......................... No adjusLft ntPemissible vorras6 En$ .................. 27 tó 29 v

Electr¡c Starting Motor

Type I

Noré: L¿ad the bate¡y wirh a eÉon p¡t. 4c- 491 1

Baüery L@d T6le. i¡ .rne¡ l(l gé11he naximum

P.|arily . .,,. ............ ......-....... ........ Néqáive c@nd

Rota ón ................................................. CtoclMts

Minlmom lull loád drenr ar 5000 ¡pm ......... 50 Anp

Minimum tull load orenr .t 1500 Am ......... 3o Añp

oú&utvóftágé ...,,,,.................................. 23 I 1.0 VWhen tle electic aiáñho úo¡dr is üewed fromrh. ddv€ énd, rhe moror @lales iñ tho ionúing

ilAá!".s

No ro¿d trdriom d x"c (77"F)

t)

t2)

(3)

(s)

(3)

Speed.... .............. .... 76,131 1633 Dmcorenr dr.w ....... ............. ... 67.5 r7.s ampvollagé.................................................23V

nghlen rhe not on the banery lem¡na io lhetollowins brqúé. ..... 30.5a3.5 N m (22 ¡ 3 rbñ)

rght !ñ thé ñot on thá gbúnd l€m¡nal lo lhetolowinqiorlue.....30.5r3.5N m€2r3lbn)

rshl€n th€ ñut on the gmund l€minal io lhetol ow¡nq iorque. ... 22s 1 0.25 N m (20 1 2 lb in)

'fishl€n ltu nut d lñe swiich leminal lo rherotowins ro!ué. ... 2.25 1 0.2s N m (20 1 2 lb ¡n)

fshr€n rhé nol on rhe moror teminal 1o ihefollowi¡s brqu€. ......30.513.5 N m (22 r 3!b f)

fght€n rh. nul on lhe morú rÉne bminal toilre róllówin! lorlue. .....313 N m {71127 bin)

9x-gsrl Slarlins ororsol€noidAsséñbly

cúr€ntmñ.úñ on á125'c (77'F)

Purl n windinss ar 20v . ............56.5i4.s4mptlold-inw¡dingsa120V. ......... ..... 14.6Amp

Type 2

whén m. €bcrric sNañjng morof is vised rrcmlhe dive end, tÉ mobr robres in t'e loll@ingdnedion. ....................................... ......... Clockwise

No load condirions d 25'c O7'F)

Sp€€d ............. .......... ........ 5500 lpm minimum.... 140 AnP mdlhúm

Vohase .... .-....-....--.-.........-- .-.24y

(r ) r€ht€n il'6 n', on lhé sóoñd tehin¿l to th8for ówing brqué ... 30.5 1 3 5 N.m (22 ! 3 tb fr)

(2) fsht€n iné ¡d on rhe bahé'y rem nar to rhefollNingro'que... ..30.5t3.5Nñ(2213|bñ)

(3) rshle¡ l,'e not on llié sbúnd teminal to t'efónMiñ! idrque. .. 2.2510.25 N m (20! 2 lbin)

(4) fg'rlen lhe nut on il'é sw .h teminar to tleirnNingrórqué ... 2.2510.25 N m (20! 2 lb ¡n)

(5) rsrrlen rhe nur on üé ñotd reminar ro rhei'nMiñq róqué ... . 30.5 r 3 5 N m (22 r 3 tb ft)

(6) Iishlen r'e ñú on rhé moro' ú.ame reminar lo theturNiñsrorque ... 305!3.5N.m(22r3rbfr)

cúféff doñsumpüon ar 25"c (77.F)

Pulliln *ind¡.gÉ at 24V .. ........ ........ 51 Añp........-...... ...... 7 Amp

Séñsor SensorCoolant Temperature Fuel Pressure

dtf,:

Engine O¡l Pressure Sensor

I'lrlld *|Ú .süy lo lhe ibndingrdqúe......-..............-.......... 1012N.m (€3 1 13 rbin)

#il

fqhlen lhé ssor .s*mblylotque...... .

{2) Pr0o w lr edcr a. wkerhshren trle *ntr a$embly ro the rólldlñg

t514rbñ)

Fuel Temperature sensor

rght€n rhé s6mor assembly !obrqué......--...................20r5

Atmospheric) Pressure Sensor

Type 2

IEhten rh€ qsor asnbty ¡c rhe fond,nc....... .. ..20rsN.m(t5!4rbn)

Speed and Tim¡ng Sensor

'-\e.'

(1) Pluo wirh eok€t A, ed(ét B, ad tutet C.

P'n cleán énsine ot on rh€ crim 3ea . pur 4p -s5e7anii*éi} compoúnd d t¡e th€áds ¡ohién ilptunborassembty b lh6 fonNino ioque _ 40i 5N.m

(30 .4 r! íi)

]lohbn ulle sénsor asembty b lhe b r.wharoque ........ _. _. 1012 N.m (s3113tb ln)

lnlet Atr Temperature Sensor

Type I

l-Bhten Ihé se¡sor a*ñbrv r.r.rcue. .... ...................... 1dr 3

lndex

arLnrdErbow- - - -- 1!.. .. ... 49

11¿.2401 Aléma@rGP16e.334s além¿ror Gp 1!

Armospheñc Pf€ssu'e Sen$f Jr

Ens'ne SuPPod lFront)ExháústMánito|d .... .. " "Exhaust Manlóld shi6ld

Housin9...... ......... ... ..

34068......................... ....3456...... .........-.'-.

FóntHoúinsandcov.6.. " "Fuel Fifter Báse.. ... . .

F0el PEssuÉ Sensor .

FuelTeñp€Élure Señsr" ... " " 'Fuel T6nsler PumP ... .

Máin B€árins Joumal.... .

Móonlinq GPFañ Dnw

5camshaft..........lrT31--- - -----

coÁ;'essDn Br¿re (lr Equ'pped)c,nn€oljngRod'''''''''''''coolan¡ TempeEluÉ sensor "Cránkése Breál¡er' .

cEñkshan....... .. .' .. __ ---crankshalt seals. . . ... ..." "

cüindef Blo.[ ....cirúderH6ad ...cvlinder Head Valves .

Hóúsins (Frcnt).....

lmFriad s¿r€! hrmstÓn

El€¿Mc Sbrti¡q Motor

Fbánarcóunds'ud ..... -Elecvón¡c unit rnieclor Mechánism .

Erscrfonic unil lnjedar Rockeram -.. _- 'Enohe oés¡gn ....... .. .

340€€ .................3456............. .... ........ . . . ..

Fnóine o¡rcooléf Bvoass Valvé . . .

Eñiñe oilFrcl Ba*...TYP€ 1, --..- ----fype 2 -- --, --

Ensine OilPán.. .

s@6€t'JGs€dd. - -1spéd dd Tms SélB

51

2335

T€blé olCdtenls.--.............,,..,,,,,.,............_...._...... 3TurboctEQ€r-.....-...............--...........-......,...,,,.,..... 13

\llw M.úanilm.............--...,,,,.,,,Vá¡E M.óánlsm Co6r..-............-...........,,,.,,,...... 3Mb.¡rro¡ oanrpér,,,,,,...-...-......-......

Wár.rUn*.--.............. ...........-...................,..,.,,. 27wai.rPump....,,,,,,.........-...........-............ _ _._....._. 2awáf.rf€mp.EtuB R€guraior.....,,,,..,,,,......._....._.. 27