D CTM3
User Manual: CTM3
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John Deere Series 220 Diesel Engines 3 COMPONENT TECHNICAL MANUAL John Deere Lawn & Grounds Care Division CTM3 (10AUG93) Replaces CTM3 (28NOV89) Litho in U.S.A. FOREWORD This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. This manual is part of a total product support program. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. TECHNICAL MANUALS—MACHINE SERVICE Use this component technical manual in conjunction with the machine technical manual. An application listing in the Specifications and General Information section identifies product-model/component typemodel relationship. See the machine technical manual for information on component removal and installation, and gaining access to the components. This manual is organized so that all the information on a particular engine is kept together in a single section. Information in each section is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, other materials needed to do the job and service parts kits. All specifications, wear tolerances, and torque values appear at the beginning of each section. FOS MANUALS—REFERENCE COMPONENT MANUALS—COMPONENT SERVICE Fundamentals of Service (FOS) Manuals cover basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes. FOS Manuals are for training new personnel and for reference by experienced technicians. Technical Manuals are concise guides for specific machines. Technical manuals are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing and repair. Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand-alone manuals covering multiple machine applications. JOHN DEERE DEALERS IMPORTANT: The changes listed below make your current CTM obsolete. Discard CTM3, dated 28 NOV 89. Please remove this page and route through your service department. • The format or “style” of the book has been changed. The familiar “modular” layout has been replaced by a two-column “floating text” format. Also, a heavy emphasis on the use of “exploded” line art, to illustrate specific yet “simple” procedures, is used. • The layout of the book also changed. It has been completely reorganized to cover a different engine “family” in its own section, similar to how a Technical manual is layed out, using sections and groups. - Sections 1 through 4 cover engine service. This includes; engine teardown, diagnosis, checks, tests, adjustments and operational tests. - Section 10 covers removal/installation and repair of accessories, primarily on Series 220 OEM Power Unit engines. - Section 20 covers Theory of Operation of the various engine systems. - Section 21 covers Electrical System component location and schematics for Series 220 OEM Power Unit engines. • Turbocharger analysis, inspection and repair information has been added. See Accessories Series 220 Power Unit Engines. • Information/model designation for Series 220 engines (3009, 3011, 3014 and 4019) have been added wherever applicable. • Engine application charts have been updated to include the latest product models. See Specifications and General Information section. • The book’s title. The title was changed from “3TN and 4TN Series Yanmar Diesel Engines” to “John Deere 220 Series Diesel Engines”, to include information pertaining to the OEM Stand-alone power packs. • A safety section, fuels, lubricants and coolant information and an alphabetical index have also been added. • A nominal or “standard” specification has been added and listed with the “wear limit” specification. 3 ABOUT THIS MANUAL This Component Technical Manual (CTM3) covers the recommended repair and adjustment procedures for the following engines: • 3 and 4TN Series Diesel Engines used in John Deere Lawn and Grounds Care and small Industrial products. • Series 220 Diesel Engines offered as OEM units. Three different configurations are available: Base industrial engine, industrial power unit or a generator drive unit. Before beginning repair of an engine, clean the engine and mount on a repair stand. This manual contains SI Metric units of measure, followed immediately by the U.S. customary units of measure. Direction of engine crankshaft rotation in this manual is referenced facing the flywheel looking toward the water pump. Front of engine is water pump end. Some components of this engine may be serviced without removing the engine from the machine. Refer to the specific machine technical manuals for information on components that can be serviced without removing the engine from the machine and for engine removal and installation procedures. Read each story completely before performing service to check engine model differences in procedure or specifications. Introduction Each section will be identified with a symbol, letter or a number. Safety S All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Specifications and General Information G 3TN66, 3TNA72 (3009) 1 3TN75, 3TN78, 3TNC78 (3011), 3TN82, 3TNA82, 3TN84 (3014) 2 4TN78T, 4TN82, 4TN84(T) (4019) 3 4TN100 4 Accessories - Series 220 Power Unit Engines 10 Engine, Air Intake and Fuel System 20 Electrical System - Series 220 Power Unit Engines 21 COPYRIGHT© 1993 JOHN DEERE HORICON WORKS Horicon, Wisconsin All rights reserved Introduction Safety RECOGNIZE SAFETY INFORMATION HANDLE FLUIDS SAFELY-AVOID FIRES S Be Prepared For Emergencies T81389 This is the safety-alert symbol. When you see this symbol on your engine or in this manual, be alert to the potential for personal injury. TS291 Follow recommended precautions and safe servicing practices. Understand Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. REPLACE SAFETY SIGNS TS227 When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure engine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. TS201 Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement. 4/7/95 S-1 Safety S USE CARE IN HANDLING AND SERVICING BATTERIES • If acid is swallowed: 1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 1.9 L (2 quarts). 3. Get medical attention immediately. SERVICE COOLING SYSTEM SAFELY TS204 TS203 Prevent Battery Explosions • Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. • Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. • Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F). Prevent Acid Burns • Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. • Avoid acid burns by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. • If you spill acid on yourself: TS281 Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. USE SAFE SERVICE PROCEDURES Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating engine. 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 15-30 minutes. 4. Get medical attention immediately. TS206 S-2 4/7/95 Safety Service Engines Safely Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Support Engine Properly and Use Proper Lifting Equipment S Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. TS229 TS228 Use Proper Tools Use tools appropriate to the work. Makeshift tools can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Use only service parts meeting John Deere specifications. If you must work on a lifted engine, securely support the engine. Do not support the engine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under an engine that is supported solely by a jack. Follow recommended procedures in this manual. Lifting heavy components incorrectly can cause severe injury or engine damage. Follow recommended procedure for removal and installation of components in the manual. Work In A Clean Area Shut Down Engine • Before starting a job: 1. Clean work area and engine. 2. Make sure you have all necessary tools to do your job. 3. Have the right parts on hand. TS230 • Before working on the engine: 1. Stop the engine and remove the key. 2. Disconnect the battery ground strap. 3. Hang a “DO NOT OPERATE” tag on the instrument panel. 4/7/95 4. Read all instructions thoroughly; do not attempt shortcuts. Illuminate Your Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the engine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. S-3 Safety S Work In A Ventilated Area Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. If you do not have an exhaust pipe extension, open the doors and get outside air into the area. Avoid Heating Near Pressurized Fluid Lines TS220 Remove Paint Before Welding Or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. USE CARE AROUND HIGHPRESSURE FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. HANDLE CHEMICAL PRODUCTS SAFELY Avoid High-Pressure Fluids X9811 S-4 TS953 TS1132 TS1133 4/7/95 Safety Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment. Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer. 4/7/95 LIVE WITH SAFETY S TS231 Before returning machine to customer, make sure engine is functioning properly, especially the safety systems. Install all guards and shields. S-5 Safety S S-6 4/7/95 G SPECIFICATIONS AND GENERAL INFORMATION General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuels, Lubricants and Coolant . . . . . . . . . . . . . . . . . . . . . . . 8 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 G General Information ENGINE SERIAL NUMBER PLATE NOTE: The engine serial number plate can be easily destroyed. Before “hot tank” cleaning the block, remove the plate or record the information elsewhere. Location All except 4TN100: The engine serial number plate is located on the rocker arm cover. 4TN100: The engine serial number plate is located on the side of the engine, under exhaust manifold. Refer to the engine model designation on your engine's serial number plate to identify as to which section to use for repair information. Factory Code CH. . . . . . . . . . . . . . . . . . Yanmar Engine Model Designation 3009D . . . . . . . . . . . . . . . Definition explained following. (See “Engine Model Designation”.) Sequential Number 000000 . . . . . . . . . . . . . . 6-digit sequential serial number Engine Model Designation 3TN and 4TN Series Engines John Deere engine model designation includes number of cylinders, usage, engine type, bore diameter, fuel injection (type) and application. For example: 3TNA72UJK Engine 3 . . . . . . . . . . . . . . . . . . . . . . . .Number of cylinders T . . . . . . . . . . . . . . . . . . . . . . . . . . . Usage (tractor) NA . . . . . . . . . . . . . . . . . . . . . . . . . . Engine type M37502 Engine Serial Number Information Each engine has a 13-digit John Deere engine serial number identifying the producing factory, engine model designation, and a 6-digit sequential number. The following are examples: 72 . . . . . . . . . . . . . . . . . . . . . . .Bore diameter U . . . . . . . . . . . . . . . Fuel Injection (Type) JK. . . . . . . . . . . . . . . . . . . . .Application Engine Type NA. . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel G . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline 3TN and 4TN Series Engines CH3029D000000 Fuel Injection (Type) CH . . . . . . . . . . Factory producing engine (Yanmar) U . . . . . . . . . . . . . . . . . . . . Indirect injection 3029D . . . . . . . . . . . . Engine model designation R . . . . . . . . . . . . . . . . . . . . . .Direct injection 000000 . . . . . . Sequential serial number Application Series 220 OEM Engines JK . . . . . . . . . . . . . . . . . . . . . . . . John Deere CH3009D000000 E-SP . . . . . . . . . . Export - Sperry Company CH . . . . . . . . . . . . . . . . . . .Factory producing engine 3009D . . . . . . . . . . . . Engine model designation 000000 . . . . . . Sequential serial number 4/7/95 G-1 G General Information Engine Model Designation -Series 220 OEM Engines G John Deere engine model designation includes number of cylinders, displacement in liters, aspiration, user code and application code. For example: Aspiration Code D . . . . . . . . . . . . . . . . . . . Naturally aspirated T . . . . . . . . . . . . . . . . . . . . . . . Turbocharged User Code F0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OEM 3009DF001 Engine 3 . . . . . . . . . . . . . . . . . . . . . . . .Number of cylinders 0.9 . . . . . . . . . . . . . . . . . . . . . . . . Liter designation D . . . . . . . . . . . . . . . . . . . . . . . Aspiration code F0 . . . . . . . . . . . . . . . . . . . . . . . . . . User code 01 . . . . . . . . . . . . . . . . . Application code Application Code 01 . . . . . . . . . . . . . . . Bare industrial engine 05 . . . . . . . . . . . . . . . Industrial power pack 06 . . . . . . . . . . . . . . . Gen set power pack ENGINE APPLICATION CHART - LAWN AND GROUNDS CARE EQUIPMENT Machine Model No. Engine Model LAWN AND GARDEN TRACTORS 330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN66UJ 332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN66UJ 430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ* 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ3 FRONT MOWERS F915 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN66UJ F925 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ F935 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ F1145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN75RJ COMPACT UTILITY TRACTORS 655 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN66UJ 670 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJK 755 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ 770 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA82RJK 855 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN75RJ 870 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN84RJK 955 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN84UJ 970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN82RJK 1070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN84RJK SKID STEER LOADERS 375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN66E-SP 575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN82E-SP 675 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4TN82E-SP GOLF AND TURF 756 Compact Utility Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ 856 Compact Utility Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN75RJ 3325 Professional Turf Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN82RJE 3365 Professional Turf Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN82RJE * 430 Lawn and Garden Tractors were built with two slightly different versions of 3TNA72UJ engines. In this manual, 3TNA72UJ engines, Serial Numbers ( - 5000), are referred to as “Early 3TNA72”. Engines with Serial Numbers (5001 - ) are referred to as “Later 3TNA72”. G-2 4/7/95 General Information ENGINE APPLICATION CHART - INDUSTRIAL EQUIPMENT Machine Model No. Engine Model EXCAVATORS 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJB 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN78RJB 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN82RJB 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN78TRJB LOADERS 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4TN100RJF 244E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN100LFB ENGINE APPLICATION CHART - OEM APPLICATION Machine Model No. Engine Model 3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72 3011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNC78 3014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN84 4019D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN84 4019T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4TN84T 4/7/95 G-3 G General Engine Specifications BASIC ENGINE SPECIFICATIONS UNIT OF MEASURE 3TN66 3TNA72 (3009) 3TN75 3TN78 Number of Cylinders ---- 3 3 3 3 Bore mm (in.) 66 (2.60) 72 (2.83) 75 (2.95) 78 (3.07) Stroke mm (in.) 64.2 (2.53) 72 (2.83) 75 (2.95) 86 (3.39) L (cu in.) 0.658 (40.15) 0.879 (53.64) 0.994 (60.70) 1.232 (75.20) Compression Ratio ---- 23:1 22.3:1 17.8:1 17.75:1 Horsepower* kW (hp) 10.4 - 12.7 (14 - 17) 12.7 - 16.4 (17 - 22) 17.9 (24) 17 (23) Firing Order ---- 1-3-2 1-3-2 1-3-2 1-3-2 Combustion System ---- Indirect Injection Indirect Injection Direct Injection Direct Injection Aspiration ---- Natural Natural Natural Natural Weight (dry) kg (lbs) 85 (187) 118 (260) 160 (353) 123 (271) Starter ---- Hitachi 0.8 kW Nippondenso 1.0 kW (Hitachi 0.8 kW on 3009) Nippondenso 1.0 kW Hitachi 2.0 kW Alternator ---- Kokosan 20A, Nippondenso 35 or 40A Kokosan 20A, Nippondenso 35 or 40A Nippondenso 35 or 40A Hitachi 25A GENERAL G Displacement * Engine horsepower will vary by application. Refer to machine technical manual or operator's manual for specific engine horsepower. G-4 4/7/95 General Engine Specifications UNIT OF MEASURE 3TNC78 (3011) 3TN82 3TNA82 3TN84 (3014) Number of Cylinders ---- 3 3 3 3 Bore mm (in.) 78 (3.07) 82 (3.23) 82 (3.23) 84 (3.31) Stroke mm (in.) 80 (3.15) 86 (3.39) 86 (3.39) 86 (3.39) L (cu in.) 1.146 (69.90) 1.362 (83) 1.362 (83) 1.429 (87.2) Compression Ratio ---- 18:1 18.06:1 18.1:1 17.8:1 Horsepower* kW (hp) 16.9 - 20.2 (22.7 - 27.1) 18 - 24.6 (24 - 33) 17.2 (24) 20.9 - 24.9 (28 - 33.5) Firing Order ---- 1-3-2 1-3-2 1-3-2 1-3-2 Combustion System ---- Direct Injection Direct Injection Direct Injection Direct Injection Aspiration ---- Natural Natural Natural Natural Weight (dry) kg (lbs) 160 (353) 190 (419) 190 (419) 153 (337) Starter ---- Nippondenso 1.0 kW Hitachi 2.0 kW, Nippondenso 1.4 kW Nippondenso 1.0 or 1.2 kW Nippondenso 1.0 or 1.2 kW Alternator ---- Nippondenso 40A Hitachi 25A, Nippondenso 35 or 40A Kokosan 20A, Nippondenso 35A Kokosan 20A, Nippondenso 35 or 40A GENERAL Displacement G * Engine horsepower will vary by application. Refer to machine technical manual or operator's manual for specific engine horsepower. 4/7/95 G-5 General Engine Specifications UNIT OF MEASURE 4TN78T 4TN82 4TN84 (4019D) 4TN84T (4019T) Number of Cylinders ---- 4 4 4 4 Bore mm (in.) 78 (3.07) 82 (3.23) 84 (3.31) 84 (3.31) Stroke mm (in.) 86 (3.39) 86 (3.39) 86 (3.39) 86 (3.39) L (cu in.) 1.643 (100) 1.816 (110.8) 1.906 (116.3) 1.906 (116.3) Compression Ratio ---- 17.75:1 18.1:1 17.8:1 17.8:1 Horsepower* kW (hp) 29 (39) 24.6 - 28 (33 - 38) 28.1 - 33.4 (37.7 - 44.8) 34.4 - 40.3 (46.1 - 54) Firing Order ---- 1-3-4-2-1 1-3-4-2-1 1-3-4-2-1 1-3-4-2-1 Combustion System ---- Direct Injection Direct Injection Direct Injection Direct Injection Aspiration ---- Turbocharged Natural Natural Turbocharged Weight (dry) kg (lbs) 230 (507) 220 (485) 194 (428) 199 (439) Starter ---- Hitachi 0.8 kW Nippondenso 1.0 or 1.4 kW, Hitachi 2.0 kW Nippondenso 1.0 or 1.4 kW Nippondenso 1.4 kW Alternator ---- Hitachi 25A Kokosan 20A, Nippondenso 35 or 40A Kokosan 20A, Nippondenso 40A Nippondenso 40A GENERAL G Displacement * Engine horsepower will vary by application. Refer to machine technical manual or operator's manual for specific engine horsepower. G-6 4/7/95 General Engine Specifications UNIT OF MEASURE 4TN100 Number of Cylinders ---- 4 Bore mm (in.) 100 (3.90) Stroke mm (in.) 110 (4.30) L (cu in.) 3.5 (211) Compression Ratio ---- N/A Horsepower* kW (hp) 38.8 - 44 (52 - 59) Firing Order ---- 1-3-4-2-1 Combustion System ---- Direct Injection Aspiration ---- Natural or Turbocharged kg (lbs) 332 (731) Starter ---- Nippondenso 1.4 kW Alternator ---- Hitachi 25A GENERAL Displacement Weight (dry) G * Engine horsepower will vary by application. Refer to machine technical manual or operator's manual for specific engine horsepower. 4/7/95 G-7 Fuels, Lubricants and Coolant DIESEL FUEL G Use either Grade No. 1-D or Grade No. 2-D fuel as defined by ASTM Designation D975 for diesel fuels. In European countries, use ISO 1585 commercial diesel fuel. NOTE: At altitudes above 1500 m (5000 ft) use Grade 1-D for all temperatures. If engine is operated under “stand-by” conditions, use grade 1-D for all temperatures. If engine is operated at temperatures of -40° to 57°C (-40° to -70°F), Grade DF-A arctic fuel is recommended. Fuel sulfur content of less than 0.5 percent is preferred, to prevent higher wear from corrosive combustion products. IMPORTANT: If fuel sulfur content exceeds 0.5 percent, the engine oil drain interval must be reduced by 50 percent. Cetane number should be no less than 40 to assure satisfactory starting and overall performance. At low temperatures and/or high altitude, a cetane number of more than 45 is recommended. NOTE: Excessive white smoke at start-up could be the result of low cetane fuel. Cloud point should be at least 6°C (10°F) below lowest expected air temperature at time of starting. Wax can separate from fuel when temperature decreases to cloud point and may plug filter. performance; these properties may result in longer engine life. NOTE: When John Deere TORQ-GARD SUPREME PLUS-50™ engine oil and a John Deere oil filter are used, the change interval may be extended by 50 hours. ALWAYS follow recommendations in the operator’s manual. John Deere TORQ-GARD SUPREME® engine oil is also recommended but standard operator’s manual oil change intervals must be maintained. Other oils may be used if they meet one or more of the following specifications: • API Service Classification CE or CD • Military Specification MIL-L-2104E or MIL-L2104D or MIL-L-2104C In European countries, oils meeting CCMC Specification D4 or D5 may be used. SAE 5W20, SAE 5W30, and arctic oil viscosity grades meeting API Service Classification CC may be used, but oil and filter must be changed at onehalf the normal interval. Oils meeting Military Specification MIL-L-46167B may be used as arctic oils. NOTE: Some increase in oil consumption may be expected when low viscosity oils are used. Check oil levels more frequently. DIESEL ENGINE OIL Use oil viscosity based on the expected air temperature range during the period between oil changes. IMPORTANT: John Deere TORQ-GARD SUPREME PLUS-50™ engine oil is not recommended during engine break-in (first 100 hours on a new or overhauled engine). The superior lubricating properties of this oil will not allow the engine to properly wear during break-in period. Use SAE 10W 30. John Deere TORQ-GARD SUPREME PLUS-50™ engine oil is recommended at all other times. This oil is specially formulated to provide superior protection against high temperature thickening and wear as well as exceptional cold weather starting G-8 TS238 4/7/95 Fuels, Lubricants and Coolant OILSCAN® AND COOLSCAN™ OILSCAN and COOLSCAN are John Deere sampling programs to help you monitor machine performance and identify potential problems before they cause serious damage. G Oil and coolant samples should be taken from each system prior to its recommended change interval. Check with your John Deere dealer for the availability of OILSCAN and COOLSCAN kits. TS1417 T6828AB GREASE Use grease based on the expected air temperature range during the service interval. The following greases are preferred: • John Deere MOLY HIGH TEMPERATURE EP GREASE • John Deere HIGH TEMPERATURE EP GREASE ENGINE COOLANT RECOMMENDATIONS CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns. Other greases may be used if they meet one of the following: Shut off engine. Remove the radiator filler cap only when the cap is cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. • SAE Multipurpose EP Grease with a maximum of 5% molybdenum disulfide • Always maintain engine coolant at correct level. • John Deere GREASE-GARD™ • SAE Multipurpose EP Grease Grease meeting Military Specification MIL-G10294F may be used as arctic grease. 4/7/95 • Coolant make-up should be mixed at same concentrations as original coolant, including inhibitors. G-9 Fuels, Lubricants and Coolant G • In tropical areas where antifreeze of John Deere Cooling Fluid is not available, use water meeting quality specifications outlined in this group and John Deere RE23182 Liquid Coolant Conditioner. The liquid coolant conditioner should be added in the amount recommended on the label for your cooling system capacity. IMPORTANT: John Deere Liquid Coolant Conditioner does not protect against freezing. In certain geographical areas where water quality is unacceptable, John Deere Engine Cooling Fluid is marketed for use in the engine cooling system. It protects the engine from corrosion and freezing down to -37°C (-35°F). John Deere Engine Cooling Fluid or John Deere Low Silicate Antifreeze are recommended for all John Deere Diesel Engines. John Deere Cooling Fluid is ready to use as it is without dilution or mixing. John Deere Low Silicate Antifreeze is concentrated and should be mixed minimum 40% maximum 60% antifreeze and distilled to deionized water. Consult your John Deere Parts Network for local availability. Water Quality Specifications Item Parts Per Million Grains Per Gallon Chlorides (maximum) . . . . . . . . . 40 2.5 Sulfates (maximum) . . . . . . . . . . 100 5.9 Total Dissolved Solids (maximum). . . . . . . . . . . . 340 20 Total Hardness (maximum). . . . . 170 10 pH Level . . . . . . . . . . . . . . . . . . . . . . 5.5 - 9.0 If Chlorides, Sulfates, or Total Dissolved Solids are higher than the above given specifications, the water must be distilled, de-mineralized, or de-ionized before using in cooling system. If Total Hardness is higher than the above given specification, and all other parameters are within the given specifications, the water must be softened before using in cooling system. Ethylene Glycol Concentrate (Antifreeze) IMPORTANT: DO NOT use methyl alcohol or methoxy propanol base concentrate. This concentrate is not compatible with additives used in supplemental coolant additives. Damage can occur to rubber seals on cylinder liners which are in contact with coolant. TS281 ENGINE COOLANT SPECIFICATIONS Water Quality Distilled, de-ioned, or soft water is preferred for use in cooling systems. Mineral (hard/tap) water should NEVER be put in a cooling system unless first tested. However, water that meets the following water quality specifications is acceptable. G-10 DO NOT use ethylene glycol concentrate sealer or stop-leak additives. DO NOT use concentrate containing less than 10% ethylene glycol. DO NOT use concentrate containing more than 0.1% anhydrous metasilicate. This type of concentrate, which is intended for use in aluminum engines, may cause a gel-like deposit to form that reduces heat transfer and coolant flow. Check container label or consult with supplier before using. 4/7/95 Fuels, Lubricants and Coolant John Deere Low Silicate Antifreeze is the ethylene glycol concentrate recommended for all John Deere Diesel Engines. This product is concentrated and should be mixed 50/50 with quality water. Add to the mixture 3% (by volume) supplemental coolant additives (SCA’s). John Deere Low Silicate Antifreeze is available in the following sizes: - TY6377 - 208 L (55 U.S. Gal) container - TY15886 - 3.8 L (1 U.S. Gal) container Contact your John Deere Parts Network for local availability. If John Deere Low Silicate Antifreeze is not available, use an ethylene glycol concentrate meeting ASTM D 4985, SAEJ1941, General Motors Performance Specification GM1899M, or formulated to GM6038M. Supplemental Coolant Additives (SCA’s) IMPORTANT: Ethylene glycol concentrate (antifreeze) DOES NOT contain sufficient additives to prevent liner erosion or pitting which could occur in wet sleeve diesel engines. ALWAYS mix the coolant solution with a supplemental coolant additive such as John Deere Liquid Coolant Conditioner or spin-on coolant filter conditioner element. CAUTION John Deere Liquid Coolant Conditioner contains alkali. Avoid contact with eyes. Avoid prolonged or repeated contact with skin. Do not take internally. In case of contact, immediately wash skin with soap and water. For eyes, flush with large amounts of water for at least 15 minutes. Call physician. KEEP OUT OF REACH OF CHILDREN. • John Deere Liquid Coolant Conditioner IMPORTANT: ALWAYS mix the 50/50 solution of ethylene glycol concentrate with quality water in a separate container BEFORE adding the SCA’s. Then add solution to the radiator. NEVER pour cold water into a hot engine, as it may crack cylinder block or head. John Deere Liquid Coolant Conditioner MUST be added at a rate of 3% (by volume) to the coolant solution. When adding John Deere Liquid Coolant Conditioner, follow the supplier’s recommendations printed on the container. John Deere Liquid Coolant Conditioner is available in the following sizes: - RE23182 473 mL (16 oz) container - RE35992 3.8 L (1 gal) container Contact your John Deere Parts Network for availability. Other approved SCA’s are: - NALCOOL 3000® - FLEETGARD®-DCA008-78L DCA2 in 473 mL (16 oz) container - FLEETGARD®-DCA60-78L DCA4 in 473 mL (16 oz) container NALCOOL 3000® is a registered trademark of the NALCO Company. FLEETGARD® is a registered trademark of the Cummins Engine Company. 4/7/95 G-11 G Fuels, Lubricants and Coolant IMPORTANT: John Deere Liquid Coolant Conditioner does NOT protect against freezing. G DO NOT over-concentrate coolant solutions with supplemental coolant additives, as this can cause silicate-dropout. When this happens, a gel-type deposit is created which retards heat transfer and coolant flow. DO NOT use soluble oil. JOHN DEERE ENGINE COOLING FLUID In certain regions of the world, John Deere Engine Cooling Fluid is marketed for use in the engine cooling system. John Deere Cooling Fluid is premixed and contains the proper mixture of quality water, low silicate antifreeze to protect the engine from freezing down to -37°C (-35°F), and supplemental coolant additives (SCA’s). CHECK EFFECTIVENESS OF COOLANT SOLUTION Prior to the recommended change interval or if concentration of coolant solution is in question, a coolant sample should be taken and a COOLSCAN analysis performed. COOLSCAN is a John Deere sampling program to help you monitor the effectiveness of your engine’s coolant solution and identify potential problems before they cause serious damage. Check with your John Deere dealer for the availability of DS0251 COOLSCAN kit. Refer to instructions provided with kit. Usually recharging your engine coolant with the recommended amount of John Deere Liquid Coolant Conditioner at the appropriate time is adequate. However, with a COOLSCAN analysis report, you will be given a more thorough evaluation of your engine coolant condition along with a detailed service recommendation. IMPORTANT: Additional SCA’s should NOT be added to the Cooling Fluid. John Deere Engine Cooling Fluid is available in the following sizes: - AL66606 (formally DD14134) - 5 L (1.3 U.S. Gal) can - AL66607 (formally DD14345) - 20 L (5.3 U.S. Gal) can - AL67171 (formally DD14136) - 60 L (15.9 U.S. Gal) drum T6828AB - AL66608 (formally DD14346) 200 L (53 U.S. Gal) drum Contact your John Deere Parts Network for local availability. G-12 4/7/95 Fuels, Lubricants and Coolant REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES (SCA’S) BETWEEN COOLANT CHANGES Through time and use, original additives eventually lose their effectiveness and must be recharged with additional supplemental coolant additives available in the form of liquid coolant conditioner. G NOTE: Service intervals listed are a recommended engineering guideline. Refer to your vehicle operator’s manual for a specific service interval. At 600 hours or 1 year service interval, it is recommended to perform a COOLSCAN analysis as described earlier. If COOLSCAN analysis is not available, recharge system per instructions printed on bottle. IMPORTANT: DO NOT CHANGE the spin-on filter element at the 600 hour or 1 year service interval. If the filter is replaced at this time, the result could be an overcharged system. This could cause “solder bloom” in the radiator because the over concentration of nitrite will attack the solder. Replace the filter only if the entire cooling system is drained and coolant replaced. RG6262 See ENGINE COOLANT SPECIFICATIONS earlier in this group for proper mixing of coolant ingredients before adding to the cooling system. FLUSHING AND SERVICING COOLING SYSTEM IMPORTANT: ALWAYS maintain coolant at correct level and concentration. DO NOT operate engine without coolant for even a few minutes. If frequent coolant make-up is required, the glycol concentration should be checked with JT05460 Refractometer to assure that the desired freeze point is maintained. Follow manufacturer’s instructions provided with refractometer. TS281 CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns. RG6261 4/7/95 Shut off engine. Remove the radiator filler cap only when the cap is cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. G-13 Fuels, Lubricants and Coolant IMPORTANT: Air must be expelled from cooling system when system is refilled. Follow procedure given in your operator’s manual. G Engine coolant MUST BE drained and replaced at a maximum of 1200 hours or 2 years of engine operating time, whichever comes first. The ethylene glycol base (antifreeze) can become depleted of SCA’s allowing various acids to form that will damage engine components. In addition, heavy metals, such as lead, copper and zinc, accumulate in the ethylene glycol base. The heavy metals come from corrosion that occurs to some degree within a cooling system. When a coolant is saturated to the point where it can no longer hold heavy metals and other dissolved solids, they settle out and act as abrasives on engine parts. After adding new coolant solution, run engine until it reaches operating temperature. This mixes the coolant solution uniformly and circulates it through the entire system. After running engine, check coolant level and entire cooling system for leaks. Contact your authorized servicing dealer or engine distributor, if there are further questions. DISPOSING OF COOLANT NOTE: Service intervals listed are a recommended engineering guideline. Refer to your vehicle operator’s manual for a specific service interval. At 1200 hours/2-year service interval, flush cooling system and replace thermostats as described in your operator’s manual. Clean cooling system with a heavy duty cooling system cleaner such as RESTORE™. Follow the FLEETGARD® instructions provided with cleaner. Refill cooling system with the appropriate coolant solution. See ENGINE COOLANT SPECIFICATIONS, earlier in this group. IMPORTANT: NEVER overfill the system. A pressurized system needs space for heat expansion without overflowing at the top of the radiator. Coolant level should be approximately 19 mm (3/4 in.) below bottom of radiator filler neck. TS1133 Improperly disposing of coolant can threaten the environment and ecology. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer. FLEETGARD® is a registered trademark of the Cummins Engine Company. RESTORE™ is a registered trademark of FLEETGARD®. G-14 4/7/95 Repair Information METRIC BOLT AND CAP SCREW TORQUE VALUES Property Class and Head Markings G Property Class and Nut TS1163 Class 4.8 a Lubricated Class 8.8 or 9.8 Dry a Lubricated a Class 10.9 a a Dry Lubricated Dry Class 12.9 a Lubricateda Drya Size Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5 M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35 M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70 M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120 M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190 M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300 M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410 M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580 M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800 M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000 M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500 M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000 M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500 DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. 4/7/95 Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. a “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated without any lubrication. G-15 Repair Information UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES SAE Grade and Head Markings G No Marks SAE Grade and Nut Marking No Marks TS1162 Grade 2b Grade 1 a Lubricated Dry a Lubricated a Grade 5, 5.1 or 5.2 a a Dry Lubricated Dry Grade 8 or 8.2 a Lubricateda Drya Size Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft 1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5 5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26 3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46 7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75 1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115 9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160 5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225 3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400 7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650 1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975 1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350 1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950 1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550 1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. G-16 Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. a “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated without any lubrication. b Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm (6 in.) long. Grade 1 applies for hex cap screws over 152 mm (6 in.) long, and for all other types of bolts and screws of any length. 4/7/95 Repair Information CLEAN ENGINE 1. Cap or plug all openings on engine. If electrical components (starter, alternator, etc.) are not removed prior to cleaning, cover with plastic and tape securely to prevent moisture from entering. G 2. Steam-clean engine thoroughly. IMPORTANT: Never steam-clean or pour cold water on an injection pump while it is still warm. To do so may cause seizure of pump parts. DISCONNECT TURBOCHARGER OIL INLET LINE 1. Drain all engine oil and coolant. IMPORTANT: When servicing turbocharged engines on a rollover stand, disconnect turbocharger oil inlet line before rolling engine over. Failure to do so may cause a hydraulic lock upon starting engine. Hydraulic lock may cause severe engine damage. Hydraulic lock occurs when trapped oil in the oil filter housing drains through the turbocharger, into exhaust and intake manifolds, and cylinder head. After starting the engine, trapped oil in the manifold and head is released into the cylinder(s) filling them with oil causing hydraulic lock and severe engine damage. 2. Disconnect turbocharger turbocharger. 4/7/95 oil inlet line at G-17 Repair Information G G-18 4/7/95 3TN66 AND 3TNA72 (3009) ENGINES Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Cylinder Head, Valves and Manifolds . . . . . . . . . . . . . . . 1-17 Pistons, Rods and Cylinder Block . . . . . . . . . . . . . . . . . . 1-32 Crankshaft, Main Bearings and Flywheel . . . . . . . . . . . . 1-42 Camshaft and Timing Gear Train. . . . . . . . . . . . . . . . . . . 1-55 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-113 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-131 Checks, Tests and Adjustments. . . . . . . . . . . . . . . . . . . 1-134 Operational Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-152 Section 1 1 3 1 Specifications ENGINE SPECIFICATIONS - 3TN66 Rocker Arm Cover Special Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (160 lb-in.) Rocker Arm Assembly Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Rocker Arm Shaft O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.97 - 9.99 mm (0.3925 - 0.3933 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.95 mm (0.3920 in.) Rocker Arm and Shaft Support I.D.'s Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.005 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.00 - 10.02 mm (0.3937 - 0.3945 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.09 mm (0.3972 in.) Push Rod Length Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 - 115 mm (4.488 - 4.528 in.) Push Rod Bend Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.) Cylinder Head and Valves Mounting Cap Screw Torque First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.) Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N•m (25 lb-ft) Cylinder Head Distortion Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) or less Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Maximum Amount of Metal to be Removed . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Valve Seat Width Intake Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 mm (0.045 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.65 mm (0.065 in.) Exhaust Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 mm (0.056 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.91 mm (0.075 in.) Intake and Exhaust Valves Valve Faces Minimum Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.) Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Valve Stem O.D. Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 mm (0.787 in.) Distance B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 mm (1.575 in.) Intake Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 - 5.48 mm (0.2149 - 0.2157 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 mm (0.2126 in.) Exhaust Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44 - 5.46 mm (0.2142 - 0.2149 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 mm (0.2126 in.) Valve Recession Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.85 mm (0.033 in.) 4/7/95 1 1-1 Specifications 1 Valve Guides Valve Guide I.D. Maximum Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 - 5.52 mm (0.216 - 0.217 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.58 mm (0.220 in.) Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 mm (0.276 in.) Valve Springs Spring Free Length Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 mm (1.102 in.) Maximum Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.032 in.) Exhaust Manifold Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.) Intake Manifold Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.) Valve Seat Angles Valve Seat Surface Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Lower Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70° Upper Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° Piston-to-Cylinder Head Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.59 - 0.74 mm (0.023 - 0.029 in.) Piston and Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (203 lb-in.) Connecting Rod Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 - 36.042 mm (1.417 - 1.419 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.07 mm (1.459 in.) Piston Ring Groove Clearance First Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.065 - 0.100 mm (0.0026 - 0.0039 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Second Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.065 mm (0.0012 - 0.0026 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Oil Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 - 0.055 mm (0.0008 - 0.0022 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Piston End Ring Gap Standard First Compression Ring and Oil Ring. . . . . . . . . . . . . . . . . . . . . 0.15 - 0.35 mm (0.006 - 0.014 in.) Second Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Pin Pin O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.991 - 20.00 mm (0.787 - 0.788 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.975 mm (0.786 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 mm (0.0018 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.00 - 20.008 mm (0.787 - 0.788 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.02 mm (0.788 in.) 1-2 4/7/95 Specifications Piston Pin, continued Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.025 - 20.038 mm (0.788 - 0.789 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.10 mm (0.781 in.) Piston O.D. Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 mm (0.197 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.927 - 65.957 mm (2.596 - 2.597 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.85 mm (2.593 in.) 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.18 - 66.21 mm (2.606 - 2.607 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.10 mm (2.602 in.) 0.50 mm (0.020 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.43 - 66.46 mm (2.615 - 2.616 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.35 mm (2.612 in.) Cylinder Bore I.D. Standard Size Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.00 - 66.03 mm (2.599 - 2.600 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.20 mm (2.606 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.25 - 66.28 mm (2.609 - 2.610 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.45 mm (2.616 in.) 0.50 mm (0.020 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.50 - 66.53 mm (2.619 - 2.620 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.70 mm (2.626 in.) Degalzing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern Crankshaft Rear Oil Seal Seal Case-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Oil Pan-to-Seal Case Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Crankshaft and Main Bearings Main Bearing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) Crankshaft Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0007 in.) Connecting Rod Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.97 - 35.98 mm (1.4161 - 1.4165 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.92 mm (1.414 in.) Main Bearing Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.97 - 39.98 mm (1.5736 - 1.5740 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.92 mm (1.572 in.) Main Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.00 - 40.042 mm (1.575 - 1.577 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.07 mm (1.578 in.) Stub Shaft (330/332 LGT, F915 FM) Stub Shaft-to-Flywheel Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 N•m (44 lb-ft) Cover-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Cover-to-Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) 4/7/95 1 1-3 Specifications 1 Flywheel Maximum Distortion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 N•m (61 lb-ft) Flywheel Plate Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Camshaft Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Camshaft Side Gap Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.15 mm (0.0020 - 0.0060 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Maximum Camshaft Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.) Lobe Height Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.97 - 30.03 mm (1.180 - 1.182 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.75 mm (1.171 in.) Journal O.D. Gear Housing and Flywheel Ends Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.94 - 35.96 mm (1.4150 - 1.4157 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.85 mm (1.4114 in.) Intermediate Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.91 - 35.94 mm (1.4138 - 1.4150 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.85 mm (1.4114 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.00 - 36.065 mm (1.417 - 1.420 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.10 mm (1.421 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.00 - 36.025 mm (1.417 - 1.418 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.10 mm (1.421 in.) Cam Followers O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.950 - 17.968 mm (0.7067 - 0.7074 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.93 mm (0.706 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.032 - 0.068 mm (0.0013 - 0.0027 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.00 - 18.018 mm (0.7087 - 0.7094 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.05 mm (0.711 in.) Timing Gear Cover Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Cover Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Crankshaft Pulley Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (85 lb-ft) Idler Gear Shaft O.D Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.959 - 19.980 mm (0.786 - 0.787 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.93 mm (0.785 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.00 - 20.021 mm (0.787 - 0.788 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.08 mm (0.791 in.) 1-4 4/7/95 Specifications Timing Gear Housing Cap Screw Torque Aluminum Housing-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Cast Iron Housing-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Oil Pan and Strainer Mounting Cap Screw Torque Oil Pan-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Oil Pan-to-Seal Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Oil Pan-to-Timing Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Oil Strainer-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Oil Pump Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) Rotor Shaft O.D.-to-Backing Plate I.D. Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.0006 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.) Rotor Recess Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Outer Rotor-to-Pump Body Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm (0.0011 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.0057 in.) Inner-to-Outer Rotor Clearance Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Oil Pressure Regulating Valve Spring Compressed Length . . . . . . . . . . . . . . . . . . . . . . . . . . .14.70 mm (0.580 in.) @12 N (2.7 lb-force) Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.90 - 24.50 mm (0.860 - 0.960 in.) Housing-to-Valve Body Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Thermostat Thermostat Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Water Pump Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Plate-to-Housing Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Fuel Injection Pump Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Fuel Injection Pump Camshaft Bearing Retaining Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.90 mm (1.217 in.) Fuel Control and Governor Linkage Governor Shaft O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.) Governor Shaft Bore I.D. Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 mm (0.321 in.) Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) Sleeve I.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20 mm (0.323 in.) Injection Pump Camshaft O.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.) Fuel Injection Nozzles Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft) Nozzle Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft) Nozzle Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft) Separator Plate Nozzle Contact Surface Maximum Wear . . . . . . . . . . . . . . . . . . 0.10 mm (0.0039 in.) 4/7/95 1 1-5 Specifications 1 Starter - Hitachi 0.8 kW Cover Bushing (Reamed Out). . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.50 - 12.53 mm (0.492 - 0.493 in.) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.70 mm (0.303 in.) Alternator - Kokosan 20A (375 SSL, 330/332 LGT, F915 FM) Flywheel Assembly-to-Coil Plate Assembly Nut Torque . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Alternator - Nippondenso 35A (655 CUT) Attaching Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Rotor Assembly Pulley Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Stator-to-Rectifier Lead Wire Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.50 mm (1.300 in.) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 mm (0.220 in.) Alternator - Nippondenso 40A (655 CUT) Minimum Rotor Slip Ring O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 mm (0.550 in.) Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft) Brush Length New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50 mm (0.170 in.) Checks, Tests and Adjustments Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 mm (0.008 in.) Connecting Rod Side Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.0079 - 0.0157 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.) Connecting Rod Bearing Clearance Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 - 0.072 mm (0.0008 - 0.0028 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Crankshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 - 0.271 mm (0.004 - 0.011 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.) Crankshaft Main Bearing Clearance Main Bearing Cap Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 - 0.072 mm (0.0008 - 0.0028 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Valve Lift (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 mm (0.300 in.) Camshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Timing Gear Backlash Standard Backlash All Except Crankshaft Gear-to-Oil Pump Gear . . . . . . . . 0.04 - 0.12 mm (0.0016 - 0.0047 in.) Crankshaft Gear-to-Oil Pump Gear . . . . . . . . . . . . . . . . . 0.11 - 0.19 mm (0.0043 - 0.0075 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Fuel Injection Nozzle Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11722 ± 480 kPa (1700 ± 70 psi) Leakage at 11032 kPa (1600 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum of 10 Seconds Chatter and Spray Pattern at 11722 ± 480 kPa (1700 ± 70 psi) Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chatter Sound Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Stream Spray Pattern Fast Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Atomized Spray Pattern 1-6 4/7/95 Specifications Thermostat Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71° C (160°F) Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F) Minimum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0.310 in.) Coolant Temperature Sensor Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107-113° C (225-235° F) Starter No-Load Amp Draw/RPM Maximum Starter Amperage Hitachi 0.8 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Amps at 7000 rpm Minimum Starter RPM Hitachi 0.8 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000 Fuel Injection Pump Static Timing Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13° BTDC (Before Top Dead Center) Distance on Outer Surface of Crankshaft Pulley for Every 0.1 mm (0.004 in.) of Shim Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1° or 1 mm (3/64 in.) Engine Crankshaft Position . . . . . . . . . . . . . . . . . . . . . . No. 1 Cylinder on TDC Compression Stroke Total Shim Pack Thickness (New Shims) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.020 in.) Delivery Valve Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 N•m (31 lb-ft) Fan/Alternator Drive Belt Tension Applied Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N (22 lb-force) Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.) Operational Tests Radiator, Bubble Test Maximum Air Pressure Into Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) Cooling System Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 kPa (17 psi) Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi) Radiator Cap Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi) Cylinder, Compression Pressure Compression Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi) Engine Oil Pressure 375 SSL Idle Speed Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3625 ± 25 rpm Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 - 392 kPa (43 - 57 psi) 330/332 LGT Idle Speed Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3350 ± 100 rpm Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 - 440 kPa (43 - 64 psi) 655 CUT Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 ± 69 kPa (53 ± 10 psi) F915 FM Idle Speed Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3635 ± 35 rpm Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 - 440 kPa (43 - 64 psi) Air Intake System Holding Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 - 69 kPa (5 - 10 psi) Fuel Supply Pump Pressure (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 kPa (15 psi) 4/7/95 1 1-7 Specifications ENGINE SPECIFICATIONS - 3TNA72 (3009) 1 Rocker Arm Cover Special Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (160 lb-in.) Rocker Arm Assembly Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Rocker Arm Shaft O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.96 - 11.98 mm (0.4711 - 0.4718 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.4706 in.) Rocker Arm and Shaft Support I.D.'s Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.005 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.00 - 12.02 mm (0.4724 - 0.4732 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.09 mm (0.4759 in.) Push Rod Length Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 - 142 mm (5.550 - 5.590 in.) Push Rod Bend Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.) Cylinder Head and Valves Mounting Cap Screw Torque First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N•m (168 lb-in.) Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft) Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 N•m (45 lb-ft) Cylinder Head Distortion Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) or less Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Maximum Amount of Metal to be Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Valve Seat Width Intake Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44 mm (0.057 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.98 mm (0.078 in.) Exhaust Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.77 mm (0.070 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 mm (0.089 in.) Intake and Exhaust Valves Valve Faces Minimum Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.) Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Valve Stem O.D. Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 mm (0.984 in.) Distance B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 mm (1.772 in.) Intake and Exhaust Valves Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm (0.2732 - 0.2740 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.90 mm (0.2717 in.) Valve Recession Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.85 mm (0.033 in.) Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.) Valve Guides Valve Guide I.D. Maximum Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm (0.275 - 0.276 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.08 mm (0.279 in.) 1-8 4/7/95 Specifications Valve Guides, continued Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 mm (0.354 in.) Valve Springs Spring Free Length Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.40 mm (1.472 in.) Maximum Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm 0.040 in.) Exhaust Manifold Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (30 lb-in.) Intake Manifold Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.) Valve Seat Angles Valve Seat Surface Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Lower Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70° Upper Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° Piston and Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (203 lb-in.) Piston-to-Cylinder Head Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.61 - 0.79 mm (0.024 - 0.031 in.) Connecting Rod Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.00 - 40.042 mm (1.575 - 1.577 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.07 mm (1.578 in.) Piston Ring Groove Clearance First Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 - 0.110 mm (0.0030 - 0.0043 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Second Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.065 mm (0.0012 - 0.0026 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Oil Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 - 0.055 mm (0.0008 - 0.0022 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Piston Ring End Gap Standard First Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.25 mm (0.004 - 0.010 in.) Second Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.) Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 - 0.35 mm (0.006 - 0.014 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Pin O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.991 - 21.00 mm (0.826 - 0.827 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.975 mm (0.825 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 mm (0.0018 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.00 - 21.009 mm (0.8268 - 0.8271 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.02 mm (0.828 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.025 - 21.038 mm (0.8278 - 0.8282 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.10 mm (0.831 in.) 4/7/95 1 1-9 Specifications 1 Piston O.D. Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0.315 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.922 - 71.952 mm (2.832 - 2.833 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.81 mm (2.827 in.) 0.25mm (0.10 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.17 - 72.20 mm (2.841 - 2.842 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.06 mm (2.837 in.) 0.50 mm (0.020 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.42 - 72.45 mm (2.851 - 2.852 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.31 mm (2.847 in.) Cylinder Bore I.D. Standard Size Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.28 mm (0.011 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.00 - 72.03 mm (2.835 - 2.836 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.20 mm (2.843 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.25 - 72.28 mm ((2.845 - 2.846 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.45 mm (2.852 in.) 0.50 mm (0.020 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.50 - 72.53 mm (2.855 - 2.856 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.70 mm (2.862 in.) Degalzing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern Crankcase Extension Housing Mounting Cap Screw Torque Flywheel Housing/Plate-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Seal Case-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Extension-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Extension-to-Timing Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Crankshaft Rear Oil Seal Seal Case-to-Block Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11N•m (96 lb-in.) Oil Pan-to-Seal Case Cap Screw Torque (430 LGT, 455 LGT, 755/56 CUT, F925/35 FM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Seal Case-to-Extension Cap Screw Torque (15 EX, 670 CUT, 3009 OEM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Crankshaft and Main Bearings Main Bearing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 N•m (58 lb-ft) Crankshaft Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0007 in.) Connecting Rod Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.97 - 39.98 mm (1.5736 - 1.5740 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.92 mm (1.572 in.) Main Bearing Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.97 - 43.98 mm (1.7311 - 1.7315 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.92 mm (1.729 in.) Main Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.00 - 44.042 mm (1.732 - 1.734 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.07 mm (1.735 in.) 1-10 4/7/95 Specifications Stub Shaft (430 LGT, F925/35 FM) Stub Shaft-to-Flywheel Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 N•m (44 lb-ft) Cover-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft) Cover-to-Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Flywheel Maximum Distortion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 N•m (61 lb-ft) Flywheel Housing/Plate Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Camshaft Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Camshaft Side Gap Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.15 mm (0.0020 - 0.0060 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Maximum Camshaft Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.) Lobe Height Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.95 - 34.05 mm (1.337 - 1.341 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.75 mm (1.329 in.) Journal O.D. Gear Housing and Flywheel Ends Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.94 - 39.96 mm (1.5724 - 1.5732 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.85 mm (1.5689 in.) Intermediate Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.91 - 39.94 mm (1.5713 - 1.5724 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.85 mm (1.5689 in.) Bushing I.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.00 - 40.065 mm (1.575 - 1.577 in.) Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.10 mm (1.579 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.00 - 40.025 mm (1.575 - 1.576 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.10 mm (1.579 in.) Cam Followers O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.927 - 20.960 mm (0.8239 - 0.8252 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.93 mm (0.824 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 - 0.094 mm (0.0016 - 0.0037 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.00 - 21.021 mm (0.8268 - 0.8276 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.05 mm (0.829 in.) Timing Gear Cover Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Cover Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Crankcase Extension Housing-to-Cover Cap Screw Torque . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Crankshaft Pulley Cap Screw Torque Early 3TNA72 (430 LGT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft) Later 3TNA72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (85 lb-ft) 4/7/95 1-11 1 Specifications 1 Idler Gear Shaft O.D Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.959 - 19.980 mm (0.786 - 0.787 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.93 mm (0.785 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.00 - 20.021 mm (0.787 - 0.788 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.08 mm (0.791 in.) Timing Gear Housing Cap Screw Torque Aluminum Housing-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (73 lb-in.) Cast Iron Housing-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Crankcase Extension-to-Housing (670 CUT, 15 EX, 3009 OEM). . . . . . . . . . . . . 22 N•m (195 lb-in.) Oil Pan and Strainer Mounting Cap Screw Torque Oil Pan/Plate-to-Extension Housing (670 CUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Oil Pan-to-Block (All Except 670 CUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Oil Pan-to-Seal Case (All Except 670, 15 EX, 3009 OEM). . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Oil Pan-to-Timing Gear Housing (All Except 670, 15 EX, 3009 OEM) . . . . . . . . . . 9 N•m (78 lb-in.) Oil Strainer-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Oil Pump - Early 3TNA72 (430 LGT) Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Governor Shaft Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Gear Housing End Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Oil Pump Gear Lock Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Outer Rotor Bore Depth-to-Outer Rotor Thickness Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 - 0.15 mm (0.003 - 0.006 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Outer Rotor-to-Bore Diameter Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.15 mm (0.004 - 0.006 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Inner Rotor-to-Outer Rotor Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.15 mm (0.004 - 0.006 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Rotor Shaft O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.670 - 12.685 mm (0.4988 - 0.4990 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.650 mm (0.4980 in.) Rotor Shaft Bore I.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.700 - 12.718 mm (0.5000 - 0.5007 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.100 mm (0.0039 in.) Rotor Shaft-to-Bore Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.006 - 0.0019 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.100 mm (0.0039 in.) Oil Pump - Later 3TNA72 Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) Rotor Recess Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Rotor Shaft O.D.-to-Backing Plate I.D. Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.0006 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.) 1-12 4/7/95 Specifications Oil Pump - Later 3TNA72, continued Outer Rotor-to-Pump Body Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm (0.0011 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.0057 in.) Inner-to-Outer Rotor Clearance Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Oil Pressure Regulating Valve -Early 3TNA72 (430 LGT) Spring Compressed Length . . . . . . . . . . . . . . . . . . 30 mm (1.180 in.) @ 29.4 ± 3.1 N (6.6 ± 0.7 lb-force) Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.50 - 40.50 mm (1.550 - 1.590 in.) Oil Pressure Regulating Valve - Later 3TNA72 Spring Compressed Length . . . . . . . . . . . . . . . . . . . . . . . . .27.50 mm (1.080 in.) @ 20.5 N (4.6 lb-force) Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.50 - 48.50 mm (1.710 - 1.910 in.) Housing-to-Valve Body Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Housing-to-Engine Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Thermostat Thermostat Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Water Pump Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Plate-to-Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Fuel Supply Pump - (670 CUT, 3009 OEM) Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Fuel Injection Pump Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Fuel Injection Pump Camshaft Bearing Retaining Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Gear-to-Camshaft Lock Nut Torque - Early 3TNA72 (430 LGT) . . . . . . . . . . . . . . . 88 N•m (65 lb-ft) Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.90 mm (1.217 in.) Fuel Control and Governor Linkage - Early 3TNA72 (430 LGT) Gear Housing End Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Governor Shaft O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 N•m (0.311 in.) Governor Shaft Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Governor Shaft Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 mm (0.321 in.) Sleeve I.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20 mm (0.362 in.) Oil Pump Rotor Shaft O.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.15mm (0.006 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.90 mm (0.350 in.) Fuel Control and Governor Linkage - Later 3TNA72 Governor Shaft O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.) Governor Shaft Bore I.D. Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 mm (0.321 in.) Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) Sleeve I.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20 mm (0.323 in.) Injection Pump Camshaft O.D. Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.) Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) 4/7/95 1-13 1 Specifications 1 Fuel Injection Nozzles Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft) Nozzle Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft) Nozzle Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft) Separator Plate Nozzle Contact Surface Maximum Wear . . . . . . . . . . . . . . . . . . 0.10 mm (0.0039 in.) Starter - Hitachi 0.8 kW (3009 OEM) Cover Bushing (Reamed Out). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.50 - 12.53 (0.492 - 0.493 in.) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.70 mm (0.303 in.) Starter Motor - Nippondenso 1.0 kW (All Except 3009 OEM) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mm (0.300 in.) Alternator - Kokosan 20A (670 CUT, 15 EX) Flywheel Assembly-to-Coil Plate Assembly Nut Torque . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Alternator - Nippondenso 35A (430 LGT, 670 CUT, 755/56 CUT, F925/35 FM) Attaching Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Rotor Assembly Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Pulley Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) Stator-to-Rectifier Lead Wire Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.50 mm (1.300 in.) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 mm (0.220 in.) Alternator - Nippondenso 40A (455 LGT, 755/56 CUT, 3009 OEM) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft) Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Minimum Rotor Slip Ring O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 mm (0.550 in.) Brush Length New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50 mm (0.170 in.) Checks, Tests and Adjustments Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Connecting Rod Side Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.0079 - 0.0157 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.) Connecting Rod Bearing Clearance Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 - 0.072 mm (0.0008 - 0.0028 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Crankshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 - 0.271 mm (0.004 - 0.011 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.) Crankshaft Main Bearing Clearance Main Bearing Cap Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 N•m (58 lb-ft) Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 - 0.072 mm (0.0008 - 0.0028 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Valve Lift (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 mm (0.300 in.) Camshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Timing Gear Backlash - Early 3TNA72 (430 LGT) Standard Backlash Fuel Injection Pump Gear-to-Oil Pump Gear . . . . . . . . . . 0.11 - 0.19 mm (0.0043 - 0.0075 in.) All Except Fuel Injection Pump Gear-to-Oil Pump Gear. 0.04 - 0.12 mm (0.0016 -0.0047 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) 1-14 4/7/95 Specifications Timing Gear Backlash - Later 3TNA72 Standard Backlash Crankshaft Gear-to-Oil Pump Gear . . . . . . . . . . . . . . . . . 0.11 - 0.19 mm (0.0043 - 0.0075 in.) All Except Crankshaft Gear-to-Oil Pump Gear . . . . . . . . 0.04 - 0.12 mm (0.0016 - 0.0047 in.) Fuel Injection Nozzle Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11722 ± 480 kPa (1700 ± 70 psi) Leakage at 11032 kPa (1600 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum of 10 Seconds Chatter and Spray Pattern at 11722 ± 480 kPa (1700 ± 70 psi) Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chatter Sound Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Stream Spray Pattern Fast Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Atomized Spray Pattern Thermostat Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71° C (160°F) Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F) Minimum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0.310 in.) Coolant Temperature Sensor Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107-113° C (225-235° F) Starter No-Load Amp Draw/RPM Maximum Starter Amperage Hitachi 0.8 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Amps at 7000 rpm Nippondenso 1.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Amps at 3000 rpm Minimum Starter RPM Hitachi 0.8 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000 Nippondenso 1.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 Fuel Injection Pump Static Timing Adjustment - Early 3TNA72 (430 LGT) Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° BTDC (Before Top Dead Center) Engine Crankshaft Position . . . . . . . . . . . . . . . . . . . No. 1 Cylinder on TDC Compression Stroke Distance On Outer Surface of Crankshaft Pulley for Every 0.1 mm (0.004 in.) of Shim Thickness . . . . . . . . . . . . . . . . . . . . . . . . . 1° or 1 mm (3/64 in.) Delivery Valve Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 N•m (31 lb-ft) Fuel Injection Pump Static Timing Adjustment - Later 3TNA72 Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13° BTDC (Before Top Dead Center) Engine Crankshaft Position . . . . . . . . . . . . . . . . . . . No. 1 Cylinder on TDC Compression Stroke Distance on Outer Surface of Flywheel Per 1° of Rotation . . . . . . . . . . . . . . . 2.62 mm (0.100 in.) Total Shim Pack Thickness (New Shims) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.020 in.) Delivery Valve Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 N•m (31 lb-ft) Fan/Alternator Drive Belt Tension Applied Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N (22 lb-force) Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.) Operational Tests Radiator, Bubble Test Maximum Air Pressure Into Cylinder 3009 OEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2455 kPa (356 psi) All Except 3009 OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) Cooling System 15 EX, 670 CUT, 3009 OEM Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi) Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) 430 LGT, 455 LGT, 755/56 CUT, F925/35 FM Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 kPa (17 psi) Minimum Pressure after 15 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi) 4/7/95 1-15 1 Specifications 1 Radiator Cap Valve Opening Pressure 15 EX, 3009 OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) 670 CUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 kPa (8 psi) 430 LGT, 455 LGT, 655 CUT, 755/56 CUT, F925/35 FM . . . . . . . . . . . . . . . . 97 kPa (14 psi) Cylinder, Compression Pressure Compression Pressure All Except 3009 OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) 3009 OEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2455 kPa (356 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi) Engine Oil Pressure F925/35 FM Idle Speed Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3635 ± 35 rpm Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 - 440 kPa (43 - 64 psi) 455 LGT Idle Speed Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3350 ± 100 rpm Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1650 ± 50 rpm Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 - 440 kPa (43 - 64 psi) 430 LGT, 755/56 CUT, 670 CUT Fast Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 ± 69 kPa (53 ± 10 psi) 15 EX Idle Speed Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2425 ± 25 rpm Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 - 345 kPa (17 - 50 psi) 3009 OEM Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 kPa (21 psi) Air Intake System Holding Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 - 69 kPa (5 - 10 psi) Minimum Fuel Supply Pump Pressure (670 CUT, 3009 OEM). . . . . . . . . . . . . . . . . . 29 kPa (4.3 psi) Fuel System Holding Pressure (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 kPa (15 psi) 1-16 4/7/95 Cylinder Head, Valves and Manifolds SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the European Microfiche Tool Catalog (MTC). JDG504 Valve Guide Driver Use to remove and install valve guides in cylinder head on 3TN66 engine. JDE118 Valve Guide Driver Use to remove and install valve guides in cylinder head on 3TNA72 (3009) engine. 1 D-20018WI Valve Guide Knurler Use to knurl inside diameter of valve guides on 3TNA72 (3009) engine. D-20020WI Valve Guide Reamer Use to ream out new valve guides on 3TNA72 (3009) engine. SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Head Gasket Kit 4/7/95 1-17 Cylinder Head, Valves and Manifolds ROCKER ARM COVER NOTE: Some models may be equipped with an oil fill extension and/or adaptor with an o-ring. Special Nut (2) 18 N•m (160 lb-in.) Oil Filler Cap 1 O-Ring (2) O-Ring Breather Fitting Crankcase Breather Tube Rocker Arm Cover Gasket Lock Washer (4) Screw (4) Baffle Breather Deflector O-Ring Seal M82004A 1-18 4/7/95 Cylinder Head, Valves and Manifolds ROCKER ARM ASSEMBLY IMPORTANT: Install center rocker arm support on shaft, aligning set screw hole in support with center hole in shaft. Removal/Installation and Disassembly/Assembly • Lubricate all parts with clean oil during assembly. 1. Remove rocker arm cover. (See procedure in this group.) • Adjust valve clearance. (See Checks, Tests and Adjustments in this section.) • Inspect all parts for wear or damage. (See Inspection procedures.) Rocker Arm Shaft 1 Mounting Nut (2) M8 26 N•m (226 lb-in.) Intake Valve Rocker Arm Set Screw Exhaust Valve Rocker Arm Rocker Arm Shaft Spring Rocker Arm Support (3) Nut Adjusting Screw Mounting Cap Screw M8 x 45 26 N•m (226 lb-in.) Valve Caps Push Rod 3TN66 4/7/95 M82257A 1-19 Cylinder Head, Valves and Manifolds Mounting Nut (2) M8 26 N•m (226 lb-in.) Exhaust Valve Rocker Arm Mounting Cap Screw M8 x 45 26 N•m (226 lb-in.) Rocker Arm Shaft 1 Rocker Arm Shaft Spring Nut Adjusting Screw Rocker Arm Support (3) Set Screw Intake Valve Rocker Arm Valve Caps Push Rod 3TNA72 (3009) Inspection M82258A Rocker Arm Shaft O.D. - 3TN66: • Measure outer diameter of rocker arm shaft at each rocker arm location. Standard . . . . . . . . . . . . . . . . . 9.97 - 9.99 mm . . . . . . . . . . . . . . . . . . . . . (0.3925 - 0.3933 in.) Wear Limit. . . . . . . . . . . 9.95 mm (0.3920 in.) Rocker Arm Shaft O.D. - 3TNA72 (3009): Standard . . . . . . . . . . . . . . . 11.96 - 11.98 mm . . . . . . . . . . . . . . . . . . . . . (0.4711 - 0.4718 in.) Wear Limit. . . . . . . . . . 11.95 mm (0.4706 in.) Replace rocker arm shaft if less than wear limit. M35262 1-20 • Measure inner diameters of rocker arms and supports. 4/7/95 Length Cylinder Head, Valves and Manifolds Feeler Gauge 1 M82023A M82022A Push Rod Length: Rocker Arm and Shaft Support I.D.’s - 3TN66: Standard . . . . . . . . . . . . . . . 10.00 - 10.02 mm . . . . . . . . . . . . . . . . . . . . . (0.3937 - 0.3945 in.) Wear Limit. . . . . . . . . . 10.09 mm (0.3972 in.) Clearance . . . . . . . . . . . . . 0.14 mm (0.005 in.) Rocker Arm and Shaft Support I.D.’s 3TNA72 (3009): Standard . . . . . . . . . . . . . . . 12.00 - 12.02 mm . . . . . . . . . . . . . . . . . . . . . (0.4724 - 0.4732 in.) Wear Limit. . . . . . . . . . 12.09 mm (0.4759 in.) Clearance . . . . . . . . . . . . . 0.14 mm (0.005 in.) 3TN66. . . . . . . . . . . . . . . . . . . . . 114 - 115 mm . . . . . . . . . . . . . . . . . . . . . . . (4.488 - 4.528 in.) 3TNA72 (3009) . . . . . . . . . . . . . 141 - 142 mm . . . . . . . . . . . . . . . . . . . . . . . (5.550 - 5.590 in.) Push Rod Bend: Wear Limit. . . . . . . . . . . . 0.08 mm (0.003 in.) Replace push rod if not within specifications. CYLINDER HEAD AND VALVES Removal/Installation Replace rocker arms or supports if I.D. is more than wear limit. 1. Remove rocker arm assembly, push rods and valve caps. (See procedure in this group.) If shaft and support/arm clearance (support/arm I.D. minus shaft O.D.) exceed wear limit, replace all parts. 2. Remove exhaust and intake manifolds. (See procedures in this group.) • Measure length and bending of push rod. 4/7/95 3. Remove water pump. (See Cooling System in this section.) 1-21 Cylinder Head, Valves and Manifolds Mounting Cap Screw (14) Dip entire cap screw in clean engine oil before installing. 1 Flywheel Oil Passage Cylinder Head Gasket M82259A 4. Remove fuel injection nozzles. (See Fuel System in this section.) IMPORTANT: Oil passage in gasket must be located over oil passage in cylinder block. Install gasket as shown. 7. Tighten mounting cap screws, in the sequence shown, in three stages of gradually-increasing torque. IMPORTANT: Cylinder head mounting cap screws must be checked for proper torque after 50 hours of engine operation. 7 13 11 1 3 9 5 10 6 2 4 Intake Manifold Side 12 8 14 Timing Gear Case Side 6. Disassemble and inspect cylinder head and valves. (See Disassembly/ Assembly and Inspection/Replacement procedures.) Flywheel Side 5. Remove glow plugs. (See procedure in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section.) Exhaust Manifold Side M82260A Torque Specifications - 3TN66: First . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.) Second . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Final . . . . . . . . . . . . . . . . . . . 34 N•m (25 lb-ft) Torque Specifications - 3TNA72 (3009): First . . . . . . . . . . . . . . . . . 19 N•m (168 lb-in.) Second . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft) Final . . . . . . . . . . . . . . . . . . . 61 N•m (45 lb-ft) 1-22 4/7/95 Cylinder Head, Valves and Manifolds Disassembly/Assembly IMPORTANT: Do not reuse stem seals if removed. Used seals will leak. NOTE: Size and shape of lifting brackets will vary due to numerous engine applications. • Apply clean engine oil on intake and exhaust valve stems during assembly. • Compress valve springs using a valve spring compressor. • Install springs with smaller pitch end or paint mark toward cylinder head. • Intake and exhaust valve guides are press fit. Remove guides only if replacement is necessary. (See Inspection/Replacement procedures.) NOTE: If new valves are installed, measure valve recession. (See Inspection/Replacement procedures.) • On 3TNA72 (3009), intake and exhaust valve seat inserts are press fit. Remove inserts only if replacement is necessary. After each valve has been assembled, tap on top of valve stem with a plastic hammer to seat retainer. • Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) Stem Seal (6) Replace. Exhaust Valve Guide (3) Rocker Arm Assembly and Cover Mounting Stud (2) Collet Halves (12) Retainer (6) Valve Spring (6) Intake Valve Guide (3) Lifting Bracket (2) Exhaust Manifold Mounting Stud (2) Valve Seat Inserts 3TNA72 (3009) Only. Exhaust Valve Intake Valve M82261A 4/7/95 1-23 1 Cylinder Head, Valves and Manifolds Inspection/Replacement Before inspection, thoroughly clean all components of carbon or dirt. Cylinder Head: 1 • Measure cylinder head flatness. Place a straightedge along each of the four sides and each diagonal. Measure clearance between straight edge and combustion surface with a feeler gauge. Valve Seat Width Straight-Edge M82029A Valve Seat Width - 3TN66: Feeler Gauge Intake Valve Standard . . . . . . . . . . . . . 1.15 mm (0.045 in.) Wear Limit. . . . . . . . . . . . 1.65 mm (0.065 in.) Exhaust Valve M82028A Cylinder Head Distortion: Standard . . . . . . . 0.05 mm (0.002 in.) or less Wear Limit. . . . . . . . . . . . 0.15 mm (0.006 in.) If distortion exceeds the wear limit, resurface or replace cylinder head. Remove only enough metal to make cylinder head flat; but do not remove more than 0.20 mm (0.008 in.). If cylinder head was resurfaced: • Measure piston-to-cylinder head clearance. (See procedure in this group.) • Measure valve recession. (See procedure in this group.) • Measure valve seat width. 1-24 Standard . . . . . . . . . . . . . 1.41 mm (0.056 in.) Wear Limit. . . . . . . . . . . . 1.91 mm (0.075 in.) Valve Seat Width - 3TNA72 (3009): Intake Valve Standard . . . . . . . . . . . . . 1.44 mm (0.057 in.) Wear Limit. . . . . . . . . . . . 1.98 mm (0.078 in.) Exhaust Valve Standard . . . . . . . . . . . . . 1.77 mm (0.070 in.) Wear Limit. . . . . . . . . . . . 2.27 mm (0.089 in.) If necessary, grind valve seats to meet specifications. (See GRIND VALVE SEATS procedure.) Intake and Exhaust Valves: • Check valve for out-of-round, bent or warped condition using a valve inspection center. Replace valve if necessary. 4/7/95 Cylinder Head, Valves and Manifolds Valve Stem O.D. - 3TN66: Distance A . . . . . . . . . . . . . . . . .20 mm (0.787 in.) Distance B . . . . . . . . . . . . . . . . .40 mm (1.575 in.) Intake Valve Standard . . . . . . . . . . . . . . . . . 5.46 - 5.48 mm . . . . . . . . . . . . . . . . . . . . . (0.2149 - 0.2157 in.) Wear Limit. . . . . . . . . . . 5.40 mm (0.2126 in.) M35307 If valve faces are worn, burned or pitted, grind valves to proper face angle. If valve face margin is less than 0.51 mm (0.020 in.) after grinding, replace valve. Exhaust Valve Standard . . . . . . . . . . . . . . . . . 5.44 - 5.46 mm . . . . . . . . . . . . . . . . . . . . . (0.2142 - 0.2149 in.) Wear Limit. . . . . . . . . . . 5.40 mm (0.2126 in.) Valve Stem O.D. - 3TNA72 (3009): Distance A . . . . . . . . . . . . . . . . .25 mm (0.984 in.) Distance B . . . . . . . . . . . . . . . . .45 mm (1.772 in.) Intake and Exhaust Valves Valve Face Angle Valve Face Margin Exhaust: 45° Intake: 30° M82030A • Measure valve stem diameter at two locations shown. Replace valve if measurement exceeds wear limit. Standard . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm . . . . . . . . . . . . . . . . . . . . . (0.2732 - 0.2740 in.) Wear Limit. . . . . . . . . . . 6.90 mm (0.2717 in.) • Measure valve recession using a depth gauge. Replace valve or cylinder head if measurement exceeds specification. Valve Recession Cylinder Head A B Depth Gauge M82031A M82032A 4/7/95 1-25 1 Cylinder Head, Valves and Manifolds Valve Recession - 3TN66: Intake Valve . . . . . . . . . . . 0.40 mm (0.016 in.) Exhaust Valve . . . . . . . . . 0.85 mm (0.033 in.) Valve Recession - 3TNA72 (3009): Intake Valve . . . . . . . . . . . 0.50 mm (0.020 in.) Exhaust Valve . . . . . . . . . 0.85 mm (0.033 in.) 1 Valve Guides: • Clean valve guides using a valve guide brush. • Measure valve guide inside diameter. Valve Guide I.D. - 3TN66: Standard . . . . . . . . . . . . . . . . . 5.50 - 5.52 mm . . . . . . . . . . . . . . . . . . . . . . . (0.216 - 0.217 in.) Wear Limit. . . . . . . . . . . . 5.58 mm (0.220 in.) Intake and exhaust valve guides are different. The exhaust valve guide has one groove and the intake valve guide has none. Install valve guides with tapered ends down. Push valve guides down until top of valve guides are a specified distance (A) from top of cylinder head. Valve Guide Height “A”: 3TN66. . . . . . . . . . . . . . . . . . .7 mm (0.276 in.) 3TNA72 (3009) . . . . . . . . . . .9 mm (0.354 in.) • Ream inside diameter of valve guides using: - 3TN66: 5.50 mm Valve Guide Reamer - 3TNA72 (3009): D-20020WI Valve Guide Reamer A Valve Guide I.D. - 3TNA72 (3009): Standard . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm . . . . . . . . . . . . . . . . . . . . . . . (0.275 - 0.276 in.) Wear Limit. . . . . . . . . . . . 7.08 mm (0.279 in.) If diameter exceeds wear limit, knurl or replace guide. If diameter is less than wear limit, determine guideto-stem clearance (guide diameter minus stem diameter). If clearance exceeds 0.15 mm (0.006 in.) but is less than 0.20 mm (0.008 in.), knurl valve guides. • Knurl valve guides using: M82193A Valve Springs: • Measure spring free length. Replace spring if measurement exceeds specification. - 3TN66: 5.50 mm Valve Guide Knurler - 3TNA72 (3009): D-20018WI Valve Guide Knurler If clearance exceeds 0.20 mm (0.008 in.), replace valve guides. • Replace valve guides using: - 3TN66: JDG504 Valve Guide Driver - 3TNA72 (3009): JDE118 Valve Guide Driver M82034A 1-26 4/7/95 Cylinder Head, Valves and Manifolds EXHAUST MANIFOLD - 3TN66 Spring Free Length: 3TN66. . . . . . . . . . . . . . . . . .28 mm (1.102 in.) 3TNA72 (3009) . . . . . . . 37.40 mm (1.472 in.) • Measure spring inclination. Replace spring if measurement exceeds specification. • Remove muffler and gasket, if equipped. • Tighten all mounting hardware to 11 N•m (97 lb-in.). Lifting Bracket Cap Screw (4) M6 x 40 Flange Nut (2) M6 1 Stud (3) Gasket M82262A 330/332 LGT Spring Inclination Square Gauge Flange Nut (2) M6 Free Length M82035A Spring Inclination: Cap Screw (4) M6 x 40 3TN66. . . . . . . . . . . . . . . . 0.80 mm (0.032 in.) 3TNA72 (3009) . . . . . . . . 1.00 mm (0.040 in.) Gasket M82263A 375 SSL Cap Screw (2) M6 x 70 Stud (3) Flange Nut (2) M6 Cap Screw (2) M6 x 40 Gasket M82264A 655 CUT, F915 FM 4/7/95 1-27 Cylinder Head, Valves and Manifolds EXHAUST MANIFOLD - 3TNA72 (3009) • Remove muffler and gasket, if equipped. Spring Pin (2) • Remove extension/elbow and gasket, if equipped. Nut and Lock Washer (2) M8 • Tighten all mounting hardware to 26 N•m (230 lb-in.). 1 Cap Screw (4) M8 x 70 Cap Screw (2) M8 x 80 Flange Nut (2) M8 Stud (4) M82266A Gasket 670 CUT Cap Screw (2) M8 x 35 Nut and Lock Washer (2) M8 Stud (4) Gasket M82264A 430 LGT (Early), 755/56 CUT, F925/35 FM Cap Screw (4) M8 x 40 Stud (4) Cap Screw (2) M8 x 55 M82267A Gasket Nut and Lock Washer (2) M8 15 EX, 455 LGT Cap Screw (2) M8 x 40 Stud (4) Nut and Lock Washer (2) M8 Gasket M82265A 430 LGT (Later) Cap Screw (4) M8 x 40 Gasket M82268A 3009 OEM 1-28 4/7/95 Cylinder Head, Valves and Manifolds INTAKE MANIFOLD - 3TN66 NOTE: On 375 SSL engine application, mounting cap screws are 22 mm long. 1. Remove fuel filter assembly mounting cap screw(s), if equipped. 2. Remove fuel injection lines, if necessary. (See Fuel System in this section.) Gasket Cap Screw M6 x 40 Cap Screw (2) M6 x 16 1 M82270A Gasket 3TNA72 (670 CUT) Gasket Cap Screw (4) M6 x 20 11 N•m (97 lb-in.) 3TN66 M82269A INTAKE MANIFOLD - 3TNA72 (3009) 1. Remove fuel filter assembly mounting cap screw(s), if equipped. Cap Screw M6 x 40 Cap Screw (2) M6 x 16 M82271A 3TNA72 (15 EX, 3009 OEM) 2. Remove fuel injection lines. (See Fuel System in this section.) Gasket 3. OEM Power Unit engine (3009): • Remove air cleaner and mount bracket. • Remove instrument panel and bracket. (See procedures in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section.) • Tighten all mounting cap screws to 11 N•m (97 lb-in.). Cap Screw (6) M6 x 20 M82272A 3TNA72 (430 and 455 LGT, F925/35 FM, 755/56 CUT) 4/7/95 1-29 Cylinder Head, Valves and Manifolds GRIND VALVE SEATS IMPORTANT: Valve seats should never be cut. Cutting a valve seat can damage its sealing surface, which may result in leaks or valve/ seat failure. Valve seats should be ground and lapped. 1 NOTE: LIGHTLY grind valve seats for a few seconds only to avoid excessive valve seat width. 1. Grind intake valve seat using a 30° seat grinder and exhaust valve seat using a 45° seat grinder. Follow tool manufacturers instructions. Lower Seat Surface 70° Valve Seat Upper Seat Surface 15° Seat Width Cylinder Head M82040A Seat Grinder If valve recession exceeds maximum specifications or seats cannot be reconditioned, replace valves, valve seats if equipped and/or cylinder head. NOTE: Valve seat inserts are available for 4TN78T engine only. LAP VALVES M82039A 2. Measure valve seat width after grinding. 3. If seat is too wide after grinding, grind lower seat surface using a 70° seat grinder until seat width is close to specifications. 4. Grind upper seat surface using a 15° seat grinder until seat width is narrowed to specifications. 5. If valve seats are ground, measure valve recession and check contact pattern between the seat and valve with bluing dye. 6. Lap valves. (See procedure in this group.) NOTE: Use a rubber type lapping tool for valves without a lapping tool groove slit. If seat does not make proper contact, lap the valve into the seat: 1. Apply small amount of fine lapping compound to face of valve. 2. Turn valve to lap valve to seat. 3. Lift valve from seat every 8 to 10 strokes. Lap until a uniform ring appears around the surface of the valve face. 4. Wash all parts in solvent to remove lapping compound. Dry parts. 5. Check position of lap mark on valve face. Lap mark must be on or near center of valve face. 1-30 4/7/95 Cylinder Head, Valves and Manifolds Lapping Tool 1 M82042A M82041A Piston-to-Cylinder Head Clearance: MEASURE PISTON-TO-CYLINDER HEAD CLEARANCE 1. Place three 10 mm (0.400 in.) long pieces of 1.50 mm (0.060 in.) diameter soft wire in three positions on the flat part of the piston head. 2. Install cylinder head and old gasket. Install cylinder head cap screws and tighten in proper sequence to specified torque. (See CYLINDER HEAD AND VALVES - Removal/Installation in this group.) 3TN66. . . . . . . . . . . . . . . . . . . . 0.59 - 0.74 mm . . . . . . . . . . . . . . . . . . . . . . . (0.023 - 0.029 in.) 3TNA72 (3009) . . . . . . . . . . . . 0.61 - 0.79 mm . . . . . . . . . . . . . . . . . . . . . . . (0.024 - 0.031 in.) If clearance is less than specifications, replace cylinder head. 3. Slowly turn crankshaft one complete revolution. 4. Remove cylinder head and gasket. 5. Measure thickness of flattened section of each piece of wire. Calculate average thickness of wires to obtain piston-to-cylinder head clearance specification. 4/7/95 1-31 Pistons, Rods and Cylinder Block SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Block Gasket Kit • Cylinder Head Gasket Kit • Oversized Pistons and Rings • Undersized Connecting Rod Bearing Inserts 1 1-32 4/7/95 Pistons, Rods and Cylinder Block PISTON AND CONNECTING ROD Removal 1. Remove oil pan and strainer tube. (See Lubrication System in this section.) 2. Remove cylinder head. (See Cylinder Head, Valves and Manifolds in this section.) 3. Check cylinder bore for ridges. These ridges can cause damage to piston if ridge is not removed. Piston and Connecting Rod 1 4. If necessary, remove ridge from top of cylinder bore using a ridge reamer. 5. Measure connecting rod side play. (See Checks, Tests and Adjustments in this section.) 6. Measure connecting rod bearing clearance. (See Checks, Tests and Adjustments in this section.) Bearing Inserts IMPORTANT: Keep connecting rods and caps together. Rods and caps are a matched set. Note alignment marks on each part. 7. Remove two cap screws, connecting rod cap and bearing inserts. Connecting Rod Cap IMPORTANT: Pistons and cylinders are matched. Pistons must be installed in the cylinders from which they are removed. Connecting Rod Cap Screw Replace. 8. Note connecting rod alignment mark in relation to the cylinders. Starting at flywheel end with cylinder number one, then two, etc. 9. Push piston and connecting rod out of cylinder bore using a wooden dowl. 10.Disassemble and inspect all parts for wear or damage. (See Disassembly and Inspection/ Replacement procedures.) M82273A Installation • Apply clean engine oil on all parts during installation. • Never reuse connecting rod cap screws, replace with new. IMPORTANT: Pistons must be installed in cylinders from which they were removed and in the same direction. Be careful not to damage crankshaft rod journal while installing piston. 1. If new piston rings were installed, deglaze cylinder bore. (See procedure in this group.) 2. Install piston and connecting rod into the cylinder from which it was removed, with piston recess on top of piston toward fuel injection pump. 4/7/95 1-33 Pistons, Rods and Cylinder Block IMPORTANT: Do not touch bearing insert surfaces. Oil and acid from your finger will corrode the bearing surface. 3. Install bearing inserts on connecting rod and rod cap, aligning tangs with grooves. IMPORTANT: Connecting rod caps must be installed on the same connecting rods they were removed from. 1 4. Match the connecting rods to caps using alignment marks. Install caps. 5. Dip entire connecting rod cap screws in clean engine oil. Install new cap screws and tighten to 23 N•m (203 lb-in.). Disassembly IMPORTANT: Pistons must be installed on the same connecting rod they were removed from. • Put a mark on each piston and connecting rod to aid in assembly. • Piston pin bushing is press fit in connecting rod. Remove bushing only if replacement is necessary. (See Inspection/Replacement procedures.) • Inspect all parts for wear or damage. Replace as necessary. (See Inspection/Replacement procedures.) 6. If a new piston and connecting rod were installed, stamp a number corresponding to the cylinder number on the connecting rod cap and connecting rod. 1st Compression Ring 2nd Compression Ring Piston Recess Fuel Injection Pump Side Oil Ring with Coil Expander Flywheel Side Piston Piston Pin Groove Retaining Ring Tangs Connecting Rod Cap Alignment Mark Piston Pin Bushing Connecting Rod Groove Connecting Rod Cap Screw M82273A M82274A 7. Install cylinder head. (See Cylinder Head, Valves and Manifolds in this section.) 8. Install oil pan and strainer tube. (See Lubrication System in this section.) 1-34 4/7/95 Pistons, Rods and Cylinder Block Assembly • Apply clean engine oil to all parts during assembly. IMPORTANT: Pistons must be installed on the same connecting rod they were removed from. 1. Assemble piston to connecting rod with piston recess on same side as connecting rod “punched” alignment mark. If a new connecting rod is used, assemble piston to connecting rod with piston recess opposite connecting rod bearing insert groove. Oil Ring Expander Oil Ring Gap Oil Ring Expander Ends 2. Install piston pin and snap rings. Oil Ring Piston Pin M82046A Piston Recess Piston 5. Install second compression ring, with chamfer toward top of piston, in middle groove. Turn ring until gap is 120o away from oil ring gap. Piston Pin Retaining Ring 6. Install first compression ring (chrome plated), with manufacturer's mark “T”, “R” or “RN” (near ring gap) toward top of piston, in top groove. Turn ring until gap is 120o away from second ring gap. 1st Compression Ring 2nd Compression Ring Connecting Rod Bearing Insert Groove Alignment Mark M82275A 3. Install oil ring expander in bottom ring groove of piston with ends above either end of piston pin. 2nd Compression Ring 120° 120° 1st Compression Ring 120° Oil Ring 4. Install oil ring over expander with ring gap opposite (180o) of expander ends. M82276A 4/7/95 1-35 1 Pistons, Rods and Cylinder Block Inspection/Replacement 1. Inspect all parts for wear or damage. Replace as necessary. 1 If bearing diameter exceeds wear limit, replace bearing inserts. 2. Measure crankshaft connecting rod journal diameter. (See Crankshaft, Main Bearings and Flywheel in this section.) If bearing clearance (bearing I.D. minus crankshaft journal O.D.) exceeds specification, grind crankshaft connecting rod journals and install undersized bearing inserts, or replace bearing inserts and crankshaft. 3. Install connecting rod cap and bearing inserts on connecting rod. Install old connecting rod cap screws and tighten to 23 N•m (203 lb-in.). 5. With rings installed on piston, measure piston ring groove clearance. Measure several places around each piston. 4. Measure connecting rod bearing diameter. M35360 Piston Ring Groove Clearance - 3TN66: M82048A Connecting Rod Bearing I.D. - 3TN66: Standard . . . . . . . . . . . . . . 36.00 - 36.042 mm . . . . . . . . . . . . . . . . . . . . . . . (1.417 - 1.419 in.) Wear Limit. . . . . . . . . . . 37.07 mm (1.459 in.) Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.) First Compression Ring Standard . . . . . . . . . . . . . . . 0.065 - 0.100 mm . . . . . . . . . . . . . . . . . . . . . (0.0026 - 0.0039 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Second Compression Ring Standard . . . . . . . . . . . . . . . 0.030 - 0.065 mm . . . . . . . . . . . . . . . . . . . . . (0.0012 - 0.0026 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Connecting Rod Bearing I.D. - 3TNA72 (3009): Standard . . . . . . . . . . . . . . 40.00 - 40.042 mm . . . . . . . . . . . . . . . . . . . . . . . (1.575 - 1.577 in.) Wear Limit. . . . . . . . . . . 40.07 mm (1.578 in.) Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.) 1-36 Oil Ring Standard . . . . . . . . . . . . . . . 0.020 - 0.055 mm . . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0022 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) 4/7/95 Pistons, Rods and Cylinder Block Piston Ring Groove Clearance - 3TNA72 (3009): First Compression Ring Standard . . . . . . . . . . . . . . . 0.075 - 0.110 mm . . . . . . . . . . . . . . . . . . . . . (0.0030 - 0.0043 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Second Compression Ring Standard . . . . . . . . . . . . . . . 0.030 - 0.065 mm . . . . . . . . . . . . . . . . . . . . . (0.0012 - 0.0026 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Oil Ring Standard . . . . . . . . . . . . . . . 0.020 - 0.055 mm . . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0022 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) If clearance exceeds wear limit, replace rings or piston. 6. Measure piston ring end gap. Push ring into cylinder bore, using a piston, until ring is approximately 30 mm (1.181 in.) from bottom of cylinder bore. Piston Ring End Gap - 3TN66: Standard First Compression Ring and Oil Ring . . . . . . . . . . . . . 0.15 - 0.35 mm . . . . . . . . . . . . . . . . . . . . . . (0.006 - 0.014 in.) Second Compression Ring . . 0.25 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.016 in.) Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Ring End Gap - 3TNA72 (3009): Standard First Compression Ring . . . . 0.10 - 0.25 mm . . . . . . . . . . . . . . . . . . . . . . (0.004 - 0.010 in.) Second Compression Ring . . 0.25 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.016 in.) Oil Ring . . . . . . . . . . . . . . . . . 0.15 - 0.35 mm . . . . . . . . . . . . . . . . . . . . . . (0.006 - 0.014 in.) Wear Limit: . . . . . . . . . . 1.50 mm (0.0591 in.) If end gap exceeds wear limit, replace rings. 7. Measure piston pin diameter. Measure diameter at six places. End Gap Cylinder Bore Measuring Positions Piston Ring Approx. 30 mm (1.181 in.) End Gap 4/7/95 M82049A M82050A 1-37 1 Pistons, Rods and Cylinder Block Piston Pin O.D. - 3TN66: Standard . . . . . . . . . . . . . . 19.991 - 20.00 mm . . . . . . . . . . . . . . . . . . . . . . . (0.787 - 0.788 in.) Wear Limit. . . . . . . . . . 19.975 mm (0.786 in.) Piston Pin O.D. - 3TNA72 (3009): 1 Standard . . . . . . . . . . . . . . 20.991 - 21.00 mm . . . . . . . . . . . . . . . . . . . . . . . (0.826 - 0.827 in.) Wear Limit. . . . . . . . . . 20.975 mm (0.825 in.) If pin diameter is less than wear limit, replace pin. 8. Measure piston pin bore diameter in piston. M82051A Piston Pin Bushing I.D. - 3TN66: Standard . . . . . . . . . . . . . 20.025 - 20.038 mm . . . . . . . . . . . . . . . . . . . . . . . (0.788 - 0.789 in.) Wear Limit. . . . . . . . . . . 20.10 mm (0.781 in.) Clearance . . . . . . . . . . . . 0.11 mm (0.0043 in.) Piston Pin Bushing I.D. - 3TNA72 (3009): M37683 Piston Pin Bore I.D. - 3TN66: Standard . . . . . . . . . . . . . . 20.00 - 20.008 mm . . . . . . . . . . . . . . . . . . . . . . . (0.787 - 0.788 in.) Wear Limit. . . . . . . . . . . 20.02 mm (0.788 in.) Clearance . . . . . . . . . . . 0.045 mm (0.0018 in.) Piston Pin Bore I.D. - 3TNA72 (3009): Standard . . . . . . . . . . . . . . 21.00 - 21.009 mm . . . . . . . . . . . . . . . . . . . . . (0.8268 - 0.8271 in.) Wear Limit. . . . . . . . . . . 21.02 mm (0.828 in.) Clearance . . . . . . . . . . . 0.045 mm (0.0018 in.) If piston pin bore exceeds wear limit, replace piston. If bore clearance (bore I.D. minus pin O.D.) exceeds specification, replace piston, piston pin or both. 9. Measure piston connecting rod. 1-38 pin bushing diameter in Standard . . . . . . . . . . . . . 21.025 - 21.038 mm . . . . . . . . . . . . . . . . . . . . . (0.8278 - 0.8282 in.) Wear Limit. . . . . . . . . . . 21.10 mm (0.831 in.) Clearance . . . . . . . . . . . . 0.11 mm (0.0043 in.) If bushing diameter exceeds wear limit, replace bushing. If bushing clearance (bushing I.D. minus pin O.D.) exceeds specification, replace bushing, piston pin or both. Piston pin bushing is press fit. Replace bushing using a driver set. When installing bushing, make sure to align oil hole in bushing with hole in connecting rod. 10.Measure piston diameter perpendicular to piston pin bore at distance A. NOTE: If engine has had a previous major overhaul, oversize pistons and rings may have been installed. Pistons and rings are available in 0.25 mm (0.010 in.) and 0.50 mm (0.020 in.) oversize. 4/7/95 Pistons, Rods and Cylinder Block 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . 66.18 - 66.21 mm . . . . . . . . . . . . . . . . . . . . . . . (2.606 - 2.607 in.) Wear Limit. . . . . . . . . . . 66.10 mm (2.602 in.) 0.50 mm (0.020 in.) Oversize Piston A M82200A Standard . . . . . . . . . . . . . . . 66.43 - 66.46 mm . . . . . . . . . . . . . . . . . . . . . . . (2.615 - 2.616 in.) Wear Limit. . . . . . . . . . . 66.35 mm (2.612 in.) Piston O.D. - 3TNA72 (3009): Distance A . . . . . . . . . . . . . . . . . .8 mm (0.315 in.) Standard Size Piston Standard . . . . . . . . . . . . . 71.922 - 71.952 mm . . . . . . . . . . . . . . . . . . . . . . . (2.832 - 2.833 in.) Wear Limit. . . . . . . . . . . 71.81 mm (2.827 in.) 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . 72.17 - 72.20 mm . . . . . . . . . . . . . . . . . . . . . . . (2.841 - 2.842 in.) Wear Limit. . . . . . . . . . . 72.06 mm (2.837 in.) M82052A Piston O.D. - 3TN66: Distance A . . . . . . . . . . . . . . . . . .5 mm (0.197 in.) Standard Size Piston Standard . . . . . . . . . . . . . 65.927 - 65.957 mm . . . . . . . . . . . . . . . . . . . . . . . (2.596 - 2.597 in.) Wear Limit. . . . . . . . . . . 65.85 mm (2.593 in.) 4/7/95 0.50 mm (0.020 in.) Oversize Piston Standard . . . . . . . . . . . . . . . 72.42 - 72.45 mm . . . . . . . . . . . . . . . . . . . . . . . (2.851 - 2.852 in.) Wear Limit. . . . . . . . . . . 72.31 mm (2.847 in.) If piston diameter is less than wear limit, install a new piston. 11.Measure cylinder bore diameter. (See procedure in this group.) 1-39 1 Pistons, Rods and Cylinder Block CYLINDER BORE 0.50 mm (0.020 in.) Oversize Bore Inspection Measure cylinder bore diameter at three positions; top, middle and bottom. At these three positions, measure in both directions; along crankshaft center line and direction of crankshaft rotation. 1 NOTE: If engine has had a previous major overhaul, oversize pistons and rings may have been installed. Standard . . . . . . . . . . . . . . . 66.50 - 66.53 mm . . . . . . . . . . . . . . . . . . . . . . . (2.619 -2.620 in.) Wear Limit. . . . . . . . . . . 66.70 mm (2.626 in.) Cylinder Bore I.D. - 3TNA72 (3009): Standard Size Bore Standard . . . . . . . . . . . . . . . 72.00 - 72.03 mm . . . . . . . . . . . . . . . . . . . . . . . (2.835 - 2.836 in.) Wear Limit . . . . . . . . . . 72.20 mm (2.843 in.) Clearance . . . . . . . . . . . . . 0.28 mm (0.011 in.) Top Position 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . 72.25 - 72.28 mm . . . . . . . . . . . . . . . . . . . . . . . (2.845 - 2.846 in.) Wear Limit. . . . . . . . . . . 72.45 mm (2.852 in.) Middle Position 0.50 mm (0.020 in.) Oversize Bore Standard . . . . . . . . . . . . . . . 72.50 - 72.53 mm . . . . . . . . . . . . . . . . . . . . . . . (2.855 - 2.856 in.) Wear Limit. . . . . . . . . . . 72.70 mm (2.862 in.) Bottom Position Direction of Crankshaft Rotation If cylinder bore exceeds wear limit, replace cylinder block or have cylinder rebored. (See Reboring procedure.) Direction of Crankshaft Centerline If cylinder is rebored, oversize pistons and rings must be installed. Pistons and rings are available in 0.25 mm (0.010 in.) and 0.50 mm (0.020 in.) oversize. M82053A Cylinder Bore I.D. - 3TN66: If clearance (cylinder bore I.D. minus piston O.D.) exceeds specification, replace cylinder block, piston or both; or rebore cylinder and install oversize piston and rings. Standard Size Bore Standard . . . . . . . . . . . . . . . 66.00 - 66.03 mm . . . . . . . . . . . . . . . . . . . . . . . (2.599 - 2.600 in.) Wear Limit . . . . . . . . . . 66.20 mm (2.606 in.) Clearance . . . . . . . . . . . . . 0.25 mm (0.010 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . 66.25 - 66.28 mm . . . . . . . . . . . . . . . . . . . . . . . (2.609 - 2.610 in.) Wear Limit. . . . . . . . . . . 66.45 mm (2.616 in.) 1-40 Deglazing IMPORTANT: If cylinder bores are to be deglazed with crankshaft installed in engine, put clean shop towels over crankshaft to protect journal and bearing surfaces from any abrasives. 1. Deglaze cylinder bores using a flex-hone with 180 grit stones. 4/7/95 Pistons, Rods and Cylinder Block 2. Use flex-hone as instructed by manufacturer to obtain a 30 - 40° cross-hatch pattern as shown. IMPORTANT: Do not use gasoline, kerosene or commercial solvents to clean cylinder bores. Solvents will not remove all abrasives from cylinder walls. 3. Remove excess abrasive residue from cylinder walls using a clean dry rag. Clean cylinder walls using clean white rags and warm soapy water. Continue to clean cylinder until white rags show no discoloration. 5. Run drill press at about 250 RPM. Move hone up and down in order to obtain a 30 - 40°crosshatch pattern. 30 - 40° 1 M52959 NOTE: Measure bore when cylinder is cool. M82054A Reboring NOTE: The cylinder block can be rebored to use oversize pistons and rings. Pistons and rings are available in 0.25 mm (0.010 in.) and 0.50 mm (0.020 in.) oversize. (See this group for cylinder bore I. D. specifications.) 1. Align center of bore to drill press center. IMPORTANT: Check stone for wear or damage. Use a rigid hone with 300 grit stones. 2. Adjust hone so lower end is even with lower end of cylinder bore. 3. Adjust rigid hone stones until they contact narrowest point of cylinder. 4. Coat cylinder with honing oil. Hone should turn by hand. Adjust if too tight. 4/7/95 6. Stop press and check cylinder diameter. NOTE: Finish should not be smooth. It should have a 30 - 40o crosshatch pattern. 7. Remove rigid hone when cylinder is within 0.03 mm (0.001 in.) of desired size. 8. Use a flex hone with 180 grit stones for honing to final size. 9. Check bore for size, taper and out-of-round. (See Inspection procedures.) IMPORTANT: Do not use solvents to clean cylinder bore. Solvents will not remove all metal particles and abrasives produced during honing. 10.Clean cylinder thoroughly using warm soapy water until clean white rags show no discoloration. 11.Dry cylinder and apply engine oil. 1-41 Crankshaft, Main Bearings and Flywheel OTHER MATERIALS Number Name Use John Deere Form-In-Place Gasket Seals rear oil seal case, crankcase extension housing, (3TNA72 - 670 CUT, 15 EX, 3009 OEM) and flywheel housing (3TNA72 - 15 EX, 3009 OEM) to engine block. LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. 1 TY15130/ NA/ #395 SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Block Gasket Kit • Undersized Main Bearing Inserts ®LOCTITE is a registered trademark of the Loctite Corp. 1-42 4/7/95 Crankshaft, Main Bearings and Flywheel CRANKCASE EXTENSION HOUSING 3TNA72 (670 CUT) 1. Remove flywheel. (See procedure in this group.) 2. Remove oil pan and oil strainer. (See Lubrication System in this section.) 1 Cap Screw (4) M6 x22 26 N•m (226 lb-in.) Cap Screw (3) M10 x 20 49 N•m (36 lb-ft) M82056 John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Crankcase Extension Housing Extension-to-Block Cap Screw (2) M8 x 45 27 N•m (20 lb-ft) Extension-to-Block Cap Screw (14) M6 x 85 27 N•m (20 lb-ft) 4/7/95 Extension-to-Timing Gear Housing Cap Screw (4) M8 x 45 22 N•m (195 lb-in.) M82277A 1-43 Crankshaft, Main Bearings and Flywheel CRANKCASE EXTENSION HOUSING 3TNA72 (15 EX and 3009 OEM) 1. Remove flywheel. (See procedure in this group.) 2. Remove oil pan and oil strainer. (See Lubrication System in this section.) 1 Cap Screw (4) M6 x22 26 N•m (226 lb-in.) Cap Screw (3) M10 x 28 49 N•m (36 lb-ft) M82056 John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Crankcase Extension Housing M82202A 1-44 4/7/95 Crankshaft, Main Bearings and Flywheel CRANKSHAFT REAR OIL SEAL 3TN66 AND 3TNA72 (430 LGT, 455 LGT, 755/56 CUT, F925/35 FM) CRANKSHAFT REAR OIL SEAL 3TNA72 (15 EX, 670 CUT, 3009 OEM) Replacement 1. Remove flywheel. (See procedure in this group.) Replacement 1. Remove flywheel plate. (See procedure in this group.) • Replace oil seal using a driver set. Install seal, with lip toward cylinder block. Install seal flush with surface of oil seal case. NOTE: If crankshaft is grooved at oil seal contact point, seal can be installed 3 mm (0.120 in.) farther into oil seal case. Rear Oil Seal • Replace oil seal using a driver set. Install seal, with lip toward cylinder block. Install seal flush with surface of oil seal case. NOTE: If crankshaft is grooved at oil seal contact point, seal can be installed 3 mm (0.120 in.) farther into oil seal case. Rear Oil Seal Seal Case-to-Block Cap Screw (6) M6 X 22 11N•m (96 lb-in.) Oil Seal Case John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Oil Seal Case Seal Case-to-Extension Cap Screw (4) M6 x 22 9 N•m (78 lb-in.) Seal Case-to-Block Cap Screw (6) M6 X 20 11N•m (96 lb-in.) 4/7/95 Oil Pan-to-Seal Case (2) 9 N•m (78 lb-in.) John Deere Form-In-Place Gasket (RTV rubber silicone sealant) M82280A M82279A 1-45 1 Crankshaft, Main Bearings and Flywheel CRANKSHAFT FRONT OIL SEAL CRANKSHAFT AND MAIN BEARINGS Replacement Removal NOTE: Timing gear covers are similar. The most common applications are shown. • Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) 1 • Replace oil seal using a driver set. Install seal with lip toward inside of gear housing cover. Install seal flush with surface of cover. 1. Check crankshaft end play. (See Checks, Tests and Adjustments in this section.) 2. Remove rear oil seal. (See procedure in this group.) 3. Remove flywheel housing, if equipped. (See procedure in this group.) 4. Remove crankcase extension housing, equipped. (See procedure in this group.) if 5. Remove timing gear housing. (See Camshaft and Timing Gear Train in this section.) Timing Gear Cover 6. Check crankshaft bearing clearance. (See Checks, Tests and Adjustments in this section.) Crankshaft Front Oil Seal IMPORTANT: Connecting rod end caps must be installed on the same connecting rods from which they were removed. Note alignment marks on caps and rods. 7. Remove connecting rod cap screws and end caps. M82281A 8. Push pistons and connecting rods away from crankshaft. IMPORTANT: Main bearing caps must be installed on the same main bearings from which they were removed. 3TN66 9. Remove main bearing cap screws, caps and cap thrust bearings. Timing Gear Cover 10.Remove crankshaft. 11.Remove block thrust bearings and main bearing inserts. Crankshaft Front Oil Seal 12.Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) M82282A 3TNA72 1-46 4/7/95 Crankshaft, Main Bearings and Flywheel Crankshaft Flywheel End Block Thrust Bearing 1 Cap Thrust Bearing Main Bearing Inserts Main Bearing Cap Screw (8) Main Bearing Cap Installation • Apply clean engine oil on all parts during installation. IMPORTANT: Do not touch bearing insert surfaces. Oil and acid from your finger will corrode the bearing surface. 1. Install grooved bearing inserts in crankshaft bearing bores, aligning tangs with slots in bores. 2. Install block thrust bearings with oil grooves facing away from engine block. NOTE: Main bearing caps have “raised arrows” that are stamped with numbers. Both correspond to their location on the engine block. The number “1” main bearing bore is at flywheel end. Install bearing caps beginning with number 1, then 2, etc. The main bearing cap at gear train end does not have a number. Also install bearing caps with the “arrow” toward the flywheel end. 4/7/95 M82283A 3. Install crankshaft. 4. Install smooth bearing inserts in main bearing caps, aligning tangs with slots in caps. 5. Install cap thrust bearings, with oil grooves facing away from cap, in the number “1” main bearing cap. 6. Install main bearing caps in their original locations with arrows pointing toward flywheel side of engine. IMPORTANT: DO NOT use high speed power tools or air wrenches to tighten main bearing cap screws. 7. Dip entire main bearing cap screws in clean engine oil. Install cap screws and tighten. DO NOT tighten to specifications. 8. Using a soft-faced hammer, tap the front end of the crankshaft then the rear end of the crankshaft to align the thrust bearings. 1-47 Crankshaft, Main Bearings and Flywheel Crankshaft Flywheel End 1 Block Thrust Bearing Grooved Bearing Insert Cap Thrust Bearing Smooth Bearing Insert Tangs Main Bearing Cap 1 2 Main Bearing Cap Screw (8) Dip in clean engine oil. 3TN66: 54 N•m (40 lb-ft) 3TNA72 (3009):79 N•m (58 lb-ft) 3 M82283A 9. Tighten main bearing cap screws to specifications. When tightening, start at center main bearing cap and work your way out, alternating to the ends. Turn crankshaft by hand. If it does not turn easily, disassemble the parts and find the cause. IMPORTANT: Connecting rod caps must be installed on the same connecting rods they were removed from. Never reuse connecting rod cap screws, replace with new. 11.Dip entire connecting rod cap screws in clean engine oil. Install new cap screws and tighten to 23 N•m (203 lb-in.). 12.Install timing gear housing. (See Camshaft and Timing Gear Train in this section.) 13.Install crankcase extension housing, if equipped. (See procedure in this group.) 14.Install flywheel housing, if equipped. (See procedure in this group.) 15.Install rear oil seal. (See procedure in this group.) 10.Match the connecting rod caps to the rods using alignment marks. Install caps. 1-48 4/7/95 Crankshaft, Main Bearings and Flywheel Inspection/Replacement Key 1. Inspect crankshaft gear for chipped or broken teeth. Replace if necessary. To replace gear: Crankshaft Gear Remove gear from crankshaft using a knife-edge puller and a press. Timing Mark CAUTION DO NOT heat oil over 182° C (360° F). Oil fumes or oil can ignite above 193° C (380° F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. M82060A 2. Inspect crankshaft for bend using v-blocks and a dial indicator. Turn crankshaft slowly and read variation on indicator. If variation is greater than 0.02 mm (0.0007 in.), replace crankshaft. Heat gear to approximately 150oC (300oF). Install gear with timing mark “A” toward press table. Align slot in gear with key in shaft. Press crankshaft into gear until gear is tight against crankshaft shoulder. Dial Indicator V-Block 4/7/95 M82061A 1-49 1 Crankshaft, Main Bearings and Flywheel 3. Measure crankshaft connecting rod journal and main bearing journal diameters. Measure several places around each journal. NOTE: If engine has had a previous major overhaul, journals may have been ground and undersized bearing inserts installed. Main Bearing Cap Screw Torque Specifications: 3TN66. . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) 3TNA72 (3009) . . . . . . . . . . 79 N•m (58 lb-ft) 5. Measure main bearing diameter. Main Bearing Journal 1 4. Install bearing inserts and main bearing cap on main bearing. Tighten main bearing cap screws to specifications. Connecting Rod Journal M82062A M35408 Connecting Rod Journal O.D. - 3TN66: Standard . . . . . . . . . . . . . . . 35.97 - 35.98 mm . . . . . . . . . . . . . . . . . . . . . (1.4161 - 1.4165 in.) Wear Limit. . . . . . . . . . . 35.92 mm (1.414 in.) Connecting Rod Journal O.D. - 3TNA72 (3009): Standard . . . . . . . . . . . . . . . 39.97 - 39.98 mm . . . . . . . . . . . . . . . . . . . . . (1.5736 - 1.5740 in.) Wear Limit. . . . . . . . . . . 39.92 mm (1.572 in.) Main Bearing Journal O.D. - 3TN66: Standard . . . . . . . . . . . . . . . 39.97 - 39.98 mm . . . . . . . . . . . . . . . . . . . . . (1.5736 - 1.5740 in.) Wear Limit. . . . . . . . . . . 39.92 mm (1.572 in.) Main Bearing Journal O.D. - 3TNA72 (3009): Standard . . . . . . . . . . . . . . . 43.97 - 43.98 mm . . . . . . . . . . . . . . . . . . . . . (1.7311 - 1.7315 in.) Wear Limit. . . . . . . . . . . 43.92 mm (1.729 in.) If journal diameter is less than wear limit, replace crankshaft or have journals ground undersize by a qualified machine shop. If journals are ground, undersize bearing inserts must be installed. Bearing inserts are available in 0.25 mm (0.010 in.) undersize. 1-50 Main Bearing I.D. - 3TN66: Standard . . . . . . . . . . . . . . 40.00 - 40.042 mm . . . . . . . . . . . . . . . . . . . . . . . (1.575 - 1.577 in.) Wear Limit. . . . . . . . . . . 40.07 mm (1.578 in.) Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.) Main Bearing I.D. - 3TNA72 (3009): Standard . . . . . . . . . . . . . . 44.00 - 44.042 mm . . . . . . . . . . . . . . . . . . . . . . . (1.732 - 1.734 in.) Wear Limit. . . . . . . . . . . 44.07 mm (1.735 in.) Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.) If bearing diameter exceeds wear limit, replace bearing inserts. If bearing clearance (bearing I.D. minus crankshaft main bearing journal O.D.) exceeds specification, replace bearing inserts and crankshaft or have crankshaft journals ground undersize by a qualified machine shop and install undersized bearing inserts. Bearing inserts are available in 0.25 mm (0.010 in.) undersize. 6. Clean and inspect oil passages in main bearing journals, connecting rod journals and main bearing bores in cylinder block. 7. Inspect crankshaft for cracks or damage. Replace if necessary. 4/7/95 Crankshaft, Main Bearings and Flywheel STUB SHAFT - 3TN66 (330/332 LGT, F915 FM) AND 3TNA72 (430 LGT, F925/35 FM) Cap Screw (2) M10 x 75 49 N•m (36 lb-ft) Nut (2) 88 N•m (65 lb-ft) 1. Remove electric clutch. (See procedure in Machine Technical Manual.) 2. Remove cover. 3. Measure stub shaft TIR (total indicated runout) using a dial indicator. If TIR exceeds (0.20 mm (0.008 in.), replace stub shaft. Cap Screw (5) M8 x 70 26 N•m (226 lb-ft) Guide Pin (2) Stub Shaft Plug Cap Screw (4) M8 x 20 59 N•m (44 lb-ft) M82286A 3TNA72 M35331 4. Remove stub shaft. Cap Screws 330/332 LGT: M10 x 60 F915FM: M10 x 35 49 N•m (36 lb-ft) 5. Measure stub shaft mounting flange flatness. Place a straight edge across stub shaft mounting surface. Measure clearance between straight edge and mounting surface with a feeler gauge. If clearance exceeds 0.05 mm (0.002 in.), replace stub shaft. Installation is done in reverse order of removal. Clip Stud (4) Cover Cap Screw (6) M8 x 50 26 N•m (226 lb-in.) Guide Pins Stub Shaft M35338 Cap Screw (4) M10 x 25 59 N•m (44 lb-ft) M82285A 3TN66 4/7/95 1-51 1 Crankshaft, Main Bearings and Flywheel FLYWHEEL 1. 3TN66 (330/332 LGT and F915 FM) and 3TNA72 (430 LGT and F925/35 FM). Remove stub shaft. (See procedure in this group.) - 3TN66 (655 CUT) and 3TNA72 (455 LGT and 755/56 CUT): Remove starter and flywheel guard. - 3TNA72 (3009 OEM): Remove bearing housing. - 3TN66 (375 SSL) and 3TNA72 (15 EX): Remove center flex coupler. (See procedure in Machine Technical Manual.) 1 Bearing Bearing Housing Pilot Bushing 3TNA72 (670 CUT) Only Cap Screw (3) 3TNA72 (3009 OEM) Only Flywheel Mounting Cap Screw (5) Replace. Apply clean engine oil on threads. 83 N•m (61 lb-ft) Flywheel Nut Clip 755/56 CUT Only Cap Screw (3) M8 x 50 Flywheel Guard 3TNA72 (455 LGT and 755/56 CUT) Only Cap Screw M8 x 55 Cap Screw M10 x 20 Clip Flywheel Guard Cap Screw (2) M8 x 12 3TN66 (655 CUT) Only 1-52 M82287A 4/7/95 Crankshaft, Main Bearings and Flywheel 2. Remove mounting cap screws and flywheel. IMPORTANT: Never reuse flywheel mounting cap screws. Always install new. • Inspect pilot bushing, if equipped, for wear or damage. Replace if necessary using a driver set. Install bushing flush with flywheel surface. • Measure flywheel flatness. Place a straight edge across flywheel surface opposite of ring gear. Measure clearance between straight edge and flywheel surface with a feeler gauge. If clearance exceeds 0.02 mm (0.0008 in.), replace flywheel. 1 Units Equipped with Stub Shaft Only M35336 FLYWHEEL HOUSING - 3TNA72 (15 EX, 3009 OEM) 1. Remove flywheel. (See procedure in this group.) 2. Remove starter. M35337 Housing-to-Block Cap Screw (6) M10 x 25 49 N•m (36 lb-ft) Flywheel Housing John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Plug Housing-to-Extension Cap Screw (3) M10 x 28 49 N•m (36 lb-ft) 4/7/95 M82288A 1-53 Crankshaft, Main Bearings and Flywheel FLYWHEEL PLATE - 3TN66 AND 3TNA72 (All Except 15 EX and 3009 OEM) Cap Washer (5) Screw (5) M8 x 8 Mounting Cap Screw (8) Flywheel M10 x 20 Plate 49 N•m (36 lb-ft) 1. Remove flywheel. (See procedure in this group.) 2. Remove starter. 1 Mounting Cap Screw (7) M10 x 20 49 N•m (36 lb-ft) Foam Seal Foam Seal Cover Early 430 LGT Only Flywheel Plate 3TNA72 (430 LGT, F925/35 FM) M82357A 3TN66 (655 CUT) Stud Mounting Cap Screw (6) M10 x 20 49 N•m (36 lb-ft) Flywheel Plate Mounting Cap Screw (7) M10 x 20 49 N•m (36 lb-ft) M82289A Foam Seal Foam Seal 3TNA72 (455 LGT, 755/56 CUT) 3TN66 (375 SSL, 330/332 LGT, F915 FM) Flywheel Plate M82290A Mounting Cap Screw (11) M10 x 20 49 N•m (36 lb-ft) 3TNA72 (670 CUT) 1-54 M82358A M82359A 4/7/95 Camshaft and Timing Gear Train SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the European Microfiche Tool Catalog (MTC). D15001NU Magnetic Follower Holder Kit Hold cam followers when removing and installing camshaft. OTHER MATERIALS 1 Number LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. TY15130/ NA/ #395 Name Use John Deere Form-In-Place Gasket Seals camshaft plug, timing gear cover and housing to engine block. TY9370/ TY9477/ #242 Thread Lock and Sealer (Medium Strength) Apply to threads of crankshaft pulley cap screw. TY9369/ NA/ #222 Thread Lock and Sealer (Low Strength) Apply to threads of studs in timing gear housing. SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Head Gasket Kit • Cylinder Block Gasket Kit ® LOCTITE is a registered trademark of the Loctite Corp. 4/7/95 1-55 Camshaft and Timing Gear Train CAMSHAFT Removal Mounting Cap Screws M8 X 16 1. Remove rocker arm assembly and push rods. (See Cylinder Head, Valves and Manifolds in this section.) 2. Remove timing gear cover. (See procedure in this group.) 1 3. Check camshaft end play. (See Checks, Tests and Adjustments in this section.) 4. Check backlash of timing gears. (See Checks, Tests and Adjustments in this section.) NOTE: If a magnetic follower holder kit is not available, turn engine until oil pan is upward, to hold cam followers away from camshaft. 5. Hold cam followers away from camshaft using a magnetic follower holder kit such as D15001NU. NOTE: Due to the odd number of teeth on the idler gear, timing marks will only align periodically. 6. Rotate crankshaft and align timing marks. IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while removing camshaft. Machined surfaces can be damaged. Timing Marks Camshaft M35501 Early 3TNA72 Installation • Apply clean engine oil on all parts during installation. IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while installing camshaft. Machined surfaces can be damaged. 1. Rotate crankshaft to align timing marks. 7. Remove two cap screws and camshaft. 2. Install camshaft. 8. Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) 3. Install and tighten mounting cap screws to 11 N•m (96 lb-in.). Mounting Cap Screws M8 X 16 4. Install timing gear cover. (See procedure in this group.) 5. Install push rods and rocker arm assembly. (See Cylinder Head, Valves and Manifolds in this section.) Timing Marks Camshaft 3TN66, Later 3TNA72 1-56 M37832 4/7/95 Camshaft and Timing Gear Train Inspection/Replacement Heat gear to approximately 150oC (300oF). 1. Check camshaft side gap using a feeler gauge. IMPORTANT: Be sure thrust plate is not between camshaft gear and camshaft shoulder while installing gear. Camshaft Gear Thrust Plate Install thrust plate if removed. Install gear with timing mark “C” side toward press table. Align slot in gear with key in shaft. Press camshaft into gear until gear is tight against camshaft shoulder. 1 Thrust plate must spin freely on camshaft. Key Camshaft Gear Side Gap M82067A Camshaft Side Gap: Standard . . . . . . . . . . . . . . . . . 0.05 - 0.15 mm . . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0060 in.) Thrust Plate M82068A Wear Limit. . . . . . . . . . . . 0.40 mm (0.016 in.) If side gap is at wear limit, remove gear and replace thrust plate. 2. Inspect gear for chipped or broken teeth. Replace if necessary. To remove/replace gear: 3. Inspect camshaft for bend using v-blocks and a dial indicator. Turn camshaft slowly and read variation on indicator. If variation is greater than 0.02 mm (0.001 in.), replace camshaft. Dial Indicator Remove gear from camshaft using a knife-edge puller and a press. CAUTION DO NOT heat oil over 182° C (360° F). Oil fumes or oil can ignite above 193° C (380° F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. Camshaft Central Bearing Areas V-Block M82291A 4. Measure camshaft lobe height. 4/7/95 1-57 Camshaft and Timing Gear Train Intermediate Standard . . . . . . . . . . . . . . . 35.91 - 35.94 mm . . . . . . . . . . . . . . . . . . . . . (1.4138 - 1.4150 in.) Wear Limit. . . . . . . . . . 35.85 mm (1.4114 in.) Lobe Height Camshaft Journal O.D. - 3TNA72 (3009): M82070A 1 Lobe Height - 3TN66: Standard . . . . . . . . . . . . . . . 29.97 - 30.03 mm . . . . . . . . . . . . . . . . . . . . . . . (1.180 - 1.182 in.) Wear Limit. . . . . . . . . . . 29.75 mm (1.171 in.) Lobe Height - 3TNA72 (3009): Standard . . . . . . . . . . . . . . . 33.95 - 34.05 mm . . . . . . . . . . . . . . . . . . . . . . . (1.337 - 1.341 in.) Wear Limit. . . . . . . . . . . 33.75 mm (1.329 in.) If lobe height is less than wear limit, replace camshaft. 5. Measure camshaft end and intermediate journal diameters. Gear Housing and Flywheel Ends Standard . . . . . . . . . . . . . . . 39.94 - 39.96 mm . . . . . . . . . . . . . . . . . . . . . (1.5724 - 1.5732 in.) Wear Limit. . . . . . . . . . 39.85 mm (1.5689 in.) Intermediate Standard . . . . . . . . . . . . . . . 39.91 - 39.94 mm . . . . . . . . . . . . . . . . . . . . . (1.5713 - 1.5724 in.) Wear Limit. . . . . . . . . . 39.85 mm (1.5689 in.) If journal diameters are less than wear limit, replace camshaft. 6. Measure camshaft bushing diameter at gear housing end. Camshaft Bushing Flywheel End Journal Oil Holes M82072 Camshaft Bushing I.D. - 3TN66: Intermediate Journals Gear Housing End Journal Standard . . . . . . . . . . . . . . 36.00 - 36.065 mm . . . . . . . . . . . . . . . . . . . . . . . (1.417 - 1.420 in.) M82292A Wear Limit. . . . . . . . . . . 36.10 mm (1.421 in.) Camshaft Journal O.D. - 3TN66: Gear Housing and Flywheel Ends Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.) Camshaft Bushing I.D. - 3TNA72 (3009): Standard . . . . . . . . . . . . . . . 35.94 - 35.96 mm . . . . . . . . . . . . . . . . . . . . . (1.4150 - 1.4157 in.) Standard . . . . . . . . . . . . . . 40.00 - 40.065 mm . . . . . . . . . . . . . . . . . . . . . . . (1.575 - 1.577 in.) Wear Limit. . . . . . . . . . 35.85 mm (1.4114 in.) Wear Limit. . . . . . . . . . . 40.10 mm (1.579 in.) Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.) 1-58 4/7/95 Camshaft and Timing Gear Train If bushing diameter exceeds wear limit, replace bushing. If bushing clearance (bushing I.D. minus camshaft journal O.D.) exceeds specification, replace bushing, camshaft or both. Camshaft Bore I.D. - 3TN66: Standard . . . . . . . . . . . . . . 36.00 - 36.025 mm . . . . . . . . . . . . . . . . . . . . . . . (1.417 - 1.418 in.) Wear Limit. . . . . . . . . . . 36.10 mm (1.421 in.) Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.) To replace bushing: Remove bushing using a chisel. Be careful not to push bushing inside of engine. Align oil holes in new bushing and cylinder block. Install bushing using a driver set. NOTE: Flywheel housing/plate must be removed to measure camshaft intermediate and flywheel end bearing diameters. Camshaft Bore I.D. - 3TNA72 (3009): Standard . . . . . . . . . . . . . . 40.00 - 40.025 mm . . . . . . . . . . . . . . . . . . . . . . . (1.575 - 1.576 in.) Wear Limit. . . . . . . . . . . 40.10 mm (1.579 in.) Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.) 7. Measure intermediate and flywheel end camshaft bore diameters using the following procedures: If bore diameter exceeds wear limit, replace cylinder block. • Remove flywheel housing/plate. (See Crankshaft, Main Bearings and Flywheel in this section.) If bore clearance (bore I.D. minus camshaft journal O.D.) exceeds specification, replace camshaft, cylinder block or both. • Remove plug using a long wooden dowel. Insert wooden dowel through gear housing side. • Apply John Deere Form-In Place Gasket, or an equivalent, on outer edge of plug. Install plug until it bottoms in bore. • Install flywheel housing/plate. CAM FOLLOWERS Removal/Installation 1. Remove cylinder head. (See Cylinder Head, Valves and Manifold in this section.) Plug M35287 • Measure intermediate and flywheel end camshaft bore diameters. IMPORTANT: Cam followers must be installed in the same bores from which they were removed. 2. Put a mark on each cam follower and cylinder block bore to aid in installation. 3. Remove cam followers. Intermediate Bores 4. Inspect all parts for wear or damage. (See Inspection procedures.) 5. Apply clean engine oil on all parts during installation. Flywheel End Bore Installation is done in the reverse order of removal. M82073 4/7/95 1-59 1 Camshaft and Timing Gear Train Inspection Cam Follower Bore I.D. - 3TN66: • Inspect cam follower contact surface for abnormal wear. Replace if necessary. Standard . . . . . . . . . . . . . . 18.00 - 18.018 mm . . . . . . . . . . . . . . . . . . . . . (0.7087 - 0.7094 in.) Wear Limit. . . . . . . . . . . 18.05 mm (0.711 in.) Clearance . . . . . . . . . . . . . . . 0.032 - 0.068 mm . . . . . . . . . . . . . . . . . . . . . (0.0013 - 0.0027 in.) Cam Follower Bore I.D. - 3TNA72 (3009): 1 Standard . . . . . . . . . . . . . . 21.00 - 21.021 mm . . . . . . . . . . . . . . . . . . . . . (0.8268 - 0.8276 in.) Wear Limit. . . . . . . . . . . 21.05 mm (0.829 in.) Abnormal Contact Normal Contact M82293A Clearance . . . . . . . . . . . . . . . 0.040 - 0.094 mm . . . . . . . . . . . . . . . . . . . . . (0.0016 - 0.0037 in.) If cam follower bore diameter exceeds wear limit, replace cylinder block. • Measure cam follower diameter. If bore clearance (bore I.D. minus follower stem O.D.) exceeds specification, replace cam follower, cylinder block or both. TIMING GEAR COVER - 3TN66 Removal/Installation M35268 1. Remove alternator and belt. 2. Remove fan, spacer, if equipped, and pulley. Cam Follower O.D. - 3TN66: 3. Remove crankshaft pulley cap screw and washer. Standard . . . . . . . . . . . . . 17.950 - 17.968 mm . . . . . . . . . . . . . . . . . . . . . (0.7067 - 0.7074 in.) 4. Remove crankshaft pulley using a two-jaw puller kit. Wear Limit. . . . . . . . . . . 17.93 mm (0.706 in.) 5. Remove tachometer, if equipped. Cam Follower O.D. - 3TNA72 (3009): Standard . . . . . . . . . . . . . 20.927 - 20.960 mm . . . . . . . . . . . . . . . . . . . . . (0.8239 - 0.8252 in.) Pulley Spacer (655 CUT Only) Wear Limit. . . . . . . . . . . 20.93 mm (0.824 in.) If diameter is less than wear limit, replace cam follower. • Measure cam follower bore diameter in cylinder block. Cap Screw (4) 11 N•m (96 lb-in.) M82294A 1-60 4/7/95 Camshaft and Timing Gear Train NOTE: It is not necessary to remove end cover and o-ring to remove timing gear cover. 6. Remove 18 mounting cap screws and timing gear cover. Installation is done in the reverse order of removal. • Tighten all mounting cap screws to 9 N•m (78 lb-in.) • Adjust fan/alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) John Deere Form-In-Place Gasket (RTV rubber silicone sealant) 1 Mounting Cap Screw (4) M6 x 50 Mounting Cap Screw (5) M6 x 30 Timing Gear Cover Tachometer End Cover O-Ring Cap 655 CUT Only Cap Screw (2) M6 x 18 O-Ring Crankshaft Pulley Washer Mounting Cap Screw (6) M6 x 65 Mounting Cap Screw (3) M6 x 40 Cap Screw Apply thread lock and sealer (medium strength) to threads. M82295A 115 N•m (85 lb-ft) 4/7/95 1-61 Camshaft and Timing Gear Train TIMING GEAR COVER - EARLY 3TNA72 (430 LGT) NOTE: It is not necessary to remove auxiliary drive cover and gasket, if equipped, or end cover and o-ring to remove timing gear cover. Removal/Installation 6. Remove 14 mounting cap screws and timing gear cover. 1. Remove alternator and belt. 2. Remove crankshaft pulley cap screw and washer. 1 3. Remove crankshaft pulley using a two-jaw puller kit. 4. Remove cotter pin and washer to disconnect fuel shutoff solenoid linkage. Installation is done in the reverse order of removal. • Tighten all mounting cap screws to 9 N•m (78 lb-in.). • Align pin in crankshaft pulley with hole in crankshaft gear. Install crankshaft pulley. • Adjust alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) Cotter Pin and Washer Hole M35272 5. Remove two nuts and one cap screw to remove bracket and fuel shutoff solenoid. Pin M35295 Nut (2) 9 N•m (78 lb-in.) Cap Screw 9 N•m (78 lb-in.) M35294 1-62 4/7/95 Camshaft and Timing Gear Train John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Timing Gear Cover End Cover Cap Screw (2) M6 x 18 1 Cap Screw (4) M8 x 35 O-Ring Gasket Mounting Cap Screw (9) M6 x 25 Mounting Cap Screw (5) M6 x 55 Early 3TNA72 (430 LGT) Crankshaft Pulley Auxiliary Drive Cover Washer Cap Screw Apply thread lock and sealer (medium strength) to threads. M82296A 88 N•m (65 lb-ft) TIMING GEAR COVER - LATER 3TNA72 Removal/Installation 3. Remove crankshaft pulley cap screw and washer. 1. Remove alternator and belt. 5. Remove tachometer, if equipped. NOTE: 430 LGT (Later) and F925/35 FM application is not equipped with a fan. Alternator belt pulley does not have to be removed to access timing gear cover. 6. 670 CUT: Remove hydraulic pump and steering pump, if equipped. (See procedures in Machine Technical Manual.) 2. Remove fan, spacer/plate, if equipped, and pulley. Pulley Spacer (3009 OEM, 670 CUT Only) 4. Remove crankshaft pulley using a two-jaw puller kit. NOTE: It is not necessary to remove auxiliary drive cover and gasket, if equipped, or end cover and o-ring to remove timing gear cover. 7. Remove mounting cap screws and timing gear cover. Installation is done in the reverse order of removal. • Tighten all mounting cap screws to 9 N•m (78 lb-in.) • Adjust fan/alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) Plate 755/56 CUT Only 4/7/95 Cap Screw (4) 11 N•m (96 lb-in.) M82297A 1-63 Camshaft and Timing Gear Train John Deere Form-In-Place Gasket (RTV rubber silicone sealant) **Mounting Cap Screw (4) M6 x 60 (755/56 CUT, 3009 OEM, 455 LGT, 670 CUT, 15 EX) M6 x 55 (430 LGT, F935 FM) Timing Gear Cover Tachometer ** 755/56 CUT, 3009 OEM, 670 CUT Only 1 Cap O-Ring O-Ring ** **Mounting Cap Screw (6) M6 x 30 Gasket Auxiliary Drive Cover Cap Screw (4) M8 x 40 End Cover Cap Screw (2) M6 x 16 (755/56 CUT, 3009 OEM, 670 CUT, 15 EX) M6 x 18 (430 LGT, F935 FM, 455 LGT) *** *Mounting Cap Screw (6) M6 x 80 Crankshaft Pulley Washer Cap Screw Apply thread lock and sealer (medium strength) to threads. 115 N•m (85 lb-ft) Alternator Bracket Mounting Cap Screw 15 EX (5) 670 CUT (6) M6 x 30 M10 x 60 M6 x 50 Cap Screw and Nut (3) M8 x 65 ** ** ** ** ** 15 EX Only * Mounting Cap Screw (8) M6 x 30 670 CUT, 15 EX 455 LGT Later 3TNA72 1-64 M82298A 4/7/95 Camshaft and Timing Gear Train IDLER GEAR - EARLY 3TNA72 (430 LGT) Removal/Installation 1. Remove timing gear cover. (See procedure in this group.) 2. Check backlash of timing gears. (See Checks, Tests and Adjustments in this section.) NOTE: Due to the odd number of teeth on the idler gear, timing marks will only align periodically. When all timing marks on gears are aligned, the piston closest to the water pump is at TDC on compression stroke. Number one cylinder is closest to the flywheel. Idler Gear Shaft O.D.: Standard . . . . . . . . . . . . . 19.959 - 19.980 mm . . . . . . . . . . . . . . . . . . . . . . . (0.786 - 0.787 in.) Wear Limit. . . . . . . . . . . 19.93 mm (0.785 in.) If shaft diameter is less than wear limit, replace idler gear shaft. To replace shaft: • Remove set screw in end of shaft. Install a gear cover mounting cap screw with washer into threaded hole. Remove idler shaft using a slide hammer and puller. • Install shaft with flange toward cylinder block. Install shaft tight against block using a softfaced hammer. Install set screw. 3. Rotate crankshaft and align timing marks. 4. Remove idler gear. 5. Inspect gear and shaft for wear or damage. (See Inspection/Replacement procedures.) Installation is done in the reverse order of removal. M35496 • Measure idler gear bushing diameter. M35491 Idler Gear Idler Gear Shaft Bushing Inspection/Replacement • Inspect gear for chipped or broken teeth. Replace if necessary. • Measure idler gear shaft diameter. M35492 Idler Gear Bushing I.D.: Standard . . . . . . . . . . . . . . 20.00 - 20.021 mm . . . . . . . . . . . . . . . . . . . . . . . (0.787 - 0.788 in.) Wear Limit. . . . . . . . . . . 20.08 mm (0.791 in.) Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.) M35494 4/7/95 If bushing diameter exceeds wear limit, replace bushing. 1-65 1 Camshaft and Timing Gear Train To replace bushing: Replace bushing using a driver set. Align oil holes in bushing and idler gear. Install bushing flush with surface of idler gear. Cap Screw (3) M6 x 12 If bushing clearance (bushing I.D. minus shaft O.D.) exceeds specification, replace bushing, shaft or both. IDLER GEAR - 3TN66 AND LATER 1 3TNA72 Removal/Installation 1. Remove timing gear cover. (See procedure in this group.) M37834 Idler Gear Shaft O.D.: 2. Check backlash of timing gears. (See Checks, Tests and Adjustments in this section.) Standard . . . . . . . . . . . . . 19.959 - 19.980 mm . . . . . . . . . . . . . . . . . . . . . . . (0.786 - 0.787 in.) NOTE: Due to the odd number of teeth on the idler gear, timing marks will only align periodically. When all timing marks on gears are aligned, the piston closest to the water pump is at TDC on compression stroke. Number one cylinder is closest to the flywheel. Wear Limit. . . . . . . . . . . 19.93 mm (0.785 in.) If shaft diameter is less than wear limit, remove three cap screws and replace idler gear shaft. • Measure idler gear bushing diameter. 3. Rotate crankshaft and align timing marks. 4. Remove snap ring, washer and gear. 5. Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) Installation is done in the reverse order of removal. M35492 Washer Snap Ring Idler Gear Bushing I.D.: Standard . . . . . . . . . . . . . . 20.00 - 20.021 mm . . . . . . . . . . . . . . . . . . . . . . . (0.787 - 0.788 in.) Wear Limit. . . . . . . . . . . 20.08 mm (0.791 in.) Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.) M37516 If bushing diameter exceeds wear limit, replace bushing. To replace bushing: Inspection/Replacement • Inspect gear for chipped or broken teeth. Replace if necessary. • Measure idler gear shaft diameter. 1-66 Replace bushing using a driver set. Align oil holes in bushing and idler gear. Install bushing flush with surface of idler gear. If bushing clearance (bushing I.D. minus shaft O.D.) exceeds specification, replace bushing, shaft or both. 4/7/95 Camshaft and Timing Gear Train TIMING GEAR HOUSING - 3TN66 Removal/Installation 1. Remove idler gear. (See procedure in this group.) 2. Remove injection pump camshaft. (See Fuel System in this section.) 3. Remove engine camshaft. (See procedure in this group.) 4. Remove oil pump. (See Lubrication System in this section.) 5. Remove water pump. (See Cooling System in this section.) 6. Remove mounting cap screws and housing. 7. Replace o-rings. Installation is done in the reverse order of removal. 1 John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Stud (4) Apply thread lock and sealer (low strength) to threads. Gasket Spring Pin (2) Timing Gear Housing Mounting Cap Screw All Except 655 CUT (4) 655 CUT (5) M6 x 16 Cast Iron - 11 N•m (96 lb-in.) Aluminum - 9 N•m (78 lb-in.) Stud (4) Apply thread lock and sealer (low strength) to threads. Alignment Dowel (2) Cover Cap Screw (2) M6 x 14 O-Rings Replace. M82299A 4/7/95 1-67 Camshaft and Timing Gear Train TIMING GEAR HOUSING EARLY 3TNA72 • Tighten all mounting cap screws to: Cast Iron . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Aluminum. . . . . . . . . . . . . . . 9 N•m (73 lb-in.) Removal/Installation 1. Remove fuel control and governor linkage. (See Fuel System in this section.) O-Rings Replace. 2. Remove idler gear. (See procedure in this group.) 1 3. Remove injection pump camshaft. (See Fuel System in this section.) 4. Remove engine camshaft. (See procedure in this group.) 5. Remove water pump. (See Cooling System in this section.) M35508 6. Remove oil pump. (See Lubrication System in this section). 7. Remove bracket. 8. Remove mounting cap screws and housing. Special Screw 9. Replace o-rings Installation is done in reverse order. • Install special screw before installing gear housing. Bracket Spring Pin (2) M35506 Stud (4) Apply thread lock and sealer (low strength) to threads. John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Timing Gear Housing Cap Screw (2) M6 x 14 Alignment Dowel Cap Screw M8 x 12 Stud Apply thread lock and sealer (low strength) to threads. Mounting Cap Screw (6) M6 x 16 Cap Screw (2) M6 x 14 Mounting Cap Screw (2) M6 x 35 Cover Gasket Special Screw Mounting Cap Screw (4) M6 x 30 M82300A 1-68 4/7/95 Camshaft and Timing Gear Train TIMING GEAR HOUSING - LATER 3TNA72 4. Remove engine camshaft. (See procedure in this group.) Removal/Installation 5. Remove oil pump. (See Lubrication System in this section.) 1. Remove idler gear. (See procedure in this group.) 2. 670 CUT and 3009 OEM: Remove fuel supply pump. (See procedure in ACCESSORIES SERIES 220 POWER UNIT ENGINES Section.) 3. Remove fuel injection pump camshaft. (See Fuel System in this section.) 4/7/95 6. Remove water pump. (See Cooling System in this section.) 7. Remove mounting cap screws and housing. 8. Replace o-rings. 1 Installation is done in reverse order of removal. 1-69 Camshaft and Timing Gear Train John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Cover All Except 455 LGT, 15 EX, 670 CUT, 3009 OEM Cap Screw (4) M8 x 12 Gasket 1 Spring Pin (2) Stud (4) Apply thread lock and sealer (low strength) to threads. Stud (4) Apply thread lock and sealer (low strength) to threads. Timing Gear Housing Mounting Cap Screw (7) M6 x 16 Cast Iron - 11 N•m (96 lb-in.) Aluminum - 9 N•m (78 lb-in.) Gasket Cover Alignment Dowel (2) Cap Screw (2) M6 x 14 Crankcase Extension-toHousing Cap Screw (4) (670 CUT, 15 EX, 3009 OEM Only) M6 x 45 (15 EX, 3009 OEM) M8 x 45 (670 CUT) 22 N•m (195 lb-in.) O-Ring (2) Replace. Fuel Supply Pump Cap Screw (2) M6 x 20 670 CUT, 3009 OEM Cap Screw M8 x 12 (15 EX Only) 455 LGT 1-70 Cover (15 EX Only) 15 EX, 670 CUT M82310A 4/7/95 Lubrication OTHER MATERIALS Number Name Use John Deere Form-In-Place Gasket Seals oil pan/plate to crankcase extension housing and/or block. LOCTITE® PRODUCTS U.S./ Canadian/ Loctite No. TY15130/ NA/ #395 1 ®LOCTITE is a registered trademark of the Loctite Corp. 4/7/95 1-71 Lubrication OIL PAN AND STRAINER - 3TN66 Removal/Installation • Approximate crankcase oil capacity is 2.5 L (2.6 qt). NOTE: On 655 CUT; Engine serial number ( - 012269), uses an aluminum oil pan. Engine serial number (012270 - ) uses a sheet metal oil pan. Size and quantity on mounting cap screws are different. • Fill engine with proper engine oil. (See SPECIFICATIONS AND GENERAL INFORMATION section.) 1 Oil Strainer John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Cap Screw (2) M6 x 12 O-Ring 11 N•m (96 lb-in.) Replace. ªªªªªªªª ªªªªªªªªª Cap Screw (10) M6 x 10 11 N•m (96 lb-in.) Oil Pan-to-Timing Gear Housing Cap Screw (4) M6 x 12 9 N•m (78 lb-in.) Oil Pan-to-Seal Case Cap Screw (2) M6 x 12 9 N•m (78 lb-in.) Oil Pan Drain Plug Washer Replace. M82302A 3TN66 (375 SSL, 330/332 LGT, F915 FM) 1-72 4/7/95 Lubrication John Deere Form-In-Place Gasket (RTV rubber silicone sealant) O-Ring Replace. Tube (Aluminum Pan) Oil Pan-to-Seal Case Cap Screw (2) M6 x30 (Aluminum Pan) M6 x 25 (Sheet Metal Pan) 9 N•m (78 lb-in.) Oil Pan 1 Cap Screw (2) M6 x 12 11 N•m (96 lb-in.) Oil Pan-to-Timing Gear Housing Cap Screw (5) M6 x 35 (Aluminum Pan) (6) M6 x 12 (Sheet Metal Pan) 9 N•m (78 lb-in.) Oil Strainer O-Ring Replace. Drain Plug Washer Replace. Plug (Aluminum Pan) Cap Screw (9) M6 x 20 (Aluminum Pan) (16) M6 x 10 (Sheet Metal Pan) 11 N•m (96 lb-in.) M82303A 3TN66 (655 CUT) OIL PAN AND STRAINER - 3TNA72 O-Ring Replace. Removal/Installation • Approximate crankcase oil capacity is: 15 EX . . . . . . . . . . . . . . . . . . . . . . . . 1.9L (2 qt) Oil Strainer Cap Screw (2) 3009D F007 OEM M6 x 10 11 N•m (96 lb-in.) 430 LGT, 455 LGT . . . . . . . . . . . . . . 2.8L (3 qt) 670 CUT . . . . . . . . . . . . . . . . . . . . 2.6L (2.7 qt) 755/56 CUT . . . . . . . . . . . . . . . . . 3.2L (3.4 qt) F925/35 FM . . . . . . . . . . . . . . . . . 3.5L (3.6 qt) 3009 OEM John Deere Form-In-Place Gasket (RTV rubber silicone sealant) F001 and 005 . . . . . . . . . . . . . . 2.9L (3.1 qt) F007 . . . . . . . . . . . . . . . . . . . . . 3.8L (3.9 qt) • Fill engine with proper engine oil. (See SPECIFICATIONS AND GENERAL INFORMATION section.) Cap Screw (20) M6 x 45 11 N•m (96 lb-in.) Cap Screw (3) M6 x 12 11 N•m (96 lb-in.) O-Ring Replace. Oil Pan Drain Plug 4/7/95 15 EX, 3009 OEM M82304A 1-73 Lubrication John Deere Form-In-Place Gasket (RTV rubber silicone sealant) O-Ring Replace. O-Ring Replace. Cap Screw (2) M6 x 10 11 N•m (96 lb-in.) John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Oil Strainer Cap Screw (2) M6 x 10 11 N•m (96 lb-in.) Oil Pan-to-Seal Case Cap Screw (2) M6 x 12 9 N•m (78 lb-in.) 1 Oil Strainer Drain Plug Washer Replace. Oil Pan/Plate Washer Drain Plug Cap Screw (8) M8 x 12 11 N•m (96 lb-in.) 670 CUT Oil Pan-toTiming Gear Housing Cap Screw (4) M6 x 12 9 N•m (78 lb-in.) Cap Screw (16) M6 x 8 11 N•m (96 lb-in.) M82305A 455 LGT M82306A O-Ring Replace. John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Cap Screw (2) M6 x 10 11 N•m (96 lb-in.) Oil Strainer Oil Pan-to-Seal Case Cap Screw (2) M6 x 22 9 N•m (78 lb-in.) Oil Pan Washer Replace. Drain Plug Cap Screw (15) M6 x 22 11 N•m (96 lb-in.) Oil Pan-to-Timing Gear Housing Cap Screw (4) M6 x 22 9 N•m (78 lb-in.) Cap Screw M6 x 45 11 N•m (96 lb-in.) Early 430 LGT M82307A 430 LGT, F925/35 FM, 755/56 CUT 1-74 4/7/95 Lubrication OIL PUMP - EARLY 3TNA72 (430 LGT) Removal 1. Remove idler gear, (See Camshaft and Timing Gear Train in this section.) 2. Loosen oil pump gear lock nut. 3. Remove fuel injection pump camshaft. (See Fuel System in this section.) 1 4. Remove oil filter and oil dipstick tube. 5. Remove two cap screws, bracket and four washers. 6. Remove two cap screws, cover and gasket. Cover and Gasket M35542 10.Remove governor shaft, washer and spacer. Bracket Spacer Washers (4) Governor Shaft and Washer Replace washer. M35543 M35539 11.Remove governor linkage assembly. 7. Remove sealing wire. 8. Loosen jam nut. Turn slow idle adjustment screw counterclockwise several turns. Sealing Wire Jam Nut M35544 Slow Idle Adjustment Screw M35540 9. Disconnect spring from governor linkage. 12.Remove oil pump gear lock nut. NOTE: Oil pump gear is press fit on rotor shaft. 13.Remove oil pump gear using a three-jaw puller. 4/7/95 1-75 Lubrication 14.Remove four cap screws, nut cover and gasket. 15.Remove oil pump assembly. NOTE: See OIL PRESSURE REGULATING VALVE if service is necessary. Rotor Shaft Assembly 16.Inspect all parts for wear or damage. (See Inspection procedures.) Identification Marks 1 Outer Rotor Spring Pin (2) M35557 Gasket Oil Pressure Regulating Cover Valve Mounting Nut 3. Align splines on rotor shaft with splines in thrust washer and governor weights. Install thrust washer, governor weights and sleeve on rotor shaft. Mounting Cap Screw (4) Oil Pump Gear Lock Nut Rotor Shaft Inner Rotor Outer Rotor Governor Weights M82308A Rotor Shaft Sleeve Installation Thrust Washer 1. Apply clean engine oil on all parts during installation. IMPORTANT: Oil pump assembly must be installed with identification marks on rotors facing toward gear housing. 2. Install rotor shaft assembly and outer rotor in gear housing with identification marks facing gear housing. M35558 4. Install oil pump gasket and cover. 5. Install four cap screws and nut. Tighten to 9 N•m (78 lb-in.). 6. Install oil pump gear and lock nut. Leave nut loose. 7. Install spacer and new washer on governor shaft. 1-76 4/7/95 Lubrication 8. Install governor linkage assembly. Cover and Gasket Bracket Washers (4) 1 M35539 M35544 9. Insert governor shaft through linkage assembly. Tighten shaft to 49 N•m (36 lb-ft). 13.Install oil dipstick tube and oil filter. 14.Install fuel injection pump camshaft. (See Fuel System in this section.) 15.Tighten oil pump gear lock nut to 27 N•m (20 lbft). Governor Linkage Washer Spacer 16.Install idler gear. (See Camshaft and Timing Gear Train in this section.) Inspection • Measure outer rotor bore depth and outer rotor thickness. Governor Shaft M35562 10.Connect spring to internal lever, then to governor assembly. M35549 M35542 11.Install gasket, cover and two cap screws. 12.Install four washers (two each hole location), bracket and two cap screws. Tighten all four cap screws to 9 N•m (78 lb-in.). M35550 4/7/95 1-77 Lubrication Outer Rotor-to-Bore Clearance: Standard . . . . . . . . . . . . . . . . . 0.08 - 0.15 mm . . . . . . . . . . . . . . . . . . . . . . . (0.003 - 0.006 in.) Wear Limit. . . . . . . . . . . . 0.25 mm (0.010 in.) If clearance (bore depth minus rotor thickness) is more than wear limit, replace timing gear housing. 1 • Measure outer rotor bore and outer rotor diameters. M35553 M35551 M35554 Inner Rotor-to-Outer Rotor Clearance: Standard . . . . . . . . . . . . . . . . . 0.10 - 0.15 mm . . . . . . . . . . . . . . . . . . . . . . . (0.004 - 0.006 in.) Wear Limit. . . . . . . . . . . . 0.25 mm (0.010 in.) If clearance (outer rotor I.D. minus inner rotor O.D.) is more than wear limit, replace oil pump assembly. M35552 • Measure rotor shaft diameter. Outer Rotor-to-Bore Diameter Clearance: Standard . . . . . . . . . . . . . . . . . 0.10 - 0.15 mm . . . . . . . . . . . . . . . . . . . . . . . (0.004 - 0.006 in.) Wear Limit. . . . . . . . . . . . 0.25 mm (0.010 in.) If clearance (bore I.D. minus rotor O.D.) is more than wear limit, replace timing gear housing. • Measure inner rotor O.D. and outer rotor I.D. M35555 1-78 4/7/95 Lubrication Rotor Shaft Diameter: Standard . . . . . . . . . . . . . 12.670 - 12.685 mm . . . . . . . . . . . . . . . . . . . . . (0.4988 - 0.4990 in.) Wear Limit. . . . . . . . . 12.650 mm (0.4980 in.) If shaft diameter is less than wear limit, replace oil pump assembly. OIL PUMP - 3TN66 and LATER 3TNA72 Removal/Installation 1. Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) 2. Check oil pump gear backlash. Replace entire oil pump assembly if backlash is more than 0.25 mm (0.010 in.). • Measure rotor shaft bore diameter. 3. Remove four mounting cap screws, oil pump and gasket. 4. Inspect all parts for wear or damage. (See Disassembly/Assembly procedures). M35556 Rotor Shaft Bore Diameter: Standard . . . . . . . . . . . . . 12.700 - 12.718 mm . . . . . . . . . . . . . . . . . . . . . (0.5000 - 0.5007 in.) Wear Limit. . . . . . . . . . . 12.80 mm (0.504 in.) Clearance Standard . . . . . . . . . . . . 0.015 - 0.048 mm . . . . . . . . . . . . . . . . . . . (0.006 - 0.0019 in.) Wear Limit. . . . . . . 0.100 mm (0.0039 in.) If bore diameter is more than wear limit, replace timing gear housing. If rotor shaft clearance (bore I.D. minus shaft O.D.) is more than wear limit, replace timing gear housing and oil pump assembly. Oil Pump Oil Pump Gasket Mounting Cap Screw M6 x 20 25 N•m (18 lb-ft) M82309A Disassembly/Assembly • Gear is press fit on rotor shaft. Remove gear using a knife edge puller and a press. • Inspect parts for wear or damage. (See Inspection procedures.) • Coat all parts with clean engine oil. 4/7/95 1-79 1 Lubrication • Install outer rotor with identification mark facing toward rotor shaft assembly. Outer Rotor Alignment Pin (2) Backing Plate Feeler Gauge Pump Body 1 Body M37776 Gear Rotor Shaft Outer Rotor-to-Pump Body Clearance: Standard . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm Inner Rotor Outer Rotor Identification Mark . . . . . . . . . . . . . . . . . . . . . (0.0011 - 0.0035 in.) M82301A Wear Limit. . . . . . . . . . . 0.13 mm (0.0051 in.) • Check inner-to-outer rotor clearance. If clearance is more than 0.15 mm (0.0059 in.), replace rotor assembly. Inspection • Check rotor shaft outer diameter and the shaft hole diameter in backing plate. If clearance is more than wear limit, replace entire assembly. Feeler Gauge Rotor Shaft and Plate Clearance: Standard . . . . . . . . . . . . . . . 0.015 - 0.048 mm Inner Rotor . . . . . . . . . . . . . . . . . . . . . (0.0006 - 0.0035 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0078 in.) • Check rotor recess. If rotors are below face of pump housing more than 0.25 mm (0.010 in.), replace rotor assembly. Feeler Gauge Straight Edge Outer Rotor M37777 OIL PRESSURE REGULATING VALVE - 3TN66 Removal/Installation 1. Remove oil filter and o-ring. 2. Remove retaining nut and valve assembly. Housing Outer Rotor M37775 • Check outer rotor-to-pump body clearance. If clearance is more than wear limit, replace entire assembly. 1-80 3. If adjusting pressure only, remove cap and add shims. Each 1 mm (0.039 in.) of shim thickness increases oil pressure 13.8 kPa (2 psi). NOTE: Valve components are not serviced individually. Replace complete regulating valve if any components are defective. 4/7/95 Lubrication 4. Inspect all parts for wear or damage. Replace complete valve if necessary. 3. Inspect all parts for wear or damage. Replace as necessary. 5. Check spring free and compressed lengths. Spring Specifications: Valve Spring Free Length . . . . . . . . . . . . . 21.90 - 24.50 mm . . . . . . . . . . . . . . . . . . . . . . . (0.860 - 0.960 in.) Shims Compressed Length . . . 14.70 mm (0.580 in.) . . . . . . . . . . . . . . . . . . . . @12 N (2.7 lb-force) 1 Cap Installation is done in the reverse order of removal. M35573 Cap Stake to Shims valve body. Valve 4. Check spring free and compressed lengths. Spring Specifications: Retaining Nut 30 N•m (22 lb-ft) Spring Free Length . . . . . . . . . . . . . 39.50 - 40.50 mm . . . . . . . . . . . . . . . . . . . . . . . (1.550 - 1.590 in.) Compressed Length . . . . . .30 mm (1.180 in.) . . . . . . . . . @ 29.4 ± 3.1 N (6.6 ± 0.7 lb-force) Valve Body O-Ring Replace. Oil FIlter M82311A OIL PRESSURE REGULATING VALVE - EARLY 3TNA72 (430 LGT) Removal/Installation 1. Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) 2. Remove cap, shims, if equipped, spring and valve. 4/7/95 IMPORTANT: If oil pressure regulating valve was disassembled to be cleaned, the same number and thickness of shims must be installed. NOTE: Shims are available in 0.20 mm (0.080 in.) and 0.30 mm (0.012 in.) sizes. 5. If adjusting oil pressure only, add shims as necessary. Each 0.20 mm (0.080 in.) of shim thickness increases oil pressure 6 kPa (0.85 psi). Each 0.30 mm (0.012 in.) shim thickness increases oil pressure 9 kPa (1.30 psi). Installation is done in the reverse order of removal. 1-81 Lubrication OIL PRESSURE REGULATING VALVE - LATER 3TNA72 NOTE: Valve components are not serviced individually. Replace complete regulating valve if any components are defective. Removal/Installation 4. Inspect all parts for wear or damage. Replace complete valve if necessary. 1. Remove oil filter. 2. Remove three cap screws, valve assembly and gasket. 1 NOTE: If adjusting engine oil pressure, retaining nut need not be removed. 3. If adjusting pressure only, remove cap and add shims. Each 1 mm (0.039 in.) of shim thickness increases oil pressure 10.9 kPa (1.6 psi). 5. Check spring free and compressed lengths. Spring Specifications: Free Length . . . . . . . . . . . . . 43.50 - 48.50 mm . . . . . . . . . . . . . . . . . . . . . . . (1.710 - 1.910 in.) Compressed Length . . . 27.50 mm (1.080 in.) . . . . . . . . . . . . . . . . . . @ 20.5 N (4.6 lb-force) Installation is done in the reverse order of removal. Gasket Cap Screw (3) M8 x 20 27 N•m (20 lb-ft) Cap Stake to valve body. O-Ring Replace. Housing Shims Retaining Nut 30 N•m (22 lb-ft) Spring Valve Oil Filter Valve Body O-Ring Replace. 1-82 M82312A 4/7/95 Cooling System OTHER MATERIALS Number Name Use John Deere Pipe Sealant with TEFLON® 3TNA72 (15 EX, 755/56 CUT): Apply to threads of plug in water pump housing. LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. TY9375/ TY9480/ #592 ®LOCTITE is a registered trademark of the Loctite Corp. ®TEFLON is a registered trademark of the Du Pont Company. 4/7/95 1-83 1 Cooling System COOLANT TEMPERATURE SENSOR Replacement Cap Screw (2) M8 x 20 9 N•m (78 lb-in.) NOTE: Some engines may also be equipped with a coolant temperature switch. Switch is located opposite of sensor in water pump housing. Replacement procedures are the same. 1 Cover O-Ring Replace. Thermostat 1. Disconnect wiring lead, if equipped. 2. Open engine drain valve to drain coolant. 3. Remove sensor and washer. 4. Test sensor. (See Checks, Tests and Adjustments in this section.) Installation is done in reverse order of removal. Coolant Temperature Sensor Coolant Temperature Switch Copper Washer Replace. Copper Washer Replace. M82314A 3TN66 Water Pump Housing Cap Screw M8 x 55 Cap Screw (2) M8 x 20 26 N•m (226 lb-in.) Cap Screw M8 x 25 Gasket M82313A Later 430 LGT, F925/35 FM, 755/56 CUT Thermostat Gasket (430 LGT Only) THERMOSTAT • Replace gaskets. • Test thermostat. (See Checks, Tests and Adjustments in this section.) 3TNA72 1-84 M82315A 4/7/95 Cooling System WATER PUMP - 3TN66 4. Remove three mounting cap screws, pump and gasket. Removal/Installation 5. Inspect all parts for wear or damage. (See Disassembly/Assembly procedures.) 1. Open engine drain valve to drain coolant. Installation is done in the reverse order of removal. 2. Remove fan/alternator drive belt. • Adjust fan/alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) 3. Remove fan, spacer, if equipped, and pulley. 1 Gasket Replace. O-Ring Replace. Pulley Fan Water Pump Mounting Cap Screw (3) M8 x 45 26 N•m (226 lb-in.) Cap Screw (4) 11 N•m (96 lb-in.) Spacer (655 CUT Only) M82316A 4/7/95 1-85 Cooling System Disassembly 2. Remove coolant temperature procedure in this group.) 1. Remove thermostat. (See procedure in this group.) sensor. (See 3. Apply heat to six plate-to-housing screws. Remove screws, plate and gasket. Plate Gasket Replace. Plate-to-Housing Screw (6) 9 N•m (78 lb-in.) 1 Bearing Shaft Impeller Pulley Flange Shaft Seal Assembly Replace. Plug 4. Apply extreme heat to pulley flange. Remove flange using a knife-edge puller set and two small nuts. Two Small Nuts Pulley Flange Water Pump Housing M82317A IMPORTANT: Impeller bore is tapered. When pressing bearing shaft from impeller, allow enough clearance between cap screw and impeller bore to prevent cap screw from binding. 6. Remove impeller from bearing shaft using a knife-edge puller, a 3/8 in. cap screw and a press. Knife-Edge Puller Set 7. Remove shaft seal assembly; (seal, ceramic seal and seal cup). Water Pump Housing 8. Inspect all parts for wear or damage. Replace as necessary. M35645 5. Place water pump assembly on a press table. Install supports under water pump housing, staying clear of impeller. Press bearing shaft assembly through water pump housing using a piece of pipe or a deep socket. 1-86 4/7/95 Cooling System Assembly 1. Install bearing shaft into pump housing, long end down, using a piece of pipe or deep socket and a press. Press shaft into pump housing until bearing surface is flush with pump housing surface. 2. Install new shaft seal over impeller side of bearing shaft, rubber seal side away from pump housing. Push shaft seal into pump housing, until it stops, using a 25 mm or 1 in. socket and a press. 5. Install a knife-edge puller around bearing shaft, between pulley flange and pump housing. Place pump housing, with knife-edge puller down, on a press table. Install impeller with ceramic seal toward shaft seal. Press impeller on bearing shaft until top of impeller is even with end of shaft. 1 IMPORTANT: Support pump housing on bearing shaft only. DO NOT support on housing or damage to housing will occur. 3. Place water pump housing on a press table. Support housing on bearing shaft using a driver disk. Install pulley flange onto shaft with straight hub facing away from housing. M35656 Press pulley flange onto bearing shaft until flange is flush with end of shaft. 6. Install new gasket, plate and six screws. Tighten to specifications. IMPORTANT: DO NOT touch lapped sealing surface of ceramic seal with bare hands. It must be clean and dry. 7. Install coolant temperature procedure in this group.) 4. Install seal cup and ceramic seal in impeller. 8. Install thermostat. (See procedure in this group.) 4/7/95 sensor. (See 1-87 Cooling System WATER PUMP - 3TNA72 4. Remove three mounting cap screws, pump and gasket. Removal/Installation 5. Inspect all parts for wear or damage. (See Disassembly/Assembly procedures.) 1. Open engine drain valve to drain coolant. Installation is done in the reverse order of removal. 2. Remove fan/alternator drive belt. NOTE: 430 LGT and F925/35 FM application is not equipped with a fan. 1 3. Remove fan and spacer/plate, if equipped, and pulley. Gasket Replace. • Adjust fan/alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) • Tighten mounting cap screws to 26 N•m (226 lb-in.). Mounting Cap Screw (3009 OEM, 455 LGT, 670 CUT Only) M8 x 20 Pulley O-Ring Replace. Spacer (3009 OEM, 655 CUT Only) Fan Water Pump Mounting Cap Screw 3009 OEM, 455 LGT, 670 CUT - (3) All Except - (4) M8 x 45 Plate 755/56 CUT Only 1-88 Cap Screw (4) 11 N•m (96 lb-in.) M82318A 4/7/95 Cooling System Disassembly 1. Remove thermostat. (See procedure in this group.) 2. Remove coolant temperature procedure in this group.) (See 3. Apply heat to plate-to-housing screws. Remove screws, plate and gasket. Plate Gasket Replace. Plate-to-Housing Screw Early 3TNA72 (3) Later 3TNA72 (5) 9 N•m (78 lb-in.) sensor. Plug (15 EX, 755/56 CUT Only) Apply Pipe Sealant with TEFLON to threads. 1 Stud (Early 430 LGT Only) Bearing Shaft Impeller Shaft Seal Assembly Replace. Pulley Flange Cap Coolant Temperature Switch Copper Washer Replace. Water Pump Housing 455 LGT M82319A 4. Apply extreme heat to pulley flange. Remove flange using a knife-edge puller set and two small nuts. Two Small Nuts Pulley Flange IMPORTANT: Impeller bore is tapered. When pressing bearing shaft from impeller, allow enough clearance between cap screw and impeller bore to prevent cap screw from binding. 6. Remove impeller from bearing shaft using a knife-edge puller, a 3/8 in. cap screw and a press. Knife-Edge Puller Set 7. Remove shaft seal assembly; (seal, ceramic seal and seal cup). Water Pump Housing 8. Inspect all parts for wear or damage. Replace as necessary. M35645 5. Place water pump assembly on a press table. Install supports under water pump housing, staying clear of impeller. Press bearing shaft assembly through water pump housing using a piece of pipe or a deep socket. 4/7/95 1-89 Cooling System Assembly 1. Install bearing shaft into pump housing, long end down, using a piece of pipe or deep socket and a press. Press shaft into pump housing until bearing surface is flush with pump housing surface. 1 2. Install new shaft seal over impeller side of bearing shaft, rubber seal side away from pump housing. Push shaft seal into pump housing, until it stops, using a 25 mm or 1 in. socket and a press. 5. Install a knife-edge puller around bearing shaft, between pulley flange and pump housing. Place pump housing, with knife-edge puller down, on a press table. Install impeller with ceramic seal toward shaft seal. Press impeller on bearing shaft until top of impeller is even with end of shaft. IMPORTANT: Support pump housing on bearing shaft only. DO NOT support on housing or damage to housing will occur. 3. Place water pump housing on a press table. Support housing on bearing shaft using a driver disk. Install pulley flange onto shaft with straight hub facing away from housing. M35656 Press pulley flange onto bearing shaft until flange is flush with end of shaft. IMPORTANT: DO NOT touch lapped sealing surface of ceramic seal with bare hands. It must be clean and dry. 4. Install seal cup and ceramic seal in impeller. 1-90 6. Install new gasket, plate and screws. Tighten to specifications. 7. Install coolant temperature procedure in this group.) sensor. (See 8. Install thermostat. (See procedure in this group.) 4/7/95 Fuel System SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the European Microfiche Tool Catalog (MTC). JDF13 Nozzle Cleaning Kit Use to clean fuel injection nozzles. OTHER MATERIALS Number LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. Name Use TY9369/ NA/ #222 Thread Lock and Sealer (Low Strength) Apply to threads of fuel shutoff lever set screw. 1 SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Block Gasket Kit • Fuel Injection Nozzle Shim Pack ® LOCTITE is a registered trademark of the Loctite Corp. 4/10/95 1-91 Fuel System FUEL SUPPLY PUMP - 3TNA72 (670 CUT, 3009 OEM) Replacement IMPORTANT: Replace all copper washers. Damaged or used washers may leak. 1 Copper Washer (4) Replace. Fuel Supply Pump Gasket Fuel Pump-to-Filter Hose Fuel Supply-toPump Hose Lock Washer (2) Mounting Screw (2) M6 x 20 11 N•m (96 lb-in.) M82135A 1-92 4/10/95 Fuel System FUEL FILTER ASSEMBLY - IF EQUIPPED IMPORTANT: Replace all copper washers. Damaged or used washers may leak. NOTE: As a result of the various engine applications for each engine model, fuel filter assemblies may or may not be mounted on the engine. Fuel filters and line routing will be different. 3TNA72 (3009 OEM) shown. 1 Nut (3) Nozzle Leak-Off Hose (Short) (2) * Bleed Valve Rubber Washer * Bleed Screw * Nozzle Leak-Off Hose (Long) Shutoff Rubber Washer Valve To Fuel Tank Mounting Base Spring O-Ring Shutoff Lever * * Filter Element Spring O-Ring Fuel Supply Pump-to-Filter Hose Filter Cover *Copper Washers Replace. Fuel Filter-toInjection Pump Hose Retaining Ring M82133A 4/10/95 1-93 Fuel System FUEL INJECTION PUMP Removal CAUTION 1 Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can damage the pump. M37785 4. Disconnect hose from fuel filter or supply pump (670 CUT, 3009 OEM), if equipped. 5. Disconnect leak-off hoses to/from injection pump. 6. 375 SSL, 655 CUT, F915 FM, 455 LGT, 755/56 CUT: - Disconnect fuel shutoff solenoid link. - Remove four nuts, shutoff solenoid bracket and gasket. Shutoff Solenoid Bracket Gasket Replace. 1. Clean the injection pump lines and area around the pump using a parts cleaning solvent or steam cleaner. IMPORTANT: When removing injection lines, DO NOT turn pump delivery valve fittings. Turning fittings may damage pump internally. 2. Loosen fuel injection line connectors slightly to release pressure in the fuel system. When loosening connectors, use another wrench to keep delivery valves from loosening. Fuel Shutoff Solenoid Link M37786 430 LGT (Early): - Remove two cap screws, nut, oil fill cover and gasket. 3. Loosen line clamp and remove fuel injection lines. 1-94 4/10/95 Fuel System DO NOT attempt to service the injection pump except for fuel delivery valves. If unit is in need of repair, it must be serviced by a qualified fuel injection repair shop. If replacement is necessary, replace entire unit. Gasket Replace. Installationl Installation is done in the reverse order of removal. Oil Fill Cover M35890 330/332 LGT, 15 EX, 430 LGT (Later), 670 CUT, F925/35 FM, 3009 OEM: - Remove four nuts, cover and gasket. IMPORTANT: If a serviced or replacement fuel injection pump is installed, measure old shim thickness and install new shims of the same thickness. • Early 3TNA72: When installing fuel injection pump into housing, align controller rack with governor linkage fork. 7. 3TN66 and Later 3TNA72: Remove pin and washer, if equipped. Disconnect governor linkage. Governor Linkage Fork Controller Rack Pin M35888 Governor Linkage M37787 IMPORTANT: If injection pump is being removed to be serviced or replaced, the same number and thickness of new shims must be installed when pump is assembled. 8. Remove four nuts to remove fuel injection pump and shims. • 3TN66 and Later 3TNA72: When connecting governor linkage to injection pump rack, attach link to rack at hole closest to injection pump gear. • Bleed the fuel system. (See Operational Tests in this section.) • If new injection pump is being installed, check and adjust injection pump timing. (See Checks, Tests and Adjustments in this section.) Fuel Injection Pump Nut (4) 20 N•m (180 lb-in.) NOTE: 3TN66 and Later 3TNA72: Governor linkage may have two holes. Connect governor linkage to injection pump rack using hole closest to injection pump gear. Shims M37788 4/10/95 1-95 1 Fuel System FUEL INJECTION PUMP CAMSHAFT - EARLY 3TNA72 (430 LGT) Removal 1. Remove fuel injection pump. (See procedure in this group.) Installation Installation is done in the reverse order of removal. • After installing camshaft assembly into housing, tap on end of camshaft gear with a plastic hammer to seat bearings in bores. 2. Remove idler gear. (See Camshaft and Timing Gear Train in this section.) 1 3. Put a shop towel between oil pump and injection pump gears. Loosen injection pump gear lock nut. 4. Remove bearing retaining screw. M35568 Lock Nut 88 N•m (65 lb-ft) Bearing Retaining Screw 20 N•m (180 lb-in.) M35536 IMPORTANT: DO NOT allow fuel injection pump camshaft lobes to hit bearing surfaces while removing camshaft. Machined surfaces may be damaged. ª ª 5. Remove fuel injection pump camshaft assembly using a slide hammer, puller set and two mounting cap screws from gear housing cover. Disassembly NOTE: Injection pump camshaft is tapered on gear end. Gear and bearings are press fit on shaft. IMPORTANT: Hold camshaft while removing gear and bearings. Shaft can be damaged if dropped. 1. Remove lock nut and lock washer. 2. Remove gear using a knife edge puler and a press. 3. Remove key. M37797 M35537 6. Disassemble and inspect all parts for wear or damage. (See Disassembly and Inspection procedures. 1-96 4. Remove bearings using a knife edge puller and a press. 5. Inspect all parts for wear or damage. (See Inspection procedures.) 4/10/95 Fuel System Assembly 2. 670 CUT and 3009 OEM: Remove fuel supply pump. (See procedure in this group.) NOTE: Install large bearing on gear end. 1. Install bearings on ends of camshaft using a 3/4 in. deep well socket and a press. Press until bearing races bottom on camshaft shoulders. 2. Install key. 3. Remove fuel control and governor linkage. (See procedure in this group.) 4. Remove idler gear. (See Camshaft and Timing Gear Train in this section.) 5. Remove bearing retaining screw. 3. Put camshaft gear on a flat surface and press camshaft assembly into gear. Press until gear face is flush with end of shaft. 1 4. Install lock washer and lock nut. Leave nut loose. Inspection Bearing Retaining Screw 20 N•m (180 lb-in.) • Measure height of each camshaft lobe. Replace camshaft if lobe height is less than 30.90 mm (1.217 in.). M37804 IMPORTANT: DO NOT allow fuel injection pump camshaft lobes to hit bearing surfaces while removing camshaft. Machined surfaces may be damaged. 6. Tap the rear of camshaft with plastic hammer to remove from housing. M35905 • Inspect camshaft bearing supports in timing gear housing. Check for cracks, damage or indications that bearings have spun in support. Replace timing gear housing if bearing bores are damaged. (See Camshaft and Timing Gear Train in this section.) Camshaft • Inspect all parts for wear or damage. Replace as necessary. M37796 FUEL INJECTION PUMP CAMSHAFT - 3TN66 AND LATER 3TNA72 7. Disassemble and inspect all parts for wear or damage. (See Disassembly and Inspection procedures.)ª ª Removal 1. Remove fuel injection pump. (See procedure in this group.) 4/10/95 1-97 Fuel System Installation Assembly Installation is done in reverse order of removal. NOTE: Install large bearing on gear end. • After installing camshaft assembly into housing, tap on end of camshaft gear with a plastic hammer to seat bearings in bores. 1. Install bearings on ends of camshaft using a 3/4 in. deep well socket and a press. Press until bearing races bottom on camshaft shoulders. 2. Install key. 3. Put camshaft gear on a flat surface and press camshaft assembly into gear. Press until gear face is flush with end of shaft. 1 Inspection • Measure height of each camshaft lobe. Replace camshaft if lobe height is less than 30.90 mm (1.217 in.). M35568 Disassembly NOTE: Gear and bearings are press fit on shaft. IMPORTANT: Hold camshaft while removing gear and bearings. Shaft can be damaged if dropped. 1. Remove gear using knife edge puller and a press. 2. Remove key. M35905 • Inspect camshaft bearing supports in timing gear housing. Check for cracks, damage or indications that bearings have spun in support. - If rear bearing bore is damaged, replace timing gear housing. (See Camshaft and Timing Gear Train in this section.) - If front bearing bore is damaged, remove three cap screws and replace support. M37797 3. Remove bearings using a knife edge puller and a press. Front Bearing Support 4. Inspect all parts for wear or damage. (See Inspection procedures.) M37803 • Inspect all parts for wear or damage. Replace as necessary. 1-98 4/10/95 Fuel System FUEL CONTROL AND GOVERNOR LINKAGE - EARLY 3TNA72 (430 LGT) Removal Cap Nuts and Seals Replace seals. Sealing Wire 1. Remove fuel injection pump. (See procedure in this group.) Bracket 2. Remove cotter pin and washer to disconnect fuel shutoff solenoid linkage. 1 M35929 9. Loosen lock nut and remove fast idle adjustment screw and seal. Seal Replace. M35272 Fast Idle Adjustment Screw 3. Remove oil filter and dipstick tube. 4. Remove two cap screws, bracket and four washers. 5. Remove two cap screws, cover and gasket. Bracket Cover and Gasket M35930 10.Loosen lock nut and remove fuel controller and seal. Seal Replace. Washers (4) Fuel Controller M35928 6. Remove sealing wire. M35932 7. Remove cap screw and slow idle screw bracket. 8. Remove cap nuts and seals. 4/10/95 1-99 Fuel System 11.Disconnect spring from throttle lever regulator. 14.Remove o-ring, e-clip and spring. O-Ring Replace. 1 E-Clip Spring M35933 12.Remove nut, throttle lever, regulator and o-ring. Throttle Lever M35937 15.Remove governor shaft, bronze washer and spacer. Regulator Governor Shaft O-Ring Replace. M35934 M35938 13.Remove set screw and fuel shutoff lever. 16.Turn governor weights until one weight is toward the engine. Remove governor linkage assembly. Set Screw Fuel Shutoff Lever M35936 M35940 1-100 4/10/95 Fuel System Installation • Coat all internal parts with clean engine oil. 1. Align splines on oil pump rotor shaft with splines in thrust washer and governor weights. Install thrust washer, governor weights and sleeve on rotor shaft. M35939 1 Sleeve 17.Remove spring pin. Governor Weights Thrust Washer M35945 2. Install spring, pin and e-clip. M35943 18.Remove e-clip, pin and spring. Pin Pin E-Clip E-Clip Spring Spring M35944 M35944 3. Install spring pin. 19.Remove sleeve, governor weights and thrust washer. Sleeve Governor Weights Thrust Washer M35948 M35945 20.Inspect all parts for wear or damage. (See Inspection procedures.) 4/10/95 1-101 Fuel System 4. Turn governor weights until one weight is toward the engine. Install governor linkage assembly. 7. Install spring, e-clip and new o-ring. O-Ring 1 E-Clip Spring M35937 M35940 8. Align groove in fuel shutoff lever with hole in timing gear housing and install lever. Make sure groove is visible through hole. 9. Apply thread lock and sealer (low strength) on threads of set screw. Install and tighten set screw. Groove M35939 Hole 5. Install spacer and new bronze washer on governor shaft. 6. Insert governor shaft through governor linkage assembly. Tighten shaft to 49 N•m (36 lb-ft). M35951 10.Install new o-ring on regulator. 11.Install throttle lever and nut. Spacer Washer Throttle Lever Regulator M35949 O-Ring M35934 1-102 4/10/95 Fuel System 12.Connect spring to throttle lever regulator then to governor linkage assembly. 15.Install slow idle screw bracket so the stop on the lever contacts the end of slow idle screw. Install and tighten cap screw. 16.Install fuel shutoff lever spring on slow idle screw bracket. 1 Fuel Shutoff Lever Spring Stop M35933 13.Install new seals and fuel controller. Tighten lock nut. Slow Idle Screw Bracket Slow Idle Screw M35954 17.Install new gasket, cover and two cap screws. 18.Install four washers (two each hole location), bracket and two cap screws. Tighten all four cap screws to 9 N•m (78 lb-in.). Seals Fuel Controller Bracket M35932 14.Install new seals and fast idle adjustment screw. Tighten lock nut. NOTE: Do not install cap nuts or sealing wire until installation procedures have been completed and fast and slow idle adjustments have been made. Idle adjustments are made after engine has been installed in the machine. Cover and Gasket Washers (4) M35928 19.Install oil dipstick tube and oil filter. 20.Connect fuel shutoff solenoid linkage and install washer and cotter pin. Seals Fast Idle Adjustment Screw M35930 M35272 4/10/95 1-103 Fuel System 21.Install fuel injection pump. (See procedure in this group.) 22.Adjust fuel shutoff solenoid. (See Checks, Tests and Adjustments in this section.) 23.Check and adjust slow and fast idle settings. (See procedure in Machine Technical Manual.) Inspection 1 NOTE: Throttle lever bushing is press fit in timing gear housing. Remove bushing only if replacement is necessary. 1. Inspect throttle lever bushing for wear or damage. Replace if necessary. To replace bushing: M35942 Governor Shaft Bore I.D. Wear Limit. . . . . . . . . . . . 8.15 mm (0.321 in.) Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.) Remove bushing using a blind hole puller set. If shaft bore exceeds wear limit, replace governor linkage. ª ª Install bushing with chamfered end toward gear housing using a driver set. Push in bushing until flush with surface of gear housing. If bore clearance (bore I.D. minus shaft O.D.) exceeds specification, replace governor shaft, governor linkage or both. 4. Measure inside diameter of sleeve. If I.D. is more than 9.20 mm (0.362 in.), replace sleeve. M35946 M35935 2. Measure governor shaft diameter. If O.D. is less than 7.90 mm (0.311 in.), replace governor shaft. 5. Measure oil pump rotor shaft diameter. M35947 M35941 Rotor Shaft O.D. 3. Measure governor shaft bore diameter in governor linkage. 1-104 Wear Limit. . . . . . . . . . . . 8.90 mm (0.350 in.) Clearance . . . . . . . . . . . . . 0.15 mm (0.006 in.) 4/10/95 Fuel System If shaft diameter is less than wear limit, replace pump rotor shaft. Inspect splines on shaft for chipped or broken teeth. If necessary, replace oil pump rotor shaft. (See Lubrication System in this section.) If clearance (sleeve I.D. minus shaft O.D.) exceeds specification, replace sleeve, oil pump rotor shaft or both. FUEL CONTROL AND GOVERNOR LINKAGE - 3TN66 AND LATER 3TNA72 Removal 4. 670 CUT, 15 EX, 375 SSL, 3009 OEM: Remove six cap screws, linkage housing and gasket. 430 LGT (Later), 330 LGT, 655 CUT, F915 FM, 455 LGT, 755/56 CUT, F925/35 FM: - Remove three cap screws and throttle cable mounting bracket. - Remove three cap screws, linkage housing and gasket. 1 Gasket Replace. Throttle Cable Mounting Bracket If equipped. 1. 375 SSL, 655 CUT, F915 FM, 455 LGT, 755/56 CUT: - Disconnect fuel shutoff solenoid link. Dipstick Tube Linkage Housing - Remove four nuts, shutoff solenoid bracket and gasket. Shutoff Solenoid Bracket Gasket Replace. M37754 5. Remove sleeve. 6. Remove nut and governor weights. Governor Weights Nut Fuel Shutoff Solenoid Link M37786 330 LGT, 15 EX, 430 LGT (Later), 670 CUT, F925/35 FM, 3009 OEM: - Remove four nuts, cover and gasket. 2. Remove pin and washer, if equipped, to disconnect governor linkage. Sleeve M37755 7. Disassemble and inspect all parts for wear or damage. (See Disassembly and Inspection procedures.) Installation Pin Installation is done in the reverse order of removal. • Governor linkage may have two holes. Connect governor linkage to injection pump rack using hole closest to injection pump gear. • Adjust fuel shutoff solenoid. (See Checks, Tests and Adjustments in this section.) Governor Linkage M37787 3. Remove dipstick tube. 4/10/95 • Check and adjust slow and fast idle settings. (See procedure in Machine Technical Manual.) • Check and adjust slow and fast idle settings. (See procedure in Machine Technical Manual.) 1-105 Fuel System Disassembly NOTE: Shims are on all engines except 670 CUT and 3009 OEM applications. 1. Remove spring. 7. Remove governor shaft, governor assembly, shims and O-ring. 2. Remove seal and sealing wire. linkage Spring Governor Linkage Assembly 1 Seal and Sealing Wire O-Ring Replace. M37759 NOTE: Washer is on 670 CUT, 455 LGT and 3009 OEM only. 3. Remove nut, washer, if equipped, and throttle lever. 4. Remove cap screw and throttle shaft retaining plate. Governor Shaft Retaining Plate M37762 8. Rotate throttle shaft assembly as shown. 9. Remove tapered pin from tapered hole using a punch. 10.Remove throttle shaft, shaft lever and O-ring. 5. Remove cap screw and governor shaft retaining plate. 6. Remove set screw, fuel shutoff lever, spring and O-ring. Shims If equipped. Governor Shaft Tapered Pin Shaft Lever Throttle Shaft Set Screw Apply thread lock and sealer (low strength) on threads. O-Ring Replace. Spring Throttle Shaft Retaining Plate O-Ring Replace. M37766 Nut Throttle Lever Fuel Shutoff Lever 1-106 M37760 4/10/95 Fuel System 11.Remove cover, gasket, fuel controller assembly, fast idle stop and slow idle stop. Nut Washer Stud Cap Nut Seals Replace. Tension Lever Cap Nut Needle Bearing (2) Clip Spring Pin Fuel Controller Assembly Seals Replace. Slow Idle Stop Gasket Replace. 1 Shim (as required) Spring Spring Pin Bracket Washer Cover Cap Screw (3) Spring E-Clip Fast Idle Stop Spring Pin (2) 670 CUT, 3009 OEM M82320A Pin Governor Lever Spring Pin 670 CUT, 3009 OEM Governor Link Pin M82322A 13.Inspect all parts for wear or damage. Replace as necessary. (See Inspection procedures.) 12.Disassemble governor linkage assembly. Shim (as required) Bushing (2) Tension Lever Assembly Assembly is done in the reverse order of disassembly. Spring Pin • Apply clean engine oil on all internal parts. Spring • When installing throttle shaft: - Install new O-ring, throttle shaft and shaft lever. Rotate shaft until rounded side of shaft is facing toward hole. Governor Lever Washer - Position shaft lever as shown and install tapered pin in tapered hole. Spring Pin Pin Governor Link Pin E-Clip M82321A All Except 670 CUT, 3009 OEM 4/10/95 1-107 Fuel System Tapered Pin Shaft Lever O-Ring 2. Measure governor shaft bore diameter in governor linkage. Governor Shaft Bore I.D. Wear Limit. . . . . . . . . . . . 8.15 mm (0.321 in.) Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.) 1 If shaft bore exceeds wear limit, replace governor linkage. Throttle Shaft M37768 Throttle Shaft If bore clearance (bore I.D. minus shaft O.D.) exceeds specification, replace governor shaft, governor linkage or both. 3. Measure inside diameter of sleeve. If I.D. is more than 8.20 mm (0.323 in.), replace sleeve. Hole Rounded Side M37769 • Seal and sealing wire are not installed until governor linkage housing installation procedures have been completed and fast and slow idle adjustments have been made. Idle adjustments are made after engine has been installed in the machine. M37756 4. Measure injection pump camshaft diameter. Inspection 1. Measure governor shaft diameter. If O.D. is less than 7.90 mm (0.311 in.), replace governor shaft. M37757 Injection Pump Camshaft O.D. Wear Limit. . . . . . . . . . . . 7.90 mm (0.311 in.) Clearance . . . . . . . . . . . . . 0.15 mm (0.006 in.) If camshaft diameter is less than wear limit, replace injection pump camshaft. (See procedure in this group.) If clearance (sleeve I.D. minus camshaft O.D.) exceeds specification, replace sleeve, injection pump camshaft or both. M37763 1-108 5. Inspect all parts for wear or damage. Replace as necessary. 4/10/95 Fuel System FUEL INJECTION NOZZLES (PINTLE-TYPE) Removal/Installation IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can damage the pump. 1. Clean the injection pump lines and area around the pump using a parts cleaning solvent or steam cleaner. NOTE: Nozzles are matched to the cylinders. If removing more than one nozzle, tag nozzles, according to the cylinder from which it was removed. IMPORTANT: When removing injection lines, DO NOT turn pump delivery valve fittings. Turning fittings may damage pump internally. 2. Loosen fuel injection line connectors slightly to release pressure in the fuel system. When loosening connectors, use another wrench to keep delivery valves from loosening. CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. M35885 3. Loosen line clamp and remove fuel injection lines. 4. Disconnect long leak-off hose. 5. Remove nuts and leak-off hose assembly. 6. Remove bronze washers and o-rings. 7. Remove injection nozzle, washers and heat protector. 8. Test injection nozzles. (See Checks, Tests and Adjustments in this section.) Installation is done in reverse order of removal. 4/10/95 1-109 1 Fuel System Nut 40 N•m (30 lb-ft) Bronze Washer Replace. 1 Leak-Off Hose Assembly O-Ring Replace. Leak-Off Hose (Long) Hose Clamp Injection Nozzle 50 N•m (37 lb-ft) Bronze Washers Replace. Heat Protector Replace. ª ª M82323A Disassembly/Assembly Injector Body Separator Plate NOTE: If servicing more than one nozzle, keep parts for each nozzle separate from one another. IMPORTANT: If injection nozzles are disassembled to be cleaned, the same number and thickness of shims must be installed. • Clean and inspect nozzle assembly. (See Cleaning/Inspection procedures.) • After assembly is complete, test injection nozzle. (See Checks, Tests and Adjustments in this section.) Nozzle Valve Shims (as required) Nozzle Body Nozzle Fitting 40 N•m (30 lb-ft) Spring Spring Seat M82324A 1-110 4/10/95 Fuel System CROSS SECTION IMPORTANT: Never use a steel brush to clean nozzles as this will distort the spray hole. 2. Remove carbon from used nozzles, and clean by washing in diesel fuel. If parts are coated with hardened carbon or lacquer, it may be necessary to use a brass wire brush (supplied in Nozzle Cleaning Kit). Injector Body 3. After removing carbon or lacquer from the exterior of nozzle, inspect sealing surfaces between separator plate and nozzle body for nicks or scratches. Shim (as required) Spring 4. Inspect condition of separator plate and nozzle body. Contact area of separator plate (both parts) must not be scored or pitted. Use an inspection magnifier (No. 16487 or equivalent) to aid in making the inspection. 5. Check nozzle contact surface on separator plate for wear. If contact surface is more than 0.10 mm (0.0039 in.), replace nozzle assembly. Nozzle Fitting Spring Seat Separator Plate Nozzle Contact Surface Sealing Surfaces Separator Plate Nozzle Body Nozzle Valve Nozzle Body M82325A Cleaning/Inspection NOTE: To clean nozzles properly, JDF13 Nozzle Cleaning Kit is recommended. The Cleaning Kit is available through the John Deere SERVICEGARD™ Catalog. M82326A 6. Inspect the piston (large) part of nozzle valve to see that it is not scratched or scored and that lower (tip) end of valve is not broken. If any of these conditions are present, replace the nozzle assembly. 1. Remove anti-corrosive grease from new or reconditioned nozzles by washing them thoroughly in diesel fuel. 4/10/95 1-111 1 Fuel System 7. Further inspect the nozzle assembly by performing a slide test. Use the following procedure: • Dip the nozzle valve in clean diesel fuel. Insert valve in nozzle body. Piston Part of Nozzle Valve • Hold nozzle vertical, and pull valve out about 1/3 of its engaged length. 1 • Release valve. Valve should slide down to its seat by its own weight. Replace nozzle assembly if the valve does not slide freely to its seat. 1-112 Nozzle Body M35919 4/10/95 Starter STARTER - HITACHI 0.8 kW Negative Brush Disassembly/Inspection Brush Spring 1. Disconnect field lead. 2. Remove two cap screws and two screws from rear cover. 3. Pry off plastic cap. 1 4. Remove e-clip, shims and rear cover. M37875 Field Lead Field Coil Brush (2) 9. Remove field coil housing from armature/ solenoid assembly. Rear Cover Cap E-Clip Shims M37923 Field Coil Housing 5. Inspect cover bushing for wear or damage. Replace if necessary. To replace bushing: Remove bushing using a blind-hole puller set. Install new bushing until it bottoms in cover bore using a driver set. M37876 10.Remove two cap screws and pivot bolt, if equipped. 11.Remove dust cover. 12.Remove solenoid and armature assemblies from end frame. Ream out bushing to 12.50 - 12.53 mm (0.492 0.493 in.). Cap Screw (2) End Frame Armature Assembly Rear Cover Bushing M37874 6. Remove field coil brushes from brush holder. 7. Pry brush springs away and pull negative brushes up enough to allow spring to hold brush in place. 8. Remove brush holder. 4/7/95 Dust Cover Solenoid Assembly M37877 1-113 Starter 13.Inspect end frame bushing for wear or damage. Replace if necessary. Replace bushing using a driver set. Install bushing flush with face of housing. Spring Plunger Solenoid Clutch Fork Pivot 1 Shims M37880 Assembly Assembly is done in the reverse order of disassembly. End Frame Bushing M37830 14.Slide pinion stopper away from retaining wire using a piece of pipe or deep socket. Remove retaining wire, pinion stopper, and clutch assembly from armature shaft. 15.Inspect clutch assembly for wear or damage. Gear should rotate in one direction only. Replace if necessary. Armature Shaft • After installing clutch assembly, pinion stopper and retaining wire on armature shaft, use two pliers to press pinion stopper over retaining wire. Retaining Wire Pinion Stopper Clutch Assembly Retaining Wire M37831 • When installing solenoid and armature assemblies into end frame, make sure fork pivot seats in notch on clutch fork. Pinion Stopper Clutch Assembly Notch M37879 16.Remove clutch fork pivot, plunger, spring and shim(s) from solenoid. 17.Inspect all parts for wear or damage. Replace as necessary. 18.Inspect and test brushes, holder, field coil and armature. (See Test procedures.) 1-114 Fork Pivot M37881 IMPORTANT: When installing rear cover, be sure field coil brush wires do not touch cover. Turn brush holder slightly to take up slack in brush wires. Press wires inward to clear rear cover. 4/7/95 Starter Test 1. Measure holder and field coil brush lengths. Minimum brush length is 7.70 mm (0.303 in.). Replace brush holder or field coil if brush length is below minimum. Field Coil Brush NOTE: Test brush holder using an ohmmeter or test light. 2. Test brush holder: Touch one probe of tester to negative brush holder and other probe to field brush holder. If there is continuity, replace the brush holder. 3. Inspect springs for wear or damage. Replace if necessary. Spring (4) 1 Field Coil Housing M82235 Negative Brush Holder IMPORTANT: Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush. 6. Inspect armature. Look for signs of dragging against pole shoes. Field Brush Holder Brush Length M82234 NOTE: Test field coil using an ohmmeter or test light. 4. Test for grounded field winding: Touch one probe of tester to field coil brush and other probe to field coil housing. Be sure the brush lead is not touching the frame. If there is continuity, the coil is grounded and the field coil housing assembly must be replaced. 5. Test for open field coil: Touch one probe of tester to each field coil brush. If there is no continuity, the field coil is open and the field coil housing assembly must be replaced. 4/7/95 7. Inspect commutator. Look for roughness, burned bars, or any material which might cause short circuits between bars. If necessary, clean and touch up with 400 sandpaper. NEVER use emery cloth. Clean all dust from armature when finished. NOTE: Test armature windings using an ohmmeter or test light. 8. Test for grounded windings: Touch probes on one commutator bar and armature shaft. Armature windings are connected in series, so only one commutator bar needs to be checked. 1-115 Starter If test shows continuity, a winding is grounded and the armature must be replaced. STARTER MOTOR - NIPPONDENSO 1.0 kW 9. Test for open circuited windings: Touch probes on two different commutator bars. Disassembly If test shows no continuity, there is an open circuit and the armature must be replaced. 1. Disconnect field lead. 2. Remove two cap screws and two screws. 3. Remove rear cover and o-ring, if equipped. Commutator Bars 1 Field Lead Armature Shaft O-Ring M82246 10.Test for short circuited windings using a growler. Put armature in a growler and hold a hacksaw blade above each slot while slowly rotating armature. If coil is shorted, the blade will vibrate on the slot. NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments. 11.If test indicates short circuited windings, clean the commutator of dust and filings. Check the armature again. If the test still indicates a short circuit, replace the armature. Screw (2) Rear Cover Cap Screw (2) M82233 4. Remove field coil brushes from brush holder. 5. Pry brush springs away and pull negative brushes up enough to allow spring to hold brush in place. 6. Remove brush holder. Brush Spring Field Coil Brush (2) Hacksaw Blade Armature Brush Holder M36754 Growler M82125A 7. Remove armature from field coil housing. 8. Remove felt washer and o-ring, if equipped. 9. Inspect and test brushes, holder, field coil and armature. (See Inspection/Test procedures.) 1-116 4/7/95 Starter Felt Washer Spring (4) Negative Brush Holder Armature Field Coil Housing 1 O-Ring M36759 Assembly Brush Length Field Brush Holder Assembly is done in the reverse order of disassembly. • Apply multipurpose grease to bearing cup inside rear cover and felt washer, if equipped. IMPORTANT: When installing rear cover, be sure field coil brush wires do not touch cover. Turn brush holder slightly to take up slack in brush wires. Press wires inward to clear rear cover. Inspection/Test/Replacement 1. Measure holder and field coil brush lengths. Minimum brush length is 8.5 mm (0.335 in.). Replace brush holder or field coil if brush length is below minimum. NOTE: Test brush holder using an ohmmeter or test light. M82234 NOTE: Test field coil using an ohmmeter or test light. 4. Test for grounded field winding: Touch one probe of tester to field coil brush and other probe to field coil housing. Be sure the brush lead is not touching the frame. If there is continuity, the coil is grounded and the field coil housing assembly must be replaced. 5. Test for open field coil: Touch one probe of tester to each field coil brush. If there is no continuity, the field coil is open and the field coil housing assembly must be replaced. Field Coil Brush 2. Test brush holder: Touch one probe of tester to negative brush holder and other probe to field brush holder. If there is continuity, replace the brush holder. 3. Inspect springs for wear or damage. Replace if necessary. Field Coil Housing M82235 4/7/95 1-117 Starter IMPORTANT: Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush. 6. Inspect armature. Look for signs of dragging against pole shoes. 1 7. Inspect commutator. Look for roughness, burned bars, or any material which might cause short circuits between bars. If necessary, clean and touch up with 400 sandpaper. NEVER use emery cloth. Clean all dust from armature when finished. NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments. 11.If test indicates short circuited windings, clean the commutator of dust and filings. Check the armature again. If the test still indicates a short circuit, replace the armature. Hacksaw Blade Armature NOTE: Test armature windings using an ohmmeter or test light. 8. Test for grounded windings: Touch probes on one commutator bar and armature shaft. Armature windings are connected in series, so only one commutator bar needs to be checked. If test shows continuity, a winding is grounded and the armature must be replaced. Growler M82125A 12.Inspect armature cover and housing bearings for wear or damage. Replace if necessary. To replace bearings: 9. Test for open circuited windings: Touch probes on two different commutator bars. If test shows no continuity, there is an open circuit and the armature must be replaced. Bearings are press fit. Remove bearings using a knife-edge puller set. IMPORTANT: Install both bearings with sealed side toward armature. Install new housing bearing tight against shoulder of shaft using a piece of pipe. Commutator Bars Install new rear cover bearing tight against shoulder of shaft using a driver set. Rear Cover Bearing Housing Bearing Armature Shaft M82236 10.Test for short circuited windings using a growler. Put armature in a growler and hold a hacksaw blade above each slot while slowly rotating armature. If coil is shorted, the blade will vibrate on the slot. 1-118 M82237 4/7/95 Starter STARTER GEAR TRAIN AND OVERRUNNING CLUTCH NIPPONDENSO 1.0 kW Plunger Spring Disassembly/Inspection 1. Remove two motor-to-clutch housing cap screws and two clutch housing-to-solenoid housing screws. Motor-to-Clutch Housing Cap Screws 1 Gear Clutch Housing M82239 NOTE: Starter is equipped with either a 33 mm (1.299 in.), 44 mm (1.732 in.) or 44.5 mm (1.752 in.) drive gear on end of clutch shaft. Disassembly procedures are slightly different. 4. Starter with 33 mm (1.299 in.) drive gear: Remove clutch assembly from housing. 5. Remove retainer, five rollers and pinion gear. M82233 6. Remove steel ball. Steel Ball Clutch Housing-toSolenoid Housing Screws Clutch Assembly Pinion Gear M82238 2. Separate clutch housing from solenoid/motor assembly. 3. Remove plunger spring and gear, if equipped. 4/7/95 Roller (5) Retainer M82240 1-119 Starter 7. Put clutch (housing) assembly into a soft-jawed vice, as shown. Clutch Housing Starter with 44 or 44.5 mm (1.732 or 1.752 in.) drive gear only. Clutch Assembly 8. Tighten vise slowly, until drive gear compresses. 9. Remove retainer and circlip. Drive Gear Retainer Circlip 1 Spring Retainer Circlip M82242 Starter with 44 or 44.5 mm (1.732 or 1.752 in.) Drive Gear Shown M82241 12.Remove washer, toothed washer, spring and clutch shaft. 13.Inspect all parts for wear or damage. Replace as necessary. CAUTION Clutch Shaft Shaft could be propelled from clutch unit with considerable force if spring is not allowed to extend fully while in vise. Spring 10.While holding clutch assembly, slowly open vise until all spring compression is relieved. 11.Starter with 33 mm (1.299 in.) drive gear: Remove drive gear and spring from clutch assembly. Starter with 44 mm (1.732 in.) or 44.5 mm (1.752 in.) drive gear: Remove drive gear, spring and clutch assembly from housing. Clutch Toothed Washer Large Washer M82243 Assembly Assembly is done in the reverse order of disassembly. • Apply multipurpose grease to bearings, clutch shaft, springs, pinion gears, retainer, rollers and steel ball. • Install large washer with flat side toward clutch assembly. • Install retainer with cupped side away from clutch assembly. 1-120 4/7/95 Starter STARTER SOLENOID NIPPONDENSO 1.0 kW Terminal Bolt Disassembly/Inspection 1. Disconnect field lead. Nut 2. Remove three screws and clip. Washer 3. Remove cover and gasket. 1 Field Lead Contact Plate O-Ring Clip Insulator M36771 Assembly Assembly is done in the reverse order of disassembly. Screw (3) M82244 4. Remove plunger. 5. Disassemble terminals. Remove parts from each terminal in order shown. NOTE: The assembly sequence of the left and right terminals is similar. Be sure solenoid terminal lead is installed between terminal bolt and contact plate. Also, be sure smaller contact plate is on the left side. 6. Inspect copper washer and contact plates for excessive burning or pitting. Clean burnt areas to improve electrical contact. Replace contacts or plunger if necessary. The solenoid is not serviceable. If defective, replace solenoid housing assembly. Solenoid Terminal Lead Contact Plates Terminal Bolt Small Contact Plate Plunger M36771 Spring Copper Washer M82245 4/7/95 1-121 Alternator ALTERNATOR - KOKOSAN 20A Disassembly/Inspection 7. Remove wire clamp. 1. Remove nut and washers. 9. Remove two screws and stator. 2. Tap on end of shaft with a soft-faced hammer to separate flywheel assembly from coil plate assembly. 10.Inspect all parts for wear or damage. Replace as necessary. 8. Remove connector from harness leads. Wire Clamp 3. Remove long spacer. 1 Lock Washer Coil plate Washer Flywheel Assembly Nut 27 N•m (20 lb-ft) Screw (2) Bearing Press fit in coil plate. Connector Coil Plate Assembly Stator M82249A Assembly Long Spacer M82247A NOTE: Bearing and flywheel are press fit on shaft. 4. Remove shaft from bearing, short spacer, washer, flywheel and sheave half, using a press. 5. Inspect all parts for wear or damage. Replace as necessary. Short Spacer Washer Flywheel Shaft Bearing Press fit on shaft. Assembly is done in the reverse order of disassembly. • With sheave half on shaft, press shaft into flywheel until sheave half bottoms on flywheel face. • With washer and short spacer installed, press new bearing onto shaft until it bottoms on spacer. VOLTAGE REGULATOR NIPPONDENSO 35A Replacement 1. Remove three attaching screws. Altaching Screw (3) M5 4 N•m (31 lb-in.) Sheave Half M82248A NOTE: Remove bearing only if replacement is necessary. 6. Inspect bearing in coil plate for wear or damage. Replace if necessary. To replace bearing: Remove bearing using a spark plug socket and a press. Install bearing into coil plate until it bottoms in bore using a 1 in. socket. 1-122 M36725 2. Remove end frame-to-rectifier nut. 4/7/95 Alternator ALTERNATOR - NIPPONDENSO 35A 3. Remove nuts and insulators. Disassembly End Frame-to-Rectifier Nut M5 4 N•m (31 lb-in.) 1. Remove three attaching screws. Attaching Screw (3) M5 4 N•m (31 lb-in.) 1 Nuts and Insulators M36726 IMPORTANT: Do not pry against stator wires. 4. Use a screwdriver to pry end frame from stator. Do not separate stator from front frame. M36725 IMPORTANT: Do not pry against stator wires. End Frame 2. Use a screwdriver to separate rotor assembly from stator assembly. Stator Stator Assembly Front Frame M36727 IMPORTANT: Do not heat connections longer than necessary to melt solder, as excess heat will damage rectifier assembly. 5. Use a soldering gun with a least 120 watt capacity to disconnect terminals. Replace voltage regulator. Rotor Assembly M36730 Rotor Assembly: Voltage Regulator • Rear bearing is press fit. Replace only if necessary. Remove bearing using a puller set. Install bearing until flush with end of rotor shaft. Press only on inner race of bearing. 3. Put rotor assembly in a soft-jawed vise. Remove nut, lock washer, sheave, fan and bushing. Terminals M36728 4. Put front frame on open jaws of vice. Use a softfaced hammer to remove rotor and spacer. Installation is done in the reverse order of removal. 5. Remove three screws, retainer, front bearing, washer and felt washer. • If additional solder is needed, use ONLY 60-40 rosin-core solder. 6. Inspect all parts for wear or damage. Replace as necessary. 4/7/95 1-123 Alternator Rear Bearing Apply multipurpose grease to O.D. during assembly. Bushing Fan Sheave Screw (3) 2 N•m (16 lb-in.) Lock Washer 1 Front Bearing Rotor Spacer Retainer Nut M14 54 N•m (40 lb-ft) Washer Felt Washer Apply multipurpose grease during assembly. Front Frame M82250A 7. Test rotor. (See Inspection/Test procedures.) Stator Assembly: 11.Use a soldering gun with at least 120 watt capacity to disconnect terminals. Remove voltage regulator. 8. Remove end frame-to-rectifier nut. 9. Remove nuts and insulators. Voltage Regulator IMPORTANT: Do not pry against stator wires. 10.Use a screwdriver to pry end frame from stator. End Frame-to-Rectifier Nut M5 4 N•m (31 lb-in.) Terminals M36728 12.Melt solder inside the connecting pipes. While solder is hot, open the flattened pipe with a needle nose pliers. Pull stator wire from pipe. Nuts and Insulators M36726 1-124 4/7/95 Alternator Inspection/Test Rotor: • Inspect the rotor slip rings for dirt build-up, rough spots, or out of roundness. If necessary, polish the surface of the slip rings using No. 00 sandpaper or 400-grit silicon carbide paper. M36739 • Touch the probes of an ohmmeter to slip rings. Replace rotor if test indicates no continuity (no needle movement). 13.Inspect and test brushes, stator and rectifier. (See Inspection/Test procedures.) Ohmmeter Assembly Assembly is done in the reverse order of disassembly. NOTE: The three pair of lead wires on the stator are not evenly spaced. Rotate the rectifier until the terminal pipes align with the stator leads. • Bend the stator lead wires, as necessary, to obtain an approximate distance of 33.50 mm (1.300 in.) from stator to rectifier. Connect the six leads using a soldering gun. Rotor Shaft Slip Rings M82110A • Touch the probes of the ohmmeter to the shaft and one of the slip rings. Repeat for other slip ring. Replace rotor if test shows continuity (needle movement). • If additional solder is needed, use ONLY 60-40 rosin-core solder. Ohmmeter IMPORTANT: Be sure six stator lead wires do not contact end frame when installed. • Before assembling stator assembly to rotor assembly, push brushes into brush holder and insert a wire through access hole in rear at end frame to lock brushes in place. Rotor Shaft Slip Rings Wire M82111A Brushes: Brushes • Inspect brush holder and brushes for damage. Brushes must slide freely and the springs must hold the brushes firmly against the slip rings of the rotor. M36748 • Assemble rotor assembly to stator assembly and fasten with three attaching screws. Remove wire from access hole. 4/7/95 • Measure brushes for wear. Minimum exposed length must be 5.50 mm (0.220 in.) or to wear limit line on brushes. Replace brushes as necessary. 1-125 1 Alternator • Use an ohmmeter or a test light to check for continuity. Check between the two brushes and between each brush and ground stud. There should be no continuity. Replace brush holderrectifier assembly if there is continuity. Insulator Brush Holder Brush Ground Stud Brushes 1 Brush Lead Wire M36736 • To replace brushes: - Melt solder from brush lead connections and remove brushes and springs. - Inspect springs for wear or damage. Replace as necessary. Insulating Washers M36745 NOTE: If additional solder is needed, use ONLY 6040 rosin-core solder. Stator: • Inspect stator for defective insulation, discoloration or a burned odor. If any of these defects are found, replace stator. Brush Lead Connections NOTE: Use an ohmmeter that is sensitive to resistance of 0 to 1 ohm. M36737 - Push brush lead wire through spring. Insert spring and brush in brush holder with lead protruding through hole in brush holder. Make sure the longest side of brush is on side of brush holder with raised lip. - Hold brushes in position so that exposed length is 13 mm (0.500 in.) - Solder brush leads in this position. Cut off excess length of brush lead wire. - Be sure insulating washers and insulator are in place. • Touch probes of an ohmmeter to each pair of stator wires. Equal continuity readings should be observed between each pair of leads. If readings are not equal, replace stator. M36740 1-126 4/7/95 Alternator • Touch one probe of the ohmmeter to the bare metal surface of stator and the other probe to a bare stator lead wire. Repeat for each wire. Replace stator if test indicates continuity. • Test the diodes by touching probes to output post and the three outer terminals. • Switch the probes and check each terminal again. There should be continuity in only one direction between each terminal and the output post. 1 M36741 Rectifier: Output Post NOTE: The three inner terminals are connected by a printed circuit in the rectifier. • Test the three inner terminals using an ohmmeter. Move probes so all terminals are cross checked. Replace the rectifier if test shows no continuity. M36743 • Test the diodes by touching probes to ground post and the three outer terminals. • Switch the probes and check each terminal again. There should be continuity in only one direction between each terminal and the ground post. A shorted diode would have continuity in both directions. An open diode would have no continuity in either direction. Replace the rectifier assembly if any of the six diodes are defective. Inner Terminals M36742 NOTE: Each of the three outer terminals on the rectifier is connected to two diodes permitting current flow in only one direction. 4/7/95 Ground Post M36744 1-127 Alternator VOLTAGE REGULATOR NIPPONDENSO 40A Nut 69 N•m (51 lb-ft) Replacement 1. Remove nut and insulator. 2. Remove three screws and cover. 1 Sheave Cover M52469 Nut and Insulator 4. Remove four screws and straighten stator wire leads. 5. Remove rectifier. Rectifier M52470 3. Remove two screws, brush holder and cover. Stator Wire Lead (4) 4. Remove three screws. Replace voltage regulator. Long Screw (2) Voltage Regulator M52471 6. Remove two nuts, two screws and end frame assembly. Short Screw Brush Holder and Cover 7. Press rotor shaft from end frame. 8. Remove spring washer. M52472 Installation is done in the reverse order of removal. Spring Washer IMPORTANT: Make sure to install short screw at location shown. Longer screw will contact frame and cause damage to the charging system. ALTERNATOR - NIPPONDENSO 40A Rotor Shaft Disassembly End Frame Assembly M52473 1. Remove voltage regulator. (See VOLTAGE REGULATOR - REPLACEMENT in this group.) 9. Remove four screws and retainer. 2. Remove nut. NOTE: Front bearing is press fit in front frame. Remove bearing only if replacement is necessary. 3. Remove sheave using a puller set. 1-128 4/7/95 Alternator 10.Inspect bearing in front frame for wear or damage. Replace if necessary. Replace bearing using a driver set and a press. Front Bearing Rear Bearing Front Frame Screw (4) 2 N•m (16 lb-in.) Retainer Rotor Core 1 Slip Rings M52474 Brushes: 11.Inspect and test brushes, stator and rectifier. (See Inspection/Test in this group.) • Inspect brush holder, brushes and springs for damage. Brushes must slide freely and springs must hold brushes firmly against the slip rings of the rotor. Assembly • Measure length of brush protruding from holder. If length is less than wear limit, replace brushes. M52475 Assembly is done in the reverse order of disassembly. • After installing rectifier, form a loop in stator wire leads, insert screws through loop and secure rectifier and wire leads. Inspection/Test Rotor: M52478 NOTE: Rear bearing and rotor assembly are not serviced separately. Damaged parts require that rotor assembly and bearing be replaced as a unit. • Inspect bearing for wear or damage. Replace complete rotor if necessary. • Inspect slip rings for dirt build-up, rough spots or out-of-roundness. If necessary, polish the surface of the slip rings using No. 00 sandpaper or 400-grit silicone carbide paper. Measure outer diameter of slip rings. Replace rotor if less than 14 mm (0.550 in.). Brush Length Specifications New. . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.) Wear Limit. . . . . . . . . . . . 4.50 mm (0.170 in.) • Check continuity between brush and terminal “A”. Check continuity between brush and terminal “B”. There should be continuity only at these points. A B • Touch the probes of an ohmmeter to slip rings. Replace rotor if test indicates no continuity (no needle movement). • Touch probes of ohmmeter to the rotor core and one of the slip rings. Repeat for other slip ring. Replace rotor if test shows continuity (needle movement). 4/7/95 M52479 1-129 Alternator Stator: Rectifier: • Inspect stator for defective insulation, discoloration or a burned odor. If any of these defects are found, replace stator. NOTE: Use an ohmmeter that is sensitive to resistance of 0 to 1 ohm. 1 • Check for continuity between each stator lead and stator body. Replace stator if test indicates continuity. To replace stator: - Scribe a mark on housing, at notch in stator, to aid in installation of a new stator. - Remove two studs. - Replace stator using a punch and hammer. NOTE: Set the ohmmeter to the K ohm range. • Check continuity between output post and each diode lead. Reverse ohmmeter leads and recheck. There should be continuity in one direction, but not the other. A shorted diode would have continuity in both directions. An open diode would have no continuity in either direction. Replace the rectifier if any of the four diodes are defective. Diode Lead (4) Stator Lead (4) Stator Body Output Post M52477 Stud (2) Scribe Mark on Housing 1-130 Notch M82251 4/7/95 Diagnosis ● ● ● ● ● Fuel shut-off valve turned off, or restricted. Solenoid linkage misadjusted. See adjustment. ● ● ● ● ● ● ● Muffler or exhaust manifold leak. Defective glow plugs. ● Injection pump or governor malfunctioning. Injection pump timing incorrect. ● Defective cranking components or connectors. ● Low compression from worn rings, cylinder bore, piston, valves or warped head. Valve clearance incorrect. ● Burned or warped valves and valve seats. Defective valve spring. Starter cranking rpm too slow. Damaged starter. Excessive engine load. ● Fuel pump leaking or not operating. See Fuel Supply Pump Pressure Test. Engine oil viscosity or level incorrect. ● Radiator. 4/7/95 ● ● ● ● ● ● ● ● ● ● ● ● ● ● 3 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 1 ● ● ● Injector pressure incorrect or leaking. Cylinder head gaskets leaking or damaged. ● Exhaust smoke black or grey or uses too much fuel. Air filter elements dirty or plugged. Replace. ● Exhaust smoke white. ● Exhaust smoke blue or uses too much oil. ● Engine operating temperature is incorrect. Engine surges, or has uneven or uncontrolled rpm. ● Engine has low oil pressure. Engine runs rough, misses, noisy, vibrates or low on power. Fuel in oil. Oil level high. ● Oil in the coolant or coolant in the oil. Engine will not stay running, or stalls frequently. Fuel pump screen, fuel filter, or fuel line restricted. Fuel dirty, contains water or wrong grade. CHECK OR SOLUTION Engine will not crank. Engine cranks but will not start or starts hard. PROBLEM OR SYMPTOM Lack of fuel at injection pump. ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART ● ● ● ● ● ● ● ● ● ● ● ● ● 1-131 Diagnosis ENGINE SYSTEM DIAGNOSIS Conditions: • Engine mounted on level surface. • Key switch off unless indicated otherwise. Test Location Normal If Not Normal 1. Engine dipstick and exterior engine surfaceengine oil check. Oil level between “L” and “H” marks. Oil not burnt, or contaminated with metal particles, fuel, or coolant. No external leakage, filter clean. Change oil and inspect for source of contamination. Check gaskets, seals, plugs, cylinder head, block, and intake manifold and breather. Change oil filter. 2. Coolant tank and radiator. Coolant level between marks on tank when engine is warm. Coolant in radiator full to top. Coolant not contaminated with oil, fuel or discolored brown. Add proper coolant mix. Radiator screen free of debris. Clean or replace. Hoses not cracked or leaking, clamps and radiator cap tight. Pressure test radiator and cap. Fan belt tight, not glazed or cracked. Replace and adjust belt tension. Fan blades not damaged or warped. Replace fan. Fuel level correct, not contaminated, correct grade of fuel, no water. Fuel pump screen and in-line filter free of debris. Fuel shutoff valve in “ON” position. Drain and clean fuel tank. Add fresh fuel. Replace filters. Fuel hoses not cracked or leaking. Replace. Fuel hose clamps tight. Replace or tighten. Fuel tank does not have vacuum. Replace fuel tank check valve. Air filter hose not cracked, clamps tight. Element not plugged. Air filter housing sealed, no dirt tracking inside filter element. Replace and tighten clamps. 1 - Cooling System Check. 3 3. Fuel tank, pump, pump screen, lines, filter, filter shutoff valve. - Fuel System Check 4. Air filter and air intake. - Air Intake System Check Drain and flush system. Check for source of contamination. Move to “ON” position. Replace element or housing. 5. Fuel shutoff solenoid. (Key in RUN position.) Fuel shutoff solenoid must pull in and stay in. Solenoid must bottom out. Shutoff shaft must still move slightly. Check shutoff solenoid adjustment. Clean any dirt from under solenoid boot. If solenoid will not pull in and hold in, see Fuel Shutoff Solenoid Circuit Test Points in ELECTRICAL section of Machine TM. 6. Glow plug indicator light. (Key in RUN position.) Indicator light should come on up to 15 seconds depending on air temperature. See Glow Plug Circuit Test Points in ELECTRICAL section of Machine TM. 1-132 4/7/95 Diagnosis ENGINE SYSTEM DIAGNOSIS - Continued Test Location Normal If Not Normal 7. Fuel filter, fuel pump. (Key switch in RUN position.) Fuel level increases in filter. Fuel pump operating - listen for humming sound. Fuel present in return hose at fuel pump. See Fuel Pump Circuit Test Points in ELECTRICAL section of Machine TM. Test fuel pump pressure. (See Operational Tests in this section.) Replace fuel filter. 8. Throttle lever and cable. Linkage not binding and adjusted correctly. Repair, replace or adjust cable. 9. Intake and exhaust valves. Cold engine. Valve clearance within specification. Valves not sticking. Check and adjust. (See Checks, Tests and Adjustments in this section.) Check valve guides and stems. 10. Fuel at injectors. (Key in START position - engine cranking.) Crack fuel injection lines at injectors. Fuel shutoff solenoid pulled in. Check spray pattern and cracking pressure. (See Checks, Tests and Adjustments in this section.) Replace injectors.See Cranking Circuit Test Points in ELECTRICAL section of Machine TM. 11. Injector ports. (Key in START position.) Cylinder compression within specification. Pressure difference between cylinders within specification. Perform cylinder compression test. (See Operational Tests in this section.) 12. Flywheel and starter. Minimum cranking rpm within specification. See Starter Amp Draw Test in ELECTRICAL section of Machine TM. 13. Injection pump timing inspection. (Key OFF.) Timing should be correct. Remove pump as the LAST possible solution. Perform injection pump static timing adjustment. (See Checks, Tests and Adjustments in this section.) Have pump tested by a qualified Service Repair Shop. 14. Injection pump idle settings. (Engine running). Engine runs smooth under load. Engine rpm to specification. See Slow Idle and Fast Idle Adjustments in ENGINE section of Machine TM. 15. Oil pressure sender port. Oil pressure in specification. Test engine oil pressure. (See Operational Tests in this section.) 16. Thermostat. (Engine at operating temperature.) Clean from corrosion, rust, or debris. Opening temperature within specification. Replace thermostat. Perform thermostat opening test. (See Checks, Tests and Adjustments in this section.) 17. Muffler. Not restricted. Replace muffler. 4/7/95 Engine must crank. 1 1-133 3 Checks, Tests and Adjustments To achieve correct engine operation. 2 I E 3 I E I No. 1 Piston at TDC Equipment: M82327A • Feeler Gauge To adjust valves, loosen nut and turn adjusting screw until clearance is 0.20 mm (0.008 in.). Hold screw while tightening nut. Procedure: NOTE: “Top Dead Center (TDC)” is the piston at its highest point. 1. Remove rocker arm cover. Feeler Gauge 2. Turn crankshaft pulley clockwise until No.1 cylinder timing mark on pulley aligns with arrow on timing gear cover. Arrow T6105BF 5. Turn crankshaft pulley one revolution (360°). This puts the piston in No. 2 cylinder at TDC compression stroke. No. 1 Timing Mark M35256 6. Measure and adjust valve clearance on the valves (arrows) with No. 2 piston at TDC. NOTE: No. 1 cylinder is the closest to the flywheel. Cylinders 3. Try to move both No. 1 cylinder rocker arms or push rods. 4. Measure and adjust valve clearance on the valves (arrows) with No. 1 piston at TDC. 1-134 E 2 I E 3 I E I Fan End If rocker arm push rods are not loose, rotate flywheel one revolution (360°). If both rocker arm push rods are loose the piston is at TDC on compression stroke. 1 Flywheel End 1 1 E Fan End Reason: Cylinders Flywheel End VALVE CLEARANCE, CHECK AND ADJUSTMENT - EARLY 3TNA72 (430 LGT) No. 2 Piston at TDC M82327A 4/7/95 Checks, Tests and Adjustments VALVE CLEARANCE, CHECK AND ADJUSTMENT - 3TN66 AND LATER 3TNA72 No. 1 TDC Mark on Flywheel Reason: Index Mark on Flywheel Plate To achieve correct engine operation. Equipment: 1 • Feeler Gauge M37501 Procedure: NOTE: Location of the index mark will be different as a result of the various engine applications. The index mark appears on the following: - 15 EX, 3009 OEM: Flywheel housing. - 330/332 LGT, F915 FM, 430 LGT (Later), F925/35 FM: Flywheel cover. - 375 SSL, 670 CUT: Flywheel plate. - 655 CUT, 455 LGT, 755/56 CUT: Flywheel guard and plate. 375 SSL, 670 CUT NOTE: No. 1 cylinder is the closest to the flywheel. 4. Try to move both No. 1 cylinder rocker arms or push rods. If rocker arm push rods are not loose, rotate flywheel one revolution (360°). If both rocker arm push rods are loose, the piston is at TDC on compression stroke. 5. Measure and adjust valve clearance on the valves (arrows) with No. 1 piston at TDC. Cylinders 1. Remove rocker arm cover. 3. Turn crankshaft pulley clockwise until No.1 cylinder TDC mark on flywheel aligns with index mark on flywheel housing/cover or plate. E 2 I E 3 I E I Fan End NOTE: “Top Dead Center (TDC)” is the piston at its highest point. Flywheel End 1 2. Remove plug from timing hole in flywheel housing/cover, if equipped. No. 1 Piston at TDC M82327A To adjust valves, loosen nut and turn adjusting screw until clearance is 0.20 mm (0.008 in.). Hold screw while tightening nut. No. 1 TDC Mark on Flywheel Feeler Gauge Index Mark on Flywheel Housing/Cover M37500 330/332 LGT, F915 FM, 430 LGT (Later), F925/35 FM, 15 EX, 3009 OEM 4/7/95 T6105BF 1-135 Checks, Tests and Adjustments 6. Turn crankshaft pulley one revolution (360°). This puts the piston in No. 2 cylinder at TDC compression stroke. 7. Measure and adjust valve clearance on the valves (arrows) with No. 2 piston at TDC. Specifications: Standard Clearance . . . . . . . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . (0.0079 - 0.0157 in.) Wear Limit. . . . . . . . . . . 0.55 mm (0.0217 in.) Results: Cylinders 2 I E E • If side play exceeds wear limit, replace connecting rod and connecting rod cap. 3 I E I Fan End Flywheel End 1 1 No. 2 Piston at TDC M82327A CONNECTING ROD SIDE PLAY CHECK CONNECTING ROD BEARING CLEARANCE CHECK Reason: To measure oil clearance between connecting rod bearing and crankshaft journal. Equipment: Reason: • PLASTIGAGE® To determine proper side clearance between crankshaft and connecting rod. Procedure: IMPORTANT: Connecting rod caps must be installed on the same connecting rod and in the same direction to prevent crankshaft and connecting rod damage. Equipment: • Feeler Gauge Procedure: 1. Insert a feeler gauge, according to specifications, between connecting rod cap and crankshaft. 1. Remove connecting rod cap. 2. Wipe oil from bearing insert and crankshaft journal. 3. Put a piece of PLASTIGAGE, or an equivalent, along the full length of the bearing insert approximately 6 mm (0.250 in.) off center. Feeler Gauge M82116A 1-136 PLASTIGAGE M35351 4. Turn crankshaft approximately 30° from bottom dead center. 4/7/95 Checks, Tests and Adjustments 5. Install connecting rod end cap and original cap screws. Tighten cap screws to 23 N•m (203 lbin.). Equipment: 6. Remove cap screws and connecting rod cap. Procedure: NOTE: The flattened PLASTIGAGE will be found on either the bearing insert or crankshaft journal. NOTE: Crankshaft end play can be measured at front end or rear end of crankshaft. Procedure is performed from the rear end. The flywheel is removed to show detail. 7. Use the graduation marks on the envelope to compare the width of the flattened PLASTIGAGE at its widest point. 8. Determine bearing clearance. The number within the graduation marks indicates the bearing clearance in inches or millimeters depending on which side of the envelope is used. • Dial Indicator 1. Fasten dial indicator to engine and position indicator tip on end of crankshaft. IMPORTANT: Do not use excessive force when moving crankshaft to avoid damaging bearings. 2. Push crankshaft toward rear as far as possible. 9. Remove PLASTIGAGE. 3. Zero the dial indicator. 4. Using a bar, gently pry the crankshaft as far forward as possible. Graduation Marks on Envelope Flattened PLASTIGAGE M82117A Specifications: Standard Clearance . . . . . . 0.020 - 0.072 mm . . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0028 in.) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) Dial Indicator Results: • If clearance exceeds wear limit, replace bearing inserts. ®PLASTIGAGE is a registered trademark of the DANA Corporation. Crankshaft M82118A Specifications: Standard Clearance . . . . . . 0.090 - 0.271 mm . . . . . . . . . . . . . . . . . . . . . . . (0.004 - 0.011 in.) Wear Limit. . . . . . . . . . . 0.33 mm (0.0129 in.) CRANKSHAFT, END PLAY CHECK Results: Reason: To determine proper side clearance between crankshaft and engine block. 4/7/95 • If end play exceeds wear limit, replace thrust bearings. 1-137 1 Checks, Tests and Adjustments CRANKSHAFT MAIN BEARING, CLEARANCE CHECK Reason: To measure oil clearance between main bearing and crankshaft journal. 7. Determine main bearing clearance. The number within the graduation marks indicates the bearing clearance in inches or millimeters depending on which side of the envelope is used. 8. Remove PLASTIGAGE. Graduation Marks on Envelope Equipment: 1 • PLASTIGAGE® Procedure: IMPORTANT: Main bearing caps must be installed on the same main bearing and in the same direction to prevent crankshaft and main bearing damage. 1. Remove main bearing cap. 2. Wipe oil from bearing insert and crankshaft journal. 3. Put a piece of PLASTIGAGE, or an equivalent, along the full length of the bearing insert approximately 6 mm (0.250 in.) off center. Flattened PLASTIGAGE M82119AE Specifications: Standard Clearance . . . . . . 0.020 - 0.072 mm . . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0028 in.) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) Results: • If clearance exceeds wear limit, replace bearing inserts. ®PLASTIGAGE is a registered trademark of the DANA Corporation. VALVE LIFT CHECK PLASTIGAGE Reason: Can indicate excessive wear on cam lobes, followers, and/or push rods. M35382 Equipment: • Dial Indicator 4. Install main bearing cap and cap screws. Tighten cap screws to: 3TN66 . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) 3TNA72 (3009) . . . . . . . . . . 79 N•m (58 lb-ft) 5. Remove cap screws and main bearing cap. NOTE: The flattened PLASTIGAGE will be found on either the bearing insert or crankshaft journal. 6. Use the graduation marks on the envelope to compare the width of the flattened PLASTIGAGE at its widest point. 1-138 Procedure: 1. Adjust valve clearance. (See procedure in this group.) 2. Remove rocker arm cover. (See Cylinder Head, Valves and Manifolds in this section.) 3. Fasten dial indicator to engine and position indicator tip on valve retainer. Valve must be fully closed and rocker arm must move freely. 4. Zero the dial indicator. 5. Manually turn crankshaft pulley clockwise (from fan end). 4/7/95 Checks, Tests and Adjustments 6. Observe dial indicator as valve is moved to the full open position. Valve lift (intake and exhaust) should be 7.5 mm (0.300 in.). Repeat for each valve. Procedure: 1. Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) 2. Fasten dial indicator to engine and position indicator tip on end of camshaft. 3. Push camshaft toward the rear as far as possible. 4. Zero the dial indicator. 1 5. Pull camshaft forward as far as possible. T6333DT Results: • If valve lift is less than specification, remove and inspect camshaft, followers and push rods. (See Camshaft and Timing Gear Train and/or Cylinder Head, Valves and Manifolds in this section.) CAMSHAFT END PLAY CHECK M37512 Specifications: Standard Clearance . . . . . . . . 0.05 - 0.20 mm . . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.) Wear Limit. . . . . . . . . . . . 0.40 mm (0.016 in.) Results: Reason: To determine proper side clearance between camshaft gear end journal and thrust plate. • If end play exceeds wear limit, remove camshaft and replace thrust plate. (See Camshaft and Timing Gear Train in this section.) Equipment: • Dial Indicator 4/7/95 1-139 Checks, Tests and Adjustments TIMING GEAR BACKLASH, CHECK EARLY 3TNA72 (430 LGT) Reason: To check for wear between meshing gears, resulting in excessive noise and poor engine performance. All Except Fuel Injection Pump Gear-to-Oil Pump Gear. . . . . . . . . . . . . 0.04 - 0.12 mm . . . . . . . . . . . . . . . . . . (0.0016 - 0.0047 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Results: Equipment: 1 • If backlash exceeds wear limit, replace meshing gears as a set: • Dial Indicator Idler Gear, Camshaft Gear, Crankshaft Gear, AND/ OR Idler Gear, Fuel Injection Pump Gear, and Oil Pump Gear. Procedure: 1. Measure backlash between meshing gears. Specifications: Standard Backlash Fuel Injection Pump Gear-to-Oil Pump Gear. . . . . . . . . . . . . 0.11 - 0.19 mm . . . . . . . . . . . . . . . . . . (0.0043 - 0.0075 in.) Fuel Injection Pump Gear-to-Idler Gear Camshaft Gear-to-Idler Gear Fuel Injection Pump Gear-to-Oil Pump Gear Idler Gear-to-Crankshaft Gear M82328A 1-140 4/7/95 Checks, Tests and Adjustments TIMING GEAR BACKLASH, CHECK 3TN66 AND LATER 3TNA72 Reason: To check for wear between meshing gears, resulting in excessive noise and poor engine performance. All Except Crankshaft Gear-to-Oil Pump Gear. . . . . . . . . . . . . 0.04 - 0.12 mm . . . . . . . . . . . . . . . . . . (0.0016 - 0.0047 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Results: Equipment: • Dial Indicator Procedure: 1. Measure backlash between meshing gears. • If backlash exceeds wear limit, replace meshing gears as a set: Idler Gear, Camshaft Gear, Crankshaft Gear, Oil Pump Gear AND/OR Idler Gear, Fuel Injection Pump Gear. Specifications: Standard Backlash Crankshaft Gear-to-Oil Pump Gear. . . . . . . . . . . . . 0.11 - 0.19 mm . . . . . . . . . . . . . . . . . . (0.0043 - 0.0075 in.) Fuel Injection Pump Gear-to-Idler Gear Camshaft Gear-to-Idler Gear Idler Gear-to-Crankshaft Gear Crankshaft Gear-to-Oil Pump Gear 4/7/95 M82252A 1-141 1 Checks, Tests and Adjustments FUEL INJECTION NOZZLE TEST (PINTLE-TYPE) Equipment: • D01109AA Diesel Fuel Injection Nozzle Tester • D01110AA Adapter Set CAUTION 1 Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. Reason: To determine opening pressure, leakage, chatter and spray pattern of the fuel injection nozzle. 1-142 • 23622 Straight Adapter • Container Connections: 1. Connect fuel injection nozzle to D01109AA Diesel Fuel Injection Nozzle Tester using parts from D01110AA Adapter Set and 23622 Straight Adapter. IMPORTANT: Use clean filtered diesel fuel when testing injection nozzles to get best test results. Procedure 1: Test fuel injection nozzle opening pressure following the Nozzle Tester manufacturer's instructions. Specifications: Opening Pressure . . . . . . . . 11722 ± 480 kPa . . . . . . . . . . . . . . . . . . . . . . . . . (1700 ± 70 psi) Results: • If pressure reading does not meet specification, disassemble injection nozzle and inspect nozzle assembly for contamination or stuck valve. If necessary, add or remove shims to change opening pressure. 4/7/95 Checks, Tests and Adjustments 23617 90° Adapter 36352 Fuel Line Assembly 23621 Straight Adapter 23622 Straight Adapter D01109AA Diesel Fuel Injection Nozzle Tester Fuel Injection Nozzle 1 Container M35913 Procedure 2: Test fuel injection nozzle leakage following the Nozzle Tester manufacturer's instructions. 1. Dry nozzle completely using a lint-free cloth. 2. Pressurize nozzle to 11032 kPa (1600 psi). 3. Watch for leakage from nozzle spray orifice. Leakage time should be a minimum of 10 seconds. Slow Hand Lever Movement . . . . . . . . . . . . . Fine Stream . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern Fast Hand Lever Movement . . . . . . . . . . . Fine Atomized . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern Correct Results: Proper Spray Angle • If leakage time does not meet specification, disassemble injection nozzle and inspect nozzle assembly for contamination. Inspect valve seating surface. Replace nozzle assembly if necessary. Procedure 3: Test fuel injection nozzle chatter and spray pattern following the Nozzle Tester manufacturer's instructions. 1. Pressurize nozzle to 11722 ± 480 kPa (1700 ± 70 psi). Correct Injection Angle Poor 2. Listen for “chatter” sound and watch spray pattern. Specifications: Slow Hand Lever Movement . . . . . . . . . . . Chatter Sound 4/7/95 M82121A 1-143 Checks, Tests and Adjustments Results: • If nozzle chatter or spray pattern does not meet specifications, disassemble injection nozzle and inspect nozzle assembly for contamination. Inspect valve seating surface. Replace nozzle assembly if necessary. 1 Thermometer • If there is excessive difference in spray angle or injection angle, incomplete atomization or sluggish starting/stopping of injection, disassemble injection nozzle and inspect nozzle assembly for contamination. Replace nozzle assembly if necessary. Thermostat M82122A THERMOSTAT OPENING TEST Reason: Specifications: To determine opening temperature of thermostat. Equipment: • Thermometer • Glass Container • Heating Unit Procedure: Begin Opening . . . . . . . . . . . . . 71° C (160° F) Fully Open . . . . . . . . . . . . . . . . 85° C (184° F) Minimum Lift Height . . . . . .8 mm (0.310 in.) Results: • If thermostat does not open according to specifications, replace. • If closing action is not smooth and slow, replace thermostat. CAUTION DO NOT allow thermostat or thermometer to rest against the side or bottom of glass container when heating water. Either may rupture if overheated. COOLANT TEMPERATURE SENSOR TEST Reason: To determine operating temperature of sensor. Equipment: 1. Suspend thermostat and a thermometer in a container of water. • Thermometer 2. Heat and stir the water. Observe opening action of thermometer and compare temperatures with specifications. • Heating Unit • Glass Container • Ohmmeter 3. Remove thermostat and observe its closing action as it cools. 1-144 4/7/95 Checks, Tests and Adjustments Procedure: Equipment: • JT05712 Current Gun CAUTION DO NOT allow switch or thermometer to rest against the side or bottom of glass container when heating water. Either may rupture if overheated. 1. Connect lead wires from ohmmeter probes, to sensor terminal and body. 2. Suspend sensor and a thermometer in a container of water. 3. Heat and stir the water. Observe water temperature when continuity occurs. Water temperature should be 107 - 113° C (225 235°F). Ohmmeter Probes • JT05719 Hand-Held Digital Tachometer • Jumper Cables • Jumper Wire Procedure: 1 1. Mount starter in a vise. NOTE: Check that battery is fully charged and of proper size to ensure accuracy of test. 2. Connect jumper cables to a 12 volt battery. 3. Connect positive (+) cable to solenoid battery terminal on starter. 4. Connect negative (-) cable to starter body. 5. Attach Current Gun to positive cable. IMPORTANT: Complete this test in 20 seconds or less to prevent starter damage. 6. Use a jumper wire to briefly connect positive (+) starter terminal to solenoid terminal “S”. Starter should engage and run. 7. Read and record starter amperage and rpm. Specifications: Coolant Temperature Sensor M82123A Results: • If continuity does not occur within temperature listed, replace sensor. STARTER NO-LOAD AMP DRAW/RPM TEST Maximum Starter Amperage Hitachi 0.8 kW. . . . . . . 60 Amps at 7000 rpm Nippondenso 1.0 kW. . 90 Amps at 3000 rpm Minimum Starter RPM Hitachi 0.8 kW. . . . . . . . . . . . . . . . . . . . . 7000 Nippondenso 1.0 kW. . . . . . . . . . . . . . . . 3000 Results: • If solenoid “clicks” or chatters and motor does not turn, replace solenoid. Reason: • If pinion gear engages and motor doesn't turn, repair or replace starter motor. To determine if starter is binding or has excessive amperage draw under no load. • If starter engages and runs but amperage is more than specifications, repair or replace starter. • If rpm is less than specification, with battery fully charged, repair or replace starter. 4/7/95 1-145 Checks, Tests and Adjustments JT05712 Current Gun JT05719 Hand-Held Digital Tachometer 1 Jumper Wire M82149A Hitachi 0.8 kW JT05712 Current Gun JT05719 Hand-Held Digital Tachometer Jumper Wire Nippondenso 1.0 kW 1-146 M82150A 4/7/95 Checks, Tests and Adjustments INJECTION PUMP STATIC TIMING ADJUSTMENT - EARLY 3TNA72 (430 LGT) Reason: Timing Tool To make sure that injection pump timing is set to manufacturers specification. 1 Equipment: • Timing Tool (No. 1 fuel injection line cut off at first bend) M35865 5. Remove glow plugs to aid in turning crankshaft pulley. • External fuel supply Procedure: IMPORTANT: Injection pump timing should be correct. Once timing is set, it will not normally change during the life of the engine, unless it was altered. 6. Turn crankshaft pulley in either direction until the No. 1 cylinder timing mark aligns with arrow on timing gear cover. Arrow Check and adjust timing only as the last option. Check fuel, fuel supply system, injectors, air intake system and cylinder compression before continuing. NOTE: The flywheel turns counterclockwise (as viewed from the flywheel end). The number one fuel injection line is toward the flywheel. No. 1 Timing Mark M35256 1. Remove the number one fuel injection line and delivery valve fitting. 7. Put a container under timing tool to collect any fuel. 2. Remove spring and delivery valve. Do not remove delivery valve seat. 8. Turn key switch to ON position. DO NOT start engine. Push fuel shutoff solenoid plunger to “hold” position. 3. Install delivery valve fitting and tighten to 42 N•m (31 lb-ft). Delivery Valve Fitting Spring Delivery Valve T6333HP 4. Install timing tool (number one fuel line cut off at first bend). 4/7/95 9. Turn flywheel clockwise (as viewed from the flywheel end) until fuel flows in a stream. 10.Slowly turn flywheel counterclockwise until fuel flow changes from a stream and then stops completely. This is the point of injection timing at which the pump is set. NOTE: If the fuel flow does not stop, the number one piston is on the exhaust stroke instead of the compression stroke. Turn flywheel one revolution and repeat Steps 6 - 10. 11.Check timing mark on camshaft pulley. The 15° timing mark must line up with the arrow on timing gear cover. 1-147 Checks, Tests and Adjustments - Install new shims with the THICKEST shim against the injection pump body and the THINNEST shim against the gear housing. 15° Timing Mark Arrow • If timing did not change, have pump tested by a diesel injection service shop. • If timing is OK: - Remove timing tool. 1 - Remove delivery valve fitting. M35868 Specifications: Injection Pump Timing. . . . . . . . . .15° BTDC . . . . . . . . . . . . . . . (Before Top Dead Center) Engine Crankshaft Position. . . . . . . . . . . . . . . . . . . No.1 Cylinder . . . . . . . . . . . . . on TDC Compression Stroke Distance On Outer Surface of Crankshaft Pulley for Every 0.1 mm (0.004 in.) of Shim Thickness . . . . . . . 1° or 1 mm (3/64 in.) Results: • If timing is not according to specifications: - Remove injection pump and shims (See Fuel System in this section.) - Measure old shims to determine shim thickness. - Measure approximate distance between timing mark and arrow. NOTE: Crankshaft pulley always turns clockwise when engine is running. - If timing mark has not reached arrow, RETARD pump timing by increasing total shim thickness. If mark has passed arrow, ADVANCE timing by decreasing total shim thickness. Use new shims. For every 0.1 mm (0.004 in.) of shim thickness, there is approximately a 1° or 1 mm (3/64 in.) change in crankshaft pulley timing. Shim Pack: Approximate Timing Change on Crankshaft Shim Size Pulley 0.2 mm (0.007 in.) . . . . . . . . 2° or 2 mm (5/64 in.) 0.3 mm (0.012 in.) . . . . . . . . . 3° or 3 mm (1/8 in.) 0.5 mm (0.020 in.) . . . . . . . 5° or 5 mm (13/64 in.) 1-148 - Install delivery valve and spring. - Install new o-ring and delivery valve fitting. Tighten to 42 N•m (31 lb-ft). - Install number one injection line. INJECTION PUMP STATIC TIMING ADJUSTMENT - 3TN66 AND LATER 3TNA72 Reason: To make sure that injection pump timing is set to manufacturers specification. Equipment: • Timing Tool (No. 1 fuel injection line cut off at first bend) • External fuel supply Procedure: IMPORTANT: Injection pump timing should be correct. Once timing is set, it will not normally change during the life of the engine, unless it was altered. Check and adjust timing only as the last option. Check fuel, fuel supply system, injectors, air intake system and cylinder compression before continuing. NOTE: The flywheel turns counterclockwise (as viewed from the flywheel end). The number one fuel injection line is toward the flywheel. 1. Remove the number one fuel injection line and delivery valve fitting. 4/7/95 Checks, Tests and Adjustments 2. Remove spring and delivery valve. Do not remove delivery valve seat. 3. Install delivery valve fitting and tighten to 42 N•m (31 lb-ft). No. 1 TDC Mark on Flywheel Delivery Valve Fitting Spring Index Mark on Flywheel Housing/Cover 1 M37500 Delivery Valve 330/332 LGT, F915 FM, 430 LGT (Later), F925/35 FM, 15 EX, 3009 OEM T6333HP 4. Install timing tool (number one fuel line cut off at first bend). No. 1 TDC Mark on Flywheel Index Mark on Flywheel Plate Timing Tool M37501 375 SSL, 670 CUT M35865 5. Remove glow plugs to aid turning crankshaft pulley. 6. Remove plug from flywheel housing/cover, if equipped. 7. Turn crankshaft pulley in either direction until the No. 1 cylinder top dead center (TDC) mark aligns with the index mark on the flywheel housing/ cover or plate. 8. Put a container under timing tool to collect any fuel. 9. Turn key switch to ON position. DO NOT start engine. Push fuel shutoff solenoid plunger to “hold” position. 10.Turn flywheel clockwise (as viewed from the flywheel end) until fuel flows in a stream. 11.Slowly turn flywheel counterclockwise until fuel flow changes from a stream and then stops completely. This is the point of injection timing at which the pump is set. NOTE: If the fuel flow does not stop, the number one piston is on the exhaust stroke instead of the compression stroke. Turn flywheel one revolution and repeat Steps 7 - 11. 12.Check timing mark on flywheel. The index mark must line up with the 13° mark on flywheel. 4/7/95 1-149 Checks, Tests and Adjustments Flywheel 13° Mark removed. If shim pack thickness is unknown or new pump is installed, replace with 0.5 mm (0.020 in.) shim pack thickness. • If timing is OK: 1 TDC Mark on Flywheel - Install rubber plug in flywheel housing/cover, if equipped. - Remove timing tool. 1 - Remove delivery valve fitting. - Install delivery valve and spring. Index Mark on Flywheel Housing/Cover or Plate - Install new o-ring and delivery valve fitting. Tighten to 42 N•m (31 lb-ft). - Install number one injection line. FAN/ALTERNATOR DRIVE BELT ADJUSTMENT T6471CS Specifications: Injection Pump Timing. . . . . . . . . .13° BTDC . . . . . . . . . . . . . . . (Before Top Dead Center) Engine Crankshaft Position. . . . . . . . . . . . . . . . . . . No.1 Cylinder . . . . . . . . . . . . . on TDC Compression Stroke Distance On Outer Surface Of Flywheel Per 1° Of Rotation. . . . . . 2.62 mm (0.100 in.) Results: Reason: To keep proper tension on belt to drive water pump and alternator. To prevent shortened belt and bearing life. Equipment: • JDG529 or JDST28 Belt Tension Gauge • Straight Edge Procedure: 1. Check belt tension between fan and alternator using Belt Tension Gauge and a straight edge. • If timing is not according to specifications: - Remove injection pump and shims. (See Fuel System in this section.) - Install new shim(s) with a total shim pack thickness of 0.5 mm (0.020 in.). Belt Deflection - Install injection pump and recheck timing. • If engine performance is poor, check air cleaners, fuel filter, fuel supply, injectors and cylinder compression before removing pump for service. Check all timing gears for wear. Retest performance. • If performance did not change, have pump tested by a diesel injection service. When reinstalling injection pump, use same thickness of shim pack 1-150 M54014 Specifications: Applied Force . . . . . . . . . . .98 N (22 lb-force) Deflection . . . . . 10 - 15 mm (0.400 - 0.600 in.) 4/7/95 Checks, Tests and Adjustments Results: • If deflection is not within specifications: - Loosen both alternator mounting cap screws/ nuts. - Apply force to FRONT alternator housing only (near the belt) until tension is correct. - Tighten cap screws/nuts. 4. Move link toward solenoid until it stops. 5. Turn plunger rod in or out of knuckle until knuckle and link holes line up. Turn out two additional turns. The additional turns insure that the solenoid bottoms out before the linkage. 6. Assemble and check for free movement when key switch is turned ON. Also check that linkage returns completely to the STOP position when key switch is turned OFF. FUEL SHUTOFF SOLENOID ADJUSTMENT Reason: Link Lock Nut To ensure that fuel shutoff solenoid retracts fully, moving the injection pump shutoff control lever far enough to allow full rack travel. Procedure: 1. Loosen lock nut. Knuckle Plunger M55698 2. Disconnect link from solenoid. 3. Hold solenoid plunger bottomed in solenoid body. 4/7/95 1-151 1 Operational Tests RADIATOR, BUBBLE TEST • If air escapes from muffler, check for worn exhaust valve. Reason: • If air escapes from air cleaner, check for worn intake valve. To determine if compression pressure is leaking from cylinder. • If air escapes from engine oil fill, check for worn piston rings. Equipment: 1 • JDG472 Adapter Procedure: 1. With coolant at proper level and radiator cap tight, run engine for 5 minutes to bring to operating temperature. 2. Remove cap from recovery tank. COOLING SYSTEM, PRESSURE TEST Reason: Inspect cooling system for leaks. Equipment: • D05104ST Cooling System Pressure Pump • JDG692 Radiator Pressure Test Kit (Adapters) 3. Check for bubbles coming from overflow hose at bottom of tank. Procedure: If bubbles are present, isolate source of compression leak: 2. Apply pressure according to specifications. - Remove injection nozzles. - Install JDG472 Adapter in injection port of cylinder to be tested. - Move piston to bottom of stroke with intake and exhaust valves closed. 1. Remove cap and attach pressure pump to radiator. 3. Check for leaks throughout cooling system. Cooling System Pressure Pump - Connect hose from compressed air source to adapter. - Apply the specified maximum air pressure into cylinder: 3TN66 . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) 3TNA72 All Except 3009 OEM . . . . . . . . . . 2448 kPa (355 psi) T6333AW Specifications - 3TN66: Maximum Pressure . . . . . . . . 117 kPa (17 psi) Minimum Pressure after 15 Seconds . . . . . . . . . . . 90 kPa (13 psi) 3009 OEM . . . . . . . . . . 2455 kPa (356 psi) - Check for bubbles in recovery tank or air escaping from muffler, air cleaner or oil fill opening. - Repeat for each cylinder. Results: • If bubbles are present, check for cracks in cylinder head and block. Check for damaged head gasket. 1-152 Specifications - 3TNA72: 15 EX, 670 CUT, 3009 OEM Maximum Pressure. . . . . . . . 97 kPa (14 psi) Minimum Pressure after 15 Seconds . . . . . . . . 88 kPa (12.8 psi) 430 LGT, 455 LGT, 755/56 CUT, F925/35 FM Maximum Pressure . . . . . . . 117 kPa (17 psi) Minimum Pressure after 15 seconds . . . . . . . . . . . 90 kPa (13 psi) 4/7/95 Operational Tests Results: Results: • Pressure should hold to specifications. If pressure decreases, check for leaks. Repair leaks or replace parts as necessary. • If cap leaks, retighten and test again. Replace cap if pressure is not within specification. • If pressure test still indicates leakage after all external leaks have been stopped, a defective head gasket, cracked block, or cylinder head may be the cause. Perform RADIATOR BUBBLE TEST. CYLINDER, COMPRESSION PRESSURE TEST RADIATOR CAP, PRESSURE TEST Reason: Reason: 1 To determine the condition of the pistons, rings, cylinder walls and valves. Equipment: Test radiator cap for operating in correct pressure range. Equipment: • JT01682 Compression Gauge Assembly • JDG472 Adapter • D05104ST Cooling System Pressure Pump Procedure: • JDG692 Radiator Pressure Test Kit (Adapters) 1. Run engine for 5 minutes to bring to operating temperature. Shut off engine. Procedure: 1. Install radiator cap on pressure pump. 2. Remove injection nozzles. (See Fuel System in this section.) 2. Apply pressure. Pressure valve in cap should open according to specifications. 3. Install Adapter and Compression Assembly in injector port. Gauge 4. Disconnect fuel shut-off solenoid connector. Cooling System Pressure Pump 5. Crank engine for three seconds with starter. 6. Record pressure reading for each cylinder. JT01682 Compression Gauge Assembly Radiator Cap T6333AX Specifications: Valve Opening Pressure 3TN66. . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi) 3TNA72 15 EX, 3009 OEM . . . . . . . 88 kPa (12.8 psi) 670 CUT . . . . . . . . . . . . . . . . . . 55 kPa (8 psi) 430 LGT, 455 LGT, 655 CUT, 755/56 CUT, F925/35 FM . . . . . . . . . . . . . . 97 kPa (14 psi) 4/7/95 JDG472 Adapter M82143 1-153 Operational Tests Specifications: 3. Connect Hose Assembly and Pressure Gauge. Compression Pressure 3TN66 . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) IMPORTANT: Do not run if no pressure present. 3TNA72 All Except 3009 OEM . . . . . . . . . . 2448 kPa (355 psi) 1 3009 OEM . . . . . . . . . . 2455 kPa (356 psi) Maximum Difference Between Cylinders . . . . . . . . 490 kPa (71 psi) NOTE: Pressure listed is for 300 m (1000 ft) above sea level. For naturally aspirated engines, reduce specification an additional 4% for each 300 m (1000 ft) of altitude. Results: • If pressure reading is below specification, squirt approximately two teaspoons of clean engine oil into cylinders through injector ports and repeat test. • If pressure increases significantly, check piston, rings and cylinder walls for wear or damage. • If pressure does not increase significantly after retest, check for leaking valves, valve seats or cylinder head gasket. ENGINE OIL PRESSURE TEST Reason: To determine if engine bearings or lubrication system components are worn. Equipment: • JT03017 Hose Assembly • JT05577 Pressure Gauge (100 psi) • JT03349 Connector (All Except 430 LGT, 15 EX) • JT03338 90° Elbow Connector (430 LGT) • JT05487 Connector (15 EX) Procedure: 1. Remove oil pressure sender. 4. Start engine. If pressure reading is below 69 kPa (10 psi), STOP ENGINE. 5. Run engine approximately five minutes to heat oil, then check oil pressure at fast and/or slow idle. Specifications - 375 SSL: Idle Speed Fast . . . . . . . . . . . . . . . . . . . 3625 ± 25 rpm Slow . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm Engine Oil Pressure . . . . . . . . . 294 - 392 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 57 psi) Specifications - 330/332 LGT: Idle Speed Fast . . . . . . . . . . . . . . . . . . 3350 ± 100 rpm Slow . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm Engine Oil Pressure . . . . . . . . . 294 - 440 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 64 psi) Specifications - 655 CUT, 430 LGT, 755/56 CUT, 670 CUT: Fast Idle . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm Engine Oil Pressure . . . . . . . . . 365 ± 69 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . (53 ± 10 psi) Specifications - F915 FM, F925/35 FM: Idle Speed Fast . . . . . . . . . . . . . . . . . . . 3635 ± 35 rpm Slow . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm Engine Oil Pressure . . . . . . . . . 294 - 440 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 64 psi) Specifications - 455 LGT: Idle Speed Fast . . . . . . . . . . . . . . . . . . 3350 ± 100 rpm Slow . . . . . . . . . . . . . . . . . . 1650 ± 50 rpm Engine Oil Pressure . . . . . . . . . 294 - 440 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 64 psi) 2. Install Connector. 1-154 4/7/95 Operational Tests Specifications - 15 EX: Idle Speed Fast . . . . . . . . . . . . . . . . . . . 2425 ± 25 rpm Slow . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm Engine Oil Pressure . . . . . . . . . 117 - 345 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . (17 - 50 psi) 6. Spray soap solution over all connections from air cleaner to intake manifold or turbocharger, if equipped, and check for leaks. IMPORTANT: When reinstalling starting aid nozzle, position arrow on nozzle pointing against intake air flow. Specifications - 3009 OEM: 1 Slow Idle. . . . . . . . . . . . . . . . . . . . . . 1300 rpm Engine Oil Pressure . . . . . . 147 kPa (21 psi) Results: • If oil pressure is not within specifications, inspect oil pressure regulating valve parts for wear or damage. Add or remove shims as necessary. (See Lubrication System in this section.) • If oil pressure does not increase, see “Engine Has Low Oil Pressure” in Diagnosis group. AIR INTAKE SYSTEM LEAKAGE TEST M82124 Results: • Find leaks and repair or replace parts as necessary. FUEL SUPPLY PUMP PRESSURE TEST - 3TNA72 (670 CUT, 3009 OEM) Reason: Check for leaks in air intake system. Reason: To determine supply pump operating pressure. Equipment: • Air Pressure Regulator Equipment: • JT03274 Hose Fitting Procedure: • JT01609 Female Quick Coupler 1. Remove air cleaner restriction indicator/switch, if equipped and install test fitting. • JT03115 Gauge w/Male Quick Coupler (0 - 150 psi) 2. Connect air pressure regulator to manifold using hose and fitting from air cleaner. Procedure: 3. Remove air cleaner cover and main filter element. 1. Disconnect supply pump-to-filter hose. 4. Put large plastic bag into and over end of main filter element. Install main filter element and cover. 2. Install Hose Fitting, Coupler and Gauge. 5. Pressurize air intake system between 34 - 69 kPa (5 - 10 psi). If air intake system cannot be pressurized, turn engine slightly to close valves. 4/7/95 3. Pull fuel shut-off cable out and crank engine using the starter. Do not run starter for more than 10 seconds at a time. Gauge should read more than 29 kPa (4.3 psi). 1-155 Operational Tests JT03115 Gauge w/Male Quick Coupler JT01609 Female Quick Coupler JT03274 Hose Fitting BLEED FUEL SYSTEM Reason: Any time the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system. Procedure: 1 Fuel Filter Supply Pump-to Filter Hose IMPORTANT: Modification or alteration of the injection pump, pump timing, or the injection nozzles in any way not approved by the manufacturer will terminate the warranty obligation. 1. Turn fuel filter shutoff valve to “OPEN” position. M82145A 2. Loosen both air bleed screws on fuel filter base. Results: • If pressure is below specification, replace fuel supply pump. Air Bleed Screws FUEL DRAIN BACK TEST Reason: Determines if air is entering the fuel system at connections, allowing fuel to siphon back to tank. Shutoff Valve RG6594 Procedure: 3. Turn ignition switch to “ON” position. 1. Disconnect fuel supply line and return line at fuel tank. 4. Operate hand primer lever of fuel supply pump, if equipped, until fuel flows free of air bubbles. Tighten bleed screws. IMPORTANT: Fuel return line MUST extend below fuel level in fuel tank before performing this test. Fill fuel tank if necessary. 2. Drain all fuel from the system, including fuel supply pump, injection pump, filter(s) and water separator, if equipped. 3. Plug end of fuel return hose. 4. Pressurize fuel system at fuel supply line, to a maximum pressure of 103 kPa (15 psi). 5. Apply liquid soap and water solution to all joints and connections in the fuel system and inspect for leaks. Results: RG6595 5. Loosen bleed screw on injection pump. Operate hand primer, if equipped, and tighten bleed screw when fuel flows free of air bubbles. • Find leaks and repair or replace parts as necessary. 1-156 4/7/95 Operational Tests 6. Start engine. If engine does not start after several attempts, proceed with steps 7 through 10. 8. Crank engine over with starter. 9. When fuel appears at injectors, tighten line nuts. 10.Start engine. If engine does not start, repeat bleed procedure. 1 RG6596 7. Loosen all three injector line nuts using a 17 mm wrench. Be sure not to loosen bottom nut of injector. 4/7/95 RG6597 1-157 Operational Tests 1 1-158 4/7/95 3TN75, 3TN78, 3TNC78 (3011) 3TN82, 3TNA82, AND 3TN84 (3014) ENGINES Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Cylinder Head, Valves and Manifolds . . . . . . . . . . . . . . . 2-17 Pistons, Rods and Cylinder Block . . . . . . . . . . . . . . . . . . 2-30 Crankshaft, Main Bearings and Flywheel . . . . . . . . . . . . 2-43 Camshaft and Timing Gear Train. . . . . . . . . . . . . . . . . . . 2-54 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116 Checks, Tests and Adjustments. . . . . . . . . . . . . . . . . . . 2-119 Operational Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136 Section 2 2 3 2 Specifications ENGINE SPECIFICATIONS - 3TN75, 3TN78, 3TNC78 (3011) Rocker Arm Cover Special Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (160 lb-in.) Rocker Arm Assembly Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Rocker Arm Shaft O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.97 - 15.98 mm (0.6286 - 0.6293 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.95 mm (0.6280 in.) Rocker Arm and Shaft Support I.D.'s Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.00 - 16.02 mm (0.630 - 0.631 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.09 mm (0.633 in.) Push Rod Length Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146.65 - 147.35 mm (5.774 - 5.801 in.) Push Rod Bend Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) or less Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) Cylinder Head and Valves Mounting Cap Screw Torque First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 N•m (31 lb-ft) Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft) Cylinder Head Distortion Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) or less Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Maximum Amount of Metal to be Removed . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Valve Seat Width Intake Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36 - 1.53 mm (0.054 - 0.060 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.98 mm (0.078 in.) Exhaust Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66 - 1.87 mm (0.065 - 0.074 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 mm (0.089 in.) Intake and Exhaust Valves Valve Faces Minimum Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.) Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Valve Stem O.D. Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 mm (1.181 in.) Distance B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 mm (1.969 in.) Intake and Exhaust Valves Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm (0.2732 - 0.2740 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.90 mm (0.2717 in.) Valve Recession Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm (0.012 - 0.020 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.) Valve Guides Valve Guide I.D. Maximum Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm (0.275 - 0.276 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.08 mm (0.279 in.) 4/7/95 2 2-1 Specifications 2 Valve Guides, continued Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 mm (0.472 in.) Valve Springs Spring Free Length Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 mm (1.654 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.50 mm (1.630 in.) Maximum Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 mm (0.044 in.) Exhaust Manifold Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Intake Manifold Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Valve Seat Angles Valve Seat Surface Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Lower Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70° Upper Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° Piston-to-Cylinder Head Clearance 3TN75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.59 - 0.77 mm (0.023 - 0.030 in.) 3TN78, 3TNC78 (3011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.63 - 0.77 mm (0.025 - 0.030 in.) Piston and Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft) Connecting Rod Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 - 43.042 mm (1.693 - 1.695 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.07 mm (1.696 in.) Piston Ring Groove Clearance First Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.070 - 0.105 mm (0.0028 - 0.0041 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Second Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 - 0.070 mm (0.0014 - 0.0028 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Oil Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.060 mm (0.0012 - 0.0024 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Piston Ring End Gap 3TN75 Compression Rings and Oil Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.) 3TN78, 3TNC78 (3011) Standard Compression Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.0010 - 0.016 in.) Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Pin Pin O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.991 - 23.00 mm (0.905 - 0.906 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.90 mm (0.902 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 mm (0.0018 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.00 - 23.009 mm (0.9055 - 0.9059 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.02 mm (0.906 in.) 2-2 4/7/95 Specifications Piston Pin, continued Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.025 - 23.038 mm (0.9065 - 0.9070 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.10 mm (0.909 in.) Piston O.D. 3TN75 Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 mm (0.492 in.) Standard Piston Size Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.91 - 74.94 mm (2.949 - 2.951 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.81 mm (2.945 in.) 0.25 mm (0.10 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.17 - 75.18 mm (2.959 - 2.960 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.06 mm (2.955 in.) 0.50 mm (0.020 in.) Oversize Piston (F1145 FM Only) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.42 - 75.43 mm (2.969 - 2.970 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.31 mm (2.965 in.) 3TN78, 3TNC78 (3011) Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 mm (0.905 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.895 - 77.925 mm (3.067 - 3.068 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.81 mm (3.063 in.) 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.15 - 78.18 mm (3.076 - 3.077 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.05 mm (3.053 in.) 0.50 mm (0.020 in.) Oversize Piston (3011 OEM Only) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.40 - 78.42 mm (3.086 - 3.087 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.30 mm (3.083 in.) Cylinder Bore I.D. 3TN75 Standard Size Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.22 mm (0.009 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.00 - 75.03 mm (2.953 - 2.954 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.20 mm (2.961 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.25 - 75.28 mm (2.963 - 2.964 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.45 mm (2.970 in.) 0.50 mm (0.020 in.) Oversize Bore (F1145 FM Only) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.50 - 75.53 mm (2.972 - 2.974 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.70 mm (2.980 in.) 3TN78, 3TNC78 (3011) Standard Size Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.22 mm (0.009 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.00 - 78.03 mm (3.071 - 3.072 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.20 mm (3.079 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.25 - 78.28 mm (3.081 - 3.082 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.45 mm (3.089 in.) 0.50 mm (0.020 in.) Oversize Bore (3011 OEM Only) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.50 - 78.53 mm (3.091 - 3.092 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.70 mm (3.099 in.) Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern 4/7/95 2 2-3 Specifications 2 Crankcase Extension Housing Mounting Cap Screw Torque Flywheel Housing/Plate-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Seal Case-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Extension-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Extension-to-Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Crankshaft Rear Oil Seal Seal Case-to-Block Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Seal Case-to-Extension Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.) Crankshaft and Main Bearings Main Bearing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 N•m (58 lb-ft) Crankshaft Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0007 in.) Connecting Rod Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.952 - 42.962 mm (1.6910 - 1.6914 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.91 mm (1.689 in.) Main Bearing Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.952 - 46.962 mm (1.8485 - 1.8489 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.91 mm (1.847 in.) Main Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.00 - 47.045 mm (1.850 - 1.852 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.10 mm (1.8541 in.) Flywheel Maximum Distortion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 N•m (61 lb-ft) 3TN75 (F1145 FM) Pulley-to-Isolator Mount Plate Cap Screw Torque . . . . . . . . . . 49 N•m (36 lb-ft) Flywheel Housing/Plate Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Camshaft Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Camshaft Side Gap Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Maximum Camshaft Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.) Lobe Height Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.635 - 38.765 mm (1.521 - 1.526 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.40 mm (1.512 in.) Journal O.D. Gear Housing and Flywheel Ends Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.92 - 44.95 mm (1.769 - 1.770 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.) Intermediate Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.91 - 44.94 mm (1.768 - 1.769 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.990 - 45.055 mm (1.771 - 1.744 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.00 - 45.025 mm (1.772 - 1.773 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.) 2-4 4/7/95 Specifications Cam Followers Stem O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.975 - 11.990 mm (0.471 - 0.472 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.93 mm (0.470 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.000 - 12.018 mm (0.472 - 0.473 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.05 mm (0.474 in.) Timing Gear Cover Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (226 lb-in.) Cover Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Crankcase Extension Housing-to-Cover Cap Screw Torque . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Crankshaft Pulley Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (85 lb-ft) Idler Gear Shaft O.D Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.950 - 45.975 mm (1.809 - 1.810 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.93 mm (1.808 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.025 mm (1.811 - 1.812 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.03 mm (1.812 in.) Timing Gear Cover Mounting Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (220 lb-in.) Oil Pan and Strainer Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Oil Pump Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) Rotor Shaft O.D.-to-Backing Plate I.D. Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.0006 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.) Rotor Recess Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.10 mm (0.0020 - 0.0039 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Outer Rotor-to-Pump Body Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 - 0.16 mm (0.0035 - 0.0063 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Inner-to-Outer Rotor Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.04 mm (0.0008 - 0.0016 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Oil Pressure Regulating Valve Spring Compressed Length . . . . . . . . . . . . . . . . . . . . . . . . .27.50 mm (1.080 in.) @ 20.5 N (4.6 lb-force) Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 mm (1.810 in.) Housing-to-Valve Body Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Housing-to-Engine Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Thermostat and Housing - 3TN78 Thermostat Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Plate-to-Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Housing Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Thermostat - 3TN75, 3TNC78 (3011) Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) 70 Water Pump - 3TN78 Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Plate-to-Housing Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (134 lb-in.) Plug-to-Housing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) 4/7/95 2 2-5 Specifications 2 Water Pump - 3TN78, continued Bottom of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 mm (0.670 in.) Top of Impeller-to-Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.) below housing Water Pump - 3TN75, 3TNC78 (3011) Adapter-to-Plate Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Plate-to-Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Plug-to-Housing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) Bottom of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 mm (0.670 in.) Top of Impeller-to-Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.) below housing Fuel Supply Pump - 3TN75, 3TNC78 (3011) External Lube Line Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Fuel Injection Pump Injection Pump Gear Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 N•m (66 lb-ft) Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (19 lb-ft) Lube Line-to-Block Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (217 lb-in.) Fuel Injection Nozzles Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (39 lb-in.) Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 N•m (31 lb-ft) Separator Plate Nozzle Contact Surface Maximum Wear . . . . . . . . . . . . . . . . . . 0.10 mm (0.0039 in.) Starter - 3TN78 (Hitachi 0.8 kW) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 mm (0.354 in.) Starter Motor - 3TN75, 3TNC78 (3011) (Nippondenso 1.0 kW) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mm (0.335 in.) Alternator - 3TN78 (Hitachi 25A) Attaching Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Rotor Assembly Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) End Frame-to-Rectifier Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Stator-to-Rectifier Lead Wire Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.50 mm (1.300 in.) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 mm (0.220 in.) Alternator - 3TN75 (Nippondenso 35A) Attaching Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Rotor Assembly Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Pulley Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) Stator-to-Rectifier Lead Wire Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.50 mm (1.300 in.) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 mm (0.220 in.) Alternator - 3TN75, 3TNC78 (3011) (Nippondenso 40A) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft) Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Minimum Rotor Slip Ring O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 mm (0.550 in.) Brush Length New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50 mm (0.170 in.) Checks, Tests and Adjustments Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Connecting Rod Side Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.0079 - 0.0157 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.) 2-6 4/7/95 Specifications Checks, Tests and Adjustments, continued Connecting Rod Bearing Clearance Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 - 0.090 mm (0.0015 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.0063 in.) Crankshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 - 0.271 mm (0.004 - 0.011 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.) Crankshaft Main Bearing Clearance Main Bearing Cap Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 N•m (58 lb-ft) Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 - 0.090 mm (0.0015 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.0063 in.) Valve Lift (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 mm (0.350 in.) Camshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Timing Gear Backlash Standard Backlash All Except Crankshaft Gear-to-Oil Pump Gear . . . . . . . . 0.04 - 0.12 mm (0.0016 - 0.0047 in.) Crankshaft Gear-to-Oil Pump Gear . . . . . . . . . . . . . . . . . 0.11 - 0.19 mm (0.0043 - 0.0075 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Fuel Injection Nozzle Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19600 ± 480 kPa (2843 ± 70 psi) Leakage at 17640 kPa (2558 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum of 5 Seconds Chatter and Spray Pattern at 19600 ± 480 kPa (2843 ± 70 psi) Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chatter Sound Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Stream Spray Pattern Fast Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Atomized Spray Pattern Thermostat Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71° C (160°F) Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F) Minimum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0.310 in.) Coolant Temperature Switch Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . 107 - 113° C (225 - 235° F) Starter No-Load Amp Draw/RPM Maximum Starter Amperage Hitachi 2.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Amps at 4500 rpm Nippondenso 1.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Amps at 3000 rpm Minimum Starter RPM Hitachi 2.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500 Nippondenso 1.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 Fuel Injection Pump Static Timing Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . 16° ± 1°BTDC (Before Top Dead Center) Engine Crankshaft Position . . . . . . . . . . . . . . . . . . . No. 1 Cylinder on TDC Compression Stroke Fan/Alternator Drive Belt Tension Applied Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N (22 lb-force) Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.) Operational Tests Radiator, Bubble Test Maximum Air Pressure Into Cylinder 3TN75, 3TN78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) 3TNC78 (3011). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi) Cooling System 3TN75 Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 kPa (17 psi) Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi) 4/7/95 2 2-7 Specifications 2 Operational Tests - Cooling System, continued 3TN78, 3TNC78 (3011) Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi) Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) Radiator Cap Valve Opening Pressure 3TN75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi) 3TN78, 3TNC78 (3011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) Cylinder, Compression Pressure Compression Pressure 3TN75, 3TN78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) 3TNC78 (3011). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi) Engine Oil Pressure 3TN75 F1145 FM Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425 rpm Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 - 440 kPa (43 - 64 psi) 855/56 CUT Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 ± 69 kPa (53 ± 10 psi) 3TN78 Idle Speed Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2450 ± 25 rpm Oil Pressure Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 kPa (38 psi) Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345 ± 48 kPa (50 ± 7 psi) 3TNC78 (3011) Low Idle Speed Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 rpm Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 kPa (21 psi) Air Intake System Holding Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 - 69 kPa (5 - 10 psi) Minimum Fuel Supply Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 kPa (4.3 psi) Fuel System Holding Pressure (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 kPa (15 psi) ENGINE SPECIFICATIONS - 3TN82, 3TNA82, 3TN84 (3014) Rocker Arm Cover Special Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (160 lb-in.) Rocker Arm Assembly Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Rocker Arm Shaft O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.97 - 15.98 mm (0.6286 - 0.6293 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.95 mm (0.6280 in.) Rocker Arm and Shaft Support I.D.'s Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.00 - 16.02 mm (0.630 - 0.631 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.09 mm (0.633 in.) Push Rod Length Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178.25 - 178.75 mm (7.018 - 7.037 in.) Push Rod Bend Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) or less Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) 2-8 4/7/95 Specifications Cylinder Head and Valves Mounting Cap Screw Torque First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (212 lb-in.) Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 N•m (36 lb-ft) Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 N•m (58 lb-ft) Cylinder Head Distortion Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) or less Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Maximum Amount of Metal to be Removed . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Valve Seat Width Intake Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.07 - 1.24 mm (0.042 - 0.049 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74 mm (0.069 in.) Exhaust Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24 - 1.45 mm (0.049 - 0.057 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.94 mm (0.076 in.) Intake and Exhaust Valves Valve Faces Minimum Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.) Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Valve Stem O.D. Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 mm (1.181 in.) Distance B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 mm (2.360 in.) Intake and Exhaust Valves Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.96 - 7.98 mm (0.3134 - 0.3142 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.3110 in.) Valve Recession Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm (0.012 - 0.020 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.) Valve Guides Valve Guide I.D. Maximum Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.01 - 8.03 (0.315 - 0.316 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10 mm (0.319 in.) Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 mm (0.591 in.) Valve Springs Spring Free Length Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 mm (1.575 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.50 mm (1.550 in.) Maximum Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 mm (0.044 in.) Exhaust Manifold Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Intake Manifold Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Valve Seat Angles Valve Seat Surface Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Lower Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70° Upper Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° Piston-to-Cylinder Head Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.64 - 0.82 mm (0.025 - 0.032 in.) Piston and Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N•m (35 lb-ft) 4/7/95 2 2-9 Specifications 2 Connecting Rod Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - 48.042 mm (1.888 - 1.891 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.07 mm (1.893 in.) Piston Ring Groove Clearance First Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 - 0.110 mm (0.0030 - 0.0043 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Second Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 - 0.080 mm (0.0018 - 0.0031 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Oil Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 - 0.060 mm (0.0010 - 0.0024 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Piston Ring End Gap 3TN82, 3TNA82 Standard First Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.) Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.) Second Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.35 mm (0.008 - 0.014 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.) 3TN84 (3014) Standard Compression Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.) Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.45 mm (0.010 - 0.018 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Pin Pin O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.987 - 26.00 mm (1.023 - 1.024 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.90 mm (1.020 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 mm (0.0018 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.00 - 26.009 mm (1.0236 - 1.0240 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.02 mm (1.024 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.025 - 26.038 mm (1.0246 - 1.0251 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.028 in.) Piston O.D. 3TN82, 3TNA82 Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 mm (0.945 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.90 - 81.93 mm (3.224 - 3.225 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.80 mm (3.221 in.) 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.15 - 82.17 mm (3.234 - 3.235 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.05 mm (3.230 in.) 0.50 mm (0.020 in.) Oversize Piston (575 SSL Only) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.40 - 82.42 mm (3.244 - 3.245 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.30 mm (3.240 in.) 2-10 4/7/95 Specifications Piston O.D., continued 3TN84 (3014) Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 mm (0.945 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.90 - 83.93 mm (3.303 - 3.304 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.80 mm (3.299 in.) 0.25 mm (0.10 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.15 - 84.17 mm (3.313 - 3.314 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.05 mm (3.309 in.) 0.50 mm (0.020 in.) Oversize Piston (3014 OEM Only) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.40 - 84.42 mm (3.323 - 3.324 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.30 mm (3.319 in.) Cylinder Bore I.D. 3TN82, 3TNA82 Standard Size Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.00 - 82.03 mm (3.228 - 3.230 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.20 mm (3.236 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.25 - 82.28 mm (3.238 - 3.239 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.45 mm (3.246 in.) 0.50 mm (0.020 in.) Oversize Bore (575 SSL Only) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.50 - 82.53 mm (3.248 - 3.249 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.70 mm (3.256 in.) 3TN84 (3014) Standard Size Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.00 - 84.03 mm (3.307 - 3.308 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.20 mm (3.315 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.25 - 84.28 mm (3.317 - 3.318 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.45 mm (3.325 in.) 0.50 mm (0.020 in.) Oversize Bore (3014 OEM Only) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.50 - 84.53 mm (3.327 - 3.328 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.70 mm (3.335 in.) Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern Crankcase Extension Housing Mounting Cap Screw Torque Flywheel Housing/Plate-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Seal Case-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Extension-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Extension-to-Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Crankshaft Rear Oil Seal Seal Case-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Seal Case-to-Extension Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.) Crankshaft and Main Bearings Main Bearing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N•m (72 lb-ft) Crankshaft Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0007 in.) Connecting Rod Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.952 - 47.962 mm (1.8879 - 1.8883 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.91 mm (1.886 in.) 4/7/95 2-11 2 Specifications 2 Crankshaft and Main Bearings, continued Main Bearing Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.952 - 46.962 mm (1.9666 - 1.9670 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.90 mm (1.965 in.) Main Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.00 - 50.045 mm (1.969 - 1.970 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.10 mm (1.972 in.) Flywheel Maximum Distortion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 N•m (61 lb-ft) Flywheel Housing/Plate Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Camshaft Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Camshaft Side Gap Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Maximum Camshaft Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.) Lobe Height Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.635 - 38.765 mm (1.521 - 1.526 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.40 mm (1.512 in.) Journal O.D. Gear Housing and Flywheel Ends Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.92 - 44.95 mm (1.769 - 1.770 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.) Intermediate Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.91 - 44.94 mm (1.768 - 1.769 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.990 - 45.055 mm (1.771 - 1.744 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.00 - 45.025 mm (1.772 - 1.773 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.) Cam Followers Stem O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.975 - 11.990 mm (0.471 - 0.472 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.93 mm (0.470 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.000 - 12.018 mm (0.472 - 0.473 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.05 mm (0.474 in.) Timing Gear Cover Cover Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Crankcase Extension Housing-to-Cover Cap Screw Torque . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Crankshaft Pulley Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (85 lb-ft) Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (226 lb-in.) Oil Pan-to-Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Idler Gear Shaft O.D Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.950 - 45.975 mm (1.809 - 1.810 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.93 mm (1.808 in.) 2-12 4/7/95 Specifications Idler Gear, continued Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.025 mm (1.811 - 1.812 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.03 mm (1.812 in.) Timing Gear Cover Mounting Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (220 lb-in.) Oil Pan and Strainer Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Oil Pump Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) Rotor Shaft O.D.-to-Backing Plate I.D. Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.0006 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.) Rotor Recess Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm (0.0011 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Outer Rotor-to-Pump Body Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.17 mm (0.0039 - 0.0067 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Inner-to-Outer Rotor Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.105 mm (0.0019 - 0.0041 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Oil Cooler - 3TN84 (955 CUT) Oil Cooler-to-Valve Body Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Oil Pressure Regulating Valve Spring Compressed Length . . . . . . . . . . . . . . . . . . . . . . . . .27.50 mm (1.080 in.) @ 20.5 N (4.6 lb-force) Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 mm (1.810 in.) Housing-to-Valve Body Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Housing-to-Engine Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Thermostat and Housing - 3TN82 (30 EX), 3TN84 (955 CUT, 3014 OEM) Thermostat Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Plate-to-Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Housing Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Thermostat - 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT) Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Water Pump - 3TN82 (30 EX), 3TN84 (955 CUT, 3014 OEM) Fan Mounting Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Plate-to-Housing Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (134 lb-in.) Plug-to-Housing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) 3TN82 (30 EX) Top of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 mm (1.060 in.) Top of Impeller-to-Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.040 in.) below housing 3TN84 (955 CUT, 3014 OEM) Bottom of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 mm (0.670 in.) Top of Impeller-to-Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.) below housing Water Pump - 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Plate-to-Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Adapter-to-Plate Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Bottom of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 mm (0.670 in.) Impeller-to-Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.) below housing 4/7/95 2-13 2 Specifications 2 Fuel Supply Pump - 3TNA82, 3TN84 (3014) External Lube Line Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Fuel Injection Pump Injection Pump Gear Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 N•m (66 lb-ft) Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (19 lb-ft) Lube Line-to-Block Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (217 lb-in.) Fuel Injection Nozzles Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (39 lb-in.) Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 N•m (31 lb-ft) Separator Plate Nozzle Contact Surface Maximum Wear . . . . . . . . . . . . . . . . . . 0.10 mm (0.0039 in.) Starter Motor - 3TN82 (30 EX) (Hitachi 2.0 kW) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 mm (0.354 in.) Starter Motor - 3TNA82, 3TN84 (3014) (Nippondenso 1.0 and 1.2 kW) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mm (0.335 in.) Starter Motor - 3TN82 (575 SSL) (Nippondenso 1.4 kW) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mm (0.335 in.) Alternator -3TNA82, 3TN84 (870 CUT) (Kokosan 20A) Flywheel Assembly-to-Coil Plate Assembly Nut Torque . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Alternator - 3TN82 (30 EX) (Hitachi 25A) Attaching Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Rotor Assembly Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) End Frame-to-Rectifier Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Stator-to-Rectifier Lead Wire Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.50 mm (1.300 in.) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 mm (0.220 in.) Alternator - 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT, 955 CUT) (Nippondenso 35A) Attaching Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Rotor Assembly Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Pulley Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) Stator-to-Rectifier Lead Wire Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.50 mm (1.300 in.) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 mm (0.220 in.) Alternator - 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) (Nippondenso 40A) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft) Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Minimum Rotor Slip Ring O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 mm (0.550 in.) Brush Length New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50 mm (0.170 in.) Checks, Tests and Adjustments Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Connecting Rod Side Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.0079 - 0.0157 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.) Connecting Rod Bearing Clearance Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 - 0.090 mm (0.0015 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.0063 in.) Crankshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 - 0.271 mm (0.004 - 0.011 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.) 2-14 4/7/95 Specifications Checks, Tests and Adjustments, continued Crankshaft Main Bearing Clearance Main Bearing Cap Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N•m (72 lb-ft) Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 - 0.090 mm (0.0015 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.0063 in.) Valve Lift (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 mm (0.350 in.) Camshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Timing Gear Backlash Standard Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.12 mm (0.0016 - 0.0047 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Fuel Injection Nozzle Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19600 ± 480 kPa (2843 ± 70 psi) Leakage at 17640 kPa (2558 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum of 5 Seconds Chatter and Spray Pattern at 19600 ± 480 kPa (2843 ± 70 psi) Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chatter Sound Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Stream Spray Pattern Fast Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Atomized Spray Pattern Thermostat Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71° C (160°F) Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F) Minimum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0.310 in.) Coolant Temperature Switch Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . 107 - 113° C (225 - 235° F) Starter No-Load Amp Draw/RPM Maximum Starter Amperage Hitachi 2.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Amps at 4500 rpm Nippondenso 1.0 and 1.2 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Amps at 3000 rpm Nippondenso 1.4 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Amps at 3500 rpm Minimum Starter RPM Hitachi 2.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500 Nippondenso 1.0 and 1.2 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 Nippondenso 1.4 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3500 Fuel Injection Pump Static Timing Adjustment Injection Pump Timing 3TN82 (575 SSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ± 1° BTDC (Before Top Dead Center) 3TN82 (30 EX), 3TNA82, 3TN84 (3014) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ± 1° BTDC Engine Crankshaft Position . . . . . . . . . . . . . . . . . . . No. 1 Cylinder on TDC Compression Stroke Fan/Alternator Drive Belt Tension Applied Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N (22 lb-force) Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.) Oil Cooler Leakage - 3TN84 (955 CUT) Applied Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206 - 483 kPa (30 - 70 psi) Operational Tests Radiator, Bubble Test Maximum Air Pressure Into Cylinder 3TN82, 3TNA82, 3TN84 (870 CUT, 955 CUT) . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) 3TN84 (3014 OEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi) Cooling System 3TN82, 3TNA82, 3TN84 (870 CUT, 3014 OEM) Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi) Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) 4/7/95 2-15 2 Specifications 2 Operational Tests - Cooling System, continued 3TN84 (955 CUT) Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 kPa (17 psi) Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi) Radiator Cap Valve Opening Pressure 3TN82, 3TNA82, 3TN84 (870 CUT, 3014 OEM) . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) 3TN84 (955 CUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi) Cylinder, Compression Pressure Compression Pressure 3TN82, 3TNA82, 3TN84 (870 CUT, 955 CUT) . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) 3TN84 (3014 OEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi) Engine Oil Pressure 3TN82 (30 EX) Idle Speed Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2450 ± 25 rpm Oil Pressure Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 kPa (38 psi) Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345 ± 48 kPa (50 ± 7 psi) 3TN82 (575 SSL) Idle Speed Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250 ± 25 rpm Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2875 ± 25 rpm Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 - 392 kPa (43 - 57 psi) 3TNA82, 3TN84 (870 CUT) Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2750 - 2800 rpm Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 ± 69 kPa (53 ± 10 psi) 3TN84 (955 CUT) Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 ± 69 kPa (53 ± 10 psi) 3TN84 (3014 OEM) Low Idle Speed Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 rpm Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 kPa (21 psi) Air Intake System Holding Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 - 69 kPa (5 - 10 psi) Minimum Fuel Supply Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 kPa (4.3 psi) Fuel System Holding Pressure (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 kPa (15 psi) 2-16 4/7/95 Cylinder Head, Valves and Manifolds SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the European Microfiche Tool Catalog (MTC). D-20018WI Valve Guide Knurler Use to knurl inside diameter of valve guides on 3TN75, 3TN78 and 3TNC78 (3011) engine. D-20019WI Valve Guide Knurler Use to knurl inside diameter of valve guides on 3TN82, 3TNA82 and 3TN84 (3014) engines. JDE118 Valve Guide Driver Use to remove and install valve guides in cylinder head. D-20020WI Valve Guide Reamer Use to ream out new valve guides on 3TN75, 3TN78 and 3TNC78 (3011) engine. 2 D-20021WI Valve Guide Reamer Use to ream out new valve guides on 3TN82, 3TNA82 and 3TN84 (3014) engines. SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Head Gasket Kits 4/7/95 2-17 Cylinder Head, Valves and Manifolds ROCKER ARM COVER • Wash packing in a safe solvent and blow dry with air pressure. If packing comes apart or is deteriorated, replace it. Crankcase Breather Cover Cap Screw (2) M8 x 16 2 Oil Filler Cap O-Ring O-Ring Replace. Extension (575 SSL) Packing Special Nut (3) 18 N•m (160 lb-in.) Screen O-Ring (575 SSL) O-Ring (3) Crankcase Breather Tube Rocker Arm Cover O-Ring Seal M82329A 2-18 4/7/95 Cylinder Head, Valves and Manifolds ROCKER ARM ASSEMBLY • Inspect all parts for wear or damage. (See Inspection procedures.) Removal/Installation and Disassembly/Assembly • Lubricate all parts with clean oil during assembly. 1. Remove rocker arm cover. (See procedure in this group.) • Adjust valve clearance. (See Checks, Tests and Adjustments in this section.) • Remove and install studs using two M8 nuts. Mounting Cap Screw (2) M8 x 25 26 N•m (226 lb-in.) 2 Adjusting Screw Rocker Arm Center Support (2) Nut Rocker Arm Shaft Spring Rocker Arm Shaft Nut (3) M8 (575 SSL) Mounting Cap Screw (6) M8 x 50 26 N•m (226 lb-in.) Exhaust Valve Rocker Arm Stud (3) Intake Valve Rocker Arm Valve Cap Push Rod Rocker Arm End Support (2) M82330A 4/7/95 2-19 Cylinder Head, Valves and Manifolds Inspection Rocker Arm and Shaft Support I.D.’s: • Measure outer diameter of rocker arm shaft. Standard . . . . . . . . . . . . . . . 16.00 - 16.02 mm . . . . . . . . . . . . . . . . . . . . . . . (0.630 - 0.631 in.) Wear Limit. . . . . . . . . . . 16.09 mm (0.633 in.) Clearance . . . . . . . . . . . . . 0.13 mm (0.005 in.) Replace rocker arms or supports if I.D. is more than wear limit. If shaft and support/arm clearance (support/arm I.D. minus shaft O.D.) exceed wear limit, replace all parts. • Measure length and bending of push rod. 2 M35262 Rocker Arm Shaft O.D.: Length Standard . . . . . . . . . . . . . . . 15.97 - 15.98 mm . . . . . . . . . . . . . . . . . . . . . (0.6286 - 0.6293 in.) Wear Limit. . . . . . . . . . 15.95 mm (0.6280 in.) Replace rocker arm shaft if less than wear limit. • Measure inner diameters of rocker arms and supports. Feeler Gauge M82023A Push Rod Length: 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 146.65 - 147.35 mm . . . . . . . . . . . . . . . . . . . . . . . (5.774 - 5.801 in.) 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . . . 178.25 - 178.75 mm . . . . . . . . . . . . . . . . . . . . . . . (7.018 - 7.037 in.) M82022A Push Rod Bend: Standard . . . . . . . 0.03 mm (0.001 in.) or less Wear Limit. . . . . . . . . . . . 0.30 mm (0.012 in.) Replace push rod if not within specifications. 2-20 4/7/95 Cylinder Head, Valves and Manifolds CYLINDER HEAD AND VALVES 4. Remove fuel injection nozzles. (See Fuel System in this section.) Removal/Installation 5. Disassemble and inspect cylinder head and valves. (See Disassembly/ Assembly and Inspection/Replacement procedures.) 1. Remove rocker arm assembly, push rods and valve caps. (See procedure in this group.) 2. Remove exhaust and intake manifolds. (See procedures in this group.) IMPORTANT: Oil passage in gasket must be located over oil passage in cylinder block. 3. Remove water pump. (See Cooling System in this section.) Mounting Cap Screw (14) Dip entire cap screw in clean engine oil before installing. 2 Flywheel Cylinder Head Gasket M82331A 4/7/95 2-21 Cylinder Head, Valves and Manifolds 6. Tighten mounting cap screws, in the sequence shown, in three stages of gradually-increasing torque. IMPORTANT: Cylinder head mounting cap screws must be checked for proper torque after 50 hours of engine operation. 6 12 7 1 10 9 2 8 11 5 4 Intake Manifold Side Timing Gear Case Side Flywheel Side 2 3 14 First . . . . . . . . . . . . . . . . . 24 N•m (212 lb-in.) Second . . . . . . . . . . . . . . . . . 48 N•m (36 lb-ft) Final . . . . . . . . . . . . . . . . . . . 78 N•m (58 lb-ft) Disassembly/Assembly Exhaust Manifold Side 13 Torque Specifications - 3TN82, 3TNA82, 3TN84 (3014): M82260A Torque Specifications - 3TN75, 3TN78, 3TNC78 (3011): First . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Second . . . . . . . . . . . . . . . . . 42 N•m (31 lb-ft) Final . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft) • Compress valve springs using a valve spring compressor. • Intake and exhaust valve guides are press fit. Remove guides only if replacement is necessary. (See Inspection/Replacement procedures.) • On 3TN75, 3TN84 (955 CUT), intake and exhaust valve seat inserts are press fit. Remove inserts only if replacement is necessary. • Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) IMPORTANT: Do not reuse stem seals if removed. Used seals will leak. • Apply clean engine oil on intake and exhaust valve stems during assembly. • Install springs with smaller pitch end or paint mark toward cylinder head. Stem Seal (6) Replace. Short Stud (6) Exhaust Valve Guide (3) Collet Halves (12) Retainer (6) Valve Spring (6) Intake Valve Guide (3) Lifting Bracket (2) Cap Screw (4) Valve Seat Inserts 3TN75 and 3TN84 (955 CUT)Only. Exhaust Manifold Mounting Stud (3 Short - 770 CUT, 870 CUT) (2 Long - All Except 770 CUT, 870 CUT) Exhaust Valve Intake Valve 2-22 M82332A 4/7/95 Cylinder Head, Valves and Manifolds NOTE: f new valves are installed, measure valve recession. (See Inspection/Replacement procedures.) After each valve has been assembled, tap on top of valve stem with a plastic hammer to seat retainer. Inspection/Replacement Valve Seat Width Before inspection, thoroughly clean all components of carbon or dirt. Cylinder Head: • Measure cylinder head flatness. Place a straightedge along each of the four sides and each diagonal. Measure clearance between straight edge and combustion surface with a feeler gauge. M82029A 2 Valve Seat Width - 3TN75, 3TN78, 3TNC78 (3011): Intake Valve Standard . . . . . . . . . . . . . . . . . 1.36 - 1.53 mm . . . . . . . . . . . . . . . . . . . . . . . (0.054 - 0.060 in.) Wear Limit. . . . . . . . . . . . 1.98 mm (0.078 in.) Straight-Edge Feeler Gauge Exhaust Valve Standard . . . . . . . . . . . . . . . . . 1.66 - 1.87 mm . . . . . . . . . . . . . . . . . . . . . . . (0.065 - 0.074 in.) Wear Limit. . . . . . . . . . . . 2.27 mm (0.089 in.) M82028A Valve Seat Width - 3TN82, 3TNA82, 3TN84 (3014): Cylinder Head Distortion: Standard . . . . . . . 0.05 mm (0.002 in.) or less Wear Limit. . . . . . . . . . . . 0.15 mm (0.006 in.) If distortion exceeds the wear limit, resurface or replace cylinder head. Remove only enough metal to make cylinder head flat; but do not remove more than 0.20 mm (0.008 in.). If cylinder head was resurfaced: • Measure piston-to-cylinder head clearance. (See procedure in this group.) • Measure valve recession. (See procedure in this group.) • Measure valve seat width. 4/7/95 Intake Valve Standard . . . . . . . . . . . . . . . . . 1.07 - 1.24 mm . . . . . . . . . . . . . . . . . . . . . . . (0.042 - 0.049 in.) Wear Limit. . . . . . . . . . . . 1.74 mm (0.069 in.) Exhaust Valve Standard . . . . . . . . . . . . . . . . . 1.24 - 1.45 mm . . . . . . . . . . . . . . . . . . . . . . . (0.049 - 0.057 in.) Wear Limit. . . . . . . . . . . . 1.94 mm (0.076 in.) If necessary, grind valve seats to meet specifications. (See GRIND VALVE SEATS procedure.) Intake and Exhaust Valves: • Check valve for out-of-round, bent or warped condition using a valve inspection center. Replace valve if necessary. 2-23 Cylinder Head, Valves and Manifolds Valve Stem O.D. - 3TN75, 3TN78, 3TNC78 (3011): Distance A . . . . . . . . . . . . . . . . .30 mm (1.181 in.) Distance B . . . . . . . . . . . . . . . . .50 mm (1.969 in.) Intake and Exhaust Valves Standard . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm . . . . . . . . . . . . . . . . . . . . . (0.2732 - 0.2740 in.) Wear Limit. . . . . . . . . . . 6.90 mm (0.2717 in.) M35307 2 • If valve faces are worn, burned or pitted, grind valves to proper face angle. If valve face margin is less than 0.51 mm (0.020 in.) after grinding, replace valve. Valve Face Angle Valve Face Margin Exhaust: 45° Intake: 30° Valve Stem O.D. - 3TN82, 3TNA82, 3TN84 (3014): Distance A . . . . . . . . . . . . . . . . .30 mm (1.181 in.) Distance B . . . . . . . . . . . . . . . . .60 mm (2.360 in.) Intake and Exhaust Valves Standard . . . . . . . . . . . . . . . . . 7.96 - 7.98 mm . . . . . . . . . . . . . . . . . . . . . (0.3134 - 0.3142 in.) Wear Limit. . . . . . . . . . . 7.90 mm (0.3110 in.) • Measure valve recession using a depth gauge. Replace valve or cylinder head if measurement exceeds wear limit. Valve Recession M82030A • Measure valve stem diameter at two locations shown. Replace valve if measurement exceeds wear limit. Cylinder Head A Depth Gauge B M82032A M82031A 2-24 4/7/95 Cylinder Head, Valves and Manifolds Valve Recession: Standard . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . (0.012 - 0.020 in.) Wear Limit. . . . . . . . . . . . 1.00 mm (0.039 in.) Valve Guides: • Clean valve guides using a valve guide brush. • Measure valve guide inside diameter. Valve Guide I.D. - 3TN75, 3TN78, 3TNC78 (3011): Standard . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm . . . . . . . . . . . . . . . . . . . . . . . (0.275 - 0.276 in.) Wear Limit. . . . . . . . . . . . 7.08 mm (0.279 in.) Valve Guide Height “A”: 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . . .12 mm (0.472 in.) 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . . . . .15 mm (0.591 in.) • Ream inside diameter of valve guides using: - 3TN75, 3TN78, 3TNC78 (3011): D-20020WI Valve Guide Reamer - 3TN82, 3TNA82, 3TN84 (3014): D-20021WI Valve Guide Reamer 2 A Valve Guide I.D. - 3TN82, 3TNA82, 3TN84 (3014): Standard . . . . . . . . . . . . . . . . . 8.01 - 8.03 mm . . . . . . . . . . . . . . . . . . . . . . . (0.315 - 0.316 in.) Wear Limit. . . . . . . . . . . . 8.10 mm (0.319 in.) If diameter exceeds wear limit, knurl or replace guide. If diameter is less than wear limit, determine guideto-stem clearance (guide diameter minus stem diameter). M82193A Valve Springs: • Measure spring free length. Replace spring if measurement exceeds wear limit. If clearance exceeds 0.15 mm (0.006 in.) but is less than 0.20 mm (0.008 in.), knurl valve guides. • Knurl valve guides using: - 3TN75, 3TN78, 3TNC78 (3011): D-20018WI Valve Guide Knurler - 3TN82, 3TNA82, 3TN84 (3014): D-20019WI Valve Guide Knurler If clearance exceeds 0.20 mm (0.008 in.), replace valve guide. • Replace valve guides using JDE118 Valve Guide Driver. Intake and exhaust valve guides are different. The exhaust valve guide has one groove and the intake valve guide has none. Install valve guides with tapered ends down. Push valve guides down until top of valve guides are a specified distance (A) from top of cylinder head. M82034A Spring Free Length - 3TN75, 3TN78, 3TNC78 (3011): Standard . . . . . . . . . . . . . . .42 mm (1.654 in.) Wear Limit. . . . . . . . . . . 41.50 mm (1.630 in.) Spring Free Length - 3TN82, 3TNA82, 3TN84 (3014): Standard . . . . . . . . . . . . . . .40 mm (1.575 in.) Wear Limit. . . . . . . . . . . 39.50 mm (1.550 in.) 4/7/95 2-25 Cylinder Head, Valves and Manifolds • Measure spring inclination. Replace spring if measurement exceeds specification. Nut and Lock Washer (2) Cap Screw (2) M8 x 60 Later 855/56 CUT Cap Screw (2) F1145 FM - M8 x 60 955 CUT - M8 x 80 Exhaust Manifold 2 Spring Inclination 1.10mm (0.044 in.) Square Gauge Cap Screw (2) F1145 FM, Later 855/56 CUT M8 x 50 955 CUT - M8 x 55 Free Length Gasket M82035A 3TN75, 3TN84 (955 CUT) EXHAUST MANIFOLD 1. Remove muffler and gasket, if equipped. Exhaust Manifold Nut (2) M8 M82334A Stud (4) • Tighten all hardware to 26 N•m (226 lb-in.). Stud (4) Cap Screw M8 x 80 Nut Cap Screw (3) M8 x 60 Cap Screw (4) M8 x 60 Gasket 3TNC78 (3011 OEM) M82335A Cap Screw M8 x 50 Gasket Exhaust Manifold 3TN75 (Early 855/56 CUT) 2-26 M82333A 4/7/95 Cylinder Head, Valves and Manifolds Exhaust Manifold Nut (2) M8 Stud (4) 4. OEM Power Unit engines (3011 and 3014): • Remove air cleaner and mount bracket. • Remove instrument panel and bracket. • Remove radiator support rod. (See procedures in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section.) • Tighten all mounting cap screws to 26 N•m (226 lb-in.). Cap Screw (4) M8 x 60 Gasket 3TN78, 3TN82, 3TN84 (3014 OEM) Exhaust Manifold Nut and Lock Washer (3) Gasket M82336A Cap Screw (2) M8 x 65 2 Intake Manifold Gasket Cap Screw (4) M8 x 25 Intake Manifold M82338A 3TN75 Gasket Cap Screw M8 x 115 3TNA82, 3TN84 (870 CUT) M82337A Cap Screw (4) M8 x 25 INTAKE MANIFOLD NOTE: Air heater removal/installation is similar to procedures found in ACCESSORIES SERIES 220 POWER UNIT ENGINES section. 3TN78, 3TN82 (30 EX) Intake Manifold M82339A Gasket 1. Remove intake air heater. (See procedure in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section.) 2. Remove fuel filter assembly mounting cap screw(s), if equipped. 3. Remove fuel injection lines. (See Fuel System in this section.) 3TN84 (3014 OEM) Cap Screw (4) M8 x 25 3TNC78 (3011 OEM), 3TN84 (3014 OEM) M82340A 4/7/95 2-27 Cylinder Head, Valves and Manifolds Intake Manifold Gasket 1. Grind intake valve seat using a 30° seat grinder and exhaust valve seat using a 45° seat grinder. Follow tool manufacturers instructions. Cap Screw (4) M8 x 25 Seat Grinder 3TN82 (575 SSL) 2 M82341A John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Gasket M82039A Plate 2. Measure valve seat width after grinding. 3. If seat is too wide after grinding, grind lower seat surface using a 70° seat grinder until seat width is close to specifications. Cap Screw (4) M8 x 25 Cap Screw (12) M6 x 14 3TNA82, 3TN84 (870 CUT) M82342A 4. Grind upper seat surface using a 15° seat grinder until seat width is narrowed to specifications. 5. If valve seats are ground, measure valve recession and check contact pattern between the seat and valve with bluing dye. 6. Lap valves. (See procedure in this group.) Intake Manifold Gasket Lower Seat Surface 70° Valve Seat Cap Screw (4) M8 x 25 Upper Seat Surface 15° 3TN84 (955 CUT) M82343A GRIND VALVE SEATS IMPORTANT: Valve seats should never be cut. Cutting a valve seat can damage its sealing surface, which may result in leaks or valve/ seat failure. Valve seats should be ground and lapped. NOTE: LIGHTLY grind valve seats for a few seconds only to avoid excessive valve seat width. 2-28 Seat Width Cylinder Head M82040A If valve recession exceeds maximum specifications or seats cannot be reconditioned, replace valves, valve seats if equipped and/or cylinder head. NOTE: Valve seat inserts are available for 3TN75 and 3TN84 (955 CUT) engines only. 4/7/95 Cylinder Head, Valves and Manifolds LAP VALVES NOTE: Use a rubber type lapping tool for valves without a lapping tool groove slit. If seat does not make proper contact, lap the valve into the seat: 1. Apply small amount of fine lapping compound to face of valve. 2. Turn valve to lap valve to seat. 3. Lift valve from seat every 8 to 10 strokes. Lap until a uniform ring appears around the surface of the valve face. 2. Install cylinder head and old gasket. Install cylinder head cap screws and tighten in proper sequence to specified torque. (See CYLINDER HEAD AND VALVES - Removal/Installation in this group.) 3. Slowly turn crankshaft one complete revolution. 4. Remove cylinder head and gasket. 5. Measure thickness of flattened section of each piece of wire. Calculate average thickness of wires to obtain piston-to-cylinder head clearance specification. 2 4. Wash all parts in solvent to remove lapping compound. Dry parts. 5. Check position of lap mark on valve face. Lap mark must be on or near center of valve face. Lapping Tool M82042A Piston-to-Cylinder Head Clearance: M82041A MEASURE PISTON-TO-CYLINDER HEAD CLEARANCE 1. Place three 10 mm (0.400 in.) long pieces of 1.50 mm (0.060 in.) diameter soft wire in three positions on the flat part of the piston head. 4/7/95 3TN75. . . . . . . . . . . . . . . . . . . . 0.59 - 0.77 mm . . . . . . . . . . . . . . . . . . . . . . . (0.023 - 0.030 in.) 3TN78, 3TNC78 (3011) . . . . . 0.63 - 0.77 mm . . . . . . . . . . . . . . . . . . . . . . . (0.025 - 0.030 in.) 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . . . . . . . 0.64 - 0.82 mm . . . . . . . . . . . . . . . . . . . . . . . (0.025 - 0.032 in.) If clearance is less than specifications, replace cylinder head. 2-29 Pistons, Rods and Cylinder Block SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Block Gasket Kit • Cylinder Head Gasket Kit • Oversized Pistons and Rings • Undersized Connecting Rod Bearing Inserts 2 2-30 4/7/95 Pistons, Rods and Cylinder Block PISTON AND CONNECTING ROD 7. Remove two cap screws, connecting rod cap and bearing inserts. Removal IMPORTANT: Pistons and cylinders are matched. Pistons must be installed in the cylinders from which they are removed. 1. Remove oil pan and strainer tube. (See Lubrication System in this section.) 2. Remove cylinder head. (See Cylinder Head, Valves and Manifolds in this section.) 3. Check cylinder bore for ridges. These ridges can cause damage to piston if ridge is not removed. 4. If necessary, remove ridge from top of cylinder bore using a ridge reamer. 5. Measure connecting rod side play. (See Checks, Tests and Adjustments in this section.) 8. Note connecting rod alignment mark in relation to the cylinders. Starting at flywheel end with cylinder number one, then two, etc. 9. Push piston and connecting rod out of cylinder bore using a wooden dowl. 10.Disassemble and inspect all parts for wear or damage. (See Disassembly and Inspection/ Replacement procedures.) 6. Measure connecting rod bearing clearance. (See Checks, Tests and Adjustments in this section.) IMPORTANT: Keep connecting rods and caps together. Rods and caps are a matched set. Note alignment marks on each part. Piston and Connecting Rod Piston and Connecting Rod Bearing Inserts Connecting Rod Cap Connecting Rod Cap Screw Replace. Bearing Inserts M82196A All Except 3TN75 Connecting Rod Cap Connecting Rod Cap Screw Replace. M82273A 3TN75 4/7/95 2-31 2 Pistons, Rods and Cylinder Block Installation • Apply clean engine oil on all parts during installation. • Never reuse connecting rod cap screws, replace with new. IMPORTANT: Pistons must be installed in cylinders from which they were removed and in the same direction. Be careful not to damage crankshaft rod journal while installing piston. Connecting Rod Cap Screw Torque Specifications: 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . . . 39 N•m (29 lb-ft) 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . . . . . 47 N•m (35 lb-ft) 6. If a new piston and connecting rod were installed, stamp a number corresponding to the cylinder number on the connecting rod cap and connecting rod. 1. If new piston rings were installed, deglaze cylinder bore. (See procedure in this group.) 2 2. Piston Recess 3TN75: Install piston and connecting rod into the cylinder from which it was removed, with piston recess on top of piston toward fuel injection pump. All Except 3TN75: Install piston and connecting rod into the cylinder from which it was removed, with alignment mark on connecting rod and/or with piston size mark on top of piston toward fuel injection pump. IMPORTANT: Do not touch bearing insert surfaces. Oil and acid from your finger will corrode the bearing surface. 3. Install bearing inserts on connecting rod and rod cap, aligning tangs with grooves. Fuel Injection Pump Side Flywheel Side Groove Connecting Rod Cap Alignment Mark Tangs IMPORTANT: Connecting rod caps must be installed on the same connecting rods they were removed from. 4. Match the connecting rods to caps using alignment marks. Install caps. 5. Dip entire connecting rod cap screws in clean engine oil. Install new cap screws and tighten to specifications. 2-32 Groove Connecting Rod Cap Screw M82273A 3TN75 4/7/95 Pistons, Rods and Cylinder Block Piston Size Mark Fuel Injection Pump Side • Piston pin bushing is press fit in connecting rod. Remove bushing only if replacement is necessary. (See Inspection/Replacement procedures.) • Inspect all parts for wear or damage. Replace as necessary. (See Inspection/Replacement procedures.) Flywheel Side 1st Compression Ring Connecting Rod Alignment Mark Groove 2nd Compression Ring 2 Oil Ring with Coil Expander Tangs Connecting Rod Cap Screw Piston Groove Piston Pin M82196A Retaining Ring All Except 3TN75 7. Install cylinder head. (See Cylinder Head, Valves and Manifolds in this section.) 8. Install oil pan and strainer tube. (See Lubrication System in this section.) Disassembly Piston Pin Bushing Connecting Rod IMPORTANT: Pistons must be installed on the same connecting rod they were removed from. • Put a mark on each piston and connecting rod to aid in assembly. 4/7/95 M82274A 3TN75 2-33 Pistons, Rods and Cylinder Block Piston Recess Piston 1st Compression Ring 2nd Compression Ring Piston Pin Oil Ring with Coil Expander Piston 2 Retaining Ring Piston Pin Snap Ring Alignment Mark Connecting Rod Piston Pin Bushing M82275A Bearing Insert Groove 3TN75 Connecting Rod All Except 3TN75 M82197A Piston Size Mark Piston Assembly • Apply clean engine oil to all parts during assembly. Piston Pin IMPORTANT: Pistons must be installed on the same connecting rod they were removed from. 1. 3TN75: Assemble piston to connecting rod with recess mark on same side as connecting rod “punched” alignment mark. If a new connecting rod is used, assemble piston to connecting rod with piston recess opposite connecting rod bearing insert groove. All except 3TN75: Assemble piston to connecting rod with piston size mark on same side as connecting rod “punched” alignment mark. If a new connecting rod is used, assemble piston to connecting rod with piston size mark opposite connecting rod bearing insert groove. Snap Ring Connecting Rod Alignment Mark Bearing Insert Groove M82198A All Except 3TN75 2-34 4/7/95 Pistons, Rods and Cylinder Block 2. Install piston pin and retaining/snap rings. 3. Install oil ring expander in bottom ring groove of piston with ends above either end of piston pin. 4. Install oil ring over expander with ring gap opposite (180o) of expander ends. 1st Compression Ring 2nd Compression Ring Oil Ring Expander Oil Ring Gap 1st Compression Ring Oil Ring Expander Ends 2nd Compression Ring 120° 120° 2 120° Oil Ring Oil Ring Piston Pin M82046A 5. 3TN75: Install second compression ring, with chamfer toward top of piston, in middle groove. Turn ring until gap is 120o ring gap. All Except 3TN75: Install second compression ring, with small diameter of taper toward top of piston, in middle groove. Turn ring until gap is 120o away from oil ring gap. M82199A All Except 3TN75 6. Install first compression ring (chrome plated), with manufacturer's mark “R”, “T” or “RN” (near ring gap) toward top of piston, in top groove. Turn ring until gap is 120o away from second ring gap. 1st Compression Ring Inspection/Replacement 2nd Compression Ring 1. Inspect all parts for wear or damage. Replace as necessary. 2. Measure crankshaft connecting rod journal diameter. (See Crankshaft, Main Bearings and Flywheel in this section.) 2nd Compression Ring 120° 120° 1st Compression Ring 3. Install connecting rod cap and bearing inserts on connecting rod. Install old connecting rod cap screws and tighten to specifications. 120° Oil Ring Connecting Rod Cap Screw Torque Specifications: 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . . . 39 N•m (29 lb-ft) 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . . . . . 47 N•m (35 lb-ft) M82276A 3TN75 4/7/95 4. Measure connecting rod bearing diameter. 2-35 Pistons, Rods and Cylinder Block M35360 2 M82048A Connecting Rod Bearing I.D. - 3TN75, 3TN78, 3TNC78 (3011): Standard . . . . . . . . . . . . . . . . 43 - 43.042 mm . . . . . . . . . . . . . . . . . . . . . . . (1.693 - 1.695 in.) Wear Limit. . . . . . . . . . . 43.07 mm (1.696 in.) Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.) Connecting Rod Bearing I.D. - 3TN82, 3TNA82, 3TN84 (3014): Standard . . . . . . . . . . . . . . . . 48 - 48.042 mm . . . . . . . . . . . . . . . . . . . . . . . (1.888 - 1.891 in.) Wear Limit. . . . . . . . . . . 48.07 mm (1.893 in.) Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.) If bearing diameter exceeds wear limit, replace bearing inserts. If bearing clearance (bearing I.D. minus crankshaft journal O.D.) exceeds specification, grind crankshaft connecting rod journals and install undersized bearing inserts, or replace bearing inserts and crankshaft. 5. With rings installed on piston, measure piston ring groove clearance. Measure several places around each piston. Piston Ring Groove Clearance - 3TN75, 3TN78, 3TNC78 (3011): First Compression Ring Standard . . . . . . . . . . . . . . . 0.070 - 0.105 mm . . . . . . . . . . . . . . . . . . . . . (0.0028 - 0.0041 in.) Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) Second Compression Ring Standard . . . . . . . . . . . . . . . 0.035 - 0.070 mm . . . . . . . . . . . . . . . . . . . . . (0.0014 - 0.0028 in.) Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) Oil Ring Standard . . . . . . . . . . . . . . . 0.030 - 0.060 mm . . . . . . . . . . . . . . . . . . . . . (0.0012 - 0.0024 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Piston Ring Groove Clearance - 3TN82, 3TNA82, 3TN84 (3014): First Compression Ring Standard . . . . . . . . . . . . . . . 0.075 - 0.110 mm . . . . . . . . . . . . . . . . . . . . . (0.0030 - 0.0043 in.) Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) Second Compression Ring Standard . . . . . . . . . . . . . . . . 0.45 - 0.080 mm . . . . . . . . . . . . . . . . . . . . . (0.0018 - 0.0031 in.) Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) 2-36 4/7/95 Pistons, Rods and Cylinder Block Oil Ring Standard . . . . . . . . . . . . . . . 0.025 - 0.060 mm . . . . . . . . . . . . . . . . . . . . . (0.0010 - 0.0024 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) If clearance exceeds wear limit, replace rings or piston. 6. Measure piston ring end gap. Push ring into cylinder bore, using a piston, until ring is approximately 30 mm (1.181 in.) from bottom of cylinder bore. End Gap Piston Ring End Gap - 3TN78, 3TNC78 (3011): Standard Compression Rings . . . . . . . . 0.25 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.016 in.) Oil Ring . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.) Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Ring End Gap - 3TN82, 3TNA82: Standard First Compression Ring . . . . 0.25 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.016 in.) Second Compression Ring . . 0.20 - 0.35 mm . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.014 in.) Oil Ring . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.) Wear Limit: . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Ring End Gap - 3TN84 (3014): Standard Compression Rings . . . . . . . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.) Oil Ring . . . . . . . . . . . . . . . . . 0.25 - 0.45 mm . . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.018 in.) Wear Limit: . . . . . . . . . . 1.50 mm (0.0591 in.) Cylinder Bore Piston Ring If end gap exceeds wear limit, replace rings. 7. Measure piston pin diameter. Measure diameter at six places. Approx. 30 mm (1.181 in.) End Gap M82049A Piston Ring End Gap - 3TN75: Compression Rings and Oil Ring Standard . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.) Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.) 4/7/95 2-37 2 Pistons, Rods and Cylinder Block M37683 Piston Pin Bore I.D. - 3TN75, 3TN78, 3TNC78 (3011): 2 Measuring Positions Standard . . . . . . . . . . . . . . 23.00 - 23.009 mm . . . . . . . . . . . . . . . . . . . . . (0.9055 - 0.9059 in.) Wear Limit. . . . . . . . . . . 23.02 mm (0.906 in.) Clearance . . . . . . . . . . . 0.045 mm (0.0018 in.) Piston Pin Bore I.D. - 3TN82, 3TNA82, 3TN84 (3014): M82050A Piston Pin O.D. - 3TN75, 3TN78, 3TNC78 (3011): Standard . . . . . . . . . . . . . . 22.991 - 23.00 mm . . . . . . . . . . . . . . . . . . . . . . . (0.905 - 0.906 in.) Wear Limit. . . . . . . . . . . 22.90 mm (0.902 in.) Piston Pin O.D. - 3TN82, 3TNA82, 3TN84 (3014): Standard . . . . . . . . . . . . . . 26.00 - 26.009 mm . . . . . . . . . . . . . . . . . . . . . (1.0236 - 1.0240 in.) Wear Limit. . . . . . . . . . . 26.02 mm (1.024 in.) Clearance . . . . . . . . . . . 0.045 mm (0.0018 in.) If piston pin bore exceeds wear limit, replace piston. If bore clearance (bore I.D. minus pin O.D.) exceeds specification, replace piston, piston pin or both. 9. Measure piston connecting rod. pin bushing diameter in Standard . . . . . . . . . . . . . . 25.987 - 26.00 mm . . . . . . . . . . . . . . . . . . . . . . . (1.023 - 1.024 in.) Wear Limit. . . . . . . . . . . 25.90 mm (1.020 in.) If pin diameter is less than wear limit, replace pin. 8. Measure piston pin bore diameter in piston. M82051A 2-38 4/7/95 Pistons, Rods and Cylinder Block Piston Pin Bushing I.D. - 3TN75, 3TN78, 3TNC78 (3011): Standard . . . . . . . . . . . . . 23.025 - 23.038 mm . . . . . . . . . . . . . . . . . . . . . (0.9065 - 0.9070 in.) Wear Limit. . . . . . . . . . . 23.10 mm (0.909 in.) Clearance . . . . . . . . . . . 0.110 mm (0.0043 in.) Piston Pin Bushing I.D. - 3TN82, 3TNA82, 3TN84 (3014): Standard . . . . . . . . . . . . . 26.025 - 26.038 mm . . . . . . . . . . . . . . . . . . . . . (1.0246 - 1.0251 in.) Wear Limit. . . . . . . . . . . 26.10 mm (1.028 in.) Clearance . . . . . . . . . . . 0.110 mm (0.0043 in.) If bushing diameter exceeds wear limit, replace bushing. If bushing clearance (bushing I.D. minus pin O.D.) exceeds specification, replace bushing, piston pin or both. Piston pin bushing is press fit. Replace bushing using a driver set. When installing bushing, make sure to align oil hole in bushing with hole in connecting rod. 10.Measure piston diameter perpendicular to piston pin bore at distance A. NOTE: If engine has had a previous major overhaul, oversize pistons and rings may have been installed. Pistons and rings are available in 0.25 mm (0.010 in.) oversize for all engines and 0.50 mm (0.020 in.) oversize for 3TN75 (F1145 FM), 3TN82 (575 SSL), 3TNC78 (3011 OEM) and 3TN84 (3014 OEM). 2 M82052A Piston O.D. - 3TN75: Distance A . . . . . . . . . . . . . . . 12.5 mm (0.492 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . 74.91 - 74.94 mm . . . . . . . . . . . . . . . . . . . . . . . (2.949 - 2.951 in.) Wear Limit. . . . . . . . . . . 74.81 mm (2.945 in.) 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . 75.17 - 75.18 mm . . . . . . . . . . . . . . . . . . . . . . . (2.959 - 2.960 in.) Wear Limit. . . . . . . . . . . 75.06 mm (2.955 in.) 0.50 mm (0.020 in.) Oversize Piston (F1145 FM Only) Standard . . . . . . . . . . . . . . . 75.42 - 75.43 mm . . . . . . . . . . . . . . . . . . . . . . . (2.969 - 2.970 in.) Wear Limit. . . . . . . . . . . 75.31 mm (2.965 in.) Piston O.D. - 3TN78, 3TNC78 (3011): Distance A . . . . . . . . . . . . . . . . .23 mm (0.905 in.) Standard Size Piston Standard . . . . . . . . . . . . . 77.895 - 77.925 mm . . . . . . . . . . . . . . . . . . . . . . . (3.067 - 3.068 in.) Wear Limit. . . . . . . . . . . 77.81 mm (3.063 in.) 0.25 mm (0.010 in.) Oversize Piston A Standard . . . . . . . . . . . . . . . 78.15 - 78.18 mm . . . . . . . . . . . . . . . . . . . . . . . (3.076 - 3.077 in.) Wear Limit. . . . . . . . . . . 78.05 mm (3.073 in.) M82200A 4/7/95 2-39 Pistons, Rods and Cylinder Block 0.50 mm (0.020 in.) Oversize Piston (3011 OEM Only) Standard . . . . . . . . . . . . . . . 78.40 - 78.42 mm . . . . . . . . . . . . . . . . . . . . . . . (3.086 - 3.087 in.) Wear Limit. . . . . . . . . . . 78.30 mm (3.083 in.) If piston diameter is less than wear limit, install a new piston. 11.Measure cylinder bore diameter. (See procedure in this group.) CYLINDER BORE Piston O.D. - 3TN82, 3TNA82: Distance A . . . . . . . . . . . . . . . . .24 mm (0.945 in.) Standard Size Piston 2 Standard . . . . . . . . . . . . . . . 81.90 - 81.93 mm . . . . . . . . . . . . . . . . . . . . . . . (3.224 - 3.226 in.) Wear Limit. . . . . . . . . . . 81.80 mm (3.221 in.) 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . 82.15 - 82.17 mm . . . . . . . . . . . . . . . . . . . . . . . (3.234 - 3.235 in.) Wear Limit. . . . . . . . . . . 82.05 mm (3.230 in.) Inspection Measure cylinder bore diameter at three positions; top, middle and bottom. At these three positions, measure in both directions; along crankshaft center line and direction of crankshaft rotation. NOTE: If engine has had a previous major overhaul, oversize pistons and rings may have been installed. Top Position 0.50 mm (0.020 in.) Oversize Piston (575 SSL Only) Standard . . . . . . . . . . . . . . . 82.40 - 82.42 mm . . . . . . . . . . . . . . . . . . . . . . . (3.244 - 3.245 in.) Wear Limit. . . . . . . . . . . 82.30 mm (3.240 in.) Middle Position Piston O.D. - 3TN84 (3014): Distance A . . . . . . . . . . . . . . . . .24 mm (0.945 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . 83.90 - 83.93 mm . . . . . . . . . . . . . . . . . . . . . . . (3.303 - 3.304 in.) Wear Limit. . . . . . . . . . . 83.80 mm (3.299 in.) 0.25 mm (0.010 in.) Oversize Piston Bottom Position Direction of Crankshaft Rotation Direction of Crankshaft Centerline Standard . . . . . . . . . . . . . . . 84.15 - 84.17 mm . . . . . . . . . . . . . . . . . . . . . . . (3.313 - 3.314 in.) Wear Limit. . . . . . . . . . . 84.05 mm (3.309 in.) 0.50 mm (0.020 in.) Oversize Piston (3014 OEM Only) Standard . . . . . . . . . . . . . . . 84.40 - 84.42 mm . . . . . . . . . . . . . . . . . . . . . . . (3.323 - 3.324 in.) Wear Limit. . . . . . . . . . . 84.30 mm (3.319 in.) 2-40 M82053A Cylinder Bore I.D. - 3TN75: Standard Size Bore Standard . . . . . . . . . . . . . . . 75.00 - 75.03 mm . . . . . . . . . . . . . . . . . . . . . . . (2.953 -2.954 in.) Wear Limit . . . . . . . . . . 75.20 mm (2.961 in.) Clearance . . . . . . . . . . . . . 0.22 mm (0.009 in.) 4/7/95 Pistons, Rods and Cylinder Block 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . 75.25 - 75.28 mm . . . . . . . . . . . . . . . . . . . . . . . (2.963 - 2.964 in.) Wear Limit. . . . . . . . . . . 75.45 mm (2.970 in.) Clearance . . . . . . . . . . . . . 0.22 mm (0.009 in.) 0.50 mm (0.020 in.) Oversize Bore (F1145 FM Only) Standard . . . . . . . . . . . . . . . 75.50 - 75.53 mm . . . . . . . . . . . . . . . . . . . . . . . (2.972 - 2.974 in.) Wear Limit. . . . . . . . . . . 75.70 mm (2.980 in.) Clearance . . . . . . . . . . . . . 0.22 mm (0.009 in.) Cylinder Bore I.D. - 3TN78, 3TNC78 (3011): Standard Size Bore Standard . . . . . . . . . . . . . . . 78.00 - 78.03 mm . . . . . . . . . . . . . . . . . . . . . . . (3.071 - 3.072 in.) Wear Limit . . . . . . . . . . 78.20 mm (3.079 in.) Clearance . . . . . . . . . . . . . 0.22 mm (0.009 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . 78.25 - 78.28 mm . . . . . . . . . . . . . . . . . . . . . . . (3.081 - 3.082 in.) Wear Limit. . . . . . . . . . . 78.45 mm (3.089 in.) 0.50 mm (0.020 in.) Oversize Bore (3011 OEM Only) Standard . . . . . . . . . . . . . . . 78.50 - 78.53 mm . . . . . . . . . . . . . . . . . . . . . . . (3.091 - 3.092 in.) Wear Limit. . . . . . . . . . . 78.70 mm (3.099 in.) Cylinder Bore I.D. - 3TN82, 3TNA82: Standard Size Bore Standard . . . . . . . . . . . . . . . 82.00 - 82.03 mm . . . . . . . . . . . . . . . . . . . . . . . (3.228 - 3.230 in.) Wear Limit . . . . . . . . . . 82.20 mm (3.236 in.) Clearance . . . . . . . . . . . . . 0.35 mm (0.014 in.) 0.50 mm (0.020 in.) Oversize Bore (575 SSL Only) Standard . . . . . . . . . . . . . . . 82.50 - 82.53 mm . . . . . . . . . . . . . . . . . . . . . . . (3.248 - 3.249 in.) Wear Limit. . . . . . . . . . . 82.70 mm (3.256 in.) Cylinder Bore I.D. - 3TN84 (3014): Standard Size Bore Standard . . . . . . . . . . . . . . . 84.00 - 84.03 mm . . . . . . . . . . . . . . . . . . . . . . . (3.307 - 3.308 in.) Wear Limit . . . . . . . . . . 84.20 mm (3.315 in.) Clearance . . . . . . . . . . . . . 0.35 mm (0.014 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . 84.25 - 84.28 mm . . . . . . . . . . . . . . . . . . . . . . . (3.317 - 3.318 in.) Wear Limit. . . . . . . . . . . 84.45 mm (3.325 in.) 0.50 mm (0.020 in.) Oversize Bore (3014 OEM Only) Standard . . . . . . . . . . . . . . . 84.50 - 84.53 mm . . . . . . . . . . . . . . . . . . . . . . . (3.327 - 3.328 in.) Wear Limit. . . . . . . . . . . 84.70 mm (3.335 in.) If cylinder bore exceeds wear limit, replace cylinder block or have cylinder rebored. (See Reboring procedure.) If cylinder is rebored, oversize pistons and rings must be installed. Pistons and rings are available in 0.25 mm (0.010 in.) oversize for all engines and 0.50 mm (0.020 in.) oversize for 3TN75 (F1145 FM), 3TN82 (575 SSL), 3TNC78 (3011 OEM), and 3TN84 (3014 OEM). If clearance (cylinder bore I.D. minus piston O.D.) exceeds specification, replace cylinder block, piston or both; or rebore cylinder and install oversize piston and rings. 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . 82.25 - 82.28 mm . . . . . . . . . . . . . . . . . . . . . . . (3.238 - 3.239 in.) Wear Limit. . . . . . . . . . . 82.45 mm (3.246 in.) 4/7/95 2-41 2 Pistons, Rods and Cylinder Block Deglazing 3. Adjust rigid hone stones until they contact narrowest point of cylinder. IMPORTANT: If cylinder bores are to be deglazed with crankshaft installed in engine, put clean shop towels over crankshaft to protect journal and bearing surfaces from any abrasives. 1. Deglaze cylinder bores using a flex-hone with 180 grit stones. 4. Coat cylinder with honing oil. Hone should turn by hand. Adjust if too tight. 5. Run drill press at about 250 RPM. Move hone up and down in order to obtain a 30 - 40°crosshatch pattern. 2. Use flex-hone as instructed by manufacturer to obtain a 30 - 40° cross-hatch pattern as shown. 2 IMPORTANT: Do not use gasoline, kerosene or commercial solvents to clean cylinder bores. Solvents will not remove all abrasives from cylinder walls. 30 - 40° 3. Remove excess abrasive residue from cylinder walls using a clean dry rag. Clean cylinder walls using clean white rags and warm soapy water. Continue to clean cylinder until white rags show no discoloration. M52959 NOTE: Measure bore when cylinder is cool. 6. Stop press and check cylinder diameter. M82054A NOTE: Finish should not be smooth. It should have a 30 - 40o crosshatch pattern. 7. Remove rigid hone when cylinder is within 0.03 mm (0.001 in.) of desired size. Reboring NOTE: The cylinder block can be rebored to use oversize pistons and rings. Pistons and rings are available in 0.25 mm (0.010 in.) oversize for all engines and 0.50 mm (0.020 in.) oversize for 3TN75 (F1145 FM), 3TN82 (575 SSL), 3TNC78 (3011 OEM) and 3TN84 (3014 OEM). (See this group for cylinder bore I. D. specifications.) 1. Align center of bore to drill press center. IMPORTANT: Check stone for wear or damage. Use a rigid hone with 300 grit stones. 8. Use a flex hone with 180 grit stones for honing to final size. 9. Check bore for size, taper and out-of-round. (See Inspection procedures.) IMPORTANT: Do not use solvents to clean cylinder bore. Solvents will not remove all metal particles and abrasives produced during honing. 10.Clean cylinder thoroughly using warm soapy water until clean white rags show no discoloration. 11.Dry cylinder and apply engine oil. 2. Adjust hone so lower end is even with lower end of cylinder bore. 2-42 4/7/95 Crankshaft, Main Bearings and Flywheel OTHER MATERIALS Number Name Use John Deere Form-In-Place Gasket Seals crankcase extension housing, rear oil seal case and flywheel housing to engine block. LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. TY15130/ NA/ #395 SERVICE PARTS KITS 2 The following kits are available through your parts catalog: • Cylinder Block Gasket Kit • Undersized Main Bearing Inserts ®LOCTITE is a registeredtrademark of the Loctite Corp. 4/7/95 2-43 Crankshaft, Main Bearings and Flywheel CRANKCASE EXTENSION HOUSING 3TN75, 3TNC78 (3011 OEM), 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) John Deere Form-In-Place Gasket (RTV rubber silicone sealant) 1. Remove flywheel. (See procedure in this group.) 2. Remove oil pan and oil strainer. (See Lubrication System in this section.) Extension-toTiming Gear Cover Cap Screw (6) M8 x 45 22 N•m (195 lb-in.) 3. Remove seal case-to-extension cap screws and flywheel plate/housing-to-extension cap screws. 2 Extensionto-Block Cap Screw (2) (3011DF006 Only) M8 x 45 27 N•m (20 lb-ft) 3TNC78 (3011 OEM) Seal Case - toExtension Cap Screw (3) M8 x 35 26 N•m (226 lb-in.) M82345A John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Flywheel Plate/Housing-toExtension Cap Screw (4) M10 x 25 (Flywheel Plate) M10 x 30 (Flywheel Housing) 49 N•m (36 lb-ft) M82056 4. Remove remaining cap screws and extension housing. Installation is done in the reverse order of removal. John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Extension-toTiming Gear Cover Cap Screw (6) M8 x 45 22 N•m (195 lb-in.) Crankcase Extension Housing Extension-to-Timing Gear Cover Cap Screw (2) M8 x 25 22 N•m (195 lb-in.) 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) M82346A CRANKCASE EXTENSION HOUSING 3TN78 (25 EX), 3TN82 (30 EX), 3TNA82 (770 CUT), 3TN84 (870 CUT) 1. Remove flywheel. (See procedure in this group.) 3TN75 2-44 Extension-to-Block Cap Screw (2) M8 x 50 27 N•m (20 lb-ft) M82344A 2. Remove oil pan/plate. (See Lubrication System in this section.) 4/7/95 Crankshaft, Main Bearings and Flywheel 3. Remove seal case-to-extension cap screws and flywheel plate/housing-to-extension cap screws. John Deere Form-InPlace Gasket (RTV rubber silicone selant) Crankcase Extension Housing 2 Seal Case - toExtension Cap Screw (3) M8 x 30 26 N•m (226 lb-in.) Flywheel Plate/Housing-toExtension Cap Screw Plate: (4) M10 x 20 Housing: (2) M10 x 25 49 N•m (36 lb-ft) Extension-toTiming Gear Cover Cap Screw (4) M8 x 25 22 N•m (195 lb-in.) M82056 4. Remove remaining cap screws and extension housing. Installation is done in the reverse order of removal. John Deere Form-InPlace Gasket (RTV rubber silicone sealant) Extension-to-Block Cap Screw (14) M8 x 85 27 N•m (20 lb-ft) Extension-to-Block Cap Screw (4) M8 x 120 27 N•m (20 lb-ft) M82348A 3TN84 (870 CUT) CRANKSHAFT REAR OIL SEAL Replacement Crankcase Extension Housing Extension to-Timing Gear Cover Cap Screw (6) M8 x 25 22 N•m (195 lb-in.) Extension-to-Block Cap Screw (4) M8 x 50 27 N•m (20 lb-ft) Extension-to-Block Cap Screw (8) M8 x 85 27 N•m (20 lb-ft) 1. Remove flywheel. (See procedure in this group.) • Replace oil seal using a driver set. Install seal, with lip toward cylinder block. Install seal flush with surface of oil seal case. NOTE: If crankshaft is grooved at oil seal contact point, seal can be installed 3 mm (0.120 in.) farther into oil seal case. On 3TN78, 3TN82 (30 EX), 3TNA82, 3TN84 (870 CUT): All nine seal case cap screws are M8 x 30 long. Extension to-Block Cap Screw (4) M8 x 120 M82347A 27 N•m (20 lb-ft) 3TN78 (25 EX), 3TN82 (30 EX), 3TNA82 (770 CUT) 4/7/95 2-45 Crankshaft, Main Bearings and Flywheel CRANKSHAFT AND MAIN BEARINGS Rear Oil Seal Seal Case-to-Block Cap Screw (6) M8 X 30 26 N•m (226 lb-in.) Oil Seal Case Removal 1. Check crankshaft end play. (See Checks, Tests and Adjustments in this section.) 2. Remove rear oil seal. (See procedure in this group.) 3. Remove flywheel housing. (See procedure in this group.) 4. Remove crankcase extension housing. (See procedure in this group.) 2 NOTE: On 3TNA82 and 3TN84 (870 CUT), crankshaft can be removed without removing timing gear cover mounting plate. Seal Case-to-Extension Cap Screw (3) M8 X 35 21 N•m (180 lb-in.) John Deere Form-In-Place Gasket (RTV rubber silicone sealant) M82349A CRANKSHAFT FRONT OIL SEAL 5. Remove timing gear cover mounting plate. (See Camshaft and Timing Gear Train in this section.) 6. Check crankshaft bearing clearance. (See Checks, Tests and Adjustments in this section.) IMPORTANT: Connecting rod end caps must be installed on the same connecting rods from which they were removed. Note alignment marks on caps and rods. 7. Remove connecting rod cap screws and end caps. Replacement • Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) • Replace oil seal using a driver set. Install seal with lip toward inside of gear housing cover. Install seal flush with surface of cover. 8. Push pistons and connecting rods away from crankshaft. IMPORTANT: Main bearing caps must be installed on the same main bearings from which they were removed. 9. Remove main bearing cap screws, caps and cap thrust bearings. Timing Gear Cover 10.Remove crankshaft. 11.Remove block thrust bearings and main bearing inserts. 12.Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) Crankshaft Front Oil Seal M82203A 2-46 4/7/95 Crankshaft, Main Bearings and Flywheel Crankshaft Flywheel End Block Thrust Bearing 2 Cap Thrust Bearing Main Bearing Inserts Main Bearing Cap Screw (8) Main Bearing Cap Installation • Apply clean engine oil on all parts during installation. IMPORTANT: Do not touch bearing insert surfaces. Oil and acid from your finger will corrode the bearing surface. 1. Install grooved bearing inserts in crankshaft bearing bores, aligning tangs with slots in bores. 2. Install block thrust bearings with oil grooves facing away from engine block. 3. Install crankshaft. 4. Install smooth bearing inserts in main bearing caps, aligning tangs with slots in caps. NOTE: Main bearing caps have “raised arrows” that are stamped with numbers. Both correspond to their location on the engine block. The number “1” main bearing bore is at flywheel end. Install bearing caps beginning with number 1, then 2, etc. The main bearing cap at gear train end does not have a number. Also install bearing caps with the “arrow” toward the flywheel end. 4/7/95 M82283A 5. Install cap thrust bearings, with oil grooves facing away from cap, in the number “1” main bearing cap. 6. Install main bearing caps in their original locations with arrows pointing toward flywheel side of engine. IMPORTANT: DO NOT use high speed power tools or air wrenches to tighten main bearing cap screws. 7. Dip entire main bearing cap screws in clean engine oil. Install cap screws and tighten. DO NOT tighten to specifications. 8. Using a soft-faced hammer, tap the front end of the crankshaft then the rear end of the crankshaft to align the thrust bearings. 9. Tighten main bearing cap screws to specifications. When tightening, start at center main bearing cap and work your way out, alternating to the ends. Turn crankshaft by hand. If it does not turn easily, disassemble the parts and find the cause. 2-47 Crankshaft, Main Bearings and Flywheel Crankshaft Flywheel End Grooved Bearing Insert Block Thrust Bearing Cap Thrust Bearing 2 Smooth Bearing Insert Tangs Main Bearing Cap 1 2 Main Bearing Cap Screw (8) Dip in clean engine oil. 3TN75, 3TN78, 3TNC78 (3011):79 N•m (58 lb-ft) 3TN82, 3TNA82, 3TN84 (3014):98 N•m (72 lb-ft) 3 M82283A IMPORTANT: Connecting rod caps must be installed on the same connecting rods they were removed from. Never reuse connecting rod cap screws, replace with new. NOTE: On 3TNA82 and 3TN84 (870 CUT), crankshaft can be installed without removing timing gear cover mounting plate. 12.Install timing gear cover mounting plate. (See Camshaft and Timing Gear Train in this section.) 10.Match the connecting rod caps to the rods using alignment marks. Install caps. 13.Install crankcase extension procedure in this group.) housing. (See 11.Dip entire connecting rod cap screws in clean engine oil. Install new cap screws and tighten to specifications. 14.Install flywheel housing. (See procedure in this group.) 15.Install rear oil seal. (See procedure in this group.) Connecting Rod Cap Screw Torque Specifications: 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . . . 39 N•m (29 lb-ft) 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . . . . . 47 N•m (35 lb-ft) 2-48 4/7/95 Crankshaft, Main Bearings and Flywheel Inspection/Replacement 1. Inspect crankshaft gear for chipped or broken teeth. Replace if necessary. To replace gear: Remove gear from crankshaft using a knife-edge puller and a press. 2. Inspect crankshaft for bend using v-blocks and a dial indicator. Turn crankshaft slowly and read variation on indicator. If variation is greater than 0.02 mm (0.0007 in.), replace crankshaft. 3. Measure crankshaft connecting rod journal and main bearing journal diameters. Measure several places around each journal. NOTE: If engine has had a previous major overhaul, journals may have been ground and undersized bearing inserts installed. CAUTION Main Bearing Journal DO NOT heat oil over 182° C (360° F). Oil fumes or oil can ignite above 193° C (380° F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. 2 Connecting Rod Journal Heat gear to approximately 150oC (300oF). Install gear with timing mark “A” toward press table. Align slot in gear with key in shaft. Press crankshaft into gear until gear is tight against crankshaft shoulder. M82062A Connecting Rod Journal O.D. - 3TN75, 3TN78, 3TNC78 (3011): Key Crankshaft Gear Standard . . . . . . . . . . . . . 42.952 - 42.962 mm . . . . . . . . . . . . . . . . . . . . . (1.6910 - 1.6914 in.) Wear Limit. . . . . . . . . . . 42.91 mm (1.689 in.) Timing Mark Connecting Rod Journal O.D. - 3TN82, 3TNA82, 3TN84 (3014): Standard . . . . . . . . . . . . . 47.952 - 47.962 mm . . . . . . . . . . . . . . . . . . . . . (1.8879 - 1.8883 in.) M82060A Wear Limit. . . . . . . . . . . 47.91 mm (1.886 in.) Dial Indicator V-Block 4/7/95 M82284A 2-49 Crankshaft, Main Bearings and Flywheel Main Bearing Journal O.D. - 3TN75, 3TN78, 3TNC78 (3011): Main Bearing I.D. - 3TN75, 3TN78, 3TNC78 (3011): Standard . . . . . . . . . . . . . 46.952 - 46.962 mm . . . . . . . . . . . . . . . . . . . . . (1.8485 - 1.8489 in.) Standard . . . . . . . . . . . . . . 47.00 - 47.045 mm . . . . . . . . . . . . . . . . . . . . . . . (1.850 - 1.852 in.) Wear Limit. . . . . . . . . . . 46.91 mm (1.847 in.) Wear Limit. . . . . . . . . . 47.10 mm (1.8541 in.) Main Bearing Journal O.D. - 3TN82, 3TNA82, 3TN84 (3014): Standard . . . . . . . . . . . . . 46.952 - 46.962 mm . . . . . . . . . . . . . . . . . . . . . (1.9666 - 1.9670 in.) Wear Limit. . . . . . . . . . . 49.90 mm (1.965 in.) 2 If journal diameter is less than wear limit, replace crankshaft or have journals ground undersize by a qualified machine shop. If journals are ground, undersize bearing inserts must be installed. Bearing inserts are available in 0.25 mm (0.010 in.) undersize. 4. Install bearing inserts and main bearing cap on main bearing. Tighten main bearing cap screws to specifications. Main Bearing Cap Screw Torque Specifications: 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . . . 79 N•m (58 lb-ft) 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . . . . . 98 N•m (72 lb-ft) Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.) Main Bearing I.D. - 3TN82, 3TNA82, 3TN84 (3014): Standard . . . . . . . . . . . . . . 50.00 - 50.045 mm . . . . . . . . . . . . . . . . . . . . . . . (1.969 - 1.970 in.) Wear Limit. . . . . . . . . . . 50.10 mm (1.972 in.) Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.) If bearing diameter exceeds wear limit, replace bearing inserts. If bearing clearance (bearing I.D. minus crankshaft main bearing journal O.D.) exceeds specification, replace bearing inserts and crankshaft or have crankshaft journals ground undersize by a qualified machine shop and install undersized bearing inserts. Bearing inserts are available in 0.25 mm (0.010 in.) undersize. 6. Clean and inspect oil passages in main bearing journals, connecting rod journals and main bearing bores in cylinder block. 7. Inspect crankshaft for cracks or damage. Replace if necessary. 5. Measure main bearing diameter. M82063 2-50 4/7/95 Crankshaft, Main Bearings and Flywheel FLYWHEEL IMPORTANT: Never reuse flywheel mounting cap screws. Always install new. 1. 3TN75 (F1145FM): Remove cooling fan, isolator, pulley, isolator mount plate and flywheel guards. - 3TN75 (855/56 CUT): Remove flywheel guards. • Inspect pilot bushing, if equipped, for wear or damage. Replace if necessary using a driver set. Install bushing flush with flywheel surface. • Measure flywheel flatness. Place a straight edge across flywheel surface opposite of ring gear. Measure clearance between straight edge and flywheel surface with a feeler gauge. If clearance exceeds 0.02 mm (0.0008 in.), replace flywheel. - 3TN84 (955 CUT): Remove isolator mount plate and flywheel guards. - 3TN78, 3TN82: Remove center flex coupler. (See procedure in Machine Technical Manual.) 2 2. Remove mounting cap screws and flywheel. M35337 Flywheel Guard (Top) Cap Screw (8) M8 x 16 Pilot Bushing 3TNA82 (770 CUT), 3TN84 (870 CUT) Only Isolator Mount Plate Flywheel Flywheel Guard (Bottom) Early 855/56 CUT 3TN84 (955 CUT) Bracket (F1145 FM Only) Flywheel Mounting Cap Screw (6) Replace. Apply clean engine oil on threads. 83 N•m (61 lb-ft) Isolator Cap Screw (3) M10 x 50 49 N•m (36 lb-ft) Pulley Cap Screw (8) M8 x 16 3TN75 (F1145FM) 4/7/95 Flywheel Guards Isolator Mount Plate M82350A 2-51 Crankshaft, Main Bearings and Flywheel FLYWHEEL HOUSING - 3TN78, 3TNC78 (3011), 3TN82, 3TN84 (3014) 1. Remove flywheel. (See procedure in this group.) NOTE: 3TNC78 (3011DF001 OEM) and 3TN84 (3014DF001 OEM) engines are equipped with a flywheel plate in place of a housing. (See procedure in this group.) 2. Remove starter. Housing-to-Block Cap Screw (6) M10 x 25 49 N•m (36 lb-ft) Housing-to-Extension Cap Screw (4) M10 x 30 49 N•m (36 lb-ft) 2 Flywheel Housing John Deere Form-In-Place Gasket (RTV rubber silicone sealant) 3TN82 (575 SSL) Mounting Cap Screw (8) M10 x 25 49 N•m (36 lb-ft) Plug 3TN78 (25 EX) , 3TN82 (30 EX) M82351A 2-52 4/7/95 Crankshaft, Main Bearings and Flywheel FLYWHEEL PLATE - 3TN75, 3TNC78 (3011), 3TNA82, 3TN84 (3014) 1. Remove flywheel. (See procedure in this group.) 2. Remove starter. Mounting Cap Screw (8) M10 x 20 49 N•m (36 lb-ft) Plate-to-Block Cap Screw (6) M10 x 20 49 N•m (36 lb-ft) Plate-to-Extension Cap Screw (4) M10 x 25 49 N•m (36 lb-ft) 2 3TN84 (870 CUT) M82353A 3TNA82, 3TN84 (870 CUT) 3TN75, 3TN84 (955 CUT) M82352A 3TN75, 3TNC78 (3011), 3TN84 (955 CUT, 3014 OEM) 4/7/95 2-53 Camshaft and Timing Gear Train SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the European Microfiche Tool Catalog (MTC). D15001NU Magnetic Follower Holder Kit Hold cam followers when removing and installing camshaft. OTHER MATERIALS 2 Number LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. TY15130/ NA/ #395 Name Use John Deere Form-In-Place Gasket Seals camshaft plug, timing gear cover and plate to engine block. TY9370/ TY9477/ #242 Thread Lock and Sealer (Medium Strength) Apply to threads of crankshaft pulley cap screw. SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Head Gasket Kit • Cylinder Block Gasket Kit ® LOCTITE is a registered trademark of the Loctite Corp. 2-54 4/7/95 Camshaft and Timing Gear Train CAMSHAFT Mounting Cap Screws M8 X 16 Removal 1. Remove rocker arm assembly and push rods. (See Cylinder Head, Valves and Manifolds in this section.) 2. Remove timing gear cover. (See procedure in this group.) 3. Check camshaft end play. (See Checks, Tests and Adjustments in this section.) 4. Check backlash of timing gears. (See Checks, Tests and Adjustments in this section.) NOTE: If a magnetic follower holder kit is not available, turn engine until oil pan is upward, to hold cam followers away from camshaft. 5. Hold cam followers away from camshaft using a magnetic follower holder kit such as D15001NU. NOTE: Due to the odd number of teeth on the idler gear, timing marks will only align periodically. 2 Timing Marks Camshaft M37836 Installation • Apply clean engine oil on all parts during installation. 6. Rotate crankshaft and align timing marks. IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while installing camshaft. Machined surfaces can be damaged. IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while removing camshaft. Machined surfaces can be damaged. 1. Rotate crankshaft to align timing marks. 7. Remove two cap screws and camshaft. 8. Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) 2. Install camshaft. 3. Install and tighten mounting cap screws to 26 N•m (226 lb-in.). 4. Install timing gear cover. (See procedure in this group.) 5. Install push rods and rocker arm assembly. (See Cylinder Head, Valves and Manifolds in this section.) 4/7/95 2-55 Camshaft and Timing Gear Train Inspection/Replacement Heat gear to approximately 150oC (300oF). 1. Check camshaft side gap using a feeler gauge. IMPORTANT: Be sure thrust plate is not between camshaft gear and camshaft shoulder while installing gear. Camshaft Gear Thrust Plate Install thrust plate if removed. Install gear with timing mark “C” side toward press table. Align slot in gear with key in shaft. Press camshaft into gear until gear is tight against camshaft shoulder. Thrust plate must spin freely on camshaft. Key 2 Camshaft Gear Side Gap M82067A Camshaft Side Gap: Standard . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm . . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.) Thrust Plate M82068A Wear Limit. . . . . . . . . . . . 0.40 mm (0.016 in.) If side gap is at wear limit, remove gear and replace thrust plate. 2. Inspect gear for chipped or broken teeth. Replace if necessary. To remove/replace gear: 3. Inspect camshaft for bend using v-blocks and a dial indicator. Turn camshaft slowly and read variation on indicator. If variation is greater than 0.02 mm (0.001 in.), replace camshaft. Dial Indicator Remove gear from camshaft using a knife-edge puller and a press. CAUTION DO NOT heat oil over 182° C (360° F). Oil fumes or oil can ignite above 193° C (380° F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. 2-56 V-Block Camshaft Central Bearing Areas M82291A 4/7/95 Camshaft and Timing Gear Train 4. Measure camshaft lobe height. If journal diameters are less than wear limit, replace camshaft. 6. Measure camshaft bushing diameter at gear housing end. Lobe Height Camshaft Bushing M82070A Lobe Height: Standard . . . . . . . . . . . . . 38.635 - 38.765 mm . . . . . . . . . . . . . . . . . . . . . . . (1.521 - 1.526 in.) 2 Oil Holes Wear Limit. . . . . . . . . . . 38.40 mm (1.512 in.) If lobe height is less than wear limit, replace camshaft. 5. Measure camshaft end and intermediate journal diameters. M82072 Camshaft Bushing I.D.: Standard . . . . . . . . . . . . . 44.990 - 45.055 mm . . . . . . . . . . . . . . . . . . . . . . . (1.771 - 1.774 in.) Wear Limit. . . . . . . . . . . 45.10 mm (1.776 in.) Flywheel End Journal Clearance . . . . . . . . . . . . 0.20 mm (0.0078 in.) If bushing diameter exceeds wear limit, replace bushing. If bushing clearance (bushing I.D. minus camshaft journal O.D.) exceeds specification, replace bushing, camshaft or both. To replace bushing: Intermediate Journals Gear Housing End Journal M82292A Camshaft Journal O.D.: Gear Housing and Flywheel Ends Remove bushing using a chisel. Be careful not to push bushing inside of engine. Align oil holes in new bushing and cylinder block. Install bushing using a driver set. NOTE: Flywheel housing/plate must be removed to measure camshaft intermediate and flywheel end bearing diameters. Standard . . . . . . . . . . . . . . . 44.92 - 44.95 mm . . . . . . . . . . . . . . . . . . . . . . . (1.769 - 1.770 in.) 7. Measure intermediate and flywheel end camshaft bore diameters using the following procedures: Wear Limit. . . . . . . . . . . 44.80 mm (1.764 in.) • Remove flywheel housing/plate. (See Crankshaft, Main Bearings and Flywheel in this section.) Intermediate Standard . . . . . . . . . . . . . . . 44.91 - 44.94 mm . . . . . . . . . . . . . . . . . . . . . . . (1.768 - 1.769 in.) • Remove plug using a long wooden dowel. Insert wooden dowel through gear housing side. Wear Limit. . . . . . . . . . . 44.80 mm (1.764 in.) 4/7/95 2-57 Camshaft and Timing Gear Train IMPORTANT: Cam followers must be installed in the same bores from which they were removed. 3. Put a mark on each cam follower and cylinder block bore to aid in installation. 4. Remove cam followers. 5. Inspect all parts for wear or damage. (See Inspection procedures.) Plug M35287 2 • Measure intermediate and flywheel end camshaft bore diameters. 6. Apply clean engine oil on all parts during installation. Installation is done in the reverse order of removal. Inspection • Inspect cam follower contact surface for abnormal wear. Replace if necessary. Intermediate Bores Flywheel End Bore M82073 Camshaft Bore I.D.: Standard . . . . . . . . . . . . . . 45.00 - 45.025 mm . . . . . . . . . . . . . . . . . . . . . . . (1.772 - 1.773 in.) Wear Limit. . . . . . . . . . . 45.10 mm (1.776 in.) Clearance . . . . . . . . . . . . . 0.20 mm (0.008 in.) If bore diameter exceeds wear limit, replace cylinder block. Normal Contact Abnormal Contact M82074A • Measure cam follower stem diameter. If bore clearance (bore I.D. minus camshaft journal O.D.) exceeds specification, replace camshaft, cylinder block or both. • Apply John Deere Form-In Place Gasket, or an equivalent, on outer edge of plug. Install plug until it bottoms in bore. • Install flywheel housing. CAM FOLLOWERS Removal/Installation M82075A 1. Remove camshaft. (See procedure in this group.) 2. Remove oil pan and strainer. (See Lubrication System in this section.) 2-58 4/7/95 Camshaft and Timing Gear Train Cam Follower Stem O.D.: 3. Remove crankshaft pulley cap screw and washer. Standard . . . . . . . . . . . . . 11.975 - 11.990 mm . . . . . . . . . . . . . . . . . . . . . . . (0.471 - 0.472 in.) 4. Remove crankshaft pulley using a two-jaw puller kit. Wear Limit. . . . . . . . . . . 11.93 mm (0.470 in.) 5. Remove key, if equipped. If stem diameter is less than wear limit, replace cam follower. • Measure cam follower bore diameter in cylinder block. Cam Follower Bore I.D.: Standard . . . . . . . . . . . . . 12.000 - 12.018 mm . . . . . . . . . . . . . . . . . . . . . . . (0.472 - 0.473 in.) Wear Limit. . . . . . . . . . . 12.05 mm (0.474 in.) Clearance . . . . . . . . . . . . . 0.10 mm (0.004 in.) If cam follower bore diameter exceeds wear limit, replace cylinder block. If bore clearance (bore I.D. minus follower stem O.D.) exceeds specification, replace cam follower, cylinder block or both. TIMING GEAR COVER Removal/Installation 6. Remove tachometer, if equipped. 7. 3TNA82 (770 CUT), 3TN84 (870 CUT): Remove hydraulic pump and steering pump, if equipped. (See procedure in Machine Technical Manual). NOTE: It is not necessary to remove auxiliary drive cover and gasket, if equipped, end cover and o-ring or fuel injection pump gear cover to remove timing gear cover. 8. Remove mounting cap screws and timing gear cover. Installation is done in the reverse order of removal. • Replace seal washer. • Tighten all mounting cap screws to 26 N•m (226 lb-in.) • All except 3TNA82 (770 CUT), 3TN84 (870 CUT): Align pin in crankshaft pulley with hole in crankshaft gear. Install crankshaft pulley. 1. Remove alternator and belt. NOTE: 3TN75 (F1145 FM) fan is mounted on flywheel end of engine. Alternator belt pulley does not have to be removed to access timing gear cover. 2. Remove fan, spacer/plate, if equipped, and pulley. Pulley Plate (3TN78, 3TN82, 3TNA82, 3TN84 (3014 OEM) Only Hole Pin M35295 • 3TNA82 (770 CUT), 3TN84 (870 CUT): Install key and crankshaft pulley. • Adjust fan/alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) Spacer 3TN84 (870 CUT) Cap Screw (4) 11 N•m (96 lb-in.) M82354A 4/7/95 2-59 2 Camshaft and Timing Gear Train Gasket Cover If equipped. Cap Screw (2) M8 x 16 John Deere Form-In-Place Gasket (RTV rubber silicone sealant) 2 Nut and Lock Washer (2) Mounting Plate-to-Cover Cap Screw (3) All Except 3TNA82, 3TN84 (870 CUT) M8 x 20 3TNA82, 3TN84 (870 CUT) Mounting Plate-toCover Cap Screw (3) 3TN75, 3TN84 (955 CUT) M8 x 16 Cap Screw (2) M6 x 16 Timing Gear Cover Tachometer 3TNC78 (3011), 3TNA82, 3TN84 O-Ring End Cover Cap Screw (2) M6 x 12 Mounting Cap Screw (3) M8 x 55 Cap Seal Washer Replace. Mounting Cap Screw M8 x 16 O-Ring Mounting Cap Screw (6) M8 x 45 Clamp 3TNC78 (3011), 3TNA82, 3TN84 (870 CUT, 3014 OEM) Crankcase Extension Housing-to-Cover Cap Screw 3TN75, 3TNC78 (3011), 3TN78, 3TN82 (30 EX), 3TNA82 (770 CUT) - (6) 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) - (2) 3TN84 (870 CUT) - (4) 22 N•m (195 lb-in.) Key 3TNA82, 3TN84 (870 CUT) Crankshaft Pulley Gasket Mounting Cap Screw (4) M8 x 85 Injection Pump Gear Cap Screw (4) Cover M8 x 12 Oil Pan-to-Cover Cap Screw (2) 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) 22 N•m (195 lb-in.) 3TN75, 3TNC78 (3011) 2-60 Washer Cap Screw Apply thread lock and sealer (medium strength) to threads. 115 N•m (85 lb-ft) M82355A 4/7/95 Camshaft and Timing Gear Train IDLER GEAR Idler Gear Shaft O.D.: Removal/Installation Standard . . . . . . . . . . . . . 45.950 - 45.975 mm . . . . . . . . . . . . . . . . . . . . . . . (1.809 - 1.810 in.) 1. Remove timing gear cover. (See procedure in this group.) Wear Limit. . . . . . . . . . . 45.93 mm (1.808 in.) 2. Check backlash of timing gears. (See Checks, Tests and Adjustments in this section.) NOTE: Due to the odd number of teeth on the idler gear, timing marks will only align periodically. When all timing marks on gears align, the piston closest to the water pump is at TDC on compression stroke. Number one cylinder is closest to the flywheel. 3. Rotate crankshaft and align timing marks. If shaft diameter is less than wear limit, replace idler gear shaft. • Measure idler gear bushing diameter. Idler Gear Bushing I.D.: Standard . . . . . . . . . . . . . . 46.00 - 46.025 mm . . . . . . . . . . . . . . . . . . . . . . . (1.811 - 1.812 in.) Wear Limit. . . . . . . . . . . 46.03 mm (1.812 in.) Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.) 4. Remove two cap screws, shaft and gear. If bushing diameter exceeds wear limit, replace bushing. 5. Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) To replace bushing: Installation is done in the reverse order of removal. Idler Gear (43T) Replace bushing using a driver set. Align oil holes in bushing and idler gear. Install bushing flush with surface of idler gear. If bushing clearance (bushing I.D. minus shaft O.D.) exceeds specification, replace bushing, shaft or both. Idler Gear Shaft Idler Gear Bushing Idler Gear Shaft Cap Screw (2) M8 x 45 M82209A M82210A Inspection/Replacement • Inspect gear for chipped or broken teeth. Replace if necessary. • Measure idler gear shaft diameter. 4/7/95 2-61 2 Camshaft and Timing Gear Train Studs John Deere Form-In-Place Gasket (RTV rubber silicone sealant) 2 3TNA82, 3TN84 (870 CUT) Timing Gear Cover Mounting Plate Stud (3) Mounting Cap Screw (3) M8 x 16 25 N•m (220 lb-in.) O-Rings Replace. M82356A TIMING GEAR COVER MOUNTING PLATE 4. Remove oil pump. (See Lubrication System in this section.) Removal/Installation 5. 3TNA82, 3TN84 (870 CUT): Remove hydraulic pump drive assembly. (See procedure in Machine Technical Manual.) 1. Remove camshaft. (See procedure in this group.) 2. Remove idler gear. (See procedure in this group.) 3. Remove fuel injection pump. (See Fuel System in this section.) 2-62 6. Remove mounting cap screws and plate. 7. Replace o-rings. Installation is done in the reverse order of removal. 4/7/95 Lubrication System OTHER MATERIALS Number Name Use John Deere Form-In-Place Gasket Seals oil pan/plate to crankcase extension housing. LOCTITE® PRODUCTS U.S./ Canadian/ Loctite No. TY15130/ NA/ #395 2 ®LOCTITE is a registered trademark of the Loctite Corp. 4/7/95 2-63 Lubrication System OIL PAN AND STRAINER Removal/Installation 2 • Approximate crankcase oil capacity is: 3TN75 . . . . . . . . . . . . . . . . . . . . . . 3.9L (4.1 qt) 3TN78, 3TN82 (30 EX), 3TNA82 . . . . . . . . . . . . . . . . . . . . 4.0L (4.2 qt) 3TNC78 (3011) DF001 and 005. . . . . . . . . . . . . 4.2L (4.4 qt) DF006. . . . . . . . . . . . . . . . . . . . 6.2L (6.5 qt) 3TN82 (575 SSL) . . . . . . . . . . . . . 6.0L (6.3 qt) 3TN84 (870 CUT) . . . . . . . . . . . . . . . . 4.8L (5.1 qt) (955 CUT) . . . . . . . . . . . . . . . . 4.3L (4.5 qt) (3014 OEM) DF001 and 005 . . . . . . . . . . 5.2L (5.4 qt) DF006 . . . . . . . . . . . . . . . . . 7.4L (7.7 qt) • Tighten all cap screws to 26 N•m (226 lb-in.). • Fill engine with proper engine oil. (See SPECIFICATIONS AND GENERAL INFORMATION section.) Gasket Replace. John Deere Form-InPlace Gasket (RTV rubber silicone sealant) Oil Strainer Cap Screw (2) M8 x 35 Oil Pan Cap Screw (16) M8 x 45 Cap Screw (4) M8 x 16 O-Ring Replace. Drain Plug M82360A 3TN75, 3TNC78 (3011DF001 and 005) Oil Strainer Cap Screw (2) 3TNA82, 3TN84 (870 CUT) Only M8 x 12 Gasket Replace. Cap Screw (2) M8 x 35 Oil Pan/Plate John Deere Form-InPlace Gasket (RTV rubber silicone sealant) Washer Replace. Drain Plug Cap Screw (8) M8 x 12 M82361A 3TN78, 3TN82 (30 EX), 3TNA82, 3TN84 (870 CUT) 2-64 4/7/95 Lubrication System Gasket Replace. John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Oil Strainer Cap Screw (2) M8 x 35 3TN84 (3014DF001 and 005 OEM) Oil Pan 2 Spacer Plate (2) Cap Screw (4) M8 x 50 Cap Screw (16) M8 x 45 O-Ring Replace. Cap Screw (4) M8 x 16 3TNC78 (3011DF006 OEM), 3TN84 (3014DF006 OEM) Drain Plug 3TNC78 (3011DF006 OEM), 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) OIL PUMP Removal/Installation M82362A 3. Remove mounting cap screws, oil pump and gasket. 1. Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) 4. Inspect all parts for wear or damage. (See Disassembly/Assembly procedures). 2. Check oil pump gear backlash. Replace entire oil pump assembly if backlash is more than 0.25 mm (0.010 in.). Oil Pump Gasket Oil Pump Oil Pump Gasket Mounting Cap Screw M6 x 25 25 N•m (18 lb-ft) Mounting Cap Screw (4) M6 x 20 25 N•m (18 lb-ft) M82215A All Except 3TN75 M82363A 3TN75 4/7/95 2-65 Lubrication System Disassembly/Assembly • Gear is press fit on rotor shaft. Remove gear using a knife edge puller and a press. • Inspect parts for wear or damage. (See Inspection procedures.) Rotor Shaft and Plate Clearance: Standard . . . . . . . . . . . . . . . 0.015 - 0.048 mm . . . . . . . . . . . . . . . . . . . . . (0.0006 - 0.0035 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0078 in.) • Coat all parts with clean engine oil. • Install outer rotor with identification mark facing toward rotor shaft assembly. • Check rotor recess. If rotors are below face of pump housing more than wear limit, replace rotor assembly. Feeler Gauge Backing Plate Straight Edge Alignment Pin (2) 2 Rotor Shaft Pump Body Gear Housing Inner Rotor Outer Rotor Outer Rotor Identification Mark M37775 Rotor Recess - 3TN75, 3TN78, 3TNC78 (3011): Standard . . . . . . . . . . . . . . . . . 0.05 - 0.10 mm M82364A 3TN75 . . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0039 in.) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) Backing Plate Alignment Pin (2) Rotor Recess - 3TN82, 3TNA82, 3TN84 (3014): Safety Valve Non-Adjustable. DO NOT Remove. Pump Body Rotor Shaft Outer Rotor Gear Standard . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm . . . . . . . . . . . . . . . . . . . . . (0.0011 - 0.0035 in.) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) • Check outer rotor-to-pump body clearance. If clearance is more than wear limit, replace entire assembly. Identification Mark Outer Rotor Inner Rotor All Except 3TN75 M82216A Feeler Gauge Inspection • Check rotor shaft outer diameter and the shaft hole diameter in backing plate. If clearance is more than wear limit, replace entire assembly. 2-66 Body M37776 4/7/95 Lubrication System Outer Rotor-to-Pump Body Clearance - 3TN75, 3TN78, 3TNC78 (3011): Standard . . . . . . . . . . . . . . . . . 0.09 - 0.16 mm 3. Disconnect coolant hoses. 4. Remove nut, oil cooler and o-rings. . . . . . . . . . . . . . . . . . . . . . (0.0035 - 0.0063 in.) Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) Outer Rotor-to-Pump Body Clearance - 3TN82, 3TNA82, 3TN84 (3014): Oil Cooler Standard . . . . . . . . . . . . . . . . . 0.10 - 0.17 mm . . . . . . . . . . . . . . . . . . . . . (0.0039 - 0.0067 in.) Nut 30 N•m (22 lb-ft) Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) • Check inner-to-outer rotor clearance. If clearance is more than wear limit, replace rotor assembly. 2 Drain Plug M48394 Feeler Gauge Inner Rotor Outer Rotor O-Rings Replace. M37777 M48395 Inner-to-Outer Rotor Clearance - 3TN75, 3TN78, 3TNC78 (3011): Standard . . . . . . . . . . . . . . . . . 0.02 - 0.04 mm . . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0016 in.) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) Inner-to-Outer Rotor Clearance - 3TN82, 3TNA82, 3TN84 (3014): 5. Pressure test oil cooler. (See Checks, Tests and Adjustments in this section.) Installation is done in reverse order of removal. OIL PRESSURE REGULATING VALVE - 3TN84 (955 CUT) Standard . . . . . . . . . . . . . . . . 0.05 - 0.105 mm . . . . . . . . . . . . . . . . . . . . . (0.0019 - 0.0041 in.) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) OIL COOLER - 3TN84 (955 CUT) 1. Remove drain plug to drain engine cooling system. Removal/Installation 1. Remove oil cooler. (See procedure in this group.) 2. Remove mounting cap screws, pressure control valve housing and gasket. NOTE: Valve components are not serviced individually. Replace complete regulating valve if any components are defective. 2. Remove oil filter. 4/7/95 2-67 Lubrication System 3. Inspect all parts for wear or damage. Replace complete regulating valve if necessary. Installation is done in the reverse order of removal. Cap Stake to valve body. 1. Remove oil filter. 2. Remove three cap screws, valve assembly and gasket. NOTE: If adjusting engine oil pressure, retaining nut need not be removed. Shims O-Ring Replace. Valve Washer Replace. Spring 2 Valve Body Plug OIL PRESSURE REGULATING VALVE - ALL EXCEPT 3TN84 (955 CUT) Removal/Installation Gasket Replace. 4. Inspect all parts for wear or damage. Replace complete valve if necessary. Pressure Control Valve Housing Mounting Cap Screw (3) M8 x 25 27 N•m (20 lb-ft) 3. If adjusting pressure only, remove cap and add shims. Each 1 mm (0.039 in.) of shim thickness increases oil pressure 15.6 kPa (2.3 psi). NOTE: Valve components are not serviced individually. Replace complete regulating valve if any components are defective. 5. Check spring free and compressed length. M82365A Spring Specifications: Free Length . . . . . . . . . . . . .46 mm (1.810 in.) Compressed Length . . . 27.50 mm (1.080 in.) . . . . . . . . . . . . . . . . . . @ 20.5 N (4.6 lb-force) Installation is done in the reverse order of removal. O-Ring Replace. Cap Stake to valve body. Gasket Housing Shims Retaining Nut 30 N•m (22 lb-ft) Spring Valve Oil Filter Valve Body Cap Screw (3) M8 x 20 27 N•m (20 lb-ft) 2-68 M82219A 4/7/95 Cooling System OTHER MATERIALS Number Name Use John Deere Pipe Sealant with TEFLON® 3TN78, 3TN82 (30 EX), 3TN84 (955 CUT, 3014 OEM): Apply to threads of plug and nipple in thermostat housing and pipe plug in water pump housing. LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. TY9375/ TY9480/ #592 2 ®LOCTITE is a registered trademark of the Loctite Corp. ®TEFLON is a registered trademark of the Du Pont Company. 4/7/95 2-69 Cooling System COOLANT TEMPERATURE SWITCH Replacement NOTE: Some engines may also be equipped with a coolant temperature sender. Sender is located opposite of switch in thermostat housing. Replacement procedures are the same. 1. Disconnect wiring lead, if equipped. 1. Drain engine coolant. 2. Remove upper radiator hose, if equipped. 3. Disconnect coolant temperature switch/sender wiring lead(s). 4. Loosen alternator-to-bracket mounting cap screw. 2. Open engine drain valve to drain coolant. 2 THERMOSTAT AND HOUSING 3TN78, 3TN82 (30 EX), 3TN84 (955 CUT, 3014 OEM) 3. Remove switch and washer. 5. Loosen clamps and remove thermostat housingto-water pump hose. 4. Test switch. (See Checks, Tests and Adjustments in this section.) 6. Remove mounting cap screws, housing and gasket. Installation is done in reverse order of removal. 7. Inspect all parts for wear or damage. Replace as necessary. Copper Washer Replace. Coolant Temperature Switch Thermostat Housing 8. Test thermostat. (See Checks, Adjustments in this section.) Tests and Installation is done in reverse order of removal. Adjust fan/alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) M82220A Cap Screw (2) M8 x 20 20 N•m (180 lb-in.) Plate Gasket Replace. Cover Gasket Replace. Copper Washer Replace. Alternator Slide Bracket Thermostat Gasket Replace. Copper Washer Replace. Cap Cap Screw (2) M6 x 16 9 N•m (78 lb-in.) Mounting Cap Screw M8 x 60 26 N•m (226 lb-in.) Gasket Replace. Coolant Temperature Switch Plug Apply Pipe Sealant with TEFLON to threads. Mounting Cap Screw M8 x 25 26 N•m (226 lb-in.) 2-70 Nipple Apply Pipe Sealant with TEFLON to threads. Housing Mounting Cap Screw M8 x 50 26 N•m (226 lb-in.) Thermostat Housing-toWater Pump Hose M82221A 4/7/95 Cooling System THERMOSTAT - 3TN75, 3TNC78 (3011), 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT) Plate 3TN78, 3TN82 (30 EX), 3TN84 (955 CUT) Only Pulley • Replace gaskets. • Test thermostat. (See Checks, Tests and Adjustments in this section.) Cap Screw (2) M8 x 20 20 N•m (180 lb-in.) Cap Screw M8 x 65 20 N•m (180 lb-in.) Cap Screw 11 N•m (96 lb-in.) Cap Screw M8 x 25 20 N•m (180 lb-in.) M82294A Cover Cover 3TN82 (575 SSL) 4. Remove lower radiator hose, if equipped. 2 5. Loosen clamps and remove thermostat housingto-water pump hose. 6. Remove three mounting cap screws, pump and gasket. Gasket Cover Gasket 7. Inspect all parts for wear or damage. (See Disassembly/Assembly procedures.) Thermostat Installation is done in the reverse order of removal. Water Pump Thermostat Housing-toWater Pump Hose M82366A WATER PUMP - 3TN78, 3TN82 (30 EX), 3TN84 (955 CUT, 3014 OEM) Removal/Installation Gasket Replace. 1. Drain engine coolant. 2. Remove fan/alternator belt. 3. 3TN78, 3TN82 (30 EX), 3TN84 (955 CUT): Remove fan, plate, if equipped, and pulley. Mounting Cap Screw (3) M8 x 60 26 N•m (226 lb-in.) M82223A 3TN84 (3014 OEM): Remove cooling fan. (See procedure in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section.) 4/7/95 2-71 Cooling System Disassembly 1. Apply heat to three plate-to-housing screws. Remove screws, plate and gasket Plate-to-Housing Screw (3) 15 N•m (134 lb-in.) Plate Plug 15 N•m (130 lb-in.) 2 Pipe Plug Apply Pipe Sealant with TEFLON to threads. Gasket Replace. Impeller Seal Cup and Ceramic Seal Replace. Shaft Seal Replace. Water Pump Housing Bearing Shaft 2. Apply extreme heat to pulley flange. Remove flange using a knife-edge puller set and two small nuts. Two Small Nuts Pulley Flange Knife-Edge Puller Set Pulley Flange M82224A 3. Place water pump assembly on a press table. Install supports under water pump housing, staying clear of impeller. Press bearing shaft assembly through water pump housing using a piece of pipe or a deep socket. IMPORTANT: Impeller bore is tapered. When pressing bearing shaft from impeller, allow enough clearance between cap screw and impeller bore to prevent cap screw from binding. 4. Remove impeller from bearing shaft using a knife-edge puller, a 3/8 in. cap screw and a press. Water Pump Housing M35645 5. Remove shaft seal, ceramic seal and seal cup. 6. Inspect all parts for wear or damage. Replace as necessary. 2-72 4/7/95 Cooling System Assembly 4. Install seal cup and ceramic seal in impeller. 1. Install bearing shaft into pump housing, long end down, using a piece of pipe or deep socket and a press. Press shaft into pump housing until bearing surface is flush with pump housing surface. 5. Install a knife-edge puller around bearing shaft, between pulley flange and pump housing. Place pump housing, with knife-edge puller down, on a press table. Install impeller with ceramic seal toward shaft seal. 2. Install new shaft seal over impeller side of bearing shaft, rubber seal side away from pump housing. Push shaft seal into pump housing, until it stops, using a 25 mm or 1 in. socket and a press. IMPORTANT: Support pump housing on bearing shaft only. DO NOT support on housing or damage to housing will occur. 3TN82 (30 EX): Press impeller on bearing shaft until top of impeller is 1 mm (0.040 in.) below housing. 3TN78, 3TN84 (955 CUT, 3014 OEM): Press impeller on bearing shaft until top of impeller is 2 mm (0.080 in.) below housing. 2 3. Place water pump housing on a press table. Support housing on bearing shaft using a driver disk. Install pulley flange onto shaft with straight hub facing away from housing. 3TN82 (30 EX): Press pulley flange onto bearing shaft until top of flange is 27 mm (1.060 in.) from top of housing. 3TN78, 3TN84 (955 CUT, 3014 OEM): Press pulley flange onto bearing shaft until bottom of flange is 17 mm (0.670 in.) from top of housing. IMPORTANT: DO NOT touch lapped sealing surface of ceramic seal with bare hands. It must be clean and dry. 4/7/95 M37905 6. Install new gasket, plate, three screws, two cap screws and nuts. Tighten to specifications. 2-73 Cooling System WATER PUMP - 3TN75, 3TNC78 (3011), 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT) 3. Remove four cap screws, fan, spacer/plate, if equipped, and pulley. Removal/Installation 1. Open engine drain valve to drain coolant. 5. Inspect all parts for wear or damage. (See Disassembly/Assembly procedures.) 2. Remove fan/alternator drive belt. Installation is done in the reverse order of removal. NOTE: 3TN75 (F1145 FM): Fan is mounted on flywheel end of engine. 4. Remove four mounting cap screws, pump and gasket. • Adjust fan/alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) 2 Gasket Replace. Mounting Cap Screw (3) M8 x 55 26 N•m (226 lb-in.) Spacer 3TN84 (870 CUT) O-Ring Replace. Fan Water Pump Pulley Mounting Cap Screw M8 x 60 26 N•m (226 lb-in.) 2-74 Plate 3TN82 (575 SSL) 3TNA82 Only Cap Screw (4) M6 x 25 11 N•m (96 lb-in.) M82367A 4/7/95 Cooling System Disassembly 3. Remove two cap screws, adapter and gasket. 1. Remove thermostat. (See procedure in this group.) 4. Apply heat to plate-to-housing cap screws. Remove cap screws, plate and gasket. 2. Remove coolant temperature procedure in this group.) switch. Shaft Seal Assembly Replace. Plug 15 N•m (130 lb-in.) Plate Plate-to-Housing Cap Screw (2) M6 x 14 9 N•m (78 lb-in.) (See Plug 15 N•m (130 lb-in.) 2 Bearing Shaft Adapter Gasket Replace. Pulley Flange Gasket Replace. Impeller Cap Copper Washer Replace. Water Pump Housing Adapter-to-Plate Cap Screw (2) M6 x 20 9 N•m (78 lb-in.) M82368A 3TN75, 3TNC78 (3011) Plate-to-Housing Cap Screw 9 N•m (78 lb-in.) Plate Gasket Replace. Plate-to-Housing Cap Screw (5) M6 x 14 9 N•m (78 lb-in.) Cap Shaft Seal Replace. Copper Washer Replace. Adapter Gasket Replace. Impeller Seal Cup and Ceramic Seal Replace. Pulley Flange Bearing Shaft Water Pump Housing Adapter-to-Plate Cap Screw (2) M6 x 20 9 N•m (78 lb-in.) M82226A 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT) 4/7/95 2-75 Cooling System 5. Apply extreme heat to pulley flange. Remove flange using a knife-edge puller set and two small nuts. Two Small Nuts Pulley Flange IMPORTANT: Support pump housing on bearing shaft only. DO NOT support on housing or damage to housing will occur. 3. Place water pump housing on a press table. Support housing on bearing shaft using a driver disk. Install pulley flange onto shaft with straight hub facing away from housing. Knife-Edge Puller Set Press pulley flange onto bearing shaft until bottom of flange is 17 mm (0.670 in.) from top of housing. Water Pump Housing IMPORTANT: DO NOT touch lapped sealing surface of ceramic seal with bare hands. It must be clean and dry. 2 M35645 6. Place water pump assembly on a press table. Install supports under water pump housing, staying clear of impeller. Press bearing shaft assembly through water pump housing using a piece of pipe or a deep socket. IMPORTANT: Impeller bore is tapered. When pressing bearing shaft from impeller, allow enough clearance between cap screw and impeller bore to prevent cap screw from binding. 4. Install seal cup and ceramic seal (shaft seal assembly) in impeller. 5. Install a knife-edge puller around bearing shaft, between pulley flange and pump housing. Place pump housing, with knife-edge puller down, on a press table. Install impeller with ceramic seal toward shaft seal. Press impeller on bearing shaft until top of impeller is 2 mm (0.080 in.) below housing. 7. Remove impeller from bearing shaft using a knife-edge puller, a 3/8 in. cap screw and a press. 8. Remove shaft seal (shaft seal assembly), ceramic seal and seal cup. 9. Inspect all parts for wear or damage. Replace as necessary. Assembly M37906 1. Install bearing shaft into pump housing, long end down, using a piece of pipe or deep socket and a press. Press shaft into pump housing until bearing surface is flush with pump housing surface. 2. Install new shaft seal over impeller side of bearing shaft, rubber seal side away from pump housing. Push shaft seal into pump housing, until it stops, using a 25 mm or 1 in. socket and a press. 2-76 6. Install new gasket, plate and cap screws. Tighten to specifications. 7. Install new gasket, adapter and cap screws. Tighten to specifications. 8. Install coolant temperature procedure in this group.) switch. (See 9. Install thermostat. (See procedure in this group.) 4/7/95 Fuel System SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the European Microfiche Tool Catalog (MTC). JDF13 Nozzle Cleaning Kit Use to clean fuel injection nozzles. SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Block Gasket Kit • Fuel Injection Nozzle Shim Pack 4/7/95 2 2-77 Fuel System FUEL SUPPLY PUMP - IF EQUIPPED Replacement NOTE: 3TN78 and 3TN82 engines are not equipped with a fuel supply pump. Oil will leak out of fuel injection pump housing when supply pump is removed. IMPORTANT: If oil has been drained out of fuel injection pump housing, add oil as necessary. Fuel injection pump can become damaged if operated dry or without proper amount of oil. 2 After fuel supply pump is installed, disconnect external lube line to fuel injection pump housing. Remove fill plug and add clean engine oil to housing. Add until oil begins to drip out of lube line hole. (For proper oil specification see SPECIFICATIONS AND GENERAL INFORMATION section.) Fill Plug Supply Pump-toFilter Hose Fuel Supply Pump External Lube Line Tighten mounting bolt to 15 N•m (130 lb-in.) M82369 Lock Washer (2) Packing Replace. Mounting Nut (2) 11 N•m (96 lb-in.) Fuel Supply Pump M82228A 2-78 4/7/95 Fuel System FUEL FILTER ASSEMBLY - IF EQUIPPED on engine application. 3TN84 (3014 OEM) shown. NOTE: Fuel filter assemblies will be slightly different for each engine model depending IMPORTANT: Replace all copper washers. Damaged or used washers may leak. End Cap Shutoff Valve Mounting Base Spring O-Ring O-Ring Filter Element 2 Spring Shutoff Lever O-Ring Filter Cover Mounting Cap Screw End Cap Nozzle Leak-Off Hose (Short) (2) Retaining Ring Fuel Filter-toInjection Pump Hose * Injection Pump Bleed-Off Hose * Nozzle Leak-Off Hose (Long) Fuel Supply Pump-to-Filter Hose * *Copper Washers Replace. Air Vent Check Valve * * M82370A 4/7/95 2-79 Fuel System FUEL INJECTION PUMP Removal CAUTION 2 Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can damage the pump. 1. Clean the injection pump lines and area around the pump using a parts cleaning solvent or steam cleaner. 2. Loosen fuel injection line connectors slightly to release pressure in the fuel system. When loosening connectors, use another wrench to keep delivery valves from loosening. 3. Loosen line clamp(s) and remove fuel injection lines. 4. Disconnect hoses to/from fuel filter, if equipped. 5. Remove external lube line. 6. Disconnect fuel shutoff solenoid link. 7. Note position of timing marks on injection pump and gear cover mounting plate. 8. Remove three mounting nuts. Injection Pump Bleed-Off-to-Filter Hose Line Clamp Fuel Injection Lines Fuel Injection Line Connectors (3) Nozzle Leak-Off Hose Delivery Valve (3) Fuel Filter-to-Injection Pump Hose Fuel Shutoff Solenoid Link Fuel Supply Pump-to-Filter Hose 2-80 External Lube Line M82371 4/7/95 Fuel System DO NOT attempt to service the injection pump or governor. If unit is in need of repair, it must be serviced by a qualified fuel injection repair shop. If replacement is necessary, replace entire unit. Timing Marks Installation 1. Install new o-ring on injection pump. Mounting Nut (3) M82230 9. Remove fan guard, if equipped. 10.Remove four cap screws, washers, cover and gasket. 11.Use chalk or paint to mark injection pump gear to idler gear. 12.Remove nut and lock washer. 2. Put injection pump onto back of gear cover mounting plate. Align key on shaft with keyway in gear. Be sure to align marks on gears made during removal. 3. Install lock washer and nut. Tighten to specification. Nut and Lock Washer M12 90 N•m (66 lb-ft) Chalk/Paint Marks Nut and Lock Washer Chalk/Paint Marks M82231 4. Install new gasket, cover, four washers and cap screws. 5. Install fan guard, if equipped. M82231 13.Pull gear from injection pump shaft using a two jaw puller. 6. Install three mounting nuts. Do not tighten. 7. Align marks on mounting plate and injection pump, to same place as when removed, and tighten mounting nuts to specifications. Timing Marks Mounting Nut (3) 26 N•m (19 lb-ft) M37794 M82230 14.Remove injection pump and o-ring. 8. Connect fuel shutoff solenoid link. 9. Connect hoses to/from fuel filter. 4/7/95 2-81 2 Fuel System 10.Install fuel injection lines and tighten line clamp cap screws. IMPORTANT: If oil has been drained out of fuel injection pump housing, add oil as necessary. Fuel injection pump can become damaged if operated dry or without proper amount of oil. 11.Remove fill plug and add clean engine oil to housing. Add until oil begins to drip out of external lube line inlet. (For proper oil specification see SPECIFICATIONS AND GENERAL INFORMATION section.) 12.Install external lube line. When installing line, put one copper washer between mounting bolt head and lube line and the other between lube line and housing. If new injection pump is being installed, check and adjust injection pump static timing. (See Checks, Tests and Adjustments in this section.) 2 Injection Pump Bleed-Off-to-Filter Hose Line Clamp Fuel Injection Lines Fuel Injection Line Connectors (3) Nozzle Leak-Off Hose Delivery Valve (3) Fuel Filter-to-Injection Pump Hose Oil Fill Plug Fuel Shutoff Solenoid Link Fuel Supply Pump-to-Filter Hose 2-82 Lube Line-to-Block Bolt 25 N•m (217 lb-in.) External Lube Line M82371 4/7/95 Fuel System FUEL INJECTION NOZZLES (HOLE-TYPE) Retaining Plate Hose Clamp Removal/Installation IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can damage the pump. 1. Clean the injection pump lines and area around the pump using a parts cleaning solvent or steam cleaner. Nut (2) 5 N•m (39 lb-in.) Leak-Off Hose Injection Nozzle Ring Heat Protector Replace. 2 CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. NOTE: Nozzles are matched to the cylinders. If removing more than one nozzle, tag nozzles, according to the cylinder from which it was removed. 2. Loosen fuel injection line connectors-to-nozzles slightly to release pressure in the fuel system. 3. Loosen line clamp(s) and remove fuel injection lines. M82092A If nozzles are stuck in cylinder head: • Grind the head of a cap screw so it fits inside a nut from an old injection line. • Use two nuts to attach a large flat washer to the cap screw. • Install assembly onto nozzle and use a puller and slide hammer to pull nozzle from cylinder head. Large Flat Washer Nuts Cap Screw Old Injection Line Nut Injection Nozzle M82126 4. Remove clamps and leak-off hoses. 7. Test injection nozzles. (See Checks, Tests and Adjustments in this section.) 5. Remove nuts and retaining plates. Installation is done in reverse order of removal. 6. Remove injection nozzle, ring and teflon heat protector. If ring and protector stay in cylinder head, thread a cap screw into protector and pull from cylinder head. 4/7/95 2-83 Fuel System Disassembly/Assembly Cross Section NOTE: If servicing more than one nozzle, keep parts for each nozzle separate from one another. • Clean and inspect nozzle assembly. (See Cleaning/Inspection procedures.) Injector Body • After assembly is complete, test injection nozzle. (See Checks, Tests and Adjustments in this section.) Fuel Return Pipe 2 Injector Body Shim (as required) Spring Shims (as required) Spring Spring Seat Spring Seat Index Pin (2) Separator Plate Separator Plate Index Pin (2) Nozzle Valve Retaining Nut Nozzle Body Retaining Nut 43 N•m (31 lb-ft) Nozzle Valve Nozzle Body M82093A 2-84 M37684 4/7/95 Fuel System Cleaning/Inspection NOTE: To clean nozzles properly, JDF13 Nozzle Cleaning Kit is recommended. The Cleaning Kit is available through the John Deere SERVICEGARD™ Catalog. 1. Remove anti-corrosive grease from new or reconditioned nozzles by washing them thoroughly in diesel fuel. IMPORTANT: Never use a steel brush to clean nozzles as this will distort the spray hole. 2. Remove carbon from used nozzles, and clean by washing in diesel fuel. If parts are coated with hardened carbon or lacquer, it may be necessary to use a brass wire brush (supplied in Nozzle Cleaning Kit). 3. After removing carbon or lacquer from the exterior of nozzle, inspect sealing surfaces between separator plate and nozzle body for nicks or scratches. 4. Inspect condition of separator plate and nozzle body. Contact area of separator plate (both parts) must not be scored or pitted. Use an inspection magnifier (No. 16487 or equivalent) to aid in making the inspection. 5. Check nozzle contact surface on separator plate for wear. If contact surface is more than 0.10 mm (0.0039 in.), replace nozzle assembly. Nozzle Contact Surface Sealing Surfaces 6. Inspect the piston (large) part of nozzle valve to see that it is not scratched or scored and that lower (tip) end of valve is not broken. If any of these conditions are present, replace the nozzle assembly. 7. Further inspect the nozzle assembly by performing a slide test. Use the following procedure: • Dip the nozzle valve in clean diesel fuel. Insert valve in nozzle body. • Hold nozzle vertical, and pull valve out about 1/3 of its engaged length. • Release valve. Valve should slide down to its seat by its own weight. Replace nozzle assembly if the valve does not slide freely to its seat. Nozzle Valve Piston Part of Nozzle Valve Nozzle Body M82095A Index Pin Separator Plate Nozzle Body M82094A 4/7/95 2-85 2 Starter STARTER IDENTIFICATION CHART The various starters covered in this group are identified by manufacturer and output rating. Field Coil Brush (2) To help identify the starters, measure the outside diameter of the motor. 2 M82232 3 2-86 Manufacturer Rated Output Motor Outside Diameter Hitachi 2.0 kW 80 mm (3.150 in.) Nippondenso 1.0 kW 68 mm (2.680 in.) Nippondenso 1.2 kW 72 mm (2.835 in.) Nippondenso 1.4 kW 76 mm (3.000 in.) 4/7/95 Starter STARTER MOTOR - HITACHI 2.0 kW 8. Inspect and test brushes, holder, field coil and armature. (See Inspection/Test procedures.) Disassembly 1. Remove two cap screws and two screws. Seal Ring If equipped 2. Remove rear cover. Field Coil Housing 2 Cap Screw (2) Screw (2) Rear Cover Wiring Lead Armature M82096 3. Remove field coil brushes from brush holder. 4. Pry brush springs away and pull negative brushes up enough to allow spring to hold brush in place. 5. Remove brush holder. M82098 3 Assembly Assembly is done in the reverse order of disassembly. • Apply multipurpose grease to bearing cup inside rear cover. Field Coil Brush (2) IMPORTANT: When installing rear cover, be sure field coil brush wires do not touch cover. Turn brush holder slightly to take up slack in brush wires. Press wires inward to clear rear cover. Brush Spring (2) Inspection/Test/Replacement 1. Measure holder and field coil brush lengths. Minimum brush length is 9 mm (0.354 in.). Replace brush holder or field coil if brush length is below minimum. Brush Holder Negative Brush (2) NOTE: Test brush holder using an ohmmeter or test light. 6. Disconnect wiring lead. 2. Test brush holder: Touch one probe of tester to negative brush holder and other probe to field brush holder. If there is continuity, replace the brush holder. 7. Remove field coil housing, armature and seal ring, if equipped. 3. Inspect springs for wear or damage. Replace if necessary. M82097 4/7/95 2-87 Starter IMPORTANT: Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush. Spring (4) Negative Brush Holder 6. Inspect armature. Look for signs of dragging against pole shoes. 7. Inspect commutator. Look for roughness, burned bars, or any material which might cause short circuits between bars. If necessary, clean and touch up with 400 sandpaper. NEVER use emery cloth. Clean all dust from armature when finished. 2 Field Brush Holder NOTE: Test armature windings using an ohmmeter or test light. Brush Length M82099 3 NOTE: Test field coil using an ohmmeter or test light. 4. Test for grounded field winding: Touch one probe of tester to field coil brush and other probe to field coil housing. Be sure the brush lead is not touching the frame. If there is continuity, the coil is grounded and the field coil housing assembly must be replaced. 5. Test for open field coil: Touch one probe of tester to each field coil brush. If there is no continuity, the field coil is open and the field coil housing assembly must be replaced. 8. Test for grounded windings: Touch probes on one commutator bar and armature shaft. Armature windings are connected in series, so only one commutator bar needs to be checked. If test shows continuity, a winding is grounded and the armature must be replaced. 9. Test for open circuited windings: Touch probes on two different commutator bars. If test shows no continuity, there is an open circuit and the armature must be replaced. Commutator Bars Field Coil Brush Armature Shaft M82101 Field Coil Housing 10.Test for short circuited windings using a growler. Put armature in a growler and hold a hacksaw blade above each slot while slowly rotating armature. If coil is shorted, the blade will vibrate on the slot. M82100 2-88 4/7/95 Starter NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments. STARTER OVERRUNNING CLUTCH HITACHI 2.0 kW 11.If test indicates short circuited windings, clean the commutator of dust and filings. Check the armature again. If the test still indicates a short circuit, replace the armature. Disassembly 1. Disconnect wiring lead. 2. Remove two cap screws. 3. Remove starter motor assembly. Hacksaw Blade Wiring Lead Armature 2 Growler M82125A 12.Inspect armature cover and housing bearings for wear or damage. Replace if necessary. Cap Screw (2) Starter Motor Assembly 3 To replace bearings: Bearings are press fit. Remove bearings using a knife-edge puller set. 4. Remove three cap screws. IMPORTANT: Install both bearings with sealed side toward armature. 5. Separate clutch housing assembly from starter housing. Remove gasket. Install new housing bearing tight against shoulder of shaft using a piece of pipe. Install new rear cover bearing tight against shoulder of shaft using a driver set. M82096 Gasket Clutch Housing Assembly Starter Housing Rear Cover Bearing Housing Bearing Cap Screw (3) M82103 M82102 4/7/95 2-89 Starter 6. Remove ring, retainer, spring, clutch assembly and clutch shaft from clutch housing. Wiring Lead 7. Inspect all parts for wear or damage. Replace as necessary. Clutch Shaft Clutch Assembly 2 Starter Solenoid Assembly Spring Cap Screws M82105 4. Remove clutch arm, clutch arm pivot, plunger and shim(s), if equipped, from solenoid. Ring 3 Clutch Housing 5. Inspect all parts for wear or damage. Replace as necessary. Retainer Solenoid M82104 Plunger Assembly Assembly is done in the reverse order of disassembly. Clutch Arm Pivot • Apply multipurpose grease to all internal components during assembly. • Install retainer with large cupped side toward clutch assembly. Shim(s) If equipped. STARTER SOLENOID - HITACHI 2.0 kW Clutch Arm M82106 Disassembly Assembly 1. Disconnect wiring lead. Assembly is done in the reverse order of disassembly. 2. Remove cap screws. 3. Remove starter solenoid assembly. • Apply multipurpose grease to all internal components during assembly. IMPORTANT: Make sure long end of clutch arm is installed all the way into starter housing. Clutch arm must be install on end of clutch shaft or starter will not operate. 2-90 4/7/95 Starter • Pull clutch shaft away from housing and insert clutch arm in starter housing. Push arm in until it stops. 5. Pry brush springs away and pull negative brushes up enough to allow spring to hold brush in place. 6. Remove brush holder. Clutch Shaft Brush Spring Field Coil Brush (2) Brush Holder Clutch Arm 2 M36754 M82107 7. Remove armature from field coil housing. 8. Remove felt washer and o-ring, if equipped. STARTER MOTOR - NIPPONDENSO 1.0 kW AND 1.2 kW 9. Inspect and test brushes, holder, field coil and armature. (See Inspection/Test procedures.) 3 Felt Washer Disassembly Armature 1. Disconnect field lead. Field Coil Housing 2. Remove two cap screws and two screws. 3. Remove rear cover and o-ring, if equipped. Field Lead O-Ring M36759 Assembly O-Ring Screw (2) Rear Cover Cap Screw (2) M82233 4. Remove field coil brushes from brush holder. 4/7/95 Assembly is done in the reverse order of disassembly. • Apply multipurpose grease to bearing cup inside rear cover and felt washer, if equipped. IMPORTANT: When installing rear cover, be sure field coil brush wires do not touch cover. Turn brush holder slightly to take up slack in brush wires. Press wires inward to clear rear cover. 2-91 Starter Inspection/Test/Replacement 1. Measure holder and field coil brush lengths. Minimum brush length is 8.5 mm (0.335 in.). Replace brush holder or field coil if brush length is below minimum. Field Coil Brush NOTE: Test brush holder using an ohmmeter or test light. 2. Test brush holder: Touch one probe of tester to negative brush holder and other probe to field brush holder. If there is continuity, replace the brush holder. 2 3. Field Coil Housing Inspect springs for wear or damage. Replace if necessary. M82235 Spring (4) Negative Brush Holder 3 IMPORTANT: Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush. 6. Inspect armature. Look for signs of dragging against pole shoes. Brush Length Field Brush Holder M82234 NOTE: Test field coil using an ohmmeter or test light. 4. Test for grounded field winding: Touch one probe of tester to field coil brush and other probe to field coil housing. Be sure the brush lead is not touching the frame. If there is continuity, the coil is grounded and the field coil housing assembly must be replaced. 7. Inspect commutator. Look for roughness, burned bars, or any material which might cause short circuits between bars. If necessary, clean and touch up with 400 sandpaper. NEVER use emery cloth. Clean all dust from armature when finished. NOTE: Test armature windings using an ohmmeter or test light. 8. Test for grounded windings: Touch probes on one commutator bar and armature shaft. Armature windings are connected in series, so only one commutator bar needs to be checked. If test shows continuity, a winding is grounded and the armature must be replaced. 5. Test for open field coil: 9. Test for open circuited windings: Touch one probe of tester to each field coil brush. If there is no continuity, the field coil is open and the field coil housing assembly must be replaced. Touch probes on two different commutator bars. If test shows no continuity, there is an open circuit and the armature must be replaced. 2-92 4/7/95 Starter IMPORTANT: Install both bearings with sealed side toward armature. Install new housing bearing tight against shoulder of shaft using a piece of pipe. Commutator Bars Install new rear cover bearing tight against shoulder of shaft using a driver set. Rear Cover Bearing Housing Bearing Armature Shaft 2 M82236 10.Test for short circuited windings using a growler. Put armature in a growler and hold a hacksaw blade above each slot while slowly rotating armature. M82237 If coil is shorted, the blade will vibrate on the slot. NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments. 11.If test indicates short circuited windings, clean the commutator of dust and filings. Check the armature again. If the test still indicates a short circuit, replace the armature. Hacksaw Blade Disassembly/Inspection 1. Remove two motor-to-clutch housing cap screws and two clutch housing-to-solenoid housing screws. Motor-to-Clutch Housing Cap Screws Armature Growler STARTER GEAR TRAIN AND OVERRUNNING CLUTCH NIPPONDENSO 1.0 kW AND 1.2 kW M82125A 12.Inspect armature cover and housing bearings for wear or damage. Replace if necessary. To replace bearings: Bearings are press fit. Remove bearings using a knife-edge puller set. 4/7/95 M82233 2-93 3 Starter Steel Ball Clutch Assembly Clutch Housing-toSolenoid Housing Screws Pinion Gear M82238 2 2. Separate clutch housing from solenoid/motor assembly. Roller (5) Retainer 3. Remove plunger spring and gear, if equipped. Plunger Spring M82240 7. Put clutch (housing) assembly into a soft-jawed vice, as shown. 8. Tighten vise slowly, until drive gear compresses. 9. Remove retainer and circlip. 3 Retainer Circlip Gear Clutch Housing M82239 NOTE: Starter is equipped with either a 33 mm (1.299 in.), 44 mm (1.732 in.) or 44.5 mm (1.752 in.) drive gear on end of clutch shaft. Disassembly procedures are slightly different. 4. Starter with 33 mm (1.299 in.) drive gear: Remove clutch assembly from housing. 5. Remove retainer, five rollers and pinion gear. 6. Remove steel ball. Starter with 44 or 44.5 (1.732 or 1.752 in.) Drive Gear Shown M82241 CAUTION Shaft could be propelled from clutch unit with considerable force if spring is not allowed to extend fully while in vise. 10.While holding clutch assembly, slowly open vise until all spring compression is relieved. 2-94 4/7/95 Starter 11.Starter with 33 mm (1.299 in.) drive gear: Remove drive gear and spring from clutch assembly. Starter with 44 mm (1.732 in.) or 44.5 mm (1.752 in.) drive gear: Remove drive gear, spring and clutch assembly from housing. Clutch Housing Starter with 44 or 44.5 mm (1.732 or 1.752 in.) drive gear only. Clutch Assembly Drive Gear Assembly Assembly is done in the reverse order of disassembly. • Apply multipurpose grease to bearings, clutch shaft, springs, pinion gears, retainer, rollers and steel ball. • Install large washer with flat side toward clutch assembly. • Install retainer with cupped side away from clutch assembly. STARTER SOLENOID NIPPONDENSO 1.0 kW AND 1.2 kW 2 Disassembly/Inspection 1. Disconnect field lead. Spring 2. Remove three screws and clip. Retainer Circlip 3. Remove cover and gasket. 3 M82242 Field Lead 12.Remove washer, toothed washer, spring and clutch shaft. Clip 13.Inspect all parts for wear or damage. Replace as necessary. Clutch Shaft Spring Screw (3) M82244 4. Remove plunger. 5. Disassemble terminals. Remove parts from each terminal in order shown. Clutch Toothed Washer Large Washer M82243 4/7/95 6. Inspect copper washer and contact plates for excessive burning or pitting. Clean burnt areas to improve electrical contact. Replace contacts or plunger if necessary. The solenoid is not serviceable. If defective, replace solenoid housing assembly. 2-95 Starter Contact Plates Solenoid Terminal Lead Spring Plunger Terminal Bolt Copper Washer 2 M82245 Terminal Bolt Small Contact Plate M36771 STARTER MOTOR - NIPPONDENSO 1.4 kW Disassembly 3 Nut Washer 1. Remove two cap screws and two screws. 2. Remove rear cover and thrust washer, if equipped. Contact Plate O-Ring Insulator M36771 Assembly Assembly is done in the reverse order of disassembly. NOTE: The assembly sequence of the left and right terminals is similar. Be sure solenoid terminal lead is installed between terminal bolt and contact plate. Also, be sure smaller contact plate is on the left side. Thrust Washer Cap Screw (2) Screw (2) Rear Cover M82096 3. Remove field coil brushes from brush holder. 4. Pry brush springs away and pull negative brushes up enough to allow spring to hold brush in place. 5. Remove brush holder. 2-96 4/7/95 Starter Assembly Field Coil Brush (2) Assembly is done in the reverse order of disassembly. • Apply multipurpose grease to bearing cup inside rear cover. IMPORTANT: When installing rear cover, be sure field coil brush wires do not touch cover. Turn brush holder slightly to take up slack in brush wires. Press wires inward to clear rear cover. Brush Spring (2) Inspection/Test/Replacement Brush Holder Negative Brush (2) M82097 6. Disconnect wiring lead and relay leads, if equipped. 7. Remove field coil housing, armature and o-ring, if equipped. 8. Inspect and test brushes, holder, field coil and armature. (See Inspection/Test procedures.) 1. Measure holder and field coil brush lengths. Minimum brush length is 8.5 mm (0.335 in.). Replace brush holder or field coil if brush length is below minimum. NOTE: Test brush holder using an ohmmeter or test light. 3 2. Test brush holder: Touch one probe of tester to negative brush holder and other probe to field brush holder. If there is continuity, replace the brush holder. 3. Inspect springs for wear or damage. Replace if necessary. Seal Ring If equipped Spring (4) Field Coil Housing Negative Brush Holder Wiring Lead Armature M82098 Field Brush Holder Brush Length M82099 NOTE: Test field coil using an ohmmeter or test light. 4. Test for grounded field winding: 4/7/95 2 2-97 Starter Touch one probe of tester to field coil brush and other probe to field coil housing. Be sure the brush lead is not touching the frame. If there is continuity, the coil is grounded and the field coil housing assembly must be replaced. 9. Test for open circuited windings: Touch probes on two different commutator bars. If test shows no continuity, there is an open circuit and the armature must be replaced. 5. Test for open field coil: Touch one probe of tester to each field coil brush. If there is no continuity, the field coil is open and the field coil housing assembly must be replaced. 2 Commutator Bars IMPORTANT: Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush. 6. Inspect armature. Look for signs of dragging against pole shoes. 3 7. Inspect commutator. Look for roughness, burned bars, or any material which might cause short circuits between bars. If necessary, clean and touch up with 400 sandpaper. NEVER use emery cloth. Clean all dust from armature when finished. Armature Shaft M82101 10.Test for short circuited windings using a growler. Put armature in a growler and hold a hacksaw blade above each slot while slowly rotating armature. If coil is shorted, the blade will vibrate on the slot. Field Coil Brush NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments. 11.If test indicates short circuited windings, clean the commutator of dust and filings. Check the armature again. If the test still indicates a short circuit, replace the armature. Field Coil Housing Hacksaw Blade Armature M82100 NOTE: Test armature windings using an ohmmeter or test light. 8. Test for grounded windings: Touch probes on one commutator bar and armature shaft. Armature windings are connected in series, so only one commutator bar needs to be checked. Growler M82125A 12.Inspect armature cover and housing bearings for wear or damage. Replace if necessary. If test shows continuity, a winding is grounded and the armature must be replaced. 2-98 4/7/95 Starter To replace bearings: Bearings are press fit. Remove bearings using a knife-edge puller set. Wiring Lead IMPORTANT: Install both bearings with sealed side toward armature. Install new housing bearing tight against shoulder of shaft using a piece of pipe. Install new rear cover bearing tight against shoulder of shaft using a driver set. Rear Cover Bearing Cap Screw (2) Starter Motor Assembly 2 M82096 Housing Bearing 5. Remove three cap screws. 6. Separate end frame assembly from bearing housing. M82102 STARTER GEAR TRAIN AND SOLENOID - NIPPONDENSO 1.4 kW Cap Screw (3) End Frame Assembly 3 Disassembly/Inspection 1. Remove two socket head screws, end cap and shim(s). Bearing Housing End Cap M37822 7. Inspect seal and needle bearing for wear or damage. Replace as necessary. To replace needle bearing: Shim(s) Remove bearing using a blind-hole puller set. Install new bearing flush with housing surface using a driver set. Bearing Housing M37820 2. Disconnect wiring lead and relay leads, if equipped. 3. Remove two cap screws. 4. Remove starter motor assembly from bearing housing. Seal Needle Bearing M37823 4/7/95 2-99 Starter 8. Remove two cap screws, plunger, spring, shims and solenoid. Replace bushing using a driver set. Install bushing flush with face of housing. End Frame Shim(s) 12.Inspect end frame bushing for wear or damage. Replace if necessary. Solenoid Cap Screw (2) Plunger 2 Spring M37824 9. Remove shims from ring gear shaft. End Frame Bushing M37830 13.Slide pinion stopper away from retaining wire using a piece of pipe or deep socket. Remove retaining wire, pinion stopper, and clutch assembly from ring gear shaft. 3 14.Inspect all parts for wear or damage. Replace as necessary. Shims Ring Gear Shaft Clutch Assembly M37821 10.Remove pivot bolt, clutch fork and clutch assembly. 11.Inspect shoes on fork for wear or damage. Replace fork if necessary. Shoes End Frame Pinion Stopper Clutch Assembly Retaining Wire Ring Gear Shaft M37827 15.Remove snap ring, washer, spring cap, and spring from clutch. 16.Inspect all parts for wear or damage. Replace as necessary. Pivot Bolt Clutch Fork 2-100 M37825 4/7/95 Starter Clutch Snap Ring Spring Spring Cap Washer M37829 Assembly 2 Assembly is done in the reverse order of disassembly. • After installing clutch assembly, pinion stopper and retaining wire on ring gear shaft, use two pliers to press pinion stopper over retaining wire. 3 Retaining Wire Pinion Stopper Clutch Assembly M37831 4/7/95 2-101 Alternator ALTERNATOR - KOKOSAN 20A 6. Inspect bearing in coil plate for wear or damage. Replace if necessary. Disassembly/Inspection To replace bearing: Remove bearing using a spark plug socket and a press. Install bearing into coil plate until it bottoms in bore using a 1 in. socket. 1. Remove nut and washers. 2. Tap on end of shaft with a soft-faced hammer to separate flywheel assembly from coil plate assembly. 7. Remove wire clamp. 8. Remove connector from harness leads. 3. Remove long spacer. 9. Remove two screws and stator. Lock Washer 10.Inspect all parts for wear or damage. Replace as necessary. Washer 2 Flywheel Assembly Wire Clamp Nut 27 N•m (20 lb-ft) Coil plate Screw (2) Coil Plate Assembly Long Spacer M82247A NOTE: Bearing and flywheel are press fit on shaft. 4. Remove shaft from bearing, short spacer, washer, flywheel and sheave half, using a press. 5. Inspect all parts for wear or damage. Replace as necessary. Bearing Press fit in coil plate. Connector Stator M82249A Assembly Assembly is done in the reverse order of disassembly. • With sheave half on shaft, press shaft into flywheel until sheave half bottoms on flywheel face. Short Spacer Washer Flywheel • With washer and short spacer installed, press new bearing onto shaft until it bottoms on spacer. Shaft Bearing Press fit on shaft. Sheave Half M82248A NOTE: Remove bearing only if replacement is necessary. 2-102 4/7/95 Alternator VOLTAGE REGULATOR HITACHI 25A Attaching Screw (4) M5 4 N•m (31 lb-in.) Two Nuts and Insulator Stator End Frame-to-Rectifier Nuts (4) M5 4 N•m (31 lb-in.) Grommet Wire Clamp Front Frame End Frame M82108 Replacement 7. Use a soldering gun with at least 120 watt capacity to disconnect five terminals. Replace voltage regulator. 1. Remove three screws and cover. 2. Remove four attaching screws, wire clamp and grommet. • If additional solder is needed, use ONLY 60-40 rosin-core solder. 3. Remove four end frame-to-rectifier nuts. ALTERNATOR - HITACHI 25A 4. Remove two nuts and insulator. IMPORTANT: Do not pry against stator wires. 5. Use a screwdriver to pry end frame from stator. Do not separate stator from front frame. Brush Holder 1. Remove three screws and cover. 2. Remove four attaching screws, wire clamp and grommet. 6. Remove two screws and insulator. Insulator Disassembly Terminals Voltage Regulator Attaching Screws (4) M5 4 N•m (31 lb-in.) Screw (2) M51602 Grommet IMPORTANT: Do not heat connections longer than necessary to melt solder, as excess heat will damage rectifier assembly. Wire Clamp M82108 4/7/95 2-103 2 Alternator IMPORTANT: Do not pry against stator wires. 3. Use a screwdriver to separate rotor assembly from stator assembly. Stator Assembly Rotor Assembly: • Rear bearing is press fit. Replace only if necessary. Remove bearing using a puller set. Install bearing until flush with end of rotor shaft. Press only on inner race of bearing. 4. Put rotor assembly in a soft-jawed vise. Remove nut, lock washer, sheave, fan and bushing. 5. Put front frame on open jaws of vice. Use a softfaced hammer to remove rotor and spacer. 6. Remove three screws, retainer and front bearing. 7. Inspect all parts for wear or damage. Replace as necessary. 2 8. Test rotor. (See Inspection/Test procedures.) Rotor Assembly M36730 Rear Bearing Apply multipurpose grease to O.D. during assembly. Screw (3) 2 N•m (16 lb-in.) Bushing Clip Rotor Spacer Retainer Nut M14 49 N•m (36 lb-ft) Front Bearing Front Frame Fan Sheave Lock Washer M82109A 2-104 4/7/95 Alternator Stator Assembly: IMPORTANT: Be sure stator lead wires do not contact end frame when installed. 9. Remove four end frame-to-rectifier nuts. 10.Remove two nuts and insulator. IMPORTANT: Do not pry against stator wires. 11.Use a screwdriver to pry end frame from stator Two Nuts and Insulator End Frame End Frame-to-Rectifier Nuts M5 4 N•m (31 lb-in.) • Before assembling stator assembly to rotor assembly, push brushes into brush holder and insert a wire through access hole to lock brushes in place. • Assemble rotor assembly to stator assembly and fasten with four attaching screws. Remove wire from access hole. 2 Access Hole M51595 12.Use a soldering gun with at least 120 watt capacity to disconnect three stator leads. Remove rectifier. End Frame M51595 Inspection/Test Rectifier Rotor: • Inspect the rotor slip rings for dirt build-up, rough spots, or out of roundness. If necessary, polish the surface of the slip rings using No. 00 sandpaper or 400-grit silicon carbide paper. Stator Leads (3) • Touch the probes of an ohmmeter to slip rings. Replace rotor if test indicates no continuity (no needle movement). Stator M51605 Ohmmeter 13.Inspect and test brushes, stator and rectifier. (See Inspection/Test procedures.) Assembly Assembly is done in the reverse order of disassembly. • Bend the stator lead wires, as necessary, to obtain an approximate distance of 33.50 mm (1.300 in.) from stator to rectifier. Connect the three leads using a soldering gun. • If additional solder is needed, use ONLY 60-40 rosin-core solder. 4/7/95 Rotor Shaft Slip Rings M82110A • Touch the probes of the ohmmeter to the shaft and one of the slip rings. Repeat for other slip ring. Replace rotor if test shows continuity (needle movement). 2-105 Alternator Ohmmeter Rotor Shaft Slip Rings 2 M82111A • Use an ohmmeter or a test light to check for continuity. Check between the two brushes and between each brush and ground stud. There should be no continuity. Replace brush holderrectifier assembly if there is continuity. • To replace brushes, melt solder from connection. Remove voltage regulator if necessary. (See VOLTAGE REGULATOR REPLACEMENT in this group.) NOTE: If additional solder is needed, use ONLY 6040 rosin-core solder. Stator: Brushes: • Inspect brush holder and brushes for damage. Brushes must slide freely and the springs must hold the brushes firmly against the slip rings of the rotor. • Measure brushes for wear. Minimum exposed length must be 5.50 mm (0.220 in.) or to wear limit line on brushes. Replace brushes as necessary. • Inspect stator for defective insulation, discoloration or a burned odor. If any of these defects are found, replace stator. NOTE: Use an ohmmeter that is sensitive to resistance of 0 to 1 ohm. • Touch probes of an ohmmeter to lead wires of stator in three possible combinations. Continuity should read approximately 0.26 ohms. If readings are not equal, replace stator. Brush Length Ohmmeter Rectifier Voltage Regulator Stator Brushes M82113A • Touch one probe of the ohmmeter to the bare metal surface of stator and the other probe to a bare stator lead wire. Repeat for each wire. Replace stator if test indicates continuity. Ground Stud Ohmmeter Brush Holder Soldered Connection M82112 Stator M82114A 2-106 4/7/95 Alternator Rectifier: • Test the diodes by touching probes to ground post and the three outer terminals. • Switch the probes and check each terminal again. There should be continuity in only one combination of each terminals and the ground post. • Test the diodes by touching probes to output post and the three outer terminals. VOLTAGE REGULATOR NIPPONDENSO 35A Replacement 1. Remove three attaching screws. Attaching Screw (3) M5 4 N•m (31 lb-in.) • Switch the probes and check each terminal again. There should be continuity in only one combination of each terminal and the output post. A shorted diode would have continuity in both directions. An open diode would have no continuity in either direction. Replace the rectifier assembly if any of the three diodes are defective. • To replace rectifier, melt solder from connection. 2 M36725 2. Remove end frame-to-rectifier nut. 3. Remove nuts and insulators. NOTE: If additional solder is needed, use ONLY 6040 rosin-core solder. End Frame-to-Rectifier Nut M5 4 N•m (31 lb-in.) Soldered Connection Nuts and Insulators M36726 IMPORTANT: Do not pry against stator wires. Outer Terminals Outer Terminal Output Post Ground Post 4. Use a screwdriver to pry end frame from stator. Do not separate stator from front frame. End Frame M82115 Stator Front Frame M36727 4/7/95 2-107 Alternator IMPORTANT: Do not heat connections longer than necessary to melt solder, as excess heat will damage rectifier assembly. IMPORTANT: Do not pry against stator wires. 2. Use a screwdriver to separate rotor assembly from stator assembly. 5. Use a soldering gun with a least 120 watt capacity to disconnect terminals. Replace voltage regulator. Stator Assembly Voltage Regulator 2 Rotor Assembly Terminals M36730 M36728 Installation is done in the reverse order of removal. • If additional solder is needed, use ONLY 60-40 rosin-core solder. ALTERNATOR - NIPPONDENSO 35A Disassembly Rotor Assembly: • Rear bearing is press fit. Replace only if necessary. Remove bearing using a puller set. Install bearing until flush with end of rotor shaft. Press only on inner race of bearing. 3. Put rotor assembly in a soft-jawed vise. Remove nut, lock washer, sheave, fan and bushing. 4. Put front frame on open jaws of vice. Use a softfaced hammer to remove rotor and spacer. 1. Remove three attaching screws. 5. Remove three screws, retainer, front bearing, washer and felt washer. Attaching Screw (3) M5 4 N•m (31 lb-in.) 6. Inspect all parts for wear or damage. Replace as necessary. M36725 2-108 4/7/95 Alternator Rear Bearing Apply multipurpose grease to O.D. during assembly. Bushing Fan Sheave Screw (3) 2 N•m (16 lb-in.) Lock Washer Front Bearing Rotor 2 Spacer Retainer Nut M14 54 N•m (40 lb-ft) Washer Felt Washer Apply multipurpose grease during assembly. Front Frame M82250A 7. Test rotor. (See Inspection/Test procedures.) Stator Assembly: 11.Use a soldering gun with at least 120 watt capacity to disconnect terminals. Remove voltage regulator. 8. Remove end frame-to-rectifier nut. 9. Remove nuts and insulators. Voltage Regulator IMPORTANT: Do not pry against stator wires. 10.Use a screwdriver to pry end frame from stator. End Frame-to-Rectifier Nut M5 4 N•m (31 lb-in.) Terminals M36728 12.Melt solder inside the connecting pipes. While solder is hot, open the flattened pipe with a needle nose pliers. Pull stator wire from pipe. Nuts and Insulators M36726 4/7/95 2-109 Alternator • Assemble rotor assembly to stator assembly and fasten with three attaching screws. Remove wire from access hole. Inspection/Test Rotor: M36739 2 13.Inspect and test brushes, stator and rectifier. (See Inspection/Test procedures.) • Inspect the rotor slip rings for dirt build-up, rough spots, or out of roundness. If necessary, polish the surface of the slip rings using No. 00 sandpaper or 400-grit silicon carbide paper. • Touch the probes of an ohmmeter to slip rings. Replace rotor if test indicates no continuity (no needle movement). Assembly Ohmmeter Assembly is done in the reverse order of disassembly. NOTE: The three pair of lead wires on the stator are not evenly spaced. Rotate the rectifier until the terminal pipes align with the stator leads. • Bend the stator lead wires, as necessary, to obtain an approximate distance of 33.50 mm (1.300 in.) from stator to rectifier. Connect the six leads using a soldering gun. • If additional solder is needed, use ONLY 60-40 rosin-core solder. Rotor Shaft Slip Rings M82110A • Touch the probes of the ohmmeter to the shaft and one of the slip rings. Repeat for other slip ring. Replace rotor if test shows continuity (needle movement). IMPORTANT: Be sure six stator lead wires do not contact end frame when installed. Ohmmeter • Before assembling stator assembly to rotor assembly, push brushes into brush holder and insert a wire through access hole in rear at end frame to lock brushes in place. Rotor Shaft Wire Slip Rings Brushes M82111A Brushes: M36748 2-110 • Inspect brush holder and brushes for damage. Brushes must slide freely and the springs must hold the brushes firmly against the slip rings of the rotor. 4/7/95 Alternator • Measure brushes for wear. Minimum exposed length must be 5.50 mm (0.220 in.) or to wear limit line on brushes. Replace brushes as necessary. • Use an ohmmeter or a test light to check for continuity. Check between the two brushes and between each brush and ground stud. There should be no continuity. Replace brush holderrectifier assembly if there is continuity. Insulator Brush Holder Brush Ground Stud Brushes Brush Lead Wire Insulating Washers M36736 M36745 • To replace brushes: - Melt solder from brush lead connections and remove brushes and springs. - Inspect springs for wear or damage. Replace as necessary. NOTE: If additional solder is needed, use ONLY 6040 rosin-core solder. Stator: • Inspect stator for defective insulation, discoloration or a burned odor. If any of these defects are found, replace stator. NOTE: Use an ohmmeter that is sensitive to resistance of 0 to 1 ohm. Brush Lead Connections • Touch probes of an ohmmeter to each pair of stator wires. Equal continuity readings should be observed between each pair of leads. If readings are not equal, replace stator. M36737 - Push brush lead wire through spring. Insert spring and brush in brush holder with lead protruding through hole in brush holder. Make sure the longest side of brush is on side of brush holder with raised lip. - Hold brushes in position so that exposed length is 13 mm (0.500 in.) - Solder brush leads in this position. Cut off excess length of brush lead wire. - Be sure insulating washers and insulator are in place. 4/7/95 M36740 2-111 2 Alternator • Touch one probe of the ohmmeter to the bare metal surface of stator and the other probe to a bare stator lead wire. Repeat for each wire. Replace stator if test indicates continuity. Output Post M36743 • Test the diodes by touching probes to ground post and the three outer terminals. 2 M36741 Rectifier: NOTE: The three inner terminals are connected by a printed circuit in the rectifier. • Test the three inner terminals using an ohmmeter. Move probes so all terminals are cross checked. Replace the rectifier if test shows no continuity. • Switch the probes and check each terminal again. There should be continuity in only one direction between each terminal and the ground post. A shorted diode would have continuity in both directions. An open diode would have no continuity in either direction. Replace the rectifier assembly if any of the six diodes are defective. Inner Terminals Ground Post M36744 M36742 NOTE: Each of the three outer terminals on the rectifier is connected to two diodes permitting current flow in only one direction. • Test the diodes by touching probes to output post and the three outer terminals. VOLTAGE REGULATOR NIPPONDENSO 40A Replacement 1. Remove nut and insulator. 2. Remove three screws and cover. • Switch the probes and check each terminal again. There should be continuity in only one direction between each terminal and the output post. 2-112 4/7/95 Alternator Nut 69 N•m (51 lb-ft) Cover Nut and Insulator Sheave M52470 3. Remove two screws, brush holder and cover. 4. Remove three screws. Replace voltage regulator. M52469 4. Remove four screws and straighten stator wire leads. 5. Remove rectifier. Long Screw (2) Voltage Regulator Rectifier Stator Wire Lead (4) Short Screw Brush Holder and Cover M52472 M52471 Installation is done in the reverse order of removal. IMPORTANT: Make sure to install short screw at location shown. Longer screw will contact frame and cause damage to the charging system. ALTERNATOR - NIPPONDENSO 40A 6. Remove two nuts, two screws and end frame assembly. 7. Press rotor shaft from end frame. 8. Remove spring washer. Spring Washer Disassembly 1. Remove voltage regulator. (See VOLTAGE REGULATOR - REPLACEMENT in this group.) 2. Remove nut. 3. Remove sheave using a puller set. Rotor Shaft End Frame Assembly M52473 4/7/95 2-113 2 Alternator 9. Remove four screws and retainer. NOTE: Front bearing is press fit in front frame. Remove bearing only if replacement is necessary. 10.Inspect bearing in front frame for wear or damage. Replace if necessary. Replace bearing using a driver set and a press. • Touch the probes of an ohmmeter to slip rings. Replace rotor if test indicates no continuity (no needle movement). • Touch probes of ohmmeter to the rotor core and one of the slip rings. Repeat for other slip ring. Replace rotor if test shows continuity (needle movement). Rear Bearing Front Bearing Front Frame 2 Screw (4) 2 N•m (16 lb-in.) Retainer Rotor Core Slip Rings M52474 M52475 11.Inspect and test brushes, stator and rectifier. (See Inspection/Test in this group.) Assembly Assembly is done in the reverse order of disassembly. Brushes: • Inspect brush holder, brushes and springs for damage. Brushes must slide freely and springs must hold brushes firmly against the slip rings of the rotor. • Measure length of brush protruding from holder. If length is less than wear limit, replace brushes. • After installing rectifier, form a loop in stator wire leads, insert screws through loop and secure rectifier and wire leads. Inspection/Test Rotor: NOTE: Rear bearing and rotor assembly are not serviced separately. Damaged parts require that rotor assembly and bearing be replaced as a unit. • Inspect bearing for wear or damage. Replace complete rotor if necessary. • Inspect slip rings for dirt build-up, rough spots or out-of-roundness. If necessary, polish the surface of the slip rings using No. 00 sandpaper or 400-grit silicone carbide paper. Measure outer diameter of slip rings. Replace rotor if less than 14 mm (0.550 in.). 2-114 M52478 Brush Length Specifications New. . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.) Wear Limit. . . . . . . . . . . . 4.50 mm (0.170 in.) • Check continuity between brush and terminal “A”. Check continuity between brush and terminal “B”. There should be continuity only at these points. 4/7/95 Alternator Rectifier: A B NOTE: Set the ohmmeter to the K ohm range. • Check continuity between output post and each diode lead. Reverse ohmmeter leads and recheck. There should be continuity in one direction, but not the other. M52479 Stator: • Inspect stator for defective insulation, discoloration or a burned odor. If any of these defects are found, replace stator. A shorted diode would have continuity in both directions. An open diode would have no continuity in either direction. Replace the rectifier if any of the four diodes are defective. 2 Diode Lead (4) NOTE: Use an ohmmeter that is sensitive to resistance of 0 to 1 ohm. • Check for continuity between each stator lead and stator body. Replace stator if test indicates continuity. To replace stator: - Scribe a mark on housing, at notch in stator, to aid in installation of a new stator. Output Post M52477 - Remove two studs. - Replace stator using a punch and hammer. Stator Lead (4) Stator Body Stud (2) Scribe Mark on Housing 4/7/95 Notch M82251 2-115 Diagnosis Air filter elements dirty or plugged. Replace. ● ● ● ● ● Fuel shut-off valve turned off, or restricted. Solenoid linkage misadjusted. See adjustment. ● ● ● ● ● 3 ● ● Muffler or exhaust manifold leak. Defective manifold heater. ● Injection pump or governor malfunctioning. Injection pump timing incorrect. ● Defective cranking components or connectors. ● Low compression from worn rings, cylinder bore, piston, valves or warped head. Valve clearance incorrect. ● Burned or warped valves and valve seats. Defective valve spring. Starter cranking rpm too slow. Damaged starter. Excessive engine load. ● Fuel pump leaking or not operating. See Fuel Supply Pump Pressure Test. Engine oil viscosity or level incorrect. ● Radiator/oil cooler leak. 2-116 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Injector pressure incorrect or leaking. Cylinder head gaskets leaking or damaged. ● ● Exhaust smoke black or grey or uses too much fuel. ● Exhaust smoke white. ● Exhaust smoke blue or uses too much oil. ● Engine operating temperature is incorrect. Engine surges, or has uneven or uncontrolled rpm. ● Engine has low oil pressure. Engine runs rough, misses, noisy, vibrates or low on power. Fuel in oil. Oil level high. 2 Oil in the coolant or coolant in the oil. Engine will not stay running, or stalls frequently. Fuel pump screen, fuel filter, or fuel line restricted. Fuel dirty, contains water or wrong grade. CHECK OR SOLUTION Engine will not crank. Engine cranks but will not start or starts hard. PROBLEM OR SYMPTOM Lack of fuel at injection pump. ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 4/7/95 Diagnosis ENGINE SYSTEM DIAGNOSIS Conditions: • Engine mounted on level surface. • Key switch off unless indicated otherwise. Test Location Normal If Not Normal 1. Engine dipstick and exterior engine surfaceengine oil check. Oil level between “L” and “H” marks. Oil not burnt, or contaminated with metal particles, fuel, or coolant. No external leakage, filter clean. Change oil and inspect for source of contamination. Check gaskets, seals, plugs, cylinder head, block, and intake manifold and breather. Change oil filter. 2. Coolant tank and radiator. Coolant level between marks on tank when engine is warm. Coolant in radiator full to top. Coolant not contaminated with oil, fuel or discolored brown. Add proper coolant mix. Radiator screen free of debris. Clean or replace. Hoses not cracked or leaking, clamps and radiator cap tight. Pressure test radiator and cap. Fan belt tight, not glazed or cracked. Replace and adjust belt tension. Fan blades not damaged or warped. Replace fan. Fuel level correct, not contaminated, correct grade of fuel, no water. Fuel pump screen and in-line filter free of debris. Fuel shutoff valve in “ON” position. Drain and clean fuel tank. Add fresh fuel. Replace filters. Fuel hoses not cracked or leaking. Replace. Fuel hose clamps tight. Replace or tighten. Fuel tank does not have vacuum. Replace fuel tank check valve. Air filter hose not cracked, clamps tight. Element not plugged. Air filter housing sealed, no dirt tracking inside filter element. Replace and tighten clamps. - Cooling System Check. 3. Fuel tank, pump, pump screen, lines, filter, filter shutoff valve. - Fuel System Check 4. Air filter and air intake. - Air Intake System Check 2 Drain and flush system. Check for source of contamination. 3 Move to “ON” position. Replace element or housing. 5. Fuel shutoff solenoid. (Key in RUN position.) Fuel shutoff solenoid must pull in and stay in. Solenoid must bottom out. Shutoff shaft must still move slightly. Check shutoff solenoid adjustment. Clean any dirt from under solenoid boot. If solenoid will not pull in and hold in, see Fuel Shutoff Solenoid Circuit Test Points in ELECTRICAL section of Machine TM. 6. Air heater indicator light. (Key in RUN position.) Indicator light should come on up to 15 seconds depending on air temperature. See Air Heater Circuit Test Points in ELECTRICAL section of Machine TM. 4/7/95 2-117 Diagnosis ENGINE SYSTEM DIAGNOSIS - Continued Test Location Normal If Not Normal 7. Fuel filter, fuel pump. (Key switch in RUN position.) Fuel level increases in filter. Fuel pump operating - listen for humming sound. Fuel present in return hose at fuel pump. See Fuel Pump Circuit Test Points in ELECTRICAL section of Machine TM. Test fuel pump pressure. (See Operational Tests in this section.) Replace fuel filter. 8. Throttle lever and cable. Linkage not binding and adjusted correctly. Repair, replace or adjust cable. 9. Intake and exhaust valves. Cold engine. Valve clearance within specification. Valves not sticking. Check and adjust. (See Checks, Tests and Adjustments in this section.) Check valve guides and stems. 10. Fuel at injectors. (Key in START position - engine cranking.) Crack fuel injection lines at injectors. Fuel shutoff solenoid pulled in. Check spray pattern and cracking pressure. (See Checks, Tests and Adjustments in this section.) Replace injectors.See Cranking Circuit Test Points in ELECTRICAL section of Machine TM. 11. Injector ports. (Key in START position.) Cylinder compression within specification. Pressure difference between cylinders within specification. Perform cylinder compression test. (See Operational Tests in this section.) 12. Flywheel and starter. Minimum cranking rpm within specification. See Starter Amp Draw Test in ELECTRICAL section of Machine TM. 13. Injection pump timing inspection. (Key OFF.) Timing should be correct. Remove pump as the LAST possible solution. Perform injection pump static timing adjustment. (See Checks, Tests and Adjustments in this section.) Have pump tested by a qualified Service Repair Shop. 14. Injection pump idle settings. (Engine running). Engine runs smooth under load. Engine rpm to specification. See Slow Idle and Fast Idle Adjustments in ENGINE section of Machine TM. 15. Oil pressure sender port. Oil pressure in specification. Test engine oil pressure. (See Operational Tests in this section.) 16. Thermostat. (Engine at operating temperature.) Clean from corrosion, rust, or debris. Opening temperature within specification. Replace thermostat. Perform thermostat opening test. (See Checks, Tests and Adjustments in this section.) 17. Muffler. Not restricted. Replace muffler. 2 3 2-118 Engine must crank. 4/7/95 Checks, Tests and Adjustments VALVE CLEARANCE, CHECK AND ADJUSTMENT Reason: To achieve correct engine operation. No. 1 TDC Mark on Flywheel Equipment: Index Mark on Flywheel Plate • Feeler Gauge Procedure: NOTE: Location of the index mark will be different as a result of the various engine applications. M37501 3TN75, 3TNC78 (3011DF001 OEM), 3TNA82, 3TN84 (870 CUT, 955 CUT, 3014DF001 OEM) 2 The index mark appears on the following: 1. Remove rocker arm cover. NOTE: No. 1 cylinder is the closest to the flywheel. 4. Try to move both No. 1 cylinder rocker arms or push rods. If rocker arm push rods are not loose, rotate flywheel one revolution (360°). If both rocker arm push rods are loose the piston is at TDC on compression stroke. 5. Measure and adjust valve clearance on the valves (arrows) with No. 2 piston at TDC. 2. Remove plug from timing hole in flywheel housing, if equipped. 3. Turn crankshaft pulley clockwise until No.1 cylinder TDC mark on flywheel aligns with index mark on flywheel housing or plate. 1 Flywheel End NOTE: “Top Dead Center (TDC)” is the piston at its highest point. Cylinders E 2 I E 3 I E I Fan End - 3TN75 (F1145 FM): Edge of flywheel guard and plate. - 3TN75 (855/56 CUT), 3TNC78 (3011DF001 OEM), 3TN84 (870 CUT, 955 CUT, 3014DF001 OEM): Flywheel plate. - 3TN78, 3TNC78 (3011DF001, 005, 006 OEM), 3TN82, 3TN84 (3014DF001, 005, 006 OEM): Flywheel housing. No. 1 Piston at TDC M82327A TDC Mark on Flywheel To adjust valves, loosen nut and turn adjusting screw until clearance is 0.20 mm (0.008 in.). Hold screw while tightening nut. Index Mark on Flywheel Housing Feeler Gauge M82372A 3TN78, 3TNC78 (3011), 3TN82, 3TN84 (3014 OEM) T6105BF 4/7/95 2-119 Checks, Tests and Adjustments 6. Turn crankshaft pulley one revolution (360°). This puts the piston in No. 2 cylinder at TDC compression stroke. 7. Measure and adjust valve clearance on the valves (arrows) with No. 2 piston at TDC. 2 2 I E • If side play exceeds wear limit, replace connecting rod and connecting rod cap. 3 I E I Fan End Flywheel End 1 Standard Clearance . . . . . . . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . (0.0079 - 0.0157 in.) Wear Limit. . . . . . . . . . . 0.55 mm (0.0217 in.) Results: Cylinders E Specifications: No. 2 Piston at TDC M82327A CONNECTING ROD SIDE PLAY CHECK CONNECTING ROD BEARING CLEARANCE CHECK Reason: To measure oil clearance between connecting rod bearing and crankshaft journal. Equipment: Reason: • PLASTIGAGE® To determine proper side clearance between crankshaft and connecting rod. Procedure: IMPORTANT: Connecting rod caps must be installed on the same connecting rod and in the same direction to prevent crankshaft and connecting rod damage. Equipment: • Feeler Gauge Procedure: 1. Remove connecting rod cap. 1. Insert a feeler gauge, according to specifications, between connecting rod cap and crankshaft. 2. Wipe oil from bearing insert and crankshaft journal. 3. Put a piece of PLASTIGAGE, or an equivalent, along the full length of the bearing insert approximately 6 mm (0.250 in.) off center. Feeler Gauge M82116A 2-120 PLASTIGAGE M35351 4. Turn crankshaft approximately 30° from bottom dead center. 4/7/95 Checks, Tests and Adjustments 5. Install connecting rod end cap and original cap screws. Tighten cap screws to: 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . . . 39 N•m (29 lb-ft) 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . . . . . 47 N•m (35 lb-ft) 6. Remove cap screws and connecting rod cap. NOTE: The flattened PLASTIGAGE will be found on either the bearing insert or crankshaft journal. 7. Use the graduation marks on the envelope to compare the width of the flattened PLASTIGAGE at its widest point. 8. Determine bearing clearance. The number within the graduation marks indicates the bearing clearance in inches or millimeters depending on which side of the envelope is used. 9. Remove PLASTIGAGE. CRANKSHAFT, END PLAY CHECK Reason: To determine proper side clearance between crankshaft and engine block. Equipment: • Dial Indicator Procedure: NOTE: Crankshaft end play can be measured at front end or rear end of crankshaft. Procedure is performed from the rear end. The flywheel is removed to show detail. 1. Fasten dial indicator to engine and position indicator tip on end of crankshaft. IMPORTANT: Do not use excessive force when moving crankshaft to avoid damaging bearings. 2. Push crankshaft toward rear as far as possible. 3. Zero the dial indicator. 4. Using a bar, gently pry the crankshaft as far forward as possible. Graduation Marks on Envelope Flattened PLASTIGAGE M82117A Specifications: Standard Clearance . . . . . . 0.038 - 0.090 mm . . . . . . . . . . . . . . . . . . . . . (0.0015 - 0.0035 in.) Wear Limit. . . . . . . . . . . 0.16 mm (0.0063 in.) Dial Indicator Results: • If clearance exceeds wear limit, replace bearing inserts. ®PLASTIGAGE is a registered trademark of the DANA Corporation. Crankshaft M82118A Specifications: Standard Clearance . . . . . . 0.090 - 0.271 mm . . . . . . . . . . . . . . . . . . . . . . . (0.004 - 0.011 in.) Wear Limit. . . . . . . . . . . 0.33 mm (0.0129 in.) Results: • If end play exceeds wear limit, replace thrust bearings. 4/7/95 2-121 2 Checks, Tests and Adjustments CRANKSHAFT MAIN BEARING, CLEARANCE CHECK Reason: To measure oil clearance between main bearing and crankshaft journal. 7. Determine main bearing clearance. The number within the graduation marks indicates the bearing clearance in inches or millimeters depending on which side of the envelope is used. 8. Remove PLASTIGAGE. Equipment: • PLASTIGAGE® Graduation Marks on Envelope Procedure: 2 IMPORTANT: Main bearing caps must be installed on the same main bearing and in the same direction to prevent crankshaft and main bearing damage. Flattened PLASTIGAGE 1. Remove main bearing cap. M82119AE 2. Wipe oil from bearing insert and crankshaft journal. 3. Put a piece of PLASTIGAGE, or an equivalent, along the full length of the bearing insert approximately 6 mm (0.250 in.) off center. Specifications: Standard Clearance . . . . . . 0.038 - 0.090 mm . . . . . . . . . . . . . . . . . . . . . (0.0015 - 0.0035 in.) Wear Limit. . . . . . . . . . . 0.06 mm (0.0063 in.) Results: • If clearance exceeds wear limit, replace bearing inserts. PLASTIGAGE ®PLASTIGAGE is a registered trademark of the DANA Corporation. VALVE LIFT CHECK M35382 4. Install main bearing cap and cap screws. Tighten cap screws to: 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . . . 79 N•m (58 lb-ft) 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . . . . . 98 N•m (72 lb-ft) 5. Remove cap screws and main bearing cap. NOTE: The flattened PLASTIGAGE will be found on either the bearing insert or crankshaft journal. 6. Use the graduation marks on the envelope to compare the width of the flattened PLASTIGAGE at its widest point. 2-122 Reason: Can indicate excessive wear on cam lobes, followers, and/or push rods. Equipment: • Dial Indicator Procedure: 1. Adjust valve clearance. (See procedure in this group.) 2. Remove rocker arm cover. (See Cylinder Head, Valves and Manifolds in this section.) 3. Fasten dial indicator to engine and position indicator tip on valve retainer. Valve must be fully closed and rocker arm must move freely. 4/7/95 Checks, Tests and Adjustments 4. Zero the dial indicator. 5. Manually turn crankshaft pulley clockwise (from fan end). 6. Observe dial indicator as valve is moved to the full open position. Valve lift (intake and exhaust) should be 8.8 mm (0.350 in.). Repeat for each valve. M37512 Specifications: 2 Standard Clearance . . . . . . . . 0.05 - 0.20 mm . . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.) Wear Limit. . . . . . . . . . . . 0.40 mm (0.016 in.) T6333DT Results: • If valve lift is less than specification, remove and inspect camshaft, followers and push rods. (See Camshaft and Timing Gear Train and/or Cylinder Head, Valves and Manifolds in this section.) Results: • If end play exceeds wear limit, remove camshaft and replace thrust plate. (See Camshaft and Timing Gear Train in this section.) TIMING GEAR BACKLASH, CHECK Reason: CAMSHAFT END PLAY CHECK To check for wear between meshing gears, resulting in excessive noise and poor engine performance. Reason: Equipment: To determine proper side clearance between camshaft gear end journal and thrust plate. Equipment: • Dial Indicator Procedure: 1. Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) 2. Fasten dial indicator to engine and position indicator tip on end of camshaft. 3. Push camshaft toward the rear as far as possible. 4. Zero the dial indicator. • Dial Indicator Procedure: 1. Measure backlash between meshing gears. Specifications - 3TN75, 3TN78, 3TNC78 (3011): Standard Backlash Crankshaft Gear-to-Oil Pump Gear. . . . . . . . . . . . . 0.11 - 0.19 mm . . . . . . . . . . . . . . . . . . (0.0043 - 0.0075 in.) All Except Crankshaft Gear-to-Oil Pump Gear. . . . . . . . . . . . . 0.04 - 0.12 mm . . . . . . . . . . . . . . . . . . (0.0016 - 0.0047 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) 5. Pull camshaft forward as far as possible. 4/7/95 2-123 Checks, Tests and Adjustments Specifications - 3TN82, 3TNA82, 3TN84 (3014): Standard Backlash . . . . . . . . . 0.04 - 0.12 mm . . . . . . . . . . . . . . . . . . . . . (0.0016 - 0.0047 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Results: • If backlash exceeds wear limit, replace meshing gears as a set: Idler Gear, Camshaft Gear, Crankshaft Gear, Oil Pump Gear AND/OR Idler Gear, Fuel Injection Pump Gear. Fuel Injection Pump Gear-to-Idler Gear Camshaft Gear-to-Idler Gear 2 Idler Gear-to-Crankshaft Gear Crankshaft Gear-to-Oil Pump Gear 2-124 M82252A 4/7/95 Checks, Tests and Adjustments FUEL INJECTION NOZZLE TEST (HOLE-TYPE) Equipment: • D01109AA Diesel Fuel Injection Nozzle Tester • D01110AA Adapter Set CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. Reason: To determine opening pressure, leakage, chatter and spray pattern of the fuel injection nozzle. 4/7/95 • 23622 Straight Adapter • Container Connections: 1. Connect fuel injection nozzle to D01109AA Diesel Fuel Injection Nozzle Tester using parts from D01110AA Adapter Set and 23622 Straight Adapter. IMPORTANT: Use clean filtered diesel fuel when testing injection nozzles to get best test results. Procedure 1: Test fuel injection nozzle opening pressure following the Nozzle Tester manufacturer's instructions. Specifications: Opening Pressure . . . . . . . . 19600 ± 480 kPa . . . . . . . . . . . . . . . . . . . . . . . . . (2843 ± 70 psi) Results: • If pressure reading does not meet specification, disassemble injection nozzle and inspect nozzle assembly for contamination or stuck valve. If necessary, add or remove shims to change opening pressure. 2-125 2 Checks, Tests and Adjustments 23617 90° Adapter 36352 Fuel Line Assembly 23621 Straight Adapter 23622 Straight Adapter D01109AA Diesel Fuel Injection Nozzle Tester 2 Fuel Injection Nozzle Container M35913 Procedure 2: Test fuel injection nozzle leakage following the Nozzle Tester manufacturer's instructions. 1. Dry nozzle completely using a lint-free cloth. 2. Pressurize nozzle to 17640 kPa (2558 psi). 3. Watch for leakage from nozzle spray orifice. Leakage time should be a minimum of 5 seconds. Results: • If leakage time does not meet specification, disassemble injection nozzle and inspect nozzle assembly for contamination. Inspect valve seating surface. Replace nozzle assembly if necessary. Procedure 3: 1. Pressurize nozzle to 19600 ± 480 kPa (2843 ± 70 psi). 2. Listen for “chatter” sound and watch spray pattern. Specifications: Slow Hand Lever Movement . . . . . . . . . . . Chatter Sound Slow Hand Lever Movement . . . . . . . . . . . . . Fine Stream . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern Fast Hand Lever Movement . . . . . . . . . . . Fine Atomized . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern Test fuel injection nozzle chatter and spray pattern following the Nozzle Tester manufacturer's instructions. 2-126 4/7/95 Checks, Tests and Adjustments Procedure: Correct CAUTION Proper Spray Angle DO NOT allow thermostat or thermometer to rest against the side or bottom of glass container when heating water. Either may rupture if overheated. 1. Suspend thermostat and a thermometer in a container of water. Correct Injection Angle 2. Heat and stir the water. Observe opening action of thermometer and compare temperatures with specifications. Poor 3. Remove thermostat and observe its closing action as it cools. Thermometer M82121A Results: • If nozzle chatter or spray pattern does not meet specifications, disassemble injection nozzle and inspect nozzle assembly for contamination. Inspect valve seating surface. Replace nozzle assembly if necessary. • If there is excessive difference in spray angle or injection angle, incomplete atomization or sluggish starting/stopping of injection, disassemble injection nozzle and inspect nozzle assembly for contamination. Replace nozzle assembly if necessary. Thermostat M82122A Specifications: Begin Opening . . . . . . . . . . . . . 71° C (160° F) Fully Open . . . . . . . . . . . . . . . . 85° C (184° F) Minimum Lift Height . . . . . .8 mm (0.310 in.) THERMOSTAT OPENING TEST Results: Reason: To determine opening temperature of thermostat. • If thermostat does not open according to specifications, replace. Equipment: • If closing action is not smooth and slow, replace thermostat. • Thermometer • Glass Container • Heating Unit 4/7/95 2-127 2 Checks, Tests and Adjustments COOLANT TEMPERATURE SWITCH TEST Reason: To determine operating temperature of sender. 2. Suspend sender and a thermometer in a container of water. 3. Heat and stir the water. Observe water temperature when continuity occurs. Water temperature should be 107 - 113° C (225 235°F). Equipment: • Thermometer Ohmmeter Probes • Glass Container • Heating Unit • Ohmmeter 2 Procedure: CAUTION DO NOT allow switch or thermometer to rest against the side or bottom of glass container when heating water. Either may rupture if overheated. 1. Connect lead wires from ohmmeter probes, to sender terminal and body. 2-128 Coolant Temperature Switch M82123A Results: • If continuity does not occur within temperature listed, replace sender. 4/7/95 Checks, Tests and Adjustments STARTER NO-LOAD AMP DRAW/RPM TEST Reason: To determine if starter is binding or has excessive amperage draw under no load. Equipment: • JT05712 Current Gun • JT05719 Hand-Held Digital Tachometer • Jumper Cables • Jumper Wire Procedure: 1. Mount starter in a vise. NOTE: Check that battery is fully charged and of proper size to ensure accuracy of test. 2. Connect jumper cables to a 12 volt battery. 3. Connect positive (+) cable to solenoid battery terminal on starter. 4. Connect negative (-) cable to starter body. Specifications: Maximum Starter Amperage Hitachi 2.0 kW. . . . . . 110 Amps at 4500 rpm Nippondenso 1.0 kW and 1.2 kW. . . . . . . . . . 90 Amps at 3000 rpm Nippondenso 1.4 kW. . 90 Amps at 3500 rpm Minimum Starter RPM Hitachi 2.0 kW. . . . . . . . . . . . . . . . . . . . . 4500 Nippondenso 1.0 kW and 1.2 kW. . . . . . . . . . . . . . . . . . . . . . . . 3000 Nippondenso 1.4 kW. . . . . . . . . . . . . . . . 3500 Results: • If solenoid “clicks” or chatters and motor does not turn, replace solenoid. • If pinion gear engages and motor doesn't turn, repair or replace starter motor. • If starter engages and runs but amperage is more than specifications, repair or replace starter. If rpm is less than specification, with battery fully charged, repair or replace starter. 5. Attach Current Gun to positive cable. IMPORTANT: Complete this test in 20 seconds or less to prevent starter damage. 6. Use a jumper wire to briefly connect positive (+) starter terminal to solenoid terminal “S”. Starter should engage and run. 7. Read and record starter amperage and rpm. 4/7/95 2-129 2 Checks, Tests and Adjustments JT05712 Current Gun JT05719 Hand-Held Digital Tachometer Jumper Wire 2 M82149A All Except Nippondenso 1.0 kW and 1.2 kW JT05712 Current Gun JT05719 Hand-Held Digital Tachometer Jumper Wire Nippondenso 1.0 kW and 1.2 kW 2-130 M82150A 4/7/95 Checks, Tests and Adjustments INJECTION PUMP STATIC TIMING ADJUSTMENT Reason: To make sure that injection pump timing is set to manufacturers specification. Equipment: • Timing Tool (No. 1 fuel injection line cut off at first bend) 3TN75, 3TN84 (3014) M82256A • External fuel supply Procedure: IMPORTANT: Injection pump timing should be correct. Once timing is set, it will not normally change during the life of the engine, unless it was altered. Check and adjust timing only as the last option. Check fuel, fuel supply system, injectors, air intake system and cylinder compression before continuing. NOTE: Normal rotation, as viewed from the flywheel end, is counterclockwise. The number one fuel injection line is toward the flywheel. 2. Remove the number one fuel injection line. 3. Install timing tool (number one fuel line cut off at first bend). Timing Tool NOTE: If injection pump has been removed from engine without disturbing engine crankshaft and pump shaft, perform Step 1 only. Otherwise, perform the entire timing procedure. 1. 3TN78, 3TNC78 (3011), 3TN82, 3TNA82: Align arrow or line on injection pump flange with the sixth mark (line) on timing gear mounting plate. 3TN75, 3TN84 (3014): Align arrow or line on injection pump flange between third and fourth marks (lines) on timing gear mounting plate. T6530AB 4. Remove rubber plug from flywheel housing, if equipped. 5. Turn crankshaft pulley in either direction until the No. 1 cylinder top dead center (TDC) mark aligns with the index mark on the flywheel housing/ plate. TDC Mark on Flywheel 1 3TN78, 3TNC78 (3011), 3TN82, 3TNA82 M82255A Index Mark on Flywheel Housing/Plate T6530AC 4/7/95 2-131 2 Checks, Tests and Adjustments 6. Prime pump to fill it with fuel. 1 L (1.06 qt) of fuel is more than adequate. 7. Hold throttle lever in run position. 8. Turn flywheel clockwise (as viewed from the flywheel end) until tip of Timing Tool has become MOIST with solid fuel. 9. Check timing mark on flywheel. The index mark must line up with the injection pump timing mark on flywheel. See specifications. Engine Crankshaft Position. . . . . . . . . . . . . . . . . . . No.1 Cylinder . . . . . . . . . . . . . on TDC Compression Stroke Results: • If timing is not according to specifications, loosen pump mounting bolts and turn pump towards engine block to retard timing or away from block to advance timing. Recheck timing. • If timing did not change, remove pump and have tested by a diesel injection service shop. 2 • If timing is OK: 25° Injection Pump Timing Marks Flywheel 20° 15° TDC Mark on Flywheel - Install rubber plug in flywheel housing, if equipped. - Remove timing tool. 1 - Install number one injection line. FAN/ALTERNATOR DRIVE BELT ADJUSTMENT Reason: Index Mark on Flywheel Housing To keep proper tension on belt to drive water pump and alternator. To prevent shortened belt and bearing life. Equipment: • JDG529 or JDST28 Belt Tension Gauge M82373A • Straight Edge Specifications: Procedure: Injection Pump Timing Mark 1. Check belt tension between fan and alternator using Belt Tension Gauge and a straight edge. 3TN75 (F1145 FM, 855/56 CUT). . . . . . . . . . . . . . .16° ± 1° BTDC . . . . . . . . . . . . . . . (Before Top Dead Center) 3TN78 (25 EX). . . . . . . . . . . . .16° ± 1° BTDC 3TNC78 (3011 OEM) . . . . . . .16° ± 1° BTDC 3TN82 (575 SSL) . . . . . . . . . . . . . .17° ± 1° BTDC (30 EX) . . . . . . . . . . . . . . . .16° ± 1° BTDC 3TNA82 (770 CUT) . . . . . . . . .16° ± 1° BTDC Belt Deflection M54014 3TN84 (870 CUT, 955 CUT, 3014 OEM) . . . . . . . . . .16° ± 1° BTDC 2-132 4/7/95 Checks, Tests and Adjustments Specifications: Applied Force . . . . . . . . . . .98 N (22 lb-force) Deflection . . . . . 10 - 15 mm (0.400 - 0.600 in.) Results: • If deflection is not within specifications: - Loosen both alternator mounting cap screws/ nuts. - Apply force to FRONT alternator housing only (near the belt) until tension is correct. - Tighten cap screws/nuts. ENGINE OIL COOLER LEAKAGE TEST - 3TN84 (955 CUT) Reason: Inspect oil cooler for leaks. Procedure: 1. Plug one end of coolant inlet or outlet passage. FUEL SHUTOFF SOLENOID ADJUSTMENT Reason: To ensure that fuel shutoff solenoid retracts fully, moving the injection pump shutoff control lever far enough to allow full rack travel. Procedure: 1. Loosen lock nut. 2. Disconnect link from solenoid. 3. Hold solenoid plunger bottomed in solenoid body. 4. Move link toward solenoid until it stops 5. Turn plunger rod in or out of knuckle until knuckle and link holes line up. Turn out two additional turns. The additional turns insure that the solenoid bottoms out before the linkage. 6. Assemble and check for free movement when key switch is turned ON. Also check that linkage returns completely to the STOP position when key switch is turned OFF. 2. Apply regulated air pressure of 206 - 483 kPa (30 - 70 psi) to other end. 3. Dip oil cooler into water and check for leaks. Plunger Optional test: If a leak did not appear, use a hot water bath to possibly open crack(s). Results: • Repair leak(s) or replace oil cooler if necessary. Link Knuckle Lock Nut M82141 4/7/95 2-133 2 Operational Tests RADIATOR, BUBBLE TEST • If air escapes from air cleaner, check for worn intake valve. Reason: • If air escapes from engine oil fill, check for worn piston rings. To determine if compression pressure is leaking from cylinder. Equipment: • JDG560 Adapter Procedure: 2 1. With coolant at proper level and radiator cap tight, run engine for 5 minutes to bring to operating temperature. 2. Remove cap from recovery tank. COOLING SYSTEM, PRESSURE TEST Reason: Inspect cooling system for leaks. Equipment: • D05104ST Cooling System Pressure Pump • JDG692 Radiator Pressure Test Kit (Adapters) 3. Check for bubbles coming from overflow hose at bottom of tank. Procedure: If bubbles are present, isolate source of compression leak: 2. Apply pressure according to specifications. - Remove injection nozzles. 1. Remove cap and attach pressure pump to radiator. 3. Check for leaks throughout cooling system. - Install JDG560 Adapter in injection port of cylinder to be tested. - Move piston to bottom of stroke with intake and exhaust valves closed. Cooling System Pressure Pump - Connect hose from compressed air source to adapter. - Apply the specified maximum air pressure into cylinder: 3TN75, 3TN78, 3TN82, 3TNA82, 3TN84 (870 CUT, 955 CUT) . . . . . 2448 kPa (355 psi) 3TNC78 (3011 OEM), 3TN84 (3014 OEM). . . . . . 2158 kPa (313 psi) - Check for bubbles in recovery tank or air escaping from muffler, air cleaner or oil fill opening. - Repeat for each cylinder. Results: • If bubbles are present, check for cracks in cylinder head and block. Check for damaged head gasket. T6333AW Specifications - 3TN75, 3TN84 (955 CUT): Maximum Pressure . . . . . . . . 117 kPa (17 psi) Minimum Pressure after 15 Seconds . . . . . . . . . . . 90 kPa (13 psi) Specifications - 3TN78, 3TNC78 (3011), 3TN82, 3TNA82, 3TN84 (870 CUT, 3014 OEM): Maximum Pressure . . . . . . . . . 97 kPa (14 psi) Minimum Pressure after 15 Seconds . . . . . . . . . 88 kPa (12.8 psi) • If air escapes from muffler, check for worn exhaust valve. 2-134 4/7/95 Operational Tests Results: Results: • Pressure should hold to specifications. If pressure decreases, check for leaks. Repair leaks or replace parts as necessary. • If cap leaks, retighten and test again. Replace cap if pressure is not within specification. • If pressure test still indicates leakage after all external leaks have been stopped, a defective head gasket, cracked block, or cylinder head may be the cause. Perform RADIATOR BUBBLE TEST. CYLINDER, COMPRESSION PRESSURE TEST RADIATOR CAP, PRESSURE TEST Reason: To determine the condition of the pistons, rings, cylinder walls and valves. 2 Equipment: Reason: Test radiator cap for operating in correct pressure range. • JT01682 Compression Gauge Assembly • JDG560 Adapter Procedure: Equipment: • D05104ST Cooling System Pressure Pump • JDG692 Radiator Pressure Test Kit (Adapters) Procedure: 1. Install radiator cap on pressure pump. 2. Apply pressure. Pressure valve in cap should open according to specifications. 1. Run engine for 5 minutes to bring to operating temperature. Shut off engine. 2. Remove injection nozzles. (See Fuel System in this section.) 3. Remove heat protector from end of injector and install on Adapter. 4. Install Adapter and Compression Gauge Assembly in injector port. Install retaining plate and tighten nuts to 4.5 N•m (39 lb-in.) 5. Hold fuel shut-off knob in shut-off position. Cooling System Pressure Pump 6. Crank engine for three seconds with starter. 7. Record pressure reading for each cylinder. Radiator Cap T6333AX Specifications: Valve Opening Pressure 3TN75, 3TN84 (955 CUT) . . . . . . . . . . 90 kPa (13 psi) 3TN78, 3TNC78 (3011), 3TN82, 3TNA82, 3TN84 (870 CUT, 3014 OEM) . . . . 88 kPa (12.8 psi) 4/7/95 JDG560 Adapter JT01682 Compression Gauge Assembly T6333EU 2-135 Operational Tests Specifications: Compression Pressure 3TN75, 3TN78, 3TN82, 3TNA82, 3TN84 (870 CUT, 955 CUT) . . . . . 2448 kPa (355 psi) 3TNC78 (3011 OEM), 3TN84 (3014 OEM). . . . . . 2158 kPa (313 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi) 2 NOTE: Pressure listed is for 300 m (1000 ft) above sea level. For naturally aspirated engines, reduce specification an additional 4% for each 300 m (1000 ft) of altitude. Results: • If pressure reading is below specification, squirt approximately two teaspoons of clean engine oil into cylinders through injector ports and repeat test. • If pressure increases significantly, check piston, rings and cylinder walls for wear or damage. • If pressure does not increase significantly after retest, check for leaking valves, valve seats or cylinder head gasket. ENGINE OIL PRESSURE TEST 5. Run engine approximately five minutes to heat oil, then check oil pressure at fast and/or slow idle. Specifications - 3TN75: F1145 FM Slow Idle. . . . . . . . . . . . . . . . . . 1450 ± 50 rpm Fast Idle . . . . . . . . . . . . . . . . . . . . . . 3425 rpm Oil Pressure . . . . . . . . . . . . . . . . 294 - 440 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 64 psi) 855/56 CUT Fast Idle . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm Oil Pressure . . . . . . . . . . . . . . . . 365 ± 69 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . (53 ± 10 psi) Specifications - 3TN78, 3TN82 (30 EX): Idle Speed Slow . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm Fast . . . . . . . . . . . . . . . . . . . . . . 2450 ± 25 rpm Oil Pressure Slow Idle. . . . . . . . . . . . . . . . . 262 kPa (38 psi) Fast Idle . . . . . . . . . . . . . . . . . . . 345 ± 48 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . . (50 ± 7 psi) Specifications - 3TNC78 (3011), 3TN84 (3014): To determine if engine bearings or lubrication system components are worn. Low Idle Speed Industrial . . . . . . . . . . . . . . . . . . . . . 1300 rpm Generator. . . . . . . . . . . . . . . . . . . . . 1200 rpm Oil Pressure . . . . . . . . . . . . . . . . . 147 kPa (21 psi) Equipment: Specifications - 3TN82 (575 SSL): Reason: • JT03017 Hose Assembly • JT05577 Pressure Gauge (100 psi) • JT05487 Connector (4TN78T) • JT03349 Connector (All Except 4TN78T) Procedure: 1. Remove oil pressure sender. 2. Install Connector. 3. Connect Hose Assembly and Pressure Gauge. IMPORTANT: Do not run if no pressure present. 4. Start engine. If pressure reading is below 69 kPa (10 psi), STOP ENGINE. 2-136 Idle Speed Slow . . . . . . . . . . . . . . . . . . . . . 1250 ± 25 rpm Fast . . . . . . . . . . . . . . . . . . . . . . 2875 ± 25 rpm Oil Pressure . . . . . . . . . . . . . . . . . . . 294 - 392 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 57 psi) Specifications - 3TNA82, 3TN84 (870 CUT): Fast Idle . . . . . . . . . . . . . . . . .2750 - 2800 rpm Oil Pressure . . . . . . . . . . . . . . . . 365 ± 69 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . (53 ± 10 psi) Specifications - 3TN84 (955 CUT): Fast Idle . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm Oil Pressure . . . . . . . . . . . . . . . . 365 ± 69 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . (53 ± 10 psi) 4/7/95 Operational Tests Results: • If oil pressure is not within specifications, inspect oil pressure regulating valve parts for wear or damage. Add or remove shims as necessary. (See Lubrication System in this section.) • If oil pressure does not increase, see “Engine Has Low Oil Pressure” in Diagnosis group. AIR INTAKE SYSTEM LEAKAGE TEST Reason: Check for leaks in air intake system. M82124 2 Results: • Find leaks and repair or replace parts as necessary. Equipment: • Air Pressure Regulator Procedure: 1. Remove air cleaner restriction indicator/switch and install test fitting. 2. Connect air pressure regulator to manifold using hose and fitting from air cleaner. 3. Remove air cleaner cover and main filter element. 4. Put large plastic bag into and over end of main filter element. Install main filter element and cover. 5. Pressurize air intake system between 34 - 69 kPa (5 - 10 psi). If air intake system cannot be pressurized, turn engine slightly to close valves. FUEL SUPPLY PUMP PRESSURE TEST - IF EQUIPPED NOTE: 3TN78 and 3TN82 engines are not equipped with a fuel supply pump. Reason: To determine supply pump operating pressure. Equipment: • JT03274 Hose Fitting • JT01609 Female Quick Coupler • JT03115 Gauge w/Male Quick Coupler (0 - 150 psi) 6. Spray soap solution over all connections from air cleaner to intake manifold or turbocharger, if equipped, and check for leaks. IMPORTANT: When reinstalling starting aid nozzle, position arrow on nozzle pointing against intake air flow. 4/7/95 2-137 Operational Tests Procedure: Procedure: 1. Disconnect supply pump-to-filter hose. 1. Disconnect fuel supply line and return line at fuel tank. 2. Install Hose Fitting, Coupler and Gauge. 3. Pull fuel shut-off cable out and crank engine using the starter. Do not run starter for more than 10 seconds at a time. Gauge should read more than 29 kPa (4.3 psi). JT03115 Gauge w/Male Quick Coupler JT01609 Female Quick Coupler 2 JT03274 Hose Fitting IMPORTANT: Fuel return line MUST extend below fuel level in fuel tank before performing this test. Fill fuel tank if necessary. 2. Drain all fuel from the system, including fuel supply pump, injection pump, filter(s) and water separator, if equipped. 3. Plug end of fuel return hose. 4. Pressurize fuel system at fuel supply line, to a maximum pressure of 103 kPa (15 psi). 5. Apply liquid soap and water solution to all joints and connections in the fuel system and inspect for leaks. Results: Fuel Filter Supply Pump-to Filter Hose • Find leaks and repair or replace parts as necessary. BLEED FUEL SYSTEM M82145A Results: • If pressure is below specification, repair or replace fuel supply pump. IMPORTANT: Modification or alteration of the injection pump, pump timing, or the injection nozzles in any way not approved by the manufacturer will terminate the warranty obligation. All engines are equipped with an automatic air venting system which makes the fuel system selfbleeding. FUEL DRAIN BACK TEST • Assure that all fuel line connections are securely tightened. Reason: • Add fuel to fuel tank. Determines if air is entering the fuel system at connections, allowing fuel to siphon back to tank. • Crank engine to allow fuel system to bleed itself. 2-138 4/7/95 4TN78T, 4TN82 AND 4TN84(T) (4019) ENGINES 3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cylinder Head, Valves and Manifolds . . . . . . . . . . . . . . . 3-17 Pistons, Rods and Cylinder Block . . . . . . . . . . . . . . . . . . 3-30 Crankshaft, Main Bearings and Flywheel . . . . . . . . . . . . 3-41 Camshaft and Timing Gear Train. . . . . . . . . . . . . . . . . . . 3-53 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119 Checks, Tests and Adjustments. . . . . . . . . . . . . . . . . . . 3-122 Operational Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-139 Section 3 3 3 Specifications ENGINE SPECIFICATIONS - 4TN78T Rocker Arm Cover Special Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (160 lb-in.) Rocker Arm Assembly Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Rocker Arm Shaft O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.97 - 15.98 mm (0.6286 - 0.6293 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.95 mm (0.6280 in.) Rocker Arm and Shaft Support I.D.'s Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.00 - 16.02 mm (0.630 - 0.631 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.09 mm (0.633 in.) Push Rod Length Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146.65 - 147.35 mm (5.774 - 5.801 in.) Push Rod Bend Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) or less Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) Cylinder Head and Valves Mounting Cap Screw Torque First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (16 lb-ft) Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 N•m (32 lb-ft) Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft) Cylinder Head Distortion Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) or less Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Maximum Amount of Metal to be Removed . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Valve Seat Width Intake Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36 - 1.53 mm (0.054 - 0.060 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.98 mm (0.078 in.) Exhaust Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66 - 1.87 mm (0.065 - 0.074 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 mm (0.089 in.) Intake and Exhaust Valves Valve Faces Minimum Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.) Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Valve Stem O.D. Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 mm (1.181 in.) Distance B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 mm (1.969 in.) Intake and Exhaust Valves Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm (0.2732 - 0.2740 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.90 mm (0.2717 in.) Valve Recession Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm (0.012 - 0.020 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.) 4/7/95 3 3-1 Specifications 3 Valve Guides Valve Guide I.D. Maximum Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm (0.275 - 0.276 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.08 mm (0.279 in.) Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 mm (0.472 in.) Valve Springs Spring Free Length Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 mm (1.575 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.50 mm (1.550 in.) Maximum Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 mm (0.044 in.) Exhaust Manifold Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Intake Manifold Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Valve Seat Angles Valve Seat Surface Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Lower Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70° Upper Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° Piston-to-Cylinder Head Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.59 - 0.77 mm (0.023 - 0.030 in.) Piston and Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft) Connecting Rod Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 - 43.042 mm (1.693 - 1.695 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.07 mm (1.696 in.) Piston Ring Groove Clearance First Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.070 - 0.105 mm (0.0028 - 0.0041 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Second Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 - 0.070 mm (0.0014 - 0.0028 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Oil Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.060 mm (0.0012 - 0.0024 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.) Piston Ring End Gap Compression Rings and Oil Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Pin Pin O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.991 - 23.00 mm (0.905 - 0.906 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.90 mm (0.902 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.018 mm (0.0007 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.00 - 23.009 mm (0.9055 - 0.9059 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.02 mm (0.906 in.) 3-2 4/7/95 Specifications Piston Pin, continued Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.025 - 23.038 mm (0.9065 - 0.9070 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.10 mm (0.909 in.) Piston O.D. Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 mm (0.905 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.895 - 77.925 mm (3.067 - 3.068 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.81 mm (3.063 in.) 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.15 - 78.18 mm (3.076 - 3.077 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.05 mm (3.073 in.) Cylinder Bore I.D. Standard Size Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.22 mm (0.009 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.00 - 78.03 mm (3.071 - 3.072 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.20 mm (3.079 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.25 - 78.28 mm (3.081 - 3.082 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.45 mm (3.089 in.) Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern Crankcase Extension Housing Mounting Cap Screw Torque Flywheel Housing/Plate-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Seal Case-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Extension-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Extension-to-Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Crankshaft Rear Oil Seal Seal Case-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Seal Case-to-Extension Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.) Crankshaft and Main Bearings Main Bearing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 N•m (58 lb-ft) Crankshaft Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0007 in.) Connecting Rod Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.952 - 42.962 mm (1.6910 - 1.6914 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.91 mm (1.689 in.) Main Bearing Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.952 - 46.962 mm (1.8485 - 1.8489 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.91 mm (1.847 in.) Main Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.00 - 47.045 mm (1.850 - 1.852 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.10 mm (1.8541 in.) Flywheel Maximum Distortion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 N•m (61 lb-ft) Flywheel Housing Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) 4/7/95 3 3-3 Specifications 3 Camshaft Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Camshaft Side Gap Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Maximum Camshaft Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.) Lobe Height Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.635 - 38.765 mm (1.521 - 1.526 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.40 mm (1.512 in.) Journal O.D. Gear Housing and Flywheel Ends Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.92 - 44.95 mm (1.769 - 1.770 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.) Intermediate Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.91 - 44.94 mm (1.768 - 1.769 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.990 - 45.055 mm (1.771 - 1.744 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.00 - 45.025 mm (1.772 - 1.773 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.) Cam Followers Stem O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.975 - 11.990 mm (0.471 - 0.472 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.93 mm (0.470 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.000 - 12.018 mm (0.472 - 0.473 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.05 mm (0.474 in.) Timing Gear Cover Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Cover Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Crankcase Extension Housing-to-Cover Cap Screw Torque . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Crankshaft Pulley Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (85 lb-ft) Idler Gear Shaft O.D Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.950 - 45.975 mm (1.809 - 1.810 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.93 mm (1.808 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.025 mm (1.811 - 1.812 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.08 mm (1.814 in.) Timing Gear Cover Mounting Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (220 lb-in.) Oil Pan and Strainer Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) 3-4 4/7/95 Specifications Oil Pump Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) Rotor Shaft O.D.-to-Backing Plate I.D. Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.0006 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.) Rotor Recess Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.10 mm (0.0020 - 0.0039 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Outer Rotor-to-Pump Body Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 - 0.16 mm (0.0035 - 0.0063 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Inner-to-Outer Rotor Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.04 mm (0.0008 - 0.0016 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Oil Cooler Oil Cooler-to-Mounting Block Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Mounting Block-to-Engine Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Piston Cooling Nozzle Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) Thermostat and Housing Thermostat Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Plate-to-Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Housing Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Water Pump Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Plate-to-Housing Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (134 lb-in.) Plug-to-Housing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) Bottom of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 mm (0.670 in.) Top of Impeller-to-Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.) below housing Fuel Injection Pump Injection Pump Gear Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 N•m (66 lb-ft) Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (19 lb-ft) Lube Line-to-Block Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (217 lb-in.) Fuel Injection Nozzles Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (39 lb-in.) Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 N•m (31 lb-ft) Separator Plate Nozzle Contact Surface Maximum Wear . . . . . . . . . . . . . . . . . . 0.10 mm (0.0039 in.) Starter - Hitachi 0.8 kW Cover Bushing (Reamed Out). . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.50 - 12.53 mm (0.492 - 0.493 in.) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.70 mm (0.303 in.) Alternator - Hitachi 25A Attaching Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Rotor Assembly Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) End Frame-to-Rectifier Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Stator-to-Rectifier Lead Wire Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.50 mm (1.300 in.) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 mm (0.220 in.) 4/7/95 3 3-5 Specifications 3 Checks, Tests and Adjustments Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Connecting Rod Side Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.0079 - 0.0157 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.) Connecting Rod Bearing Clearance Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 - 0.090 mm (0.0015 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.0063 in.) Crankshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 - 0.271 mm (0.004 - 0.011 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.) Crankshaft Main Bearing Clearance Main Bearing Cap Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 N•m (58 lb-ft) Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 - 0.090 mm (0.0015 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.0063 in.) Valve Lift (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 mm (0.350 in.) Camshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Timing Gear Backlash Standard Backlash All Except Crankshaft Gear-to-Oil Pump Gear . . . . . . . . 0.04 - 0.12 mm (0.0016 - 0.0047 in.) Crankshaft Gear-to-Oil Pump Gear . . . . . . . . . . . . . . . . . 0.11 - 0.19 mm (0.0043 - 0.0075 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Fuel Injection Nozzle Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19600 ± 480 kPa (2843 ± 70 psi) Leakage at 17640 kPa (2558 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum of 5 Seconds Chatter and Spray Pattern at 19600 ± 480 kPa (2843 ± 70 psi) Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chatter Sound Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Stream Spray Pattern Fast Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Atomized Spray Pattern Thermostat Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71° C (160°F) Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F) Minimum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0.310 in.) Coolant Temperature Switch Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . 107 - 133° C (225 - 235° F) Starter No-Load Amp Draw/RPM Maximum Starter Amperage Hitachi 0.8 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Amps at 7000 rpm Minimum Starter RPM Hitachi 0.8 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000 Fuel Injection Pump Static Timing Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14° BTDC (Before Top Dead Center) Engine Crankshaft Position . . . . . . . . . . . . . . . . . . . No. 1 Cylinder on TDC Compression Stroke Distance on Outer Surface of Flywheel Per 1° of Rotation . . . . . . . . . . . . . . . 2.88 mm (0.110 in.) Timing Lines on Pump Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5° Apart 3-6 4/7/95 Specifications Checks, Tests and Adjustments, continued Fan/Alternator Drive Belt Tension Applied Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N (22 lb-force) Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.) Oil Cooler Leakage Applied Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206 - 483 kPa (30 - 70 psi) Operational Tests Radiator, Bubble Test Maximum Air Pressure Into Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) Cooling System Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi) Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) Radiator Cap Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) Cylinder, Compression Pressure Minimum Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi) Engine Oil Pressure Idle Speed Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2750 ± 25 rpm Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm Oil Pressure Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 ± 48kPa (50 ± 7 psi) Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 kPa (31 psi) Air Intake System Holding Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 - 69 kPa (5 - 10 psi) Minimum Fuel Supply Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 kPa (4.3 psi) Fuel System Holding Pressure (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 kPa (15 psi) 3 ENGINE SPECIFICATIONS - 4TN82, 4TN84(T) (4019) Rocker Arm Cover Special Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (160 lb-in.) Rocker Arm Assembly Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Rocker Arm Shaft O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.97 - 15.95 mm (0.6286 - 0.6293 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.96 mm (0.6280 in.) Rocker Arm and Shaft Support I.D.'s Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.00 - 16.02 mm (0.630 - 0.631 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.09 mm (0.633 in.) Push Rod Length Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178.25 - 178.75 mm (7.018 - 7.037 in.) Push Rod Bend Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) or less Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) 4/7/95 3-7 Specifications 3 Cylinder Head and Valves Mounting Cap Screw Torque First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft) Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 N•m (58 lb-ft) Cylinder Head Distortion Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) or less Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Maximum Amount of Metal to be Removed . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Valve Seat Width Intake Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.07 - 1.24 mm (0.042 - 0.049 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74 mm (0.069 in.) Exhaust Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24 - 1.45 mm (0.049 - 0.057 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.94 mm (0.076 in.) Intake and Exhaust Valves Valve Faces Minimum Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.) Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Valve Stem O.D. Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 mm (1.181 in.) Distance B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 mm (2.360 in.) Intake Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.96 - 7.98 mm (0.3134 - 0.3142 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.3110 in.) Exhaust Valve Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.96 - 7.97 mm (0.3134 - 0.3138 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.3110 in.) Valve Recession Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm (0.012 - 0.020 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.) Valve Guides Valve Guide I.D. Maximum Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.01 - 8.03 (0.315 - 0.316 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10 mm (0.319 in.) Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 mm (0.591 in.) Valve Springs Spring Free Length Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 mm (1.575 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.50 mm (1.550 in.) Maximum Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 mm (0.044 in.) Exhaust Manifold Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Intake Manifold Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) 3-8 4/7/95 Specifications Valve Seat Angles Valve Seat Surface Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Lower Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70° Upper Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° Piston-to-Cylinder Head Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.64 - 0.82 mm (0.025 - 0.032 in.) Piston and Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N•m (35 lb-ft) Connecting Rod Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - 48.042 mm (1.888 - 1.891 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.07 mm (1.893 in.) Piston Ring Groove Clearance First Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 - 0.110 mm (0.0030 - 0.0043 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Second Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 - 0.080 mm (0.0018 - 0.0031 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Oil Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 - 0.060 mm (0.0010 - 0.0024 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Piston Ring End Gap 4TN82 Standard First Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.) Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.) Second Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.35 mm (0.008 - 0.014 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.) 4TN84 (4019D) Standard Compression Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.) Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.45 mm (0.010 - 0.018 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.) 4TN84T (4019T) Standard First Compression Ring and Oil Ring. . . . . . . . . . . . . . . . . . 0.25 - 0.45 mm (0.010 - 0.018 in.) Second Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Pin Pin O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.987 - 26.00 mm (1.023 - 1.024 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.90 mm (1.020 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.022 mm (0.0009 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.00 - 26.009 mm (1.0236 - 1.0240 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.02 mm (1.024 in.) 4/7/95 3 3-9 Specifications 3 Piston Pin, continued Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.025 - 26.038 mm (1.0246 - 1.0251 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.028 in.) Piston O.D. 4TN82 Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 mm (0.945 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.90 - 81.93 mm (3.224 - 3.225 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.80 mm (3.220 in.) 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.15 - 82.18 mm (3.234 - 3.235 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.05 mm (3.230 in.) 0.50 mm (0.020 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.40 - 82.42 mm (3.244 - 3.245 in.) Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.30 mm (3.240 in.) 4TN84(T) (4019) Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 mm (0.945 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.90 - 83.93 mm (3.303 - 3.304 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.80 mm (3.299 in.) 0.25 mm (0.10 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.15 - 84.18 mm (3.313 - 3.314 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.05 mm (3.309 in.) 0.50 mm (0.020 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.40 - 84.42 mm (3.323 - 3.324 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.30 mm (3.319 in.) Cylinder Bore I.D. 4TN82 Standard Size Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.00 - 82.03 mm (3.228 - 3.230 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.20 mm (3.236 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.25 - 82.28 mm (3.238 - 3.239 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.45 mm (3.246 in.) 0.50 mm (0.020 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.50 - 82.53 mm (3.248 - 3.249 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.70 mm (3.256 in.) 4TN84(T) (4019) Standard Size Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.00 - 84.03 mm (3.307 - 3.308 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.20 mm (3.315 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.25 - 84.28 mm (3.317 - 3.318 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.45 mm (3.325 in.) 3-10 4/7/95 Specifications 4TN84(T) (4019), continued 0.50 mm (0.020 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.50 - 84.53 mm (3.327 - 3.328 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.70 mm (3.335 in.) Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern Balancer Assembly - 4TN82RJK, 4TN84RJK Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Drive Gear Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 N•m (78 lb-ft) Retaining Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Crankcase Extension Housing Mounting Cap Screw Torque Flywheel Housing/Plate-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Seal Case-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Extension-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Extension-to-Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Crankshaft Rear Oil Seal Seal Case-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Seal Case-to-Extension Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.) Crankshaft and Main Bearings Main Bearing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N•m (72 lb-ft) Crankshaft Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0007 in.) Connecting Rod Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.952 - 47.962 mm (1.8879 - 1.8883 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.91 mm (1.886 in.) Main Bearing Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.952 - 46.962 mm (1.9666 - 1.9670 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.90 mm (1.965 in.) Main Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.00 - 50.045 mm (1.969 - 1.970 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.10 mm (1.972 in.) Flywheel Maximum Distortion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 N•m (61 lb-ft) Flywheel Housing Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Flywheel Plate Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Camshaft Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Camshaft Side Gap Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Maximum Camshaft Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.) Lobe Height Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.635 - 38.765 mm (1.521 - 1.526 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.40 mm (1.512 in.) 4/7/95 3-11 3 Specifications 3 Camshaft, continued Journal O.D. Gear Housing and Flywheel Ends Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.92 - 44.95 mm (1.769 - 1.770 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.) Intermediate Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.91 - 44.94 mm (1.768 - 1.769 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.990 - 45.055 mm (1.771 - 1.744 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.00 - 45.025 mm (1.772 - 1.773 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.) Cam Followers Stem O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.975 - 11.990 mm (0.471 - 0.472 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.93 mm (0.470 in.) Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.000 - 12.018 mm (0.472 - 0.473 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.05 mm (0.474 in.) Timing Gear Cover Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Cover Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Crankcase Extension Housing-to-Cover Cap Screw Torque . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.) Crankshaft Pulley Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (85 lb-ft) Idler Gear Shaft O.D Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.950 - 45.975 mm (1.809 - 1.810 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.93 mm (1.808 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.025 mm (1.811 - 1.812 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.08 mm (1.814 in.) Timing Gear Cover Mounting Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (220 lb-in.) Oil Pan and Strainer Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Oil Pump Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) Rotor Shaft O.D.-to-Backing Plate I.D. Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.0006 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.) Rotor Recess Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm (0.0011 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) 3-12 4/7/95 Specifications Oil Pump, continued Outer Rotor-to-Pump Body Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.17 mm (0.0039 - 0.0067 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Inner-to-Outer Rotor Clearance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.105 mm (0.0019 - 0.0041 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Oil Cooler - 4TN84T (4019TF001 and 005) Oil Cooler-to-Mounting Block Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Mounting Block-to-Engine Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Oil Pressure Regulating Valve - All Except 4TN84T (4019TF001 and 005) Spring Compressed Length . . . . . . . . . . . . . . . . . . . . . . . . .27.50 mm (1.080 in.) @ 20.5 N (4.6 lb-force) Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 mm (1.810 in.) Housing-to-Valve Body Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Housing-to-Engine Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Piston Cooling Nozzles - 4TN84T (4019TF001 and 005) Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) Thermostat and Housing - 4TN82RJE, 4TN82ESP and 4TN84(T) (4019) Thermostat Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Plate-to-Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Housing Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Thermostat - 4TN82RJK and 4TN84RJK Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Water Pump - 4TN82RJE, 4TN82ESP and 4TN84(T) (4019) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Plate-to-Housing Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (134 lb-in.) Plug-to-Housing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) 4TN82RJE and 4TN82ESP Top of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 mm (1.060 in.) Top of Impeller-to-Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.040 in.) below housing 4TN84(T) (4019) Bottom of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 mm (0.670 in.) Top of Impeller-to-Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.) below housing Water Pump - 4TN82RJK and 4TN84RJK Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Plate-to-Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) Adapter-to-Plate Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.) 4TN82RJK Top of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 mm (1.060 in.) Impeller-to-Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.040 in.) below housing 4TN84RJK Bottom of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 mm (0.670 in.) Impeller-to-Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.) below housing Fuel Supply Pump - All Except 4TN82RJE and 4TN82ESP External Lube Line Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) 4/7/95 3-13 3 Specifications 3 Fuel Injection Pump Injection Pump Gear Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 N•m (66 lb-ft) Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (19 lb-ft) Lube Line-to-Block Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (217 lb-in.) Fuel Injection Nozzles Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (39 lb-in.) Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 N•m (31 lb-ft) Separator Plate Nozzle Contact Surface Maximum Wear . . . . . . . . . . . . . . . . . . 0.10 mm (0.0039 in.) Starter Motor - 4TN82RJE (Hitachi 2.0 kW) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 mm (0.354 in.) Starter Motor - 4TN82RJK, 4TN84RJK (Nippondenso 1.0 kW) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mm (0.335 in.) Starter Motor - 4TN82ESP, 4TN84(T) (4019) (Nippondenso 1.4 kW) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mm (0.335 in.) Alternator - 4TN82RJK, 4TN84RJK (Kokosan 20A) Flywheel Assembly-to-Coil Plate Assembly Nut Torque . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Alternator - 4TN82, 4TN84RJK (Nippondenso 35A) Attaching Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Rotor Assembly Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Pulley Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) Stator-to-Rectifier Lead Wire Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.50 mm (1.300 in.) Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 mm (0.220 in.) Alternator - 4TN82ESP/RJE, 4TN84(T) (4019) (Nippondenso 40A) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft) Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Minimum Rotor Slip Ring O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 mm (0.550 in.) Brush Length New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50 mm (0.170 in.) Checks, Tests and Adjustments Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Connecting Rod Side Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.0079 - 0.0157 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.) Connecting Rod Bearing Clearance Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 - 0.090 mm (0.0015 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.0063 in.) Crankshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 - 0.271 mm (0.004 - 0.011 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.) Crankshaft Main Bearing Clearance Main Bearing Cap Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N•m (72 lb-ft) Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 - 0.090 mm (0.0015 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.0063 in.) Valve Lift (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 mm (0.350 in.) 3-14 4/7/95 Specifications Checks, Tests and Adjustments, continued Camshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) Timing Gear Backlash Standard Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.12 mm (0.0016 - 0.0047 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Fuel Injection Nozzle Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19600 ± 480 kPa (2843 ± 70 psi) Leakage at 17640 kPa (2558 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum of 5 Seconds Chatter and Spray Pattern at 19600 ± 480 kPa (2843 ± 70 psi) Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chatter Sound Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Stream Spray Pattern Fast Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Atomized Spray Pattern Thermostat Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71° C (160°F) Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F) Minimum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0.310 in.) Coolant Temperature Switch Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . 107 - 133° C (225 - 235° F) Starter No-Load Amp Draw/RPM Maximum Starter Amperage Hitachi 2.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Amps at 4500 rpm Nippondenso 1.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Amps at 3000 rpm Nippondenso 1.4 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Amps at 3500 rpm Minimum Starter RPM Hitachi 2.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500 Nippondenso 1.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 Nippondenso 1.4 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3500 Fuel Injection Pump Static Timing Adjustment Injection Pump Timing Mark 4TN82 (970 CUT, 675 SSL, 3325/65 GM) . . . . . . 15° ± 1° BTDC (Before Top Dead Center) 4TN84 (1070 CUT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° ± 1° BTDC (4019D OEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16° ± 1° BTDC 4TN84T (4019T OEM) 4019TF001 and 005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° ± 1° BTDC 4019TF006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12° ± 1° BTDC Engine Crankshaft Position . . . . . . . . . . . . . . . . . . . No. 1 Cylinder on TDC Compression Stroke Fan/Alternator Drive Belt Tension Applied Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N (22 lb-force) Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.) Oil Cooler Leakage - 4TN84T (4019TF001 and 005) Applied Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206 - 483 kPa (30 - 70 psi) Operational Tests Radiator, Bubble Test Maximum Air Pressure Into Cylinder 4TN82RJK, 4TN84RJK, 4TN82RJE, 4TN82ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) 4TN84(T) (4019) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi) 4/7/95 3-15 3 Specifications 3 Cooling System 4TN82RJK, 4TN84RJK, 4TN84(T) (4019) Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi) Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) 4TN82RJE, 4TN82ESP Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa (10 psi) Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 kPa (8 psi) Radiator Cap Valve Opening Pressure 4TN82RJK, 4TN84RJK, 4TN84(T) (4019) . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) 4TN82RJE, 4TN82ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 kPa (8 psi) Cylinder, Compression Pressure Minimum Compression Pressure 4TN82RJK, 4TN84RJK, 4TN82RJE, 4TN82ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) 4TN84(T) (4019) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi) Engine Oil Pressure 4TN82RJE Idle Speed Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800 rpm Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 ± 50 rpm Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 - 440 kPa (43 - 64 psi) 4TN82ESP Idle Speed Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2875 ± 25 rpm Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 ± 25 rpm Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 - 392 kPa (43 - 57 psi) 4TN82RJK, 4TN84RJK Fast Idle Speed 4TN82RJK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2750 - 2800 rpm 4TN84RJK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2850 - 2900 rpm Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 ± 69 kPa (53 ± 10 psi) 4TN84(T) (4019) Low Idle Speed Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 rpm Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 kPa (21 psi) Air Intake System Holding Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 - 69 kPa (5 - 10 psi) Minimum Fuel Supply Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 kPa (4.3 psi) Fuel System Holding Pressure (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 kPa (15 psi) 3-16 4/7/95 Cylinder Head, Valves and Manifolds SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the European Microfiche Tool Catalog (MTC). D-20018WI Valve Guide Knurler Use to knurl inside diameter of valve guides on 4TN78T engine. D-20019WI Valve Guide Knurler Use to knurl inside diameter of valve guides on 4TN82 and 4TN84(T)(4019) engines. JDE118 Valve Guide Driver Use to remove and install valve guides in cylinder head. D-20020WI Valve Guide Reamer Use to ream out new valve guides on 4TN78T engine. D-20021WI Valve Guide Reamer Use to ream out new valve guides on 4TN82 and 4TN84(T)(4019) engines. 3 SERVICE PARTS KITS The following kits are available through your parts catalog: 3 • Cylinder Head Gasket Kits 4/7/95 3-17 Cylinder Head, Valves and Manifolds ROCKER ARM COVER • Wash packing in a safe solvent and blow dry with air pressure. If packing comes apart or is deteriorated, replace it. Crankcase Breather Cover Oil Filler Cap Cap Screw (2) M8 x 16 O-Ring O-Ring Replace. Special Nut (3) 18 N•m (160 lb-in.) Extension If Equipped. Packing Screen 3 O-Ring (3) O-Ring If Equipped. 3 Crankcase Breather Tube Rocker Arm Cover O-Ring Seal M82189A 3-18 4/7/95 Cylinder Head, Valves and Manifolds ROCKER ARM ASSEMBLY • Inspect all parts for wear or damage. (See Inspection procedures.) Removal/Installation and Disassembly/Assembly • Lubricate all parts with clean oil during assembly. 1. Remove rocker arm cover. (See procedure in this group.) • Adjust valve clearance. (See Checks, Tests and Adjustments in this section.) • Remove and install studs using two M8 nuts. Rocker Arm Shaft Mounting Cap Screw (3) M8 x 25 26 N•m (226 lb-in.) Rocker Arm Shaft Spring 3 Mounting Cap Screw (7) M8 x 50 26 N•m (226 lb-in.) Rocker Arm Center Support (3) Nut Nut (3) M8 Exhaust Valve Rocker Arm Stud (3) Intake Valve Rocker Arm Valve Cap Adjusting Screw Push Rod Rocker Arm End Support (2) M82190A 4/7/95 3-19 3 Cylinder Head, Valves and Manifolds Inspection Rocker Arm and Shaft Support I.D.’s: • Measure outer diameter of rocker arm shaft. Standard. . . . . . . . . . . . . . . . 16.00 - 16.02 mm . . . . . . . . . . . . . . . . . . . . . . . .(0.630 - 0.631 in.) Wear Limit . . . . . . . . . . . 16.09 mm (0.633 in.) Clearance . . . . . . . . . . . . . 0.13 mm (0.005 in.) Replace rocker arms or supports if I.D. is more than wear limit. If shaft and support/arm clearance (support/arm I.D. minus shaft O.D.) exceed wear limit, replace all parts. • Measure length and bending of push rod. M35262 Rocker Arm Shaft O.D.: Standard. . . . . . . . . . . . . . . . 15.97 - 15.95 mm . . . . . . . . . . . . . . . . . . . . . .(0.6286 - 0.6293 in.) Wear Limit. . . . . . . . . . 15.95 mm (0.6280 in.) 3 Replace rocker arm shaft if less than wear limit. • Measure inner diameters of rocker arms and supports. Length 3 Feeler Gauge M82023A Push Rod Length: 4TN78T. . . . . . . . . . . . . . . 146.65 - 147.35 mm . . . . . . . . . . . . . . . . . . . . . . . .(5.774 - 5.801 in.) 4TN82, 4TN84(T)(4019) . . . . . . . . 178.25 - 178.75 mm . . . . . . . . . . . . . . . . . . . . . . . .(7.018 - 7.037 in.) Push Rod Bend: M82022A Standard. . . . . . . . 0.03 mm (0.001 in.) or less Wear Limit . . . . . . . . . . . . 0.30 mm (0.012 in.) Replace push rod if not within specifications. 3-20 4/7/95 Cylinder Head, Valves and Manifolds CYLINDER HEAD AND VALVES 4. Remove fuel injection nozzles. (See Fuel System in this section.) Removal/Installation 5. Disassemble and inspect cylinder head and valves. (See Disassembly/ Assembly and Inspection/Replacement procedures.) 1. Remove rocker arm assembly, push rods and valve caps. (See procedure in this group.) 2. Remove exhaust and intake manifolds. (See procedures in this group.) IMPORTANT: Oil passage in gasket must be located over oil passage in cylinder block. 3. Remove water pump. (See Cooling System in this section.) 3 Mounting Cap Screw (18) Dip entire cap screw in clean engine oil before installing. 3 Flywheel Cylinder Head Gasket M82191A 4/7/95 3-21 Cylinder Head, Valves and Manifolds 6. Tighten mounting cap screws, in the sequence shown, in three stages of gradually-increasing torque. IMPORTANT: Cylinder head mounting cap screws must be checked for proper torque after 50 hours of engine operation. Torque Specifications - 4TN82, 4TN84(T)(4019): First . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft) Second . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Final . . . . . . . . . . . . . . . . . . . 78 N•m (58 lb-ft) Disassembly/Assembly • Compress valve springs using a valve spring compressor. 18 16 12 10 14 8 3 6 1 2 5 4 7 9 Intake Manifold Side 3 13 11 15 17 Timing Gear Case Side Flywheel Side Exhaust Manifold Side • On 4TN78T, intake and exhaust valve seat inserts are press fit. Remove inserts only if replacement is necessary. • Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) M82025A IMPORTANT: Do not reuse stem seals if removed. Used seals will leak. Torque Specifications - 4TN78T: 3 • Intake and exhaust valve guides are press fit. Remove guides only if replacement is necessary. (See Inspection/Replacement procedures.) First . . . . . . . . . . . . . . . . . . . 22 N•m (16 lb-ft) Second . . . . . . . . . . . . . . . . . 43 N•m (32 lb-ft) Final . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft) • Apply clean engine oil on intake and exhaust valve stems during assembly. • Install springs with smaller pitch end or paint mark toward cylinder head. Stem Seal (8) Replace. Short Stud (8) Exhaust Valve Guide (4) Collet Halves (16) Retainer (8) Valve Spring (8) Intake Valve Guide (4) Lifting Bracket (2) Cap Screw (4) M10 x 20 Valve Seat Inserts 4TN78T Only. Exhaust Manifold Mounting Stud (2-Long or 4-Short) If equipped. Exhaust Valve Intake Valve 3-22 M82192A 4/7/95 Cylinder Head, Valves and Manifolds NOTE: If new valves are installed, measure valve recession. (See Inspection/Replacement procedures.) • Measure valve recession. (See procedure in this group.) • Measure valve seat width. After each valve has been assembled, tap on top of valve stem with a plastic hammer to seat retainer. Inspection/Replacement Before inspection, thoroughly clean all components of carbon or dirt. Cylinder Head: Valve Seat Width • Measure cylinder head flatness. Place a straightedge along each of the four sides and each diagonal. Measure clearance between straight edge and combustion surface with a feeler gauge. M82029A 3 Valve Seat Width - 4TN78T: Intake Valve M82027A Standard . . . . . . . . . . . . . . . . . 1.36 - 1.53 mm . . . . . . . . . . . . . . . . . . . . . . . (0.054 - 0.060 in.) Wear Limit. . . . . . . . . . . . 1.98 mm (0.078 in.) Exhaust Valve Standard . . . . . . . . . . . . . . . . . 1.66 - 1.87 mm . . . . . . . . . . . . . . . . . . . . . . . (0.065 - 0.074 in.) Wear Limit. . . . . . . . . . . . 2.27 mm (0.089 in.) Straight-Edge Feeler Gauge Valve Seat Width - 4TN82, 4TN84(T)(4019): Intake Valve M82028A Cylinder Head Distortion: Standard . . . . . . . 0.05 mm (0.002 in.) or less Wear Limit. . . . . . . . . . . . 0.15 mm (0.006 in.) If distortion exceeds the wear limit, resurface or replace cylinder head. Remove only enough metal to make cylinder head flat; but do not remove more than 0.20 mm (0.008 in.). If cylinder head was resurfaced: • Measure piston-to-cylinder head clearance. (See procedure in this group.) 4/7/95 Standard . . . . . . . . . . . . . . . . . 1.07 - 1.24 mm . . . . . . . . . . . . . . . . . . . . . . . (0.042 - 0.049 in.) Wear Limit. . . . . . . . . . . . 1.74 mm (0.069 in.) Exhaust Valve Standard . . . . . . . . . . . . . . . . . 1.24 - 1.45 mm . . . . . . . . . . . . . . . . . . . . . . . (0.049 - 0.057 in.) Wear Limit. . . . . . . . . . . . 1.94 mm (0.076 in.) If necessary, grind valve seats to meet specifications. (See GRIND VALVE SEATS procedure.) Intake and Exhaust Valves: • Check valve for out-of-round, bent or warped condition using a valve inspection center. Replace valve if necessary. 3-23 3 Cylinder Head, Valves and Manifolds Valve Stem O.D. - 4TN78T: Distance A . . . . . . . . . . . . . . . . .30 mm (1.181 in.) Distance B . . . . . . . . . . . . . . . . .50 mm (1.969 in.) Intake and Exhaust Valves Standard . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm . . . . . . . . . . . . . . . . . . . . . (0.2732 - 0.2740 in.) Wear Limit. . . . . . . . . . . 6.90 mm (0.2717 in.) Valve Stem O.D. - 4TN82, 4TN84(T)(4019): M35307 • If valve faces are worn, burned or pitted, grind valves to proper face angle. If valve face margin is less than 0.51 mm (0.020 in.) after grinding, replace valve. 3 3 Distance A . . . . . . . . . . . . . . . . .30 mm (1.181 in.) Distance B . . . . . . . . . . . . . . . . .60 mm (2.360 in.) Intake Valve Standard . . . . . . . . . . . . . . . . . 7.96 - 7.98 mm . . . . . . . . . . . . . . . . . . . . . (0.3134 - 0.3142 in.) Wear Limit. . . . . . . . . . . 7.90 mm (0.3110 in.) Exhaust Valve Valve Face Angle Valve Face Margin Exhaust: 45° Intake: 30° M82030A • Measure valve stem diameter at two locations shown. Replace valve if measurement exceeds wear limit. A Standard . . . . . . . . . . . . . . . . . 7.96 - 7.97 mm . . . . . . . . . . . . . . . . . . . . . (0.3134 - 0.3138 in.) Wear Limit. . . . . . . . . . . 7.90 mm (0.3110 in.) • Measure valve recession using a depth gauge. Replace valve or cylinder head if measurement exceeds wear limit. Valve Recession Cylinder Head B Depth Gauge M82031A M82032A 3-24 4/7/95 Cylinder Head, Valves and Manifolds Valve Recession: Standard . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . (0.012 - 0.020 in.) Wear Limit . . . . . . . . . . . 1.00 mm (0.039 in.) • Ream inside diameter of valve guides using: - 4TN78T: D-20020WI Valve Guide Reamer - 4TN82, 4TN84(T)(4019): D-20021WI Valve Guide Reamer Valve Guides: Clean valve guides using a valve guide brush. Measure valve guide inside diameter. A Valve Guide I.D. - 4TN78T: Standard . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm . . . . . . . . . . . . . . . . . . . . . . . (0.275 - 0.276 in.) Wear Limit . . . . . . . . . . . 7.08 mm (0.279 in.) Maximum Clearance . . . 0.20 mm (0.008 in.) Valve Guide I.D. - 4TN82, 4TN84(T)(4019): Standard . . . . . . . . . . . . . . . . . 8.01 - 8.03 mm . . . . . . . . . . . . . . . . . . . . . . . (0.315 - 0.316 in.) Wear Limit . . . . . . . . . . . 8.10 mm (0.319 in.) If diameter exceeds wear limit, knurl or replace guide. 3 M82193A Valve Springs: • Measure spring free length. Replace spring if measurement exceeds wear limit. If diameter is less than wear limit, determine guideto-stem clearance (guide diameter minus stem diameter). If clearance exceeds 0.15 mm (0.006 in.) but is less than 0.20 mm (0.008 in.), knurl valve guides. • Knurl valve guides using: - 4TN78T: D-20018WI Valve Guide Knurler - 4TN82, 4TN84(T)(4019): D-20019WI Valve Guide Knurler If clearance exceeds 0.20 mm (0.008 in.), replace valve guide. • Replace valve guides using JDE118 Valve Guide Driver. Intake and exhaust valve guides are different. The exhaust valve guide has one groove and the intake valve guide has none. Install valve guides with tapered ends down. Push valve guides down until top of valve guides are a specified distance (A) from top of cylinder head. M82034A Spring Free Length: Standard . . . . . . . . . . . . . . . 40 mm (1.575 in.) Wear Limit . . . . . . . . . . 39.50 mm (1.550 in.) Valve Guide Height “A”: 4TN78T . . . . . . . . . . . . . . . . 12 mm (0.472 in.) 4TN82, 4TN84(T)(4019) . . . 15 mm (0.591 in.) 4/7/95 3-25 3 Cylinder Head, Valves and Manifolds • Measure spring inclination. Replace spring if measurement exceeds specification. EXHAUST MANIFOLD 1. Remove muffler and gasket, if equipped. NOTE: Turbocharger removal/installation procedures are similar to unit used on Series 220 Engines. Follow procedures used in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section. Service procedures are also similar. 2. Remove turbocharger, if equipped. (See procedure in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section). 3 Square Gauge Spring Inclination 1.10mm (0.044 in.) Free Length 3 M82035A INTAKE MANIFOLD NOTE: Air heater removal/installation is similar to procedures found in ACCESSORIES SERIES 220 POWER UNIT ENGINES section. 1. Remove intake air heater. (See procedure in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section.) 2. Remove fuel filter assembly mounting cap screw(s), if equipped. 3. Remove fuel injection lines. (See Fuel System in this section.) 4. OEM Power Unit engine (4019): • Remove air cleaner and mount bracket. • Remove instrument panel and bracket. • Remove radiator support rod. (See procedures in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section.) 3-26 4/7/95 Cylinder Head, Valves and Manifolds Nut (4) M8 26 N•m (226 lb-in.) Exhaust Manifold Cap Screw (2) M8 x 60 26 N•m (226 lb-in.) Stud (4) Cap Screw (6) M8 x 80 26 N•m (226 lb-in.) Gasket Nut (2) M10 26 N•m (226 lb-in.) Cap Screw Long 26 N•m (226 lb-in.) 4TN82RJK, 4TN84RJK 4TN82ESP/RJE, 4TN84(4019D) Exhaust Manifold Stud (3) 3 Gasket Exhaust Manifold Cap Screw M8 x 85 26 N•m (226 lb-in.) Gasket Cap Screw (4) M8 x 100 26 N•m (226 lb-in.) Cap Screw (3) M8 x 65 26 N•m (226 lb-in.) 4TN78T, 4TN84T(4019T) M82195A Intake Manifold Gasket Intake Manifold Gasket 4TN78T, 4TN82, 4TN84 Cap Screw (5) M8 x 35 26 N•m (226 lb-in.) Cap Screw (5) M8 x 35 26 N•m (226 lb-in.) 4TN84(T)(4019) M82194A 4/7/95 3-27 3 Cylinder Head, Valves and Manifolds GRIND VALVE SEATS IMPORTANT: Valve seats should never be cut. Cutting a valve seat can damage its sealing surface, which may result in leaks or valve/ seat failure. Valve seats should be ground and lapped. NOTE: LIGHTLY grind valve seats for a few seconds only to avoid excessive valve seat width. 1. Grind intake valve seat using a 30° seat grinder and exhaust valve seat using a 45° seat grinder. Follow tool manufacturers instructions. Lower Seat Surface 70° Valve Seat Upper Seat Surface 15° Seat Width Cylinder Head M82040A 3 Seat Grinder 3 If valve recession exceeds maximum specifications or seats cannot be reconditioned, replace valves, valve seats if equipped and/or cylinder head. NOTE: Valve seat inserts are available for 4TN78T engine only. LAP VALVES M82039A 2. Measure valve seat width after grinding. 3. If seat is too wide after grinding, grind lower seat surface using a 70° seat grinder until seat width is close to specifications. 4. Grind upper seat surface using a 15° seat grinder until seat width is narrowed to specifications. 5. If valve seats are ground, measure valve recession and check contact pattern between the seat and valve with bluing dye. 6. Lap valves. (See procedure in this group.) 3-28 NOTE: Use a rubber type lapping tool for valves without a lapping tool groove slit. If seat does not make proper contact, lap the valve into the seat: 1. Apply small amount of fine lapping compound to face of valve. 2. Turn valve to lap valve to seat. 3. Lift valve from seat every 8 to 10 strokes. Lap until a uniform ring appears around the surface of the valve face. 4. Wash all parts in solvent to remove lapping compound. Dry parts. 4/7/95 Cylinder Head, Valves and Manifolds 5. Check position of lap mark on valve face. Lap mark must be on or near center of valve face. 3. Slowly turn crankshaft one complete revolution. 4. Remove cylinder head and gasket. 5. Measure thickness of flattened section of each piece of wire. Calculate average thickness of wires to obtain piston-to-cylinder head clearance specification. Lapping Tool M82041A 3 MEASURE PISTON-TO-CYLINDER HEAD CLEARANCE 1. Place three 10 mm (0.400 in.) long pieces of 1.50 mm (0.060 in.) diameter soft wire in three positions on the flat part of the piston head. 2. Install cylinder head and old gasket. Install cylinder head cap screws and tighten in proper sequence to specified torque. (See CYLINDER HEAD AND VALVES - Removal/Installation in this group.) M82042A 3 Piston-to-Cylinder Head Clearance: 4TN78T . . . . . . . . . . . . . . . . . . .0.59 - 0.77 mm . . . . . . . . . . . . . . . . . . . . . . . (0.023 - 0.030 in.) 4TN82, 4TN84(T)(4019) . . . . .0.64 - 0.82 mm . . . . . . . . . . . . . . . . . . . . . . . (0.025 - 0.032 in.) If clearance is less than specifications, replace cylinder head. 4/7/95 3-29 Pistons, Rods and Cylinder Block SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Block Gasket Kit • Cylinder Head Gasket Kit • Oversized Pistons and Rings • Undersized Connecting Rod Bearing Inserts 3 3-30 4/7/95 Pistons, Rods and Cylinder Block PISTON AND CONNECTING ROD Removal 1. Remove oil pan and strainer tube. (See Lubrication System in this section.) 2. Remove cylinder head. (See Cylinder Head, Valves and Manifolds in this section.) 3. Check cylinder bore for ridges. These ridges can cause damage to piston if ridge is not removed. 4. If necessary, remove ridge from top of cylinder bore using a ridge reamer. Piston and Connecting Rod 5. Measure connecting rod side play. (See Checks, Tests and Adjustments in this section.) 6. Measure connecting rod bearing clearance. (See Checks, Tests and Adjustments in this section.) IMPORTANT: Keep connecting rods and caps together. Rods and caps are a matched set. Note alignment marks on each part. Bearing Inserts 3 Connecting Rod Cap 7. Remove two cap screws, connecting rod cap and bearing inserts. IMPORTANT: Pistons and cylinders are matched. Pistons must be installed in the cylinders from which they are removed. 8. Note connecting rod alignment mark in relation to the cylinders. Starting at flywheel end with cylinder number one, then two, etc. 9. Push piston and connecting rod out of cylinder bore using a wooden dowl. 10.Disassemble and inspect all parts for wear or damage. (See Disassembly and Inspection/ Replacement procedures.) Connecting Rod Cap Screw Replace. M82196A Installation • Apply clean engine oil on all parts during installation. • Never reuse connecting rod cap screws, replace with new. IMPORTANT: Pistons must be installed in cylinders from which they were removed and in the same direction. Be careful not to damage crankshaft rod journal while installing piston. 1. If new piston rings were installed, deglaze cylinder bore. (See procedure in this group.) 2. Install piston and connecting rod into the cylinder from which it was removed, with piston size mark on top of piston toward fuel injection pump. 4/7/95 3-31 Pistons, Rods and Cylinder Block IMPORTANT: Do not touch bearing insert surfaces. Oil and acid from your finger will corrode the bearing surface. 3. Install bearing inserts on connecting rod and rod cap, aligning tangs with grooves. IMPORTANT: Connecting rod caps must be installed on the same connecting rods they were removed from. 3 7. Install cylinder head. (See Cylinder Head, Valves and Manifolds in this section.) 8. Install oil pan and strainer tube. (See Lubrication System in this section.) Disassembly IMPORTANT: Pistons must be installed on the same connecting rod they were removed from. 4. Match the connecting rods to caps using alignment marks. Install caps. • Put a mark on each piston and connecting rod to aid in assembly. 5. Dip entire connecting rod cap screws in clean engine oil. Install new cap screws and tighten to specifications. • Piston pin bushing is press fit in connecting rod. Remove bushing only if replacement is necessary. (See Inspection/Replacement procedures.) Connecting Rod Cap Screw Torque Specifications: 4TN78T . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft) 4TN82, 4TN84(T)(4019) . . . 47 N•m (35 lb-ft) 6. If a new piston and connecting rod were installed, stamp a number corresponding to the cylinder number on the connecting rod cap and connecting rod • Inspect all parts for wear or damage. Replace as necessary. (See Inspection/Replacement procedures.) 1st Compression Ring 2nd Compression Ring Piston Size Mark Fuel Injection Pump Side Oil Ring with Coil Expander Piston Flywheel Side Piston Pin Snap Ring Groove Tangs Connecting Rod Cap Alignment Mark Connecting Rod Cap Screw Piston Pin Bushing Connecting Rod Groove M82197A M82196A 3-32 4/7/95 Pistons, Rods and Cylinder Block Assembly • Apply clean engine oil to all parts during assembly. IMPORTANT: Pistons must be installed on the same connecting rod they were removed from. 1. Assemble piston to connecting rod with piston size mark on same side as connecting rod “punched” alignment mark. If a new connecting rod is used, assemble piston to connecting rod with piston size mark opposite connecting rod bearing insert groove. Oil Ring Expander Oil Ring Gap Oil Ring Expander Ends 2. Install piston pin and snap rings. Oil Ring Piston Pin M82046A Piston Size Mark Piston 5. Install second compression ring, with small diameter of taper toward top of piston, in middle groove. Turn ring until gap is 120o away from oil ring gap. Piston Pin 6. Install first compression ring (chrome plated), with manufacturer's mark “R”, “T” or “RN” (near ring gap) toward top of piston, in top groove. Turn ring until gap is 120o away from second ring gap. 1st Compression Ring Snap Ring 2nd Compression Ring Connecting Rod Bearing Insert Groove Alignment Mark 1st Compression Ring M82198A 3. Install oil ring expander in bottom ring groove of piston with ends above either end of piston pin. 2nd Compression Ring 120° 120° 120° Oil Ring 4. Install oil ring over expander with ring gap opposite (180o) of expander ends. M82199A 4/7/95 3-33 3 Pistons, Rods and Cylinder Block Inspection/Replacement 1. Inspect all parts for wear or damage. Replace as necessary. If bearing diameter exceeds wear limit, replace bearing inserts. 2. Measure crankshaft connecting rod journal diameter. (See Crankshaft, Main Bearings and Flywheel in this section.) If bearing clearance (bearing I.D. minus crankshaft journal O.D.) exceeds specification, grind crankshaft connecting rod journals and install undersized bearing inserts, or replace bearing inserts and crankshaft. 3. Install connecting rod cap and bearing inserts on connecting rod. Install old connecting rod cap screws and tighten to specifications. 5. With rings installed on piston, measure piston ring groove clearance. Measure several places around each piston. Connecting Rod Cap Screw Torque Specifications: 4TN78T . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft) 4TN82, 4TN84(T) (4019) . . 47 N•m (35 lb-ft) 3 4. Measure connecting rod bearing diameter. M35360 Piston Ring Groove Clearance - 4TN78T: First Compression Ring Standard . . . . . . . . . . . . . . . 0.070 - 0.105 mm . . . . . . . . . . . . . . . . . . . . . (0.0028 - 0.0041 in.) Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) M82048A Connecting Rod Bearing I.D. - 4TN78T: Standard . . . . . . . . . . . . . . . . 43 - 43.042 mm . . . . . . . . . . . . . . . . . . . . . . . (1.693 - 1.695 in.) Wear Limit. . . . . . . . . . . 43.07 mm (1.696 in.) Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.) Connecting Rod Bearing I.D. - 4TN82, 4TN84(T)(4019): Second Compression Ring Standard . . . . . . . . . . . . . . . 0.035 - 0.070 mm . . . . . . . . . . . . . . . . . . . . . (0.0014 - 0.0028 in.) Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) Oil Ring Standard . . . . . . . . . . . . . . . 0.030 - 0.060 mm . . . . . . . . . . . . . . . . . . . . . (0.0012 - 0.0024 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0078 in.) Standard . . . . . . . . . . . . . . . . 48 - 48.042 mm . . . . . . . . . . . . . . . . . . . . . . . (1.888 - 1.891 in.) Wear Limit. . . . . . . . . . . 48.07 mm (1.893 in.) Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.) 3-34 4/7/95 Pistons, Rods and Cylinder Block Piston Ring Groove Clearance - 4TN82, 4TN84(T)(4019): First Compression Ring Standard . . . . . . . . . . . . . . . 0.075 - 0.110 mm . . . . . . . . . . . . . . . . . . . . . (0.0030 - 0.0043 in.) Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) Piston Ring End Gap - 4TN78T: Compression Rings and Oil Ring Standard . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.) Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Ring End Gap - 4TN82: Second Compression Ring Standard . . . . . . . . . . . . . . . . 0.45 - 0.080 mm . . . . . . . . . . . . . . . . . . . . . (0.0018 - 0.0031 in.) Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) Oil Ring Standard . . . . . . . . . . . . . . . 0.025 - 0.060 mm . . . . . . . . . . . . . . . . . . . . . (0.0010 - 0.0024 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) If clearance exceeds wear limit, replace rings or piston. 6. Measure piston ring end gap. Push ring into cylinder bore, using a piston, until ring is approximately 30 mm (1.181 in.) from bottom of cylinder bore. End Gap Cylinder Bore Standard First Compression Ring . . . . 0.25 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.016 in.) Second Compression Ring . . 0.20 - 0.35 mm . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.014 in.) Oil Ring . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.) Wear Limit: . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Ring End Gap - 4TN84 (4019D): Standard Compression Rings . . . . . . . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.) Oil Ring . . . . . . . . . . . . . . . . . 0.25 - 0.45 mm . . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.018 in.) Wear Limit: . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Ring End Gap - 4TN84T (4019T): Standard First Compression Ring and Oil Ring . . . . . . . . . . . . . 0.25 - 0.45 mm . . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.018 in.) Second Compression Ring . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.) Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.) If end gap exceeds wear limit, replace rings. 7. Measure piston pin diameter. Measure diameter at six places. Piston Ring Approx. 30 mm (1.181 in.) End Gap 4/7/95 M82049A 3-35 3 Pistons, Rods and Cylinder Block Piston Pin Bore I.D. - 4TN78T: Standard . . . . . . . . . . . . . . 23.00 - 23.009 mm . . . . . . . . . . . . . . . . . . . . . (0.9055 - 0.9059 in.) Wear Limit. . . . . . . . . . . 23.02 mm (0.906 in.) Clearance . . . . . . . . . . . 0.018 mm (0.0007 in.) Piston Pin Bore I.D. - 4TN82, 4TN84(T)(4019): Standard . . . . . . . . . . . . . . 26.00 - 26.009 mm . . . . . . . . . . . . . . . . . . . . . (1.0236 - 1.0240 in.) Wear Limit. . . . . . . . . . . 26.02 mm (1.024 in.) Clearance . . . . . . . . . . . 0.022 mm (0.0009 in.) If piston pin bore exceeds wear limit, replace piston. Measuring Positions 3 If bore clearance (bore I.D. minus pin O.D.) exceeds specification, replace piston, piston pin or both. 9. Measure piston connecting rod. pin bushing diameter in M82050A Piston Pin O.D. - 4TN78T: Standard . . . . . . . . . . . . . . 22.991 - 23.00 mm . . . . . . . . . . . . . . . . . . . . . . . (0.905 - 0.906 in.) Wear Limit. . . . . . . . . . . 22.90 mm (0.902 in.) Piston Pin O.D. - 4TN82, 4TN84(T)(4019): Standard . . . . . . . . . . . . . . 25.987 - 26.00 mm . . . . . . . . . . . . . . . . . . . . . . . (1.023 - 1.024 in.) Wear Limit. . . . . . . . . . . 25.90 mm (1.020 in.) M82051A If pin diameter is less than wear limit, replace pin. 8. Measure piston pin bore diameter in piston. Piston Pin Bushing I.D. - 4TN78T: Standard . . . . . . . . . . . . . 23.025 - 23.038 mm . . . . . . . . . . . . . . . . . . . . . (0.9065 - 0.9070 in.) Wear Limit. . . . . . . . . . . 23.10 mm (0.909 in.) Clearance . . . . . . . . . . . 0.110 mm (0.0043 in.) Piston Pin Bushing I.D. - 4TN82,4TN84(T)(4019): M37683 3-36 Standard . . . . . . . . . . . . . 26.025 - 26.038 mm . . . . . . . . . . . . . . . . . . . . . (1.0246 - 1.0251 in.) Wear Limit. . . . . . . . . . . 26.10 mm (1.028 in.) Clearance . . . . . . . . . . . 0.110 mm (0.0043 in.) 4/7/95 Pistons, Rods and Cylinder Block If bushing diameter exceeds wear limit, replace bushing. If bushing clearance (bushing I.D. minus pin O.D.) exceeds specification, replace bushing, piston pin or both. Piston pin bushing is press fit. Replace bushing using a driver set. When installing bushing, make sure to align oil hole in bushing with hole in connecting rod. 10.Measure piston diameter perpendicular to piston pin bore at distance A. NOTE: If engine has had a previous major overhaul, oversize pistons and rings may have been installed. Pistons and rings are available in 0.25 mm (0.010 in.) oversize for all engines and 0.50 mm (0.020 in.) oversize for 4TN82 and 4TN84(T)(4019). Piston O.D. - 4TN78T: Distance A . . . . . . . . . . . . . . . . .23 mm (0.905 in.) Standard Size Piston Standard . . . . . . . . . . . . . 77.895 - 77.925 mm . . . . . . . . . . . . . . . . . . . . . . . (3.067 - 3.068 in.) Wear Limit. . . . . . . . . . . 77.81 mm (3.063 in.) 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . 78.15 - 78.18 mm . . . . . . . . . . . . . . . . . . . . . . . (3.076 - 3.077 in.) Wear Limit. . . . . . . . . . . 78.05 mm (3.073 in.) Piston O.D. - 4TN82: Distance A . . . . . . . . . . . . . . . . .24 mm (0.945 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . 81.90 - 81.93 mm . . . . . . . . . . . . . . . . . . . . . . . (3.224 - 3.225 in.) Wear Limit. . . . . . . . . . . 81.80 mm (3.220 in.) 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . 82.15 - 82.18 mm . . . . . . . . . . . . . . . . . . . . . . . (3.234 - 3.235 in.) Wear Limit. . . . . . . . . . . 82.05 mm (3.230 in.) 0.50 mm (0.020 in.) Oversize Piston A M82200A Standard . . . . . . . . . . . . . . . 82.40 - 82.42 mm . . . . . . . . . . . . . . . . . . . . . . . (3.244 - 3.245 in.) Wear Limit. . . . . . . . . . . 82.30 mm (3.240 in.) Piston O.D. - 4TN84(T)(4019) Distance A . . . . . . . . . . . . . . . . .24 mm (0.945 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . 83.90 - 83.93 mm . . . . . . . . . . . . . . . . . . . . . . . (3.303 - 3.304 in.) Wear Limit. . . . . . . . . . . 83.80 mm (3.299 in.) 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . 84.15 - 84.18 mm . . . . . . . . . . . . . . . . . . . . . . . (3.313 - 3.314 in.) Wear Limit. . . . . . . . . . . 84.05 mm (3.309 in.) M82052A 4/7/95 3-37 3 Pistons, Rods and Cylinder Block 0.50 mm (0.020 in.) Oversize Piston Cylinder Bore I.D. - 4TN78T: Standard . . . . . . . . . . . . . . . 84.40 - 84.42 mm . . . . . . . . . . . . . . . . . . . . . . . (3.323 - 3.324 in.) Wear Limit. . . . . . . . . . . 84.30 mm (3.319 in.) If piston diameter is less than wear limit, install a new piston. 11.Measure cylinder bore diameter. (See procedure in this group.) Standard Size Bore Standard . . . . . . . . . . . . . . . 78.00 - 78.03 mm . . . . . . . . . . . . . . . . . . . . . . . (3.071 - 3.072 in.) Wear Limit . . . . . . . . . . 78.20 mm (3.079 in.) Clearance . . . . . . . . . . . . . 0.22 mm (0.009 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . 78.25 - 78.28 mm . . . . . . . . . . . . . . . . . . . . . . . (3.081 - 3.082 in.) Wear Limit. . . . . . . . . . . 78.45 mm (3.089 in.) CYLINDER BORE Inspection 3 Measure cylinder bore diameter at three positions; top, middle and bottom. At these three positions, measure in both directions; along crankshaft center line and direction of crankshaft rotation. NOTE: If engine has had a previous major overhaul, oversize pistons and rings may have been installed. Cylinder Bore I.D. - 4TN82: Standard Size Bore Standard . . . . . . . . . . . . . . . 82.00 - 82.03 mm . . . . . . . . . . . . . . . . . . . . . . . (3.228 - 3.230 in.) Wear Limit . . . . . . . . . . 82.20 mm (3.236 in.) Clearance . . . . . . . . . . . . . 0.35 mm (0.014 in.) 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . 82.25 - 82.28 mm . . . . . . . . . . . . . . . . . . . . . . . (3.238 - 3.239 in.) Wear Limit. . . . . . . . . . . 82.45 mm (3.246 in.) Top Position 0.50 mm (0.020 in.) Oversize Bore Middle Position Standard . . . . . . . . . . . . . . . 82.50 - 82.53 mm . . . . . . . . . . . . . . . . . . . . . . . (3.248 - 3.249 in.) Wear Limit. . . . . . . . . . . 82.70 mm (3.256 in.) Bottom Position Cylinder Bore I.D. - 4TN84(T)(4019): Standard Size Bore Direction of Crankshaft Rotation Standard . . . . . . . . . . . . . . . 84.00 - 84.03 mm . . . . . . . . . . . . . . . . . . . . . . . (3.307 - 3.308 in.) Wear Limit . . . . . . . . . . 84.20 mm (3.315 in.) Clearance . . . . . . . . . . . . . 0.35 mm (0.014 in.) Direction of Crankshaft Centerline 0.25 mm (0.010 in.) Oversize Bore M82053A 3-38 Standard . . . . . . . . . . . . . . . 84.25 - 84.28 mm . . . . . . . . . . . . . . . . . . . . . . . (3.317 - 3.318 in.) Wear Limit. . . . . . . . . . . 84.45 mm (3.325 in.) 4/7/95 Pistons, Rods and Cylinder Block 0.50 mm (0.020 in.) Oversize Bore Standard . . . . . . . . . . . . . . . 84.50 - 84.53 mm . . . . . . . . . . . . . . . . . . . . . . . (3.327 - 3.328 in.) Wear Limit. . . . . . . . . . . 84.70 mm (3.335 in.) If cylinder bore exceeds wear limit, replace cylinder block or have cylinder rebored. (See Reboring procedure.) If cylinder is rebored, oversize pistons and rings must be installed. Pistons and rings are available in 0.25 mm (0.010 in.) oversize for all engines and 0.50 mm (0.020 in.) oversize for 4TN82 and 4TN84(T)(4019). If clearance (cylinder bore I.D. minus piston O.D.) exceeds specification, replace cylinder block, piston or both; or rebore cylinder and install oversize piston and rings. Deglazing IMPORTANT: If cylinder bores are to be deglazed with crankshaft installed in engine, put clean shop towels over crankshaft to protect journal and bearing surfaces from any abrasives. 1. Deglaze cylinder bores using a flex-hone with 180 grit stones. 2. Use flex-hone as instructed by manufacturer to obtain a 30 - 40° cross-hatch pattern as shown. IMPORTANT: Do not use gasoline, kerosene or commercial solvents to clean cylinder bores. Solvents will not remove all abrasives from cylinder walls. 3. Remove excess abrasive residue from cylinder walls using a clean dry rag. Clean cylinder walls using clean white rags and warm soapy water. Continue to clean cylinder until white rags show no discoloration. 4/7/95 M82054A Reboring NOTE: The cylinder block can be rebored to use oversize pistons and rings. Pistons and rings are available in 0.25 mm (0.010 in.) oversize for all engines and 0.50 mm (0.020 in.) oversize for 4TN82 and 4TN84(T)(4019). (See this group for cylinder bore I. D. specifications.) 1. Align center of bore to drill press center. IMPORTANT: Check stone for wear or damage. Use a rigid hone with 300 grit stones. 2. Adjust hone so lower end is even with lower end of cylinder bore. 3. Adjust rigid hone stones until they contact narrowest point of cylinder. 4. Coat cylinder with honing oil. Hone should turn by hand. Adjust if too tight. 5. Run drill press at about 250 RPM. Move hone up and down in order to obtain a 30 - 40°crosshatch pattern. 3-39 3 Pistons, Rods and Cylinder Block NOTE: Measure bore when cylinder is cool. 6. Stop press and check cylinder diameter. NOTE: Finish should not be smooth. It should have a 30 - 40o crosshatch pattern. 30 - 40° 7. Remove rigid hone when cylinder is within 0.03 mm (0.001 in.) of desired size. 8. Use a flex hone with 180 grit stones for honing to final size. 9. Check bore for size, taper and out-of-round. (See Inspection procedures.) IMPORTANT: Do not use solvents to clean cylinder bore. Solvents will not remove all metal particles and abrasives produced during honing. M52959 3 10.Clean cylinder thoroughly using warm soapy water until clean white rags show no discoloration. 11.Dry cylinder and apply engine oil. 3-40 4/7/95 Crankshaft, Main Bearings and Flywheel OTHER MATERIALS Number Name Use John Deere Form-In-Place Gasket Seals crankcase extension housing, rear oil seal case and flywheel housing to engine block. LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. TY15130/ NA/ #395 SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Block Gasket Kit • Undersized Main Bearing Inserts 3 ®LOCTITE is a registeredtrademark of the Loctite Corp. 4/7/95 3-41 Crankshaft, Main Bearings and Flywheel BALANCER ASSEMBLY - 4TN82RJK, 4TN84RJK Oil Strainer O-Ring Replace. Removal/Installation 1. Remove oil pan. (See Lubrication System in this section.) NOTE: Crankcase extension is removed to show detail. 2. Align balancer-to-crankshaft timing marks. IMPORTANT: Rotate crankshaft to find timing marks or scribe a mark across balancer gear and crankshaft gear teeth before removing balancer assembly. Mounting Cap Screw (6) 27 N•m (20 lb-ft) M48309 3 Installation is done in the reverse order of removal. • Align balancer-to-crankshaft timing marks when installing balancer assembly. 3 Timing Marks Disassembly/Assembly 1. Remove nut, drive gear, cap screws and shaft assemblies. NOTE: Driven gears are press fit on balancer shafts. 2. Remove driven gear using a knife-edge puller and a press. 3. Remove retaining plate. M48268 3. Remove oil strainer. (See Lubrication System in this section.) 4. Remove six mounting cap screws. 5. Remove balancer assembly and o-ring. 6. Disassemble and inspect balancer assembly. (See Disassembly/Inspection procedures.) 3-42 4. Inspect all parts for wear or damage. Replace as necessary. NOTE: Shaft bushings cannot be replaced separately. Replace balancer housing if necessary. If drive gear is damaged, check balancer gear on crankshaft for damage. Replace if necessary. (See CRANKSHAFT Inspection/Replacement procedure in this group.) 4/7/95 Crankshaft, Main Bearings and Flywheel Housing Shaft Bushing Timing Marks Nut 106 N•m (78 lb-ft) Drive Gear M48312 Driven Gear Shaft Retaining Plate Cap Screw (2) M8 x 16 27 N•m (20 lb-ft) CRANKCASE EXTENSION HOUSING 4TN78T, 4TN82RJK, 4TN84RJK 1. Remove flywheel. (See procedure in this group.) M48311 Assembly is done in the reverse order of disassembly. 2. Remove oil pan/plate. (See Lubrication System in this section.) Cap Screw (2) 4TN78T: M10 x 25 4TN82, 4TN84: M10 x 20 49 N•m (36 lb-ft) • Install retaining plate on shaft with grooves toward driven gear. • Press driven gear on balancer shaft until flush with beveled edge. Install gear with timing marks facing away from retainer plate. • Apply clean engine oil on all parts during assembly. • Align driven gear timing marks when installing balancer shaft assemblies. Cap Screw (3) M8 x 30 26 N•m (226 lb-in.) M48310 John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Crankcase Extension Housing Cap Screw (4) M8 x 120 27 N•m (20 lb-ft) Cap Screw (8) M8 x 50 22 N•m (195 lb-in.) Cap Screw (14) 27 N•m (20 lb-ft) 4/7/95 M82201A 3-43 3 Crankshaft, Main Bearings and Flywheel CRANKCASE EXTENSION HOUSING 4TN82RJE, 4TN82ESP, 4TN84(T)(4019) 1. Remove flywheel. (See procedure in this group.) 2. Remove oil pan and oil strainer. (See Lubrication System in this section.) 3 Cap Screw (3) M8 x 35 26 N•m (226 lb-in.) 3 Cap Screw (4) M10 x 30 49 N•m (36 lb-ft) M82056 John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Crankcase Extension Housing Cap Screw (2) M8 x 50 27 N•m (20 lb-ft) Cap Screw (2) M8 x 25 22 N•m (195 lb-in.) M82202A 3-44 4/7/95 Crankshaft, Main Bearings and Flywheel CRANKSHAFT REAR OIL SEAL Replacement • Replace oil seal using a driver set. Install seal with lip toward inside of gear housing cover. Install seal flush with surface of cover. 1. Remove flywheel. (See procedure in this group.) • Replace oil seal using a driver set. Install seal, with lip toward cylinder block. Install seal flush with surface of oil seal case. Timing Gear Cover NOTE: If crankshaft is grooved at oil seal contact point, seal can be installed 3 mm (0.120 in.) farther into oil seal case. Crankshaft Front Oil Seal On 4TN78T, 4TN82RJK, 4TN84RJK: All nine seal case cap screws are M8 x 30 long. M82203A 3 Rear Oil Seal Seal Case-to-Block Cap Screw (6) M8 X 30 26 N•m (226 lb-in.) Oil Seal Case CRANKSHAFT AND MAIN BEARINGS Removal 1. Check crankshaft end play. (See Checks, Tests and Adjustments in this section.) 2. Remove rear oil seal. (See procedure in this group.) 3. Remove flywheel housing. (See procedure in this group.) 4. Remove crankcase extension housing. (See procedure in this group.) Seal Case-to-Extension Cap Screw (3) M8 X 35 21 N•m (180 lb-in.) John Deere Form-In-Place Gasket (RTV rubber silicone sealant) M82057A CRANKSHAFT FRONT OIL SEAL Replacement • Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) 4/7/95 5. Remove balancer assembly, if equipped. (See procedure in this group.) NOTE: On 4TN82 (970 CUT) and 4TN84 (1070 CUT), crankshaft can be removed without removing timing gear cover mounting plate. 6. Remove timing gear cover mounting plate. (See Camshaft and Timing Gear Train in this section.) 7. Check crankshaft bearing clearance. (See Checks, Tests and Adjustments in this section.) IMPORTANT: Connecting rod end caps must be installed on the same connecting rods from which they were removed. Note alignment marks on caps and rods. 3-45 Crankshaft, Main Bearings and Flywheel 8. Remove connecting rod cap screws and end caps. 9. Push pistons and connecting rods away from crankshaft. IMPORTANT: Main bearing caps must be installed on the same main bearings from which they were removed. 10.Remove main bearing cap screws, caps and cap thrust bearings. 11.Remove crankshaft. 12.Remove block thrust bearings and main bearing inserts. 13.Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) Crankshaft Flywheel End 3 3 Block Thrust Bearing Cap Thrust Bearing Main Bearing Inserts Main Bearing Cap Main Bearing Cap Screw (10) M82059A 3-46 4/7/95 Crankshaft, Main Bearings and Flywheel Installation • Apply clean engine oil on all parts during installation. IMPORTANT: Do not touch bearing insert surfaces. Oil and acid from your finger will corrode the bearing surface. 1. Install grooved bearing inserts in crankshaft bearing bores, aligning tangs with slots in bores. 2. Install block thrust bearings with oil grooves facing away from engine block. 3. Install crankshaft. 4. Install smooth bearing inserts in main bearing caps, aligning tangs with slots in caps. NOTE: Main bearing caps have “raised arrows” that are stamped with numbers. Both correspond to their location on the engine block. The number “1” main bearing bore is at flywheel end. Install bearing caps beginning with number 1, then 2, etc. The main bearing cap at gear train end does not have a number. Also install bearing caps with the “arrow” toward the flywheel end. 4/7/95 5. Install cap thrust bearings, with oil grooves facing away from cap, in the number “1” main bearing cap. 6. Install main bearing caps in their original locations with arrows pointing toward flywheel side of engine. IMPORTANT: DO NOT use high speed power tools or air wrenches to tighten main bearing cap screws. 7. Dip entire main bearing cap screws in clean engine oil. Install cap screws and tighten. DO NOT tighten to specifications. 8. Using a soft-faced hammer, tap the front end of the crankshaft then the rear end of the crankshaft to align the thrust bearings. 9. Tighten main bearing cap screws to specifications. When tightening, start at center main bearing cap and work your way out, alternating to the ends. Turn crankshaft by hand. If it does not turn easily, disassemble the parts and find the cause. 3-47 3 Crankshaft, Main Bearings and Flywheel Crankshaft Flywheel End Grooved Bearing Insert Tangs Block Thrust Bearing Cap Thrust Bearing 3 Smooth Bearing Insert Main Bearing Cap 3 Main Bearing Cap Screw (10) Dip in clean engine oil. 4TN78T: 79 N•m (58 lb-ft) 4TN82, 4TN84(T)(4019): 98 N•m (72 lb-ft) 1 2 3 4 M82059A IMPORTANT: Connecting rod caps must be installed on the same connecting rods they were removed from. NOTE: On 4TN82 (970 CUT) and 4TN84 (1070 CUT), crankshaft can be installed without removing timing gear cover mounting plate. Never reuse connecting rod cap screws, replace with new. 12.Install timing gear cover mounting plate. (See Camshaft and Timing Gear Train in this section.) 10.Match the connecting rod caps to the rods using alignment marks. Install caps. 13.Install balancer, if equipped. (See procedure in this group.) 11.Dip entire connecting rod cap screws in clean engine oil. Install new cap screws and tighten to specifications. 14.Install crankcase extension procedure in this group.) Connecting Rod Cap Screw Torque Specifications: housing. (See 15.Install flywheel housing. (See procedure in this group.) 16.Install rear oil seal. (See procedure in this group.) 4TN78T . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft) 4TN82, 4TN84(T)(4019) . . . 47 N•m (35 lb-ft) 3-48 4/7/95 Crankshaft, Main Bearings and Flywheel Inspection/Replacement Key 1. Inspect crankshaft gear for chipped or broken teeth. Replace if necessary. To replace gear: Crankshaft Gear Remove gear from crankshaft using a knife-edge puller and a press. Timing Mark CAUTION DO NOT heat oil over 182° C (360° F). Oil fumes or oil can ignite above 193° C (380° F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. Heat gear to approximately 150oC (300oF). Install gear with timing mark “A” toward press table. Align slot in gear with key in shaft. Press crankshaft into gear until gear is tight against crankshaft shoulder. M82060A 2. If equipped, inspect balancer gear on crankshaft for chipped or broken teeth. Replace if necessary. To replace gear: - Scribe a mark across crankshaft at location of timing mark on gear, to aid in assembly. - Remove gear using a knife-edge puller and a press. - Heat gear to approximately 150°C (300°F). Install new gear with timing mark facing away from press table. Align timing mark on gear with mark on crankshaft made during disassembly. Press gear onto crankshaft until gear is tight against crankshaft shoulder. 3. Inspect crankshaft for bend using v-blocks and a dial indicator. Turn crankshaft slowly and read variation on indicator. If variation is greater than 0.02 mm (0.0007 in.), replace crankshaft. Dial Indicator V-Block 4/7/95 M82061A 3-49 3 Crankshaft, Main Bearings and Flywheel 4. Measure crankshaft connecting rod journal and main bearing journal diameters. Measure several places around each journal. NOTE: If engine has had a previous major overhaul, journals may have been ground and undersized bearing inserts installed. Main Bearing Journal If journal diameter is less than wear limit, replace crankshaft or have journals ground undersize by a qualified machine shop. If journals are ground, undersize bearing inserts must be installed. Bearing inserts are available in 0.25 mm (0.010 in.) undersize. 5. Install bearing inserts and main bearing cap on main bearing. Tighten main bearing cap screws to specifications. Main Bearing Cap Screw Torque Specifications: 4TN78T . . . . . . . . . . . . . . . . 79 N•m (58 lb-ft) 4TN82, 4TN84(T)(4019) . . . . . . . . . . 98 N•m (72 lb-ft) 6. Measure main bearing diameter. Connecting Rod Journal 3 3 M82062A Connecting Rod Journal O.D. - 4TN78T: Standard . . . . . . . . . . . . . 42.952 - 42.962 mm . . . . . . . . . . . . . . . . . . . . . (1.6910 - 1.6914 in.) Wear Limit. . . . . . . . . . . 42.91 mm (1.689 in.) Connecting Rod Journal O.D. - 4TN82, 4TN84(T)(4019): Standard . . . . . . . . . . . . . 47.952 - 47.962 mm . . . . . . . . . . . . . . . . . . . . . (1.8879 - 1.8883 in.) Wear Limit. . . . . . . . . . . 47.91 mm (1.886 in.) Main Bearing Journal O.D. - 4TN78T: Standard . . . . . . . . . . . . . 46.952 - 46.962 mm . . . . . . . . . . . . . . . . . . . . . (1.8485 - 1.8489 in.) Wear Limit. . . . . . . . . . . 46.91 mm (1.847 in.) M82063 Main Bearing I.D. - 4TN78T: Standard . . . . . . . . . . . . . . 47.00 - 47.045 mm . . . . . . . . . . . . . . . . . . . . . . . (1.850 - 1.852 in.) Wear Limit. . . . . . . . . . 47.10 mm (1.8541 in.) Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.) Main Bearing I.D. - 4TN82, 4TN84(T)(4019): Standard . . . . . . . . . . . . . . 50.00 - 50.045 mm Main Bearing Journal O.D. - 4TN82, 4TN84(T)(4019): Standard . . . . . . . . . . . . . 46.952 - 46.962 mm . . . . . . . . . . . . . . . . . . . . . (1.9666 - 1.9670 in.) . . . . . . . . . . . . . . . . . . . . . . . (1.969 - 1.970 in.) Wear Limit. . . . . . . . . . . 50.10 mm (1.972 in.) Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.) Wear Limit. . . . . . . . . . . 49.90 mm (1.965 in.) 3-50 4/7/95 Crankshaft, Main Bearings and Flywheel If bearing diameter exceeds wear limit, replace bearing inserts. If bearing clearance (bearing I.D. minus crankshaft main bearing journal O.D.) exceeds specification, replace bearing inserts and crankshaft or have crankshaft journals ground undersize by a qualified machine shop and install undersized bearing inserts. Bearing inserts are available in 0.25 mm (0.010 in.) undersize. 7. Clean and inspect oil passages in main bearing journals, connecting rod journals and main bearing bores in cylinder block. FLYWHEEL IMPORTANT: Never reuse flywheel mounting cap screws. Always install new. • Inspect pilot bushing, if equipped, for wear or damage. Replace if necessary using a driver set. Install bushing flush with flywheel surface. • Measure flywheel flatness. Place a straight edge across flywheel surface opposite of ring gear. Measure clearance between straight edge and flywheel surface with a feeler gauge. If clearance exceeds 0.02 mm (0.0008 in.), replace flywheel. 8. Inspect crankshaft for cracks or damage. Replace if necessary. 3 M35337 Flywheel Pilot Bushing (4TN82RJK, 4TN84RJK only) Flywheel Housing/Plate Flywheel Mounting Cap Screw (6) Replace. Apply clean engine oil on threads. 83 N•m (61 lb-ft) M82204A 4/7/95 3-51 Crankshaft, Main Bearings and Flywheel FLYWHEEL HOUSING - 4TN78T, 4TN82RJE, 4TN82ESP, 4TN84(T) (4019 DF/TF005 and 006) NOTE: 4TN84(T)(4019 DF/TF001) engines are equipped with a flywheel plate in place of a housing. (See procedure in this group.) 1. Remove flywheel. (See procedure in this group.) 2. Remove starter. Housing-to-Block Cap Screw (6) M10 x 25 49 N•m (36 lb-ft) 3 Flywheel Housing John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Housing-to-Extension Cap Screw 4TN78T: (2) 4TN82, 4TN84(T)(4019): (4) 4TN78T: M10 x 25 4TN82, 4TN84(T)(4019): M10 x 30 49 N•m (36 lb-ft) 3 Plug M82205A FLYWHEEL PLATE - 4TN82RJK, 4TN84RJK, 4TN84(T)(4019 DF/TF001) 1. Remove flywheel. (See procedure in this group.) Mounting Cap Screw (8) M10 x 20 49 N•m (36 lb-ft) Flywheel Plate 2. Remove starter. M82206A 3-52 4/7/95 Camshaft and Timing Gear Train SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the European Microfiche Tool Catalog (MTC). D15001NU Magnetic Follower Holder Kit Hold cam followers when removing and installing camshaft. OTHER MATERIALS Number LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. TY15130/ NA/ #395 Name Use John Deere Form-In-Place Gasket Seals camshaft plug, timing gear cover and plate to engine block. TY9370/ TY9477/ #242 Thread Lock and Sealer (Medium Strength) 3 Apply to threads of crankshaft pulley cap screw. 3 SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Head Gasket Kit • Cylinder Block Gasket Kit ® LOCTITE is a registered trademark of the Loctite Corp. 4/7/95 3-53 Camshaft and Timing Gear Train CAMSHAFT Mounting Cap Screws M8 X 16 Removal 1. Remove rocker arm assembly and push rods. (See Cylinder Head, Valves and Manifolds in this section.) 2. Remove timing gear cover. (See procedure in this group.) 3. Check camshaft end play. (See Checks, Tests and Adjustments in this section.) 4. Check backlash of timing gears. (See Checks, Tests and Adjustments in this section.) 3 NOTE: If a magnetic follower holder kit is not available, turn engine until oil pan is upward, to hold cam followers away from camshaft. 5. Hold cam followers away from camshaft using a magnetic follower holder kit such as D15001NU. 3 NOTE: Due to the odd number of teeth on the idler gear, timing marks will only align periodically. Timing Marks Camshaft M37836 Installation • Apply clean engine oil on all parts during installation. 6. Rotate crankshaft and align timing marks. IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while installing camshaft. Machined surfaces can be damaged. IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while removing camshaft. Machined surfaces can be damaged. 1. Rotate crankshaft to align timing marks. 7. Remove two cap screws and camshaft. 8. Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) 2. Install camshaft. 3. Install and tighten mounting cap screws to 26 N•m (226 lb-in.). 4. Install timing gear cover. (See procedure in this group.) 5. Install push rods and rocker arm assembly. (See Cylinder Head, Valves and Manifolds in this section.) 3-54 4/7/95 Camshaft and Timing Gear Train Inspection/Replacement Heat gear to approximately 150oC (300oF). 1. Check camshaft side gap using a feeler gauge. IMPORTANT: Be sure thrust plate is not between camshaft gear and camshaft shoulder while installing gear. Camshaft Gear Thrust Plate Install thrust plate if removed. Install gear with timing mark “C” side toward press table. Align slot in gear with key in shaft. Press camshaft into gear until gear is tight against camshaft shoulder. Thrust plate must spin freely on camshaft. Key Camshaft Gear 3 Side Gap M82067A Camshaft Side Gap: Standard . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm . . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.) 3 Thrust Plate M82068A Wear Limit. . . . . . . . . . . . 0.40 mm (0.016 in.) If side gap is at wear limit, remove gear and replace thrust plate. 2. Inspect gear for chipped or broken teeth. Replace if necessary. To remove/replace gear: 3. Inspect camshaft for bend using v-blocks and a dial indicator. Turn camshaft slowly and read variation on indicator. If variation is greater than 0.02 mm (0.001 in.), replace camshaft. Dial Indicator Remove gear from camshaft using a knife-edge puller and a press. CAUTION DO NOT heat oil over 182° C (360° F). Oil fumes or oil can ignite above 193° C (380° F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. Camshaft Central Bearing Area V-Block M82069A 4. Measure camshaft lobe height. 4/7/95 3-55 Camshaft and Timing Gear Train If journal diameters are less than wear limit, replace camshaft. 6. Measure camshaft bushing diameter at gear housing end. Lobe Height Camshaft Bushing M82070A Lobe Height: Standard . . . . . . . . . . . . . 38.635 - 38.765 mm . . . . . . . . . . . . . . . . . . . . . . . (1.521 - 1.526 in.) 3 M82072 Wear Limit. . . . . . . . . . . 38.40 mm (1.512 in.) If lobe height is less than wear limit, replace camshaft. 3 Oil Holes 5. Measure camshaft end and intermediate journal diameters. Camshaft Bushing I.D.: Standard . . . . . . . . . . . . . 44.990 - 45.055 mm . . . . . . . . . . . . . . . . . . . . . . . (1.771 - 1.774 in.) Wear Limit. . . . . . . . . . . 45.10 mm (1.776 in.) Clearance . . . . . . . . . . . . 0.20 mm (0.0079 in.) If bushing diameter exceeds wear limit, replace bushing. Flywheel End Journal If bushing clearance (bushing I.D. minus camshaft journal O.D.) exceeds specification, replace bushing, camshaft or both. To replace bushing: Intermediate Journal Remove bushing using a chisel. Be careful not to push bushing inside of engine. Align oil holes in new bushing and cylinder block. Install bushing using a driver set. Gear Housing End Journal M82071A Camshaft Journal O.D.: Gear Housing and Flywheel Ends Standard . . . . . . . . . . . . . . . 44.92 - 44.95 mm . . . . . . . . . . . . . . . . . . . . . . . (1.769 - 1.770 in.) Wear Limit. . . . . . . . . . . 44.80 mm (1.764 in.) Intermediate NOTE: Flywheel housing must be removed to measure camshaft intermediate and flywheel end bearing diameters. 7. Measure intermediate and flywheel end camshaft bore diameters using the following procedures: • Remove flywheel housing. (See Crankshaft, Main Bearings and Flywheel in this section.) • Remove plug using a long wooden dowel. Insert wooden dowel through gear housing side. Standard . . . . . . . . . . . . . . . 44.91 - 44.94 mm . . . . . . . . . . . . . . . . . . . . . . . (1.768 - 1.769 in.) Wear Limit. . . . . . . . . . . 44.80 mm (1.764 in.) 3-56 4/7/95 Camshaft and Timing Gear Train CAM FOLLOWERS Removal/Installation 1. Remove camshaft. (See procedure in this group.) 2. Remove oil pan and strainer. (See Lubrication System in this section.) Plug M35287 • Measure intermediate and flywheel end camshaft bore diameters. IMPORTANT: Cam followers must be installed in the same bores from which they were removed. 3. Put a mark on each cam follower and cylinder block bore to aid in installation. 4. Remove cam followers. 5. Inspect all parts for wear or damage. (See Inspection procedures.) 6. Apply clean engine oil on all parts during installation. Intermediate Bore 3 Installation is done in the reverse order of removal. 3 Inspection Flywheel End Bore M82073 • Inspect cam follower contact surface for abnormal wear. Replace if necessary. Camshaft Bore I.D.: Standard . . . . . . . . . . . . . . 45.00 - 45.025 mm . . . . . . . . . . . . . . . . . . . . . . . (1.772 - 1.773 in.) Wear Limit. . . . . . . . . . . 45.10 mm (1.776 in.) Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.) If bore diameter exceeds wear limit, replace cylinder block. If bore clearance (bore I.D. minus camshaft journal O.D.) exceeds specification, replace camshaft, cylinder block or both. Normal Contact Abnormal Contact M82074A • Apply John Deere Form-In Place Gasket, or an equivalent, on outer edge of plug. Install plug until it bottoms in bore. • Install flywheel housing. 4/7/95 3-57 Camshaft and Timing Gear Train • Measure cam follower stem diameter. Spacer/Plate If equipped. Pulley Cap Screw (4) 11 N•m (96 lb-in.) M82207A M82075A Cam Follower Stem O.D.: 3 Standard . . . . . . . . . . . . . 11.975 - 11.990 mm . . . . . . . . . . . . . . . . . . . . . . . (0.471 - 0.472 in.) Wear Limit. . . . . . . . . . . 11.93 mm (0.470 in.) 3 If stem diameter is less than wear limit, replace cam follower. • Measure cam follower bore diameter in cylinder block. Cam Follower Bore I.D.: Standard . . . . . . . . . . . . . 12.000 - 12.018 mm . . . . . . . . . . . . . . . . . . . . . . . (0.472 - 0.473 in.) Wear Limit. . . . . . . . . . . 12.05 mm (0.474 in.) Clearance . . . . . . . . . . . . . 0.10 mm (0.004 in.) If cam follower bore diameter exceeds wear limit, replace cylinder block. If bore clearance (bore I.D. minus follower stem O.D.) exceeds specification, replace cam follower, cylinder block or both. 3. Remove crankshaft pulley cap screw and washer. 4. Remove crankshaft pulley using a two-jaw puller kit. 5. Remove tachometer, if equipped. 6. 4TN82RJK (970 CUT), 4TN84RJK (1070 CUT): Remove hydraulic pump and steering pump, if equipped. (See procedure in Machine Technical Manual). NOTE: It is not necessary to remove auxiliary drive cover and gasket, if equipped, end cover and o-ring or fuel injection pump gear cover to remove timing gear cover. 7. Remove 18 mounting cap screws and timing gear cover. Installation is done in the reverse order of removal. • Replace seal washer. • Tighten all mounting cap screws to 26 N•m (226 lb-in.) • Align pin in crankshaft pulley with hole in crankshaft gear. Install crankshaft pulley. • Adjust fan/alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) TIMING GEAR COVER Removal/Installation Hole 1. Remove alternator and belt. 2. Remove fan, spacer/plate, if equipped, and pulley. Pin M35295 3-58 4/7/95 Camshaft and Timing Gear Train Mounting Plate-to-Cover Cap Screw (2) M8 x 20 John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Timing Gear Cover Cap O-Ring End Cover Tachometer is optional. Cap Screw (2) M6 x 12 Mounting Cap Screw (3) M8 x 55 Seal Washer Replace. O-Ring 3 Mounting Cap Screw M8 x 16 Crankshaft Pulley Clamp If equipped. Washer Mounting Cap Screw (6) M8 x 45 Gasket Cap Screw (4) M8 x 12 Crankcase Extension Housing-to-Cover Cap Screw (2) M8 x 25 22 N•m (195 lb-in.) Injection Pump Gear Cover Mounting Cap Screw (4) M8 x 85 IDLER GEAR Removal/Installation 1. Remove timing gear cover. (See procedure in this group.) 2. Check backlash of timing gears. (See Checks, Tests and Adjustments in this section.) Cap Screw Apply thread lock and sealer (medium strength) to threads. 115 N•m (85 lb-ft) M82208A NOTE: Due to the odd number of teeth on the idler gear, timing marks will only align periodically. When all timing marks on gears align, the piston closest to the water pump is at TDC on compression stroke. Number one cylinder is closest to the flywheel. 3. Rotate crankshaft and align timing marks. 4. Remove two cap screws, shaft and gear. 4/7/95 3 3-59 Camshaft and Timing Gear Train 5. Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) Installation is done in the reverse order of removal. Idler Gear (43T) If shaft diameter is less than wear limit, replace idler gear shaft. • Measure idler gear bushing diameter. Idler Gear Bushing I.D.: Standard . . . . . . . . . . . . . . 46.00 - 46.025 mm . . . . . . . . . . . . . . . . . . . . . . . (1.811 - 1.812 in.) Idler Gear Shaft Wear Limit. . . . . . . . . . . 46.08 mm (1.814 in.) Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.) If bushing diameter exceeds wear limit, replace bushing. To replace bushing: 3 Cap Screw (2) M8 x 45 Replace bushing using a driver set. Align oil holes in bushing and idler gear. Install bushing flush with surface of idler gear. M82209A If bushing clearance (bushing I.D. minus shaft O.D.) exceeds specification, replace bushing, shaft or both. 3 Inspection/Replacement • Inspect gear for chipped or broken teeth. Replace if necessary. Idler Gear Bushing • Measure idler gear shaft diameter. Idler Gear Shaft O.D.: Idler Gear Shaft Standard . . . . . . . . . . . . . 45.950 - 45.975 mm . . . . . . . . . . . . . . . . . . . . . . . (1.809 - 1.810 in.) Wear Limit. . . . . . . . . . . 45.93 mm (1.808 in.) 3-60 M82210A 4/7/95 Camshaft and Timing Gear Train John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Mounting Cap Screw (4) M8 x 16 25 N•m (220 lb-in.) Timing Gear Cover Mounting Plate Stud (3) 3 O-Rings Replace. 3 M82211A TIMING GEAR COVER MOUNTING PLATE Removal/Installation 1. Remove camshaft. (See procedure in this group.) 2. Remove idler gear. (See procedure in this group.) 3. Remove fuel injection pump. (See Fuel System in this section.) 4. Remove oil pump. (See Lubrication System in this section.) 5. Remove mounting cap screws and plate. 6. Replace o-rings. Installation is done in the reverse order of removal. 4/7/95 3-61 Lubrication System OTHER MATERIALS Number Name Use TY15130/ NA/ #395 John Deere Form-In-Place Gasket Seals oil pan to crankcase extension housing. TY9375/ TY9480/ filter John Deere Pipe Sealant with TEFLON® #592 4TN78T and 4TN84T (4019TF001 and 005): Apply to threads of plug in oil mounting block. LOCTITE® PRODUCTS U.S./ Canadian/ Loctite No. 3 ®LOCTITE is a registered trademark of the Loctite Corp. ®TEFLON is a registered trademark of the Du Pont Company. 3-62 4/7/95 Lubrication System OIL PAN AND STRAINER Removal/Installation John Deere Form-In-Place Gasket (RTV rubber silicone sealant) • Approximate crankcase oil capacity is: 4TN78T. . . . . . . . . . . . . . . . . . . . . . . 7.5L (8 qt) Gasket Replace. Oil Strainer 4TN82RJK . . . . . . . . . . . . . . . . . . 5.3L (5.6 qt) 4TN82RJE/ESP . . . . . . . . . . . . . . . . 5.7L (6 qt) 4TN84RJK . . . . . . . . . . . . . . . . . . 5.3L (5.6 qt) 4TN84(T)(4019) Oil Pan 4019D/TF001 and 005 . . . . . . . 6.8L (7.1 qt) Cap Screw (2) M8 x 35 4019D/TF006 . . . . . . . . . . . . . . 9.5L (9.9 qt) • Tighten all cap screws to 26 N•m (226 lb-in.). • Fill engine with proper engine oil. (See SPECIFICATIONS AND GENERAL INFORMATION section.) Cap Screw (20) M8 x 45 Spacer Plate (2) Cap Screw (4) M8 x 16 O-Ring Replace. 4TN82RJE, 4TN82ESP Drain Plug M82213A Cap Screw 4TN82RJK, 4TN84RJK (1) 4TN78T (2) M8 x 12 Gasket Replace. Oil Strainer Cap Screw (2) M8 x 35 O-Ring (4TN78T) or Copper Washer (4TN82RJK, 4TN84RJK) Replace. Drain Plug 4TN78T, 4TN82RJK, 4TN84RJK 4/7/95 John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Oil Pan/Cover Cap Screw (20) M8 x 12 (4TN82RJK, 4TN84RJK) M8 x 25 (4TN78T) M82212A 3-63 3 3 Lubrication System Gasket Oil Strainer John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Cap Screw (2) M8 x 35 4019D/TF006 Oil Pan (4019D/TF001, 005) Spacer Plate (2) Cap Screw (18) M8 x 45 3 Cap Screw (4) M8 x 50 O-Ring Replace. Cap Screw (4) M8 x 16 Drain Plug 4TN84(T)(4019) M82214A OIL PUMP Removal/Installation 1. Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) Oil Pump 2. Check oil pump gear backlash. Replace entire oil pump assembly if backlash is more than 0.25 mm (0.010 in.). 3. Remove four mounting cap screws, oil pump and gasket. 4. Inspect all parts for wear or damage. (See Disassembly/Assembly procedures). Oil Pump Gasket Mounting Cap Screw M6 x 25 25 N•m (18 lb-ft) M82215A Disassembly/Assembly • Gear is press fit on rotor shaft. Remove gear using a knife edge puller and a press. NOTE: Safety valve is on 4TN78T and 4TN84T (4019TF001 and 005) only. • Inspect parts for wear or damage. (See Inspection procedures.) • Coat all parts with clean engine oil. 3-64 4/7/95 Lubrication System • Install outer rotor with identification mark facing toward rotor shaft assembly. Rotor Recess - 4TN82, 4TN84(T)(4019): Standard . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm . . . . . . . . . . . . . . . . . . . . . (0.0011 - 0.0035 in.) Backing Plate Alignment Pin (2) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) Safety Valve Non-Adjustable. DO NOT Remove. Pump Body • Check outer rotor-to-pump body clearance. If clearance is more than wear limit, replace entire assembly Rotor Shaft Outer Rotor Outer Rotor Gear Identification Mark Feeler Gauge Inner Rotor M82216A 3 Body M37776 Inspection • Check rotor shaft outer diameter and the shaft hole diameter in backing plate. If clearance is more than wear limit, replace entire assembly Outer Rotor-to-Pump Body Clearance - 4TN78T: Standard . . . . . . . . . . . . . . . . . 0.09 - 0.16 mm . . . . . . . . . . . . . . . . . . . . . (0.0035 - 0.0063 in.) Rotor Shaft and Plate Clearance: Standard . . . . . . . . . . . . . . . 0.015 - 0.048 mm Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) . . . . . . . . . . . . . . . . . . . . . (0.0006 - 0.0035 in.) Outer Rotor-to-Pump Body Clearance - 4TN82, 4TN84(T)(4019): Wear Limit. . . . . . . . . . . 0.20 mm (0.0078 in.) Standard . . . . . . . . . . . . . . . . . 0.10 - 0.17 mm • Check rotor recess. If rotors are below face of pump housing more than wear limit, replace rotor assembly. Feeler Gauge Straight Edge . . . . . . . . . . . . . . . . . . . . . (0.0039 - 0.0067 in.) Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) • Check inner-to-outer rotor clearance. If clearance is more than wear limit, replace rotor assembly. Feeler Gauge Inner Rotor Housing Outer Rotor M37775 Rotor Recess - 4TN78T: Standard . . . . . . . . . . . . . . . . . 0.05 - 0.10 mm Outer Rotor M37777 . . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0039 in.) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) 4/7/95 3-65 3 Lubrication System Inner-to-Outer Rotor Clearance - 4TN78T: Standard . . . . . . . . . . . . . . . . . 0.02 - 0.04 mm . . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0016 in.) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) 4. Remove mounting bolt, oil cooler and o-rings. 5. Remove three cap screws, oil filter mounting block and gasket. NOTE: See OIL PRESSURE REGULATING VALVE if service is necessary. Inner-to-Outer Rotor Clearance - 4TN82, 4TN84(T)(4019): Standard . . . . . . . . . . . . . . . . 0.05 - 0.105 mm . . . . . . . . . . . . . . . . . . . . . (0.0019 - 0.0041 in.) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) OIL COOLER - 4TN78T AND 4TN84T (4019TF001 and 005) 3 NOTE: 3. Disconnect coolant hoses. 6. Inspect all parts for wear or damage. Replace as necessary. NOTE: Oil cooler bypass valve components are not seviced seperately. Bypass valve and mounting block are replaced as an assembly. Remove parts only to inspect for wear or damage. 7. Pressure test oil cooler. (See Checks, Tests and Adjustments in this section.) 4TN84T(4019TF001 and 005): Approximate cooling system capacity is 4.7L (4.9 qt). Installation is done in reverse order of removal. 1. 4TN84T(4019TF001 and 005): Drain cooling system. 2. Remove oil filter. • Close drain valve and fill radiator with proper coolant to top of filler neck. (See SPECIFICATIONS AND GENERAL INFORMATION section.) Oil Pressure Regulating Valve Mounting Block Oil Cooler By-Pass Valve O-Rings Replace. Gasket Plug Apply Pipe Sealant with TEFLON. Mounting Stud Mounting Bolt 30 N•m (22 lb-ft) Oil Filter O-Ring Oil Cooler 3-66 Cap Screw (3) M8 x 65 27 N•m (20 lb-ft) M82217A 4/7/95 Lubrication System OIL PRESSURE REGULATING VALVE - 4TN78T AND 4TN84T (4019TF001 and 005) OIL PRESSURE REGULATING VALVE - 4TN82, 4TN84 (4019DF) AND 4TN84T (4019TF006) Removal/Installation Removal/Installation • Inspect all parts for wear or damage. Replace as necessary. 1. Remove oil filter. 2. Remove three cap screws, valve assembly and gasket. NOTE: If adjusting engine oil pressure, retaining nut need not be removed. Plug Copper Washer Replace. 3. If adjusting pressure only, remove cap and add shims. Each 1 mm (0.039 in.) of shim thickness increases oil pressure 15.6 kPa (2.3 psi). Shims Spring NOTE: Valve components are not serviced individually. Replace complete regulating valve if any components are defective. Valve 4. Inspect all parts for wear or damage. Replace complete valve if necessary. 5. Check spring free and compressed length. Spring Specifications: Free Length . . . . . . . . . . . . .46 mm (1.810 in.) Compressed Length . . . 27.50 mm (1.080 in.) . . . . . . . . . . . . . . . . . . @ 20.5 N (4.6 lb-force) M82218A 4/7/95 Installation is done in the reverse order of removal. 3-67 3 3 Lubrication System Cap Stake to valve body. O-Ring Replace. Gasket Housing Shims Retaining Nut 30 N•m (22 lb-ft) Spring Valve Oil Filter Valve Body 3 Cap Screw (3) M8 x 20 27 N•m (20 lb-ft) M82219A PISTON COOLING NOZZLES - 4TN78T AND 4TN84T (4019TF001 and 005) Piston Cooling Nozzle Replacement 1. Remove oil pan and strainer. (See procedure in this group.) • Install nozzle with locating pin in locating hole of cylinder block. Mounting Bolt 15 N•m (130 lb-in.) M51580 Locating Pin M51581 3-68 4/7/95 Cooling System OTHER MATERIALS Number Name Use John Deere Pipe Sealant with TEFLON® 4TN78T, 4TN82RJE, 4TN82ESP and 4TN84(T)(4019): Apply to threads of plug and nipple in thermostat housing and pipe plug in water pump housing. LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. TY9375/ TY9480/ #592 3 ®LOCTITE is a registered trademark of the Loctite Corp. ®TEFLON is a registered trademark of the Du Pont Company. 4/7/95 3-69 Cooling System COOLANT TEMPERATURE SWITCH Replacement THERMOSTAT AND HOUSING 4TN78T, 4TN82RJE, 4TN82ESP AND 4TN84(T) (4019) NOTE: Some engines may also be equipped with a coolant temperature sender. Sender is located opposite of switch in thermostat housing. Replacement procedures are the same. 1. Disconnect wiring lead, if equipped. 2. Remove upper radiator hose, if equipped. 3. Disconnect coolant temperature switch/sender wiring lead(s). 4. Loosen alternator-to-bracket mounting cap screw. 2. Open engine drain valve to drain coolant. 3 1. Drain engine coolant. 3. Remove switch and washer. 5. Loosen clamps and remove thermostat housingto-water pump hose. 4. Test switch. (See Checks, Tests and Adjustments in this section.) 6. Remove mounting cap screws, housing and gasket. Installation is done in reverse order of removal. 7. Inspect all parts for wear or damage. Replace as necessary. Copper Washer Replace. Coolant Temperature Switch 8. Test thermostat. (See Checks, Adjustments in this section.) Thermostat Housing Tests and Installation is done in reverse order of removal. • Adjust fan/alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) M82220A Cap Screw (2) M8 x 20 20 N•m (180 lb-in.) Plate Gasket Replace. Cover Gasket Replace. Copper Washer Replace. Alternator Slide Bracket Thermostat Gasket Replace. Copper Washer Replace. Cap Cap Screw (2) M6 x 16 9 N•m (78 lb-in.) Mounting Cap Screw M8 x 60 26 N•m (226 lb-in.) Gasket Replace. Coolant Temperature Switch Plug Apply Pipe Sealant with TEFLON to threads. Mounting Cap Screw M8 x 25 26 N•m (226 lb-in.) 3-70 Nipple Apply Pipe Sealant with TEFLON to threads. Housing Mounting Cap Screw M8 x 50 26 N•m (226 lb-in.) Thermostat Housing-toWater Pump Hose M82221A 4/7/95 Cooling System THERMOSTAT - 4TN82RJK AND 4TN84RJK Pulley Plate 4TN78T, 4TN82RJE, 4TN84RJK Only • Replace gaskets. • Test thermostat. (See Checks, Tests and Adjustments in this section.) Cap Screw 11 N•m (96 lb-in.) Cap Screw (2) M8 x 20 20 N•m (180 lb-in.) Cover M82294A Cover Gasket Thermostat Gasket 4. Remove lower radiator hose, if equipped. 5. Loosen clamps and remove thermostat housingto-water pump hose. 6. Remove three mounting cap screws, pump and gasket. 7. Inspect all parts for wear or damage. (See Disassembly/Assembly procedures.) Installation is done in the reverse order of removal. M82222A WATER PUMP - 4TN78T, 4TN82RJE, 4TN82ESP AND 4TN84(T) (4019) Water Pump Thermostat Housing-toWater Pump Hose Removal/Installation 1. Drain engine coolant. 2. Remove fan/alternator belt. 3. 4TN78T, 4TN82RJE, 4TN82ESP, 4TN84RJK: Remove fan, plate, if equipped, and pulley. 4TN84(T) (4019): Remove cooling fan. (See procedure in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section.) 4/7/95 Gasket Replace. Mounting Cap Screw (3) M8 x 60 26 N•m (226 lb-in.) M82223A 3-71 3 Cooling System Disassembly 1. Apply heat to three plate-to-housing screws. Remove screws, plate and gasket Plate-to-Housing Screw (3) 15 N•m (134 lb-in.) Plate Plug 15 N•m (130 lb-in.) Pipe Plug Apply Pipe Sealant with TEFLON to threads. Gasket Replace. 3 Impeller Seal Cup and Ceramic Seal Replace. Shaft Seal Replace. Water Pump Housing Bearing Shaft 2. Apply extreme heat to pulley flange. Remove flange using a knife-edge puller set and two small nuts. Two Small Nuts Pulley Flange Knife-Edge Puller Set Pulley Flange M82224A 3. Place water pump assembly on a press table. Install supports under water pump housing, staying clear of impeller. Press bearing shaft assembly through water pump housing using a piece of pipe or a deep socket. IMPORTANT: Impeller bore is tapered. When pressing bearing shaft from impeller, allow enough clearance between cap screw and impeller bore to prevent cap screw from binding. 4. Remove impeller from bearing shaft using a knife-edge puller, a 3/8 in. cap screw and a press. Water Pump Housing M35645 5. Remove shaft seal, ceramic seal and seal cup. 6. Inspect all parts for wear or damage. Replace as necessary. 3-72 4/7/95 Cooling System Assembly 1. Install bearing shaft into pump housing, long end down, using a piece of pipe or deep socket and a press. Press shaft into pump housing until bearing surface is flush with pump housing surface. 2. Install new shaft seal over impeller side of bearing shaft, rubber seal side away from pump housing. Push shaft seal into pump housing, until it stops, using a 25 mm or 1 in. socket and a press. 5. Install a knife-edge puller around bearing shaft, between pulley flange and pump housing. Place pump housing, with knife-edge puller down, on a press table. Install impeller with ceramic seal toward shaft seal. 4TN82RJE and 4TN82ESP: Press impeller on bearing shaft until top of impeller is 1 mm (0.040 in.) below housing. 4TN78T and 4TN84(T)(4019): Press impeller on bearing shaft until top of impeller is 2 mm (0.080 in.) below housing. IMPORTANT: Support pump housing on bearing shaft only. DO NOT support on housing or damage to housing will occur. 3. Place water pump housing on a press table. Support housing on bearing shaft using a driver disk. Install pulley flange onto shaft with straight hub facing away from housing. 3 4TN82RJE and 4TN82ESP: Press pulley flange onto bearing shaft until top of flange is 27 mm (1.060 in.) from top of housing. 4TN78T and 4TN84(T)(4019): Press pulley flange onto bearing shaft until bottom of flange is 17 mm (0.670 in.) from top of housing. IMPORTANT: DO NOT touch lapped sealing surface of ceramic seal with bare hands. It must be clean and dry. M37905 6. Install new gasket, plate, three screws, two cap screws and nuts. Tighten to specifications. 4. Install seal cup and ceramic seal in impeller. 4/7/95 3-73 Cooling System WATER PUMP - 4TN82RJK AND 4TN84RJK 3. Remove four cap screws, fan, spacer and pulley. 4. Remove four mounting cap screws, pump and gasket. Removal/Installation 1. Open engine drain valve to drain coolant. 5. Inspect all parts for wear or damage. (See Disassembly/Assembly procedures.) 2. Remove fan/alternator drive belt. Installation is done in the reverse order of removal. • Adjust fan/alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) Gasket Replace. Mounting Cap Screw (3) M8 x 55 26 N•m (226 lb-in.) O-Ring Replace. 3 Pulley Fan Water Pump Mounting Cap Screw M8 x 60 26 N•m (226 lb-in.) Spacer Cap Screw (4) M6 x 25 1 N•m (96 lb-in.)1 3-74 M82225A 4/7/95 Cooling System Disassembly 3. Remove two cap screws, adapter and gasket. 1. Remove thermostat. (See procedure in this group.) 4. Apply heat to six plate-to-housing cap screws. Remove cap screws, plate and gasket. 2. Remove coolant temperature procedure in this group.) switch. (See Plate-to-Housing Cap Screw 9 N•m (78 lb-in.) Plate Gasket Replace. Plate-to-Housing Cap Screw (5) M6 x 14 9 N•m (78 lb-in.) Cap 3 Shaft Seal Replace. Copper Washer Replace. Adapter Gasket Replace. Impeller Pulley Flange Seal Cup and Ceramic Seal Replace. Water Pump Housing 5. Apply extreme heat to pulley flange. Remove flange using a knife-edge puller set and two small nuts. Two Small Nuts Pulley Flange Knife-Edge Puller Set Bearing Shaft Adapter-to-Plate Cap Screw (2) M6 x 20 9 N•m (78 lb-in.) M82226A 6. Place water pump assembly on a press table. Install supports under water pump housing, staying clear of impeller. Press bearing shaft assembly through water pump housing using a piece of pipe or a deep socket. IMPORTANT: Impeller bore is tapered. When pressing bearing shaft from impeller, allow enough clearance between cap screw and impeller bore to prevent cap screw from binding. Water Pump Housing M35645 4/7/95 3-75 Cooling System 7. Remove impeller from bearing shaft using a knife-edge puller, a 3/8 in. cap screw and a press. 8. Remove shaft seal, ceramic seal and seal cup. 9. Inspect all parts for wear or damage. Replace as necessary. Assembly 1. Install bearing shaft into pump housing, long end down, using a piece of pipe or deep socket and a press. Press shaft into pump housing until bearing surface is flush with pump housing surface. 3 4. Install seal cup and ceramic seal in impeller. 5. Install a knife-edge puller around bearing shaft, between pulley flange and pump housing. Place pump housing, with knife-edge puller down, on a press table. Install impeller with ceramic seal toward shaft seal. 4TN82RJK: Press impeller on bearing shaft until top of impeller is 1 mm (0.040 in.) below housing. 4TN84RJK: Press impeller on bearing shaft until top of impeller is 2 mm (0.080 in.) below housing. 2. Install new shaft seal over impeller side of bearing shaft, rubber seal side away from pump housing. Push shaft seal into pump housing, until it stops, using a 25 mm or 1 in. socket and a press. IMPORTANT: Support pump housing on bearing shaft only. DO NOT support on housing or damage to housing will occur. 3. Place water pump housing on a press table. Support housing on bearing shaft using a driver disk. Install pulley flange onto shaft with straight hub facing away from housing. 4TN82RJK: Press pulley flange onto bearing shaft until top of flange is 27 mm (1.060 in.) from top of housing. 4TN84RJK: Press pulley flange onto bearing shaft until bottom of flange is 17 mm (0.670 in.) from top of housing. M37906 6. Install new gasket, plate and six cap screws. Tighten to specifications. 7. Install new gasket, adapter and cap screws. Tighten to specifications. 8. Install coolant temperature procedure in this group.) switch. (See 9. Install thermostat. (See procedure in this group.) IMPORTANT: DO NOT touch lapped sealing surface of ceramic seal with bare hands. It must be clean and dry. 3-76 4/7/95 Fuel System SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the European Microfiche Tool Catalog (MTC). JDF13 Nozzle Cleaning Kit Use to clean fuel injection nozzles. SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Block Gasket Kit • Fuel Injection Nozzle Shim Pack 3 4/7/95 3-77 Fuel System FUEL SUPPLY PUMP - IF EQUIPPED Replacement NOTE: 4TN78T, 4TN82RJE and 4TN82ESP engines are not equipped with a fuel supply pump. Fill Plug Oil will leak out of fuel injection pump housing when supply pump is removed. IMPORTANT: If oil has been drained out of fuel injection pump housing, add oil as necessary. Fuel injection pump can become damaged if operated dry or without proper amount of oil. 3 After fuel supply pump is installed, disconnect external lube line to fuel injection pump housing. Remove fill plug and add clean engine oil to housing. Add until oil begins to drip out of lube line hole (For proper oil specification see SPECIFICATIONS AND GENERAL INFORMATION section.) Supply Pump-toFilter Hose Fuel Supply Pump External Lube Line Tighten mounting bolt to 15 N•m (130 lb-in.) M82227 3 Lock Washer (2) Fill Plug Packing Replace. Mounting Nut (2) 11 N•m (96 lb-in.) Fuel Supply Pump M82228A 3-78 4/7/95 Fuel System FUEL FILTER ASSEMBLY - IF EQUIPPED IMPORTANT: Replace all copper washers. Damaged or used washers may leak. NOTE: Fuel filter assemblies will be slightly different for each engine model depending on engine application. 4TN84(T) (4019 OEM) shown. End Cap Mounting Base Shutoff Valve Spring O-Ring O-Ring Filter Element Spring Shutoff Lever 3 O-Ring Filter Cover Mounting Cap Screw End Cap Nozzle Leak-Off Hose (Short) (3) Retaining Ring Fuel Filter-toInjection Pump Hose * Injection Pump Bleed-Off Hose * Nozzle Leak-Off Hose (Long) Fuel Supply Pump-to-Filter Hose *Copper Washers Replace. * Air Vent Check Valve * * M82134A 4/7/95 3-79 Fuel System FUEL INJECTION PUMP Removal CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. 3 3 If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can damage the pump. 1. Clean the injection pump lines and area around the pump using a parts cleaning solvent or steam cleaner. 2. Loosen fuel injection line connectors slightly to release pressure in the fuel system. When loosening connectors, use another wrench to keep delivery valves from loosening. 3. Loosen line clamp(s) and remove fuel injection lines. 4. Disconnect hoses to/from fuel filter, if equipped. 5. Remove external lube line. 6. Disconnect fuel shutoff solenoid link. 7. Note position of timing marks on injection pump and gear cover mounting plate. 8. Remove three mounting nuts. Injection Pump Bleed-Off-to-Filter Hose Fuel Injection Line Connectors (4) Fuel Injection Lines Nozzle Leak-Off Hose Line Clamp(s) Delivery Valve (4) Fuel Filter-to-Injection Pump Hose Fuel Shutoff Solenoid Link Fuel Supply Pump-to-Filter Hose 3-80 External Lube Line M82229 4/7/95 Fuel System DO NOT attempt to service the injection pump or governor. If unit is in need of repair, it must be serviced by a qualified fuel injection repair shop. If replacement is necessary, replace entire unit. Timing Marks Installationl 1. Install new o-ring on injection pump. Mounting Nut (3) M82230 9. Remove fan guard, if equipped. 10.Remove four cap screws, washers, cover and gasket. 11.Use chalk or paint to mark injection pump gear to idler gear. 12.Remove nut and lock washer. 2. Put injection pump onto back of gear cover mounting plate. Align key on shaft with keyway in gear. Be sure to align marks on gears made during removal. 3. Install lock washer and nut. Tighten to specification. 3 Nut and Lock Washer M12 90 N•m (66 lb-ft) Chalk/Paint Marks Nut and Lock Washer Chalk/Paint Marks M82231 4. Install new gasket, cover, four washers and cap screws. 5. Install fan guard, if equipped. M82231 13.Pull gear from injection pump shaft using a two jaw puller. 6. Install three mounting nuts. Do not tighten. 7. Align marks on mounting plate and injection pump, to same place as when removed, and tighten mounting nuts to specifications. Timing Marks Mounting Nut (3) 26 N•m (19 lb-ft) M37794 M82230 14.Remove injection pump and o-ring. 8. Connect fuel shutoff solenoid link. 9. Connect hoses to/from fuel filter. 4/7/95 3-81 Fuel System 10.Install fuel injection lines and tighten line clamp cap screws. IMPORTANT: If oil has been drained out of fuel injection pump housing, add oil as necessary. Fuel injection pump can become damaged if operated dry or without proper amount of oil. 11.Remove fill plug and add clean engine oil to housing. Add until oil begins to drip out of external lube line inlet. (For proper oil specification see SPECIFICATIONS AND GENERAL INFORMATION section.) 12.Install external lube line. When installing line, put one copper washer between mounting bolt head and lube line and the other between lube line and housing. If new injection pump is being installed, check and adjust injection pump static timing. (See Checks, Tests and Adjustments in this section.) Injection Pump Bleed-Off-to-Filter Hose Fuel Injection Line Connectors (4) Fuel Injection Lines 3 3 Nozzle Leak-Off Hose Line Clamp(s) Delivery Valve (4) Fuel Filter-to-Injection Pump Hose Fuel Shutoff Solenoid Link Oil Fill Plug Lube Line-to-Block Bolt 25 N•m (217 lb-in.) Fuel Supply Pump-to-Filter Hose 3-82 External Lube Line M82229 4/7/95 Fuel System FUEL INJECTION NOZZLES (HOLE-TYPE) Retaining Plate Hose Clamp Removal/Installation IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can damage the pump. 1. Clean the injection pump lines and area around the pump using a parts cleaning solvent or steam cleaner. Nut (2) 5 N•m (39 lb-in.) Leak-Off Hose Injection Nozzle Ring Heat Protector Replace. CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. NOTE: Nozzles are matched to the cylinders. If removing more than one nozzle, tag nozzles, according to the cylinder from which it was removed. 2. Loosen fuel injection line connectors-to-nozzles slightly to release pressure in the fuel system. 3. Loosen line clamp(s) and remove fuel injection lines. 3 M82092A If nozzles are stuck in cylinder head: • Grind the head of a cap screw so it fits inside a nut from an old injection line. • Use two nuts to attach a large flat washer to the cap screw. • Install assembly onto nozzle and use a puller and slide hammer to pull nozzle from cylinder head. Large Flat Washer Nuts Cap Screw Old Injection Line Nut Injection Nozzle M82126 4. Remove clamps and leak-off hoses. 7. Test injection nozzles. (See Checks, Tests and Adjustments in this section.) 5. Remove nuts and retaining plates. Installation is done in reverse order of removal. 6. Remove injection nozzle, ring and teflon heat protector. If ring and protector stay in cylinder head, thread a cap screw into protector and pull from cylinder head. 4/7/95 3-83 Fuel System Disassembly/Assembly Cross Section NOTE: If servicing more than one nozzle, keep parts for each nozzle separate from one another. • Clean and inspect nozzle assembly. (See Cleaning/Inspection procedures.) Injector Body • After assembly is complete, test injection nozzle. (See Checks, Tests and Adjustments in this section.) 3 Injector Body Fuel Return Pipe Shim (as required) Spring 3 Shims (as required) Spring Spring Seat Spring Seat Index Pin (2) Separator Plate Separator Plate Index Pin (2) Nozzle Valve Retaining Nut Nozzle Body Retaining Nut 43 N•m (31 lb-ft) Nozzle Valve Nozzle Body M82093A 3-84 M37684 4/7/95 Fuel System Cleaning/Inspection NOTE: To clean nozzles properly, JDF13 Nozzle Cleaning Kit is recommended. The Cleaning Kit is available through the John Deere SERVICEGARD™ Catalog. 1. Remove anti-corrosive grease from new or reconditioned nozzles by washing them thoroughly in diesel fuel. IMPORTANT: Never use a steel brush to clean nozzles as this will distort the spray hole. 2. Remove carbon from used nozzles, and clean by washing in diesel fuel. If parts are coated with hardened carbon or lacquer, it may be necessary to use a brass wire brush (supplied in Nozzle Cleaning Kit). 3. After removing carbon or lacquer from the exterior of nozzle, inspect sealing surfaces between separator plate and nozzle body for nicks or scratches. 4. Inspect condition of separator plate and nozzle body. Contact area of separator plate (both parts) must not be scored or pitted. Use an inspection magnifier (No. 16487 or equivalent) to aid in making the inspection. 5. Check nozzle contact surface on separator plate for wear. If contact surface is more than 0.10 mm (0.0039 in.), replace nozzle assembly. Nozzle Contact Surface Sealing Surfaces 6. Inspect the piston (large) part of nozzle valve to see that it is not scratched or scored and that lower (tip) end of valve is not broken. If any of these conditions are present, replace the nozzle assembly. 7. Further inspect the nozzle assembly by performing a slide test. Use the following procedure: • Dip the nozzle valve in clean diesel fuel. Insert valve in nozzle body. • Hold nozzle vertical, and pull valve out about 1/3 of its engaged length. • Release valve. Valve should slide down to its seat by its own weight. Replace nozzle assembly if the valve does not slide freely to its seat. Nozzle Valve Piston Part of Nozzle Valve Nozzle Body M82095A Index Pin Separator Plate Nozzle Body M82094A 4/7/95 3-85 3 Starter STARTER IDENTIFICATION CHART The various starters covered in this group are identified by manufacturer and output rating. Field Coil Brush (2) To help identify the starters, measure the outside diameter of the motor. M82232 3 3 3-86 Manufacturer Rated Output Motor Outside Diameter Hitachi 0.8 kW N/A Hitachi 2.0 kW 80 mm (3.150 in.) Nippondenso 1.0 kW 68 mm (2.680 in.) Nippondenso 1.4 kW 76 mm (3.000 in.) 4/7/95 Starter STARTER - HITACHI 0.8 kW 8. Remove brush holder. Disassembly/Inspection Negative Brush 1. Disconnect field lead. 2. Remove two cap screws and two screws from rear cover. Brush Spring 3. Pry off plastic cap. 4. Remove e-clip, shims and rear cover. Field Lead Field Coil Brush (2) M37875 9. Remove field coil housing from armature/ solenoid assembly. 3 Rear Cover Cap E-Clip 3 Shims M37923 5. Inspect cover bushing for wear or damage. Replace if necessary. To replace bushing: Remove bushing using a blind-hole puller set. Install new bushing until it bottoms in cover bore using a driver set. Ream out bushing to 12.50 - 12.53 mm (0.492 0.493 in.). Field Coil Housing M37876 10.Remove two cap screws and pivot bolt, if equipped. 11.Remove dust cover. 12.Remove solenoid and armature assemblies from end frame. Cap Screw (2) End Frame Armature Assembly Rear Cover Bushing M37874 6. Remove field coil brushes from brush holder. 7. Pry brush springs away and pull negative brushes up enough to allow spring to hold brush in place. Dust Cover Solenoid Assembly M37877 4/7/95 3-87 Starter 13.Inspect end frame bushing for wear or damage. Replace if necessary. Spring Replace bushing using a driver set. Install bushing flush with face of housing. Solenoid Shims Plunger Clutch Fork Pivot End Frame Bushing M37830 pinion stopper away from retaining wire 3 14.Slide using a piece of pipe or deep socket. Remove retaining wire, pinion stopper, and clutch assembly from armature shaft. 3 15.Inspect clutch assembly for wear or damage. Gear should rotate in one direction only. Replace if necessary. M37880 Assembly Assembly is done in the reverse order of disassembly. • After installing clutch assembly, pinion stopper and retaining wire on armature shaft, use two pliers to press pinion stopper over retaining wire. Armature Shaft Retaining Wire Retaining Wire Pinion Stopper Clutch Assembly M37831 Pinion Stopper Clutch Assembly M37879 • When installing solenoid and armature assemblies into end frame, make sure fork pivot seats in notch on clutch fork. 16.Remove clutch fork pivot, plunger, spring and shim(s) from solenoid. 17.Inspect all parts for wear or damage. Replace as necessary. 18.Inspect and test brushes, holder, field coil and armature. (See Test procedures.) 3-88 4/7/95 Starter NOTE: Test field coil using an ohmmeter or test light. 4. Test for grounded field winding: Touch one probe of tester to field coil brush and other probe to field coil housing. Be sure the brush lead is not touching the frame. If there is continuity, the coil is grounded and the field coil housing assembly must be replaced. Notch Fork Pivot 5. Test for open field coil: Touch one probe of tester to each field coil brush. If there is no continuity, the field coil is open and the field coil housing assembly must be replaced. M37881 IMPORTANT: When installing rear cover, be sure field coil brush wires do not touch cover. Turn brush holder slightly to take up slack in brush wires. Press wires inward to clear rear cover. Field Coil Brush 3 Test 3 1. Measure holder and field coil brush lengths. Minimum brush length is 7.70 mm (0.303 in.). Replace brush holder or field coil if brush length is below minimum. NOTE: Test brush holder using an ohmmeter or test light. 2. Test brush holder: Touch one probe of tester to negative brush holder and other probe to field brush holder. If there is continuity, replace the brush holder. 3. Inspect springs for wear or damage. Replace if necessary. Field Coil Housing M82235 IMPORTANT: Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush. 6. Inspect armature. Look for signs of dragging against pole shoes. Spring (4) Negative Brush Holder 7. Inspect commutator. Look for roughness, burned bars, or any material which might cause short circuits between bars. If necessary, clean and touch up with 400 sandpaper. NEVER use emery cloth. Clean all dust from armature when finished. NOTE: Test armature windings using an ohmmeter or test light. Field Brush Holder Brush Length M82234 4/7/95 8. Test for grounded windings: Touch probes on one commutator bar and armature shaft. Armature windings are connected in series, so only one commutator bar needs to be checked. 3-89 Starter If test shows continuity, a winding is grounded and the armature must be replaced. STARTER MOTOR - HITACHI 2.0 kW 9. Test for open circuited windings: Touch probes on two different commutator bars. Disassembly If test shows no continuity, there is an open circuit and the armature must be replaced. 1. Remove two cap screws and two screws. 2. Remove rear cover. Commutator Bars Armature Shaft 3 3 M82246 10.Test for short circuited windings using a growler. Put armature in a growler and hold a hacksaw blade above each slot while slowly rotating armature. If coil is shorted, the blade will vibrate on the slot. NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments. 11.If test indicates short circuited windings, clean the commutator of dust and filings. Check the armature again. If the test still indicates a short circuit, replace the armature. Cap Screw (2) Screw (2) Rear Cover M82096 3. Remove field coil brushes from brush holder. 4. Pry brush springs away and pull negative brushes up enough to allow spring to hold brush in place. 5. Remove brush holder. Field Coil Brush (2) Hacksaw Blade Brush Spring (2) Armature Brush Holder Growler Negative Brush (2) M82125A M82097 6. Disconnect wiring lead. 7. Remove field coil housing, armature and seal ring, if equipped. 3-90 4/7/95 Starter 8. Inspect and test brushes, holder, field coil and armature. (See Inspection/Test procedures.) Spring (4) Seal Ring If equipped Negative Brush Holder Field Coil Housing Field Brush Holder Brush Length 3 M82099 Wiring Lead Armature M82098 Assembly Assembly is done in the reverse order of disassembly. • Apply multipurpose grease to bearing cup inside rear cover. IMPORTANT: When installing rear cover, be sure field coil brush wires do not touch cover. Turn brush holder slightly to take up slack in brush wires. Press wires inward to clear rear cover. NOTE: Test field coil using an ohmmeter or test light. 4. Test for grounded field winding: Touch one probe of tester to field coil brush and other probe to field coil housing. Be sure the brush lead is not touching the frame. If there is continuity, the coil is grounded and the field coil housing assembly must be replaced. 5. Test for open field coil: Touch one probe of tester to each field coil brush. If there is no continuity, the field coil is open and the field coil housing assembly must be replaced. Field Coil Brush Inspection/Test/Replacement 1. Measure holder and field coil brush lengths. Minimum brush length is 9 mm (0.354 in.). Replace brush holder or field coil if brush length is below minimum. NOTE: Test brush holder using an ohmmeter or test light. Field Coil Housing 2. Test brush holder: Touch one probe of tester to negative brush holder and other probe to field brush holder. If there is continuity, replace the brush holder. 3. Inspect springs for wear or damage. Replace if necessary. 4/7/95 M82100 3-91 3 Starter IMPORTANT: Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush. 6. Inspect armature. Look for signs of dragging against pole shoes. 7. Inspect commutator. Look for roughness, burned bars, or any material which might cause short circuits between bars. If necessary, clean and touch up with 400 sandpaper. NEVER use emery cloth. Clean all dust from armature when finished. NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments. 11.If test indicates short circuited windings, clean the commutator of dust and filings. Check the armature again. If the test still indicates a short circuit, replace the armature. Hacksaw Blade Armature NOTE: Test armature windings using an ohmmeter or test light. 3 3 8. Test for grounded windings: Touch probes on one commutator bar and armature shaft. Armature windings are connected in series, so only one commutator bar needs to be checked. If test shows continuity, a winding is grounded and the armature must be replaced. 9. Test for open circuited windings: Touch probes on two different commutator bars. If test shows no continuity, there is an open circuit and the armature must be replaced. Growler M82125A 12.Inspect armature cover and housing bearings for wear or damage. Replace if necessary. To replace bearings: Bearings are press fit. Remove bearings using a knife-edge puller set. IMPORTANT: Install both bearings with sealed side toward armature. Install new housing bearing tight against shoulder of shaft using a piece of pipe. Commutator Bars Install new rear cover bearing tight against shoulder of shaft using a driver set. Rear Cover Bearing Housing Bearing Armature Shaft M82101 10.Test for short circuited windings using a growler. Put armature in a growler and hold a hacksaw blade above each slot while slowly rotating armature. M82102 If coil is shorted, the blade will vibrate on the slot. 3-92 4/7/95 Starter STARTER OVERRUNNING CLUTCH HITACHI 2.0 kW 6. Remove ring, retainer, spring, clutch assembly and clutch shaft from clutch housing. Disassembly 7. Inspect all parts for wear or damage. Replace as necessary. 1. Disconnect wiring lead. Clutch Shaft 2. Remove two cap screws. 3. Remove starter motor assembly. Clutch Assembly Wiring Lead Spring 3 Cap Screw (2) Ring Starter Motor Assembly Clutch Housing 3 Retainer M82096 M82104 4. Remove three cap screws. 5. Separate clutch housing assembly from starter housing. Remove gasket. Gasket Clutch Housing Assembly Assembly Assembly is done in the reverse order of disassembly. • Apply multipurpose grease to all internal components during assembly. • Install retainer with large cupped side toward clutch assembly. Starter Housing STARTER SOLENOID - HITACHI 2.0 kW Cap Screw (3) Disassembly M82103 1. Disconnect wiring lead. 2. Remove cap screws. 3. Remove starter solenoid assembly. 4/7/95 3-93 Starter • Pull clutch shaft away from housing and insert clutch arm in starter housing. Push arm in until it stops. Wiring Lead Clutch Shaft Starter Solenoid Assembly Clutch Arm Cap Screws M82105 3 4. Remove clutch arm, clutch arm pivot, plunger and shim(s), if equipped, from solenoid. 5. Inspect all parts for wear or damage. Replace as necessary. 3 Solenoid M82107 STARTER MOTOR - NIPPONDENSO 1.0 kW Disassembly Plunger 1. Disconnect field lead. 2. Remove two cap screws and two screws. Clutch Arm Pivot 3. Remove rear cover and o-ring, if equipped. Field Lead Shim(s) If equipped. Clutch Arm O-Ring M82106 Assembly Screw (2) Assembly is done in the reverse order of disassembly. • Apply multipurpose grease to all internal components during assembly. IMPORTANT: Make sure long end of clutch arm is installed all the way into starter housing. Clutch arm must be install on end of clutch shaft or starter will not operate. Rear Cover Cap Screw (2) M82233 4. Remove field coil brushes from brush holder. 5. Pry brush springs away and pull negative brushes up enough to allow spring to hold brush in place. 6. Remove brush holder. 3-94 4/7/95 Starter Inspection/Test/Replacement Brush Spring Field Coil Brush (2) 1. Measure holder and field coil brush lengths. Minimum brush length is 8.5 mm (0.335 in.). Replace brush holder or field coil if brush length is below minimum. NOTE: Test brush holder using an ohmmeter or test light. Brush Holder 2. Test brush holder: M36754 7. Remove armature from field coil housing. 8. Remove felt washer and o-ring, if equipped. Touch one probe of tester to negative brush holder and other probe to field brush holder. If there is continuity, replace the brush holder. 3. Inspect springs for wear or damage. Replace if necessary. 9. Inspect and test brushes, holder, field coil and armature. (See Inspection/Test procedures.) Spring (4) Negative Brush Holder Felt Washer 3 Armature 3 Field Coil Housing O-Ring Brush Length M36759 Field Brush Holder Assembly Assembly is done in the reverse order of disassembly. • Apply multipurpose grease to bearing cup inside rear cover and felt washer, if equipped. IMPORTANT: When installing rear cover, be sure field coil brush wires do not touch cover. Turn brush holder slightly to take up slack in brush wires. Press wires inward to clear rear cover. M82234 NOTE: Test field coil using an ohmmeter or test light. 4. Test for grounded field winding: Touch one probe of tester to field coil brush and other probe to field coil housing. Be sure the brush lead is not touching the frame. If there is continuity, the coil is grounded and the field coil housing assembly must be replaced. 5. Test for open field coil: Touch one probe of tester to each field coil brush. If there is no continuity, the field coil is open and the field coil housing assembly must be replaced. 4/7/95 3-95 Starter Field Coil Brush Commutator Bars Field Coil Housing Armature Shaft M82235 3 3 IMPORTANT: Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush. 6. Inspect armature. Look for signs of dragging against pole shoes. 7. Inspect commutator. Look for roughness, burned bars, or any material which might cause short circuits between bars. If necessary, clean and touch up with 400 sandpaper. NEVER use emery cloth. Clean all dust from armature when finished. NOTE: Test armature windings using an ohmmeter or test light. M82236 10.Test for short circuited windings using a growler. Put armature in a growler and hold a hacksaw blade above each slot while slowly rotating armature. If coil is shorted, the blade will vibrate on the slot. NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments. 11.If test indicates short circuited windings, clean the commutator of dust and filings. Check the armature again. If the test still indicates a short circuit, replace the armature. Hacksaw Blade Armature 8. Test for grounded windings: Touch probes on one commutator bar and armature shaft. Armature windings are connected in series, so only one commutator bar needs to be checked. If test shows continuity, a winding is grounded and the armature must be replaced. 9. Test for open circuited windings: Touch probes on two different commutator bars. If test shows no continuity, there is an open circuit and the armature must be replaced. 3-96 Growler M82125A 12.Inspect armature cover and housing bearings for wear or damage. Replace if necessary. To replace bearings: Bearings are press fit. Remove bearings using a knife-edge puller set. 4/7/95 Starter IMPORTANT: Install both bearings with sealed side toward armature. Install new housing bearing tight against shoulder of shaft using a piece of pipe. Install new rear cover bearing tight against shoulder of shaft using a driver set. Clutch Housing-toSolenoid Housing Screws Rear Cover Bearing Housing Bearing M82238 2. Separate clutch housing from solenoid/motor assembly. 3. Remove plunger spring and gear, if equipped. Plunger Spring 3 M82237 3 STARTER GEAR TRAIN AND OVERRUNNING CLUTCH NIPPONDENSO 1.0 kW Disassembly/Inspection 1. Remove two motor-to-clutch housing cap screws and two clutch housing-to-solenoid housing screws. Gear Clutch Housing M82239 NOTE: Starter is equipped with either a 33 mm (1.299 in.), 44 mm (1.732 in.) or 44.5 mm (1.752 in.) drive gear on end of clutch shaft. Disassembly procedures are slightly different. Motor-to-Clutch Housing Cap Screws 4. Starter with 33 mm (1.299 in.) drive gear: Remove clutch assembly from housing. 5. Remove retainer, five rollers and pinion gear. 6. Remove steel ball. M82233 4/7/95 3-97 Starter 11.Starter with 33 mm (1.299 in.) drive gear: Remove drive gear and spring from clutch assembly. Steel Ball Clutch Assembly Starter with 44 mm (1.732 in.) or 44.5 mm (1.752 in.) drive gear: Remove drive gear, spring and clutch assembly from housing. Pinion Gear Clutch Housing Sarter with 44 or 44.5 mm (1.732 or 1.752 in.) drive gear only. Clutch Assembly Roller (5) Drive Gear Retainer M82240 3 7. Put clutch (housing) assembly into a soft-jawed vice, as shown. Spring 8. Tighten vise slowly, until drive gear compresses. 3 Retainer Circlip 9. Remove retainer and circlip. M82242 Retainer Circlip 12.Remove washer, toothed washer, spring and clutch shaft. 13.Inspect all parts for wear or damage. Replace as necessary. Clutch Shaft Spring Starter with 44 or 44.5 (1.732 or 1.752 in.) Drive Gear Shown M82241 CAUTION Shaft could be propelled from clutch unit with considerable force if spring is not allowed to extend fully while in vise. Clutch Toothed Washer Large Washer M82243 10.While holding clutch assembly, slowly open vise until all spring compression is relieved. 3-98 4/7/95 Starter Assembly Assembly is done in the reverse order of disassembly. Contact Plates • Apply multipurpose grease to bearings, clutch shaft, springs, pinion gears, retainer, rollers and steel ball. • Install large washer with flat side toward clutch assembly. Spring Plunger • Install retainer with cupped side away from clutch assembly. Copper Washer STARTER SOLENOID NIPPONDENSO 1.0 kW M82245 Disassembly/Inspection 1. Disconnect field lead. 3 Terminal Bolt 2. Remove three screws and clip. 3. Remove cover and gasket. 3 Nut Washer Field Lead Clip Contact Plate O-Ring Insulator M36771 Assembly Screw (3) M82244 4. Remove plunger. 5. Disassemble terminals. Remove parts from each terminal in order shown. 6. Inspect copper washer and contact plates for excessive burning or pitting. Clean burnt areas to improve electrical contact. Replace contacts or plunger if necessary. The solenoid is not serviceable. If defective, replace solenoid housing assembly. 4/7/95 Assembly is done in the reverse order of disassembly. NOTE: The assembly sequence of the left and right terminals is similar. Be sure solenoid terminal lead is installed between terminal bolt and contact plate. Also, be sure smaller contact plate is on the left side. 3-99 Starter Field Coil Brush (2) Solenoid Terminal Lead Brush Spring (2) Terminal Bolt Small Contact Plate STARTER MOTOR - NIPPONDENSO 3 1.4 kW Negative Brush (2) M82097 6. Disconnect wiring lead and relay leads, if equipped. Disassembly 3 1. Brush Holder M36771 Remove two cap screws and two screws. 2. Remove rear cover and thrust washer, if equipped. 7. Remove field coil housing, armature and o-ring, if equipped. 8. Inspect and test brushes, holder, field coil and armature. (See Inspection/Test procedures.) Seal Ring If equipped Field Coil Housing Thrust Washer Cap Screw (2) Screw (2) Rear Cover M82096 3. Remove field coil brushes from brush holder. 4. Pry brush springs away and pull negative brushes up enough to allow spring to hold brush in place. 5. Remove brush holder. 3-100 Wiring Lead Armature M82098 4/7/95 Starter Assembly Assembly is done in the reverse order of disassembly. • Apply multipurpose grease to bearing cup inside rear cover. IMPORTANT: When installing rear cover, be sure field coil brush wires do not touch cover. Turn brush holder slightly to take up slack in brush wires. Press wires inward to clear rear cover. Inspection/Test/Replacement 1. Measure holder and field coil brush lengths. Minimum brush length is 8.5 mm (0.335 in.). Replace brush holder or field coil if brush length is below minimum. NOTE: Test brush holder using an ohmmeter or test light. 2. Test brush holder: Touch one probe of tester to negative brush holder and other probe to field brush holder. If there is continuity, replace the brush holder. Touch one probe of tester to field coil brush and other probe to field coil housing. Be sure the brush lead is not touching the frame. If there is continuity, the coil is grounded and the field coil housing assembly must be replaced. 5. Test for open field coil: Touch one probe of tester to each field coil brush. If there is no continuity, the field coil is open and the field coil housing assembly must be replaced. IMPORTANT: Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush. 6. Inspect armature. Look for signs of dragging against pole shoes. 7. Inspect commutator. Look for roughness, burned bars, or any material which might cause short circuits between bars. If necessary, clean and touch up with 400 sandpaper. NEVER use emery cloth. Clean all dust from armature when finished. Field Coil Brush 3. Inspect springs for wear or damage. Replace if necessary. Spring (4) Negative Brush Holder Field Coil Housing M82100 Field Brush Holder NOTE: Test armature windings using an ohmmeter or test light. Brush Length 8. Test for grounded windings: M82099 NOTE: Test field coil using an ohmmeter or test light. 4. Test for grounded field winding: 4/7/95 Touch probes on one commutator bar and armature shaft. Armature windings are connected in series, so only one commutator bar needs to be checked. If test shows continuity, a winding is grounded and the armature must be replaced. 3-101 3 3 Starter 9. Test for open circuited windings: To replace bearings: Touch probes on two different commutator bars. If test shows no continuity, there is an open circuit and the armature must be replaced. Bearings are press fit. Remove bearings using a knife-edge puller set. IMPORTANT: Install both bearings with sealed side toward armature. Install new housing bearing tight against shoulder of shaft using a piece of pipe. Commutator Bars Install new rear cover bearing tight against shoulder of shaft using a driver set. Rear Cover Bearing Housing Bearing 3 3 Armature Shaft M82101 10.Test for short circuited windings using a growler. Put armature in a growler and hold a hacksaw blade above each slot while slowly rotating armature. If coil is shorted, the blade will vibrate on the slot. NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments. M82102 STARTER GEAR TRAIN AND SOLENOID - NIPPONDENSO 1.4 kW Disassembly/Inspection 1. Remove two socket head screws, end cap and shim(s). 11.If test indicates short circuited windings, clean the commutator of dust and filings. Check the armature again. If the test still indicates a short circuit, replace the armature. End Cap Hacksaw Blade Shim(s) Armature M37820 Growler M82125A 12.Inspect armature cover and housing bearings for wear or damage. Replace if necessary. 3-102 2. Disconnect wiring lead and relay leads, if equipped. 3. Remove two cap screws. 4. Remove starter motor assembly from bearing housing. 4/7/95 Starter 8. Remove two cap screws, plunger, spring, shims and solenoid. Wiring Lead End Frame Shim(s) Solenoid Cap Screw (2) Starter Motor Assembly Cap Screw (2) M82096 Plunger Spring 5. Remove three cap screws. M37824 6. Separate end frame assembly from bearing housing. 9. Remove shims from ring gear shaft. 3 Cap Screw (3) End Frame Assembly 3 Shims Ring Gear Shaft Bearing Housing M37821 M37822 7. Inspect seal and needle bearing for wear or damage. Replace as necessary. 10.Remove pivot bolt, clutch fork and clutch assembly. 11.Inspect shoes on fork for wear or damage. Replace fork if necessary. To replace needle bearing: Remove bearing using a blind-hole puller set. Install new bearing flush with housing surface using a driver set. Shoes End Frame Clutch Assembly Bearing Housing Pivot Bolt Seal Clutch Fork M37825 Needle Bearing M37823 4/7/95 12.Inspect end frame bushing for wear or damage. Replace if necessary. 3-103 Starter Replace bushing using a driver set. Install bushing flush with face of housing. Clutch Snap Ring Spring Spring Cap Washer End Frame Bushing 3 M37830 13.Slide pinion stopper away from retaining wire using a piece of pipe or deep socket. Remove retaining wire, pinion stopper, and clutch assembly from ring gear shaft. 14.Inspect all parts for wear or damage. Replace as necessary. M37829 Assembly Assembly is done in the reverse order of disassembly. • After installing clutch assembly, pinion stopper and retaining wire on ring gear shaft, use two pliers to press pinion stopper over retaining wire. 3 Clutch Assembly Pinion Stopper Retaining Wire Ring Gear Shaft M37827 Retaining Wire Pinion Stopper Clutch Assembly M37831 15.Remove snap ring, washer, spring cap, and spring from clutch. 16.Inspect all parts for wear or damage. Replace as necessary. 3-104 4/7/95 Alternator ALTERNATOR - KOKOSAN 20A 6. Inspect bearing in coil plate for wear or damage. Replace if necessary. Disassembly/Inspection To replace bearing: Remove bearing using a spark plug socket and a press. Install bearing into coil plate until it bottoms in bore using a 1 in. socket. 1. Remove nut and washers. 2. Tap on end of shaft with a soft-faced hammer to separate flywheel assembly from coil plate assembly. 7. Remove wire clamp. 8. Remove connector from harness leads. 3. Remove long spacer. 9. Remove two screws and stator. Lock Washer 10.Inspect all parts for wear or damage. Replace as necessary. Washer Flywheel Assembly Wire Clamp Nut 27 N•m (20 lb-ft) 3 Coil plate Screw (2) Coil Plate Assembly Long Spacer M82247A NOTE: Bearing and flywheel are press fit on shaft. 4. Remove shaft from bearing, short spacer, washer, flywheel and sheave half, using a press. 5. Inspect all parts for wear or damage. Replace as necessary. Bearing Press fit in coil plate. Connector Stator M82249A Assembly Assembly is done in the reverse order of disassembly. • With sheave half on shaft, press shaft into flywheel until sheave half bottoms on flywheel face. Short Spacer Washer Flywheel • With washer and short spacer installed, press new bearing onto shaft until it bottoms on spacer. Shaft Bearing Press fit on shaft. Sheave Half M82248A NOTE: Remove bearing only if replacement is necessary. 4/7/95 3-105 Alternator VOLTAGE REGULATOR HITACHI 25A Attaching Screw (4) M5 4 N•m (31 lb-in.) Two Nuts and Insulator Stator End Frame-to-Rectifier Nuts (4) M5 4 N•m (31 lb-in.) Grommet Wire Clamp Front Frame End Frame 3 M82108 Replacement 17.Use a soldering gun with at least 120 watt capacity to disconnect five terminals. Replace voltage regulator. 3 11.Remove three screws and cover. 12.Remove four attaching screws, wire clamp and grommet. • If additional solder is needed, use ONLY 60-40 rosin-core solder. 13.Remove four end frame-to-rectifier nuts. ALTERNATOR - HITACHI 25A 14.Remove two nuts and insulator. IMPORTANT: Do not pry against stator wires. 15.Use a screwdriver to pry end frame from stator. Do not separate stator from front frame. Brush Holder 1. Remove three screws and cover. 2. Remove four attaching screws, wire clamp and grommet. 16.Remove two screws and insulator. Insulator Disassembly Terminals Voltage Regulator Attaching Screws (4) M5 4 N•m (31 lb-in.) Screw (2) M51602 Grommet IMPORTANT: Do not heat connections longer than necessary to melt solder, as excess heat will damage rectifier assembly. Wire Clamp M82108 3-106 4/7/95 Alternator IMPORTANT: Do not pry against stator wires. 3. Use a screwdriver to separate rotor assembly from stator assembly. Stator Assembly Rotor Assembly: • Rear bearing is press fit. Replace only if necessary. Remove bearing using a puller set. Install bearing until flush with end of rotor shaft. Press only on inner race of bearing. 4. Put rotor assembly in a soft-jawed vise. Remove nut, lock washer, sheave, fan and bushing. 5. Put front frame on open jaws of vice. Use a softfaced hammer to remove rotor and spacer. 6. Remove three screws, retainer and front bearing. 7. Inspect all parts for wear or damage. Replace as necessary. 8. Test rotor. (See Inspection/Test procedures.) Rotor Assembly 3 M36730 Rear Bearing Apply multipurpose grease to O.D. during assembly. Screw (3) 2 N•m (16 lb-in.) Bushing Clip Rotor Spacer Retainer Nut M14 49 N•m (36 lb-ft) Front Bearing Front Frame Fan Sheave Lock Washer M82109A 4/7/95 3-107 Alternator Stator Assembly: IMPORTANT: Be sure stator lead wires do not contact end frame when installed. 9. Remove four end frame-to-rectifier nuts. 10.Remove two nuts and insulator. IMPORTANT: Do not pry against stator wires. 11.Use a screwdriver to pry end frame from stator Two Nuts and Insulator End Frame 3 3 End Frame-to-Rectifier Nuts M5 4 N•m (31 lb-in.) • Before assembling stator assembly to rotor assembly, push brushes into brush holder and insert a wire through access hole to lock brushes in place. • Assemble rotor assembly to stator assembly and fasten with four attaching screws. Remove wire from access hole. Access Hole M51595 12.Use a soldering gun with at least 120 watt capacity to disconnect three stator leads. Remove rectifier. End Frame M51595 Inspection/Test Rectifier Rotor: • Inspect the rotor slip rings for dirt build-up, rough spots, or out of roundness. If necessary, polish the surface of the slip rings using No. 00 sandpaper or 400-grit silicon carbide paper. Stator Leads (3) • Touch the probes of an ohmmeter to slip rings. Replace rotor if test indicates no continuity (no needle movement). Stator M51605 Ohmmeter 13.Inspect and test brushes, stator and rectifier. (See Inspection/Test procedures.) Assembly Assembly is done in the reverse order of disassembly. • Bend the stator lead wires, as necessary, to obtain an approximate distance of 33.50 mm (1.300 in.) from stator to rectifier. Connect the three leads using a soldering gun. • If additional solder is needed, use ONLY 60-40 rosin-core solder. 3-108 Rotor Shaft Slip Rings M82110A • Touch the probes of the ohmmeter to the shaft and one of the slip rings. Repeat for other slip ring. Replace rotor if test shows continuity (needle movement). 4/7/95 Alternator Ohmmeter • Use an ohmmeter or a test light to check for continuity. Check between the two brushes and between each brush and ground stud. There should be no continuity. Replace brush holderrectifier assembly if there is continuity. • To replace brushes, melt solder from connection. Remove voltage regulator if necessary. (See VOLTAGE REGULATOR REPLACEMENT in this group.) Rotor Shaft Slip Rings M82111A NOTE: If additional solder is needed, use ONLY 6040 rosin-core solder. Stator: Brushes: • Inspect brush holder and brushes for damage. Brushes must slide freely and the springs must hold the brushes firmly against the slip rings of the rotor. • Measure brushes for wear. Minimum exposed length must be 5.50 mm (0.220 in.) or to wear limit line on brushes. Replace brushes as necessary. • Inspect stator for defective insulation, discoloration or a burned odor. If any of these defects are found, replace stator. 3 NOTE: Use an ohmmeter that is sensitive to resistance of 0 to 1 ohm. • Touch probes of an ohmmeter to lead wires of stator in three possible combinations. Continuity should read approximately 0.26 ohms. If readings are not equal, replace stator. Brush Length Ohmmeter Rectifier Voltage Regulator Stator Brushes M82113A • Touch one probe of the ohmmeter to the bare metal surface of stator and the other probe to a bare stator lead wire. Repeat for each wire. Replace stator if test indicates continuity. Ground Stud Ohmmeter Brush Holder Soldered Connection M82112 Stator M82114A 4/7/95 3-109 Alternator Rectifier: • Test the diodes by touching probes to ground post and the three outer terminals. • Switch the probes and check each terminal again. There should be continuity in only one combination of each terminals and the ground post. • Test the diodes by touching probes to output post and the three outer terminals. VOLTAGE REGULATOR NIPPONDENSO 35A Replacement 1. Remove three attaching screws. Altaching Screw (3) M5 4 N•m (31 lb-in.) • Switch the probes and check each terminal again. There should be continuity in only one combination of each terminal and the output post. 3 A shorted diode would have continuity in both directions. An open diode would have no continuity in either direction. Replace the rectifier assembly if any of the three diodes are defective. • To replace rectifier, melt solder from connection. 3 NOTE: M36725 2. Remove end frame-to-rectifier nut. 3. Remove nuts and insulators. If additional solder is needed, use ONLY 6040 rosin-core solder. End Frame-to-Rectifier Nut M5 4 N•m (31 lb-in.) Soldered Connection Nuts and Insulators M36726 IMPORTANT: Do not pry against stator wires. Outer Terminals Outer Terminal Output Post Ground Post 4. Use a screwdriver to pry end frame from stator. Do not separate stator from front frame. End Frame M82115 Stator Front Frame M36727 3-110 4/7/95 Alternator IMPORTANT: Do not heat connections longer than necessary to melt solder, as excess heat will damage rectifier assembly. IMPORTANT: Do not pry against stator wires. 2. Use a screwdriver to separate rotor assembly from stator assembly. 5. Use a soldering gun with a least 120 watt capacity to disconnect terminals. Replace voltage regulator. Stator Assembly Voltage Regulator Rotor Assembly Terminals M36730 M36728 Installation is done in the reverse order of removal. • If additional solder is needed, use ONLY 60-40 rosin-core solder. ALTERNATOR - NIPPONDENSO 35A Disassembly Rotor Assembly: • Rear bearing is press fit. Replace only if necessary. Remove bearing using a puller set. Install bearing until flush with end of rotor shaft. Press only on inner race of bearing. 3. Put rotor assembly in a soft-jawed vise. Remove nut, lock washer, sheave, fan and bushing. 4. Put front frame on open jaws of vice. Use a softfaced hammer to remove rotor and spacer. 1. Remove three attaching screws. 5. Remove three screws, retainer, front bearing, washer and felt washer. Attaching Screw (3) M5 4 N•m (31 lb-in.) 6. Inspect all parts for wear or damage. Replace as necessary. M36725 4/7/95 3-111 3 Alternator Rear Bearing Apply multipurpose grease to O.D. during assembly. Bushing Fan Sheave Screw (3) 2 N•m (16 lb-in.) Lock Washer Front Bearing Rotor Spacer Retainer 3 Nut M14 54 N•m (40 lb-ft) Washer Felt Washer Apply multipurpose grease during assembly. 3 Front Frame M82250A 7. Test rotor. (See Inspection/Test procedures.) Stator Assembly: 11.Use a soldering gun with at least 120 watt capacity to disconnect terminals. Remove voltage regulator. 8. Remove end frame-to-rectifier nut. 9. Remove nuts and insulators. Voltage Regulator IMPORTANT: Do not pry against stator wires. 10.Use a screwdriver to pry end frame from stator. End Frame-to-Rectifier Nut M5 4 N•m (31 lb-in.) Terminals M36728 12.Melt solder inside the connecting pipes. While solder is hot, open the flattened pipe with a needle nose pliers. Pull stator wire from pipe. Nuts and Insulators M36726 3-112 4/7/95 Alternator • Assemble rotor assembly to stator assembly and fasten with three attaching screws. Remove wire from access hole. Inspection/Test Rotor: M36739 13.Inspect and test brushes, stator and rectifier. (See Inspection/Test procedures.) • Inspect the rotor slip rings for dirt build-up, rough spots, or out of roundness. If necessary, polish the surface of the slip rings using No. 00 sandpaper or 400-grit silicon carbide paper. • Touch the probes of an ohmmeter to slip rings. Replace rotor if test indicates no continuity (no needle movement). Assembly Ohmmeter Assembly is done in the reverse order of disassembly. 3 NOTE: The three pair of lead wires on the stator are not evenly spaced. Rotate the rectifier until the terminal pipes align with the stator leads. • Bend the stator lead wires, as necessary, to obtain an approximate distance of 33.50 mm (1.300 in.) from stator to rectifier. Connect the six leads using a soldering gun. • If additional solder is needed, use ONLY 60-40 rosin-core solder. Rotor Shaft Slip Rings M82110A • Touch the probes of the ohmmeter to the shaft and one of the slip rings. Repeat for other slip ring. Replace rotor if test shows continuity (needle movement). IMPORTANT: Be sure six stator lead wires do not contact end frame when installed. Ohmmeter • Before assembling stator assembly to rotor assembly, push brushes into brush holder and insert a wire through access hole in rear at end frame to lock brushes in place. Rotor Shaft Wire Slip Rings Brushes M82111A Brushes: M36748 4/7/95 • Inspect brush holder and brushes for damage. Brushes must slide freely and the springs must hold the brushes firmly against the slip rings of the rotor. 3-113 Alternator • Measure brushes for wear. Minimum exposed length must be 5.50 mm (0.220 in.) or to wear limit line on brushes. Replace brushes as necessary. • Use an ohmmeter or a test light to check for continuity. Check between the two brushes and between each brush and ground stud. There should be no continuity. Replace brush holderrectifier assembly if there is continuity. Insulator Brush Holder Brush Ground Stud Brushes Brush Lead Wire 3 Insulating Washers M36736 3 M36745 • To replace brushes: - Melt solder from brush lead connections and remove brushes and springs. - Inspect springs for wear or damage. Replace as necessary. NOTE: If additional solder is needed, use ONLY 6040 rosin-core solder. Stator: • Inspect stator for defective insulation, discoloration or a burned odor. If any of these defects are found, replace stator. NOTE: Use an ohmmeter that is sensitive to resistance of 0 to 1 ohm. Brush Lead Connections • Touch probes of an ohmmeter to each pair of stator wires. Equal continuity readings should be observed between each pair of leads. If readings are not equal, replace stator. M36737 - Push brush lead wire through spring. Insert spring and brush in brush holder with lead protruding through hole in brush holder. Make sure the longest side of brush is on side of brush holder with raised lip. - Hold brushes in position so that exposed length is 13 mm (0.500 in.) - Solder brush leads in this position. Cut off excess length of brush lead wire. - Be sure insulating washers and insulator are in place. 3-114 M36740 4/7/95 Alternator • Touch one probe of the ohmmeter to the bare metal surface of stator and the other probe to a bare stator lead wire. Repeat for each wire. Replace stator if test indicates continuity. Output Post M36743 • Test the diodes by touching probes to ground post and the three outer terminals. M36741 Rectifier: NOTE: The three inner terminals are connected by a printed circuit in the rectifier. • Test the three inner terminals using an ohmmeter. Move probes so all terminals are cross checked. Replace the rectifier if test shows no continuity. • Switch the probes and check each terminal again. There should be continuity in only one direction between each terminal and the ground post. A shorted diode would have continuity in both directions. An open diode would have no continuity in either direction. Replace the rectifier assembly if any of the six diodes are defective. Inner Terminals Ground Post M36744 M36742 NOTE: Each of the three outer terminals on the rectifier is connected to two diodes permitting current flow in only one direction. • Test the diodes by touching probes to output post and the three outer terminals. VOLTAGE REGULATOR NIPPONDENSO 40A Replacement 1. Remove nut and insulator. 2. Remove three screws and cover. • Switch the probes and check each terminal again. There should be continuity in only one direction between each terminal and the output post. 4/7/95 3-115 3 Alternator Nut 69 N•m (51 lb-ft) Cover Nut and Insulator Sheave M52470 3. Remove two screws, brush holder and cover. 4. Remove three screws. Replace voltage regulator. M52469 4. Remove four screws and straighten stator wire leads. 5. Remove rectifier. Long Screw (2) 3 Voltage Regulator Rectifier Stator Wire Lead (4) 3 Short Screw Brush Holder and Cover M52472 M52471 Installation is done in the reverse order of removal. IMPORTANT: Make sure to install short screw at location shown. Longer screw will contact frame and cause damage to the charging system. ALTERNATOR - NIPPONDENSO 40A 6. Remove two nuts, two screws and end frame assembly. 7. Press rotor shaft from end frame. 8. Remove spring washer. Spring Washer Disassembly 1. Remove voltage regulator. (See VOLTAGE REGULATOR - REPLACEMENT in this group.) 2. Remove nut. 3. Remove sheave using a puller set. Rotor Shaft End Frame Assembly M52473 3-116 4/7/95 Alternator 9. Remove four screws and retainer. NOTE: Front bearing is press fit in front frame. Remove bearing only if replacement is necessary. 10.Inspect bearing in front frame for wear or damage. Replace if necessary. Replace bearing using a driver set and a press. • Touch the probes of an ohmmeter to slip rings. Replace rotor if test indicates no continuity (no needle movement). • Touch probes of ohmmeter to the rotor core and one of the slip rings. Repeat for other slip ring. Replace rotor if test shows continuity (needle movement). Rear Bearing Front Bearing Front Frame Screw (4) 2 N•m (16 lb-in.) Retainer Rotor Core Slip Rings M52474 M52475 11.Inspect and test brushes, stator and rectifier. (See Inspection/Test in this group.) Assembly Assembly is done in the reverse order of disassembly. Brushes: • Inspect brush holder, brushes and springs for damage. Brushes must slide freely and springs must hold brushes firmly against the slip rings of the rotor. • Measure length of brush protruding from holder. If length is less than wear limit, replace brushes. • After installing rectifier, form a loop in stator wire leads, insert screws through loop and secure rectifier and wire leads. Inspection/Test Rotor: NOTE: Rear bearing and rotor assembly are not serviced separately. Damaged parts require that rotor assembly and bearing be replaced as a unit. • Inspect bearing for wear or damage. Replace complete rotor if necessary. • Inspect slip rings for dirt build-up, rough spots or out-of-roundness. If necessary, polish the surface of the slip rings using No. 00 sandpaper or 400-grit silicone carbide paper. Measure outer diameter of slip rings. Replace rotor if less than 14 mm (0.550 in.). 4/7/95 M52478 Brush Length Specifications New. . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.) Wear Limit. . . . . . . . . . . . 4.50 mm (0.170 in.) • Check continuity between brush and terminal “A”. Check continuity between brush and terminal “B”. There should be continuity only at these points. 3-117 3 Alternator Rectifier: A B NOTE: Set the ohmmeter to the K ohm range. • Check continuity between output post and each diode lead. Reverse ohmmeter leads and recheck. There should be continuity in one direction, but not the other. M52479 Stator: • Inspect stator for defective insulation, discoloration or a burned odor. If any of these defects are found, replace stator. A shorted diode would have continuity in both directions. An open diode would have no continuity in either direction. Replace the rectifier if any of the four diodes are defective. Diode Lead (4) NOTE: Use an ohmmeter that is sensitive to resistance of 0 to 1 ohm. 3 3 • Check for continuity between each stator lead and stator body. Replace stator if test indicates continuity. To replace stator: - Scribe a mark on housing, at notch in stator, to aid in installation of a new stator. - Remove two studs. - Replace stator using a punch and hammer. Output Post M52477 Stator Lead (4) Stator Body Stud (2) Scribe Mark on Housing 3-118 Notch M82251 4/7/95 Diagnosis ● ● ● ● ● Fuel shut-off valve turned off, or restricted. Solenoid linkage misadjusted. See adjustment. ● ● ● ● ● ● ● Muffler or exhaust manifold leak. Defective manifold heater. ● Injection pump or governor malfunctioning. Injection pump timing incorrect. ● Defective cranking components or connectors. ● Low compression from worn rings, cylinder bore, piston, valves or warped head. Valve clearance incorrect. ● Burned or warped valves and valve seats. Defective valve spring. Starter cranking rpm too slow. Damaged starter. Excessive engine load. ● Fuel pump leaking or not operating. See Fuel Supply Pump Pressure Test. Engine oil viscosity or level incorrect. ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Turbocharger ● 3 3 ● Radiator/oil cooler leak. 4/7/95 ● ● ● Injector pressure incorrect or leaking. Cylinder head gaskets leaking or damaged. ● Exhaust smoke black or grey or uses too much fuel. Air filter elements dirty or plugged. Replace. ● Exhaust smoke white. ● Exhaust smoke blue or uses too much oil. ● Engine operating temperature is incorrect. Engine surges, or has uneven or uncontrolled rpm. ● Engine has low oil pressure. Engine runs rough, misses, noisy, vibrates or low on power. Fuel in oil. Oil level high. ● Oil in the coolant or coolant in the oil. Engine will not stay running, or stalls frequently. Fuel pump screen, fuel filter, or fuel line restricted. Fuel dirty, contains water or wrong grade. CHECK OR SOLUTION Engine will not crank. Engine cranks but will not start or starts hard. PROBLEM OR SYMPTOM Lack of fuel at injection pump. ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART ● ● ● ● ● ● ● ● ● ● ● ● ● ● 3-119 Diagnosis ENGINE SYSTEM DIAGNOSIS Conditions: • Engine mounted on level surface. • Key switch off unless indicated otherwise. Test Location Normal If Not Normal 1. Engine dipstick and exterior engine surfaceengine oil check. Oil level between “L” and “H” marks. Oil not burnt, or contaminated with metal particles, fuel, or coolant. No external leakage, filter clean. Change oil and inspect for source of contamination. Check gaskets, seals, plugs, cylinder head, block, and intake manifold and breather. Change oil filter. 2. Coolant tank and radiator. Coolant level between marks on tank when engine is warm. Coolant in radiator full to top. Coolant not contaminated with oil, fuel or discolored brown. Add proper coolant mix. Radiator screen free of debris. Clean or replace. Hoses not cracked or leaking, clamps and radiator cap tight. Pressure test radiator and cap. Fan belt tight, not glazed or cracked. Replace and adjust belt tension. Fan blades not damaged or warped. Replace fan. Fuel level correct, not contaminated, correct grade of fuel, no water. Fuel pump screen and in-line filter free of debris. Fuel shutoff valve in “ON” position. Drain and clean fuel tank. Add fresh fuel. Replace filters. Fuel hoses not cracked or leaking. Replace. Fuel hose clamps tight. Replace or tighten. Fuel tank does not have vacuum. Replace fuel tank check valve. Air filter hose not cracked, clamps tight. Element not plugged. Air filter housing sealed, no dirt tracking inside filter element. Replace and tighten clamps. - Cooling System Check. 3 3 3. Fuel tank, pump, pump screen, lines, filter, filter shutoff valve. - Fuel System Check 4. Air filter and air intake. - Air Intake System Check Drain and flush system. Check for source of contamination. Move to “ON” position. Replace element or housing. 5. Fuel shutoff solenoid. (Key in RUN position.) Fuel shutoff solenoid must pull in and stay in. Solenoid must bottom out. Shutoff shaft must still move slightly. Check shutoff solenoid adjustment. Clean any dirt from under solenoid boot. If solenoid will not pull in and hold in, see Fuel Shutoff Solenoid Circuit Test Points in ELECTRICAL section of Machine TM. 6. Air heater indicator light. (Key in RUN position.) Indicator light should come on up to 15 seconds depending on air temperature. See Air Heater Circuit Test Points in ELECTRICAL section of Machine TM. 3-120 4/7/95 Diagnosis ENGINE SYSTEM DIAGNOSIS - Continued Test Location Normal If Not Normal 7. Fuel filter, fuel pump. (Key switch in RUN position.) Fuel level increases in filter. Fuel pump operating - listen for humming sound. Fuel present in return hose at fuel pump. See Fuel Pump Circuit Test Points in ELECTRICAL section of Machine TM. Test fuel pump pressure. (See Operational Tests in this section.) Replace fuel filter. 8. Throttle lever and cable. Linkage not binding and adjusted correctly. Repair, replace or adjust cable. 9. Intake and exhaust valves. Cold engine. Valve clearance within specification. Valves not sticking. Check and adjust. (See Checks, Tests and Adjustments in this section.) Check valve guides and stems. 10. Fuel at injectors. (Key in START position - engine cranking.) Crack fuel injection lines at injectors. Fuel shutoff solenoid pulled in. Check spray pattern and cracking pressure. (See Checks, Tests and Adjustments in this section.) Replace injectors.See Cranking Circuit Test Points in ELECTRICAL section of Machine TM. 11. Injector ports. (Key in START position.) Cylinder compression within specification. Pressure difference between cylinders within specification. Perform cylinder compression test. (See Operational Tests in this section.) 12. Flywheel and starter. Minimum cranking rpm within specification. See Starter Amp Draw Test in ELECTRICAL section of Machine TM. 13. Injection pump timing inspection. (Key OFF.) Timing should be correct. Remove pump as the LAST possible solution. Perform injection pump static timing adjustment. (See Checks, Tests and Adjustments in this section.) Have pump tested by a qualified Service Repair Shop. 14. Injection pump idle settings. (Engine running). Engine runs smooth under load. Engine rpm to specification. See Slow Idle and Fast Idle Adjustments in ENGINE section of Machine TM. 15. Oil pressure sender port. Oil pressure in specification. Test engine oil pressure. (See Operational Tests in this section.) 16. Thermostat. (Engine at operating temperature.) Clean from corrosion, rust, or debris. Opening temperature within specification. Replace thermostat. Perform thermostat opening test. (See Checks, Tests and Adjustments in this section.) 17. Muffler. Not restricted. Replace muffler. 4/7/95 Engine must crank. 3-121 3 3 Checks, Tests and Adjustments VALVE CLEARANCE, CHECK AND ADJUSTMENT Reason: To achieve correct engine operation. 1 2 I E 3 I E 4 I E I E Fan End Flywheel End Cylinders Equipment: No. 1 Piston at TDC • Feeler Gauge T6479AB To adjust valves, loosen nut and turn adjusting screw until clearance is 0.20 mm (0.008 in.). Hold screw while tightening nut. Procedure: 1. Remove rocker arm cover. 2. Remove plug from timing hole on flywheel housing. 3 NOTE: “Top Dead Center (TDC)” is the piston at its highest point. Feeler Gauge 3. Turn crankshaft pulley clockwise until No.1 cylinder TDC mark on flywheel aligns with index mark on flywheel housing. 3 TDC Mark on Flywheel T6105BF 6. Turn crankshaft pulley one revolution (360°). This puts the piston in No. 4 cylinder at TDC compression stroke. Index Mark on Flywheel Housing T6469AJ 7. Measure and adjust valve clearance on the valves (arrows) with No. 4 piston at TDC. NOTE: No. 1 cylinder is the closest to the flywheel. 5. Measure and adjust valve clearance on the valves (arrows) with No. 1 piston at TDC. 3-122 E 2 I E 3 I E 4 I E I Fan End If rocker arm push rods are not loose, rotate flywheel one revolution (360°). If both rocker arm push rods are loose the piston is at TDC on compression stroke. Cylinders 1 Flywheel End 4. Try to move both No. 1 cylinder rocker arms or push rods. No. 4 Piston at TDC T6479AB 4/7/95 Checks, Tests and Adjustments CONNECTING ROD SIDE PLAY CHECK Equipment: Reason: Procedure: To determine proper side clearance between crankshaft and connecting rod. Equipment: • Feeler Gauge • PLASTIGAGE® IMPORTANT: Connecting rod caps must be installed on the same connecting rod and in the same direction to prevent crankshaft and connecting rod damage. 1. Remove connecting rod cap. 2. Wipe oil from bearing insert and crankshaft journal. Procedure: 1. Insert a feeler gauge, according to specifications, between connecting rod cap and crankshaft. 3. Put a piece of PLASTIGAGE, or an equivalent, along the full length of the bearing insert approximately 6 mm (0.250 in.) off center. 3 3 PLASTIGAGE M35351 Feeler Gauge 4. Turn crankshaft approximately 30° from bottom dead center. M82116A Specifications: Standard Clearance . . . . . . . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . (0.0079 - 0.0157 in.) Wear Limit. . . . . . . . . . . 0.55 mm (0.0217 in.) Results: • If side play exceeds wear limit, replace connecting rod and connecting rod cap. CONNECTING ROD BEARING CLEARANCE CHECK Reason: 5. Install connecting rod end cap and original cap screws. Tighten cap screws to: 4TN78T . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft) 4TN82, 4TN84(T)(4019) . . . 47 N•m (35 lb-ft) 6. Remove cap screws and connecting rod cap. NOTE: The flattened PLASTIGAGE will be found on either the bearing insert or crankshaft journal. 7. Use the graduation marks on the envelope to compare the width of the flattened PLASTIGAGE at its widest point. 8. Determine bearing clearance. The number within the graduation marks indicates the bearing clearance in inches or millimeters depending on which side of the envelope is used. To measure oil clearance between connecting rod bearing and crankshaft journal. 4/7/95 3-123 Checks, Tests and Adjustments 9. Remove PLASTIGAGE. 3. Zero the dial indicator. 4. Using a bar, gently pry the crankshaft as far forward as possible. Graduation Marks on Envelope Flattened PLASTIGAGE M82117A Specifications: 3 Standard Clearance . . . . . . 0.038 - 0.090 mm . . . . . . . . . . . . . . . . . . . . . (0.0015 - 0.0035 in.) Wear Limit. . . . . . . . . . . 0.16 mm (0.0063 in.) Results: 3 • If clearance exceeds wear limit, replace bearing inserts. ®PLASTIGAGE is a registered trademark of the DANA Corporation. Dial Indicator Crankshaft M82118A Specifications: Standard Clearance . . . . . . 0.090 - 0.271 mm . . . . . . . . . . . . . . . . . . . . . . . (0.004 - 0.011 in.) Wear Limit. . . . . . . . . . . 0.33 mm (0.0129 in.) Results: CRANKSHAFT, END PLAY CHECK • If end play exceeds wear limit, replace thrust bearings. Reason: To determine proper side clearance between crankshaft and engine block. CRANKSHAFT MAIN BEARING, CLEARANCE CHECK Equipment: Reason: • Dial Indicator Procedure: NOTE: Crankshaft end play can be measured at front end or rear end of crankshaft. Procedure is performed from the rear end. The flywheel is removed to show detail. 1. Fasten dial indicator to engine and position indicator tip on end of crankshaft. IMPORTANT: Do not use excessive force when moving crankshaft to avoid damaging bearings. 2. Push crankshaft toward rear as far as possible. 3-124 To measure oil clearance between main bearing and crankshaft journal. Equipment: • PLASTIGAGE® Procedure: IMPORTANT: Main bearing caps must be installed on the same main bearing and in the same direction to prevent crankshaft and main bearing damage. 1. Remove main bearing cap. 2. Wipe oil from bearing insert and crankshaft journal. 4/7/95 Checks, Tests and Adjustments 3. Put a piece of PLASTIGAGE, or an equivalent, along the full length of the bearing insert approximately 6 mm (0.250 in.) off center. Specifications: Standard Clearance . . . . . . 0.038 - 0.090 mm . . . . . . . . . . . . . . . . . . . . . (0.0015 - 0.0035 in.) Wear Limit. . . . . . . . . . . 0.06 mm (0.0063 in.) Results: • If clearance exceeds wear limit, replace bearing inserts. PLASTIGAGE ®PLASTIGAGE is a registered trademark of the DANA Corporation. VALVE LIFT CHECK M35382 Reason: 4. Install main bearing cap and cap screws. Tighten cap screws to: 4TN78T . . . . . . . . . . . . . . . . 79 N•m (58 lb-ft) 4TN82, 4TN84(T)(4019) . . . 98 N•m (72 lb-ft) 5. Remove cap screws and main bearing cap. NOTE: The flattened PLASTIGAGE will be found on either the bearing insert or crankshaft journal. 6. Use the graduation marks on the envelope to compare the width of the flattened PLASTIGAGE at its widest point. Can indicate excessive wear on cam lobes, followers, and/or push rods. Equipment: • Dial Indicator 3 Procedure: 1. Adjust valve clearance. (See procedure in this group.) 2. Remove rocker arm cover. (See Cylinder Head, Valves and Manifolds in this section.) 7. Determine main bearing clearance. The number within the graduation marks indicates the bearing clearance in inches or millimeters depending on which side of the envelope is used. 3. Fasten dial indicator to engine and position indicator tip on valve retainer. Valve must be fully closed and rocker arm must move freely. 8. Remove PLASTIGAGE. 5. Manually turn crankshaft pulley clockwise (from fan end). Graduation Marks on Envelope 4. Zero the dial indicator. 6. Observe dial indicator as valve is moved to the full open position. Valve lift (intake and exhaust) should be 8.8 mm (0.350 in.). Repeat for each valve. Flattened PLASTIGAGE M82119AE 4/7/95 3 3-125 Checks, Tests and Adjustments Procedure: 1. Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) 2. Fasten dial indicator to engine and position indicator tip on end of camshaft. 3. Push camshaft toward the rear as far as possible. 4. Zero the dial indicator. 5. Pull camshaft forward as far as possible. T6333DT Results: 3 • If valve lift is less than specification, remove and inspect camshaft, followers and push rods. (See Camshaft and Timing Gear Train and/or Cylinder Head, Valves and Manifolds in this section.) 3 CAMSHAFT END PLAY CHECK Reason: To determine proper side clearance between camshaft gear end journal and thrust plate. Equipment: • Dial Indicator M37512 Specifications: Standard Clearance . . . . . . . . 0.05 - 0.20 mm . . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.) Wear Limit. . . . . . . . . . . . 0.40 mm (0.016 in.) Results: • If end play exceeds wear limit, remove camshaft and replace thrust plate. (See Camshaft and Timing Gear Train in this section.) 3-126 4/7/95 Checks, Tests and Adjustments TIMING GEAR BACKLASH, CHECK Reason: To check for wear between meshing gears, resulting in excessive noise and poor engine performance. Equipment: • Dial Indicator Procedure: Specifications - 4TN78T: Standard Backlash Crankshaft Gear-to-Oil Pump Gear. . . . . . . . . . . . . 0.11 - 0.19 mm . . . . . . . . . . . . . . . . . . (0.0043 - 0.0075 in.) All Except Crankshaft Gear-to-Oil Pump Gear. . . . . . . . . . . . . 0.04 - 0.12 mm . . . . . . . . . . . . . . . . . . (0.0016 - 0.0047 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Specifications - 4TN82, 4TN84(T)(4019): 1. Measure backlash between meshing gears. Standard Backlash . . . . . . . . . 0.04 - 0.12 mm . . . . . . . . . . . . . . . . . . . . . (0.0016 - 0.0047 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Results: • If backlash exceeds wear limit, replace meshing gears as a set: Idler Gear, Camshaft Gear, Crankshaft Gear, Oil Pump Gear AND/OR Idler Gear, Fuel Injection Pump Gear. Fuel Injection Pump Gear-to-Idler Gear Camshaft Gear-to-Idler Gear Idler Gear-to-Crankshaft Gear Crankshaft Gear-to-Oil Pump Gear 4/7/95 M82252A 3-127 3 3 Checks, Tests and Adjustments FUEL INJECTION NOZZLE TEST (HOLE-TYPE) Equipment: • D01109AA Diesel Fuel Injection Nozzle Tester • D01110AA Adapter Set CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. 3 3 If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. Reason: To determine opening pressure, leakage, chatter and spray pattern of the fuel injection nozzle. 3-128 • 23622 Straight Adapter • Container Connections: 1. Connect fuel injection nozzle to D01109AA Diesel Fuel Injection Nozzle Tester using parts from D01110AA Adapter Set and 23622 Straight Adapter. IMPORTANT: Use clean filtered diesel fuel when testing injection nozzles to get best test results. Procedure 1: Test fuel injection nozzle opening pressure following the Nozzle Tester manufacturer's instructions. Specifications: Opening Pressure . . . . . . . . 19600 ± 480 kPa . . . . . . . . . . . . . . . . . . . . . . . . . (2843 ± 70 psi) Results: • If pressure reading does not meet specification, disassemble injection nozzle and inspect nozzle assembly for contamination or stuck valve. If necessary, add or remove shims to change opening pressure. 4/7/95 Checks, Tests and Adjustments 23617 90° Adapter 36352 Fuel Line Assembly 23621 Straight Adapter 23622 Straight Adapter D01109AA Diesel Fuel Injection Nozzle Tester Fuel Injection Nozzle Container M35913 Procedure 2: Test fuel injection nozzle leakage following the Nozzle Tester manufacturer's instructions. 1. Dry nozzle completely using a lint-free cloth. 2. Pressurize nozzle to 17640 kPa (2558 psi). 3. Watch for leakage from nozzle spray orifice. Leakage time should be a minimum of 5 seconds. Results: • If leakage time does not meet specification, disassemble injection nozzle and inspect nozzle assembly for contamination. Inspect valve seating surface. Replace nozzle assembly if necessary. Procedure 3: 1. Pressurize nozzle to 19600 ± 480 kPa (2843 ± 70 psi). 2. Listen for “chatter” sound and watch spray pattern. Specifications: Slow Hand Lever Movement . . . . . . . . . . . Chatter Sound Slow Hand Lever Movement . . . . . . . . . . . . . Fine Stream . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern Fast Hand Lever Movement . . . . . . . . . . . Fine Atomized . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern Test fuel injection nozzle chatter and spray pattern following the Nozzle Tester manufacturer's instructions. 4/7/95 3-129 3 3 Checks, Tests and Adjustments Procedure: Correct CAUTION Proper Spray Angle DO NOT allow thermostat or thermometer to rest against the side or bottom of glass container when heating water. Either may rupture if overheated. 1. Suspend thermostat and a thermometer in a container of water. Correct Injection Angle 2. Heat and stir the water. Observe opening action of thermometer and compare temperatures with specifications. Poor 3. Remove thermostat and observe its closing action as it cools. 3 3 Thermometer M82121A Results: • If nozzle chatter or spray pattern does not meet specifications, disassemble injection nozzle and inspect nozzle assembly for contamination. Inspect valve seating surface. Replace nozzle assembly if necessary. • If there is excessive difference in spray angle or injection angle, incomplete atomization or sluggish starting/stopping of injection, disassemble injection nozzle and inspect nozzle assembly for contamination. Replace nozzle assembly if necessary. Thermostat M82122A Specifications: Begin Opening . . . . . . . . . . . . . 71° C (160° F) Fully Open . . . . . . . . . . . . . . . . 85° C (184° F) Minimum Lift Height . . . . . .8 mm (0.310 in.) THERMOSTAT OPENING TEST Results: Reason: To determine opening temperature of thermostat. • If thermostat does not open according to specifications, replace. Equipment: • If closing action is not smooth and slow, replace thermostat. • Thermometer • Glass Container • Heating Unit 3-130 4/7/95 Checks, Tests and Adjustments COOLANT TEMPERATURE SWITCH TEST Reason: To determine operating temperature of sender. 2. Suspend sender and a thermometer in a container of water. 3. Heat and stir the water. Observe water temperature when continuity occurs. Water temperature should be 107 - 113° C (225 235°F). Equipment: • Thermometer Ohmmeter Probes • Glass Container • Heating Unit • Ohmmeter Procedure: CAUTION DO NOT allow switch or thermometer to rest against the side or bottom of glass container when heating water. Either may rupture if overheated. 1. Connect lead wires from ohmmeter probes, to sender terminal and body. 4/7/95 3 Coolant Temperature Switch M82123A 3 Results: • If continuity does not occur within temperature listed, replace sender. 3-131 Checks, Tests and Adjustments STARTER NO-LOAD AMP DRAW/RPM TEST Reason: To determine if starter is binding or has excessive amperage draw under no load. Equipment: • JT05712 Current Gun • JT05719 Hand-Held Digital Tachometer • Jumper Cables • Jumper Wire Procedure: 1. Mount starter in a vise. 3 NOTE: Check that battery is fully charged and of proper size to ensure accuracy of test. 2. Connect jumper cables to a 12 volt battery. 3 3. Connect positive (+) cable to solenoid battery terminal on starter. 4. Connect negative (-) cable to starter body. 5. Attach Current Gun to positive cable. Specifications: Maximum Starter Amperage Hitachi 0.8 kW. . . . . . . 60 Amps at 7000 rpm Hitachi 2.0 kW. . . . . . 110 Amps at 4500 rpm Nippondenso 1.0 kW. . 90 Amps at 3000 rpm Nippondenso 1.4 kW. . 90 Amps at 3500 rpm Minimum Starter RPM Hitachi 0.8 kW. . . . . . . . . . . . . . . . . . . . . 7000 Hitachi 2.0 kW. . . . . . . . . . . . . . . . . . . . . 4500 Nippondenso 1.0 kW. . . . . . . . . . . . . . . . 3000 Nippondenso 1.4 kW. . . . . . . . . . . . . . . . 3500 Results: • If solenoid “clicks” or chatters and motor does not turn, replace solenoid. • If pinion gear engages and motor doesn't turn, repair or replace starter motor. • If starter engages and runs but amperage is more than specifications, repair or replace starter. • If rpm is less than specification, with battery fully charged, repair or replace starter. IMPORTANT: Complete this test in 20 seconds or less to prevent starter damage. 6. Use a jumper wire to briefly connect positive (+) starter terminal to solenoid terminal “S”. Starter should engage and run. 7. Read and record starter amperage and rpm. 3-132 4/7/95 Checks, Tests and Adjustments JT05712 Current Gun JT05719 Hand-Held Digital Tachometer Jumper Wire 3 3 M82149A All Except Nippondenso 1.0 kW JT05712 Current Gun JT05719 Hand-Held Digital Tachometer Jumper Wire Nippondenso 1.0 kW 4/7/95 M82150A 3-133 Checks, Tests and Adjustments INJECTION PUMP STATIC TIMING ADJUSTMENT - 4TN78T TDC Mark on Flywheel Index Mark on Flywheel Housing Reason: To make sure that injection pump timing is set to manufacturers specification. Equipment: • Timing Tool (No. 1 fuel injection line cut off at first bend) • External fuel supply M82253A 5. Prime pump to fill it with fuel. 1 L (1.06 qt) of fuel is more than adequate. Procedure: 3 IMPORTANT: Injection pump timing should be correct. Once timing is set, it will not normally change during the life of the engine, unless it was altered. 3 Check and adjust timing only as the last option. Check fuel, fuel supply system, injectors, air intake system and cylinder compression before continuing. 6. Hold throttle lever in run position. 7. Turn flywheel clockwise (as viewed from the flywheel end) until tip of Timing Tool has become MOIST with solid fuel. 8. Check timing mark on flywheel. The index mark must line up with the 14° mark on flywheel. Flywheel NOTE: Normal rotation, as viewed from the flywheel end, is counterclockwise. The number one fuel injection line is toward the flywheel. 1. Remove the number one fuel injection line. TDC Mark on Flywheel 2. Install timing tool (number one fuel line cut off at first bend). Timing Tool Index Mark on Flywheel Housing T6530AB M82254A 3. Remove rubber plug from flywheel housing. 4. Turn crankshaft pulley in either direction until the No. 1 cylinder top dead center (TDC) mark aligns with the index mark on the flywheel housing. 3-134 4/7/95 Checks, Tests and Adjustments Specifications: Injection Pump Timing. . . . . . . . . .14° BTDC . . . . . . . . . . . . . . . (Before Top Dead Center) Engine Crankshaft Position. . . . . . . . . . . . . . . . . . . No.1 Cylinder . . . . . . . . . . . . . on TDC Compression Stroke Distance On Outer Surface Of Flywheel Per 1° Of Rotation. . . . . . 2.88 mm (0.110 in.) Timing Lines On Pump Mounting Plate . . . . . . . . . . . . . . . .2.5° Apart Results: • If timing is not according to specifications, loosen pump mounting bolts and turn pump towards engine block to retard timing or away from block to advance timing. Recheck timing. • If timing did not change, remove pump and have tested by a diesel injection service shop. • If timing is OK: Procedure: IMPORTANT: Injection pump timing should be correct. Once timing is set, it will not normally change during the life of the engine, unless it was altered. Check and adjust timing only as the last option. Check fuel, fuel supply system, injectors, air intake system and cylinder compression before continuing. NOTE: If injection pump has been removed from engine without disturbing engine crankshaft and pump shaft, perform Step 1 only. Otherwise, perform the entire timing procedure. 1. 4TN82: Align arrow or line on injection pump flange with the sixth mark (line) on timing gear mounting plate. 3 4TN84(T)(4019): Align arrow or line on injection pump flange between third and fourth marks (lines) on timing gear mounting plate. 3 - Install rubber plug in flywheel housing. - Remove timing tool. - Install number one injection line. INJECTION PUMP STATIC TIMING ADJUSTMENT - 4TN82 AND 4TN84(T)(4019) Reason: 4TN82 M82255A To make sure that injection pump timing is set to manufacturers specification. Equipment: • Timing Tool (No. 1 fuel injection line cut off at first bend) • External fuel supply 4TN84(T)(4019) M82256A 4/7/95 3-135 Checks, Tests and Adjustments NOTE: Normal rotation, as viewed from the flywheel end, is counterclockwise. The number one fuel injection line is toward the flywheel. 2. Remove the number one fuel injection line. 3. Install timing tool (number one fuel line cut off at first bend). Timing Tool 6. Prime pump to fill it with fuel. 1 L (1.06 qt) of fuel is more than adequate. 7. Hold throttle lever in run position. 8. Turn flywheel clockwise (as viewed from the flywheel end) until tip of Timing Tool has become MOIST with solid fuel. 9. Check timing mark on flywheel. The index mark must line up with injection pump timing mark on flywheel. See specifications. 25° Injection Pump Timing Marks Flywheel 20° 15° TDC Mark on Flywheel 1 3 T6530AB 3 4. Remove rubber plug from flywheel housing, if equipped. 5. Turn crankshaft pulley in either direction until the No. 1 cylinder top dead center (TDC) mark aligns with the index mark on the flywheel housing/ plate. Index Mark on Flywheel Housing TDC Mark on Flywheel 1 M82373A Specifications: Injection Pump Timing Mark Index Mark on Flywheel Housing/Plate T6530AC 4TN82 (970 CUT, 675 SSL, 3325/65 GM) . . . . . . . . . . . . . .15° ± 1° BTDC . . . . . . . . . . . . . . . (Before Top Dead Center) 4TN84 (1070 CUT) . . . . . . . . . . . .15° ± 1° BTDC (4019D OEM) . . . . . . . . . .16° ± 1° BTDC 4TN84T (4019T OEM) 4019TF001 and 005 . . . . . .15° ± 1° BTDC 4019TF006 . . . . . . . . . . . . .12° ± 1° BTDC Engine Crankshaft Position. . . . . . . . . . . . . . . . . . . . . . No. 1 Cylinder . . . . . . . . . . . . . . . . on TDC Compression Stroke 3-136 4/7/95 Checks, Tests and Adjustments Results: Specifications: • If timing is not according to specifications, loosen pump mounting bolts and turn pump towards engine block to retard timing or away from block to advance timing. Recheck timing. • If timing did not change, remove pump and have tested by a diesel injection service shop. Applied Force . . . . . . . . . . .98 N (22 lb-force) Deflection . . . . . 10 - 15 mm (0.400 - 0.600 in.) Results: • If deflection is not within specifications: - Loosen both alternator mounting cap screws/ nuts. • If timing is OK: - Install rubber plug in flywheel housing, if equipped. - Remove timing tool. - Apply force to FRONT alternator housing only (near the belt) until tension is correct. - Tighten cap screws/nuts. - Install number one injection line. FAN/ALTERNATOR DRIVE BELT ADJUSTMENT ENGINE OIL COOLER LEAKAGE TEST - 4TN78T AND 4TN84T (4019TF001 and 005) Reason: Reason: To keep proper tension on belt to drive water pump and alternator. To prevent shortened belt and bearing life. Inspect oil cooler for leaks. Equipment: 1. Plug one end of coolant inlet or outlet passage. • JDG529 or JDST28 Belt Tension Gauge • Straight Edge 3 3 Procedure: 2. Apply regulated air pressure of 206 - 483 kPa (30 - 70 psi) to other end. 3. Dip oil cooler into water and check for leaks. Procedure: 1. Check belt tension between fan and alternator using Belt Tension Gauge and a straight edge. Optional test: If a leak did not appear, use a hot water bath to possibly open crack(s). Results: • Repair leak(s) or replace oil cooler if necessary. Belt Deflection M54014 4/7/95 3-137 Checks, Tests and Adjustments FUEL SHUTOFF SOLENOID ADJUSTMENT Reason: To ensure that fuel shutoff solenoid retracts fully, moving the injection pump shutoff control lever far enough to allow full rack travel. 5. Turn plunger rod in or out of knuckle until knuckle and link holes line up. Turn out two additional turns. The additional turns insure that the solenoid bottoms out before the linkage. 6. Assemble and check for free movement when key switch is turned ON. Also check that linkage returns completely to the STOP position when key switch is turned OFF. Procedure: 1. Loosen lock nut. Plunger 2. Disconnect link from solenoid. Link 3. Hold solenoid plunger bottomed in solenoid body. 4. Move link toward solenoid until it stops Knuckle 3 Lock Nut M82141 3 3-138 4/7/95 Operational Tests RADIATOR, BUBBLE TEST • If air escapes from air cleaner, check for worn intake valve. Reason: • If air escapes from engine oil fill, check for worn piston rings. To determine if compression pressure is leaking from cylinder. Equipment: • JDG560 Adapter Procedure: 1. With coolant at proper level and radiator cap tight, run engine for 5 minutes to bring to operating temperature. 2. Remove cap from recovery tank. COOLING SYSTEM, PRESSURE TEST Reason: Inspect cooling system for leaks. Equipment: • D05104ST Cooling System Pressure Pump • JDG692 Radiator Pressure Test Kit (Adapters) 3. Check for bubbles coming from overflow hose at bottom of tank. Procedure: If bubbles are present, isolate source of compression leak: 2. Apply pressure according to specifications. - Remove injection nozzles. 1. Remove cap and attach pressure pump to radiator. 3. Check for leaks throughout cooling system. - Install JDG560 Adapter in injection port of cylinder to be tested. - Move piston to bottom of stroke with intake and exhaust valves closed. Cooling System Pressure Pump - Connect hose from compressed air source to adapter. - Apply the specified maximum air pressure into cylinder: 4TN78T, 4TN82RJK, 4TN84RJK, 4TN82RJE, 4TN82ESP . . . . . . . . . . . . . 2448 kPa (355 psi) 4TN84(T)(4019) . . . . . . . . . 2158 kPa (313 psi) - Check for bubbles in recovery tank or air escaping from muffler, air cleaner or oil fill opening. T6333AW Specifications - 4TN78T, 4TN82RJK, 4TN84RJK, 4TN84(T)(4019): Maximum Pressure . . . . . . . . . 97 kPa (14 psi) Minimum Pressure after 15 Seconds . . . . . . . . . 88 kPa (12.8 psi) - Repeat for each cylinder. Specifications - 4TN82RJE, 4TN82ESP: Results: • If bubbles are present, check for cracks in cylinder head and block. Check for damaged head gasket. Maximum Pressure . . . . . . . . . 69 kPa (10 psi) Minimum Pressure after 15 Seconds . . . . . . . . . . . . 55 kPa (8 psi) • If air escapes from muffler, check for worn exhaust valve. 4/7/95 3-139 3 3 Operational Tests Results: Results: • Pressure should hold to specifications. If pressure decreases, check for leaks. Repair leaks or replace parts as necessary. • If cap leaks, retighten and test again. Replace cap if pressure is not within specification. • If pressure test still indicates leakage after all external leaks have been stopped, a defective head gasket, cracked block, or cylinder head may be the cause. Perform RADIATOR BUBBLE TEST. CYLINDER, COMPRESSION PRESSURE TEST RADIATOR CAP, PRESSURE TEST Test radiator cap for operating in correct pressure range. • JT01682 Compression Gauge Assembly • JDG560 Adapter Procedure: Equipment: • D05104ST Cooling System Pressure Pump 3 To determine the condition of the pistons, rings, cylinder walls and valves. Equipment: Reason: 3 Reason: • JDG692 Radiator Pressure Test Kit (Adapters) Procedure: 1. Install radiator cap on pressure pump. 2. Apply pressure. Pressure valve in cap should open according to specifications. 1. Run engine for 5 minutes to bring to operating temperature. Shut off engine. 2. Remove injection nozzles. (See Fuel System in this section.) 3. Remove heat protector from end of injector and install on Adapter. 4. Install Adapter and Compression Gauge Assembly in injector port. Install retaining plate and tighten nuts to 4.5 N•m (39 lb-in.) 5. Hold fuel shut-off knob in shut-off position. Cooling System Pressure Pump 6. Crank engine for three seconds with starter. 7. Record pressure reading for each cylinder. Radiator Cap T6333AX Specifications: Valve Opening Pressure 4TN78T, 4TN82RJK, 4TN84RJK, 4TN84(T)(4019) . . . . . . . . . . 88 kPa (12.8 psi) 4TN82RJE, 4TN82ESP . . . . . . 55 kPa (8 psi) JDG560 Adapter JT01682 Compression Gauge Assembly 3-140 T6333EU 4/7/95 Operational Tests Specifications: Minimum Compression Pressure 4TN78T, 4TN82RJK, 4TN84RJK, 4TN82RJE, 4TN82ESP . . . . . . . . . . . . . 2448 kPa (355 psi) 4TN84(T)(4019) . . . . . . . . . 2158 kPa (313 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi) NOTE: Pressure listed is for 300 m (1000 ft) above sea level. For naturally aspirated engines, reduce specification an additional 4% for each 300 m (1000 ft) of altitude. For turbo charged engines, reduce specification an additional 3.6% (4TN78T) or 3% (4TN84T)(4019T) for each additional 300 m (1000 ft) of altitude. IMPORTANT: Do not run if no pressure present. 4. Start engine. If pressure reading is below 69 kPa (10 psi), STOP ENGINE. 5. Run engine approximately five minutes to heat oil, then check oil pressure at fast and/or slow idle. JT05577 Pressure Gauge 3 JT03017 Hose Assembly Results: • If pressure reading is below specification, squirt approximately two teaspoons of clean engine oil into cylinders through injector ports and repeat test. 3 • If pressure increases significantly, check piston, rings and cylinder walls for wear or damage. • If pressure does not increase significantly after retest, check for leaking valves, valve seats or cylinder head gasket. Connector T6471FB ENGINE OIL PRESSURE TEST Reason: To determine if engine bearings or lubrication system components are worn. Equipment: • JT03017 Hose Assembly • JT05577 Pressure Gauge (100 psi) • JT05487 Connector (4TN78T) • JT03349 Connector (All Except 4TN78T) Procedure: 1. Remove oil pressure sender. 2. Install Connector. 3. Connect Hose Assembly and Pressure Gauge. 4/7/95 Specifications - 4TN78T: Idle Speed Fast . . . . . . . . . . . . . . . . . . . . . . 2750 ± 25 rpm Slow . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm Engine Oil Pressure Fast Idle . . . . . . . . . .345 ± 48 kPa (50 ± 7 psi) Slow Idle. . . . . . . . . . . . . . . . . 214 kPa (31 psi) Specifications - 4TN82RJE: Idle Speed Fast . . . . . . . . . . . . . . . . . . . . . . . . . . 2800 rpm Slow . . . . . . . . . . . . . . . . . . . . . 1000 ± 50 rpm Engine Oil Pressure . . . . . . . . . . . . 294 - 440 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 64 psi) 3-141 Operational Tests Specifications - 4TN82ESP: Idle Speed Fast . . . . . . . . . . . . . . . . . . . . . . 2875 ± 25 rpm Slow . . . . . . . . . . . . . . . . . . . . . . 900 ± 25 rpm Engine Oil Pressure . . . . . . . . . . . . 294 - 392 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (43 - 57 psi) Specifications - 4TN82RJK, 4TN84RJK: Fast Idle Speed 4TN82RJK . . . . . . . . . . . . . . .2750 - 2800 rpm 4TN84RJK . . . . . . . . . . . . . . .2850 - 2900 rpm Engine Oil Pressure . . . . . . . . . . . . 365 ± 69 kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (53 ± 10 psi) filter element. Install main filter element and cover. 5. Pressurize air intake system between 34 - 69 kPa (5 - 10 psi). If air intake system cannot be pressurized, turn engine slightly to close valves. 6. Spray soap solution over all connections from air cleaner to intake manifold or turbocharger, if equipped, and check for leaks. IMPORTANT: When reinstalling starting aid nozzle, position arrow on nozzle pointing against intake air flow. 3 Specifications - 4TN84(T)(4019): 3 Low Idle Speed Industrial . . . . . . . . . . . . . . . . . . . . . 1300 rpm Generator. . . . . . . . . . . . . . . . . . . . . 1200 rpm Engine Oil Pressure . . . . . . . . . . 147 kPa (21 psi) M82124 Results: • If oil pressure is not within specifications, inspect oil pressure regulating valve parts for wear or damage. Add or remove shims as necessary. (See Lubrication System in this section.) • If oil pressure does not increase, see “Engine Has Low Oil Pressure” in Diagnosis group. AIR INTAKE SYSTEM LEAKAGE TEST Reason: Check for leaks in air intake system. Equipment: • Air Pressure Regulator Procedure: 1. Remove air cleaner restriction indicator/switch and install test fitting. 2. Connect air pressure regulator to manifold using hose and fitting from air cleaner. Results: • Find leaks and repair or replace parts as necessary. FUEL SUPPLY PUMP PRESSURE TEST - IF EQUIPPED NOTE: 4TN78T, 4TN82RJE and 4TN82ESP engines are not equipped with a fuel supply pump. Reason: To determine supply pump operating pressure. Equipment: • JT03274 Hose Fitting • JT01609 Female Quick Coupler • JT03115 Gauge w/Male Quick Coupler (0 - 150 psi) 3. Remove air cleaner cover and main filter element. 4. Put large plastic bag into and over end of main 3-142 4/7/95 Operational Tests Procedure: Procedure: 1. Disconnect supply pump-to-filter hose. 1. Disconnect fuel supply line and return line at fuel tank. 2. Install Hose Fitting, Coupler and Gauge. 3. Pull fuel shut-off cable out and crank engine using the starter. Do not run starter for more than 10 seconds at a time. Gauge should read more than 29 kPa (4.3 psi). JT03115 Gauge w/Male Quick Coupler JT01609 Female Quick Coupler JT03274 Hose Fitting IMPORTANT: Fuel return line MUST extend below fuel level in fuel tank before performing this test. Fill fuel tank if necessary. 2. Drain all fuel from the system, including fuel supply pump, injection pump, filter(s) and water separator, if equipped. 3. Plug end of fuel return hose. 4. Pressurize fuel system at fuel supply line, to a maximum pressure of 103 kPa (15 psi). 5. Apply liquid soap and water solution to all joints and connections in the fuel system and inspect for leaks. 3 Results: Fuel Filter Supply Pump-to Filter Hose • Find leaks and repair or replace parts as necessary. 3 BLEED FUEL SYSTEM M82145A Results: • If pressure is below specification, repair or replace fuel supply pump. IMPORTANT: Modification or alteration of the injection pump, pump timing, or the injection nozzles in any way not approved by the manufacturer will terminate the warranty obligation. All engines are equipped with an automatic air venting system which makes the fuel system selfbleeding. FUEL DRAIN BACK TEST • Assure that all fuel line connections are securely tightened. Reason: • Add fuel to fuel tank. Determines if air is entering the fuel system at connections, allowing fuel to siphon back to tank. • Crank engine to allow fuel system to bleed itself. 4/7/95 3-143 4TN100 ENGINE Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Cylinder Head, Valves and Manifolds . . . . . . . . . . . . . . . . 4-8 Pistons, Rods and Cylinder Block . . . . . . . . . . . . . . . . . . 4-21 Crankshaft, Main Bearings and Flywheel . . . . . . . . . . . . 4-30 Camshaft and Timing Gear Train. . . . . . . . . . . . . . . . . . . 4-40 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60 Starter (Nippondenso 1.4 kW) . . . . . . . . . . . . . . . . . . . . . 4-70 Alternator (Hitachi 25A) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80 Checks, Tests and Adjustments. . . . . . . . . . . . . . . . . . . . 4-83 Operational Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97 Section 4 4 4 Specifications ENGINE SPECIFICATIONS - 4TN100 Rocker Arm Cover Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Rocker Arm Assembly Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Push Rod Bend Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) or Less Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) Push Rod Length Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178.25 - 178.75 mm (7.018 - 7.037 in.) Rocker Arm and Shaft Support I.D.'s Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.50 - 18.52 mm (0.728 - 0.729 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.60 mm (0.732 in.) Rocker Arm Shaft O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.46 - 18.48 mm (0.727 - 0.728 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.35 mm (0.722 in.) Cylinder Head and Valves Cylinder Head Distortion Maximum Amount of Metal to be Removed . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) or Less Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Mounting Cap Screw Torque First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N•m (72 lb-ft) Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 N•m (116 lb-ft) Valve Seat Width (Exhaust Valve) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.02 - 2.33 mm (0.079 - 0.089 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.73 mm (0.108 in.) Valve Seat Width (Intake Valve) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38 - 1.62 mm (0.054 - 0.064 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 mm (0.084 in.) Intake and Exhaust Valves Valve Face Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Minimum Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.) Valve Recession Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 mm (0.071 in.) Valve Stem O.D. (Exhaust Valve) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.94 - 8.96 mm (0.3520 - 0.3528 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.90 mm (0.3504 in.) Valve Stem O.D. (Intake Valve) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.96 - 8.98 mm (0.3528 - 0.3535 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.90 mm (0.3504 in.) Valve Guides Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50 mm (0.453 in.) Valve Guide I.D. 4/7/95 4 4-1 Specifications 4 Maximum Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.00 - 9.02 mm (0.354 - 0.355 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 mm (0.358 in.) Valve Springs Maximum Spring Tension . . . . . . . . . . . . . . . . . . . . . . . 41.50 mm (1.634 in.) at 12.6 N (5.7 lb force) Spring Free Length Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 mm (1.693 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.50 mm (1.673 in.) Maximum Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 mm (0.047 in.) Exhaust Manifold Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Intake Manifold Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Valve Seat Angles Lower Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70° Upper Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° Valve Seat Surface Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Piston-to-Cylinder Head Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.71 - 0.89 mm (0.028 - 0.035 in.) Piston and Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N•m (69 lb-ft) Connecting Rod Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 - 60.042 mm (2.3622 - 2.3639 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.10 mm (2.3661 in.) Piston Ring Groove Clearance First Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 - 0.125 mm (0.0035 - 0.0049 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.) Oil Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.065 mm (0.0012 - 0.0026 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Second Compression Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 - 0.070 mm (0.0014 - 0.0028 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Piston Ring End Gap Compression Rings Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.0098 - 0.0157 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.) Oil Ring Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm (0.0118 - 0.0197 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.) Piston Pin Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.022 mm (0.0009 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.00 - 34.011 mm (1.3386 - 1.3390 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.02 mm (1.3393 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.061 mm (0.0024 in.) 4-2 4/7/95 Specifications Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.03 - 34.05 mm (1.3398 - 1.3406 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.10 mm (1.3425 in.) Pin O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.989 - 34.00 mm (1.3381 - 1.3386 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.90 mm (1.3346 in.) Piston O.D. 0.25 mm (0.010 in.) Oversize Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.15 - 100.18 mm (3.943 - 3.944 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.05 mm (3.939 in.) Standard Size Piston Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.895 - 99.925 mm (3.9329 - 3.9341 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.79 mm (3.9287 in.) Cylinder Bore I.D. 0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.25 - 100.28 mm (3.947 - 3.948 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.45 mm (3.955 in.) Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° Cross-Hatch Pattern Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° Cross-Hatch Pattern Standard Size Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.41 mm (0.016 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.00 - 100.03 mm (3.9370 - 3.9382 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.15 mm (3.9429 in.) Crankcase Extension Housing Mounting Cap Screw Torque Extension-to-Block (M12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft) Extension-to-Block (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Extension-to-Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.) Flywheel Housing-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Seal Case-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.) Crankshaft Rear Oil Seal Seal Case-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Seal Case-to-Extension Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.) Crankshaft Front Oil Seal Depth . . . . . . . . . . . . . . . . . . . . . 3.18 mm (0.125 in.) Below Surface of Cover Crankshaft and Main Bearings Connecting Rod Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.952 -59.964 mm (2.3603 - 2.3608 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.90 mm (2.3583 in.) Crankshaft Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0007 in.) Crankshaft and Main Bearings - Continued Main Bearing Cap Screw Torque Initial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 N•m (100 lb-ft) Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 N•m (145 lb-ft) Main Bearing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.00 - 60.042 mm (2.3622 - 2.3639 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.10 mm (2.3661 in.) Main Bearing Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.952 - 69.964 mm (2.7540 - 2.7545 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.90 mm (2.7520 in.) 4/7/95 4 4-3 Specifications 4 Flywheel Maximum Distortion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 N•m (145 lb-ft) Flywheel Housing Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Camshaft Bore I.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.00 - 57.03 mm (2.2441 - 2.2453 in.) Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.10 mm (2.2480 in.) Bushing Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 mm (0.062 in.) Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.006 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.98 - 57.05 mm (2.2433 - 2.2461 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.10 mm (2.2480 in.) Camshaft Side Gap Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.29 mm (0.0114 in.) End Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.91 - 56.94 mm (2.2406 - 2.2417 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.80 mm (2.2362 in.) Intermediate Journal O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.89 - 56.92 mm (2.2398 - 2.2409 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.80 mm (2.2362 in.) Lobe Height Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.435 - 48.565 mm (1.9069 - 1.9120 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.20 mm (1.897 in.) Maximum Camshaft Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.0020 in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Cam Followers Bore I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.052 mm (0.0020 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.249 - 14.270 mm (0.5610 - 0.5618 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30 mm (0.5630 in.) Cam Followers - Continued Stem O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.218 - 14.233 mm (0.5598 - 0.5604 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17 mm (0.5579 in.) Timing Gear Cover Cover Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 N•m (47 lb-ft) Fan Spacer-to-Water Pump Socket-Head Cap Screw Torque . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Crankshaft Pulley Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (85 lb-ft) Idler Gear Bushing I.D. Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 mm (0.0030 in.) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.025 mm (1.8110 - 1.8120 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.09 mm (1.8146 in.) Shaft O.D. Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.95 - 45.975 mm (1.8091 - 1.8100 in.) 4-4 4/7/95 Specifications Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.9 mm (1.8071 in.) Timing Gear Housing Mounting Cap Screw Torque Extension-to-Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.) Gear Housing-to-Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (220 lb-in.) Oil Strainer Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Oil Pan Mounting Cap Screw Torque Oil Pan-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Oil Pan-to-Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.) Oil Pump Inner-to-Outer Rotor Maximum Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Maximum Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Maximum Outer Rotor Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) Outer Rotor-to-Pump Housing Maximum Clearance . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Rotor Shaft Assembly-to-Housing Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (53 lb-in.) Rotor Shaft O.D.-to-Housing I.D. Maximum Clearance . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) Oil Cooler Adapter-to-Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft) Oil Cooler-to-Housing Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Oil Cooler By-Pass Valve Spring Compressed Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 mm (1.450 in.) @ 3.75 N (0.840 lb force) Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 mm (2.480 in.) Oil Pressure Regulating Valve Spring Compressed Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 mm (1.970 in.) @ 5.40 N (1.200 lb force) Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 mm (2.010 in.) Piston Cooling Nozzle Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) Thermostat Cover Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Water Pump Adapter Fitting-to-Housing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (199 lb-in.) Adapter-to-Plate Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (91 lb-in.) Bottom of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 mm (0.433 in.) Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 N•m (47 lb-ft) Fan Spacer-to-Pump Socket-Head Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) Impeller-to-Pump Housing Clearance . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 1.10 mm (0.012 - 0.043 in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) Plate-to-Housing Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (134 lb-in.) Plug-to-Housing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) Fuel Supply Pump Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.) External Lube Line Inlet Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) Fuel Injection Pump External Lube Line Inlet Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) Lube Line-to-Block Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (217 lb-in.) Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft) Fuel Injection Nozzles Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (39 lb-in.) Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 N•m (31 lb-ft) 4/7/95 4 4-5 Specifications 4 Separator Plate Nozzle Contact Surface Maximum Wear . . . . . . . . . . . . . . . . . . 0.10 mm (0.0039 in.) Starter Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mm (0.335 in.) Alternator Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 mm (0.220 in.) Rotor Assembly Pulley Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.) Rotor-to-Stator Assembly Attaching Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Stator Assembly End Frame-to-Rectifier Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Stator-to-Rectifier Lead Wire Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.50 mm (1.300 in.) Checks, Tests and Adjustments Camshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.29 mm (0.0114 in.) Connecting Rod Bearing Clearance Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.036 - 0.090 mm (0.0014 - 0.0035 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) Connecting Rod Side Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.0079 - 0.0157 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.0177 in.) Coolant Temperature Sender Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . 107 - 133° C (225 - 235° F) Thermostat Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71° C (160° F) Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F) Minimum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0.310 in.) Checks, Tests and Adjustments - Continued Crankshaft End Play Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.132 - 0.223 mm (0.0052 - 0.0088 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.29 mm (0.0114 in.) Crankshaft Main Bearing Clearance Main Bearing Cap Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 N•m (145 lb-ft) Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.036 - 0.093 mm (0.0014 - 0.0037 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.0040 in.) Fan/Alternator Drive Belt Applied Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N (22 lb-force) Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.) Fuel Injection Nozzle Chatter and Spray Pattern at 20100 ± 490 kPa (2915 ± 71 psi) Pressure Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chatter Sound Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Stream Spray Pattern Fast Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Atomized Spray Pattern Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum 5 Seconds at 18100 kPa (2625 psi) Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19615 kPa (2850 psi) Injection Pump Static Timing Distance on Outer Surface of Flywheel per 1° of Rotation . . . . . . . . . . . . . . . . 3.5 mm (0.130 in.) Engine Crankshaft Position . . . . . . . . . . . . . . . . . . . No. 1 Cylinder on TDC Compression Stroke Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16° BTDC (Before Top Dead Center) Timing Lines on Pump Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2° Apart 4-6 4/7/95 Specifications Starter, No-Load Amp Draw/RPM Maximum Starter Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 amps at 3500 rpm Minimum Starter RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3500 Timing Gear Backlash Standard Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 - 0.16 mm (0.0031 - 0.0063 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.) Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) Valve Lift Intake and Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 mm (0.256 in.) Operational Tests Air Intake System Holding Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 - 69 kPa (5 - 10 psi) Cooling System Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi) Minimum Pressure After 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) Cylinder Compression Pressure Compression Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2942 kPa (427 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588 kPa (85 psi) Engine Oil Pressure Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2375 ± 50 rpm Oil Pressure Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343 - 441 kPa (50 - 64 psi) Oil Pressure Slow Idle (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 kPa (14 psi) Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 ± 50 rpm Fuel Supply Pump Pressure (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 kPa (31 psi) Fuel System Holding Pressure (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 kPa (15 psi) Radiator Cap Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) 4/7/95 4 4-7 Cylinder Head, Valves and Manifolds SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the European Microfiche Tool Catalog (MTC). JT07092 Valve Guide Knurler (9 mm) Use to knurl inside diameter of valve guides. JDE118 Valve Guide Driver Use to remove and install valve guides in cylinder head. JT07091 Valve Guide Reamer (9 mm) Use to ream out new valve guides. OTHER MATERIALS Number Name Use John Deere Pipe Sealant with TEFLON® Apply to threads of fitting on top of cylinder head. LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. 4 TY9375/ TY9480/ #592 SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Head Gasket Kit ®LOCTITE is a registered trademark of the Loctite Corp. ®TEFLON is a registered trademark of the Du Pont Company. 4-8 4/7/95 Cylinder Head, Valves and Manifolds ROCKER ARM COVER Oil Fill Cap O-Ring Cap Screw (10) M8 x 25 26 N•m (226 lb-in.) Gasket Crankcase Breather Tube 4 M82020A 4/7/95 4-9 Cylinder Head, Valves and Manifolds ROCKER ARM ASSEMBLY Removal/Installation and Disassembly/Assembly 1. Remove rocker arm cover. (See procedure in this group.) • Inspect all parts for wear or damage. (See Inspection procedures.) IMPORTANT: Install rocker arm support, with alignment cap screw on rocker arm shaft, with raised letter “F” facing toward other supports. Install remaining rocker arm supports on rocker arm shaft with raised letter “F” facing away from support with alignment cap screw. • Adjust valve clearance. (See Checks, Tests and Adjustments in this section.) • Lubricate all parts with clean oil during assembly. Alignment Cap Screw Rocker Arm Shaft 4 Rocker Arm Shaft Spring Mounting Cap Screw (6) 26 N•m (226 lb-in.) Push Rod Adjusting Screw Mounting Nut (2) 26 N•m (226 lb-in.) Intake Valve Rocker Arm Exhaust Valve Rocker Arm Rocker Arm Support M82021A 4-10 4/7/95 Cylinder Head, Valves and Manifolds Inspection Rocker Arm and Shaft Support I.D.’s: • Measure outer diameter of rocker arm shaft. Standard . . . . . . . . . . . . . . . 18.50 - 18.52 mm . . . . . . . . . . . . . . . . . . . . . . . (0.728 - 0.729 in.) Wear Limit. . . . . . . . . . . 18.60 mm (0.732 in.) Clearance . . . . . . . . . . . . . 0.06 mm (0.002 in.) Replace rocker arms or supports if I.D. is more than wear limit. If shaft and support/arm clearance (support/arm I.D. minus shaft O.D.) exceed wear limit, replace all parts. • Measure length and bending of push rod. M35262 Rocker Arm Shaft O.D.: Length Standard . . . . . . . . . . . . . . . 18.46 - 18.48 mm . . . . . . . . . . . . . . . . . . . . . . . (0.727 - 0.728 in.) Wear Limit. . . . . . . . . . . 18.35 mm (0.722 in.) Replace rocker arm shaft if less than wear limit. • Measure inner diameters of rocker arms and supports. 4 Feeler Gauge M82023A Push Rod Length: Standard . . . . . . . . . . . . . 178.25 - 178.75 mm . . . . . . . . . . . . . . . . . . . . . . . (7.018 - 7.037 in.) Push Rod Bend: Standard . . . . . . . 0.05 mm (0.002 in.) or less Wear Limit. . . . . . . . . . . . 0.30 mm (0.012 in.) Replace push rod if not within specifications. M82022A 4/7/95 4-11 Cylinder Head, Valves and Manifolds CYLINDER HEAD AND VALVES NOTE: Fitting must be removed to remove mounting cap screw. Removal/Installation 5. Disassemble and inspect cylinder head and valves. (See Disassembly/ Assembly and Inspection/Replacement procedures.) 1. Remove rocker arm assembly and push rods. (See procedures in this group.) 2. Remove exhaust and intake manifolds. (See procedures in this group.) 3. Remove water pump. (See Cooling System in this section.) IMPORTANT: Oil passage in gasket must be located over oil passage in cylinder block. Install gasket as shown. 4. Remove fuel injection nozzles. (See Fuel System in this section.) Mounting Cap Screw (18) Dip entire cap screw in clean engine oil before installing. Fitting Apply Pipe Sealant with TEFLON to threads. 4 Flywheel Oil Passage Cylinder Head Gasket M82024A 4-12 4/7/95 Cylinder Head, Valves and Manifolds 6. Tighten mounting cap screws, in the sequence shown, in three stages of gradually-increasing torque. Disassembly/Assembly • Compress valve springs using a valve spring compressor. IMPORTANT: Cylinder head mounting cap screws must be checked for proper torque after 50 hours of engine operation. • Intake and exhaust valve guides are press fit. Remove guides only if replacement is necessary. (See Inspection/Replacement procedures.) • Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) 18 16 12 10 14 8 3 6 1 2 5 4 Intake Manifold Side 7 9 13 11 15 17 Timing Gear Case Side Flywheel Side Exhaust Manifold Side IMPORTANT: Do not reuse stem seals if removed. Used seals will leak. • Apply clean engine oil on intake and exhaust valve stems during assembly. NOTE: If new valves are installed, measure valve recession. (See Inspection/Replacement procedures.) M82025A After each valve has been assembled, tap on top of valve stem with a plastic hammer to seat retainer. Torque Specifications: 4 First . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) Second . . . . . . . . . . . . . . . . . 98 N•m (72 lb-ft) Final . . . . . . . . . . . . . . . . . 157 N•m (116 lb-ft) Stem Seal (8) Replace Short Stud (8) Collet Halves (16) Retainer (8) Exhaust Valve Guide (4) Lifting Bracket (2) Valve Spring (8) Intake Valve Guide (4) Long Stud (2) Cap Screw (4) M10 x 20 Exhaust Valve Intake Valve 4/7/95 M82026A 4-13 Cylinder Head, Valves and Manifolds Inspection/Replacement Before inspection, thoroughly clean all components of carbon or dirt. Cylinder Head: • Measure cylinder head flatness. Place a straightedge along each of the four sides and each diagonal. Measure clearance between straight edge and combustion surface with a feeler gauge. Valve Seat Width M82029A Valve Seat Width: Intake Valve: M82027A 4 Standard . . . . . . . . . . . . . . . . . 1.38 - 1.62 mm . . . . . . . . . . . . . . . . . . . . . . . (0.054 - 0.064 in.) Wear Limit. . . . . . . . . . . . 2.12 mm (0.084 in.) Exhaust Valve: Straight-Edge Feeler Gauge Standard . . . . . . . . . . . . . . . . . 2.02 - 2.23 mm . . . . . . . . . . . . . . . . . . . . . . . (0.079 - 0.089 in.) Wear Limit. . . . . . . . . . . . 2.73 mm (0.108 in.) If necessary, grind valve seats to meet specifications. (See GRIND VALVE SEATS procedure.) Intake and Exhaust Valves: M82028A • Check valve for out-of-round, bent or warped condition using a valve inspection center. Replace valve if necessary. Cylinder Head Distortion: Standard . . . . . . . 0.05 mm (0.002 in.) or less Wear Limit. . . . . . . . . . . . 0.20 mm (0.008 in.) If distortion exceeds the wear limit, resurface or replace cylinder head. Remove only enough metal to make cylinder head flat; but do not remove more than 0.20 mm (0.008 in.). If cylinder head was resurfaced: • Measure piston-to-cylinder head clearance. (See procedure in this group.) M35307 • Measure valve recession. (See procedure in this group.) • Measure valve seat width. 4-14 4/7/95 Cylinder Head, Valves and Manifolds • If valve faces are worn, burned or pitted, grind valves to proper face angle. If valve face margin is less than 0.51mm (0.020 in.) after grinding, replace valve. Valve Face Angle Valve Face Margin Exhaust: 45° Intake: 30° Valve Recession Cylinder Head Depth Gauge M82030A • Measure valve stem diameter at two locations shown. Replace valve if measurement exceeds wear limit. 4 M82032A 40 mm (1.570 in.) 60 mm (2.360 in.) Valve Recession: Standard . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.) Wear Limit. . . . . . . . . . . . 1.80 mm (0.071 in.) Valve Guides: • Clean valve guides using a valve guide brush. • Measure valve guide inside diameter. Valve Guide I.D.: M82031A Valve Stem O.D.: Intake Valve: Standard . . . . . . . . . . . . . . . . . 8.96 - 8.98 mm . . . . . . . . . . . . . . . . . . . . . (0.3528 - 0.3535 in.) Wear Limit: . . . . . . . . . . 8.90 mm (0.3504 in.) Exhaust Valve: Standard . . . . . . . . . . . . . . . . . 8.94 - 8.96 mm . . . . . . . . . . . . . . . . . . . . . (0.3520 - 0.3528 in.) Wear Limit. . . . . . . . . . . 8.90 mm (0.3504 in.) • Measure valve recession using a depth gauge. Replace valve or cylinder head if measurement exceeds wear limit. 4/7/95 Standard . . . . . . . . . . . . . . . . . 9.00 - 9.02 mm . . . . . . . . . . . . . . . . . . . . . . . (0.354 - 0.355 in.) Wear Limit. . . . . . . . . . . . 9.10 mm (0.358 in.) If diameter exceeds wear limit, knurl or replace guide. If diameter is less than wear limit, determine guideto-stem clearance (guide diameter minus stem diameter). If clearance exceeds 0.15 mm (0.006 in.) but is less than 0.20 mm (0.008 in.), knurl valve guide using JT07092 Knurler. If clearance exceeds 0.20 mm (0.008 in.), replace valve guide. • Replace valve guides using JDE118 Valve Guide Driver. 4-15 Cylinder Head, Valves and Manifolds Intake and exhaust valve guides are different. The exhaust valve guide has two grooves and the intake valve guide has one. Install valve guides with grooves upward. Push valve guides down until top of valve guides are 11.50 mm (0.453 in.) from top of cylinder head. • Measure spring inclination. Replace spring if measurement exceeds specification. Ream inside diameter of valve guides using JT07091 Valve Guide Reamer. Square Gauge Spring Inclination 1.20mm (0.047 in.) Free Length Intake Valve Guide 4 Exhaust Valve Guide M82035A M82033A Valve Springs: • Measure spring free length. Replace spring if measurement exceeds wear limit. • Measure spring tension. Replace spring if measurement exceeds specification. 41.50 mm (1.634 in.) at 12.6 N (5.7 lb-force) Spring Tension Tester M82034A Spring Free Length: Standard . . . . . . . . . . . . . . .43 mm (1.693 in.) Wear Limit. . . . . . . . . . . 42.50 mm (1.673 in.) 4-16 M82036A 4/7/95 Cylinder Head, Valves and Manifolds EXHAUST MANIFOLD NOTE: Turbocharger removal/installation procedures are similar to unit used on Series 220 Engines. Follow procedures used in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section. Service procedures are also similar. 1. Remove turbocharger, if equipped. (See procedure in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section). EXHAUST MANIFOLD WITH TURBOCHARGER Cap Screw (4) M8 x 50 26 N•m (226 lb-in.) Cap Screw (4) M8 x 40 26 N•m (226 lb-in.) Stud (4) Cap Screw M8 x 110 26 N•m (226 lb-in.) Stud (4) Exhaust Manifold Gasket Gasket Cap Screw (3) M8 x 70 26 N•m (226 lb-in.) Exhaust Manifold EXHAUST MANIFOLD WITHOUT TURBOCHARGER 4/7/95 Cap Screw (4) M8 x 40 26 N•m (226 lb-in.) M82037A 4-17 4 Cylinder Head, Valves and Manifolds INTAKE MANIFOLD NOTE: Air heater removal/installation is similar to procedures found in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section. 1. Remove intake air heater. (See procedure in ACCESSORIES - SERIES 220 POWER UNIT ENGINES section.) 2. Remove two fuel filter assembly mounting cap screws. 3. Remove dipstick tube. NOTE: Before placing intake manifold on engine, install one M8 x 70 cap screw in manifold at position shown. Cap Screw (4) M8 x 15 4 Cover Gasket Gasket Cap Screw M8 x 115 26 N•m (226 lb-in.) Intake Manifold Cap Screw (3) M8 x 70 26 N•m (226 lb-in.) 4-18 Cap Screw (5) M8 x 20 26 N•m (226 lb-in.) M82038A 4/7/95 Cylinder Head, Valves and Manifolds GRIND VALVE SEATS 6. Lap valves. (See procedure in this group.) IMPORTANT: Valve seats should never be cut. Cutting a valve seat can damage its sealing surface, which may result in leaks or valve/ seat failure. Valve seats should be ground and lapped. NOTE: LIGHTLY grind valve seats for a few seconds only to avoid excessive valve seat width. 1. Grind intake valve seat using a 30° seat grinder and exhaust valve seat using a 45° seat grinder. Follow tool manufacturers instructions. Lower Seat Surface 70° Valve Seat Upper Seat Surface 15° Seat Width Cylinder Head M82040A Seat Grinder If valve recession exceeds maximum specifications or seats cannot be reconditioned, replace valves and cylinder head. LAP VALVES M82039A NOTE: Use a rubber type lapping tool for valves without a lapping tool groove slit. 2. Measure valve seat width after grinding. If seat does not make proper contact, lap the valve into the seat: 3. If seat is too wide after grinding, grind lower seat surface using a 70° seat grinder until seat width is close to specifications. 1. Apply small amount of fine lapping compound to face of valve. 4. Grind upper seat surface using a 15° seat grinder until seat width is narrowed to specifications. 5. If valve seats are ground, measure valve recession and check contact pattern between the seat and valve with bluing dye. 4/7/95 2. Turn valve to lap valve to seat. 3. Lift valve from seat every 8 to 10 strokes. Lap until a uniform ring appears around the surface of the valve face. 4. Wash all parts in solvent to remove lapping compound. Dry parts. 4-19 4 Cylinder Head, Valves and Manifolds 5. Check position of lap mark on valve face. Lap mark must be on or near center of valve face. 3. Slowly turn crankshaft one complete revolution. 4. Remove cylinder head and gasket. 5. Measure thickness of flattened section of each piece of wire. Calculate average thickness of wires to obtain piston-to-cylinder head clearance specification. Lapping Tool M82041A MEASURE PISTON-TO-CYLINDER HEAD CLEARANCE 4 1. Place three 10 mm (0.400 in.) long pieces of 1.50 mm (0.060 in.) diameter soft wire in three positions on the flat part of the piston head. M82042A If clearance is less than 0.71 - 0.89 mm (0.028 0.035 in.), replace cylinder head. 2. Install cylinder head and old gasket. Install cylinder head cap screws and tighten in proper sequence to specified torque. (See CYLINDER HEAD AND VALVES - Removal/Installation in this group.) 4-20 4/7/95 Pistons, Rods and Cylinder Block SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Block Gasket Kit • Cylinder Head Gasket Kit • Connecting Rod Cap Screws • Oversized Pistons and Rings • Undersized Connecting Rod Bearing Inserts 4 4/7/95 4-21 Pistons, Rods and Cylinder Block PISTON AND CONNECTING ROD Removal 1. Remove oil pan and strainer tube. (See Lubrication System in this section.) 2. Remove cylinder head. (See Cylinder Head, Valves and Manifolds in this section.) 3. Check cylinder bore for ridges. These ridges can cause damage to piston if ridge is not removed. 4. If necessary, remove ridge from top of cylinder bore using a ridge reamer. Piston and Connecting Rod 5. Measure connecting rod side play. (See Checks, Tests and Adjustments in this section.) 6. Measure connecting rod bearing clearance. (See Checks, Tests and Adjustments in this section.) IMPORTANT: Keep connecting rods and caps together. Rods and caps are a matched set. Note alignment marks on each part. 4 7. Bearing Inserts Connecting Rod Cap Remove two cap screws, connecting rod cap and bearing inserts. IMPORTANT: Pistons and cylinders are matched. Pistons must be installed in the cylinders from which they are removed. 8. Note connecting rod alignment mark in relation to the cylinders. Starting at flywheel end with cylinder number one, then two, etc. 9. Push piston and connecting rod out of cylinder bore using a wooden dowl. 10.Disassemble and inspect all parts for wear or damage. (See Disassembly and Inspection/ Replacement procedures.) Connecting Rod Cap Screw M82043A Installation • Apply clean engine oil on all parts during installation. • Never reuse connecting rod cap screws, Replace with new. IMPORTANT: Pistons must be installed in cylinders from which they were removed and in the same direction. Be careful not to damage crankshaft rod journal while installing piston. 1. If new piston rings were installed, deglaze cylinder bore. (See procedure in this group.) 2. Install piston and connecting rod into the cylinder from which it was removed, with piston size mark on top of piston toward camshaft. 4-22 4/7/95 Pistons, Rods and Cylinder Block IMPORTANT: Do not touch bearing insert surfaces. Oil and acid from your finger will corrode the bearing surface. 3. Install bearing inserts on connecting rod and rod cap, aligning tangs with grooves. IMPORTANT: Connecting rod caps must be installed on the same connecting rods they were removed from. 7. Install cylinder head. (See Cylinder Head, Valves and Manifolds in this section.) 8. Install oil pan and strainer tube. (See Lubrication System in this section.) Disassembly IMPORTANT: Pistons must be installed on the same connecting rod they were removed from. 4. Match the connecting rods to caps using alignment marks. Install caps. • Put a mark on each piston and connecting rod to aid in assembly. 5. Dip entire connecting rod cap screws in clean engine oil. Install new cap screws and tighten to specifications. • Piston pin bushing is press fit in connecting rod. Remove bushing only if replacement is necessary. (See Inspection/Replacement procedures.) 6. If a new piston and connecting rod were installed, stamp a number corresponding to the cylinder number on the connecting rod cap and connecting rod. • Inspect all parts for wear or damage. Replace as necessary. (See Inspection/Replacement procedures.) 1st Compression Ring Piston Size Mark Camshaft Side 2nd Compression Ring Flywheel Side Oil Ring with Coil Expander Piston Groove Tangs Groove Connecting Rod Cap Alignment Mark Connecting Rod Cap Screw Dip in clean engine oil. 98 N•m (69 lb-ft) Piston Pin Snap Ring Piston Pin Bushing Connecting Rod M82043A M82044A 4/7/95 4-23 4 Pistons, Rods and Cylinder Block Assembly • Apply clean engine oil to all parts during assembly. IMPORTANT: Pistons must be installed on the same connecting rod they were removed from. 1. Assemble piston to connecting rod with piston size mark opposite connecting rod “punched” alignment mark. If a new connecting rod is used, assemble piston to connecting rod with piston size mark on same side as connecting rod bearing insert groove. Oil Ring Expander Oil Ring Gap Oil Ring Expander Ends 2. Install piston pin and snap rings. Oil Ring Piston Pin M82046A Piston Size Mark 4 Piston 5. Install second compression ring, with chamfer toward top of piston, in middle groove. Turn ring until gap is 120o away from oil ring gap. Piston Pin 6. Install first compression ring, with manufacturer's mark “R” (near ring gap) toward top of piston, in top groove. Turn ring until gap is 120o away from second ring gap. 1st Compression Ring 2nd Compression Ring Snap Ring Connecting Rod Bearing Insert Groove Alignment Mark M82045A 3. Install oil ring expander in bottom ring groove of piston with ends above either end of piston pin. 2nd Compression Ring 120° 1st Compression Ring 120° 120° Oil Ring 4. Install oil ring over expander with ring gap opposite (180o) of expander ends. M82047A 4-24 4/7/95 Pistons, Rods and Cylinder Block Inspection/Replacement 1. Inspect all parts for wear or damage. Replace as necessary. 5. With rings installed on piston, measure piston ring groove clearance. Measure several places around each piston. 2. Measure crankshaft connecting rod journal diameter. (See Crankshaft, Main Bearings and Flywheel in this section.) 3. Install connecting rod cap and bearing inserts on connecting rod. Install old connecting rod cap screws and tighten to 93 N•m (69 lb-ft). 4. Measure connecting rod bearing diameter. M35360 Piston Ring Groove Clearance: First Compression Ring: Standard . . . . . . . . . . . . . . . 0.090 - 0.125 mm . . . . . . . . . . . . . . . . . . . . . (0.0035 - 0.0049 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Second Compression Ring: M82048A Standard . . . . . . . . . . . . . . . 0.035 - 0.070 mm . . . . . . . . . . . . . . . . . . . . . (0.0014 - 0.0028 in.) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) Connecting Rod Bearing I.D.: Standard . . . . . . . . . . . . . . . . 60 - 60.042 mm . . . . . . . . . . . . . . . . . . . . . (2.3622 - 2.3639 in.) Wear Limit. . . . . . . . . . 60.10 mm (2.3661 in.) Clearance . . . . . . . . . . . . . 0.09 mm (0.004 in.) Oil Ring: Standard . . . . . . . . . . . . . . . 0.030 - 0.065 mm . . . . . . . . . . . . . . . . . . . . . (0.0012 - 0.0026 in.) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) If bearing diameter exceeds wear limit, replace bearing inserts. If clearance exceeds wear limit, replace rings or piston. If bearing clearance (bearing I.D. minus crankshaft journal O.D.) exceeds specification, grind crankshaft connecting rod journals and install undersized bearing inserts, or replace bearing inserts and crankshaft. 6. Measure piston ring end gap. Push ring into cylinder bore, using a piston, until ring is approximately 30 mm (1.181 in.) from bottom of cylinder bore. 4/7/95 4-25 4 Pistons, Rods and Cylinder Block End Gap Cylinder Bore Measuring Positions Piston Ring 4 Approx. 30 mm (1.181 in.) End Gap M82049A Piston Ring End Gap: Compression Rings: Standard . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . (0.0098 - 0.0157 in.) Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.) Oil Ring: Standard . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm . . . . . . . . . . . . . . . . . . . . . (0.0118 - 0.0197 in.) Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.) M82050A Piston Pin O.D.: Standard . . . . . . . . . . . . . . 33.989 - 34.00 mm . . . . . . . . . . . . . . . . . . . . . (1.3381 - 1.3386 in.) Wear Limit. . . . . . . . . . 33.90 mm (1.3346 in.) If pin diameter is less than wear limit, replace pin. 8. Measure piston pin bore diameter in piston. If end gap exceeds wear limit, replace rings. 7. Measure piston pin diameter. Measure diameter at six places. M37683 4-26 4/7/95 Pistons, Rods and Cylinder Block Piston Pin Bore I.D.: Standard . . . . . . . . . . . . . . 34.00 - 34.011 mm . . . . . . . . . . . . . . . . . . . . . (1.3386 - 1.3390 in.) Wear Limit. . . . . . . . . . 34.02 mm (1.3393 in.) Clearance . . . . . . . . . . . 0.022 mm (0.0009 in.) If piston pin bore exceeds wear limit, replace piston. If bore clearance (bore I.D. minus pin O.D.) exceeds specification, replace piston, piston pin or both. 9. Measure piston connecting rod. pin bushing diameter in Piston pin bushing is press fit. Replace bushing using a driver set. When installing bushing, make sure to align oil hole in bushing with hole in connecting rod. 10.Measure piston diameter perpendicular to piston pin bore 25.50 mm (1.004 in.) from bottom of piston. NOTE: If engine has had a previous major overhaul, oversize pistons and rings may have been installed. Pistons and rings are available in 0.25 mm (0.010 in.) oversize. 4 M82052A M82051A Piston O.D.: Standard Size Piston: Piston Pin Bushing I.D.: Standard . . . . . . . . . . . . . . . 34.03 - 34.05 mm . . . . . . . . . . . . . . . . . . . . . (1.3398 - 1.3406 in.) Wear Limit. . . . . . . . . . 34.10 mm (1.3425 in.) Clearance . . . . . . . . . . . 0.061 mm (0.0024 in.) If bushing diameter exceeds wear limit, replace bushing. If bushing clearance (bushing I.D. minus pin O.D.) exceeds specification, replace bushing, piston pin or both. Standard . . . . . . . . . . . . . 99.895 - 99.925 mm . . . . . . . . . . . . . . . . . . . . . (3.9329 - 3.9341 in.) Wear Limit. . . . . . . . . . 99.79 mm (3.9287 in.) 0.25 mm (0.010 in.) Oversize Piston: Standard . . . . . . . . . . . . . 100.15 - 100.18 mm . . . . . . . . . . . . . . . . . . . . . . . (3.943 - 3.944 in.) Wear Limit. . . . . . . . . . 100.05 mm (3.939 in.) If piston diameter is less than wear limit, install a new piston. 11.Measure cylinder bore diameter. (See procedure in this group.) 4/7/95 4-27 Pistons, Rods and Cylinder Block CYLINDER BORE If cylinder bore exceeds wear limit, replace cylinder block or have cylinder rebored. (See Reboring procedure.) Inspection Measure cylinder bore diameter at three positions; top, middle and bottom. At these three positions, measure in both directions; along crankshaft center line and direction of crankshaft rotation. NOTE: If engine has had a previous major overhaul, oversize pistons and rings may have been installed. If cylinder is rebored, oversize pistons and rings must be installed. Pistons and rings are available in 0.25 mm (0.010 in.) oversize. If clearance (cylinder bore I.D. minus piston O.D.) exceeds specification, replace cylinder block, piston or both; or rebore cylinder and install oversize piston and rings. Deglazing IMPORTANT: If cylinder bores are to be deglazed with crankshaft installed in engine, put clean shop towels over crankshaft to protect journal and bearing surfaces from any abrasives. Top Position Middle Position 1. Deglaze cylinder bores using a flex-hone with 180 grit stones. 4 2. Use flex-hone as instructed by manufacturer to obtain a 30 - 40° cross-hatch pattern as shown. Bottom Position IMPORTANT: Do not use gasoline, kerosene or commercial solvents to clean cylinder bores. Solvents will not remove all abrasives from cylinder walls. Direction of Crankshaft Rotation 3. Remove excess abrasive residue from cylinder walls using a clean dry rag. Clean cylinder walls using clean white rags and warm soapy water. Continue to clean cylinder until white rags show no discoloration. Direction of Crankshaft Centerline M82053A Cylinder Bore I.D.: Standard Size Bore: Standard . . . . . . . . . . . . . 100.00 - 100.03 mm . . . . . . . . . . . . . . . . . . . . . (3.9370 - 3.9382 in.) Wear Limit . . . . . . . . 100.15 mm (3.9429 in.) Clearance . . . . . . . . . . . . . 0.41 mm (0.016 in.) 0.25 mm (0.010 in.) Oversize Bore: M82054A Standard . . . . . . . . . . . . . 100.25 - 100.28 mm . . . . . . . . . . . . . . . . . . . . . . . (3.947 - 3.948 in.) Wear Limit. . . . . . . . . . 100.45 mm (3.955 in.) 4-28 4/7/95 Pistons, Rods and Cylinder Block Reboring NOTE: Measure bore when cylinder is cool. NOTE: The cylinder block can be rebored to use 0.25 mm (0.010 in.) oversize pistons and rings. (See this group for cylinder bore I. D. specifications.) 6. Stop press and check cylinder diameter. NOTE: Finish should not be smooth. It should have a 30 - 40o crosshatch pattern. 1. Align center of bore to drill press center. 7. Remove rigid hone when cylinder is within 0.03 mm (0.001 in.) of desired size. IMPORTANT: Check stone for wear or damage. Use a rigid hone with 300 grit stones. 8. Use a flex hone with 180 grit stones for honing to final size. 2. Adjust hone so lower end is even with lower end of cylinder bore. 9. Check bore for size, taper and out-of-round. (See Inspection procedures.) 3. Adjust rigid hone stones until they contact narrowest point of cylinder. 4. Coat cylinder with honing oil. Hone should turn by hand. Adjust if too tight. IMPORTANT: Do not use solvents to clean cylinder bore. Solvents will not remove all metal particles and abrasives produced during honing. 5. Run drill press at about 250 RPM. Move hone up and down in order to obtain a 30 - 40°crosshatch pattern. 10.Clean cylinder thoroughly using warm soapy water until clean white rags show no discoloration. 11.Dry cylinder and apply engine oil. 4 30 - 40° M52959 4/7/95 4-29 Crankshaft, Main Bearings and Flywheel OTHER MATERIALS Number Name Use John Deere Form-In-Place Gasket Seals crankcase extension housing and rear oil seal case to engine block. LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. TY15130/ NA/ #395 SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Block Gasket Kit • Undersized Main Bearing Inserts • Flywheel Mounting Cap Screws 4 ® LOCTITE is a registered trademark of the Loctite Corp. 4-30 4/7/95 Crankshaft, Main Bearings and Flywheel CRANKCASE EXTENSION HOUSING 1. Remove flywheel. (See procedure in this group.) 2. Remove oil pan and oil strainer. (See Lubrication System in this section.) 3. Remove oil dipstick and tube, if equipped. NOTE: 4TN100LFB shown. 4TN100RJF is not equipped with an oil dipstick tube. Cap Screw (3) M8 x 25 21 N•m (180 lb-in.) Cap Screw (4) M10 x 30 49 N•m (36 lb-ft) 4 M82056 Oil Dipstick Intake Manifold Cap Screw M10 x 16 John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Oil Dipstick Tube O-Ring Cap Screw (2) M8 X 70 26 N•m (226 lb-in.) Cap Screw (6) M12 X 85 88 N•m (65 lb-ft) 4/7/95 Cap Screw (4) M8 x 35 21 N•m (180 lb-in.) Washer (6) Crankcase Extension Housing M82055A 4-31 Crankshaft, Main Bearings and Flywheel CRANKSHAFT REAR OIL SEAL Replacement • Replace oil seal using a driver set. Install seal with lip toward inside of gear housing cover. Install seal 3.18 mm (0.125 in.) below surface of cover. 1. Remove flywheel. (See procedure in this group.) • Replace oil seal using a driver set. Install seal, with lip toward cylinder block. Install seal flush with surface of oil seal case. Timing Gear Cover Rear Oil Seal Seal Case-to-Block Cap Screw (5) M8 X 25 26 N•m (226 lb-in.) Crankshaft Front Oil Seal Oil Seal Case M82058A CRANKSHAFT AND MAIN BEARINGS 4 Removal 1. Check crankshaft end play. (See Checks, Tests and Adjustments in this section.) Seal Case-to-Extension Cap Screw (3) M8 X 25 21 N•m (180 lb-in.) John Deere Form-In-Place Gasket (RTV rubber silicone sealant) M82057A CRANKSHAFT FRONT OIL SEAL Replacement • Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) 4-32 2. Remove rear oil seal. (See procedure in this group.) 3. Remove flywheel housing. (See procedure in this group.) 4. Remove crankcase extension housing. (See procedure in this group.) 5. Remove timing gear housing. (See Camshaft and Timing Gear Train in this section.) 6. Check crankshaft bearing clearance. (See Checks, Tests and Adjustments in this section.) IMPORTANT: Connecting rod end caps must be installed on the same connecting rods from which they were removed. Note alignment marks on caps and rods. 4/7/95 Crankshaft, Main Bearings and Flywheel 7. Remove connecting rod cap screws and end caps. 8. Push pistons and connecting rods away from crankshaft. IMPORTANT: Main bearing caps must be installed on the same main bearings from which they were removed. 9. Remove main bearing cap screws, caps and cap thrust bearings. 10.Remove crankshaft. 11.Remove block thrust bearings and main bearing inserts. 12.Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) Crankshaft Flywheel End 4 Block Thrust Bearing Cap Thrust Bearing Main Bearing Inserts Main Bearing Cap Main Bearing Cap Screw (10) M82059A 4/7/95 4-33 Crankshaft, Main Bearings and Flywheel Installation • Apply clean engine oil on all parts during installation. IMPORTANT: Do not touch bearing insert surfaces. Oil and acid from your finger will corrode the bearing surface. 1. Install grooved bearing inserts in crankshaft bearing bores, aligning tangs with slots in bores. 2. Install block thrust bearings with oil grooves facing away from engine block. 3. Install crankshaft. 4. Install smooth bearing inserts in main bearing caps, aligning tangs with slots in caps. 4 NOTE: Main bearing caps have “raised arrows” that are stamped with numbers. Both correspond to their location on the engine block. The number “1” main bearing bore is at flywheel end. Install bearing caps beginning with number 1, then 2, etc. The main bearing cap at gear train end does not have a number. Also install bearing caps with the “arrow” toward the flywheel end. 4-34 5. Install cap thrust bearings, with oil grooves facing away from cap, in the number “1” main bearing cap. 6. Install main bearing caps in their original locations with arrows pointing toward flywheel side of engine. IMPORTANT: DO NOT use high speed power tools or air wrenches to tighten main bearing cap screws. 7. Dip entire main bearing cap screws in clean engine oil. Install cap screws and tighten. DO NOT tighten to specifications. 8. Using a soft-faced hammer, tap the front end of the crankshaft then the rear end of the crankshaft to align the thrust bearings. 9. Tighten main bearing cap screws to specifications. When tightening, start at center main bearing cap and work your way out, alternating to the ends. Turn crankshaft by hand. If it does not turn easily, disassemble the parts and find the cause. 4/7/95 Crankshaft, Main Bearings and Flywheel Crankshaft Flywheel End Grooved Bearing Insert Tangs Block Thrust Bearing Cap Thrust Bearing Smooth Bearing Insert Main Bearing Cap 4 Main Bearing Cap Screw (10) Dip in clean engine oil. Initial: 136 N•m (100 lb-ft) Final: 196 N•m (145 lb-ft) 1 2 3 4 M82059A IMPORTANT: Connecting rod caps must be installed on the same connecting rods they were removed from. Never reuse connecting rod cap screws, replace with new. 10.Match the connecting rod caps to the rods using alignment marks. Install caps. 12.Install timing gear housing. (See Camshaft and Timing Gear Train in this section.) 13.Install crankcase extension procedure in this group.) housing. (See 14.Install flywheel housing. (See procedure in this group.) 15.Install rear oil seal. (See procedure in this group.) 11.Dip entire connecting rod cap screws in clean engine oil. Install new cap screws and tighten to 98 N•m (69 lb-ft). 4/7/95 4-35 Crankshaft, Main Bearings and Flywheel Inspection/Replacement 1. Inspect gear for chipped or broken teeth. Replace if necessary. Heat gear to approximately 150o C (300o F). Install gear with timing mark “A” toward press table. Align slot in gear with key in shaft. Press crankshaft into gear until gear is tight against crankshaft shoulder. To replace gear: Remove gear from crankshaft using a knife-edge puller and a press. Key Crankshaft Gear CAUTION Timing Mark DO NOT heat oil over 182° C (360° F). Oil fumes or oil can ignite above 193° C (380° F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. M82060A 2. Inspect crankshaft for bend using v-blocks and a dial indicator. Turn crankshaft slowly and read variation on indicator. If variation is greater than 0.02 mm (0.0007 in.), replace crankshaft. 4 Dial Indicator V-Block M82061A 4-36 4/7/95 Crankshaft, Main Bearings and Flywheel 3. Measure crankshaft connecting rod journal and main bearing journal diameters. Measure several places around each journal. 4. Install bearing inserts and main bearing cap on main bearing. Tighten main bearing cap screws to 196 N•m (145 lb-ft). NOTE: If engine has had a previous major overhaul, journals may have been ground and undersized bearing inserts installed. 5. Measure main bearing diameter. Main Bearing Journal M82063 Connecting Rod Journal M82062A Connecting Rod Journal O.D.: Main Bearing I.D.: Standard . . . . . . . . . . . . . . 60.00 - 60.042 mm . . . . . . . . . . . . . . . . . . . . . (2.3622 - 2.3639 in.) Standard . . . . . . . . . . . . . 59.952 - 59.964 mm . . . . . . . . . . . . . . . . . . . . . (2.3603 - 2.3608 in.) Wear Limit. . . . . . . . . . 60.10 mm (2.3661 in.) Wear Limit. . . . . . . . . . 59.90 mm (2.3583 in.) If bearing diameter exceeds wear limit, replace bearing inserts. Main Bearing Journal O.D.: Standard . . . . . . . . . . . . . 69.952 - 69.964 mm . . . . . . . . . . . . . . . . . . . . . (2.7540 - 2.7545 in.) Wear Limit. . . . . . . . . . 69.90 mm (2.7520 in.) Clearance . . . . . . . . . . . . . 0.09 mm (0.004 in.) If bearing clearance (bearing I.D. minus crankshaft main bearing journal O.D.) exceeds specification, replace bearing inserts and crankshaft or have crankshaft journals ground undersize by a qualified machine shop and install undersized bearing inserts. If journal diameter is less than wear limit, replace crankshaft or have journals ground undersize by a qualified machine shop. Bearing inserts are available in 0.25 mm (0.010 in.) undersize. If journals are ground, undersize bearing inserts must be installed. Bearing inserts are available in 0.25 mm (0.010 in.) undersize. 6. Clean and inspect oil passages in main bearing journals, connecting rod journals and main bearing bores in cylinder block. 7. Inspect crankshaft for cracks or damage. Replace if necessary. 4/7/95 4-37 4 Crankshaft, Main Bearings and Flywheel FLYWHEEL IMPORTANT: Never reuse flywheel mounting cap screws. Always install new. • Inspect pilot bearing, if equipped, for wear or damage. Replace if necessary using a driver set. Install bearing flush with flywheel surface. • Measure flywheel flatness. Place a straight edge across flywheel surface opposite of ring gear. Measure clearance between straight edge and flywheel surface with a feeler gauge. If clearance exceeds 0.02 mm (0.0008 in.), replace flywheel. M35337 Flywheel Pilot Bearing (4TN100RJF only) 4 Flywheel Flywheel Mounting Cap Screw (6) Replace. Apply clean engine oil on threads. 196 N•m (145 lb-ft) M82064A 4-38 4/7/95 Crankshaft, Main Bearings and Flywheel FLYWHEEL HOUSING 1. Remove flywheel. (See procedure in this group.) 2. Remove starter. Housing-to-Block Cap Screw (8) M10 X 25 49 N•m (36 lb-ft) Flywheel 4 Plug Housing-to-Extension Cap Screw (4) M10 X 30 49 N•m (36 lb-ft) 4/7/95 M82065A 4-39 Camshaft and Timing Gear Train SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the European Microfiche Tool Catalog (MTC). D15001NU Magnetic Follower Holder Kit Hold cam followers when removing and installing camshaft. OTHER MATERIALS Number Name Use TY15130/ NA/ #395 John Deere Form-In-Place Gasket Seals camshaft plug, timing gear cover and housing to engine block. TY9370/ TY9477/ #242 Thread Lock and Sealer (Medium Strength) Apply to threads of crankshaft pulley cap screw. LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. 4 SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Head Gasket Kit • Cylinder Block Gasket Kit ® LOCTITE is a registered trademark of the Loctite Corp. 4-40 4/7/95 Camshaft and Timing Gear Train CAMSHAFT Removal Mounting Cap Screws (2) M8 X 16 Camshaft 1. Remove rocker arm assembly and push rods. (See Cylinder Head, Valves and Manifolds in this section.) 2. Remove timing gear cover. (See procedure in this group.) 3. Check camshaft end play. (See Checks, Tests and Adjustments in this section.) 4. Check backlash of timing gears. (See Checks, Tests and Adjustments in this section.) NOTE: If a magnetic follower holder kit is not available, turn engine until oil pan is upward, to hold cam followers away from camshaft. 5. Hold cam followers away from camshaft using a magnetic follower holder kit such as D15001NU. NOTE: Due to the odd number of teeth on the idler gear, timing marks will only align periodically. Timing Marks M82066 Installation 4 • Apply clean engine oil on all parts during installation. 6. Rotate crankshaft and align timing marks. IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while installing camshaft. Machined surfaces can be damaged. IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while removing camshaft. Machined surfaces can be damaged. 1. Rotate crankshaft to align timing marks. 7. Remove two cap screws and camshaft. 8. Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) 2. Install camshaft. 3. Install and tighten mounting cap screws to 26 N•m (226 lb-in.). 4. Install timing gear cover. (See procedure in this group.) 5. Install push rods and rocker arm assembly. (See Cylinder Head, Valves and Manifolds in this section.) 4/7/95 4-41 Camshaft and Timing Gear Train Inspection/Replacement Heat gear to approximately 150oC (300oF). 1. Check camshaft side gap using a feeler gauge. IMPORTANT: Be sure thrust plate is not between camshaft gear and camshaft shoulder while installing gear. Camshaft Gear Thrust Plate Install thrust plate if removed. Install gear with timing mark “C” side toward press table. Align slot in gear with key in shaft. Press camshaft into gear until gear is tight against camshaft shoulder. Thrust plate must spin freely on camshaft. Key Camshaft Gear Side Gap M82067A 4 Camshaft Side Gap: Standard . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm . . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.) Thrust Plate M82068A Wear Limit. . . . . . . . . . . 0.29 mm (0.0114 in.) If side gap is at wear limit, remove gear and replace thrust plate. 2. Inspect gear for chipped or broken teeth. Replace if necessary. To remove/replace gear: 3. Inspect camshaft for bend using v-blocks and a dial indicator. Turn camshaft slowly and read variation on indicator. If variation is greater than 0.05 mm (0.0020 in.), replace camshaft. Dial Indicator Remove gear from camshaft using a knife-edge puller and a press. CAUTION DO NOT heat oil over 182° C (360° F). Oil fumes or oil can ignite above 193° C (380° F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. Camshaft Central Bearing Area V-Block M82069A 4. Measure camshaft lobe height. 4-42 4/7/95 Camshaft and Timing Gear Train If journal diameters are less than wear limit, replace camshaft. 6. Measure camshaft bushing diameter at gear housing end. Lobe Height Camshaft Bushing M82070A Lobe Height: Standard . . . . . . . . . . . . . 48.435 - 48.565 mm . . . . . . . . . . . . . . . . . . . . . (1.9069 - 1.9120 in.) Oil Holes M82072 Wear Limit. . . . . . . . . . . 48.20 mm (1.897 in.) If lobe height is less than wear limit, replace camshaft. 5. Measure camshaft end and intermediate journal diameters. Camshaft Bushing I.D.: Standard . . . . . . . . . . . . . . . 56.98 - 57.05 mm . . . . . . . . . . . . . . . . . . . . . (2.2433 - 2.2461 in.) Wear Limit. . . . . . . . . . 57.10 mm (2.2480 in.) Clearance . . . . . . . . . . . . . 0.14 mm (0.006 in.) If bushing diameter exceeds wear limit, replace bushing. Flywheel End Journal To replace bushing: Remove bushing using a chisel. Be careful not to push bushing inside of engine. Align oil holes in new bushing and cylinder block. Install bushing 1.6 mm (0.062 in.) below surface of cylinder block using a driver set. Intermediate Journal Gear Housing End Journal M82071A Camshaft Journal O.D.: Gear Housing and Flywheel Ends: Standard . . . . . . . . . . . . . . . 56.91 - 56.94 mm . . . . . . . . . . . . . . . . . . . . . (2.2406 - 2.2417 in.) Wear Limit. . . . . . . . . . 56.80 mm (2.2362 in.) Intermediate: Standard . . . . . . . . . . . . . . . 56.89 - 56.92 mm . . . . . . . . . . . . . . . . . . . . . (2.2398 - 2.2409 in.) If bushing clearance (bushing I.D. minus camshaft journal O.D.) exceeds specification, replace bushing, camshaft or both. NOTE: Flywheel housing must be removed to measure camshaft intermediate and flywheel end bearing diameters. 7. Measure intermediate and flywheel end camshaft bore diameters using the following procedures: • Remove flywheel housing. (See Crankshaft, Main Bearings and Flywheel in this section.) • Remove plug using a long wooden dowel. Insert wooden dowel through gear housing side. Wear Limit. . . . . . . . . . 56.80 mm (2.2362 in.) 4/7/95 4-43 4 Camshaft and Timing Gear Train CAM FOLLOWERS Removal/Installation 1. Remove camshaft. (See procedure in this group.) 2. Remove oil pan and strainer. (See Lubrication System in this section.) Plug M35287 • Measure intermediate and flywheel end camshaft bore diameters. IMPORTANT: Cam followers must be installed in the same bores from which they were removed. 3. Put a mark on each cam follower and cylinder block bore to aid in installation. 4. Remove cam followers. 5. Inspect all parts for wear or damage. (See Inspection procedures.) 6. Apply clean engine oil on all parts during installation. Intermediate Bore Installation is done in the reverse order of removal. 4 Inspection Flywheel End Bore M82073 • Inspect cam follower contact surface for abnormal wear. Replace if necessary. Camshaft Bore I.D.: Standard . . . . . . . . . . . . . . . 57.00 - 57.03 mm . . . . . . . . . . . . . . . . . . . . . (2.2441 - 2.2453 in.) Wear Limit. . . . . . . . . . 57.10 mm (2.2480 in.) Clearance . . . . . . . . . . . . . 0.12 mm (0.005 in.) If bore diameter exceeds wear limit, replace cylinder block. If bore clearance (bore I.D. minus camshaft journal O.D.) exceeds specification, replace camshaft, cylinder block or both. Normal Contact Abnormal Contact M82074A • Apply John Deere Form-In Place Gasket, or an equivalent, on outer edge of plug. Install plug until it bottoms in bore. • Install flywheel housing. 4-44 4/7/95 Camshaft and Timing Gear Train • Measure cam follower stem diameter. 3. Remove cap screw and washer. 4. Remove crankshaft pulley using a two-jaw puller kit. 5. Remove key. Pulley Spacer M82075A Cam Follower Stem O.D.: Standard . . . . . . . . . . . . . 14.218 - 14.233 mm . . . . . . . . . . . . . . . . . . . . . (0.5598 - 0.5604 in.) Wear Limit. . . . . . . . . . 14.17 mm (0.5579 in.) If stem diameter is less than wear limit, replace cam follower. • Measure cam follower bore diameter in cylinder block. Socket-Head Cap Screw (4) M8 x 50 11 in.)N•m (96 lb- 4 Fan Cam Follower Bore I.D.: Standard . . . . . . . . . . . . . 14.249 - 14.270 mm . . . . . . . . . . . . . . . . . . . . . (0.5610 - 0.5618 in.) Wear Limit. . . . . . . . . . 14.30 mm (0.5630 in.) Clearance . . . . . . . . . . . 0.052 mm (0.0020 in.) If cam follower bore diameter exceeds wear limit, replace cylinder block. If bore clearance (bore I.D. minus follower stem O.D.) exceeds specification, replace cam follower, cylinder block or both. Cap Screw (4) M10 x 20 Apply thread lock and sealer (medium strength) to threads. 65 N•m (47 lb-ft) M82076A NOTE: It is not necessary to remove auxiliary drive cover and gasket, end cover and o-ring or fuel injection pump gear cover to remove timing gear cover. 6. Remove 18 mounting cap screws and timing gear cover. Installation is done in the reverse order of removal. • Replace seal washer. TIMING GEAR COVER • Tighten all mounting cap screws to 26 N•m (226 lb-in.). Removal/Installation • Adjust fan/alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) 1. Remove alternator and belt. 2. Remove fan, spacer and pulley. 4/7/95 4-45 Camshaft and Timing Gear Train Mounting Cap Screw M8 x 45 Gasket Auxiliary Drive Cover Mounting Cap Screw M8 x 75 Mounting Cap Screw (2) M8 x 50 Mounting Plate Cap Screw (2) M8 x 20 Mounting Cap Screw M8 x 45 O-Ring End Cover Cap Screw (2) M8 x 20 Mounting Cap Screws M8 x 45 4 Mounting Cap Screws M8 x 75 John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Mounting Cap Screw M8 x 45 Key Crankshaft Pulley Timing Gear Cover Washer Mounting Cap Screw M8 x 45 Mounting Cap Screw M8 x 75 Injection Pump Gear Cover Seal Washer Replace Mounting Cap Screw M8 x 40 Mounting Cap Screw (3) M8 x 45 IDLER GEAR Removal/Installation 1. Remove timing gear cover. (See procedure in this group.) 2. Check backlash of timing gears. (See Checks, Tests and Adjustments in this section.) Cap Screw M8 x 20 Mounting Cap Screw (2) M8 x 90 Cap Screw Apply thread lock and sealer (medium strength) to threads. 115 N•m (85 lb-ft) M82077A NOTE: Due to the odd number of teeth on the idler gear, timing marks will only align periodically. When all timing marks on gears are aligned, the piston closest to the water pump is at TDC on compression stroke. Number one cylinder is closest to the flywheel. 3. Rotate crankshaft and align timing marks. 4. Remove two cap screws, shaft and gear. 4-46 4/7/95 Camshaft and Timing Gear Train 5. Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) If bushing diameter exceeds wear limit, replace bushing. Installation is done in the reverse order of removal. To replace bushing: Idler Gear (51T) Replace bushing using a driver set. Align oil holes in bushing and idler gear. Install bushing flush with surface of idler gear. If bushing clearance (bushing I.D. minus shaft O.D.) exceeds specification, replace bushing, shaft or both. Idler Gear Shaft Idler Gear Bushing Idler Gear Shaft Cap Screw (2) M8 x 45 M82078A Inspection/Replacement • Inspect gear for chipped or broken teeth. Replace if necessary. • Measure idler gear shaft diameter. Idler Gear Shaft O.D.: M82079A 4 TIMING GEAR HOUSING Removal/Installation 1. Remove camshaft. (See procedure in this group.) 2. Remove idler gear. (See procedure in this group.) Standard . . . . . . . . . . . . . . 45.95 - 45.975 mm . . . . . . . . . . . . . . . . . . . . . (1.8091 - 1.8100 in.) 3. Remove fuel injection pump. (See Fuel System in this section.) Wear Limit. . . . . . . . . . . 45.9 mm (1.8071 in.) 4. Remove mounting cap screws and housing. If shaft diameter is less than wear limit, replace idler gear shaft. Installation is done in the reverse order of removal. • Measure idler gear bushing diameter. Idler Gear Bushing I.D.: Standard . . . . . . . . . . . . . . 46.00 - 46.025 mm . . . . . . . . . . . . . . . . . . . . . (1.8110 - 1.8120 in.) Wear Limit. . . . . . . . . . 46.09 mm (1.8146 in.) Clearance . . . . . . . . . . . 0.075 mm (0.0030 in.) 4/7/95 4-47 Camshaft and Timing Gear Train John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Timing Gear Housing Mounting Cap Screw M8 x 45 25 N•m (220 lb-in.) 4 Mounting Cap Screw (4) M8 x 35 21 N•m (180 lb-in.) AUXILIARY DRIVE GEAR - IF EQUIPPED Remove timing gear cover. (See procedure in this group.) NOTE: Bearings are slip fit in timing gear housing and cover and press fit on drive gear ends. Mounting Cap Screw (5) M8 x 20 25 N•m (220 lb-in.) M82080A Auxiliary Drive Gear Ball Bearing Inspect all parts for wear or damage. Replace as necessary. M82081 4-48 4/7/95 Lubrication System OTHER MATERIALS Number Name Use TY15130/ NA/ #395 John Deere Form-In-Place Gasket Seals oil pan to crankcase extension housing. TY9375/ TY9480/ #592 John Deere Pipe Sealant with TEFLON® Apply to threads of plug in oil cooler. LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. 4 ®LOCTITE is a registered trademark of the Loctite Corp. ®TEFLON is a registered trademark of the Du Pont Company. 4/7/95 4-49 Lubrication System OIL PAN AND STRAINER • Replace all O-rings and copper washers, if equipped. Removal/Installation • Fill engine with proper engine oil. (See SPECIFICATIONS AND GENERAL INFORMATION section.) • Approximate crankcase oil capacity is 12.7L (13.4 qt.). Drain Plug Assembly (4TN100LFB) 4 Copper Washer (2) Replace Cap Screw (4) M8 x 30 21 N•m (180 lb-in.) Drain Plug (4TN100RJF) O-Ring (4TN100RJF) Replace O-Ring Replace John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Oil Strainer Tube Cap Screw with Lock Washer (2) M8 x 16 26 N•m (226 lb-in.) Oil Pan Cap Screw (4) M8 x 30 21 N•m (180 lb-in.) 4-50 Cap Screw (18) M8 x 85 26 N•m (226 lb-in.) Cap Screw (2) M8 x 16 26 N•m (226 lb-in.) M82082A 4/7/95 Lubrication System OIL PUMP • Coat all parts with clean engine oil. Removal/Installation • Install outer rotor with identification mark facing toward rotor shaft assembly. 1. Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) 2. Check oil pump gear backlash. Replace entire oil pump assembly if backlash is more than 0.25 mm (0.010 in.). Housing Outer Rotor Safety Valve Non-Adjustable. Do not remove. Cap Screws M6 x 25 6 N•m (53 lb-in.) 3. Remove idler shaft and gear. (See Camshaft and Timing Gear Train in this section.) 4. Remove two mounting cap screws, oil pump and gasket. 5. Inspect all parts for wear or damage. (See Disassembly/Assembly procedures). Oil Pump Gasket Oil Pump Mounting Cap Screw M8 x 16 25 N•m (18 lb-ft) Identification Mark Cap Screw (2) M6 x 16 6 N•m (53 lb-in.) Rotor Shaft Assembly 4 M51574 Inspection • Check rotor shaft outer diameter and the shaft hole diameter in housing. If clearance is more than 0.20 mm (0.008 in.), replace entire assembly. Housing Mounting Cap Screw M8 x 50 25 N•m (18 lb-ft) Rotor Shaft Assembly M51568 Disassembly/Assembly • Do not remove gear to remove cap screws. Do not disassemble rotor shaft assembly other than shown. If any parts are worn or damaged, replace as an assembly. M51570 • Inspect parts for wear or damage. (See Inspection procedures.) 4/7/95 4-51 Lubrication System • Check outer rotor recess. If outer rotor is below face of pump housing more than 0.25 mm (0.010 in.), replace entire assembly. Feeler Gauge Inner Rotor Feeler Gauge Straight Edge Outer Rotor M51573 Housing Outer Rotor M51571 • Check outer rotor-to-pump housing clearance. If clearance is more than 0.25 mm (0.010 in.), replace entire assembly. OIL COOLER 1. Remove fuel injection pump. (See Fuel System in this section.) • Replace O-ring, copper washer and gaskets. Damaged or used parts will leak. • Pressure test oil cooler. (See Checks, Tests and Adjustments section.) 4 Outer Rotor NOTE: Oil cooler adapter is slip fit on water pump with an O-ring seal. Feeler Gauge Water Pump Housing M51572 • Check inner-to-outer rotor clearance. If clearance is more than 0.25 mm (0.010 in.), replace entire assembly. O-Ring Oil Cooler Adapter 4-52 M51577 4/7/95 Lubrication System Cap Screw (10) M8 x 50 24 N•m (18 lb-ft) Oil Cooler Housing Gasket Plug Copper Washer Oil Cooler Flange Nut (4) 49 N•m (36 lb-ft) Gasket (2) Gasket Adapter Cap Screw (8) M8 x 35 24 N•m (18 lb-ft) Oil Cooler By-Pass Valve Oil Pressure Regulating Valve Cap Screw (3) M8 x 20 24 N•m (18 lb-ft) Cap Screw M8 x 25 24 N•m (18 lb-ft) Cap Screw M8 x 20 24 N•m (18 lb-ft) Plug Apply Pipe Sealant with TEFLON. M82083A NOTE: See OIL COOLER BY-PASS VALVE and OIL PRESSURE REGULATING VALVE if service is necessary. Copper Washer OIL COOLER BY-PASS VALVE NOTE: Oil cooler is removed to show detail. • Inspect parts for wear or damage. Check spring free and compressed lengths. Replace parts as necessary. • Replace copper washer. A used washer may leak. Plug Valve Spring M51578 Spring Specifications: Free Length . . . . . . . . . . . . .63 mm (2.480 in.) Compressed Length . . . . . .37 mm (1.450 in.) . . . . . . . . . . . . . . . . . @ 3.75N (0.840 lb force) 4/7/95 4-53 4 Lubrication System OIL PRESSURE REGULATING VALVE PISTON COOLING NOZZLES NOTE: Oil cooler is removed to show detail. Replacement • Inspect parts for wear or damage. Check spring free and compressed lengths. Replace parts as necessary. 1. Remove oil pan and strainer. (See procedure in this group.) • Install nozzle with locating pin in locating hole of cylinder block. Piston Cooling Nozzle Shim If equipped Plug Valve Spring Copper Washer 4 M51579 Mounting Bolt 15 N•m (130 lb-in.) M51580 • Replace copper washer. A used washer may leak. NOTE: Valve assembly may or may not be equipped with shims. Locating Pin Spring Specifications: Free Length . . . . . . . . . . . . 51 mm (2.010 in.). Compressed Length . . . . . .50 mm (1.970 in.) . . . . . . . . . . . . . . . . . @ 5.40N (1.200 lb force) M51581 4-54 4/7/95 Cooling System OTHER MATERIALS Number Name Use TY9375/ TY9480/ #592 John Deere Pipe Sealant with TEFLON® Apply to threads of coolant temperature sender, heater hose fitting and adapter fitting. TY9370/ TY9477/ #242 Thread Lock and Sealer (Medium Strength) Apply to threads of fan-to-spacer cap screws. LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. 4 ® TEFLON is a registered trademark of the Du Pont Company. ® LOCTITE is a registered trademark of the Loctite Corp. 4/7/95 4-55 Cooling System COOLANT TEMPERATURE SENDER • Replace copper washer. • Test sender. (See Checks, Tests and Adjustments in this section.) • Apply Pipe Sealant with TEFLON, or equivalent to threads of sender. Cover Cover Gasket Thermostat Coolant Temperature Sender Copper Washer Water Pump Cap Screw (4) M6 x 14 20 N•m (180 lb-in.) Gasket M82084A 4 THERMOSTAT • Replace gaskets. M82085A • Test thermostat. (See Checks, Tests and Adjustments in this section.) 4-56 4/7/95 Cooling System WATER PUMP 5. Remove four socket head cap screws, spacer and pulley. Removal/Installation 6. Remove five mounting cap screws, pump and gasket. 1. Open engine drain valve to drain coolant. 2. Remove fan/alternator drive belt. 7. Inspect all parts for wear or damage. (See Disassembly/Assembly procedures.) 3. Remove alternator slide bracket-to-water pump cap screw. Installation is done in the reverse order of removal. 4. Remove four cap screws and fan. • Replace gasket and o-ring. • Adjust fan/alternator drive belt tension. (See Checks, Tests and Adjustments in this section.) Alternator Slide Bracket Gasket Cap Screw M8 x 20 Mounting Cap Screw (5) M8 x 65 26 N•m (226 lb-in.) O-Ring 4 Fan Pulley Water Pump Spacer Socket-Head Cap Screw (4) M8 x 50 11 N•m (96 lb-in.) Cap Screw (4) M10 x 20 Apply thread lock and sealer (medium strength) to threads. 65 N•m (47 lb-ft) M82086A 4/7/95 4-57 Cooling System Disassembly 3. Remove two screws, adapter and gasket. 1. Remove thermostat. (See procedure in this group.) 4. Remove two M8 cap screws and nuts. 2. Remove coolant temperature procedure in this group.) sender. (See 5. Apply heat to six plate-to-housing screws. Remove screws, plate and gasket. Heater Hose Fitting Apply Pipe Sealant with TEFLON to threads. Adapter-to-Plate Screw (2) 10 N•m (91 lb-in.) Plate Plate-to-Housing Screw (6) 15 N•m (134 lb-in.) Adapter Fitting Apply Pipe Sealant with TEFLON to threads. 23 N•m (199 lb-in.) Gasket Nut (2) Cap 4 Copper Washer Adapter Plug 15 N•m (130 lb-in.) Gasket Cap Screw (2) M8 x 60 15 N•m (134 lb-in.) Pulley Flange Impeller Seal Cup Ceramic Seal Shaft Seal Water Pump Housing Bearing Shaft M82087A 4-58 4/7/95 Cooling System 6. Apply extreme heat to pulley flange. Remove flange using a knife-edge puller set and two small nuts. Two Small Nuts Pulley Flange Knife-Edge Puller Set IMPORTANT: Support pump housing on bearing shaft only. DO NOT support on housing or damage to housing will occur. 3. Place water pump housing on a press table. Support housing on bearing shaft using a driver disk. Install pulley flange onto shaft with straight hub facing away from housing. Press pulley flange onto bearing shaft until bottom of flange is 11 mm (0.433 in.) from top of housing. IMPORTANT: DO NOT touch lapped sealing surface of ceramic seal with bare hands. It must be clean and dry. Water Pump Housing M35645 7. Place water pump assembly on a press table. Install supports under water pump housing, staying clear of impeller. Press bearing shaft assembly through water pump housing using a piece of pipe or a deep socket. IMPORTANT: Impeller bore is tapered. When pressing bearing shaft from impeller, allow enough clearance between cap screw and impeller bore to prevent cap screw from binding. 4. Install seal cup and ceramic seal in impeller. 5. Install a knife-edge puller around bearing shaft, between pulley flange and pump housing. Place pump housing, with knife-edge puller down, on a press table. Install impeller with ceramic seal toward shaft seal. Press impeller on bearing shaft until shaft end is flush with impeller ID surface OR clearance between impeller and pump housing is 0.30 - 1.10 mm (0.012 - 0.043 in.). Clearance Specification Bearing Shaft End 8. Remove impeller from bearing shaft using a knife-edge puller, a 3/8 in. cap screw and a press. 9. Remove shaft seal, ceramic seal and seal cup. 10.Inspect all parts for wear or damage. Replace as necessary. Impeller ID Assembly M51567 NOTE: Replace shaft seal, ceramic seal, seal cup, gaskets and copper washer. 6. Install new gasket, plate, six screws, two cap screws and nuts. 1. Install bearing shaft into pump housing, long end down, using a piece of pipe or deep socket and a press. Press shaft into pump housing until bearing surface is flush with pump housing surface. 7. Install new gasket, adapter and screws. 2. Install new shaft seal over impeller side of bearing shaft, rubber seal side away from pump housing. Push shaft seal into pump housing, until it stops, using a 25 mm or 1 in. socket and a press. 4/7/95 8. Install coolant temperature procedure in this group.) sender. (See 9. Install thermostat. (See procedure in this group.) 4-59 4 Fuel System SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the European Microfiche Tool Catalog (MTC). JDF13 Nozzle Cleaning Kit Use to clean fuel injection nozzles. SERVICE PARTS KITS The following kits are available through your parts catalog: • Cylinder Block Gasket Kit • Fuel Injection Nozzle Shim Pack 4 4-60 4/7/95 Fuel System FUEL SUPPLY PUMP NOTE: Oil will leak out of fuel injection pump housing when shaft or pump body is removed. • Inspect all parts for wear or damage. Replace as necessary. Fill Plug Replace all o-rings and copper washers. Damaged or used parts will leak. • Replace seal if necessary. Remove seal using a blind-hole puller set. Install seal, lips toward holder, flush with pump body. Fuel Supply Pump • Install holder into pump body with small hole in holder toward bottom of pump body. IMPORTANT: If oil has been drained out of fuel injection pump housing, add oil as necessary. Fuel injection pump can become damaged if operated dry or without proper amount of oil. After fuel supply pump is installed, disconnect external lube line to fuel injection pump housing. Remove fill plug and add clean engine oil to housing. Add until oil begins to drip out of lube line hole (For proper oil specification see SPECIFICATIONS AND GENERAL INFORMATION section.) 4/7/95 External Lube Line Tighten mounting bolt to 15 N•m (130 lb-in.) M82089 4 4-61 Fuel System Supply Pump-toFilter Hose Hose Clamp Cover Fitting Copper Washer Hand Primer Assembly Fitting Copper Washer O-Ring Gasket Retaining Wire Spring (2) Roller Valve (2) Shaft Lock Washer (3) 4 Washer (2) Seal Mounting Nut (3) 11 N•m (96 lb-in.) Shaft Holder Slide Pivot (2) Pump Body Plunger Spring Plug 4-62 Copper Washer M82088A 4/7/95 Fuel System FUEL FILTER ASSEMBLY IMPORTANT: Replace all copper washers. Damaged or used washers may leak. End Cap Nozzle Leak-Off Hose (Short) (3) Nozzle Leak-Off Hose (Long) Bleed Valve Rubber Washer * Bleed Valve Mounting Cap Screw (2) * * * ** To Fuel Tank Mounting Bracket 4 Fuel Filter Fuel Supply Pump-to-Filter Hose Fuel Filter-to-Injection Pump Hose Injection Pump Bleed-Off Hose * Air Vent Check Valve 4/7/95 *Copper Washers Replace * From Fuel Tank M82090A 4-63 Fuel System FUEL INJECTION PUMP Removal IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can damage the pump. CAUTION 1. Clean the injection pump lines and area around the pump using a parts cleaning solvent or steam cleaner. Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. 4 2. Loosen fuel injection line connectors slightly to release pressure in the fuel system. When loosening connectors, use another wrench to keep delivery valves from loosening. 3. Loosen line clamp and remove fuel injection lines. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. 5. Remove external lube line. 6. Scribe an alignment mark across injection pump and gear case housing. Injection Pump Bleed-Off-to-Filter Hose Line Clamp Fuel Injection Line Connectors (4) 4. Disconnect hoses to/from fuel filter. Fuel Injection Lines Fuel Supply Pump-to-Filter Hose Fuel Filter-to-Injection Pump Hose Oil Filler Neck Assembly and Gasket Delivery Valve (4) Mounting Cap Screws Cap Screw (2) Alignment Mark Mounting Cap Screw 4-64 External Lube Line Mounting Cap Screw (3) M82091 4/7/95 Fuel System 7. Remove two cap screws, oil filler neck assembly and gasket. 8. Use chalk or paint to mark injection pump gear to notch on gear case housing. Injection Pump Gear Gear Case Housing O-Ring Alignment Mark Injection Pump Gear Case Housing Notch Injection Pump M51585 Notch Injection Pump Gear M51583 9. Remove six mounting cap screws, injection pump and o-ring. DO NOT attempt to service the injection pump or governor. If unit is in need of repair, it must be serviced by a qualified fuel injection repair shop. If replacement is necessary, replace entire unit. Installation 1. Install new o-ring on injection pump. 2. Put injection pump onto gear case housing. Align mark, made on injection pump gear during removal, with notch on housing. 5. Install new gasket, oil filler neck assembly and two cap screws. 6. Connect hoses to/from fuel filter. 7. Install fuel injection lines and tighten line clamp cap screws. IMPORTANT: If oil has been drained out of fuel injection pump housing, add oil as necessary. Fuel injection pump can become damaged if operated dry or without proper amount of oil. 8. Remove fill plug and add clean engine oil to housing. Add until oil begins to drip out of external lube line inlet. (For proper oil specification see SPECIFICATIONS AND GENERAL INFORMATION section.) 3. Install six mounting cap screws. Do not tighten. 9. Install external lube line. When installing line, put one copper washer between mounting bolt head and lube line and the other between lube line and housing. 4. Align marks on housing and injection pump, made during removal, and tighten mounting cap screws. If new injection pump is being installed, check and adjust injection pump static timing. (See Checks, Tests and Adjustments in this section.) 4/7/95 4-65 4 Fuel System Injection Pump Bleed-Off-to-Filter Hose Line Clamp Fuel Supply Pump-to-Filter Hose Fuel Injection Lines Fuel Filter-to-Injection Pump Hose Oil Filler Neck Assembly and Gasket Oil Fill Plug Mounting Cap Screws M8 x 90 27 N•m (20 lb-ft) Lube Line-to-Block Bolt 25 N•m (217 lb-in.) Cap Screw (2) M8 x 25 4 External Lube Line Inlet Tighten Mounting Bolt to 15 N•m (130 lb-in.) Alignment Mark Mounting Cap Screw M8 x 16 27 N•m (20 lb-ft) External Lube Line Mounting Cap Screw (3) M8 x 25 27 N•m (20 lb-ft) M82091 FUEL INJECTION NOZZLES (HOLE-TYPE) Removal/Installation IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can damage the pump. 1. Clean the injection pump lines and area around the pump using a parts cleaning solvent or steam cleaner. 4-66 CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. 4/7/95 Fuel System NOTE: Nozzles are matched to the cylinders. If removing more than one nozzle, tag nozzles, according to the cylinder from which it was removed. Large Flat Washer Nuts Cap Screw 2. Loosen fuel injection line connectors-to-nozzles slightly to release pressure in the fuel system. Old Injection Line Nut 3. Loosen line clamp and remove fuel injection lines. Injection Nozzle 4. Remove clamps and leak-off hoses. M82126 5. Remove nuts and retaining plates. 6. Remove injection nozzle, ring and teflon heat protector. If ring and protector stay in cylinder head, thread a cap screw into protector and pull from cylinder head. Disassembly/Assembly NOTE: If servicing more than one nozzle, keep parts for each nozzle separate from one another. Retaining Plate Hose Clamp Nut (2) 5 N•m (39 lb-in.) 7. Test injection nozzles. (See Checks, Tests and Adjustments in this section.) Leak-Off Hose • Clean and inspect nozzle assembly. (See Cleaning/Inspection procedures.) 4 • After assembly is complete, test injection nozzle. (See Checks, Tests and Adjustments in this section.) Injection Nozzle Ring Heat Protector Replace. Injector Body M82092A Shims (as required) If nozzles are stuck in cylinder head: Spring • Grind the head of a cap screw so it fits inside a nut from an old injection line. • Use two nuts to attach a large flat washer to the cap screw. • Install assembly onto nozzle and use a puller and slide hammer to pull nozzle from cylinder head. Spring Seat Separator Plate Index Pin (2) Nozzle Valve Nozzle Body Retaining Nut 43 N•m (31 lb-ft) M82093A 4/7/95 4-67 Fuel System Cross Section 1. Remove anti-corrosive grease from new or reconditioned nozzles by washing them thoroughly in diesel fuel. IMPORTANT: Never use a steel brush to clean nozzles as this will distort the spray hole. Injector Body Fuel Return Pipe 2. Remove carbon from used nozzles, and clean by washing in diesel fuel. If parts are coated with hardened carbon or lacquer, it may be necessary to use a brass wire brush (supplied in Nozzle Cleaning Kit). 3. After removing carbon or lacquer from the exterior of nozzle, inspect sealing surfaces between separator plate and nozzle body for nicks or scratches. 4. Inspect condition of separator plate and nozzle body. Contact area of separator plate (both parts) must not be scored or pitted. Use an inspection magnifier (No. 16487 or equivalent) to aid in making the inspection. Shim (as required) Spring 5. Check nozzle contact surface on separator plate for wear. If contact surface is more than 0.10 mm (0.0039 in.), replace nozzle assembly. 4 Spring Seat Index Pin (2) Nozzle Contact Surface Separator Plate Sealing Surfaces Index Pin Separator Plate Retaining Nut Nozzle Body Nozzle Valve Nozzle Body M37684 M82094A Cleaning/Inspection NOTE: To clean nozzles properly, JDF13 Nozzle Cleaning Kit is recommended. The Cleaning Kit is available through the John Deere SERVICEGARD™ Catalog. 4-68 6. Inspect the piston (large) part of nozzle valve to see that it is not scratched or scored and that lower (tip) end of valve is not broken. If any of these conditions are present, replace the nozzle assembly. 4/7/95 Fuel System 7. Further inspect the nozzle assembly by performing a slide test. Use the following procedure: • Dip the nozzle valve in clean diesel fuel. Insert valve in nozzle body. • Hold nozzle vertical, and pull valve out about 1/3 of its engaged length. • Release valve. Valve should slide down to its seat by its own weight. Replace nozzle assembly if the valve does not slide freely to its seat. Nozzle Valve Piston Part of Nozzle Valve Nozzle Body 4 M82095A 4/7/95 4-69 Starter (Nippondenso 1.4 kW) STARTER MOTOR 8. Inspect and test brushes, holder, field coil and armature. (See Inspection/Test procedures.) Disassembly 1. Remove two cap screws and two screws. 2. Remove rear cover and thrust washer, if equipped. Seal Ring If equipped Field Coil Housing Thrust Washer Cap Screw (2) Screw (2) 4 Wiring Lead Rear Cover Armature M82098 M82096 3. Remove field coil brushes from brush holder. Assembly 4. Pry brush springs away and pull negative brushes up enough to allow spring to hold brush in place. Assembly is done in the reverse order of disassembly. • Apply multipurpose grease to bearing cup inside rear cover. 5. Remove brush holder. IMPORTANT: When installing rear cover, be sure field coil brush wires do not touch cover. Turn brush holder slightly to take up slack in brush wires. Press wires inward to clear rear cover. Field Coil Brush (2) Inspection/Test/Replacement Brush Spring (2) 1. Measure holder and field coil brush lengths. Minimum brush length is 8.5 mm (0.335 in.). Replace brush holder or field coil if brush length is below minimum. Brush Holder 2. Test brush holder: Negative Brush (2) M82097 6. Disconnect wiring lead and relay leads, if equipped. 7. Remove field coil housing, armature and o-ring, if equipped. 4-70 NOTE: Test brush holder using an ohmmeter or test light. Touch one probe of tester to negative brush holder and other probe to field brush holder. If there is continuity, replace the brush holder. 3. Inspect springs for wear or damage. Replace if necessary. 4/7/95 Starter (Nippondenso 1.4 kW) IMPORTANT: Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush. Spring (4) Negative Brush Holder 7. Inspect armature. Look for signs of dragging against pole shoes. 8. Inspect commutator. Look for roughness, burned bars, or any material which might cause short circuits between bars. If necessary, clean and touch up with 400 sandpaper. NEVER use emery cloth. Clean all dust from armature when finished. Field Brush Holder NOTE: Test armature windings using an ohmmeter or test light. Brush Length 9. Test for grounded windings: M82099 NOTE: Test field coil using an ohmmeter or test light. 4. Inspect springs for wear or damage. Replace if necessary. 5. Test for grounded field winding: Touch one probe of tester to field coil brush and other probe to field coil housing. Be sure the brush lead is not touching the frame. If there is continuity, the coil is grounded and the field coil housing assembly must be replaced. Touch probes on one commutator bar and armature shaft. Armature windings are connected in series, so only one commutator bar needs to be checked. If test shows continuity, a winding is grounded and the armature must be replaced. 10.Test for open circuited windings: Touch probes on two different commutator bars. If test shows no continuity, there is an open circuit and the armature must be replaced. Commutator Bars 6. Test for open field coil: Touch one probe of tester to each field coil brush. If there is no continuity, the field coil is open and the field coil housing assembly must be replaced. Field Coil Brush Armature Shaft M82101 Field Coil Housing M82100 4/7/95 4-71 4 Starter (Nippondenso 1.4 kW) 11.Test for short circuited windings using a growler. Put armature in a growler and hold a hacksaw blade above each slot while slowly rotating armature. Rear Cover Bearing Housing Bearing If coil is shorted, the blade will vibrate on the slot. NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments. 12.If test indicates short circuited windings, clean the commutator of dust and filings. Check the armature again. If the test still indicates a short circuit, replace the armature. M82102 STARTER GEAR TRAIN AND SOLENOID Hacksaw Blade Disassembly/Inspection Armature 1. Remove two socket head screws, end cap and shim(s). 4 Growler M82125A End Cap 13.Inspect armature cover and housing bearings for wear or damage. Replace if necessary. Shim(s) To replace bearings: Bearings are press fit. Remove bearings using a knife-edge puller set. IMPORTANT: Install both bearings with sealed side toward armature. Install new housing bearing tight against shoulder of shaft using a piece of pipe. Install new rear cover bearing tight against shoulder of shaft using a driver set. M37820 2. Disconnect wiring lead and relay leads, if equipped. 3. Remove two cap screws. 4. Remove starter motor assembly from bearing housing. 4-72 4/7/95 Starter (Nippondenso 1.4 kW) 8. Remove two cap screws, plunger, spring, shims and solenoid. Wiring Lead End Frame Shim(s) Solenoid Cap Screw (2) Starter Motor Assembly Cap Screw (2) M82096 Plunger Spring 5. Remove three cap screws. M37824 6. Separate end frame assembly from bearing housing. 9. Remove shims from ring gear shaft. Cap Screw (3) End Frame Assembly 4 Shims Ring Gear Shaft Bearing Housing M37821 M37822 7. Inspect seal and needle bearing for wear or damage. Replace as necessary. 10.Remove pivot bolt, clutch fork and clutch assembly. 11.Inspect shoes on fork for wear or damage. Replace fork if necessary. To replace needle bearing: Remove bearing using a blind-hole puller set. Install new bearing flush with housing surface using a driver set. Shoes End Frame Clutch Assembly Bearing Housing Pivot Bolt Seal Clutch Fork M37825 Needle Bearing M37823 4/7/95 12.Inspect end frame bushing for wear or damage. Replace if necessary. 4-73 Starter (Nippondenso 1.4 kW) Replace bushing using a driver set. Install bushing flush with face of housing. 16.Inspect all parts for wear or damage. Replace as necessary. Clutch Snap Ring Spring Spring Cap End Frame Bushing Washer M37830 13.Slide pinion stopper away from retaining wire using a piece of pipe or deep socket. Remove retaining wire, pinion stopper, and clutch assembly from ring gear shaft. 14.Inspect all parts for wear or damage. Replace as necessary. 4 Clutch Assembly Pinion Stopper Assembly Assembly is done in the reverse order of disassembly. • After installing clutch assembly, pinion stopper and retaining wire on ring gear shaft, use two pliers to press pinion stopper over retaining wire. Retaining Wire Retaining Wire Ring Gear Shaft M37827 15.Remove snap ring, washer, spring cap, and spring from clutch. 4-74 M37829 Pinion Stopper Clutch Assembly M37831 4/7/95 Alternator (Hitachi 25A) VOLTAGE REGULATOR Attaching Screw (4) M5 4 N•m (31 lb-in.) Two Nuts and Insulator Stator End Frame-to-Rectifier Nuts (4) M5 4 N•m (31 lb-in.) Grommet Wire Clamp Front Frame End Frame M82108 Replacement 7. Use a soldering gun with at least 120 watt capacity to disconnect five terminals. Replace voltage regulator. 1. Remove three screws and cover. 2. Remove four attaching screws, wire clamp and grommet. • If additional solder is needed, use ONLY 60-40 rosin-core solder. 3. Remove four end frame-to-rectifier nuts. ALTERNATOR 4. Remove two nuts and insulator. IMPORTANT: Do not pry against stator wires. 5. Use a screwdriver to pry end frame from stator. Do not separate stator from front frame. Brush Holder 1. Remove three screws and cover. 2. Remove four attaching screws, wire clamp and grommet. 6. Remove two screws and insulator. Insulator Disassembly Terminals Voltage Regulator Attaching Screws (4) M5 4 N•m (31 lb-in.) Screw (2) M51602 Grommet IMPORTANT: Do not heat connections longer than necessary to melt solder, as excess heat will damage rectifier assembly. Wire Clamp M82108 4/7/95 4-75 4 Alternator (Hitachi 25A) IMPORTANT: Do not pry against stator wires. 3. Use a screwdriver to separate rotor assembly from stator assembly. Stator Assembly Rotor Assembly: • Rear bearing is press fit. Replace only if necessary. Remove bearing using a puller set. Install bearing until flush with end of rotor shaft. Press only on inner race of bearing. 4. Put rotor assembly in a soft-jawed vise. Remove nut, lock washer, sheave, fan and bushing. 5. Put front frame on open jaws of vice. Use a softfaced hammer to remove rotor and spacer. 6. Remove three screws, retainer and front bearing. 7. Inspect all parts for wear or damage. Replace as necessary. 8. Test rotor. (See Inspection/Test procedures.) Rotor Assembly 4 M36730 Rear Bearing Apply multipurpose grease to O.D. during assembly. Screw (3) 2 N•m (16 lb-in.) Bushing Clip Rotor Spacer Retainer Nut M14 49 N•m (36 lb-ft) Front Bearing Front Frame Fan Sheave Lock Washer M82109A 4-76 4/7/95 Alternator (Hitachi 25A) Stator Assembly: IMPORTANT: Be sure stator lead wires do not contact end frame when installed. 9. Remove four end frame-to-rectifier nuts. 10.Remove two nuts and insulator. IMPORTANT: Do not pry against stator wires. 11.Use a screwdriver to pry end frame from stator Two Nuts and Insulator End Frame End Frame-to-Rectifier Nuts M5 4 N•m (31 lb-in.) • Before assembling stator assembly to rotor assembly, push brushes into brush holder and insert a wire through access hole to lock brushes in place. • Assemble rotor assembly to stator assembly and fasten with four attaching screws. Remove wire from access hole. Access Hole M51595 12.Use a soldering gun with at least 120 watt capacity to disconnect three stator leads. Remove rectifier. End Frame M51595 4 Inspection/Test Rectifier Rotor: • Inspect the rotor slip rings for dirt build-up, rough spots, or out of roundness. If necessary, polish the surface of the slip rings using No. 00 sandpaper or 400-grit silicon carbide paper. Stator Leads (3) • Touch the probes of an ohmmeter to slip rings. Replace rotor if test indicates no continuity (no needle movement). Stator M51605 Ohmmeter 13.Inspect and test brushes, stator and rectifier. (See Inspection/Test procedures.) Assembly Assembly is done in the reverse order of disassembly. • Bend the stator lead wires, as necessary, to obtain an approximate distance of 33.50 mm (1.300 in.) from stator to rectifier. Connect the three leads using a soldering gun. • If additional solder is needed, use ONLY 60-40 rosin-core solder. 4/7/95 Rotor Shaft Slip Rings M82110A • Touch the probes of the ohmmeter to the shaft and one of the slip rings. Repeat for other slip ring. Replace rotor if test shows continuity (needle movement). 4-77 Alternator (Hitachi 25A) Ohmmeter • Use an ohmmeter or a test light to check for continuity. Check between the two brushes and between each brush and ground stud. There should be no continuity. Replace brush holderrectifier assembly if there is continuity. • To replace brushes, melt solder from connection. Remove voltage regulator if necessary. (See VOLTAGE REGULATOR REPLACEMENT in this group.) Rotor Shaft Slip Rings M82111A Stator: Brushes: • Inspect brush holder and brushes for damage. Brushes must slide freely and the springs must hold the brushes firmly against the slip rings of the rotor. 4 NOTE: If additional solder is needed, use ONLY 6040 rosin-core solder. • Measure brushes for wear. Minimum exposed length must be 5.50 mm (0.220 in.) or to wear limit line on brushes. Replace brushes as necessary. • Inspect stator for defective insulation, discoloration or a burned odor. If any of these defects are found, replace stator. NOTE: Use an ohmmeter that is sensitive to resistance of 0 to 1 ohm. • Touch probes of an ohmmeter to lead wires of stator in three possible combinations. Continuity should read approximately 0.26 ohms. If readings are not equal, replace stator. Brush Length Ohmmeter Rectifier Voltage Regulator Stator Brushes M82113A • Touch one probe of the ohmmeter to the bare metal surface of stator and the other probe to a bare stator lead wire. Repeat for each wire. Replace stator if test indicates continuity. Ground Stud Brush Holder Soldered Connection M82112 4-78 4/7/95 Alternator (Hitachi 25A) Ohmmeter A shorted diode would have continuity in both directions. An open diode would have no continuity in either direction. Replace the rectifier assembly if any of the six diodes are defective. • To replace rectifier, melt solder from connection. NOTE: If additional solder is needed, use ONLY 6040 rosin-core solder. Stator M82114A Rectifier: Soldered Connection • Test the diodes by touching probes to ground post and the three outer terminals. • Switch the probes and check each terminal again. There should be continuity in only one combination of each terminals and the ground post. • Test the diodes by touching probes to output post and the three outer terminals. • Switch the probes and check each terminal again. There should be continuity in only one combination of each terminal and the output post. 4/7/95 Outer Terminals Outer Terminal Output Post Ground Post M82115 4-79 4 Diagnosis ● ● ● ● ● Fuel shut-off valve turned off, or restricted. Solenoid linkage misadjusted. See adjustment. ● ● ● ● ● 4 ● ● Muffler or exhaust manifold leak. Defective manifold heater. ● Injection pump or governor malfunctioning. Injection pump timing incorrect. ● Defective cranking components or connectors. ● Low compression from worn rings, cylinder bore, piston, valves or warped head. Valve clearance incorrect. ● Burned or warped valves and valve seats. Defective valve spring. Starter cranking rpm too slow. Damaged starter. Excessive engine load. ● Fuel pump leaking or not operating. See Fuel Supply Pump Pressure Test. Engine oil viscosity or level incorrect. ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Radiator/oil cooler leak. ● Turbocharger ● 4-80 ● ● ● Injector pressure incorrect or leaking. Cylinder head gaskets leaking or damaged. ● Exhaust smoke black or grey or uses too much fuel. Air filter elements dirty or plugged. Replace. ● Exhaust smoke white. ● Exhaust smoke blue or uses too much oil. ● Engine operating temperature is incorrect. Engine surges, or has uneven or uncontrolled rpm. ● Engine has low oil pressure. Engine runs rough, misses, noisy, vibrates or low on power. Fuel in oil. Oil level high. ● Oil in the coolant or coolant in the oil. Engine will not stay running, or stalls frequently. Fuel pump screen, fuel filter, or fuel line restricted. Fuel dirty, contains water or wrong grade. CHECK OR SOLUTION Engine will not crank. Engine cranks but will not start or starts hard. PROBLEM OR SYMPTOM Lack of fuel at injection pump. ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART ● ● ● ● ● ● ● ● ● ● ● ● ● ● 4/7/95 Diagnosis ENGINE SYSTEM DIAGNOSIS Conditions: • Engine mounted on level surface. • Key switch off unless indicated otherwise. Test Location Normal If Not Normal 1. Engine dipstick and exterior engine surfaceengine oil check. Oil level between “L” and “H” marks. Oil not burnt, or contaminated with metal particles, fuel, or coolant. No external leakage, filter clean. Change oil and inspect for source of contamination. Check gaskets, seals, plugs, cylinder head, block, and intake manifold and breather. Change oil filter. 2. Coolant tank and radiator. Coolant level between marks on tank when engine is warm. Coolant in radiator full to top. Coolant not contaminated with oil, fuel or discolored brown. Add proper coolant mix. Radiator screen free of debris. Clean or replace. Hoses not cracked or leaking, clamps and radiator cap tight. Pressure test radiator and cap. Fan belt tight, not glazed or cracked. Replace and adjust belt tension. Fan blades not damaged or warped. Replace fan. Fuel level correct, not contaminated, correct grade of fuel, no water. Fuel pump screen and in-line filter free of debris. Fuel shutoff valve in “ON” position. Drain and clean fuel tank. Add fresh fuel. Replace filters. Fuel hoses not cracked or leaking. Replace. Fuel hose clamps tight. Replace or tighten. Fuel tank does not have vacuum. Replace fuel tank check valve. Air filter hose not cracked, clamps tight. Element not plugged. Air filter housing sealed, no dirt tracking inside filter element. Replace and tighten clamps. - Cooling System Check. 3. Fuel tank, pump, pump screen, lines, filter, filter shutoff valve. - Fuel System Check 4. Air filter and air intake. - Air Intake System Check Drain and flush system. Check for source of contamination. 4 Move to “ON” position. Replace element or housing. 5. Fuel shutoff solenoid. (Key in RUN position.) Fuel shutoff solenoid must pull in and stay in. Solenoid must bottom out. Shutoff shaft must still move slightly. Check shutoff solenoid adjustment. Clean any dirt from under solenoid boot. If solenoid will not pull in and hold in, see Fuel Shutoff Solenoid Circuit Test Points in ELECTRICAL section of Machine TM. 6. Air heater indicator light. (Key in RUN position.) Indicator light should come on up to 15 seconds depending on air temperature. See Air Heater Circuit Test Points in ELECTRICAL section of Machine TM. 4/7/95 4-81 Diagnosis ENGINE SYSTEM DIAGNOSIS - Continued 4 Test Location Normal If Not Normal 7. Fuel filter, fuel pump. (Key switch in RUN position.) Fuel level increases in filter. Fuel pump operating - listen for humming sound. Fuel present in return hose at fuel pump. See Fuel Pump Circuit Test Points in ELECTRICAL section of Machine TM. Test fuel pump pressure. (See Operational Tests in this section.) Replace fuel filter. 8. Throttle lever and cable. Linkage not binding and adjusted correctly. Repair, replace or adjust cable. 9. Intake and exhaust valves. Cold engine valve clearance of 0.30 mm (0.012 in.). Valves not sticking. Check and adjust. (See Checks, Tests and Adjustments in this section.) Check valve guides and stems. 10. Fuel at injectors. (Key in START position - engine cranking.) Crack fuel injection lines at injectors. Fuel shutoff solenoid pulled in. Check spray pattern and cracking pressure. (See Checks, Tests and Adjustments in this section.) Replace injectors.See Cranking Circuit Test Points in ELECTRICAL section of Machine TM. 11. Injector ports. (Key in START position.) Minimum compression of 2942 kPa (427 psi) with a 588 kPa (85 psi) maximum difference between cylinders. Perform cylinder compression test. (See Operational Tests in this section.) 12. Flywheel and starter. Minimum cranking rpm - 300 rpm. See Starter Amp Draw Test in ELECTRICAL section of Machine TM. 13. Injection pump timing inspection. (Key OFF.) Timing should be correct. Remove pump as the LAST possible solution. 14. Injection pump idle settings. (Engine running). 15. Oil pressure sender port. Slow idle at 900 + 50 rpm. Fast idle at 2375 + 50 rpm. Perform injection pump static timing adjustment. (See Checks, Tests and Adjustments in this section.) Have pump tested by a qualified Service Repair Shop. See Slow Idle and Fast Idle Adjustments in ENGINE section of Machine TM. Minimum oil pressure at 900 rpm is 98 kPa (14 psi). Test engine oil pressure. (See Operational Tests in this section.) 16. Thermostat. (Engine at operating temperature.) Clean from corrosion, rust, or debris. Opening temperature 71°C (160°F) or 85°C (184°F). Replace thermostat. 17. Muffler. Not restricted. Replace muffler. 4-82 Engine must crank. 4/7/95 Checks, Tests and Adjustments VALVE CLEARANCE CHECK AND ADJUSTMENT Cylinders To achieve correct engine operation. Equipment: • Feeler Gauge 1 2 I E 3 I E 4 I E I E Fan End Flywheel End Reason: No. 1 Piston at TDC Procedure: T6479AB 1. Remove rocker arm cover. 2. Remove plug from timing hole on flywheel housing. To adjust valves, loosen nut and turn adjusting screw until clearance is 0.30 mm (0.012 in.). Hold screw while tightening nut. NOTE: “Top Dead Center (TDC)” is the piston at its highest point. 3. Turn crankshaft pulley clockwise until No.1 cylinder TDC mark on flywheel aligns with index mark on flywheel housing. Feeler Gauge 4 TDC Mark on Flywheel T6105BF Index Mark on Flywheel Housing 6. Turn crankshaft pulley one revolution (360°). This puts the piston in No. 4 cylinder at TDC compression stroke. T6469AJ NOTE: No. 1 cylinder is the closest to the flywheel. 7. Measure and adjust valve clearance on the valves (arrows) with No. 4 piston at TDC. 4. Try to move both No. 1 cylinder rocker arms or push rods. E 2 I E 3 I E 4 I E I Fan End 5. Measure and adjust valve clearance on the valves (arrows) with No. 1 piston at TDC. Cylinders 1 Flywheel End If rocker arm push rods are not loose, rotate flywheel one revolution (360°). If both rocker arm push rods are loose the piston is at TDC on compression stroke. No. 4 Piston at TDC T6479AB 4/7/95 4-83 Checks, Tests and Adjustments CONNECTING ROD SIDE PLAY CHECK Equipment: Reason: Procedure: To determine proper side clearance between crankshaft and connecting rod. Equipment: • Feeler Gauge • PLASTIGAGE® IMPORTANT: Connecting rod caps must be installed on the same connecting rod and in the same direction to prevent crankshaft and connecting rod damage. 1. Remove connecting rod cap. 2. Wipe oil from bearing insert and crankshaft journal. Procedure: 1. Insert a feeler gauge, according to specifications, between connecting rod cap and crankshaft. 3. Put a piece of PLASTIGAGE, or an equivalent, along the full length of the bearing insert approximately 6 mm (0.250 in.) off center. 4 PLASTIGAGE M35351 Feeler Gauge 4. Turn crankshaft approximately 30° from bottom dead center. M82116A Specifications: Standard Clearance . . . . . . . . 0.20 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . (0.0079 - 0.0157 in.) Wear Limit. . . . . . . . . . . 0.45 mm (0.0177 in.) Results: • If side play exceeds wear limit, replace connecting rod and connecting rod cap. CONNECTING ROD BEARING CLEARANCE CHECK 5. Install connecting rod end cap and original cap screws. Tighten cap screws to 118 N•m (87 lbft). 6. Remove cap screws and connecting rod cap. NOTE: The flattened PLASTIGAGE will be found on either the bearing insert or crankshaft journal. 7. Use the graduation marks on the envelope to compare the width of the flattened PLASTIGAGE at its widest point. 8. Determine bearing clearance. The number within the graduation marks indicates the bearing clearance in inches or millimeters depending on which side of the envelope is used. Reason: To measure oil clearance between connecting rod bearing and crankshaft journal. 4-84 4/7/95 Checks, Tests and Adjustments 9. Remove PLASTIGAGE. 3. Zero the dial indicator. 4. Using a bar, gently pry the crankshaft as far forward as possible. Graduation Marks on Envelope Flattened PLASTIGAGE M82117A Specifications: Standard Clearance . . . . . . 0.036 - 0.090 mm . . . . . . . . . . . . . . . . . . . . . (0.0014 - 0.0035 in.) Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) Results: • If clearance exceeds wear limit, replace bearing inserts. ®PLASTIGAGE is a registered trademark of the DANA Corporation. Dial Indicator Crankshaft M82118A Specifications: Standard Clearance . . . . . . 0.132 - 0.223 mm . . . . . . . . . . . . . . . . . . . . . (0.0052 - 0.0088 in.) Wear Limit. . . . . . . . . . . 0.29 mm (0.0114 in.) Results: CRANKSHAFT END PLAY CHECK • If end play exceeds wear limit, replace thrust bearings. Reason: To determine proper side clearance between crankshaft and engine block. CRANKSHAFT MAIN BEARING CLEARANCE CHECK Equipment: Reason: • Dial Indicator To measure oil clearance between main bearing and crankshaft journal. Procedure: NOTE: Crankshaft end play can be measured at front end or rear end of crankshaft. Procedure is performed from the rear end. The flywheel is removed to show detail. 1. Fasten dial indicator to engine and position indicator tip on end of crankshaft. IMPORTANT: Do not use excessive force when moving crankshaft to avoid damaging bearings. 2. Push crankshaft toward rear as far as possible. 4/7/95 Equipment: • PLASTIGAGE® Procedure: IMPORTANT: Main bearing caps must be installed on the same main bearing and in the same direction to prevent crankshaft and main bearing damage. 1. Remove main bearing cap. 2. Wipe oil from bearing insert and crankshaft journal. 4-85 4 Checks, Tests and Adjustments 3. Put a piece of PLASTIGAGE, or an equivalent, along the full length of the bearing insert approximately 6 mm (0.250 in.) off center. Results: • If clearance exceeds wear limit, replace bearing inserts. ®PLASTIGAGE is a registered trademark of the DANA Corporation. VALVE LIFT CHECK PLASTIGAGE Reason: Can indicate excessive wear on cam lobes, followers, and/or push rods. M35382 Equipment: • Dial Indicator 4. Install main bearing cap and cap screws. Tighten cap screws to 196 N•m (145 lb-ft). 5. Remove cap screws and main bearing cap. 4 NOTE: The flattened PLASTIGAGE will be found on either the bearing insert or crankshaft journal. Procedure: 1. Adjust valve clearance. (See procedure in this group.) 2. Remove rocker arm cover. (See Cylinder Head, Valves and Manifolds in this section.) 6. Use the graduation marks on the envelope to compare the width of the flattened PLASTIGAGE at its widest point. 3. Fasten dial indicator to engine and position indicator tip on valve retainer. Valve must be fully closed and rocker arm must move freely. 7. Determine main bearing clearance. The number within the graduation marks indicates the bearing clearance in inches or millimeters depending on which side of the envelope is used. 4. Zero the dial indicator. 5. Manually turn crankshaft pulley clockwise (from fan end). 6. Observe dial indicator as valve is moved to the full open position. Valve lift (intake and exhaust) should be 6.5 mm (0.256 in.). 8. Remove PLASTIGAGE. Repeat for each valve. Graduation Marks on Envelope Flattened PLASTIGAGE M82119AE Specifications: T6333DT Standard Clearance . . . . . . 0.036 - 0.093 mm . . . . . . . . . . . . . . . . . . . . . (0.0014 - 0.0037 in.) Wear Limit. . . . . . . . . . . 0.09 mm (0.0040 in.) 4-86 4/7/95 Checks, Tests and Adjustments Results: • If valve lift is less than specification, remove and inspect camshaft, followers and push rods. (See Camshaft and Timing Gear Train and/or Cylinder Head, Valves and Manifolds in this section.) 4. Zero the dial indicator. 5. Pull camshaft forward as far as possible. CAMSHAFT END PLAY CHECK Reason: To determine proper side clearance between camshaft gear end journal and thrust plate. M37512 Equipment: • Dial Indicator Procedure: 1. Remove timing gear cover. (See Camshaft and Timing Gear Train in this section.) 2. Fasten dial indicator to engine and position indicator tip on end of camshaft. 3. Push camshaft toward the rear as far as possible. 4/7/95 Specifications: Standard Clearance . . . . . . . . 0.05 - 0.20 mm . . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.) Wear Limit. . . . . . . . . . . 0.29 mm (0.0114 in.) 4 Results: • If end play exceeds wear limit, remove camshaft and replace thrust plate. (See Camshaft and Timing Gear Train in this section.) 4-87 Checks, Tests and Adjustments TIMING GEAR BACKLASH CHECK Reason: To check for wear between meshing gears, resulting in excessive noise and poor engine performance. Specifications: Standard Backlash . . . . . . . . . 0.08 - 0.16 mm . . . . . . . . . . . . . . . . . . . . . (0.0031 - 0.0063 in.) Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.) Results: Equipment: • Dial Indicator Procedure: 1. Measure backlash between meshing gears. • If backlash exceeds wear limit, replace meshing gears as a set: Idler Gear, Camshaft Gear, Crankshaft Gear AND/ OR Idler Gear, Fuel Injection Pump Gear, Oil Pump Gear. Camshaft Gear-to-Idler Gear Fuel Injection Pump Gear-to-Idler Gear 4 Idler Gear-to-Crankshaft Gear Idler Gear-to-Oil Pump Gear M82120A 4-88 4/7/95 Checks, Tests and Adjustments FUEL INJECTION NOZZLE TEST (HOLE-TYPE) Equipment: • D01109AA Diesel Fuel Injection Nozzle Tester • D01110AA Adapter Set CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgable source. Such information is available from the Deere & Company Medical Department in Moline, Illinois, U.S.A. • 23622 Straight Adapter • Container Connections: 1. Connect fuel injection nozzle to D01109AA Diesel Fuel Injection Nozzle Tester using parts from D01110AA Adapter Set and 23622 Straight Adapter. IMPORTANT: Use clean filtered diesel fuel when testing injection nozzles to get best test results. Procedure 1: Test fuel injection nozzle opening pressure following the Nozzle Tester manufacturer's instructions. Specifications: Opening Pressure . . . . .19615 kPa (2850 psi) Reason: To determine opening pressure, leakage, chatter and spray pattern of the fuel injection nozzle. 4/7/95 Results: • If pressure reading does not meet specification, disassemble injection nozzle and inspect nozzle assembly for contamination or stuck valve. If necessary, add or remove shims to change opening pressure. 4-89 4 Checks, Tests and Adjustments 23617 90° Adapter 36352 Fuel Line Assembly 23621 Straight Adapter 23622 Straight Adapter D01109AA Diesel Fuel Injection Nozzle Tester Fuel Injection Nozzle Container M35913 Procedure 2: fuel injection nozzle leakage following 4 Test Nozzle Tester manufacturer's instructions. the 1. Dry nozzle completely using a lint-free cloth. 2. Pressurize nozzle to 18100 kPa (2625 psi). 3. Watch for leakage from nozzle spray orifice. Leakage time should be a minimum of 5 seconds. Results: • If leakage time does not meet specification, disassemble injection nozzle and inspect nozzle assembly for contamination. Inspect valve seating surface. Replace nozzle assembly if necessary. Procedure 3: 1. Pressurize nozzle to 20100 ± 490 kPa (2915 ± 71 psi). 2. Listen for “chatter” sound and watch spray pattern. Specifications: Slow Hand Lever Movement . . . . . . . . . . . Chatter Sound Slow Hand Lever Movement . . . . . . . . . . . . . Fine Stream . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern Fast Hand Lever Movement . . . . . . . . . . . Fine Atomized . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern Test fuel injection nozzle chatter and spray pattern following the Nozzle Tester manufacturer's instructions. 4-90 4/7/95 Checks, Tests and Adjustments Procedure: Correct CAUTION Proper Spray Angle DO NOT allow thermostat or thermometer to rest against the side or bottom of glass container when heating water. Either may rupture if overheated. 1. Suspend thermostat and a thermometer in a container of water. Correct Injection Angle 2. Heat and stir the water. Observe opening action of thermometer and compare temperatures with specifications. Poor 3. Remove thermostat and observe its closing action as it cools. 4 Thermometer M82121A Results: • If nozzle chatter or spray pattern does not meet specifications, disassemble injection nozzle and inspect nozzle assembly for contamination. Inspect valve seating surface. Replace nozzle assembly if necessary. • If there is excessive difference in spray angle or injection angle, incomplete atomization or sluggish starting/stopping of injection, disassemble injection nozzle and inspect nozzle assembly for contamination. Replace nozzle assembly if necessary. Thermostat M82122A Specifications: Begin Opening . . . . . . . . . . . . . 71° C (160° F) Fully Open . . . . . . . . . . . . . . . . 85° C (184° F) Minimum Lift Height . . . . . .8 mm (0.310 in.) THERMOSTAT OPENING TEST Results: Reason: To determine opening temperature of thermostat. • If thermostat does not open according to specifications, replace. Equipment: • If closing action is not smooth and slow, replace thermostat. • Thermometer • Glass Container • Heating Unit 4/7/95 4-91 Checks, Tests and Adjustments COOLANT TEMPERATURE SENDER TEST 2. Suspend sender and a thermometer in a container of water. Reason: 3. Heat and stir the water. Observe water temperature when continuity occurs. Water temperature should be 107-113° C (225-235° F). To determine operating temperature of sender. Equipment: • Thermometer Ohmmeter Probes • Glass Container • Heating Unit • Ohmmeter Procedure: CAUTION 4 DO NOT allow sender or thermometer to rest against the side or bottom of glass container when heating water. Either may rupture if overheated. 1. Connect lead wires from ohmmeter probes, to sender terminal and body. 4-92 Coolant Temperature Sender M82123A Results: • If continuity does not occur within temperature listed, replace sender. 4/7/95 Checks, Tests and Adjustments STARTER NO-LOAD AMP DRAW/RPM TEST 5. Attach Current Gun to positive cable. IMPORTANT: Complete this test in 20 seconds or less to prevent starter damage. Reason: To determine if starter is binding or has excessive amperage draw under no load. 6. Use a jumper wire to briefly connect positive (+) starter terminal to solenoid terminal “S”. Starter should engage and run. Equipment: 7. Read and record starter amperage and rpm. • JT05712 Current Gun Specifications: • JT05719 Photo Tachometer Maximum Starter Amperage. . . . . . . . . . . .90 amps at 3500 rpm Minimum Starter RPM . . . . . . . . . . . . . 3500 • Jumper Cables • Jumper Wire Procedure: Results: 1. Mount starter in a vise. NOTE: Check that battery is fully charged and of proper size to ensure accuracy of test. • If solenoid “clicks” or chatters and motor does not turn, replace solenoid. 2. Connect jumper cables to a 12 volt battery. • If pinion gear engages and motor doesn't turn, repair or replace starter motor. 3. Connect positive (+) cable to solenoid battery terminal on starter. • If starter engages and runs but amperage is more than specifications, repair or replace starter. 4. Connect negative (-) cable to starter body. • If rpm is less than specification, with battery fully charged, repair or replace starter. JT05719 Tachometer JT05712 Current Gun Jumper Wire Negative (-) Jumper Cable Positive (+) Jumper Cable LV066AE 4/7/95 4-93 4 Checks, Tests and Adjustments INJECTION PUMP STATIC TIMING ADJUSTMENT TDC Mark on Flywheel Reason: Equipment: • Timing Tool (No. 1 fuel injection line cut off at first bend) • External fuel supply Index Mark on Flywheel Housing T6530AC 5. Operate hand operated primer pump to fill injection pump with fuel. Procedure: IMPORTANT: Injection pump timing should be correct. Once timing is set, it will not normally change during the life of the engine, unless it was altered. 4 1 To make sure that injection pump timing is set to manufacturers specification. Check and adjust timing only as the last option. Check fuel, fuel supply system, injectors, air intake system and cylinder compression before continuing. NOTE: Normal rotation, as viewed from the flywheel end, is counterclockwise. The number one fuel injection line is toward the flywheel. 1. Remove the number one fuel injection line. 6. Hold throttle lever in RUN position. 7. Turn flywheel clockwise (as viewed from flywheel end) until tip of Timing Tool has become MOIST with solid fuel. This is the point of injection timing at which the pump is set. 8. Check timing mark on flywheel. The index mark must line up with the 16° mark on flywheel. Flywheel Injection Pump Timing Marks Flywheel 16° 12° TDC Mark on Flywheel 2. Install timing tool (number one fuel line cut off at first bend). 1 Timing Tool Index Mark on Flywheel Housing T6530AB 3. Remove rubber plug from flywheel housing. 4. Turn crankshaft pulley in either direction until the No. 1 cylinder top dead center (TDC) mark aligns with the index mark on the flywheel housing. 4-94 T6471CS 4/7/95 Checks, Tests and Adjustments Specifications: Injection Pump Timing. . . . . . . . . .16° BTDC . . . . . . . . . . . . . . . (Before Top Dead Center) Engine Crankshaft Position. . . . . . . . . . . . . . . . . . . No.1 Cylinder . . . . . . . . . . . . . on TDC Compression Stroke Belt Deflection Distance On Outer Surface Of Flywheel Per 1° Of Rotation. . . . . . . 3.5 mm (0.130 in.) Timing Lines On Pump Mounting Plate . . . . . . . . . . . . . . . . . 2° Apart Results: • If timing is not according to specifications, loosen pump mounting bolts and turn pump towards engine block to retard timing or away from block to advance timing. Recheck timing. • If timing did not change, remove pump and have tested by a diesel injection service shop. • If timing is OK: M54014 Specifications: Applied Force . . . . . . . . . . .98 N (22 lb-force) Deflection . . . . . 10 - 15 mm (0.400 - 0.600 in.) Results: • If deflection is not within specifications: - Loosen both alternator mounting cap screws. - Install rubber plug in flywheel housing. - Apply force to FRONT alternator housing only (near the belt) until tension is correct. - Remove timing tool. - Tighten cap screws. - Install number one injection line. FAN/ALTERNATOR DRIVE BELT ADJUSTMENT ENGINE OIL COOLER LEAKAGE TEST Reason: Reason: Inspect oil cooler for leaks. To keep proper tension on belt to drive water pump and alternator. To prevent shortened belt and bearing life. Procedure: Equipment: 2. Apply regulated air pressure of 206 - 483 kPa (30 - 70 psi) to other end. • JDG529 or JDST28 Belt Tension Gauge • Straight Edge Procedure: 1. Check belt tension between fan and alternator using Belt Tension Gauge and a straight edge. 4/7/95 1. Plug one end of coolant inlet or outlet passage. 3. Dip oil cooler into water and check for leaks. 4. Optional test: If a leak did not appear, use a hot water bath to possibly open crack(s). Results: • Repair leak(s) or replace oil cooler if necessary. 4-95 4 Operational Tests RADIATOR BUBBLE TEST COOLING SYSTEM PRESSURE TEST Reason: Reason: To determine if compression pressure is leaking from cylinder. Inspect cooling system for leaks. Equipment: Equipment: • D05104ST Cooling System Pressure Pump • JDG560 Adapter Procedure: Procedure: 1. With coolant at proper level and radiator cap tight, run engine for 5 minutes to bring to operating temperature. 1. Remove cap and attach pressure pump to radiator. 2. Apply 97 kPa (14 psi) maximum pressure. 3. Check for leaks throughout cooling system. 2. Remove cap from recovery tank. 3. Check for bubbles coming from overflow hose at bottom of tank. Cooling System Pressure Pump If bubbles are present, isolate source of compression leak: 4 - Remove injection nozzles. - Install JDG560 Adapter in injection port of cylinder to be tested. T6333AW - Move piston to bottom of stroke with intake and exhaust valves closed. - Connect hose from compressed air source (2942 kPa (427 psi) maximum) to adapter. - Check for bubbles in recovery tank or air escaping from muffler, air cleaner or oil fill opening. - Repeat for each cylinder. Results: • If bubbles are present, check for cracks in cylinder head and block. Check for damaged head gasket. • If air escapes from muffler, check for worn exhaust valve. Specifications: Minimum pressure after 15 seconds . . . . . . . . . . 88 kPa (12.8 psi) Results: • Pressure should hold to specifications. If pressure decreases, check for leaks. Repair leaks or replace parts as necessary. • If pressure test still indicates leakage after all external leaks have been stopped, a defective head gasket, cracked block, or cylinder head may be the cause. Perform RADIATOR BUBBLE TEST. • If air escapes from air cleaner, check for worn intake valve. • If air escapes from engine oil fill, check for worn piston rings. 4-96 4/7/95 Operational Tests RADIATOR CAP PRESSURE TEST Procedure: Reason: 1. Run engine for 5 minutes to bring to operating temperature. Shut off engine. Test radiator cap for operating in correct pressure range. 2. Remove injection nozzles. (See Fuel System in this section.) Equipment: 3. Remove heat protector from end of injector and install on Adapter. • D05104ST Cooling System Pressure Pump Procedure: 4. Install Adapter and Compression Gauge Assembly in injector port. Install retaining plate and tighten nuts to 4.5 N•m (39 lb-in.). 1. Install radiator cap on pressure pump. 5. Hold fuel shut-off knob in shut-off position. 2. Apply pressure. Pressure valve in cap should open at 88 kPa (12.8 psi). 6. Crank engine for five seconds with starter. 7. Record pressure reading for each cylinder. Cooling System Pressure Pump 4 Radiator Cap T6333AX Results: • If cap leaks, retighten and test again. Replace cap if pressure is not within specification. CYLINDER COMPRESSION PRESSURE TEST Reason: To determine the condition of the pistons, rings, cylinder walls and valves. Equipment: • JT01682 Compression Gauge Assembly • JDG560 Adapter JDG560 Adapter JT01682 Compression Gauge Assembly T6333EU Specifications: Compression Pressure . . . 2942 kPa (427 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . 588 kPa (85 psi) NOTE: Pressure listed is for 300 m (1000 ft) above sea level. Reduce specification an additional 3.6% for each additional 300 m (1000 ft) of altitude. Results: • If pressure reading is below specification, squirt approximately two teaspoons of clean engine oil into cylinders through injector ports and repeat test. 4/7/95 4-97 Operational Tests • If pressure increases significantly, check piston, rings and cylinder walls for wear or damage. JT05577 Pressure Gauge • If pressure does not increase significantly after retest, check for leaking valves, valve seats or cylinder head gasket. ENGINE OIL PRESSURE TEST Reason: JT03017 Hose Assembly To determine if engine bearings or lubrication system components are worn. Equipment: • JT05487 Connector • JT03017 Hose Assembly • JT05577 Pressure Gauge (100 psi) Procedure: 4 1. JT05487 Connector Remove oil pressure sender. 2. Install connector. T6471FB 3. Connect Hose Assembly and Pressure Gauge. IMPORTANT: Do not run if no pressure present. 4. Start engine. If pressure reading is below 69 kPa (10 psi), STOP ENGINE. 5. Run engine approximately five minutes to heat oil, then check oil pressure at fast and slow idle. Specifications: Fast Idle . . . . . . . . . . . . . . . . . . .2375 ±50 rpm Slow Idle. . . . . . . . . . . . . . . . . . . .900 ±50 rpm Engine Oil Pressure: Fast Idle . . . . . . .343 - 441 kPa (50 - 64 psi) Slow Idle (Minimum) . . . . . 98 kPa (14 psi) Results: • If oil pressure is not within specifications, inspect oil pressure regulating valve parts for wear or damage. Add or remove shims as necessary. (See Lubrication System in this section.) • If oil pressure does not increase, see “Engine Has Low Oil Pressure” in Diagnosis group. 4-98 4/7/95 Operational Tests AIR INTAKE SYSTEM LEAKAGE TEST FUEL SUPPLY PUMP PRESSURE TEST Reason: Reason: Check for leaks in air intake system. To determine supply pump operating pressure. Equipment: Equipment: • Air Pressure Regulator • JT03274 Hose Fitting Procedure: • JT01609 Female Quick Coupler 1. Remove air cleaner restriction indicator/switch and install test fitting. • JT03115 Gauge w/Male Quick Coupler (0 - 150 psi) 2. Connect air pressure regulator to manifold using hose and fitting from air cleaner. Procedure: 3. Remove air cleaner cover and main filter element. 1. Disconnect supply pump-to-filter hose. 4. Put large plastic bag into and over end of main filter element. Install main filter element and cover. 2. Install Hose Fitting, Coupler and Gauge. 5. Pressurize air intake system between 34 - 69 kPa (5 - 10 psi). If air intake system cannot be pressurized, turn engine slightly to close valves. 3. Pull fuel shut-off cable out and crank engine using the starter. Do not run starter for more than 10 seconds at a time. Gauge should read more than 216 kPa (31 psi). 6. Spray soap solution over all connections from air cleaner to intake manifold or turbocharger, if equipped, and check for leaks. JT03115 Gauge w/Male Quick Coupler JT01609 Female Quick Coupler IMPORTANT: When reinstalling starting aid nozzle, position arrow on nozzle pointing against intake air flow. JT03274 Hose Fitting Supply Pump-to Filter Hose Fuel Filter T6471CU M82124 Results: • Find leaks and repair or replace parts as necessary. 4/7/95 Results: • If pressure is below specification, repair or replace fuel supply pump. 4-99 4 Operational Tests FUEL DRAIN BACK TEST Reason: Determines if air is entering the fuel system at connections, allowing fuel to siphon back to tank. Procedure: 1. Disconnect fuel supply line and return line at fuel tank. IMPORTANT: Fuel return line MUST extend below fuel level in fuel tank before performing this test. Fill fuel tank if necessary. 2. Drain all fuel from the system, including fuel supply pump, injection pump, filter(s) and water separator, if equipped. 3. Plug end of fuel return hose. 4. Pressurize fuel system at fuel supply line, to a maximum pressure of 103 kPa (15 psi). 5. Apply liquid soap and water solution to all joints and connections in the fuel system and inspect for leaks. Results: • Find leaks and repair or replace parts as necessary. 4 4-100 4/7/95 Operational Tests 4 4/7/95 4-101 ACCESSORIES SERIES 220 POWER UNIT ENGINES Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Intake and Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . 10-5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43 Engine Tune-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 Operational Tests and Adjustments . . . . . . . . . . . . . . . . 10-47 Dealer Fabricated Tools . . . . . . . . . . . . . . . . . . . . . . . . . 10-62 Section 10 10 10 Specifications ENGINE ACCESSORIES SPECIFICATIONS Turbocharger Rotor Shaft Axial Play Without Waste Gate (RHB3) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.022 - 0.053 mm (0.0008 - 0.0021 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm (0.0028 in.) With Waste Gate (RHB5) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.06 mm (0.0012 - 0.0024 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.0035 in.) Rotor Shaft Radial Play Without Waste Gate (RHB3) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.061 - 0.093 mm (0.0024 - 0.0037 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.0047 in.) With Waste Gate (RHB5) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 - 0.13 mm (0.0031 - 0.0051 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.17 mm (0.0067 in.) Thrust Bearing-to-Center Housing Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 N•m (9 lb-in.) Seal Plate-to-Center Housing Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 N•m (9 lb-in.) Compressor Wheel Lock Nut Torque RHB3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 N•m (9 lb-in.) RHB5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 N•m (17 lb-in.) Center Housing-to-Turbine Housing Cap Screw Torque RHB3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 N•m (108 lb-in.) RHB5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 N•m (247 lb-in.) Center Housing-to-Compressor Housing Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . .4 N•m (39 lb-in.) Turbine Wheel/Shaft Deflection RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 mm (0.00008) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 mm (0.00019) RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 mm (0.00039) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.011 mm (0.00043) Turbine Shaft O.D. RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.257 - 6.263 mm (0.2463 - 0.2466 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.250 mm (0.2461 in.) RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.99 - 8.00 mm (0.3146 - 0.3150 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.980 mm (0.3142 in.) Shaft Seal Ring Groove Width RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.038 - 1.062 mm (0.0409 - 0.0418 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.070 mm (0.0421 in.) RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.250 - 1.280 mm (0.0492 - 0.0504 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.290 mm (0.0508 in.) Oil Thrower Seal Ring Groove Widths Small End RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.82 - 0.83 mm (0.0323 - 0.0327 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.84 mm (0.0331 in.) 4/7/95 10-1 10 Specifications 10 Oil Thrower Seal Ring Groove Widths, Small End - continued RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.02 - 1.03 mm (0.0402 - 0.0406 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 mm (0.0437 in.) Large End RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.02 - 1.03 mm (0.0402 - 0.0406 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.04 mm (0.0409 in.) RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 - 1.23 mm (0.0480 - 0.0484 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31 mm (0.0516 in.) Seal Plate I.D.s Side Without Slot RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.968 - 8.00 mm (0.3137 - 03150 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.015 mm (0.3156 in.) RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.00 - 10.02 mm (0.3937 - 0.3945 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.05 mm (0.3957 in.) Side With Slot RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.987 - 10.025 mm (0.3932 - 0.3947 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.04 mm (0.3953 in.) RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40 - 12.42 mm (0.4882 - 0.4890 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.45 mm (0.4902 in.) Thrust Bushing Shoulder Length RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.632 - 3.642 mm (0.1430 - 0.1434 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.650 mm (0.1437 in.) RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.04 - 4.05 mm (0.1591 - 0.1594 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.07 mm (0.1602 in.) Thrust Bearing Thickness RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59 - 3.61 mm (0.1413 - 0.1421 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58 mm (0.1409 in.) RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.99 - 4.01 mm (0.1571 - 0.1579 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.98 mm (0.1567 in.) Journal Bearing I. D. RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.275 - 6.285 mm (0.2470 - 0.2474 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.290 mm (0.2476 in.) RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.01 - 8.03 mm (0.3154 - 0.3161 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.04 mm (0.3165 in.) Journal Bearing O.D. RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.940 - 9.946 mm (0.3913 - 0.3916 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.930 mm (0.3909 in.) 10-2 4/7/95 Specifications Journal Bearing O. D. - continued RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.32 - 12.33 mm (0.4850 - 0.4854 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.31 mm (0.4846 in.) Seal Ring Surface I.D. RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.00 - 11.018 mm (0.4331 - 0.4338 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.03 mm (0.4343 in.) RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.00 - 15.02 mm (0.5906 - 0.5913 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.05 mm (0.5925 in.) Journal Bearing Surface I.D. RHB3 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.995 - 10.005 mm (0.3935 - 0.3939 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.01 mm (0.3941 in.) RHB5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40 - 12.41 mm (0.4882 - 0.4886 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.42 mm (0.4890 in.) Fan/Alternator Belt Applied Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N (22 lb-force) Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.) Glow Plug Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35 - 1.65 ohms Coolant Temperature Sender Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110° C (230° F) Operational Tests and Adjustments Radiator Bubble Test Maximum Air Pressure Into Cylinder 3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2455 kPa (356 psi) 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84). . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi) Cooling System Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi) Minimum Pressure after 10 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) Radiator Cap Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi) Cylinder Compression Pressure - 3009 Compression Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2455 kPa (356 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi) Cylinder Compression Pressure - 3011, 3014, 4019 Compression Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi) Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi) Engine Oil Pressure Low Idle Speed Industrial Application All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm Generator Application 3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 rpm Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 kPa (21 psi) Air Intake System Holding Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 - 69 kPa (5 - 10 psi) Fuel Supply Pump Pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 kPa (4.3 psi) Fuel System Holding Pressure (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 kPa (15 psi) 4/7/95 10-3 10 Specifications 10 Slow Idle Speed Industrial Application All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm Generator Application 3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 rpm Fast Idle Speed - 3009 Industrial Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm Generator Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3800 rpm Fast Idle Speed - 3011, 3014 and 4019 Industrial Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm Generator Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900 rpm Fuel Shutoff Solenoid Maximum Pull-in Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Amps for 1/2 second Maximum Hold-In Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 amp continuous Starter Amp Draw/RPM 3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Amps at 300 rpm 3011 (3TNC78) and 3014 (3TN84) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Amps at 300 rpm 4019 (4TN84) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 0 Amps at 1100 rpm No-Load Amp Draw RPM 3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Amps at 7000 rpm 3011 (3TNC78) and 3014 (3TN84) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Amps at 3000 rpm 4019 (4TN84) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Amps at 3500 rpm Regulated Amperage Fast Idle Speed Industrial Application All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm Generator Application 3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3800 rpm 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900 rpm Minimum Regulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 amps Unregulated Amperage Fast Idle Speed Industrial Application All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm Generator Application 3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3800 rpm 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900 rpm Minimum Regulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 amps Regulated Voltage Fast Idle Speed Industrial Application All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm Generator Application 3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3800 rpm 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900 rpm Regulated Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 - 14.7 VDC 10-4 4/7/95 Intake and Exhaust Systems SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARD® Catalog or in the European Microfiche Tool Catalog (MTC). *DFRG1 Extended Indicator Tip (RHB3) Attach to a dial indicator gauge to check radial play of turbocharger rotor shaft. *DFRG2 Extended Indicator Tip (RHB5) Attach to a dial indicator gauge to check radial play of turbocharger rotor shaft. OTHER MATERIALS Number LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. TY9370/ TY9477/ #242 TY15130/ NA/ #395 Name Use Thread Lock and Sealer (Medium Strength) Apply to threads of turbocharger thrust bearing and seal plate mounting screws. John Deere Form-In-Place Gasket Seals turbocharger seal plate and compressor housing to center housing. * Fabricated tool, dealer made. (See Dealer Fabricated Tools in this section for instruction to make tools.) ® LOCTITE is a registered trademark of the Loctite Corp. 4/7/95 10-5 10 Intake and Exhaust Systems AIR CLEANER - 3009 (3TNA72) Inspection Isolator Pad (2) Mounting Bracket Rain Cap Collar Seal Washer Flywheel End Element 10 Hose Clamp (2) Air Cleaner Housing Air Cleaner-to-Intake Manifold Hose M82182A 10-6 4/7/95 Intake and Exhaust Systems AIR CLEANER - 3011(3TNC78), 3014 (3TN84) AND 4019D (4TN84) Inspection Isolator Pad (2) Primary Element Mounting Bracket Rain Cap Secondary Safety Element (Optional) Hose Clamp (2) Air Cleaner Housing Dust Pan Assembly Baffle 10 Seal Washer Flywheel End Air Cleaner-to-Intake Manifold Hose M82183AE 4/7/95 10-7 Intake and Exhaust Systems AIR CLEANER - 4019T (4TN84T) Inspection Isolator Pad (2) Primary Element Mounting Bracket Rain Cap Secondary Safety Element (Optional) Large Hose Clamp (2) 10 Dust Pan Assembly Baffle Air Cleaner-toTurbocharger Hose Seal Washer Small Hose Clamp (2) Flywheel End Turbocharger-to-Intake Manifold Hose M82184AE 10-8 4/7/95 Intake and Exhaust Systems MUFFLER - 3009 (3TNA72) CAUTION Removal/Installation Muffler may be hot. Allow muffler to cool before removing. A hot muffler can cause serious burns. Muffler Mounting Nut (4) Gasket Fan Side 10 Mounting Nut (2) Adapter Gasket M82188AE 4/7/95 10-9 Intake and Exhaust Systems MUFFLER - 3011 (3TNC78), 3014 (3TN84) AND 4019D (4TN84) CAUTION Removal/Installation Muffler may be hot. Allow muffler to cool before removing. A hot muffler can cause serious burns. Muffler Mounting Nut (4) Fan Side 10 Gasket M82127AE 10-10 4/7/95 Intake and Exhaust Systems MUFFLER - 4019T (4TN84T) CAUTION Removal/Installation Muffler may be hot. Allow muffler to cool before removing. A hot muffler can cause serious burns. Gasket Muffler Mounting Nut (4) Support Bracket Fan Side 10 Cap Screw (2) M8 x 18 Cap Screw (2) M8 x 22 M82128AE 4/7/95 10-11 Intake and Exhaust Systems EXTENDING TURBOCHARGER LIFE Turbochargers are designed to last the life of the engine, but, because they operate at such high speeds (100,000 rpm or more); a moments carelessness can cause them to fail in seconds. The major causes of turbocharger failures are attributed to: - Lack of lube oil (quick starts and hot shutdowns) - Oil contamination - Ingestion of foreign objects - Restricted oil drainage - Low oil level - Operation on excessive side slopes - Abnormally high exhaust temperatures Lack of Lube Oil 10 Oil not only lubricates the turbo's spinning shaft and bearings, it also carries away heat. When oil flow stops or is reduced, heat is immediately transferred from the hot turbine wheel to the bearings, which are also heating up because of the increased friction due to the lack of oil. This combination causes the turbo shaft temperature to increase rapidly. If oil flow does not increase and the process continues, bearings will fail. Once the bearings fail (which can happen in seconds) seals, shaft, turbine and compressor wheels can also be damaged. Oil levels and pressure should always be closely monitored. All worn hoses and lines should be replaced. The turbo oil supply line should be checked frequently to make sure it is not kinked or bent. It should always be replaced with a line of equal size, length and strength. The easiest way to damage a turbo is through improper start-up and shutdown procedures. Always idle the engine for at least 30 seconds (no load) after start-up and before shutdown. Warming the engine up before applying a load allows oil pressure to build up and lines to fill with oil. Idling the engine before shutdown allows the engine and turbo to cool. “Hot” shutdowns can cause the turbo to fail. After high-speed operation the turbo will continue to rotate long after the engine has been shut off and oil pressure has dropped to zero. This will cause heat to build up and create possible bearing damage. It can also cause carbon and varnish deposits to form. Oil Contamination A second cause of turbo failure is contaminated oil. It can be caused by a worn or damaged oil filter or not changing the lube oil at recommended intervals. Expecting the oil filter to remove dirt, sand, metal chips, ect. from the oil before they reach the engine or turbocharger can be a costly mistake. Contaminated oil may completely bypass the engine oil filter if; the oil filter or oil cooler is clogged, the filter is improperly installed, or the oil is thick during cold weather. The principle causes of turbo bearing lubrication problems are low oil pressure, a bent, plugged or undersized oil lube supply line, plugged or restricted oil galleries in the turbo, or improper machine startup and shutdown procedures. 10-12 4/7/95 Intake and Exhaust Systems Four good ways of avoiding oil contamination are: - Always inspect the engine thoroughly during a major overhaul. Look especially for any sludge or debris left in lube oil galleries. - Change lube oil at recommended intervals. Analysis of oil samples at filter change periods can help identify potentially harmful contaminants in the oil. - Clean the area around the oil fill cap before adding oil. - Use a clean container when adding oil. Injestion of Foreign Objects The third cause of turbo damage is the injestion of foreign objects. Foreign objects or particles can be injested and cause damage to the turbo on both compressor and turbine sides. This is easy to avoid. On the compressor side, foreign objects usually take the form of dust, sand, or shreds of air cleaner element that enter through improperly installed air cleaner elements. Leaky air inlet piping (loose clamps or torn rubber joints) or torn pleats in drytype air cleaner elements also create problems. The result is erosion of compressor blades that can cause the delicately balanced wheel to wobble. IMPORTANT: Whenever an internal engine failure (valve, valve seat, piston) occurs, a thorough inspection of the turbocharger MUST BE performed before returning engine to service. Restricted Oil Drainage There are two primary reasons for restricted drainage: - A blocked drain tube, due to either damage or a buildup of sludged oil. - High crankcase pressure, due to restricted crankcase breather or excessive engine blowby. Periodically check both the turbocharger oil drain tube and engine breather tube for damage or restriction. Correction of these conditions lead to longer turbo life. Abnormally High Exhaust Temperatures A fifth cause of turbocharger damage is abnormally high exhaust temperatures. Elevated exhaust temperatures cause choking of oil which can lead to bearing failure. Extreme over-temperature operation can cause wheel burst. There are two basic causes of over-temperature: - Restricted air flow. - Overpowering the engine. In either case the engine has more fuel than available air for proper combustion. This overfueled condition leads to elevated exhaust temperatures. Causes of restricted air flow can include damaged inlet piping, clogged air filters, excessive exhaust restriction, or operation at extreme altitudes. Overpowering generally is due to improper fuel delivery or injection timing. If overtemperature operation has been identified, an inspection of the air inlet and exhaust systems should be performed. Also check the fuel delivery and timing. A fourth cause of turbocharger damage is restricted lube oil drainage. The lubricating oil carries away heat generated by friction of the bearings and from the hot exhaust gases. If drainage back to the sump is impeded, the bearings will overheat with damage that will ultimately lead to failure. 4/7/95 10-13 10 Intake and Exhaust Systems TURBOCHARGER - YANMAR (RHB3 and RHB5) Removal NOTE: Model number RHB5 is equipped with a waste gate system. Removal/installation procedures are the same for both. Model RHB3 turbocharger is shown. 1. Remove muffler. (See procedure in this group.) CAUTION Turbocharger may be hot. Allow turbocharger to cool before removing. A hot turbocharger can cause serious burns. IMPORTANT: When cleaning turbocharger, do not spray directly into compressor or turbine housings. If inspection is required, do not clean exterior of turbocharger prior to removal. Cleaning can remove evidence of a potential failure mode. 2. Remove air cleaner-to-turbocharger hose and clamps. 3. Remove turbocharger-to-intake manifold hose and clamps. 4. Remove lube line clamp cap screw. 5. Remove lube line mounting cap screw and two copper washers. 6. Remove two oil drain line cap Disconnect line and remove o-ring. screws. 7. Remove three nuts, turbocharger and gasket. Lube Line Mounting Cap Screw and Washers 10 Turbocharger-to-Intake Manifold Hose Air Cleaner-toTurbocharger Hose Turbocharger Oil Drain Line Cap Screws Lube Line Clamp Cap Screw M82185 10-14 4/7/95 Intake and Exhaust Systems 8. Diagnose the cause of failure, if necessary. (See TURBOCHARGER FAILURE ANALYSIS.) Rotor Shaft Axial Play Check 9. Inspect turbocharger. (See TURBOCHARGER SEVEN-STEP INSPECTION.) 1. Fasten dial indicator to turbine housing and position indicator tip on end of rotor shaft at turbine housing end. 10.Check rotor shaft axial and radial play. (See Rotor Shaft Axial and Radial Play Check procedures.) 2. Move rotor shaft in axial direction. Record measurement. 11.Disassemble and inspect all parts for wear or damage, if necessary. (See Disassembly procedures.) Installation 1. Prelube turbocharger: Fill oil inlet or drain port with clean oil and turn rotating assembly (by hand) to properly lubricate bearings. Magnetic Base Turbine Housing Dial Indicator Axial Direction 2. Install new gasket, turbocharger and three nuts. 3. Install new o-ring and connect oil drain line. Install and tighten two mounting cap screws. 4. Install two new copper washers and lube line mounting cap screw. M82186A 5. Install lube line clamp cap screw. 6. Install turbocharger-to-intake manifold hose and clamps. 7. Install air cleaner-to-turbocharger hose and clamps. 8. Install muffler. (See procedure in this group.) IMPORTANT: A new or repaired turbocharger does not have an adequate oil supply for immediate start-up of engine. Perform the following steps to prevent damage to turbocharger bearings. 9. Push the throttle lever to the “STOP” position or disconnect fuel shutoff solenoid connector, if equipped. Axial Play Specifications: Without Waste Gate (RHB3) 10 Standard . . . . . . . . . . . . . . . 0.022 - 0.053 mm . . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0021 in.) Wear Limit. . . . . . . . . . . 0.07 mm (0.0028 in.) With Waste Gate (RHB5) Standard . . . . . . . . . . . . . . . . . 0.03 - 0.06 mm . . . . . . . . . . . . . . . . . . . . . (0.0012 - 0.0024 in.) Wear Limit. . . . . . . . . . . 0.09 mm (0.0035 in.) If axial play is not within specifications, disassemble and inspect all components for wear or damage. (See Disassembly procedures.) 10.Crank engine over with starter until oil pressure gauge needle registers within the “GREEN” zone of pressure gauge. DO NOT crank engine longer than 30 seconds at a time to avoid damaging the starter. 4/7/95 10-15 Intake and Exhaust Systems Rotor Shaft Radial Play Check 1. Attach DFRG1 or DFRG2 Extended Indicator Tip to Dial Indicator gauge. 2. Fasten dial indicator to bottom of turbocharger mounting flange. Insert extended indicator tip through oil drain opening and position tip on rotor shaft. 3. Hold both turbine and compressor wheels and move rotor shaft in radial direction. Record measurement. Radial Play Specifications: Without Waste Gate (RHB3) Standard . . . . . . . . . . . . . . . 0.061 - 0.093 mm . . . . . . . . . . . . . . . . . . . . . (0.0024 - 0.0037 in.) Wear Limit. . . . . . . . . . . 0.12 mm (0.0047 in.) With Waste Gate (RHB5) Standard . . . . . . . . . . . . . . . . . 0.08 - 0.13 mm . . . . . . . . . . . . . . . . . . . . . (0.0031 - 0.0051 in.) Wear Limit. . . . . . . . . . . 0.17 mm (0.0067 in.) If radial play is not within specifications, disassemble and inspect all components for wear or damage. (See Disassembly procedures.) Dial Indicator Magnatic Base DFRG1 or DFRG2 Extended Indicator Tip 10 Mounting Flange Oil Drain Compressor Wheel Turbine Wheel Radial Direction Oil Inlet M82187A 10-16 4/7/95 Intake and Exhaust Systems Disassembly NOTE: Model number RHB5 is equipped with a waste gate system. Service procedures are the same for both unless noted otherwise. Model RHB5 turbocharger is illustrated throughout service procedures. Compressor Housing Alignment Marks 1. Remove circlip and disconnect rod. 2. Remove clamps and hose. 3. Remove two cap screws, waste gate actuator and spacer(s), if equipped. Oil Inlet Port Lock Plate (4) Spacer(s) Cap Screw (4) M5 x 10 M82159 Circlip 7. Scribe alignment marks across turbine housing and center housing to aid in assembly. Hose and Clamps Waste Gate Actuator M82158 8. Remove four cap screws, lock plates and turbine housing. 10 Turbine Housing Alignment Marks 4. Scribe alignment marks across compressor housing and center housing to aid in assembly. 5. Remove four cap screws and lock plates. IMPORTANT: Be careful when removing compressor housing. Damage to compressor wheel blades can occur. 6. Tap on compressor housing with a plastic hammer to remove from center housing. Lock Plate (4) Cap Screw (4) M6 x 10 (RHB3) M8 x 10 (RHB5) M82160 4/7/95 10-17 Intake and Exhaust Systems NOTE: Lock nut has left-hand threads. 9. Remove lock nut and compressor wheel. 14.Insert two existing M5 cap screws (compressor housing-to-center housing cap screws) into threaded holes and pull out seal plate. Holes Compressor Wheel Lock Nut M4 (RHB3) M5 (RHB5) M82161 Seal Plate Assembly 10.Remove turbine wheel/shaft and heat protector. Mounting Screw (RHB3: 2) M3 x 12 (RHB5: 3) Replace. 11.Remove seal ring. M82163 15.Remove oil thrower assembly from seal plate. 16.Remove seal rings. 10 Large Seal Ring Replace. Heat Protector Small Seal Ring Replace. Oil Thrower Turbine Wheel/Shaft Seal Ring Replace. Seal Plate M82164 M82162 12.Model RHB3: Tap two holes in seal plate using a 5 mm, 0.80 thread tap. 17.Remove thrust bearing mounting screws. 18.Remove thrust bearing, thrust bushing and journal bearing. 13.Remove seal plate mounting screws. 10-18 4/7/95 Intake and Exhaust Systems Assembly 1. If removed, install two new retaining rings into center housing with “open end” of rings facing toward oil outlet port. Journal Bearing 2. Coat journal bearing with clean engine oil and install in center housing. Thrust Bearing Retaining Rings Thrust Bushing Mounting Screw (RHB3: 2) (RHB5: 4) M3 x 7 Replace. Journal Bearing M82165 19.Remove retaining ring and journal bearing from turbine side. NOTE: There are two retaining rings inside center housing. Remove only if replacement is necessary. Retaining Ring M82166 3. Install turbine side retaining ring with beveled edge toward journal bearing and with “open end” in direction shown. Oil Inlet Port End Retaining Ring Journal Bearing Match Up Contact Surface Viewed from Compressor Side (RBH3) Viewed from Turbine Side (RBH5) Retaining Ring Replace. M82166 20.Inspect all parts for wear or damage. Replace as necessary. (See Inspection procedures.) 4/7/95 M82167A 4. Install new seal ring on turbine shaft. 5. Install heat protector and turbine wheel/shaft with “open end” of seal ring facing toward oil inlet port. Turbine wheel/shaft should “snap” into place. 10-19 10 Intake and Exhaust Systems 9. Position seal rings on oil thrower as shown and insert thrower into seal plate. Oil thrower should “snap” into place. Oil Inlet Port Large Seal Ring Heat Protector Small Seal Ring Oil Thrower Turbine Wheel/Shaft Seal Ring Seal Plate M82164 M82162 Seal Plate 6. Coat journal bearing and thrust bushing with clean engine oil and install in center housing. 7. Install thrust bearing and mounting screws. 10 45° Slot Thrust Bearing Viewed from Seal Plate Side Without Slot M82169A 10.Clean mating surfaces of center housing and seal plate assembly using Clean and Cure Primer. Journal Bearing Thrust Bushing Mounting Screw (RHB3: 2) M3 x 7 (RHB5: 4) Apply thread lock and sealer (medium strength) to threads. 1 N•m (9 lb-in.) 11.Install seal plate assembly with slot toward oil outlet port. 12.Install mounting screws. M82168 8. Install new seal rings on oil thrower. 10-20 4/7/95 Intake and Exhaust Systems Turbine Housing Alignment Marks Slot Seal Plate Assembly Oil Outlet Port Mounting Screw (RHB3: 2) M3 x 12 (RHB5: 4) John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Apply thread lock and sealer (medium strength) to threads. 1 N•m (9 lb-in.) Lock Plate (4) Cap Screw (4) RHB3: M6 x 10 12 N•m (108 lb-in.) RHB5: M8 x 10 28 N•m (247 lb-in.) M82160 M82170 NOTE: Lock nut has left-hand threads. 13.Install compressor wheel and lock nut. 16.Clean mating surfaces of center housing and compressor housing using Clean and Cure Primer. Apply a coat of John Deere Form-InPlace Gasket (RTV rubber silicone sealant) on compressor housing. 10 17.Install compressor housing. 18.Align marks made during disassembly and install lock plates and cap screws. Compressor Wheel Alignment Marks Compressor Housing Lock Nut RHB3: M4 1 N•m (9 lb-in.) RHB5: M5 2 N•m (17 lb-in.) Lock Plate (4) M82161 14.Install turbine housing. 15.Align marks made during disassembly and install lock plates and cap screws. Cap Screw (4) M5 x 10 4 N•m (39 lb-in.) M82159 4/7/95 10-21 Intake and Exhaust Systems 19.Install spacer(s), if equipped, waste gate actuator and two cap screws. Tighten cap screws to 4 N•m (39 lb-in.). 20.Install hose and clamps. RHB5 Standard . . . . . . . . . . . . . 0.010 mm (0.00039) Wear Limit. . . . . . . . . . . . 0.011 mm (0.00043) 21.Connect rod and install circlip. If variation is more than wear limit, replace wheel/ shaft. 22.Prelube turbocharger: Fill oil inlet or drain port with clean oil and turn rotating assembly (by hand) to properly lubricate bearings. 3. Measure turbine shaft diameter and seal ring groove width. Oil Inlet Port Shaft Seal Ring Groove Width Spacer(s) Circlip Turbine Shaft O.D. Hose and Clamps M82172A Turbine Shaft O.D.: RHB3 Waste Gate Actuator M82158 10 Inspection 1. Inspect all parts for wear or damage. Replace as necessary. 2. Inspect turbine wheel/shaft for bend using vblock and a dial indicator. Turn wheel/shaft slowly and read variation on indicator. Standard . . . . . . . . . . . . . . . 6.257 - 6.263 mm . . . . . . . . . . . . . . . . . . . . . (0.2463 - 0.2466 in.) Wear Limit. . . . . . . . . . 6.250 mm (0.2461 in.) RHB5 Standard . . . . . . . . . . . . . . . . . 7.99 - 8.00 mm . . . . . . . . . . . . . . . . . . . . . (0.3146 - 0.3150 in.) Wear Limit. . . . . . . . . . 7.980 mm (0.3142 in.) Shaft Seal Ring Groove Width: RHB3 Dial Indicator Standard . . . . . . . . . . . . . . . 1.038 - 1.062 mm . . . . . . . . . . . . . . . . . . . . . (0.0409 - 0.0418 in.) Wear Limit. . . . . . . . . . 1.070 mm (0.0421 in.) V-Block RHB5 M82171A Turbine Wheel/Shaft Deflection: RHB3 Standard . . . . . . . . . . . . . 0.002 mm (0.00008) Wear Limit. . . . . . . . . . . . 0.005 mm (0.00019) 10-22 Standard . . . . . . . . . . . . . . . 1.250 - 1.280 mm . . . . . . . . . . . . . . . . . . . . . (0.0492 - 0.0504 in.) Wear Limit. . . . . . . . . . 1.290 mm (0.0508 in.) If turbine shaft diameter is less than wear limit, replace turbine wheel/shaft and journal bearings. If ring groove width is greater than wear limit, replace turbine wheel/shaft. 4/7/95 Intake and Exhaust Systems 4. Measure seal ring groove widths in oil thrower. Seal Ring Groove Width (Large End) Seal Ring Groove Width (Small End) Seal Plate Seal Ring Surface I.D. (Large) Seal Ring Surface I.D. (Small) Oil Thrower Slot M82173A Oil Thrower Seal Ring Groove Widths: Small End RHB3 Standard . . . . . . . . . . . . . . . . . 0.82 - 0.83 mm . . . . . . . . . . . . . . . . . . . . . (0.0323 - 0.0327 in.) Wear Limit. . . . . . . . . . . 0.84 mm (0.0331 in.) RHB5 Standard . . . . . . . . . . . . . . . . . 1.02 - 1.03 mm . . . . . . . . . . . . . . . . . . . . . (0.0402 - 0.0406 in.) Wear Limit. . . . . . . . . . . 1.11 mm (0.0437 in.) Large End RHB3 Standard . . . . . . . . . . . . . . . . . 1.02 - 1.03 mm . . . . . . . . . . . . . . . . . . . . . (0.0402 - 0.0406 in.) Wear Limit. . . . . . . . . . . 1.04 mm (0.0409 in.) RHB5 M82174A Seal Plate I.D.s: Side Without Slot RHB3 Standard . . . . . . . . . . . . . . . . 7.968 - 8.00 mm . . . . . . . . . . . . . . . . . . . . . (0.3137 - 0.3150 in.) Wear Limit. . . . . . . . . . 8.015 mm (0.3156 in.) RHB5 Standard . . . . . . . . . . . . . . . 10.00 - 10.02 mm . . . . . . . . . . . . . . . . . . . . . (0.3937 - 0.3945 in.) Wear Limit. . . . . . . . . . 10.05 mm (0.3957 in.) Side With Slot RHB3 Standard . . . . . . . . . . . . . . 9.987 - 10.025 mm . . . . . . . . . . . . . . . . . . . . . (0.3932 - 0.3947 in.) Wear Limit. . . . . . . . . . 10.04 mm (0.3953 in.) RHB5 Standard . . . . . . . . . . . . . . . . . 1.22 - 1.23 mm . . . . . . . . . . . . . . . . . . . . . (0.0480 - 0.0484 in.) Wear Limit. . . . . . . . . . . 1.31 mm (0.0516 in.) Standard . . . . . . . . . . . . . . . 12.40 - 12.42 mm . . . . . . . . . . . . . . . . . . . . . (0.4882 - 0.4890 in.) Wear Limit. . . . . . . . . . 12.45 mm (0.4902 in.) If either ring groove width is greater than wear limit, replace oil thrower. If either inside diameter is less than wear limit, replace seal plate. 5. Measure inside diameters (seal ring surfaces) of seal plate. 6. Measure length of thrust bushing shoulder. 4/7/95 10-23 10 Intake and Exhaust Systems Journal Bearing I.D.: RHB3 Standard . . . . . . . . . . . . . . . 6.275 - 6.285 mm . . . . . . . . . . . . . . . . . . . . . (0.2470 - 0.2474 in.) Wear Limit. . . . . . . . . . 6.290 mm (0.2476 in.) RHB5 Thrust Bushing Shoulder Length M82175A Thrust Bushing Shoulder Length: RHB3 Standard . . . . . . . . . . . . . . . 3.632 - 3.642 mm . . . . . . . . . . . . . . . . . . . . . (0.1430 - 0.1434 in.) Wear Limit. . . . . . . . . . 3.650 mm (0.1437 in.) RHB5 Standard . . . . . . . . . . . . . . . . . 8.01 - 8.03 mm . . . . . . . . . . . . . . . . . . . . . (0.3154 - 0.3161 in.) Wear Limit. . . . . . . . . . . 8.04 mm (0.3165 in.) Journal Bearing O.D.: RHB3 Standard . . . . . . . . . . . . . . . 9.940 - 9.946 mm . . . . . . . . . . . . . . . . . . . . . (0.3913 - 0.3916 in.) Wear Limit. . . . . . . . . . 9.930 mm (0.3909 in.) RHB5 Standard . . . . . . . . . . . . . . . . . 4.04 - 4.05 mm . . . . . . . . . . . . . . . . . . . . . (0.1591 - 0.1594 in.) Wear Limit. . . . . . . . . . . 4.07 mm (0.1602 in.) Standard . . . . . . . . . . . . . . . 12.32 - 12.33 mm . . . . . . . . . . . . . . . . . . . . . (0.4850 - 0.4854 in.) Wear Limit. . . . . . . . . . 12.31 mm (0.4846 in.) If shoulder length is more than wear limit, replace If inside diameter is more than wear limit, replace both journal bearings and turbine wheel/shaft. 7. Measure thrust bearing thickness. If outside diameter is less than wear limit, replace both journal bearings, turbine wheel/shaft and center housing. 10 thrust bushing. Thrust Bearing Thickness: RHB3 Standard . . . . . . . . . . . . . . . . . 3.59 - 3.61 mm . . . . . . . . . . . . . . . . . . . . . (0.1413 - 0.1421 in.) Wear Limit. . . . . . . . . . . 3.58 mm (0.1409 in.) 9. Inspect center housing for cracks or damage. Measure inside diameters (seal ring surface and journal bearing surfaces) of center housing. RHB5 Standard . . . . . . . . . . . . . . . . . 3.99 - 4.01 mm . . . . . . . . . . . . . . . . . . . . . (0.1571 - 0.1579 in.) Wear Limit. . . . . . . . . . . 3.98 mm (0.1567 in.) If bearing thickness is less than wear limit, replace thrust bearing. Seal Ring Surface I.D. 8. Measure outside and inside diameters of journal bearings. Journal Bearing Surface I.D.s 10-24 M82176A 4/7/95 Intake and Exhaust Systems Seal Ring Surface I.D.: RHB3 Standard . . . . . . . . . . . . . . 11.00 - 11.018 mm . . . . . . . . . . . . . . . . . . . . . (0.4331 - 0.4338 in.) Wear Limit. . . . . . . . . . 11.03 mm (0.4343 in.) RHB5 Standard . . . . . . . . . . . . . . . 15.00 - 15.02 mm . . . . . . . . . . . . . . . . . . . . . (0.5906 - 0.5913 in.) Wear Limit. . . . . . . . . . 15.05 mm (0.5925 in.) Journal Bearing Surface I.D.: RHB3 Standard . . . . . . . . . . . . . . 9.995 - 10.005 mm . . . . . . . . . . . . . . . . . . . . . (0.3935 - 0.3939 in.) Wear Limit. . . . . . . . . . 10.01 mm (0.3941 in.) RHB5 Standard . . . . . . . . . . . . . . . 12.40 - 12.41 mm . . . . . . . . . . . . . . . . . . . . . (0.4882 - 0.4886 in.) Wear Limit. . . . . . . . . . 12.42 mm (0.4890 in.) If seal ring surface diameter is more than wear limit, replace center housing. If journal bearing surface diameters are more than wear limit, replace center housing, journal bearings and turbine wheel/shaft. 10 4/7/95 10-25 Intake and Exhaust Systems TURBOCHARGER FAILURE ANALYSIS Problem Possible Cause Suggested Remedy Compressor Housing Inlet Defects Foreign Object Damage Objects left in intake system. Disassemble and inspect intake system for foreign objects. Inspect engine for internal damage. Leaking and/or defective intake system. Inspect air intake system connections and air cleaner. Repair or replace as necessary. Inspect air intake related engine components. Compressor Wheel Rub 10 Failure of journal bearings and/ or thrust bushing and bearing. Determine if engine and/or operator contributed to lack of lubrication, contaminated lubrication, excessive temperature, or debris generating engine failure in progress. Manufacturing defects. Correct as required. (See Disassembly and Inspection procedures in this group.) Compressor Housing Outlet Defects Oil and/or Dirt in Housing Restricted air intake system. Inspect and clean air cleaner. Prolonged periods of low RPM engine idling. Check with operator to confirm conditions. (See Operators manual.) Defective seal ring on oil thrower or defective seal around seal plate. Repair as necessary. (See Disassembly and Inspection in this group. Restricted oil drain line. Inspect and clear oil drain line as required. Internal engine failure. Inspect and repair engine as required. Oil leaking from turbine shaft seal ring. Repair as necessary. (See Disassembly and Inspection in this group.) Excessive operating temperature. Check for restricted air intake. Turbine Housing Inlet Defects Oil in Housing Internal Walls Deteriorated Check engine for overfueling. Check injection pump timing. 10-26 4/7/95 Intake and Exhaust Systems Problem Possible Cause Suggested Remedy Turbine Housing Outlet Defects Turbine Wheel Rub Failure of journal bearings and/ or thrust bushing and bearing. Determine if engine and/or operator contributed to lack of lubrication, contaminated lubrication, excessive temperature, or debris generating engine failure in progress. Manufacturing defect. Correct as required. (See Disassembly and Inspection procedures in this group.) Leaking air intake system. Foreign Object Damage Oil and/or Excessive Carbon Internal engine failure. Inspect and repair engine as required. Objects left in intake system. Disassemble and inspect air intake system. (See AIR CLEANER in this group.) Leaking air intake system. Correct as required. Internal engine failure. Verified by oil in turbine housing. Correct as required. Turbine shaft seal ring failure. Inspect for excessive heat from overfueling and/or restricted air intake. Prolonged periods of low RPM engine idling. Verify with operator to run engine under load or a higher RPM. (See Operator’s manual). Restricted oil drain line. Inspect and clean oil drain line as required. Engine Center Housing and Joint Defects Leaks from Casting Defective casting. Replace turbocharger. Leaks from Joints Loose attaching screws. Tighten to specifications. (See Assembly procedures in this group.) Defective heat shield or deteriorated sealant. Inspect and repair as required. (See Disassembly and Assembly procedures in this group.) Internal Center Housing Defects Excessive Carbon Build-up in Housing or on Shaft 4/7/95 Hot engine shut-down. Review proper operation with operator as shown in Operator’s manual. Excessive operating temperature. Restricted air intake; Overfueling or mistimed engine. Restricted oil drain line. Inspect and clean oil drain lines as required. Operating engine at high speeds & loads immediately after start-up. Idle engine for a few minutes to allow oil to reach bearings before applying heavy loads. 10-27 10 Intake and Exhaust Systems TURBOCHARGER SEVEN-STEP INSPECTION Compressor Wheel The following inspection procedure is recommended for systematic failure analysis of a suspected failed turbocharger. This procedure will help to identify when a turbocharger has failed, and why it has failed, so the primary cause of the failure can be corrected. Proper diagnosis of a non-failed turbocharger is important for two reasons. First, identification of a non-failed turbocharger will lead to further investigation and repair of the cause of a performance complaint. Second, proper diagnosis eliminates the unnecessary expense incurred when a non-failed turbocharger is replaced. The seven recommended inspection steps, which are explained in detail on the following pages, are: 10 RG4523 NOTE: You will need a good light source for this check. 3. Check compressor inlet for wheel rub on the housing (arrow). Look very closely for any score marks on the housing itself and check the tips of the compressor wheel blades for damage. - Compressor Housing Inlet and Compressor Wheel - Compressor Housing Outlet - Turbine Housing Inlet - Turbine Housing Outlet and Turbine Wheel - External Center Housing and Joints - Internal Center Housing - Turbo Bench Test NOTE: To enhance the turbocharger inspection, an inspection sheet (Form No. DS-2280 available from Distribution Service Center) can be used that lists the inspection steps in the proper order and shows potential failure modes for each step. Check off each step as you complete the inspection and record any details or problems obtained during inspection. Retain this with the work order for future reference. RG4524 Compressor Housing Outlet 1. Check compressor housing outlet. The outlet should be clean and free of dirt or oil. 2. Mark it on your checklist if dirt or oil is found and continue the inspection. Compressor Housing Inlet and Compressor Wheel 1. Check compressor inlet and wheel for foreign object damage. NOTE: Foreign object damage may be extensive or minor. In either case, the source of the foreign object must be found and corrected to eliminate further damages. 2. Mark findings on your checklist and continue the inspection. 10-28 Model RHB5 Compressor Housing Outlet M82154 4/7/95 Intake and Exhaust Systems Turbine Housing Inlet 1. Check the turbine housing inlet port for oil in housing, excessive carbon deposit or erosion of walls. 2. Inspect the wheel blades and housing for evidence of wheel rub (arrow). Wheel rub can bend the tips of the blades with the housing showing wear or damage. NOTE: If the inlet is wet with oil or has excessive carbon deposits, an engine problem is likely. Wall erosion (cracking or missing pieces), indicate excessive exhaust temperature. Turbine Housing Inlet Port RG4528 External Center Housing and Joints 1. Visually check the outside of the center housing, all connections to the compressor housing, and turbine housing for oil. Model RHB5 M82155 NOTE: If oil is present, make sure it is not coming from a leak at the oil supply or return line. Turbine Housing Outlet and Turbine Wheel 1. Use a flashlight to look up inside the turbine housing outlet and check blades for foreign object damage. 10 Center Housing Turbine Housing Outlet Model RHB5 M82157 Internal Center Housing Blades Model RHB5 M82156 4/7/95 1. Using a flashlight, look through the oil return hole to check the condition of the shaft and/or bearings. There should not be excess carbon deposits on the shaft or in the housing. 10-29 Intake and Exhaust Systems Oil Return Hole Model RHB5 M82155 2. Excessive “blueing” or “coking” of oil along the complete length of the shaft indicates a possible lack of lubrication caused by an engine failure, or improper operation, such as hot shutdowns. Turbine Wheel/Shaft Model RHB5 M82157 3. Pull up on the compressor end of the shaft and press down on the turbine end while rotating shaft. Neither the compressor wheel nor the turbine wheel should contact the housing at any point. NOTE: There will be some “play” because the bearings inside the center housing are free floating. 10 RG4531 Turbo Bench Test 1. Mount the turbocharger in a vise. 2. Rotate the shaft, using both hands, to check rotation and clearance. The shaft should turn freely, however, there may be a slight amount of drag. M82157 10-30 4/7/95 Intake and Exhaust Systems 4. Check shaft endplay by moving the shaft back and forth while rotating. There will be some endplay but not to the extent that the wheels contact the housings. M82157 NOTE: These diagnostic procedures will allow you to determine the condition of the turbocharger. If the turbocharger has failed, analysis of your inspection notes should direct you to the specific areas of the engine to correct the problems causing the turbocharger failure. (See TURBOCHARGER FAILURE ANALYSIS.) It is not unusual to find that a turbocharger has not failed. If your turbocharger passes all the inspections, the problem lies somewhere else. IMPORTANT: Before you finalize your conclusion that the turbocharger has not failed, it is strongly recommended to check rotor shaft axial and radial play. (See procedures in this group.) These procedures are not required if a failure mode has already been identified. 10 4/7/95 10-31 Cooling System RADIATOR Fan Guard Removal/Inspection Upper Radiator Hose c CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. Fan Shroud NOTE: Approximate cooling system capacity is: 3009 3011 3014 4019 ................ ................ ................ ................ Lower Radiator Hose 3.5 L (3.7 qt) 3.7 L (3.9 qt) 4.0 L (4.2 qt) 4.7 L (4.9 qt) 1. Remove radiator cap and open drain valve to drain cooling system. 2. Remove fan guard. 10 3. Remove four fan shroud mounting cap screws, and place shroud over fan. 4. Remove upper and lower radiator hoses. Drain Hose Drain Valve M82129 6. Support bottom of radiator and remove four mounting cap screws. 7. Remove radiator. 5. Disconnect drain hose. CAUTION Reduce compressed air to less than 210 kPa (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. 10-32 4/7/95 Cooling System 8. Check radiator for debris lodged in fins. Clean radiator using compressed air or pressure washer. Alternator Mount/ Lift Bracket 9. Inspect radiator for bent fins, cracks and damaged seams. Repair as necessary. Fan Guard Fan Shroud Radiator Mounting Cap Screws M82130 Installation Installation is done in the reverse order of removal. • Close drain valve and fill radiator with proper coolant to top of filler neck. (See SPECIFICATIONS AND GENERAL INFORMATION section.) Flange Nut M82131 10 Installation Installation is done in the reverse order of removal. • Install fan with blade curve facing AWAY from engine. • Adjust belt tension. (See procedure in this group.) • Start engine and allow it to reach proper operating temperature. Check radiator, hoses and connections for leaks. Adjust coolant level in recovery tank. COOLING FAN Fan Blade Curve Removal 1. Remove fan guard, if equipped. Engine 2. Loosen alternator mount/lift bracket cap screws and flange nut. 3. Remove four fan shroud mounting cap screws, if equipped, and move shroud toward engine. M82132 4. Remove four cap screws, fan and spacer, if equipped. 4/7/95 10-33 Cooling System FAN/ALTERNATOR BELT Adjustment Replacement 1. Use JDG529 or JDST28 Belt Tension Gauge and a straight edge to check belt deflection between fan and alternator pulleys. 1. Remove fan guard, if equipped. 2. Loosen alternator mount/lift bracket cap screws and flange nut. 3. Replace belt. 4. Adjust belt tension. (See Adjustment procedure.) Belt Deflection Alternator Mount/ Lift Bracket M54014 Specifications: Applied Force . . . . . . . . . . .98 N (22 lb-force) Belt Deflection . . . . . . . . . . . . . . . . 10 - 15 mm . . . . . . . . . . . . . . . . . . . . . . . (0.400 - 0.600 in.) If deflection is not according to specifications: Fan Guard - Loosen alternator mounting cap screws and nut. 10 - Apply force to FRONT alternator housing only (near the belt) until tension is correct. - Tighten cap screws and nut. Fan/Alternator Belt Flange Nut 10-34 M82131 4/7/95 Fuel System FUEL FILTER ASSEMBLY - 3009 (3TNA72) IMPORTANT: Replace all copper and rubber washers. Damaged or used washers may leak. Nut (3) Nozzle Leak-Off Hose (Short) (2) * Bleed Valve Rubber Washer * Bleed Screw * 10 Nozzle Leak-Off Hose (Long) Shutoff Rubber Washer Valve To Fuel Tank Mounting Base Spring O-Ring Shutoff Lever * * Filter Element Spring O-Ring Fuel Supply Pump-to-Filter Hose Filter Cover *Copper Washers Replace. Fuel Filter-toInjection Pump Hose Retaining Ring M82133A 4/7/95 10-35 Fuel System FUEL FILTER ASSEMBLY - 3011 (3TNC78), 3014 (3TN84) AND 4019 (4TN84) IMPORTANT: Replace all copper and rubber washers. Damaged or used washers may leak. End Cap Mounting Base Shutoff Valve Spring O-RIng O-Ring Shutoff Lever Filter Element Spring Mounting Cap Screw O-Ring Filter Cover End Cap Nozzle Leak-Off Hose (Short) (2 or 3) Retaining Ring 10 Fuel Supply Pump-to-Filter Hose Fuel Filterto-Injection Pump Hose * * Injection Pump Bleed-Off Hose Nozzle Leak-Off Hose (Long) *Copper Washers Replace. Air Vent Check Valve * * 10-36 M82134A 4/7/95 Fuel System FUEL SUPPLY PUMP - 3009 (3TNA72) Removal/Installation IMPORTANT: Replace all copper washers. Damaged or used washers may leak. Copper Washer (4) Replace. Fuel Supply Pump Gasket Fuel Pump-to-Filter Hose Fuel Supply-toPump Hose Mounting Screw (2) Lock Washer (2) 10 M82135A 4/7/95 10-37 Fuel System FUEL SUPPLY PUMP - 3011 (3TNC78), 3014 (3TN84) AND 4019 (4TN84) Removal/Installation Fuel Pump-to-Filter Hose Lock Washer (2) Mounting Nut (2) Packing Fuel Supply Pump 10 Fuel Supply-to-Pump Hose M82136A 10-38 4/7/95 Electrical System GLOW PLUGS - IF EQUIPPED AIR HEATER - IF EQUIPPED Removal/Installation Removal/Installation 1. Remove air cleaner assembly. (See Intake and Exhaust System in this section.) 1. Remove air intake hose. 2. Disconnect wiring leads and remove glow plug. 2. Disconnect wiring lead. 3. Test glow plugs. (See Test procedure.) 3. Scribe a mark across heater and intake manifold to aid in installation. Installation is done in the reverse order of removal. 4. Remove four cap screws, heater and gasket. Installation is done in the reverse order of removal. Wiring Leads Air Heater Glow Plug Wiring Lead M81237 M82137 Test NOTE: Test glow plug using an ohmmeter. 10 Touch one probe of tester to glow plug terminal and the other probe to body. If resistance is not within 1.35 - 1.65 ohms, replace glow plug. Teminal Body M46296 4/7/95 10-39 Electrical System INSTRUMENT PANEL Mount Bracket (2) Mounting Screw (4) Red Warning Lamp (3) Water Temperature Spacer (4) Oil Pressure Charge Isolator (4) Instrument Panel Blue Warning Lamp Preheat Key Switch Tachometer Cable Cap (2) Optional: Oil Pressure Guage Water Temperature Gauge 10 Tachometer Timer M82138A 10-40 4/7/95 Electrical System OIL PRESSURE SWITCH Test Replacement Equipment: • Thermometer • Glass Container • Heating Unit Oil Pressure Switch • Ohmmeter Procedure: Wiring Lead M82139 COOLANT TEMPERATURE SENDER Replacement IMPORTANT: Replace copper washer. Damaged or used washer may leak. CAUTION DO NOT allow sender or thermometer to rest against the side or bottom of glass container when heating water. Either may rupture if overheated. 1. Connect lead wires from ohmmeter probes, to sender terminal and body. 2. Suspend sender and a thermometer in a container of water. 3. Heat and stir the water. Observe water temperature when continuity occurs. If continuity does not occur at 110° C (230° F), replace sender. Copper Washer Replace. Coolant Temperature Sender Thermometer Ohmmeter Probes Wiring Lead M82140 Coolant Temperature Sender 4/7/95 M82123A 10-41 10 Electrical System FUEL SHUTOFF SOLENOID Replacement NOTE: 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84) shown. 3009 (3TNA72) is similar. • Ajust. (See Operational Tests and Adjustments in this section.) Clip and Washer Wire Connector Fuel Shutoff Solenoid M82141 10 10-42 4/7/95 Miscellaneous RADIATOR MOUNT - IF EQUIPPED • Inspect isolators for cracks, wear or damage. Replace if necessary. Support Rod 3009 Left Hand Support Pillar Isolator (2) 10 Support Rod 3014 Support Rod 3011, 4019 Right Hand Support Pillar Support Bracket Engine Foot (2) 4/7/95 Side Support Plate (2) M82142A 10-43 Engine Tune-Up GENERAL TUNE-UP RECOMMENDATIONS ALTITUDE COMPENSATION GUIDELINES The following services are recommended each time a tune-up is performed: High elevations may affect engine performance. As a general rule, these guidelines will apply: • Change oil and filter. (See Operator's Manual.) • Replace fuel filter and clean sediment bowl. (See Fuel System in this section.) • Clean crankcase vent tube. (See this group.) • Check air intake system. Replace air cleaner elements. (See Operator's Manual) • Check exhaust system. (See this group.) • Check and service engine cooling system. (See this group.) • Check electrical system. (See this group.) 10 Naturally Aspirated Engines Four percent power reduction per 300 m (1000 ft) rise in elevation above sea level. Engine may have to be defueled when a substantial percentage of operating time occurs at 1500 m (5000 ft) or higher. Turbocharged Engines Three percent power reduction per 300 m (1000 ft) rise in elevation above sea level. Engine may have to be defueled when a substantial percentage of operating time occurs at 2250 m (7500 ft) or higher. • Check fuel injection system. Check engine/ injection pump timing: check and adjust speed advance, clean injection nozzles and adjust injection nozzle opening pressure. (See Fuel System in the appropriate ENGINE section.) If engine required less fuel for acceptable performance at higher elevation, contact your local authorized fuel injection pump repair station for service. • Check engine oil pressure. Adjust if necessary. (See Operational Tests and Adjustments in this section.) PRELIMINARY ENGINE TESTING • Check engine valve clearance. Adjust if necessary. (See Checks, Tests and Adjustments in the appropriate ENGINE section.) • Check engine speeds. Adjust if necessary. (See Operational Tests and Adjustments in this section.) • Check engine performance on dynamometer. (See Operational Tests and Adjustments in this section.) 10-44 Before tuning up an engine, determine whether a tune-up will restore operating efficiency. When there is doubt, the following preliminary tests will help to determine if the engine can be tuned-up. Choose from the following procedures only those necessary to restore the unit. 1. After engine has stopped for several hours, carefully loosen crankcase drain plug and watch for any water to seep out. A few drops could be due to condensation, but any more than this would indicate problems which require engine repairs rather than just a tune-up. 4/7/95 Engine Tune-Up 2. With engine stopped, inspect engine coolant for an oil film. With engine running, inspect coolant for air bubbles. (See Radiator Bubble Test in Operational Tests and Adjustments in this section.) Either condition would indicate problems which require engine repairs rather than just a tune-up. 3. Perform a dynamometer test and record power output. (See Operational Tests and Adjustments in this section.) Repeat dynamometer test after tune-up, so power output before and after tune-up can be compared. 4. Perform compression test. (See Operational Tests and Adjustments in this section.) AIR INTAKE SYSTEM Check 1. Replace air cleaner filter element(s). 2. Check condition of air intake hose(s). Replace any hose that is cracked, split, or otherwise in poor condition. 3. Check hose clamps for tightness. Replace any clamp that cannot be properly tightened. This will help prevent dust from entering the air intake system which could cause serious engine damage. EXHAUST SYSTEM CRANKCASE VENTILATION SYSTEM Check 1. Inspect crankcase ventilation system for restrictions. Lack of ventilation causes sludge to form in engine crankcase. This can lead to clogging of oil passages, filters and screens, resulting in serious engine damage. 2. Clean crankcase vent hose with solvent and compressed air if restricted. 3. 3009 (3TNA72): Remove rocker arm cover and clean crankcase ventilator. 3011 (3TNC78), 3014 (3TN84) and 4019 (4TN84): Remove and clean crankcase ventilator assembly. Check 1. Inspect exhaust system for leaks or restrictions. Check manifold for cracks. Repair or replace as necessary. COOLING SYSTEM Check and Service 1. Remove any trash that has accumulated on the radiator. 2. Visually inspect entire cooling system for leaks or damage. Repair or replace as necessary. 3. Remove and check thermostat. (See Cooling System in the appropriate ENGINE section.) Ventilator Assembly CAUTION Do not drain coolant until the coolant temperature is below operating temperature. Always loosen drain cock slowly to relieve any excess pressure. Vent Hose RG6589 4. Drain cooling system by opening drain cocks on radiator and engine block. All Except 3009 (3TNA72) Shown 4/7/95 10-45 10 Engine Tune-Up 5. Close drain cocks and fill cooling system with clean water. 6. Run engine until it reaches operating temperature (about 10 minutes) to stir up possible rust or sediment. 7. Stop engine and immediately drain the water before rust and sediment settle. 8. Close drain cocks and fill the cooling system with a good commercial radiator cleaner and water. Follow the instructions with the cleaner. 9. After cleaning the cooling system, fill with water to flush the system. Run the engine about 10 minutes, then drain out flushing water. IMPORTANT: Air must be expelled from cooling system when system is refilled. Loosen coolant temperature sender or plug in thermostat housing to allow air to escape when filling system. Retighten sender or plug when all the air has been expelled. 10.Fill cooling system with SPECIFICATIONS AND INFORMATION section.) 10 coolant. (See GENERAL 11.Run engine until it reaches operating temperature. This mixes solution uniformly and circulates it through the entire system. The normal engine coolant temperature range is 70° 80° C (160° - 180° F). FAN/ALTERNATOR BELT Inspection Check condition of fan/alternator belt and replace if cracked, frayed or excessively worn. Check belt tension and adjust as necessary. (See Cooling System in this section.) ELECTRICAL SYSTEM Check 1. Clean battery and cables with a damp cloth. If corrosion is present, remove it and wash the terminals with a solution of ammonia or baking soda in water. Then flush area with clean water. 2. Coat battery terminals and connectors with petroleum jelly mixed with baking soda to retard corrosion. 3. Test battery. If battery is not near full charge, try to find out why. 4. On low-maintenance batteries, check level of electrolyte in each cell of battery. If water is needed, use clean, mineral-free water. If water must be added to batteries more often than every 250 hours, alternator may be overcharging. NOTE: Water cannot be added to maintenance-free batteries. NOTE: Coolant level should be approximately 19 mm (3/4 in.) below bottom of radiator filler neck. 5. If battery appears to be either undercharged or overcharged, check alternator and charging circuit. 12.After running engine, check coolant level and entire cooling system for leaks. 6. Check tension of fan/alternator drive belt. (See FAN/ALTERNATOR BELT-Adjustment in Cooling System in this section.) 13.Check system for holding pressure. (See Cooling System Pressure Test in Operational Tests and Adjustments in this section.) 10-46 7. Check operation of starting motor and gauges. 4/7/95 Operational Tests and Adjustments DYNAMOMETER TEST 2. Operate engine at one-half load until coolant and crankcase oil temperatures are up to normal. NOTE: High elevations may affect engine performance. (See ALTITUDE COMPENSATION GUIDELINES in Engine Tune-up in this section.) 1. Connect engine to dynamometer manufacturer's instructions. 3. Run engine at fast idle. 4. Gradually increase load on engine until speed is reduced to rated speed rpm. using 5. Read horsepower on dynamometer. 6. Compare readings taken with power rating level for your engine application listed in the following chart. DYNAMOMETER TEST SPECIFICATIONS Engine Model Pump Option Code Injection Pump Assembly Part Number 3009DF001 1601 RG60070 STD 3000 3300 15.4 (20.7) 3009DF005 1601 RG60070 STD 3000 3300 15.4 (20.7) 3009DF007 1601 RG60132 3-5% 3600 3800 14.2 (19.0) 3011DF001 1601 RG60187 STD 3000 3300 20.2 (27.1) 3011DF005 1601 RG60187 STD 3000 3300 20.2 (27.1) 3011DF006 1601 RG60464 3-5% 1800 1900 13.0 (17.4) 3014DF001 1601 RG60269 STD 3000 3300 24.9 (33.5) 3014DF005 1601 RG60269 STD 3000 3300 24.9 (33.5) 3014DF006 1601 RG60293 3-5% 1800 1900 16.0 (21.5) 4019DF001 1601 RG60330 STD 3000 3300 33.4 (44.8) 4019DF005 1601 RG60330 STD 3000 3300 33.4 (44.8) 4019DF006 1601 RG60410 3-5% 1800 1900 22.0 (29.5) 4019TF001 1601 RG60425 STD 3000 3300 40.3 (54.0) 4019TF005 1601 RG60425 STD 3000 3300 40.3 (54.0) 4019TF006 1601 RG60459 3-5% 1800 1900 27.2 (36.5) Governor Regulation Rated Speed (rpm) Fast Idle (rpm) Power Rating* kW (BHP) *Industrial Intermittent Gross or Generator Standby Net. 4/7/95 10-47 10 Operational Tests and Adjustments RADIATOR BUBBLE TEST • If air escapes from muffler, check for worn exhaust valve. Reason: • If air escapes from air cleaner, check for worn intake valve. To determine if compression pressure is leaking from cylinder. Equipment: • JDG560 Adapter • If air escapes from engine oil fill, check for worn piston rings. COOLING SYSTEM PRESSURE TEST Reason: Procedure: Inspect cooling system for leaks. 1. With coolant at proper level and radiator cap tight, run engine for 5 minutes to bring to operating temperature. Equipment: • D05104ST Cooling System Pressure Pump 2. Remove cap from recovery tank. 3. Check for bubbles coming from overflow hose at bottom of tank. If bubbles are present, isolate source of compression leak: Procedure: 1. Remove cap and attach pressure pump to radiator. 2. Apply 97 kPa (14 psi) maximum pressure. 3. Check for leaks throughout cooling system. - Remove injection nozzles. - Install JDG560 Adapter in injection port of cylinder to be tested. 10 - Move piston to bottom of stroke with intake and exhaust valves closed. Cooling System Pressure Pump - Connect hose from compressed air source to adapter. - Apply the specified maximum air pressure into cylinder: 3009 (3TNA72) . . . . . . . . . 2455 kPa (356 psi) 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84) . . . . . . . . . . . 2158 kPa (313 psi) - Check for bubbles in recovery tank or air escaping from muffler, air cleaner or oil fill opening. - Repeat for each cylinder. Results: • If bubbles are present, check for cracks in cylinder head and block. Check for damaged head gasket. 10-48 T6333AW Specifications: Minimum Pressure after 10 seconds . . . . . . . . . . 88 kPa (12.8 psi) Results: • Pressure should hold to specifications. If pressure decreases, check for leaks. Repair leaks or replace parts as necessary. • If pressure test still indicates leakage after all external leaks have been stopped, a defective head gasket, cracked block, or cylinder head may be the cause. Perform RADIATOR BUBBLE TEST. 4/7/95 Operational Tests and Adjustments RADIATOR CAP PRESSURE TEST 3. Remove injection nozzles. (See Fuel System in the appropriate ENGINE section.) Reason: 4. Install Adapter Assembly. Test radiator cap for operating in correct pressure range. and Compression Gauge 5. Disconnect fuel shutoff solenoid connector. 6. Crank engine for five seconds with starter. Equipment: • D05104ST Cooling System Pressure Pump 7. Record pressure reading for each cylinder. JT01682 Compression Gauge Assembly Procedure: 1. Install radiator cap on pressure pump. 2. Apply pressure. Pressure valve in cap should open at 88 kPa (12.8 psi). Cooling System Pressure Pump JDG472 Adapter M82143 Radiator Cap T6333AX Results: • If cap leaks, retighten and test again. Replace cap if pressure is not within specification. 10 Specifications: Compression Pressure . . . 2455 kPa (356 psi) Maximum Difference Between Cylinders . . . . . . . . 490 kPa (71 psi) CYLINDER COMPRESSION PRESSURE TEST - 3009 (3TNA72) NOTE: Pressure listed is for 300 m (1000 ft) above sea level. Reduce specification an additional four percent for each additional 300 m (1000 ft) of altitude. Reason: Results: To determine the condition of the pistons, rings, cylinder walls and valves. Equipment: • JT01682 Compression Gauge Assembly • JDG472 Adapter Procedure: 1. Run engine for 5 minutes to bring to operating temperature. Shut off engine. • If pressure reading is below specification, squirt approximately two teaspoons of clean engine oil into cylinders through injector ports and repeat test. • If pressure increases significantly, check piston, rings and cylinder walls for wear or damage. • If pressure does not increase significantly after retest, check for leaking valves, valve seats or cylinder head gasket. 2. Remove air cleaner assembly. (See Intake and Exhaust System in this section.) 4/7/95 10-49 Operational Tests and Adjustments CYLINDER COMPRESSION PRESSURE TEST - 3011 (3TNC78), 3014 (3TN84) AND 4019 (4TN84) Specifications: Compression Pressure . . . 2158 kPa (313 psi) Maximum Difference Between Cylinders . . . . . . . . 490 kPa (71 psi) Reason: To determine the condition of the pistons, rings, cylinder walls and valves. Equipment: • JT01682 Compression Gauge Assembly • JDG560 Adapter Procedure: NOTE: Pressure listed is for 300 m (1000 ft) above sea level. For naturally aspirated engines, reduce specification an additional four percent for each additional 300 m (1000 ft) of altitude. For turbocharged engines, reduce specification an additional three percent for each additional 300 m (1000 ft) of altitude. Results: 1. Run engine for 5 minutes to bring to operating temperature. Shut off engine. 2. Remove air cleaner assembly. (See Intake and Exhaust System in this section.) • If pressure reading is below specification, squirt approximately two teaspoons of clean engine oil into cylinders through injector ports and repeat test. 3. Remove injection nozzles. (See Fuel System in the appropriate ENGINE section.) • If pressure increases significantly, check piston, rings and cylinder walls for wear or damage. 4. Remove heat protector from end of injector and install on Adapter. • If pressure does not increase significantly after retest, check for leaking valves, valve seats or cylinder head gasket. 10 5. Install Adapter and Compression Gauge Assembly in injector port. Install retaining plate and tighten nuts to 4.5 N•m (39 lb-in.) ENGINE OIL PRESSURE TEST 6. Disconnect fuel shutoff solenoid connector. 7. Crank engine for five seconds with starter. 8. Record pressure reading for each cylinder. Reason: To determine if engine bearings or lubrication system components are worn. Equipment: • JT03349 Connector • JT03017 Hose Assembly • JT05577 Pressure Gauge (100 psi) Procedure: 1. Remove oil pressure sender. 2. Install Connector. JDG560 Adapter JT01682 Compression Gauge Assembly 10-50 T6333EU 3. Connect Hose Assembly and Pressure Gauge. IMPORTANT: Do not run engine if no pressure present. 4/7/95 Operational Tests and Adjustments 4. Start engine. If pressure reading is below 69 kPa (10 psi), STOP ENGINE. AIR INTAKE SYSTEM LEAKAGE TEST 5. Run engine approximately five minutes to heat oil, then check oil pressure at low idle. Reason: Check for leaks in air intake system. Equipment: • Air Pressure Regulator Procedure: 1. Remove air cleaner restriction indicator, if equipped, and install test fitting. JT05577 Pressure Gauge JT03349 Connector 2. Connect air pressure regulator to manifold using hose and fitting from air cleaner. 3. Remove air cleaner cover and main filter element. 4. Put large plastic bag into and over end of main filter element. Install main filter element and cover. 5. Pressurize air intake system within 34 - 69 kPa (5 - 10 psi). If air intake system cannot be pressurized, turn engine slightly to close valves. JT03017 Hose Assembly M82144 Specifications: Low Idle Speed 6. Spray soap solution over all connections from air cleaner to intake manifold or turbocharger, if equipped, and check for leaks. Industrial Application All . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm Generator Application 3009 (3TNA72) . . . . . . . . . . . . . . . . 1300 rpm 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84) . . . . . . . . . . . . . . . . . . 1200 rpm Engine Oil Pressure . . . . . . . . . . 147 kPa (21 psi) Results: • If oil pressure is not within specifications, inspect oil pressure regulating valve parts for wear or damage. Add or remove shims as necessary. (See Lubrication System in the appropriate ENGINE section.) M82124 Results: • Find leaks and repair or replace parts as necessary. • If oil pressure does not increase, see “Engine Has Low Oil Pressure” in Diagnosis in the appropriate ENGINE section. 4/7/95 10-51 10 Operational Tests and Adjustments FUEL SUPPLY PUMP PRESSURE TEST FUEL DRAIN BACK TEST Reason: Reason: To determine supply pump operating pressure. Equipment: Determines if air is entering the fuel system at connections, allowing fuel to siphon back to tank. Procedure: • JT03274 Hose Fitting 1. Disconnect fuel supply line and return line at fuel tank. • JT01609 Female Quick Coupler • JT03115 Gauge w/Male Quick Coupler (0 - 150 psi) Procedure: IMPORTANT: Fuel return line MUST extend below fuel level in fuel tank before performing this test. Fill fuel tank if necessary. 2. Install Hose Fitting, Coupler and Gauge. 2. Drain all fuel from the system, including fuel supply pump, injection pump, filter(s) and water separator, if equipped. 3. Disconnect fuel shutoff solenoid connector. 3. Plug end of fuel return hose. 4. Crank engine using the starter. Do not run starter for more than 10 seconds at a time. Gauge should read more than 29 kPa (4.3 psi). 4. Pressurize fuel system, at fuel supply line, to a maximum pressure of 103 kPa (15 psi). 1. Disconnect supply pump-to-filter hose. JT03315 Gauge w/Male Quick Coupler 10 5. Apply liquid soap and water solution to all joints and connections in the fuel system and inspect for leaks. Results: JT01609 Female Quick Coupler • Find leaks and repair or replace parts as necessary. JT03274 Hose Fitting BLEED FUEL SYSTEM - 3009 (3TNA72) Reason: Any time the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system. Supply Pump-toFilter Hose Fuel Filter Procedure: M82145A Results: • If pressure is below specification, repair or replace fuel supply pump. IMPORTANT: Modification or alteration of the injection pump, pump timing, or the injection nozzles in any way not approved by the manufacturer will terminate the warranty obligation. 1. Turn fuel filter shutoff valve to “OPEN” position. 2. Loosen both air bleed screws on fuel filter base. 10-52 4/7/95 Operational Tests and Adjustments 9. When fuel appears at injectors, tighten line nuts. 10.Start engine. If engine does not start, repeat bleed procedure. Air Bleed Screws Shutoff Valve RG6594 3. Turn ignition switch to “ON” position. 4. Operate hand primer lever of fuel supply pump until fuel flows free of air bubbles. Tighten bleed screws. RG6597 BLEED FUEL SYSTEM - 3011 (3TNC78), 3014 (3TN84) AND 4019 (4TN84) IMPORTANT: Modification or alteration of the injection pump, pump timing, or the injection nozzles in any way not approved by the manufacturer will terminate the warranty obligation. RG6595 5. Loosen bleed screw on injection pump. Operate hand primer and tighten bleed screw when fuel flows free of air bubbles. 6. Start engine. If engine does not start after several attempts, proceed with steps 7 through 10. All engines are equipped with an automatic air venting system which makes the fuel system selfbleeding. • Assure that all fuel line connections are securely tightened. • Add fuel to fuel tank. • Crank engine to allow fuel system to bleed itself. SLOW IDLE SPEED ADJUSTMENT Reason: To achieve proper slow idle rpm setting. Provides adequate rpm to keep engine running smoothly without stalling. Equipment: RG6596 • JT05719 Hand-Held Digital Tachometer 7. Loosen all three injector line nuts using a 17 mm wrench. Be sure not to loosen bottom nut of injector. 8. Crank engine over with starter. 4/7/95 10-53 10 Operational Tests and Adjustments Procedure: Equipment: 1. Start engine and run for five minutes. • JT05719 Hand-Held Digital Tachometer 2. Visually check that injection pump throttle lever is against slow idle stop screw. Procedure: 3. Check engine speed at flywheel using the Digital Tachometer. NOTE: Make sure air cleaner is clean and not restricted. Clean or replace air cleaner element(s) as necessary. 1. Start engine and run for five minutes. 2. Push against injection pump throttle lever to insure it is against fast idle stop screw. Nut Idling Adjustment Screw 3. Check engine speed at flywheel using the Digital Tachometer. Screw Control Lever Sealed Wire Nut M82146A 10 Specifications: Industrial Application M55700 All . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm Specifications: Generator Application 3009 (3TNA72) . . . . . . . . . . . . . . . . 1300 rpm 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84) . . . . . . . . . . . . . . . . . . 1200 rpm Results: • If slow idle rpm is not according to specifications, loosen nut and turn screw. After adjustment, tighten nut. FAST IDLE SPEED ADJUSTMENT 3009 (3TNA72) Industrial Application . . . . . . . . . . 3300 rpm Generator Application . . . . . . . . . . 3800 rpm Results: NOTE: Some adjustment can be made without removing sealed wire. Attempt to make the adjustment before removing wire. • If fast idle rpm is not according to specifications, loosen nut and turn screw until fast idle speed is correct. After adjustment, tighten nut. • If engine still does not meet fast idle specifications, have pump inspected by a diesel injection service. Reason: To achieve proper fast idle rpm setting. Provides proper speed for PTO operation and insures that engine is running at proper rpm's for peak performance. 10-54 4/7/95 Operational Tests and Adjustments FAST IDLE SPEED ADJUSTMENT 3011 (3TNC78), 3014 (3TN84) AND 4019 (4TN84) FUEL SHUTOFF SOLENOID AMPERAGE TEST Reason: Reason: To achieve proper fast idle rpm setting. Provides proper speed for PTO operation and insures that engine is running at proper rpm's for peak performance. To test condition of fuel shutoff solenoid windings and check for fuel pump linkage binding creating excessive current draw. Equipment: • JT05719 Hand-Held Digital Tachometer Equipment: • JT05712 Current Gun Procedure: Procedure: NOTE: Make sure air cleaner is clean and not restricted. Clean or replace air cleaner element(s) as necessary. 1. Test system ground connections and battery. 1. Start engine and run for five minutes. 3. Attach current gun to white wire of fuel shutoff solenoid. 2. Push against injection pump throttle lever to insure it is against fast idle stop screw. 3. Check engine speed at flywheel using the Digital Tachometer. 2. Perform circuit tests to ensure voltage at solenoid. 4. Set current gun for DC current. 5. Turn key switch ON. Maximum pull-in amperage should be 50 amps for 1/2 second. 6. Move current gun to red wire. Maximum hold-in amperage should be 1 amp continuous. Nut Maximum Speed Adjustment Screw Fuel Shutoff Solenoid Control Lever JT05712 Current Gun M82147A Specifications: Industrial Application . . . . . . . . . . 3300 rpm Generator Application . . . . . . . . . . 1900 rpm Results: • If fast idle rpm is not according to specifications, loosen nut and turn screw until fast idle speed is correct. After adjustment, tighten nut. • If engine still does not meet fast idle specifications, have pump inspected by a diesel injection service. 4/7/95 M82148A Results: • If readings do not meet specifications, check for binding linkage and adjust as needed or replace solenoid. 10-55 10 Operational Tests and Adjustments FUEL SHUTOFF SOLENOID ADJUSTMENT STARTER AMP DRAW/RPM TEST Reason: Reason: To ensure that fuel shutoff solenoid retracts fully, moving the injection pump shutoff control lever far enough to allow full rack travel. To determine the amperage required to crank the engine and check starter motor operation under load. Equipment: • JT05685 Battery Load Tester Procedure: • JT05719 Hand-Held Digital Tachometer 1. Loosen lock nut. IMPORTANT: Turn load knob fully counterclockwise before making connections. 2. Disconnect link from solenoid. 3. Hold solenoid plunger bottomed in solenoid body. 4. Move link toward solenoid until it stops. 5. Turn plunger rod in or out of knuckle until knuckle and link holes line up. Turn out two additional turns. The additional turns insure that the solenoid bottoms out before the linkage. 6. Assemble and check for free movement when key switch is turned ON. Also check that linkage returns completely to the STOP position when key switch is turned OFF. 10 NOTE: Engine should be at normal operating temperature when performing this test for an accurate amperage reading. Procedure: 1. Turn load knob fully counterclockwise. 2. Connect Battery Load Tester to battery. 3. Disconnect fuel shutoff solenoid connector. 4. Check system ground connections. Be sure battery is fully charged. 5. Crank engine. Read and record voltage at meter. Plunger 6. Use Tachometer to read and record cranking rpm. Link 7. Turn key switch to OFF position. Adjust load knob until battery voltage is the same as when engine is cranking. 8. Read amperage on meter. Lock Nut Knuckle M82141 Specifications: 3009 (3TNA72) . . . . . . 200 Amps at 300 rpm 3011 (3TNC78) and 3014 (3TN84) . . . . . . . . 230 Amps at 300 rpm 4019 (4TN84) . . . . . . . 350 Amps at 1100 rpm 9. Turn load knob fully counterclockwise. Results: • If amp reading is not to specification, or to specification but rpm is low, perform STARTER NO-LOAD AMP DRAW/RPM TEST. 10-56 4/7/95 Operational Tests and Adjustments STARTER NO-LOAD AMP DRAW/RPM TEST 4. Connect negative (-) cable to starter body. Attach Current Gun to positive (+) cable. Reason: IMPORTANT: Complete this test in 20 seconds or less to prevent starter damage. To determine condition of starter. 5. Use a jumper wire to briefly connect positive (+) starter terminal to solenoid. Equipment: 6. Measure starter amperage and rpm. • JT05712 Current Gun Specifications: • JT05719 Hand-Held Digital Tachometer 3009 (3TNA72) . . . . . . 60 Amps at 7000 rpm 3011 (3TNC78) and 3014 (3TN84) . . . . . . . . 90 Amps at 3000 rpm 4019 (4TN84) . . . . . . . . 90 Amps at 3500 rpm Procedure: 1. Remove starter from engine. NOTE: Check that battery is fully charged and of proper size to ensure accuracy of test. 2. Connect jumper cables to battery. Results: • If starter amps or rpm are not to specification, repair or replace starter. 3. Connect positive (+) cable to positive (battery) terminal on starter. JT05719 Hand-Held Digital Tachometer 10 JT05712 Current Gun Jumper Wire 3009 and 4019 4/7/95 M82149A 10-57 Operational Tests and Adjustments JT05712 Current Gun JT05719 Hand-Held Digital Tachometer Jumper Wire M82150A 3011 and 3014 10 STARTER SOLENOID TEST 5. Connect jumper wire between terminals. • Starter runs: Replace solenoid. Reason: To determine if starter solenoid or starter motor is defective. • Starter does not run: Check battery cables then replace starter. Equipment: • Jumper Wire Large Terminals Procedure: 1. Disconnect fuel shutoff solenoid connector. Starter Solenoid Terminal 2. Disconnect single wire connector from starter solenoid. 3. Connect jumper wire to positive (+) battery terminal and briefly jump to starter solenoid terminal. Connector M82151 3011 and 4019 Shown • Starter runs: Solenoid is good. • Starter does not run: Go to step 4. 4. Remove rubber boots from starter solenoid large terminals. REGULATED AMPERAGE TEST Reason: To determine regulated charging output of the alternator. 10-58 4/7/95 Operational Tests and Adjustments Fast Idle Speed Specifications: Equipment: • JT05712 Current Gun Industrial Application • JT05685 Battery Load Tester All . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm Generator Application Procedure: 1. Turn load knob of Battery Tester fully out (counterclockwise) before connecting to battery. 2. Connect Battery Tester to battery. 3. Attach Current Gun to alternator red wire. Set Current Gun for DC current. IMPORTANT: Perform this test quickly to prevent damage to battery tester. DO NOT apply full load to battery for more than 10 seconds. 4. Start and run engine at fast idle (full throttle). 3009 (3TNA72) . . . . . . . . . . . . . . . . 3800 rpm 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84) . . . . . . . . . . . . . . . . . . 1900 rpm 5. Turn load knob in until voltage read on the tester voltage scale is 11 volts and read amperage on Current Gun. Minimum regulated amperage should be 35 amps. Results: • If reading is less than specifications, verify voltage at the alternator regulator terminal and good alternator ground. If voltage and ground are OK, perform UNREGULATED AMPERAGE TEST to determine if alternator or voltage regulator is defective. 10 JT05685 Battery Load Tester JT05712 Current Gun M82152A 4/7/95 10-59 Operational Tests and Adjustments UNREGULATED AMPERAGE TEST Reason: To determine charging output of the alternator stator. • If reading is less than specifications, verify voltage at the alternator regulator terminal and good alternator ground. If voltage and ground are OK, replace the alternator. • If reading meets the specification, replace the regulator. Equipment: • JT05712 Current Gun REGULATED VOLTAGE TEST Procedure: 1. Attach Current Gun to alternator red wire. Set Current Gun for DC current. IMPORTANT: Perform this test quickly to prevent damage to battery. DO NOT apply full load to battery for more than 10 seconds. 2. Start and run engine at fast idle (full throttle). Reason: To determine regulated voltage output of the alternator regulator. Equipment: • Voltmeter Fast Idle Speed Specifications: Procedure: Industrial Application 1. Remove surface charge from battery by placing a small load on the battery for 15 seconds. All . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm Generator Application 10 Results: 3009 (3TNA72) . . . . . . . . . . . . . . . . 3800 rpm 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84) . . . . . . . . . . . . . . . . . . 1900 rpm 3. Insert a Phillips screwdriver through hole in rear cover of alternator, to ground the regulator to the rear cover. Read amperage on current gun. Minimum regulated amperage should be 35 amps. JT05712 Current Gun 2. Set voltmeter to DC volts scale. 3. Connect meter red lead to positive (+) battery terminal. 4. Connect meter black lead to negative (-) battery terminal. 5. Start and run engine at fast idle (full throttle). Fast Idle Speed Specifications: Industrial Application All . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm Generator Application 3009 (3TNA72) . . . . . . . . . . . . . . . . 3800 rpm 3011 (3TNC78), 3014 (3TN84), 4019 (4TN84) . . . . . . . . . . . . . . . . . . 1900 rpm 6. Read meter several times during five minutes of running time. Regulated voltage should be within 12.2 - 14.7 VDC. Hole M82153A 10-60 IMPORTANT: Do not allow the battery voltage to exceed 15.5 volts or the battery and charging system will be damaged. 4/7/95 Operational Tests and Adjustments Results: • If the DC voltage stays below the minimum specification, verify voltage at the alternator regulator terminal and good alternator ground. If voltage and ground are OK, perform UNREGULATED AMPERAGE TEST to determine if alternator or voltage regulator is defective. • If the DC voltage goes above the maximum specification, replace the regulator. 10 4/7/95 10-61 Dealer Fabricated Tools DFRG1 EXTENDED INDICATOR TIP (RHB3) Ø3 mm (0.1181 in.) R10 mm (0.3937 in.) R5 mm (0.1968 in.) 6 mm (0.236 in.) M 2.6 P 0.45 1 mm (0.0393 in.) 8 mm (0.3149 in.) 10 mm 20 mm (0.3937 in.) (0.787 in.) 30 mm (1.180 in.) M82177A Extended indicator tip is used to check radial play of turbocharger rotor shaft. Attach extended tip to a dial indicator gauge. Material required: Extended indicator tip from a local supplier. Approximately 0.118 in. dia. x 3 in. long. Heat and bend to size shown. 10 10-62 4/7/95 Dealer Fabricated Tools DFRG2 EXTENDED INDICATOR TIP (RHB5) Ø5 mm (0.1968 in.) R10 mm (0.3937 in.) R5 mm (0.1968 in.) 7 mm (0.2755 in.) M 2.6 P 0.45 1 mm (0.0393 in.) 8 mm (0.3149 in.) 10 mm 15 mm (0.3937 in.) (0.5905 in.) 40 mm (1.5748 in.) M82177A Extended indicator tip is used to check radial play of turbocharger rotor shaft. Attach extended tip to a dial indicator gauge. 4/7/95 Material required: Extended indicator tip from a local supplier. Approximately 0.197 in. dia. x 3 in. long. Heat and bend to size shown. 10 10-63 Dealer Fabricated Tools 10 10-64 4/7/95 ENGINE, AIR INTAKE AND FUEL SYSTEM Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4 20 Section 20 20 Component Location INTRODUCTION This section provides an overview of the compact three and four cylinder in-line diesel engines used in John Deere Grounds Care and Industrial products. These compact engines are also available as OEM stand-alone power packs. The TN Series diesel engines are offered as base engines only and are mainly used in tractor applications. The Series 220 diesel engines are offered as OEM units with three different configurations available. A base industrial engine, an industrial power unit, and a generator drive unit. Features on the power units include an air cleaner kit, muffler, radiator kit and instrument panel. While most parts in the TN Series Engines are identical and interchangeable with Series 220 Engines, specifications are not always the same. General appearance, repair procedures, and operation of sub-systems are similar and often even identical. There are two “types” of engines; Indirect Injection 3TN66 and 3TNA72 (3009) and Direct Injection All except 3TN66 and 3TNA72 (3009). The following is a complete engine listing with the approximate horsepower ratings: NOTE: The TN Series horsepower ratings are averages as a result of the numerous tractor applications for each engine. NOTE: The Series 220 engines are NOT repower engines for tractor application. TN Series Engines Model Number kW (hp) Rating 3TN6611.9 (16) SAE Net @ 3200 rpm 3TNA7216.4 (22) SAE Net @ 3600 rpm 3TN7517.9 (24) SAE Net @ 3200 rpm 3TN7817 (23) SAE Net @ 2500 rpm 3TN8221.4 (28.7) SAE Net @ 2800 rpm 3TNA8217.2 (24) SAE Net @ 2600 rpm 3TN8420.9 (28) SAE Net @ 2600 rpm 4TN78T29 (39) SAE Net @ 2650 rpm 4TN8228.9 (38.8) SAE Net @ 2800 rpm 4TN8428.7 (38.5) SAE Net @ 2600 rpm 4TN10041 (55) SAE Net @ 2200 rpm 20 Series 220 Engines (OEM) Model (Engine) Intermittent Gross Power, kW (hp) @ 3000 rpm 3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4 (20.7) 3011 (3TNC78). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2 (27.1) 3014 (3TN84) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.9 (33.5) 4019D (4TN84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.4 (44.8) 4019T (4TN84T). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.3 (54) 4/7/95 20-1 Component Location 20 INDIRECT INJECTION (IDI) ENGINE COMPONENTS M82000A 20-2 4/7/95 Component Location 20 DIRECT INJECTION (DI) ENGINE COMPONENTS M82001A 4/7/95 20-3 Theory of Operation ENGINE BALANCER OPERATION 4TN82 and 4TN84 Function: To minimize engine vibrations resulting from unbalanced movements. NOTE: TN Series 4TN82 and 4TN84 engines are fitted with balancer shafts, because the engines are used as rigid-mount, structural members. Series 220 OEM 4019D (4TN84) and 4019T (4TN84T) engines are “loose” engines and do not have balancer shafts. These engines may be “soft” mounted if vibration is a concern. Theory of Operation: In-line 4 cylinder engines with crankshaft throws 180° apart have some unbalanced forces of the reciprocating parts. Most of these forces are offset by parts moving in opposite directions. However, the forces are not entirely cancelled. During each 45° segment of crankshaft rotation, the No. 1 piston and connecting rod moves a different distance than the No. 2 piston and connecting rod. Since the crankshaft throws move at equal speed, the parts moving farther must also move faster. As engine speeds increase and/or parts get heavier, vibrations resulting from the unbalanced movements may become objectionable. To minimize these vibrations the engines have a balancer assembly mounted to the block, below the crankshaft. It is driven by a gear on the crankshaft. The balancer has two shafts, counter-rotating, with balancing weights, turning at double crankshaft RPM. The balancer weights are timed to the crankshaft so that when No. 1 piston travels downward from TDC to horizontal crankshaft position, the balancer weights both move upward. The weights are then positioned so they can move downward as the No. 2 piston moves up from horizontal crankshaft position to TDC. 20 20-4 4/7/95 4/7/95 BDC TDC 1 2 45° 36MM 90° 3 50MM 70MM 4 135° ENGINE BALANCER OPERATION - 4TN82 and 4TN84 9MM 16MM 77MM 5 86MM Theory of Operation 20 1 CYL 2 CYL M82002A 20-5 Theory of Operation COOLING SYSTEM OPERATION Function: The coolant pump circulates coolant through the cooling system, drawing hot coolant from the engine block, circulating it through the radiator for cooling. Theory of Operation: The pressurized cooling system includes the radiator, water pump, fan and thermostat. During the warm-up period, the thermostat remains closed and coolant is directed through a by-pass tube to the suction side of the coolant pump. The coolant then circulates through the cylinder block providing a fast warm-up period. Once the engine has reached operating temperature, the thermostat opens and coolant is pumped from the bottom of the radiator via the lower radiator hose into the cylinder block. Here it circulates through the block and around the cylinders. From the block, coolant is then directed through the cylinder head, and into thermostat housing. With the thermostat open, 82° C (180° F), warm engine coolant passes through the housing into the top of the radiator where it is circulated to dissipate heat. When coolant system pressure exceeds 48 kPa (7 psi), a valve in the radiator cap opens to allow coolant to discharge into the coolant recovery tank. When temperature is reduced, a vacuum is produced in the radiator and coolant is drawn back out of the coolant recovery tank through a valve in the radiator cap. 3TN84UJ, 4TN78T, 4TN84T (4019T) and 4TN100 are equipped with an oil cooler. The oil cooler is used to help reduce the temperature of engine oil. Pressurized oil enters the oil cooler and passes through a network of tubing surrounded by engine coolant. Heat transfers from the oil to the coolant, thus reducing oil temperature. A coolant temperature sender senses critical coolant temperature and sends a signal to an indicator light and/or gauge in the instrument panel. 20 20-6 4/7/95 Theory of Operation Thermostat Cylinder Head Coolant Recovery Tank By-Pass Tube Cylinder Block Radiator Coolant Pump Oil Cooler COOLING SYSTEM OPERATION M82003A 20 4/7/95 20-7 Theory of Operation CRANKCASE BREATHER OPERATION - 3TN66, 3TNA72 (3009) and 4TN100 Oil Filler Cap Valve Cover Nut Breather Pipe Joint Fitting Breather Tube Valve Cover Baffle Gasket Baffle Breather Deflector 20 Valve Cover Gasket CRANKCASE BREATHER OPERATION - 3TN66, 3TNA72 (3009) and 4TN100 M82004A Function: Theory of Operation: Vents crankcase fuel and water vapor out of engine without losing engine oil, controls the pressurization of the crankcase. During normal engine operation, unburned fuel vapors and water vapors, tend to contaminate the crankcase. Most of these vapors are expelled by the exchange of air which is controlled by the breather. The crankcase is slightly pressurized by the leakage of compression around the pistons. The air is circulated by the movement of the pistons. 20-8 4/7/95 Theory of Operation CRANKCASE BREATHER OPERATION - ALL EXCEPT 3TN66, 3TNA72 (3009) and 4TN100 Oil Filler Cap Cap Valve Cover Nut Plate O-Ring Deflector Breather Tube Valve Cover 20 Valve Cover O-Ring CRANKCASE BREATHER OPERATION - ALL EXCEPT 3TN66, 3TNA72 (3009) and 4TN100 M82005A Function: Theory of Operation: Vents crankcase fuel and water vapor out of engine without losing engine oil, controls the pressurization of the crankcase. During normal engine operation, unburned fuel vapors and water vapors tend to contaminate the crankcase. Most of these vapors are expelled by the exchange of air which is controlled by the breather. The crankcase is slightly pressurized by the leakage of compression around the pistons. The air is circulated by the movement of the pistons. 4/7/95 20-9 Theory of Operation AIR CLEANER OPERATION - 3009 (3TNA72) Rain Cap Collar Air Cleaner Housing Seal Washer Element Metal Shield Unloader Valve AIR CLEANER OPERATION - 3009 (3TNA72) M82006AE Function: 20 Air cleaner filters air needed for combustion. Theory of Operation: Air enters the air cleaner inlet and is directed into the side of a metal shield. This starts a high-speed centrifugal motion of air which continues around the element until it reaches the far end of the air cleaner housing, to an unloader valve. 20-10 Most of the dust is separated from the air by centrifugal force that causes heavy dust particles to enter the opening at the top of the unloader valve. The remaining air enters the element. The dirt that is deposited in the unloader valve is removed by the rubber diaphragm at the base of unloader valve. When the engine is running, a pulsing action is created in the intake system by each intake stroke of engine. This pulsing action causes the rubber diaphragm to open and close, thus emptying the unloader valve. 4/7/95 Theory of Operation AIR CLEANER OPERATION - 3011 (3TNC78), 3014 (3TN84), 4019D (4TN84) and 4019T (4TN84T) Primary Element Fins Rain Cap Secondary Safety Element Seal Washer To Intake Manifold Dust Pan Assembly Air Cleaner Housing Baffle AIR CLEANER OPERATION - 3011 (3TNC78), 3014 (3TN84), 4019D (4TN84) AND 4019T (4TN84T) M82007AE Function: Air cleaner filters air needed for combustion. Theory of Operation: Air enters the air cleaner inlet and is forced into a high-speed centrifugal motion by fins on the primary element. When the air reaches the end of the air cleaner housing, the dirt passes through a slot in top of the dust pan assembly. 4/7/95 Most of the dust is separated from the air by centrifugal force that causes the heavy dust particles to enter the opening at the top of the dust pan assembly. The remaining air enters the primary element, then secondary safety element to cylinder head. Remove the baffle to empty dust pan assembly. Dust pan should be emptied daily. 20-11 20 Theory of Operation TURBOCHARGER OPERATION 4TN78T, 4TN84T (4019T) and 4TN100 Engine oil under pressure from the engine lubrication system is pumped through passages in the bearing housing and directed to the bearings. Function: The turbocharger contains two floating bearings that have clearance between the bearing O.D. and housing wall as well as a clearance between the bearing I.D. and the shaft O.D. To force more air into the engine cylinders to allow the engine to efficiently burn more fuel, thereby producing more power. Theory of Operation: The turbocharger provides additional air to burn more fuel and produce more power without increasing the size of the engine. In the thinner air of high altitudes, the turbocharger turbine wheel may turn as fast as 186,000 rpm to maintain power. Exhaust gases from the engine pass through a turbine housing, causing a shaft to rotate before the exhaust gas is discharged. A compressor wheel, also mounted on the shaft, rotates in the compressor housing. Inlet air is drawn into the housing, where it is compressed and delivered to engine cylinders. These clearances are lubricated by the oil supply and the bearings are protected by a cushion of oil. The pressure-free oil drains by gravity from the center housing to the engine crankcase. The turbocharger may be equipped with a waste gate. If the turbocharger goes above specified pressure, a diaphragm sensing inlet pressure from the compressor, opens a waste gate valve to allow excess exhaust gases to bypass the turbine. The waste gate valve limits boost pressure at high rpm to prevent damage to the engine. 20 20-12 4/7/95 Theory of Operation Shaft Turbine Housing Oil Inlet To Muffler From Air Cleaner Compressor Wheel Oil Outlet Floating Bearings Turbine Wheel From Exhaust Manifold To Intake Manifold Compressor Housing Center Housing TURBOCHARGER OPERATION - 4TN78T, 4TN84T (4019T) AND 4TN100 M82008A From Air Cleaner Compressor Turbine Turbocharger 20 Diaphram Intake Manifold Waste Gate Valve To Muffler Exhaust Manifold Cylinder M82019A 4/7/95 20-13 Theory of Operation LUBRICATION SYSTEM OPERATION Lube oil holes in main bearing oil grooves are provided to direct oil to the camshaft bearings. Function: A drilled passage from the rear camshaft bearing through the cylinder block and cylinder head supplies lubricating oil to the rocker arm shaft. The hollow shaft distributes oil to the rocker arms, tappets and valves. A full pressure system lubricates engine parts with clean oil. NOTE: Safety valve and oil cooler are on 3TN84UJ, 4TN78T, 4TN84T (4019T) and 4TN100 engines only. Piston cooling nozzles are on 4TN78T, 4TN84T (4019T) and 4TN100 engines only. Theory of Operation: The pressure lubrication system consists of a positive displacement gear-driven pump, oil strainer, full flow oil filter, oil pressure regulating valve and an electrical pressure warning switch. Some models are also equipped with an oil cooler, safety valve and piston cooling nozzles. The pump draws lubrication oil from the oil pan through a strainer and a suction tube. The oil is then pumped through an oil passage to the oil filter, oil cooler, if equipped, and through the engine block main oil galley. 20 Oil passages direct from the main oil galley, through external oil lines, route lubricating oil to the fuel injection pump and turbocharger, if equipped. An oil pressure switch activates an indicator light to alert the operator to shut down the engine if oil pressure drops below a specification. A safety valve (by-pass) (3TN84UJ, 4TN78T, 4TN84T (4019T), 4TN100 only) is located in the oil pump housing. Should the difference between the pressure in the main oil galley and oil pump become excessive, this valve would open and let oil bypass the filter and oil cooler to reach the main galley faster. This valve has a permanent setting which cannot be changed. From the main oil galley, oil is forwarded under pressure to the crankshaft main bearing journals, idler gear shaft and piston cooling nozzles, if equipped. Drilled cross-passages in the crankshaft distribute the oil from the main bearings to connecting rod bearings. 20-14 4/7/95 4/7/95 Safety Valve Oil Strainer Oil Pump Crank Pin Valve Rocker Arm Shaft Idler Gear Face Valve Oil Pressure Regulating Valve Fuel Injection Pump Oil Pan Piston Turbocharger Piston Cooling Nozzle LUBRICATION SYSTEM OPERATION Tappet Valve Rocker Arm Crank Journal Camshaft Bearing Engine Block Main Oil Galley Oil Cooler Idler Gear Shaft Oil Filter By-Pass Valve By-Pass Valve Theory of Operation 20 M82009A 20-15 Theory of Operation OIL FILTER OPERATION By-Pass Valve OIL FILTER OPERATION M53983 Function: 20 Filters contaminates from the oil between oil/filter changes. Theory of Operation: The oil filter is equipped with a bypass valve to ensure adequate engine lubrication if the filter is clogged or oil viscosity is too heavy to properly flow through the filter. Bypass valve opens at 96 kPa (14 psi) pressure differential. Pressurized oil is directed from the oil pump to the oil filter. Oil flows through the filter element to the main oil galley and to the engine components. 20-16 4/7/95 Theory of Operation OIL PRESSURE REGULATING VALVE OPERATION Engine Filtered Oil-to-Main Oil Galley Poppet Spring Filtered Oil-to-Crankcase Filter Mounting Base OIL PRESSURE REGULATING VALVE OPERATION M53993 Function: Regulates engine oil pressure. Theory of Operation: The oil pressure regulating valve is located in the oil filter mounting base stud. Filtered oil passes through the pressure regulating valve to the main oil galley. The oil pressure regulating valve is set to maintain a pressure of 294 - 440 kPa (43 - 64 psi). NOTE: All pressure regulating valves operate the same. The most common mounting location is shown. 4TN100 valve is located in the oil cooler housing and 4TN78T and 4TN84T (4019T) valve is located in oil filter and cooler mounting bracket. If oil pressure is higher than the valve is set for, a poppet spring is overcome, opening the relief valve. When opened, a passage is opened to route oil back to the crankcase. 4/7/95 20-17 20 Theory of Operation OIL COOLER OPERATION - 3TN84UJ, 4TN78T, 4TN84T (4019T) AND 4TN100 NOTE: 4TN78T and 4TN84T (4019T) is shown. Oil cooler assembly on 3TN84UJ and 4TN100 engines is different in shape, but operation is the same. Function: The oil cooler helps reduce the temperature of engine oil. Theory of Operation: After passing through the oil filter, pressurized oil enters the oil cooler and passes through a network of tubing surrounded by engine coolant. Prior to entering the oil cooler, the engine coolant passes through the radiator, which transfers much of the coolant's heat into the surrounding air. The coolant, its temperature now reduced, enters the oil cooler and passes over the warmer tubing. Heat transfers from the oil to the coolant, thus reducing oil temperature. Oil then flows into the engine block main oil galley through the filter bracket. The oil cooler keeps the maximum oil temperature below 115° C (175° F). The oil filter bracket on 4TN78T and 4TN84T (4019T) (cooler housing on 4TN100), contains a bypass valve for the oil cooler. If the oil cooler would become plugged, pressure would build to exceed the spring force, opening the valve and directing oil to the engine block, by-passing the oil cooler. The oil filter bracket also contains an oil pressure regulating valve. See OIL PRESSURE REGULATING VALVE OPERATION. 20 20-18 4/7/95 Theory of Operation Oil Pressure Regulating Valve Oil Cooler By-Pass Valve To Main Oil Galley Oil Cooler To Crankcase From Oil Pump Oil Filter Bracket Oil Filter Oil Filter Bracket Oil Cooler 20 Oil Filter OIL COOLER OPERATION - 3TN84UJ, 4TN78T, 4TN84T (4019T) AND 4TN100 M82010AE 4/7/95 20-19 Theory of Operation PISTON COOLING NOZZLE OPERATION - 4TN78T, 4TN84T (4019T) and 4TN100 Function: Cooling nozzles direct lube oil to underside of pistons to lower piston temperature and thermal load. Cooling the pistons also reduces thermal expansion and carbon deposits in the piston ring grooves. Theory of Operation: Lube oil from the engine block main oil galley passes a check valve in the nozzle mounting bolt, then flows through a small steel pipe creating a jet spray. This jet spray coats the underside of the piston, cooling the piston as a whole. The check valve's opening pressure is factory set at 148 - 245 kPa (21.5 - 35.5 psi). The oil spray amount is 21.3 L/min (5.6 gal/min) at an oil pressure of 343 kPa (50 psi). 20 20-20 4/7/95 Theory of Operation Piston Jet Spray Engine Block Main Oil Galley Check Valve Nozzle Mounting Bolt Piston Cooling Nozzle PISTON COOLING NOZZLE OPERATION - 4TN78T, 4TN84T (4019T) AND 4TN100 M82011A 4/7/95 20-21 20 Theory of Operation FUEL SYSTEM OPERATION NOTE: On 3TNA72 (3009) IDI engine, fuel supply pump is part of the engine (attached to fuel injection pump) for OEM application only. On 3TN82, 3TN78, 4TN78T and some 4TN82 DI engines, the fuel supply pump is separate from the engine. Function: Fuel system supplies fuel to injection nozzles. Theory of Operation: Fuel supply pump draws fuel from a vented fuel tank through a water separator and directs fuel through a fuel filter to the fuel gallery of an injection pump. The injection pump meters fuel as determined by the governor and delivers it at high pressure to the injection nozzles. The injection nozzle prevents flow until high pressure is reached, opening the valve and spraying atomized fuel into the combustion chamber. Injection lines have trapped fuel whenever injection is not taking place. 3TN66 and 3TNA72 (3009) (IDI engine): A small amount of fuel leaks past the nozzle valve to lubricate the fuel injection nozzle. This leakage is then returned to the fuel tank. All except 3TN66 and 3TNA72 (3009) (DI engine): A small amount of fuel leaks past the nozzle valve to lubricate the fuel injection nozzle. This leakage combines with excess fuel from the injection pump and is returned to tank. Any air in the fuel system is bled out with return fuel to the fuel tank. 20 20-22 4/7/95 4/7/95 Water Separator Water Separator Fuel Filter Fuel Injection Pump Fuel Supply Pump Fuel Injection Nozzles Engine Air Vent DI Engine - All Except 3TN66 and 3TNA72 (3009) Local Procurement Fuel Tank FUEL SYSTEM OPERATION Fuel Injection Pump Fuel Injection Nozzles Engine Fuel Filter Fuel Supply Pump IDI Engine - 3TN66 and 3TNA72 (3009) Local Procurement Return Fuel Fuel Tank Return Fuel Theory of Operation 20 M82012A 20-23 Theory of Operation FUEL INJECTION PUMP OPERATION Function: Injection pump regulates fuel flow from fuel supply pump to injectors. Theory of Operation: Bottom of Plunger Stroke: When the plunger is in the downward position, filtered medium pressure fuel from the fuel supply pump flows through the fuel inlet fitting, to the fuel gallery. Fuel flows from the fuel gallery through the inlet orifice and fills the plunger area. Whenever the plunger is in the downward position, the delivery valve is held closed against the valve seat, by spring pressure and trapped fuel pressure. In this position, fuel flow to the fuel injection line and nozzle is blocked. The fuel injection pump is a variable-displacement, in-line plunger-type pump. It is located on the right side of the engine. The pump is driven by a camshaft which turns at one-half engine speed. 20 20-24 4/7/95 Theory of Operation Fuel Injection Line Fuel Inlet Fitting Spring Delivery Valve Valve Seat Fuel Gallery Inlet Orifice Barrel Plunger Control Sleeve Control Rack Roller Tappet Camshaft Medium Pressure Fuel 20 Trapped Fuel FUEL INJECTION PUMP OPERATION (BOTTOM OF PLUNGER STROKE) M82013AE 4/7/95 20-25 Theory of Operation Theory of Operation - Continued: Top of Plunger Stroke: When the roller tappet is moved up by the camshaft, the inlet orifice is blocked by the plunger. Fuel in the plunger area is compressed and forced against the delivery valve. When fuel pressure is high enough to overcome the spring, the delivery valve is lifted upward off the valve seat. High pressure fuel flows past the delivery valve to the fuel injection line and then to the fuel injection nozzle. The delivery valve is held open only when the fuel pressure in the plunger area is greater than the delivery valve spring pressure. As the plunger continues moving upward, the plunger helix aligns with the inlet orifice. The pressure in the plunger area is higher than the pressure in the fuel gallery. This causes fuel to flow from the plunger area, through the plunger helix and inlet orifice to the fuel gallery. Fuel flow through the inlet orifice causes pressure in the plunger area to decrease. With pressure equal on both sides of the delivery valve, spring force closes the delivery valve and stops the fuel flow to injection nozzle. A governor-operated control rack is connected to the control sleeve and plunger to regulate the quantity of fuel delivery to the nozzles. The control sleeve turns the plunger and increases or decreases the amount of plunger movement before the plunger helix and inlet orifice are aligned. 20 20-26 4/7/95 Theory of Operation Fuel Injection Line Fuel Inlet Fitting Spring Delivery Valve Valve Seat Fuel Gallery Inlet Orifice Plunger Helix Barrel Plunger Control Sleeve Control Rack Roller Tappet Camshaft High Pressure Fuel 20 Medium Presure Fuel FUEL INJECTION PUMP OPERATION (TOP OF PLUNGER STROKE) M82014AE 4/7/95 20-27 Theory of Operation GOVERNOR OPERATION Function: Governor maintains a set engine speed under varying loads. Theory of Operation: The injection pump governor is a mechanical centrifugal flyweight type. On 3TN66 and 3TNA72 (3009) (IDI) engines, it is contained in a housing mounted to the timing gear case and is serviced separately from the injection pump. On all except 3TN66 and 3TNA72 (3009) (DI) engines, the governor is assembled to the injection pump and serviced with the pump. Governor internal components and operation are similar. The flyweights are mounted on the injection pump camshaft. The flyweights move the thrust sleeve in and out with changes in engine RPM. The thrust sleeve works against a button on the governor lever. The governor lever is connected to the injection pump control rack by the fuel control link. The governor spring connects the tension lever assembly to the throttle lever. NOTE: Due to the variety and number of tractor applications, information on all horsepower ratings for TN Series engines are not available. Refer to individual machine Technical manual for proper horsepower ratings. Series 220 Engines (OEM) Model 20 NET Power kW (hp) @Rated rpm 3009DF001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous . . . . . . . . . . . . . 3009DF005. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent . . . . . . . . . . . . . 3009DF007. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . 3011DF001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous . . . . . . . . . . . . . 3011DF005. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent . . . . . . . . . . . . . 3011DF006. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . 3014DF001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous . . . . . . . . . . . . . 3014DF005. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent . . . . . . . . . . . . . 3014DF006. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . 4019DF001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous . . . . . . . . . . . . . 4019DF005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent . . . . . . . . . . . . . 4019DF006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . 4019TF001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous . . . . . . . . . . . . . 4019TF005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent . . . . . . . . . . . . . 4019TF006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . 20-28 12.8 (17.1) @ 3000 14.2 (19.0) @ 3000 14.2 (19.0) @ 3600 16.9 (22.7) @ 3000 18.8 (25.2) @ 3000 10.2 (13.7) @ 1800 21.3 (28.6) @ 3000 23.5 (31.5) @ 3000 12.9 (17.3) @ 1800 28.1 (37.7) @ 3000 30.9 (41.4) @ 3000 18.7 (25.0) @ 1800 34.4 (46.1) @ 3000 37.8 (50.7) @ 3000 24.6 (33.0) @ 1800 4/7/95 Theory of Operation High Idle Stop Torque Spring Capsule Throttle Shaft Governor Spring Fuel Control Lever Tension Lever Throttle Lever Fuel Control Link Control Rack Low Idle Stop Governor Lever Assembly Thrust Sleeve Enrichment Spring 20 Flyweights GOVERNOR OPERATION M54070 4/7/95 20-29 Theory of Operation Theory of Operation - Continued: Starting: When the key switch is turned to “ON”, a fuel solenoid pulls the shutoff lever to the “RUN” position. This permits the governor spring to move the tension lever, pulling the control rack left. The enrichment spring extends, pulling the rack an additional amount to give starting fuel delivery. After the engine starts as speed increases, centrifugal force moves the flyweights outward forcing the thrust sleeve against the button on the governor lever. The enrichment spring compresses and remains compressed while the engine is running. The forces generated by the flyweights against the governor lever overcome governor spring tension, pushing the rack to the right. This reduces fuel delivery to an amount that will maintain the RPM established by the speed control lever setting. When the key is turned “OFF”, the fuel control solenoid is de-energized. The spring on the shutoff lever rotates the shaft so the high spot moves the governor lever to the right, pushing the rack to a “NO” fuel position, stopping the engine. 20 20-30 4/7/95 Theory of Operation Governor Spring Tension Lever Starting Fuel Delivery Max. Fuel Min. Fuel Shutoff Lever Governor Lever Enrichment Spring 20 GOVERNOR OPERATION - STARTING M48495 4/7/95 20-31 Theory of Operation Theory of Operation - Continued: High Idle, Maximum Torque: When a load is applied, decreasing engine speed, the flyweight force is reduced against the governor lever. The spring can then pull the lever assembly and the rack to increase fuel delivery and bring RPM back up to preset speed. Additional load would further reduce the flyweight force permitting the governor spring to pull tension lever against the torque spring, compressing it and moving the rack to the maximum torque fuel delivery. A high idle adjusting screw and low idle screw, provide stops for the speed control lever. 20 20-32 4/7/95 Theory of Operation High Idle Screw Governor Spring Torque Spring Max. Fuel Min. Fuel Low Idle Screw Governor Lever 20 GOVERNOR OPERATION - HIGH IDLE, MAXIMUM TORQUE M48496 4/7/95 20-33 Theory of Operation INDIRECT INJECTION NOZZLE OPERATION (PINTLE TYPE) 3TN66 and 3TNA72 (3009) Function: Injection nozzle injects fuel in an atomized form into a precombustion chamber. Theory of Operation: The pintle type nozzle is used on indirect injection engines 3TN66 and 3TNA72 (3009). It is different from the hole-type nozzle in that it is threaded into the cylinder head. High pressure fuel from the pump flows through an inlet passage to the pintle valve. When pressure against the valve increases above spring tension, the valve is lifted off its seat, permitting fuel to be forced through a nozzle body orifice in an atomized form into the precombustion chamber. A small amount of fuel leaks past the pintle valve to lubricate valve and body, then flows through a return passage to return lines and tank. The pintle valve is shim adjustable to regulate the opening pressure. The fuel injection nozzle has an inward opening pintle-type valve. 20 20-34 4/7/95 Theory of Operation Fuel Inlet Passage Return Connector Return Line Injector Body Fuel Return Passage Shim Spring Nozzle Fitting Spring Seat Pintle (Valve) Separator Plate 20 Nozzle Body High Pressure Fuel Orifice Return Fuel Valve Seat INDIRECT INJECTION NOZZLE OPERATION (PINTLE TYPE) M82015AE 4/7/95 20-35 Theory of Operation DIRECT INJECTION NOZZLE OPERATION (HOLE TYPE) - ALL EXCEPT 3TN66 and 3TNA72 (3009) Function: High pressure fuel from the injection pump flows through a fuel inlet passage. Pressure builds beneath the nozzle valve. When the fuel pressure reaches specified pressure it overcomes the nozzle spring tension. The nozzle valve retracts into the nozzle body and fuel is injected into the engine. Injection nozzle injects fuel in an atomized form into the combustion chamber. The nozzle valve is automatically pushed down by the nozzle spring and closed after fuel is injected. Theory of Operation: Leakage (return fuel) flows from between the nozzle valve and nozzle body to the hole on top of the nozzle spring through the return pipe and back into the fuel tank. The hole type nozzle is used on direct injection engines 3TN75 and larger. It is different from the pintle type nozzle in that it is held in the cylinder head by a retaining bracket instead of being threaded. The nozzle valve is shim adjustable to regulate the opening pressure. 20 20-36 4/7/95 Theory of Operation Return Pipe Shim Spring Retainer Dowel Pin 20 Seat Nozzle Valve Nozzle Body Nozzle Nut Injection Holes Nozzle Valve Seat High Pressure Fuel Return Fuel DIRECT INJECTION NOZZLE OPERATION (HOLE TYPE) M82016A 4/7/95 20-37 Theory of Operation PRECOMBUSTION CHAMBER OPERATION (INDIRECT INJECTION) 3TN66 and 3TNA72 (3009) Function: The precombustion chamber is a small turbulent area where the fuel is injected, mixed with a limited amount of air, and the start of ignition takes place. Theory of Operation: A precombustion chamber is located in the cylinder head with a small opening into the cylinder. As the piston comes up on the compression stroke, some of the air is forced through the opening into the precombustion chamber. The opening is shaped to direct this air flow into a turbulent action as it is being compressed and heated. At 16° BTDC crankshaft rotation, injection of fuel begins. The injection nozzle sprays atomized fuel into the precombustion chamber turbulent air. Heat from the compressed air ignites the fuel, increasing pressure in the precombustion chamber forcing the burning mixture into the cylinder where it mixes with the air in the piston swirl cup. Expansion for the burning mixture forces the piston down on its power stroke. When starting a cold engine, compression pressure may not provide enough heat to ignite the fuel when injected into a cold precombustion chamber. An electrically operated glow plug is installed into the precombustion chamber to provide added heat to ignite the fuel as it is injected. The glow plugs are energized during starting, and also may be preheated by turning key switch counterclockwise and holding for up to 30 seconds. 20 20-38 4/7/95 Theory of Operation Injection Nozzle Glow Plug Intake Valve Exhaust Valve Precombustion Chamber Cylinder Swirl Cup 20 Combustion PRECOMBUSTION CHAMBER OPERATION (INDIRECT INJECTION) M82017AE 4/7/95 20-39 Theory of Operation COMBUSTION CHAMBER OPERATION (DIRECT INJECTION) ALL EXCEPT 3TN66 and 3TNA72 (3009) At 16° BTDC crankshaft rotation, fuel is injected by the multi-hole injection nozzle. The swirling action of the air thoroughly mixes the atomized fuel and air for complete burning, as the piston travels into the power stroke. Function: When starting a cold engine, compression of ambient temperature air may not provide enough heat for ignition. To aid cold temperature starting, an electrically operated heater element is located at the intake manifold inlet. The heater is energized during starting and also may be pre-heated by turning key switch counterclockwise and holding for up to 30 seconds. The combustion chamber is an area where the fuel is injected, mixed with a limited amount of air, and the start of ignition takes place. Theory of Operation: A swirl cup is formed in the head of the piston. As the piston travels upward on its compression stroke, the shape of the cup causes the air to swirl as it is compressed and heated. 20 20-40 4/7/95 Theory of Operation Injection Nozzle Intake Valve Exhaust Valve Combustion Chamber Piston Swirl Cup 20 High Pressure Fuel COMBUSTION CHAMBER OPERATION (DIRECT INJECTION) M82018AE 4/7/95 20-41 ELECTRICAL SYSTEM SERIES 220 POWER UNIT ENGINES Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1 Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-2 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-4 21 Section 21 21 Electrical System INTRODUCTION This section provides component location and schematics of the electrical system used on OEM stand-alone power packs. The Series 220 diesel engines are offered as OEM units with two different power unit configurations available for each model. Features on the power units include an air cleaner kit, muffler, radiator kit and instrument panel. The following is a complete engine listing of all Series 220 Power Units: Power Unit Model Number Engine Model Number Description 3009DF005 3TNA72 Industrial Power Unit 3009DF007 3TNA72 3600 rpm gen-set Power Unit 3011DF005 3TNC78 Industrial Power Unit 3011DF006 3TNC78 1800 rpm gen-set Power Unit 3014DF005 3TN84 Industrial Power Unit 3014DF006 3TN84 1800 rpm gen-set Power Unit 4019DF005 4TN84 Industrial Power Unit 4019DF006 4TN84 1800 rpm gen-set Power Unit 4019TF005 4TN84T Industrial Power Unit 4019TF006 4TN84T 1800 rpm gen-set Power Unit 21 4/7/95 21-1 Component Location Instrument Panel Air Heater (Glow Plugs on 3009D Engine) Coolant Temperature Sensor Optional. Fuel Shutoff Solenoid Oil Pressure Switch Additional Oil Pressure Sensor is Optional. RG6604 Coolant Temperature Switch 21 Alternator Starter RG6605 ENGINE ELECTRICAL COMPONENTS 21-2 4/7/95 Component Location Preheat Indicator Coolant Temperature Gauge Optional. Oil Pressure Gauge Optional. Charge Indicator Oil Pressure Indicator Coolant Temperature Indicator Key Switch Preheat Timer M82178A INSTRUMENT PANEL COMPONENTS 21 4/7/95 21-3 Schematics LEGEND FOR ELECTRICAL SCHEMATIC - 3009 POWER UNIT B1 - Oil Pressure Switch B2 - Coolant Temperature Switch D1 - Preheat Timer D2 - Fuel Shutoff Solenoid Timer F1 - 30-amp Fuse G1 - 12-volt Battery G2 - Alternator H1 - Preheat Indicator H2 - Charge Indicator H3 - Oil Pressure Indicator H4 - Coolant Temperature Indicator K1 - Fuel Injection Relay M1 - Starter R1 - Glow Plugs S1 - Battery Switch S2 - Key Switch V1 - Diode X1 - 4-Wire Connector, at Preheat Timer X2 - 10-Wire Connector, Main Harness-to-Instrument Panel X3 - 3-Wire Connector, at Fuel Shutoff Solenoid X4 - 1-Wire Bullet Connector, at Oil Pressure Switch X5 - 1-Wire Connector, at Starter X6 - 2-Wire Connector, at Alternator X7 - 1-Wire Bullet Connector, at Coolant Temperature Switch 21 X8 - 1-Wire Connector, Fuel Injection Relay-to-Fuse X9 - 1-Wire Connector, at Fuel Injection Relay-to-Shutoff Solenoid X10 - 2-Wire Connector, at Fuel Injection Relay X11 - 1-Wire Bullet Connector, Preheat Indicator Positive Lead X12 - 1-Wire Bullet Connector, Preheat Indicator Negative Lead X13 - 1-Wire Bullet Connector, Charge Indicator Positive Lead X14 - 1-Wire Bullet Connector, Charge Indicator Negative Lead X15 - 1-Wire Bullet Connector, Oil Pressure Indicator Positive Lead X16 - 1-Wire Bullet Connector, Oil Pressure Indicator Negative Lead X17 - 1-Wire Bullet Connector, Collant Temperature Indicator Positive Lead X18 - 1-Wire Bullet Connector, Collant Temperature Indicator Negative Lead X19 - 4-Wire Connector, at Fuel Shutoff Solenoid Timer Y1 - Fuel Shutoff Solenoid 21-4 4/7/95 Schematics 21 4/7/95 21-5 Schematics 21 M82179AE 21-6 4/7/95 Schematics 21 M82179AF 4/7/95 21-7 Schematics LEGEND FOR ELECTRICAL SCHEMATIC - 3011, 3014 AND 4019 POWER UNITS B1 - Oil Pressure Switch B2 - Coolant Temperature Switch D1 - Preheat Timer D2 - Fuel Shutoff Solenoid Timer F1 - 10-amp Fuse G1 - 12-volt Battery G2 - Alternator H1 - Preheat Indicator H2 - Charge Indicator H3 - Oil Pressure Indicator H4 - Coolant Temperature Indicator M1 - Starter R1 - Air Heater S1 - Battery Switch S2 - Key Switch X1 - 4-Wire Connector, at Preheat Timer X2 - 10-Wire Connector, Main Harness-to-Instrument Panel X3 - 3-Wire Connector, at Fuel Shutoff Solenoid X4 - 1-Wire Bullet Connector, at Oil Pressure Switch X5 - 1-Wire Connector, at Starter X6 - 2-Wire Connector, at Alternator X7 - 1-Wire Bullet Connector, at Coolant Temperature Switch X8 - 1-Wire Bullet Connector, Preheat Indicator Positive Lead X9 - 1-Wire Bullet Connector, Preheat Indicator Negative Lead 21 X10 - 1-Wire Bullet Connector, Charge Indicator Positive Lead X11 - 1-Wire Bullet Connector, Charge Indicator Negative Lead X12 - 1-Wire Bullet Connector, Oil Pressure Indicator Positive Lead X13 - 1-Wire Bullet Connector, Oil Pressure Indicator Negative Lead X14 - 1-Wire Bullet Connector, Coolant Temperature Indicator Positive Lead X15 - 1-Wire Bullet Connector, Coolant Temperature Indicator Negative Lead Y1 - Fuel Shutoff Solenoid 21-8 4/7/95 Schematics 21 4/7/95 21-9 Schematics 21 M82180AE 21-10 4/7/95 Schematics 21 M82180AF 4/7/95 21-11 Schematics LEGEND FOR ELECTRICAL SCHEMATIC - OPTIONAL EQUIPMENT B3 - Coolant Temperature Sender B4 - Oil Pressure Sender P1 - Coolant Temperature Gauge P2 - Oil Pressure Gauge X2 - 10-Wire Connector, Main Harness-to-Instrument Panel X20 - 1-Wire Bullet Connector, at Coolant Temperature Sender X21 - 1-Wire Bullet Connector, at Oil Pressure Sender 21 21-12 4/7/95 Schematics 21 M82181AE 4/7/95 21-13 Schematics 21 21-14 4/7/95 Index A Air Cleaner Operation 3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . 20-10 3011 (3TNC78), 3014 (3TN84), 4019D (4TN84), 4019T (4TN84T) . . . . . 20-11 Air Cleaner, Inspection 3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 3011, 3014, 4019D . . . . . . . . . . . . . . . . . . . 10-7 4019T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Air Heater, Removal/Installation . . . . . . . . . . 10-39 Air Intake System, Check . . . . . . . . . . . . . . . . 10-45 Air Intake System, Leakage Test 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-51 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-155 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-137 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-137 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-142 Alternator - 3TN66 (375 SSL, 330/332 LGT, F915 FM) (Kokosan 20A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-122 Disassembly/Inspection . . . . . . . . . . . . . . 1-122 Alternator - 3TN66 (655 CUT) (Nippondenso 35A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-125 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1-123 Test/Inspection . . . . . . . . . . . . . . . . . . . . . 1-125 Alternator - 3TN66 (655 CUT) (Nippondenso 40A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-129 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1-128 Inspection/Test . . . . . . . . . . . . . . . . . . . . . 1-129 Alternator - 3TN75 (855/56 CUT), 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT, 955 CUT) (Nippondenso 35A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2-110 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 2-108 Inspection/Test . . . . . . . . . . . . . . . . . . . . . 2-110 Alternator - 3TN75, 3TNC78 (3011), 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) (Nippondenso 40A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2-114 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 2-113 Inspection/Test . . . . . . . . . . . . . . . . . . . . . 2-114 Alternator - 3TN78, 3TN82 (30 EX) (Hitachi 25A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2-105 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 2-103 Inspection/Test . . . . . . . . . . . . . . . . . . . . . 2-105 4/7/95 Alternator - 3TNA72 (430 LGT, 670 CUT, 755/56 CUT, F925/35 FM) (Nippondenso 35A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-125 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1-123 Test/Inspection . . . . . . . . . . . . . . . . . . . . . 1-125 Alternator - 3TNA72 (455 LGT, 755/56 CUT, 3009 OEM) (Nippondenso 40A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-129 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1-128 Inspection/Test . . . . . . . . . . . . . . . . . . . . . 1-129 Alternator - 3TNA72 (670 CUT, 15 EX) (Kokosan 20A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-122 Disassembly/Inspection . . . . . . . . . . . . . . 1-122 Alternator - 3TNA82, 3TN84 (870 CUT) (Kokosan 20A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2-102 Disassembly/Inspection . . . . . . . . . . . . . . 2-102 Alternator - 4TN100 (Hitachi 25A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-75 Inspection/Test . . . . . . . . . . . . . . . . . . . . . . 4-77 Alternator - 4TN78T (Hitachi 25A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-108 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-106 Inspection/Test . . . . . . . . . . . . . . . . . . . . . 3-108 Alternator - 4TN82, 4TN84RJK (Nippondenso 35A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-113 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-111 Inspection/Test . . . . . . . . . . . . . . . . . . . . . 3-113 Alternator - 4TN82ESP/RJE, 4TN84(T) (4019) (Nippondenso 40A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-117 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-116 Inspection/Test . . . . . . . . . . . . . . . . . . . . . 3-117 Alternator - 4TN82RJK, 4TN84RJK (Kokosan 20A) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-105 Disassembly/Inspection . . . . . . . . . . . . . . 3-105 Altitude Compensation Guidelines . . . . . . . . . 10-44 Amperage Test - 3009, 3011, 3014, 4019 Regulated . . . . . . . . . . . . . . . . . . . . . . . . . 10-58 Unregulated. . . . . . . . . . . . . . . . . . . . . . . . 10-60 Auxiliary Drive Gear 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48 Index-1 I Index B Balancer Assembly - 4TN82RJK, 4TN84RJK Disassembly/Assembly . . . . . . . . . . . . . . . . 3-42 Removal/Installation . . . . . . . . . . . . . . . . . . 3-42 Basic Engine Specifications . . . . . . . . . . . . . . . . G-4 C I Cam Followers - 3TN66, 3TNA72 (3009) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60 Removal/Installation . . . . . . . . . . . . . . . . . . 1-59 Cam Followers - 3TN75, 3TN78, 3TNC78 (3011) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 Removal/Installation . . . . . . . . . . . . . . . . . . 2-58 Cam Followers - 3TN82, 3TNA82, 3TN84 (3014) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 Removal/Installation . . . . . . . . . . . . . . . . . . 2-58 Cam Followers - 4TN100 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Removal/Installation . . . . . . . . . . . . . . . . . . 4-44 Cam Followers - 4TN78T, 4TN82, 4TN84(T) (4019) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 Removal/Installation . . . . . . . . . . . . . . . . . . 3-57 Camshaft - 3TN66, 3TNA72 (3009) End Play Check. . . . . . . . . . . . . . . . . . . . . 1-139 Inspection/Replacement . . . . . . . . . . . . . . . 1-57 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-56 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56 Camshaft - 3TN75, 3TN78, 3TNC78 (3011) End Play Check. . . . . . . . . . . . . . . . . . . . . 2-123 Inspection/Replacement . . . . . . . . . . . . . . . 2-56 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Camshaft - 3TN82, 3TNA82, 3TN84 (3014) End Play Check. . . . . . . . . . . . . . . . . . . . . 2-123 Inspection/Replacement . . . . . . . . . . . . . . . 2-56 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Camshaft - 4TN100 End Play Check. . . . . . . . . . . . . . . . . . . . . . 4-87 Inspection/Replacement . . . . . . . . . . . . . . . 4-42 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Camshaft - 4TN78T, 4TN82, 4TN84(T) (4019) End Play Check. . . . . . . . . . . . . . . . . . . . . 3-126 Inspection/Replacement . . . . . . . . . . . . . . . 3-55 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 Combustion Chamber Operation (Direct Injection). . . . . . . . . . . . . . . . . . . . . . . 20-40 Index-2 Component Location Engine Components - Direct Injection . . . . 20-3 Engine Components - Indirect Injection . . . 20-2 Engine Electrical Components . . . . . . . . . . 21-2 Instrument Panel Components . . . . . . . . . . 21-3 Connecting Rod Check - 3TN66, 3TNA72 (3009) Bearing Clearance. . . . . . . . . . . . . . . . . . . 1-136 Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . 1-136 Connecting Rod Check - 3TN75, 3TN78, 3TNC78 (3011) Bearing Clearance. . . . . . . . . . . . . . . . . . . 2-120 Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120 Connecting Rod Check - 3TN82, 3TNA82, 3TN84 (3014) Bearing Clearance. . . . . . . . . . . . . . . . . . . 2-120 Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120 Connecting Rod Check - 4TN100 Bearing Clearance. . . . . . . . . . . . . . . . . . . . 4-84 Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84 Connecting Rod Check - 4TN78T, 4TN82, 4TN84(T) (4019) Bearing Clearance. . . . . . . . . . . . . . . . . . . 3-123 Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123 Coolant Temperature Sender Replacement . . . . . . . . . . . . . . . . . . . . . . . 10-41 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41 Coolant Temperature Sender - 4TN100 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-56 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92 Coolant Temperature Sensor - 3TN66, 3TNA72 (3009) Replacement . . . . . . . . . . . . . . . . . . . . . . . . 1-84 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-144 Coolant Temperature Switch - 3TN75, 3TN78, 3TNC78 (3011) Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-70 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128 Coolant Temperature Switch - 3TN82, 3TNA82, 3TN84 (3014) Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-70 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128 Coolant Temperature Switch - 4TN78T, 4TN82, 4TN84(T) (4019) Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-70 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131 Cooling Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 4/7/95 Index Cooling System Check and Service . . . . . . . . . . . . . . . . . . 10-45 Flushing and Servicing . . . . . . . . . . . . . . . . G-13 Theory of Operation . . . . . . . . . . . . . . . . . . 20-6 Cooling System, Pressure Test 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-48 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-152 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-134 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-134 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-139 Crankcase Breather Operation 3TN66, 3TNA72 (3009), 4TN100 . . . . . . . 20-8 All Except 3TN66, 3TNA72 (3009), 4TN100 . . . . . . . . . . . . . . 20-9 Crankcase Extension Housing 3TN75, 3TNC78 (3011 OEM), 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) . . . . . . . . . . . . . . . . 2-44 3TN78 (25 EX), 3TN82 (30 EX), 3TNA82 (770 CUT), 3TN84 (870 CUT). . . . . . . . . . . . . . . . . . . . . . . . . . 2- 44 3TNA72 (15 EX and 3009 OEM). . . . . . . . 1-44 3TNA72 (670 CUT) . . . . . . . . . . . . . . . . . . 1-43 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 4TN78T, 4TN82RJK, 4TN84RJK . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 4TN82RJE, 4TN82ESP, 4TN84(T) (4019) . . . . . . . . . . . . . . . . . . . . 3-44 Crankcase Ventilation System, Check . . . . . . 10-45 Crankshaft and Main Bearings - 3TN66, 3TNA72 (3009) Inspection/Replacement . . . . . . . . . . . . . . . 1-49 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-47 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46 Crankshaft and Main Bearings - 3TN75, 3TN78, 3TNC78 (3011) Inspection/Replacement . . . . . . . . . . . . . . . 2-49 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Crankshaft and Main Bearings - 3TN82, 3TNA82, 3TN84 (3014) Inspection/Replacement . . . . . . . . . . . . . . . 2-49 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Crankshaft and Main Bearings - 4TN100 Inspection/Replacement . . . . . . . . . . . . . . . 4-36 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 4/7/95 Crankshaft and Main Bearings - 4TN78T, 4TN82, 4TN84(T) (4019) Inspection/Replacement . . . . . . . . . . . . . . . 3-49 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Crankshaft Front Oil Seal 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-46 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-46 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-46 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-45 Crankshaft Main Bearing, Clearance Check 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-138 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-122 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-122 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-124 Crankshaft Rear Oil Seal 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-45 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-45 3TNA72 (15 EX, 670 CUT, 3009 OEM) . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 3TNA72 (430 LGT, 455 LGT, 755/56 CUT, F925/35 FM) . . . . . . . . . . . . . 1-45 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-45 Crankshaft, End Play Check 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-137 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-121 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-121 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-124 Cylinder Bore - 3TN66, 3TNA72 (3009) Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40 Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 Cylinder Bore - 3TN75, 3TN78, 3TNC78 (3011) Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Cylinder Bore - 3TN82, 3TNA82, 3TN84 (3014) Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Cylinder Bore - 4TN100 Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Index-3 I Index Cylinder Bore - 4TN78T, 4TN82, 4TN84(T) (4019) Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Cylinder Head and Valves - 3TN66, 3TNA72 (3009) Disassembly/Assembly . . . . . . . . . . . . . . . . 1-23 Inspection/Replacement . . . . . . . . . . . . . . . 1-24 Removal/Installation . . . . . . . . . . . . . . . . . . 1-21 Cylinder Head and Valves - 3TN75, 3TN78, 3TNC78 (3011) Disassembly/Assembly . . . . . . . . . . . . . . . . 2-22 Inspection/Replacement . . . . . . . . . . . . . . . 2-23 Removal/Installation . . . . . . . . . . . . . . . . . . 2-21 Cylinder Head and Valves - 3TN82, 3TNA82, 3TN84 (3014) Disassembly/Assembly . . . . . . . . . . . . . . . . 2-22 Inspection/Replacement . . . . . . . . . . . . . . . 2-23 Removal/Installation . . . . . . . . . . . . . . . . . . 2-21 Cylinder Head and Valves - 4TN100 Disassembly/Assembly . . . . . . . . . . . . . . . . 4-13 Inspection/Replacement . . . . . . . . . . . . . . . 4-14 Removal/Installation . . . . . . . . . . . . . . . . . . 4-12 Cylinder Head and Valves - 4TN78T, 4TN82, 4TN84(T) (4019) Disassembly/Assembly . . . . . . . . . . . . . . . . 3-22 Inspection/Replacement . . . . . . . . . . . . . . . 3-23 Removal/Installation . . . . . . . . . . . . . . . . . . 3-21 Cylinder, Compression Pressure Test 3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49 3011, 3014, 4019 . . . . . . . . . . . . . . . . . . . 10-50 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-153 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-135 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-135 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-140 I D Dealer Fabricated Tools DFRG1 Extended Indicator Tip . . . . . . . . 10-62 DFRG2 Extended Indicator Tip . . . . . . . . 10-63 Diagnosis 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-132 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-117 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-117 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-120 Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . G-8 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8 Dynamometer Test - 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47 Index-4 E Electrical Component Location Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-2 Instrument Panel . . . . . . . . . . . . . . . . . . . . . 21-3 Electrical Schematic 3009 Power Unit . . . . . . . . . . . . . . . . . . . . . 21-4 3011, 3014 and 4019 Power Units . . . . . . . 21-8 Optional Equipment . . . . . . . . . . . . . . . . . 21-12 Electrical System, Check . . . . . . . . . . . . . . . . 10-46 Engine Application Chart Industrial Equipment. . . . . . . . . . . . . . . . . . . G-3 Lawn and Grounds Care Equipment. . . . . . . G-2 OEM Application . . . . . . . . . . . . . . . . . . . . . G-3 Engine Balancer Operation . . . . . . . . . . . . . . . . 20-4 Engine Coolant Recommendations. . . . . . . . . . . . . . . . . . . . . G-9 Specifications . . . . . . . . . . . . . . . . . . . . . . . G-10 Engine Oil Pressure, Test 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-50 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-154 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-136 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-136 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-141 Engine Serial Number Plate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1 Serial Number Information . . . . . . . . . . . . . . G-1 Engine Specifications 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 3TNA72 (3009). . . . . . . . . . . . . . . . . . . . . . . 1-8 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . . 2-1 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . . 2-8 4TN78T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 4TN82, 4TN84(T) (4019) . . . . . . . . . . . . . . . 3-8 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Engine, Clean . . . . . . . . . . . . . . . . . . . . . . . . . . G-17 Exhaust Manifold 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-26 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-26 3TNA72 (3009). . . . . . . . . . . . . . . . . . . . . . 1-28 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-26 Exhaust System, Check. . . . . . . . . . . . . . . . . . 10-45 F Fan/Alternator Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 10-34 Replacement . . . . . . . . . . . . . . . . . . . . . . . 10-34 4/7/95 Index Fan/Alternator Drive Belt, Adjustment 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-150 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-132 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-132 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-137 Fan/Alternator Drive Belt, Inspection . . . . . . 10-46 Fast Idle Speed Adjustment 3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54 3011, 3014, 4019 . . . . . . . . . . . . . . . . . . . 10-55 Flywheel 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-52 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-51 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-51 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-51 Flywheel Housing 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54 3TN78, 3TNC78 (3011), 3TN82, 3TN84 (3014) . . . . . . . . . . . . . . . . . . . . . . . 2-52 3TNA72 (15 EX, 3009 OEM) . . . . . . . . . . 1-53 3TNA72 (All Except 15 EX and 3009 OEM) . . . . . . . . . . . . . . . . . . . . . . . . . 1-54 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 4TN78T, 4TN82RJE, 4TN82ESP, 4TN84(T) (4019) . . . . . . . . . . . . . . . . . . . . 3-52 Flywheel Plate 3TN75, 3TNC78 (3011), 3TNA82, 3TN84 (3014) . . . . . . . . . . . . . . . . . . . . . . . 2-53 4TN82RJK, 4TN84RJK, 4TN84(T) (4019) . . . . . . . . . . . . . . . . . . . . 3-52 Fuel Control and Governor Linkage 3TN66 and Later 3TNA72 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-107 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1-106 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1-108 Installation . . . . . . . . . . . . . . . . . . . . . . . . 1-105 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105 Fuel Control and Governor Linkage Early 3TNA72 (430 LGT) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1-104 Installation . . . . . . . . . . . . . . . . . . . . . . . . 1-101 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-99 Fuel Drain Back Test 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-52 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-156 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-138 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-138 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100 4TN78, 4TN82, 4TN84(T) (4019) . . . . . . 3-143 4/7/95 Fuel Filter Assembly 3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 3011, 3014 and 4019. . . . . . . . . . . . . . . . . 10-36 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-93 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-79 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-79 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-79 Fuel Injection Nozzles - 3TN66, 3TNA72 (3009) Cleaning/Inspection . . . . . . . . . . . . . . . . . 1-111 Cross Section . . . . . . . . . . . . . . . . . . . . . . 1-111 Disassembly/Assembly . . . . . . . . . . . . . . . 1-110 Removal/Installation . . . . . . . . . . . . . . . . . 1-109 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142 Fuel Injection Nozzles - 3TN75, 3TN78, 3TNC78 (3011) Cleaning/Inspection . . . . . . . . . . . . . . . . . . 2-85 Cross Section . . . . . . . . . . . . . . . . . . . . . . . 2-84 Disassembly/Assembly . . . . . . . . . . . . . . . . 2-84 Removal/Installation . . . . . . . . . . . . . . . . . . 2-83 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125 Fuel Injection Nozzles - 3TN82, 3TNA82, 3TN84 (3014) Cleaning/Inspection . . . . . . . . . . . . . . . . . . 2-85 Cross Section . . . . . . . . . . . . . . . . . . . . . . . 2-84 Disassembly/Assembly . . . . . . . . . . . . . . . . 2-84 Removal/Installation . . . . . . . . . . . . . . . . . . 2-83 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125 Fuel Injection Nozzles - 4TN100 Cleaning/Inspection . . . . . . . . . . . . . . . . . . 4-68 Cross Section . . . . . . . . . . . . . . . . . . . . . . . 4-68 Disassembly/Assembly . . . . . . . . . . . . . . . . 4-67 Removal/Installation . . . . . . . . . . . . . . . . . . 4-66 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89 Fuel Injection Nozzles - 4TN78T, 4TN82, 4TN84(T) (4019) Cleaning/Inspection . . . . . . . . . . . . . . . . . . 3-85 Cross Section . . . . . . . . . . . . . . . . . . . . . . . 3-84 Disassembly/Assembly . . . . . . . . . . . . . . . . 3-84 Removal/Installation . . . . . . . . . . . . . . . . . . 3-83 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128 Fuel Injection Pump - 3TN66, 3TNA72 (3009) Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-95 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94 Fuel Injection Pump - 3TN75, 3TN78, 3TNC78 (3011) Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 Static Timing Adjustment . . . . . . . . . . . . . 2-131 Index-5 I Index I Fuel Injection Pump - 3TN82, 3TNA82, 3TN84 (3014) Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 Static Timing Adjustment . . . . . . . . . . . . . 2-131 Fuel Injection Pump - 4TN100 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-65 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64 Static Timing Adjustment . . . . . . . . . . . . . . 4-94 Fuel Injection Pump - 4TN78T, 4TN82, 4TN84(T) (4019) Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-81 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80 Fuel Injection Pump Camshaft 3TN66 and Later 3TNA72 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 1-98 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-98 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-97 Fuel Injection Pump Camshaft Early 3TNA72 (430 LGT) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-97 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 1-96 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-97 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-96 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96 Fuel Injection Pump Operation . . . . . . . . . . . 20-24 Fuel Injection Pump Static Timing Adjustment 3TN66 and Later 3TNA72 . . . . . . . . . . . . 1-148 4TN78T. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134 4TN82, 4TN84(T) (4019) . . . . . . . . . . . . . 3-135 Early 3TNA72 (430 LGT) . . . . . . . . . . . . 1-147 Fuel Shutoff Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . 10-42 Fuel Shutoff Solenoid - 3009, 3011, 3014, 4019 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 10-56 Amperage Test . . . . . . . . . . . . . . . . . . . . . 10-55 Fuel Shutoff Solenoid, Adjustment 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-151 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-133 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-133 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-138 Fuel Supply Pump - 3009 Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 10-52 Removal/Installation . . . . . . . . . . . . . . . . . 10-37 Fuel Supply Pump - 3011, 3014, 4019 Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 10-52 Removal/Installation . . . . . . . . . . . . . . . . . 10-38 Index-6 Fuel Supply Pump - 3TN75, 3TNC78 (3011), 3TNA82, 3TN84 (3014) Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 2-137 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-78 Fuel Supply Pump - 3TNA72 (670 CUT, 3009 OEM) Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 1-155 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 1-92 Fuel Supply Pump - 4TN100 Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . 4-99 Removal/Installation . . . . . . . . . . . . . . . . . . 4-61 Fuel Supply Pump - 4TN82, 4TN84(T) (4019) Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 3-142 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-78 Fuel System Operation . . . . . . . . . . . . . . . . . . 20-22 Fuel System, Bleed 3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 3011, 3014, 4019 . . . . . . . . . . . . . . . . . . . 10-53 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-156 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-138 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-138 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-143 G General Tune-Up Recommendations . . . . . . . 10-44 Glow Plugs Removal/Installation . . . . . . . . . . . . . . . . . 10-39 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39 Governor Operation . . . . . . . . . . . . . . . . . . . . 20-28 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9 I Idler Gear - 3TN66 and Later 3TNA72 Inspection/Replacement . . . . . . . . . . . . . . . 1-66 Removal/Installation . . . . . . . . . . . . . . . . . . 1-66 Idler Gear - 3TN75, 3TN78, 3TNC78 (3011) Inspection/Replacement . . . . . . . . . . . . . . . 2-61 Removal/Installation . . . . . . . . . . . . . . . . . . 2-61 Idler Gear - 3TN82, 3TNA82, 3TN84 (3014) Inspection/Replacement . . . . . . . . . . . . . . . 2-61 Removal/Installation . . . . . . . . . . . . . . . . . . 2-61 Idler Gear - 4TN100 Inspection/Replacement . . . . . . . . . . . . . . . 4-47 Removal/Installation . . . . . . . . . . . . . . . . . . 4-46 Idler Gear - 4TN78T, 4TN82, 4TN84(T) (4019) Inspection/Replacement . . . . . . . . . . . . . . . 3-60 Removal/Installation . . . . . . . . . . . . . . . . . . 3-59 Idler Gear - Early 3TNA72 (430 LGT) Inspection/Replacement . . . . . . . . . . . . . . . 1-65 Removal/Installation . . . . . . . . . . . . . . . . . . 1-65 4/7/95 Index Injection Nozzle Operation Hole Type . . . . . . . . . . . . . . . . . . . . . . . . . 20-36 Pintle Type . . . . . . . . . . . . . . . . . . . . . . . . 20-34 Instrument Panel - 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 Intake Manifold 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-27 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-27 3TNA72 (3009). . . . . . . . . . . . . . . . . . . . . . 1-29 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-26 L Lubrication System Operation . . . . . . . . . . . . 20-14 M Muffler, Removal/Installation 3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 3011, 3014, 4019D . . . . . . . . . . . . . . . . . . 10-10 4019T . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 O Oil Cooler - 3TN84 (955 CUT) Leakage Test . . . . . . . . . . . . . . . . . . . . . . . 2-133 Removal/Installation . . . . . . . . . . . . . . . . . . 2-67 Oil Cooler - 4TN100 Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . 4-52 Removal/Installation . . . . . . . . . . . . . . . . . . 4-52 Oil Cooler - 4TN8T, 4TN84T (4019TF001, 005) Leakage Test . . . . . . . . . . . . . . . . . . . . . . . 3-137 Removal/Installation . . . . . . . . . . . . . . . . . . 3-66 Oil Cooler By-Pass Valve 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53 Oil Cooler Operation . . . . . . . . . . . . . . . . . . . 20-18 Oil Filter Operation. . . . . . . . . . . . . . . . . . . . . 20-16 Oil Pan and Strainer 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-64 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-64 3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-73 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-63 4/7/95 Oil Pressure Regulating Valve 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-68 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-68 3TN84 (955 CUT) . . . . . . . . . . . . . . . . . . . 2-67 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 4TN78T, 4TN84T (4019TF001, 005). . . . . 3-67 4TN82, 4TN84 (4019DF), 4TN84T (4019TF006) . . . . . . . . . . . . . . . . 3-67 Early 3TNA72 (430 LGT) . . . . . . . . . . . . . 1-81 Later 3TNA72. . . . . . . . . . . . . . . . . . . . . . . 1-82 Theory of Operation . . . . . . . . . . . . . . . . . 20-17 Oil Pressure Switch, Replacement . . . . . . . . . 10-41 Oil Pump - 3TN66 and Later 3TNA72 Disassembly/Assembly . . . . . . . . . . . . . . . . 1-79 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80 Removal/Installation . . . . . . . . . . . . . . . . . . 1-79 Oil Pump - 3TN75, 3TN78, 3TNC78 (3011) Disassembly/Assembly . . . . . . . . . . . . . . . . 2-66 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Removal/Installation . . . . . . . . . . . . . . . . . . 2-65 Oil Pump - 3TN82, 3TNA82, 3TN84 (3014) Disassembly/Assembly . . . . . . . . . . . . . . . . 2-66 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Removal/Installation . . . . . . . . . . . . . . . . . . 2-65 Oil Pump - 4TN100 Disassembly/Assembly . . . . . . . . . . . . . . . . 4-51 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51 Removal/Installation . . . . . . . . . . . . . . . . . . 4-51 Oil Pump - 4TN78T, 4TN82, 4TN84(T) (4019) Disassembly/Assembly . . . . . . . . . . . . . . . . 3-64 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65 Removal/Installation . . . . . . . . . . . . . . . . . . 3-64 Oil Pump - Early 3TNA72 (430 LGT) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-76 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75 I P Piston and Connecting Rod - 3TN66, 3TNA72 (3009) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . Inspection/Replacement . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 1-34 1-36 1-33 1-33 Index-7 Index I Piston and Connecting Rod - 3TN75, 3TN78, 3TNC78 (3011) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Inspection/Replacement . . . . . . . . . . . . . . . 2-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Piston and Connecting Rod - 3TN82, 3TNA82, 3TN84 (3014) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Inspection/Replacement . . . . . . . . . . . . . . . 2-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Piston and Connecting Rod - 4TN100 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Inspection/Replacement . . . . . . . . . . . . . . . 4-25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Piston and Connecting Rod - 4TN78T, 4TN82, 4TN84(T) (4019) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Inspection/Replacement . . . . . . . . . . . . . . . 3-34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Piston Cooling Nozzles 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 4TN78T, 4TN84T (4019TF001, 005). . . . . 3-68 Theory of Operation . . . . . . . . . . . . . . . . . 20-20 Piston-to-Cylinder Head Clearance 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-31 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-29 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-29 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-29 Precombustion Chamber Operation (Indirect Injection) . . . . . . . . . . . . . . . . . . . . . 20-38 Preliminary Engine Testing . . . . . . . . . . . . . . 10-44 Radiator Mount - If Equipped. . . . . . . . . . . . . 10-43 Radiator, Bubble Test 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-48 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-152 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-134 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-134 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-139 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96 Regulated Voltage Test 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-60 Rocker Arm Assembly - 3TN66, 3TNA72 (3009) Disassembly/Assembly . . . . . . . . . . . . . . . . 1-19 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 Removal/Installation . . . . . . . . . . . . . . . . . . 1-19 Rocker Arm Assembly - 3TN75, 3TN78, 3TNC78 (3011) Disassembly/Assembly . . . . . . . . . . . . . . . . 2-19 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Removal/Installation . . . . . . . . . . . . . . . . . . 2-19 Rocker Arm Assembly - 3TN82, 3TNA82, 3TN84 (3014) Disassembly/Assembly . . . . . . . . . . . . . . . . 2-19 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Removal/Installation . . . . . . . . . . . . . . . . . . 2-19 Rocker Arm Assembly - 4TN100 Disassembly/Assembly . . . . . . . . . . . . . . . . 4-10 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Removal/Installation . . . . . . . . . . . . . . . . . . 4-10 Rocker Arm Assembly - 4TN78T, 4TN82, 4TN84(T) (4019) Disassembly/Assembly . . . . . . . . . . . . . . . . 3-19 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Removal/Installation . . . . . . . . . . . . . . . . . . 3-19 Rocker Arm Cover 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-18 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-18 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-18 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-18 R S Radiator Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-33 Removal/Inspection . . . . . . . . . . . . . . . . . 10-32 Radiator Cap, Pressure Test 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-49 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-153 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-135 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-135 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-140 Slow Idle Speed Adjustment 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-53 Specifications Engine Accessories . . . . . . . . . . . . . . . . . . . 10-1 Starter - 3TN66 (Hitachi 0.8 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-114 Disassembly/Inspection . . . . . . . . . . . . . . 1-113 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115 Index-8 4/7/95 Index Starter - 3TNA72 (3009 OEM) (Hitachi 0.8 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-114 Disassembly/Inspection . . . . . . . . . . . . . . 1-113 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115 Starter - 4TN78T (Hitachi 0.8 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88 Disassembly/Inspection . . . . . . . . . . . . . . . 3-87 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89 Starter Gear Train and Overrunning Clutch 3TN75, 3TNC78 (3011), 3TNA82, 3TN84 (870 CUT, 955 CUT) (Nippondenso 1.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95 Disassembly/Inspection . . . . . . . . . . . . . . . 2-93 Starter Gear Train and Overrunning Clutch 3TNA72 (All Except 3009 OEM) (Nippondenso 1.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-120 Disassembly/Inspection . . . . . . . . . . . . . . 1-119 Starter Gear Train and Overrunning Clutch 3TNA82, 3TN84 (870 CUT, 3014 OEM) (Nippondenso 1.2 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95 Disassembly/Inspection . . . . . . . . . . . . . . . 2-93 Starter Gear Train and Overrunning Clutch 4TN82RJK, 4TN84RJK (Nippondenso 1.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99 Disassembly/Inspection . . . . . . . . . . . . . . . 3-97 Starter Gear Train and Solenoid - 3TN82 (575 SSL) (Nippondenso 1.4 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2-101 Disassembly/Inspection . . . . . . . . . . . . . . . 2-99 Starter Gear Train and Solenoid - 4TN100 (Nippondenso 1.4 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74 Disassembly/Inspection . . . . . . . . . . . . . . . 4-72 Starter Gear Train and Solenoid - 4TN82ESP, 4TN84(T) (4019) (Nippondenso 1.4 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-104 Disassembly/Inspection . . . . . . . . . . . . . . 3-102 Starter Identification Chart 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-86 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-86 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-86 Starter Motor - 3TN75, 3TNC78 (3011), 3TNA82, 3TN84 (870 CUT, 955 CUT) (Nippondenso 1.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-91 Inspection/Test/Replacement . . . . . . . . . . . 2-92 4/7/95 Starter Motor - 3TN78, 3TN82 (30 EX) (Hitachi 2.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-87 Inspection/Test/Replacement . . . . . . . . . . . 2-87 Starter Motor - 3TN82 (575 SSL) (Nippondenso 1.4 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-96 Inspection/Test/Replacement . . . . . . . . . . . 2-97 Starter Motor - 3TNA72 (All Except 3009 OEM) (Nippondenso 1.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-117 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1-116 Inspection/Test/Replacement . . . . . . . . . . 1-117 Starter Motor - 3TNA82, 3TN84 (870 CUT, 3014 OEM) (Nippondenso 1.2 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-91 Inspection/Test/Replacement . . . . . . . . . . . 2-92 Starter Motor - 4TN100 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-70 Inspection/Test/Replacement . . . . . . . . . . . 4-70 Starter Motor - 4TN82ESP, 4TN84(T) (4019) (Nippondenso 1.4 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-101 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-100 Inspection/Test/Replacement . . . . . . . . . . 3-101 Starter Motor - 4TN82RJE (Hitachi 2.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-90 Inspection/Test/Replacement . . . . . . . . . . . 3-91 Starter Motor - 4TN82RJK, 4TN84RJK (Nippondenso 1.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-94 Inspection/Test/Replacement . . . . . . . . . . . 3-95 Starter Overrunning Clutch - 3TN78, 3TN82 (30 EX) (Hitachi 2.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-89 Starter Overrunning Clutch - 4TN82RJE (Hitachi 2.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-93 Starter Solenoid - 3TN75, 3TNC78 (3011), 3TNA82, 3TN84 (870 CUT, 955 CUT) (Nippondenso 1.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96 Disassembly/Inspection . . . . . . . . . . . . . . . 2-95 Index-9 I Index Starter Solenoid - 3TN78, 3TN82 (30 EX) (Hitachi 2.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-90 Starter Solenoid - 3TNA72 (All Except 3009 OEM) (Nippondenso 1.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-121 Disassembly/Inspection . . . . . . . . . . . . . . 1-121 Starter Solenoid - 3TNA82, 3TN84 (870 CUT 3014 OEM) (Nippondenso 1.2 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96 Disassembly/Inspection . . . . . . . . . . . . . . . 2-95 Starter Solenoid - 4TN82RJE (Hitachi 2.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-93 Starter Solenoid - 4TN82RJK, 4TN84RJK (Nippondenso 1.0 kW) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99 Disassembly/Inspection . . . . . . . . . . . . . . . 3-99 Starter Solenoid, Test 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-58 Starter, AMP Draw/RPM Test 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-56 Starter, No-Load AMP Draw/RPM Test 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-57 Starter, No-Load Amp Draw/RPM Test 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-145 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-129 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-129 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-132 Stub Shaft 3TN66 (330/332 LGT, F915 FM). . . . . . . . 1-51 3TNA72 (430 LGT, F925/35 FM) . . . . . . . 1-51 T I Thermostat - 3TN66, 3TNA72 (3009) Opening Test. . . . . . . . . . . . . . . . . . . . . . . 1-144 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 1-84 Thermostat - 3TN75, 3TNC78 (3011), 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT) Opening Test. . . . . . . . . . . . . . . . . . . . . . . 2-127 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-71 Thermostat - 4TN100 Opening Test. . . . . . . . . . . . . . . . . . . . . . . . 4-91 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-56 Thermostat - 4TN78T, 4TN82, 4TN84(T) (4019) Opening Test. . . . . . . . . . . . . . . . . . . . . . . 3-130 Thermostat - 4TN82RJK, 4TN84RJK Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-71 Index-10 Thermostat and Housing - 3TN78, 3TN82 (30 EX), 3TN84 (955 CUT, 3014 OEM) Opening Test. . . . . . . . . . . . . . . . . . . . . . . 2-127 Thermostat Replacement . . . . . . . . . . . . . . 2-70 Thermostat and Housing - 4TN78T, 4TN82RJE, 4TN82ESP, 4TN84(T) (4019) Opening Test. . . . . . . . . . . . . . . . . . . . . . . 3-130 Thermostat Replacement . . . . . . . . . . . . . . 3-70 Timing Gear Backlash, Check 3TN66 and Later 3TNA72 . . . . . . . . . . . . 1-141 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-123 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-123 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-127 Early 3TNA72 (430 LGT) . . . . . . . . . . . . 1-140 Timing Gear Cover 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-59 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-59 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-58 Early 3TNA72 (430 LGT) . . . . . . . . . . . . . 1-62 Later 3TNA72. . . . . . . . . . . . . . . . . . . . . . . 1-63 Timing Gear Cover Mounting Plate 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-62 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-62 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-61 Timing Gear Housing 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-67 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47 Early 3TNA72. . . . . . . . . . . . . . . . . . . . . . . 1-68 Later 3TNA72. . . . . . . . . . . . . . . . . . . . . . . 1-69 Torque Values Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-15 Unified Inch . . . . . . . . . . . . . . . . . . . . . . . . G-16 Troubleshooting Chart 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-131 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-116 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-116 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-119 Turbocharger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 10-17 Disconnect Oil Inlet Line . . . . . . . . . . . . . . G-17 Extending Life . . . . . . . . . . . . . . . . . . . . . 10-12 Failure Analysis . . . . . . . . . . . . . . . . . . . . 10-26 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Rotor Shaft Axial Play Check. . . . . . . . . . 10-15 Rotor Shaft Radial Play Check . . . . . . . . . 10-16 Seven-Step Inspection. . . . . . . . . . . . . . . . 10-28 Theory of Operation . . . . . . . . . . . . . . . . . 20-12 4/7/95 Index V W Valve Clearance, Check and Adjustment 3TN66 and Later 3TNA72 . . . . . . . . . . . . 1-135 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-119 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-119 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-122 Early 3TNA72 (430 LGT) . . . . . . . . . . . . 1-134 Valve Lift Check 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-138 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-122 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-122 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-125 Valve Seats, Grind 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-30 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-28 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-28 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-28 Valves, Lap 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-30 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-29 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-29 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-28 Voltage Regulator, Replacement (Hitachi 25A) 3TN78, 3TN82 (30 EX) . . . . . . . . . . . . . . 2-103 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75 4TN78T. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106 Voltage Regulator, Replacement (Nippondenso 35A) 3TN66 (655 CUT) . . . . . . . . . . . . . . . . . . 1-122 3TN75, (855/56 CUT), 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT, 955 CUT) . . . . . . . . . . . . . . . . 2-107 3TNA72 (430 LGT, 670 CUT, 755/56 CUT, F925/35 FM) . . . . . . . . . . . . 1-122 4TN82, 4TN84RJK. . . . . . . . . . . . . . . . . . 3-110 Voltage Regulator, Replacement (Nippondenso 40A) 3TN66 (655 CUT) . . . . . . . . . . . . . . . . . . 1-128 3TN75, 3TNC78 (3011), 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM). . . . . . . . . 2-112 3TNA72 (455 LGT, 755/56 CUT, 3009 OEM) . . . . . . . . . . . . . . . . . . . . . . . . 1-128 4TN82ESP/RJE, 4TN84(T) (4019) . . . . . 3-115 Water Pump - 3TN66 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 1-86 Removal/Installation . . . . . . . . . . . . . . . . . . 1-85 Water Pump - 3TN75, 3TNC78 (3011), 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-75 Removal/Installation . . . . . . . . . . . . . . . . . . 2-74 Water Pump - 3TN78, 3TN82 (30 EX), 3TN84 (955 CUT, 3014 OEM) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-72 Removal/Installation . . . . . . . . . . . . . . . . . . 2-71 Water Pump - 3TNA72 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 1-89 Removal/Installation . . . . . . . . . . . . . . . . . . 1-88 Water Pump - 4TN100 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-58 Removal/Installation . . . . . . . . . . . . . . . . . . 4-57 Water Pump - 4TN78T, 4TN82RJE, 4TN82ESP, 4TN84(T) (4019) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-72 Removal/Installation . . . . . . . . . . . . . . . . . . 3-71 Water Pump - 4TN82RJK, 4TN84RJK Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-75 Removal/Installation . . . . . . . . . . . . . . . . . . 3-74 4/7/95 I Index-11 Index I Index-12 4/7/95 John Deere Series 220 Diesel Engines CTM3 (10AUG93)
Source Exif Data:
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