Manual Oficina c4.2 c6.4 Caterpilla

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Modelo: 315D L EXCAVATOR CJN
Configurao: 315D L Excavator CJN00001-UP (MACHINE) POWERED BY
C4.2 Engine
Especificaes
C4.2 and C6.4 Engines for Caterpillar Built Machines
Nmero de Mdia -KENR6740-04 Data de Publicao -01/04/2008 Data de Atualizao -29/04/2008
i02861478
Engine Design
SMCS - 1201
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
Illustration 1 g01425351
(A) Exhaust valves
(B) Inlet valves
Bore ... 102 mm (4.02 inch)
Stroke ... 130 mm (5.12 inch)
Displacement ... 4.2 L (256 cu in)
Cylinder arrangement ... In-line
Valves per cylinder ... 4
In order to check the engine valve lash setting, the engine must be cold and the engine must be
stopped.
Engine valve lash
Inlet ... 0.25 mm (0.010 inch)

Exhaust ... 0.40 mm (0.016 inch)
Type of combustion ... Direct injection
Firing order ... 1-3-4-2
The crankshaft rotation is viewed from the flywheel end of the engine. Crankshaft rotation ...
Counterclockwise
Note: The front end of the engine is opposite of the flywheel end of the engine. The left side of the
engine and the right side of the engine are viewed from the flywheel end of the engine. The No. 1
cylinder is the front cylinder.
Direitos Autorais 1993 - 2017 Caterpillar Inc. Wed Feb 8 14:18:46 UTC-0200 2017
Todos os Direitos Reservados.
Rede Particular Para Licenciados SIS.
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C4.2 Engine
Teste e Ajustes
C4.2 and C6.4 Engine for Caterpillar Built Machines
i02859277
Engine Valve Lash - Inspect/Adjust

SMCS - 1102-025
Be sure the engine cannot be started while this maintenance is being

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

Adjustment of the Height of the Valve Bridge

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

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

0.25 mm (0.010 inch) 0.40 mm (0.016 inch)
TC Compression Stroke 1-2-4 1-3-5
TC Exhaust Stroke (1) 3-5-6 2-4-6
Firing Order 1-5-3-6-2-4 (2)

(1) 360 from TC compression stroke
(2) The No. 1 cylinder is at the front of the engine.
If the measurement is not within this range, an adjustment is necessary. Refer to "Valve Lash
Adjustment" for the proper procedure.
Valve Lash Adjustment

Use the following procedure to adjust the valve lash.
Valve lash
1. Ensure that the No. 1 piston is at the top center position on the compression stroke.
Table 2
TC Compression Stroke Inlet Valves Exhaust Valves
Valve Lash
0.25 mm (0.010 inch) 0.40 mm (0.016 inch)
Cylinders 1-2-4 1-3-5
2. Adjust the valve lash according to Table 3.
3. Loosen the adjustment locknut (3) .
4. Place the appropriate feeler gauge between rocker arm and the valve bridge. Then, turn the
adjustment screw (4) in a clockwise direction. Slide the feeler gauge between the rocker arm
and the valve bridge. Continue turning the adjustment screw (4) until a slight drag is felt on the
feeler gauge. Remove the feeler gauge.
5. Tighten the adjustment locknut (3) to a torque of 4 1 Nm (35 9 lb in). Do not allow the
adjustment screw (4) to turn while you are tightening the adjustment locknut (3) . Recheck the
valve lash after tightening the adjustment locknut (3) .
6. Rotate the engine 360 degrees in the direction of the engine rotation. This will put the No. 6
piston at the top center position on the compression stroke.
Table 3
TC Exhaust Stroke Inlet Valves Exhaust Valves
Valve Lash
0.25 mm (0.010 inch) 0.40 mm (0.016 inch)
Cylinders 3-5-6 2-4-6
7. Adjust the valve lash according to Table 4.
8. Loosen the adjustment locknut (3) .
9. Place the appropriate feeler gauge between rocker arm and the valve bridge. Then, turn the
adjustment screw (4) in a clockwise direction. Slide the feeler gauge between the rocker arm
and the valve bridge. Continue turning the adjustment screw until a slight drag is felt on the
feeler gauge. Remove the feeler gauge.
10. Tighten the adjustment locknut (3) to a torque of 4 1 Nm (35 9 lb in). Do not allow the
adjustment screw (4) to turn while you are tightening the adjustment locknut (2) . Recheck the
valve lash after tightening the adjustment locknut (3) .
Adjusting the valve lash several times in a short period indicates wear in a different part of the
engine. Find the problem and make any necessary repairs in order to prevent more damage to the
engine.
Rapid wear of the camshaft and tappets can occur if insufficient valve lash is not corrected.
Insufficient valve lash can also be an indication of faulty valve seats. The following items are
reasons for faulty seats of the valves: faulty fuel injection nozzles, restrictions to the air inlet, dirty
air filters, incorrect fuel setting and overloading the engine.
Broken valve stems, broken pushrods, or broken spring retainers can be caused by insufficient valve
lash that is not corrected. A fast increase in valve lash can be an indication of any of the following
items:
z Worn camshaft and tappets
z Worn rocker arms
z Bent pushrods
z Loose adjustment screws for valve lash
z Broken socket on the upper end of pushrod
Fuel in the lubrication oil may be a possible cause of rapid wear of the camshaft and the tappets.
Dirty lubrication oil may also be a possible cause of rapid wear of the camshaft and tappets.
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C4.2 Engine
Especificaes
i02972601
Camshaft
SMCS - 1210
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BWW1-UP
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BYM1-UP
S/N - BZF1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - EAX1-UP
S/N - FAL1-UP
S/N - FMH1-UP
S/N - GKS1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - JLG1-UP
S/N - KBD1-UP
S/N - KGF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDT1-UP
S/N - NAS1-UP
S/N - NCM1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PDP1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SBP1-UP
S/N - SBZ1-UP
S/N - SED1-UP
S/N - TAE1-UP
S/N - TGY1-UP
S/N - WFD1-UP
S/N - WGC1-UP
S/N - XCK1-UP
S/N - YDS1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
(1) Maximum permissible temperature of the camshaft gear for installation on the camshaft ... 250
C (480 F)
NOTICE
Do not use a torch to heat the gear. A torch can unevenly heat the gear
causing warpage. The hardness of the gear may also be changed with
the use of a torch.
(A) Diameters of camshaft journals
Table 1
Number of Journal Standard Diameter Service Limit (1)
1, 2, 3
53.94 to 53.96 mm (2.124 to 2.124 inch) 53.90 mm (2.122 inch)
4
(1) The service limit is the maximum dimension or the service limit is the minimum dimension that is specified for a
part. Replace the part if the service limit is reached.
(2) Torque for two bolts ... 12 2 Nm (105 18 lb in)

: ) & * " # 2 $ 015 11985
U ! "# $ % & ' ( ) & "# ( * ' ) * + " ,
1- M * ) & ' * . * + " $ / C0 -
2- M * ) & + * ' " & ' / D0 -
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( " & # ' " * ' ) * + " -
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:# + - - - 6- 1; 5 . . / 0- 25 22 " # ' 0
S & < "' ". " & + " & 3 * ) - - - 6- 962 . . / 0- 24 5 1 " # ' 0
S & < "' ". " & + " & " # - - - ; - 6; 5 . . / 0- 2226 " # ' 0
Note: R % * ' ' * . * " & < " ' " . " & + " " & * ' ( -
Note: Use a dial indicator and blocks in order to determine the runout of the camshaft. Take one half
of the dial indicator reading as the runout.
(3) Maximum permissible runout for camshaft ... 0.04 mm (0.002 inch)
(4) Measure the camshaft bearing with a dial indicator. Subtract the diameter of the camshaft journal
in order to give bearing clearances. Refer to Table 4 for the clearance between the camshaft journals
and the bushings.
Table 2
Number of Journal Standard Diameter Repair Limit (1)
1, 2, 3
4
(1) The repair limit is the maximum dimension or the repair limit is the minimum dimension that is specified for a part.
Repair the part if the repair limit is reached.
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Especificaes
i02980079
Crankshaft
SMCS - 1202
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(1) Crankshaft main bearing journal
(2) Support the crankshaft in a set of vee blocks. Measure the runout dimension at the center journal.
Maximum runout ... 0.07 0.03 mm (0.003 0.001 inch)
(3) Crankshaft end play ... 0.100 to 0.264 mm (0.0039 to 0.0104 inch)
Note: The maximum repair limit is 0.300 mm (0.0118 inch).
Replace the standard thrust plates if the end play exceeds the standard clearance. Three oversize
thrust plates are available as replacements if the end play still exceeds the maximum limit. Generally,
the rear journal is likely to be worn more rapidly than the front journal. If necessary, replace the rear
thrust plate. Refer to Table 1 for oversize thrust plates.
Table 1
Dimensions for Grinding of Crankshaft

Oversize Thrust Plates
Oversize Thrust Oversize (front or Oversize (front or

Tolerance
Plate rear) rear)
0.15 mm (0.006 inch) 33.15 mm (1.305 inch) 33.30 mm (1.311 inch) 0.039 mm (0.0015
inch)
inch)
inch)
Torque for the crankshaft pulley nut ... 706 59 Nm (520 44 lb ft)
The maximum temperature for installing the crankshaft gear is the following value. ... 250 C (482
F)
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Especificaes
i02980802
Fuel Injection Nozzles

SMCS - 1254
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BWW1-UP
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BYM1-UP
S/N - BZF1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - EAX1-UP
S/N - FAL1-UP
S/N - FMH1-UP
S/N - GKS1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - JLG1-UP
S/N - KBD1-UP
S/N - KGF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDT1-UP
S/N - NAS1-UP
S/N - NCM1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PDP1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SBP1-UP
S/N - SBZ1-UP
S/N - SED1-UP
S/N - TAE1-UP
S/N - TGY1-UP
S/N - WFD1-UP
S/N - WGC1-UP
S/N - XCK1-UP
S/N - YDS1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
(2) Clamp
(3) O-ring seal
(1) Torque for the bolt ... 29 3 Nm (21 2 lb ft)
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Especificaes
i02980088
Cylinder Block
SMCS - 1201
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(1) Torque for four bolts ... 108 5 Nm (80 4 lb ft)
(3) Measure the amount of the warpage of the cylinder block with a straightedge and feeler gauge.
Maximum allowable clearance ... 0.05 mm (0.002 inch)
Repair limit ... 0.20 mm (0.008 inch)
Resurface the top of the block if the repair limit is reached.
(4) Measure the inside diameter of the cylinder sleeve that is parallel to the crankshaft. Measure the
inside diameter of the cylinder liner that is in a perpendicular position to the crankshaft. Measure the
top, the middle and the bottom of the cylinder liner. Refer to Table 2 for tolerances of the cylinder
liner.
Table 1
Tolerances of Cylinder Sleeves

Standard at Assembly Repair Limit (1) Service Limit (2)
Inside
102.010 to 102.045 mm (4.0161 to 102.200 mm (4.0236 102.700 mm (4.0433
Diameter
4.0175 inch) inch) inch)
Out of Round
N/A N/A
0.010 mm (0.0004 inch)
Taper N/A N/A

0.015 mm (0.0006 inch)
Repair a part if the repair limit is reached.
Bore the cylinder to the specified oversize dimension if the inside diameter reaches the repair limit
but the inside diameter does not reach the service limit. Refer to Table 3.
Hone the liner to +0.25 mm (+0.010 inch) or +0.50 mm (+0.020 inch) oversize. Hone the liner to an
accuracy within 0.010 to 0.045 mm (0.0004 to 0.0018 inch).
Determine the oversize dimension that is necessary in order to clean up the cylinder if any liner has
uneven wear.
Replace all cylinder liners that are in excess of the service limit.
Note: Refinish all liners to the same oversize dimension. Use a ridge reamer in order to cut the ridge
of the cylinder if the liner is in good condition. Hone the cylinder bore.
Table 2
Oversize Bore Cylinder Bore Size
102.260 mm (4.0260 inch)

0.250 mm (0.0098 inch)
102.295 mm (4.0274 inch)
102.510 mm (4.0358 inch)

0.500 mm (0.0197 inch)
102.545 mm (4.0372 inch)
(5) Service limit of cylinder liner ... 102.700 mm (4.0433 inch)
Note: Replace all cylinder liners that exceed the service limit.
Use the following procedure in order to replace the cylinder liners.

1. Set up a boring machine on the cylinder block. Align the boring machine with the center of the
bottom of the cylinder liner with the least worn area.
2. Bore the liner until the thickness is 0.50 mm (0.020 inch).
3. Remove the remainder of the liner. Be careful not to damage the cylinder block.
4. Install a new liner. Align the liner with the top of the cylinder block.
5. The bore of the cylinder must be 102.000 to 102.035 mm (4.0157 to 4.0171 inch).
Diameter for the main bearing bores ... 95.000 mm (3.7402 inch)
Maximum diameter of the main bearing bores ... 95.022 mm (3.7410 inch)
New height of deck from centerline of crankshaft to deck ... 307.00 0.05 mm (12.086 0.002 inch)
Minimum height from the centerline of crankshaft to deck ... 306.70 mm (12.075 inch)
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Especificaes
i02982121
Fuel Injection Pump

SMCS - 1251; 1290
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BWW1-UP
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BYM1-UP
S/N - BZF1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - EAX1-UP
S/N - FAL1-UP
S/N - FMH1-UP
S/N - GKS1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - JLG1-UP
S/N - KBD1-UP
S/N - KGF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDT1-UP
S/N - NAS1-UP
S/N - NCM1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PDP1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SBP1-UP
S/N - SBZ1-UP
S/N - SED1-UP
S/N - TAE1-UP
S/N - TGY1-UP
S/N - WFD1-UP
S/N - WGC1-UP
S/N - XCK1-UP
S/N - YDS1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
(1) Torque for solenoid valve group ... 70 5 Nm (50 4 lb ft)
(2) Torque for two plugs ... 60 6 Nm (44 4 lb ft)
(3) Torque for plug ... 24 2 Nm (18 1 lb ft)
(4) Lubricate three seals with clean engine oil before assembly.
(5) Torque for two plugs ... 40 3 Nm (30 2 lb ft)
(6) Torque for bolt ... 12 3 Nm (105 27 lb in)
(7) Torque for bolt ... 9 1 Nm (80 9 lb in)
(8) Torque for five bolts ... 30 2 Nm (22 1 lb ft)

(9) Torque for connector ... 25.0 2.5 Nm (18 2 lb ft)
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Especificaes
i02830711
Engine Oil Pump

SMCS - 1304
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BWW1-UP
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BYM1-UP
S/N - BZF1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - EAX1-UP
S/N - FAL1-UP
S/N - FMH1-UP
S/N - GKS1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - JLG1-UP
S/N - KBD1-UP
S/N - KGF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDT1-UP
S/N - NAS1-UP
S/N - NCM1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PDP1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SBP1-UP
S/N - SBZ1-UP
S/N - SED1-UP
S/N - TAE1-UP
S/N - TGY1-UP
S/N - WFD1-UP
S/N - WGC1-UP
S/N - XCK1-UP
S/N - YDS1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
(1) Driven gear assembly
(2) Drive gear assembly
(5) Spindle
NOTICE
Before operation, the pump must be lubricated with clean engine oil
and the pump must turn freely by hand or damage to parts can be the
result.
Note: The minimum acceptable oil pressure at low idle is 98 kPa (14 psi).
Heat the oil pump gear (3) to 180 to 220 C (356 to 428 F) and support the end of the drive gear
shaft in order to install the oil pump gear. Press the oil pump gear until the oil pump gear is flush
with the end of the shaft.
NOTICE
the use of a torch.
The backlash between the oil pump gear (3) and the idler gear (4) is the following. ... 0.100 to 0.190
mm (0.0039 to 0.0075 inch)
Note: Replace the gears if the backlash exceeds 0.35 mm (0.014 inch).
Note: The oil pump gear and the drive gear assembly are not serviceable if the oil pump gear is
removed.
(6) Housing for oil pump gear
Maximum distance between the oil pump gear assembly and the oil pump housing
Distance above the housing ... 0.020 mm (0.0008 inch)
Distance below the housing ... 0.034 mm (0.0013 inch)
Note: The service limit of the oil pump gear assembly is 0.150 mm (0.0059 inch) below the oil pump
housing.
Note: Measure the clearance between the oil pump gears and the oil pump housing with a feeler
gauge.
Clearance between the oil pump gears and the oil pump housing ... 0.050 to 0.098 mm (0.0020 to
0.0039 inch)
Note: The service limit of the oil pump gear assembly is 0.10 mm (0.004 inch).
< -- !% " 3 / 01415 05 8
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( % ) 1 1 1 01 04 % 01 00 $ $ * 01 005 % 01 003 ! " ( ,
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9 ( # ) ! ( - ! $ ! % & 01 1: $ $ * 01 006 ! " ( , 1
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Inside diameter of idler gear bushing ... 25.000 to 25.021 mm (0.9842 to 0.9851 inch)
Maximum diameter of idler gear bushing for oil pump ... 25.059 mm (0.9866 inch)
(B) Spindle
Diameter of spindle ... 24.939 to 24.960 mm (0.9818 to 0.9827 inch)
Minimum diameter of spindle for oil pump ... 24.901 mm (0.9804 inch)
(9) Torque for bolts ... 35 6 Nm (26 4 lb ft)
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Especificaes
i02970181
Cylinder Head
SMCS - 1100
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZF1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(1) Dimension for the cylinder head
Use a straightedge and a feeler gauge to check the cylinder head for warpage.
Flatness of the cylinder head over total span ... 0.05 mm (0.002 inch)
Resurface the cylinder head if the warpage exceeds the following value. ... 0.20 mm (0.008
inch)
Gasket thickness of cylinder head ... 1.70 0.05 mm (0.067 0.002 inch)
Note: The repair limit of the contact surface of the gasket and the repair limit of the cylinder block
surface is 0.20 mm (0.008 inch).
Note: Put clean engine oil on the threads of the cylinder head bolts.
Tighten the bolt 1 through bolt 17 in the numerical sequence that is shown in Illustration 2 to 137 5
Nm (100 4 lb ft).
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Especificaes
i02970181
Cylinder Head
SMCS - 1100
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZF1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(1) Dimension for the cylinder head
Use a straightedge and a feeler gauge to check the cylinder head for warpage.
Flatness of the cylinder head over total span ... 0.05 mm (0.002 inch)
Resurface the cylinder head if the warpage exceeds the following value. ... 0.20 mm (0.008
inch)
Gasket thickness of cylinder head ... 1.70 0.05 mm (0.067 0.002 inch)
Note: The repair limit of the contact surface of the gasket and the repair limit of the cylinder block
surface is 0.20 mm (0.008 inch).
Note: Put clean engine oil on the threads of the cylinder head bolts.
Tighten the bolt 1 through bolt 17 in the numerical sequence that is shown in Illustration 2 to 137 5
Nm (100 4 lb ft).
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C4.2 Engine
Especificaes
i02972801
Engine Oil Pan

SMCS - 1302
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(1) Torque for 28 bolts ... 18 2 Nm (13 1 lb ft)
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C4.2 Engine
Especificaes
i02970240
Exhaust Manifold
SMCS - 1059
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(1) Torque for nine nuts ... 18 2 Nm (13 1 lb ft)
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C4.2 Engine
Especificaes
i02980079
Crankshaft
SMCS - 1202
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(1) Crankshaft main bearing journal
(2) Support the crankshaft in a set of vee blocks. Measure the runout dimension at the center journal.
Maximum runout ... 0.07 0.03 mm (0.003 0.001 inch)
(3) Crankshaft end play ... 0.100 to 0.264 mm (0.0039 to 0.0104 inch)
Note: The maximum repair limit is 0.300 mm (0.0118 inch).
Replace the standard thrust plates if the end play exceeds the standard clearance. Three oversize
thrust plates are available as replacements if the end play still exceeds the maximum limit. Generally,
the rear journal is likely to be worn more rapidly than the front journal. If necessary, replace the rear
thrust plate. Refer to Table 1 for oversize thrust plates.
Table 1
Dimensions for Grinding of Crankshaft

Oversize Thrust Plates
Oversize Thrust Oversize (front or Oversize (front or

Tolerance
Plate rear) rear)
inch)
inch)
inch)
Torque for the crankshaft pulley nut ... 706 59 Nm (520 44 lb ft)
The maximum temperature for installing the crankshaft gear is the following value. ... 250 C (482
F)
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i02759135
Connecting Rod Bearing Journal

SMCS - 1202; 1219; 1225
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BWW1-UP
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BYM1-UP
S/N - BZF1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - EAX1-UP
S/N - FAL1-UP
S/N - FMH1-UP
S/N - GKS1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - JLG1-UP
S/N - KBD1-UP
S/N - KGF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDT1-UP
S/N - NAS1-UP
S/N - NCM1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PDP1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SBP1-UP
S/N - SBZ1-UP
S/N - SED1-UP
S/N - TAE1-UP
S/N - TGY1-UP
S/N - WFD1-UP
S/N - WGC1-UP
S/N - XCK1-UP
S/N - YDS1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
Table 1
Original size journal 64.945 to 64.965 mm (2.5569 to 2.5577 inch)
Undersize journal
64.695 to 64.715 mm (2.5470 to 2.5478 inch)
0.25 mm (0.010 inch)
Undersize journal
64.445 to 64.465 mm (2.5372 to 2.5380 inch)
0.50 mm (0.020 inch)
Undersize journal
64.195 to 64.215 mm (2.5274 to 2.5281 inch)
0.75 mm (0.030 inch)
The clearance between a new bearing and a new journal is the following value. ... 0.035 to 0.100 mm
(0.0014 to 0.0039 inch)
An undersized bearing is required if the clearance between the connecting rod journal and the
bearing is in excess of the service limit of 0.200 mm (0.0079 inch). If the crankshaft is worn
excessively, or if the crankshaft is uneven, an undersized bearing is required. If an undersized
bearing is required, grind the crankshaft to a dimension listed in Table 2.
Note: The allowable tolerance for rod bearing journals that are out of round is 0.010 mm (0.0004
inch). The maximum repair limit is 0.030 mm (0.0012 inch). If the repair limit is exceeded, regrind
the bearing journals to the specified dimension.
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C4.2 Engine
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i02978141
Connecting Rod
SMCS - 1218
(1) Matching marks that are used to align the cap to the connecting rod
(A) The upper oil hole is 40 degrees above the horizontal centerline.
(B) The lower oil hole is 30 degrees below the horizontal centerline.
(C) The end of the piston pin bearing is 30 degrees below the lower oil hole.
(D) Bore of piston pin bearing ... 34.020 to 34.045 mm (1.3394 to 1.3404 inch)
The clearance between the piston pin bearing and the piston pin is 0.023 to 0.054 mm (0.0009 to
0.0021 inch).
Note: A clearance for the piston pin to the piston pin bearing over 0.080 mm (0.0031 inch) is
excessive. Replace the piston pin or replace the bearing if the clearance is excessive.
Note: Before assembly, put clean engine oil on the bolt threads and all surfaces that make contact
between the bolt and connecting rod caps.
(2) Torque for nuts ... 103 5 Nm (75 4 lb ft)
Note: Measure the bores of each of the connecting rods and record the dimension of the bores.
(E) Bore in connecting rod ... 64.000 mm to 64.019 mm (2.5197 inch to 2.5204 inch)
(3) Use a feeler gauge to measure the end play. End play of the connecting rod should be within 0.15
to 0.35 mm (0.006 to 0.014 inch).
Note: Replace the connecting rod if the end play exceeds 0.50 mm (0.020 inch).
Assemble the piston (4) and connecting rods. Ensure that the markings (5) on the piston and the
marks (1) on the connecting rod are on the same side.
Install the piston assembly with the marks (1) on the connecting rod toward the camshaft (6) .
(F) Piston projection
Use the following procedure to measure the height of each piston above the cylinder block. If
clearances are not in the acceptable range, inspect the components for wear or damage.
1. Determine the top center position of the piston with a dial indicator assembly.
2. Install the dial indicator assembly on the top of the block. Set the needle of the dial indicator to
zero.
3. Measure projection (F) at three places on the top of the piston. Take an average of the three
measurements in order to determine the projection. Subtract the projection from the installed
thickness of the cylinder head gasket in order to determine the clearance between the top of the
piston and the cylinder head.
Installed thickness of the cylinder head gasket ... 1.70 0.10 mm (0.067 0.004 inch)
Piston projection ... 0.55 to 1.15 mm (0.022 to 0.045 inch)
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C4.2 Engine
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i02876647
Main Bearing Journal

SMCS - 1202; 1203
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BWW1-UP
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BYM1-UP
S/N - BZF1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - EAX1-UP
S/N - FAL1-UP
S/N - FMH1-UP
S/N - GKS1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - JLG1-UP
S/N - KBD1-UP
S/N - KGF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDT1-UP
S/N - NAS1-UP
S/N - NCM1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PDP1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SBP1-UP
S/N - SBZ1-UP
S/N - SED1-UP
S/N - TAE1-UP
S/N - TGY1-UP
S/N - WFD1-UP
S/N - WGC1-UP
S/N - XCK1-UP
S/N - YDS1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
(1) Main bearing cap
(2) Dial indicator
Procedure to measure the bore of main bearing journal
1. Put the main bearing caps in position in the cylinder block. Apply clean engine oil on the main
bearing bolts. Install the main bearing bolts and tighten the main bearing bolts to a torque of
137 5 Nm (100 4 lb ft).
2. Measure the main bearing bores with a dial indicator. Subtract the diameter of the crankshaft
journal from the inside diameter of the main bearing in order to determine the bearing
clearance on the main journal. Clearance between the crankshaft journal and the main bearing
is 0.050 to 0.118 mm (0.0020 to 0.0047 inch).
Note: Replace the bearings or refinish the crankshaft to the next undersize bearing if the main
bearing clearance exceeds 0.20 mm (0.008 inch).
Note: The allowable tolerance for main bearing journals that are out of round is 0.010 mm (0.0004
9$$ & %2 %1 4 2 6 013* 811.
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3 T ! " # $ % & ' ' ' 13( ) * N+ , 100 ) . $ # " %
T2 # $ ! 1
Thickness for Crankshaft Main Bearing

Size of Crankshaft Main Bearing Journal Bearing Thickness
= 16 14 2 $ & 1> ! 7 4 2 $

2' . ( ( % 2' . 90 , , 0' 09( * % 0' 0980 1 4 3 /
U4 0 ! & 1 > !
0' 2* , , 0' 010 1 4 3 / 2' 602 % 2' 61* , , 0' 102. % 0' 1030 1 4 3 /
U4 0 ! & 1 > !
0' * 0 , , 0' 020 1 4 3 / 2' ( 2( % 2' ( . 0 , , 0' 10( . % 0' 10( 9 1 4 3 /
U4 0 ! & 1 > !
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T2 # $ ! 2

1
= 16 14 2 $ & 1> ! 7 4 2 $
89' 9* % 89' 9( , , 3' * . 1 % 3' * . 2 1 4 3 /
U4 0 ! & 1 > ! 7 4 2 $
89' ( 0 % 89' ( 2 , , 3' * 31 % 3' * 32 1 4 3 /
0' 2* , , 0' 010 1 4 3 /
U4 0 ! & 1 > ! 7 4 2 $
89' . * % 89' . ( , , 3' * 21 % 3' * 22 1 4 3 /
0' * 0 , , 0' 020 1 4 3 /
U4 0 ! & 1 > ! 7 4 2 $
89' 20 % 89' 22 , , 3' * 12 % 3' * 13 1 4 3 /
0' ( * , , 0' 030 1 4 3 /
1 R! 6 1 4 0 % / ! , 2 1 4 # ! 2 1 4 6 7 4 2 $& % %/ ! 4 ! A % 4 0 ! & 1 > ! 0 1 , ! 4 & 1 4 1 " % / ! ! < 2 1 $ 1 , 1 % " 89' 8* , , 3' * 3( 1 4 3 / 1 &
! A 3 ! ! 0 ! 0 '
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C4.2 Engine
Especificaes
i02970360
Rocker Shaft
SMCS - 1102
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(1) Bore in rocker arm bushing for shaft ... 24.949 to 24.975 mm (0.9822 to 0.9833 inch)
(2) Diameter of rocker arm shaft ... 24.915 to 24.928 mm (0.9809 to 0.9814 inch)
Clearance of rocker arm bushing and shaft
Minimum ... 0.021 mm (0.0008 inch)

Maximum ... 0.060 mm (0.0024 inch)
(3) Align the oil holes in rocker arm bushing (4) with the oil holes in the rocker arm when the rocker
arm bushing is replaced.
(7) Torque for bolt ... 74 5 Nm (55 4 lb ft)

Valve lash adjustment
Turn the crankshaft until the timing mark on the crankshaft pulley is aligned with the pointer on the
timing gear housing in order to adjust the valve lash. Both the No. 1 inlet valve and the No. 1
exhaust valve pushrods must not be in tension against the rocker arms.
Inlet valve lash ... 0.25 mm (0.010 inch)
Exhaust valve lash ... 0.40 mm (0.016 inch)
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i02972601
Camshaft
SMCS - 1210
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BWW1-UP
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BYM1-UP
S/N - BZF1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - EAX1-UP
S/N - FAL1-UP
S/N - FMH1-UP
S/N - GKS1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - JLG1-UP
S/N - KBD1-UP
S/N - KGF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDT1-UP
S/N - NAS1-UP
S/N - NCM1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PDP1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SBP1-UP
S/N - SBZ1-UP
S/N - SED1-UP
S/N - TAE1-UP
S/N - TGY1-UP
S/N - WFD1-UP
S/N - WGC1-UP
S/N - XCK1-UP
S/N - YDS1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
(1) Maximum permissible temperature of the camshaft gear for installation on the camshaft ... 250
C (480 F)
NOTICE
the use of a torch.
(A) Diameters of camshaft journals
Table 1
Number of Journal Standard Diameter Service Limit (1)
1, 2, 3
4

: ) & * " # 2 $ 015 11985
U ! "# $ % & ' ( ) & "# ( * ' ) * + " ,
1- M * ) & ' * . * + " $ / C0 -
2- M * ) & + * ' " & ' / D0 -
2 - S) + & * ' + * ' " & ' . * ) & . # " # S % 2 & . ' * . * + " $ " # S % 1- T
( " & # ' " * ' ) * + " -
/ B0 S% ' " " ( ' * . * + "
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:# + - - - 6- 1; 5 . . / 0- 25 22 " # ' 0
S & < "' ". " & + " & 3 * ) - - - 6- 962 . . / 0- 24 5 1 " # ' 0
S & < "' ". " & + " & " # - - - ; - 6; 5 . . / 0- 2226 " # ' 0
Note: R % * ' ' * . * " & < " ' " . " & + " " & * ' ( -
Note: Use a dial indicator and blocks in order to determine the runout of the camshaft. Take one half
of the dial indicator reading as the runout.
(3) Maximum permissible runout for camshaft ... 0.04 mm (0.002 inch)
(4) Measure the camshaft bearing with a dial indicator. Subtract the diameter of the camshaft journal
in order to give bearing clearances. Refer to Table 4 for the clearance between the camshaft journals
and the bushings.
Table 2
Number of Journal Standard Diameter Repair Limit (1)
1, 2, 3
4
Repair the part if the repair limit is reached.
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C4.2 Engine
Especificaes
i02970360
Rocker Shaft
SMCS - 1102
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(1) Bore in rocker arm bushing for shaft ... 24.949 to 24.975 mm (0.9822 to 0.9833 inch)
(2) Diameter of rocker arm shaft ... 24.915 to 24.928 mm (0.9809 to 0.9814 inch)
Clearance of rocker arm bushing and shaft
Minimum ... 0.021 mm (0.0008 inch)

Maximum ... 0.060 mm (0.0024 inch)
(3) Align the oil holes in rocker arm bushing (4) with the oil holes in the rocker arm when the rocker
arm bushing is replaced.

Valve lash adjustment
Turn the crankshaft until the timing mark on the crankshaft pulley is aligned with the pointer on the
timing gear housing in order to adjust the valve lash. Both the No. 1 inlet valve and the No. 1
exhaust valve pushrods must not be in tension against the rocker arms.
Inlet valve lash ... 0.25 mm (0.010 inch)
Exhaust valve lash ... 0.40 mm (0.016 inch)
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Connecting Rod
SMCS - 1218
(1) Matching marks that are used to align the cap to the connecting rod
(A) The upper oil hole is 40 degrees above the horizontal centerline.
(B) The lower oil hole is 30 degrees below the horizontal centerline.
(C) The end of the piston pin bearing is 30 degrees below the lower oil hole.
(D) Bore of piston pin bearing ... 34.020 to 34.045 mm (1.3394 to 1.3404 inch)
The clearance between the piston pin bearing and the piston pin is 0.023 to 0.054 mm (0.0009 to
0.0021 inch).
Note: A clearance for the piston pin to the piston pin bearing over 0.080 mm (0.0031 inch) is
excessive. Replace the piston pin or replace the bearing if the clearance is excessive.
Note: Before assembly, put clean engine oil on the bolt threads and all surfaces that make contact
between the bolt and connecting rod caps.
(2) Torque for nuts ... 103 5 Nm (75 4 lb ft)
Note: Measure the bores of each of the connecting rods and record the dimension of the bores.
(E) Bore in connecting rod ... 64.000 mm to 64.019 mm (2.5197 inch to 2.5204 inch)
(3) Use a feeler gauge to measure the end play. End play of the connecting rod should be within 0.15
to 0.35 mm (0.006 to 0.014 inch).
Note: Replace the connecting rod if the end play exceeds 0.50 mm (0.020 inch).
Assemble the piston (4) and connecting rods. Ensure that the markings (5) on the piston and the
marks (1) on the connecting rod are on the same side.
Install the piston assembly with the marks (1) on the connecting rod toward the camshaft (6) .
(F) Piston projection
Use the following procedure to measure the height of each piston above the cylinder block. If
clearances are not in the acceptable range, inspect the components for wear or damage.
1. Determine the top center position of the piston with a dial indicator assembly.
2. Install the dial indicator assembly on the top of the block. Set the needle of the dial indicator to
zero.
3. Measure projection (F) at three places on the top of the piston. Take an average of the three
measurements in order to determine the projection. Subtract the projection from the installed
thickness of the cylinder head gasket in order to determine the clearance between the top of the
piston and the cylinder head.
Installed thickness of the cylinder head gasket ... 1.70 0.10 mm (0.067 0.004 inch)
Piston projection ... 0.55 to 1.15 mm (0.022 to 0.045 inch)
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Especificaes
i02759135

SMCS - 1202; 1219; 1225
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BWW1-UP
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BYM1-UP
S/N - BZF1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - EAX1-UP
S/N - FAL1-UP
S/N - FMH1-UP
S/N - GKS1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - JLG1-UP
S/N - KBD1-UP
S/N - KGF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDT1-UP
S/N - NAS1-UP
S/N - NCM1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PDP1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SBP1-UP
S/N - SBZ1-UP
S/N - SED1-UP
S/N - TAE1-UP
S/N - TGY1-UP
S/N - WFD1-UP
S/N - WGC1-UP
S/N - XCK1-UP
S/N - YDS1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
Table 1
Original size journal 64.945 to 64.965 mm (2.5569 to 2.5577 inch)
Undersize journal
64.695 to 64.715 mm (2.5470 to 2.5478 inch)
0.25 mm (0.010 inch)
Undersize journal
64.445 to 64.465 mm (2.5372 to 2.5380 inch)
0.50 mm (0.020 inch)
Undersize journal
64.195 to 64.215 mm (2.5274 to 2.5281 inch)
0.75 mm (0.030 inch)
The clearance between a new bearing and a new journal is the following value. ... 0.035 to 0.100 mm
(0.0014 to 0.0039 inch)
An undersized bearing is required if the clearance between the connecting rod journal and the
bearing is in excess of the service limit of 0.200 mm (0.0079 inch). If the crankshaft is worn
excessively, or if the crankshaft is uneven, an undersized bearing is required. If an undersized
bearing is required, grind the crankshaft to a dimension listed in Table 2.
Note: The allowable tolerance for rod bearing journals that are out of round is 0.010 mm (0.0004
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C4.2 Engine
Especificaes
i02980088
Cylinder Block
SMCS - 1201
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(3) Measure the amount of the warpage of the cylinder block with a straightedge and feeler gauge.
Maximum allowable clearance ... 0.05 mm (0.002 inch)
Repair limit ... 0.20 mm (0.008 inch)
Resurface the top of the block if the repair limit is reached.
(4) Measure the inside diameter of the cylinder sleeve that is parallel to the crankshaft. Measure the
inside diameter of the cylinder liner that is in a perpendicular position to the crankshaft. Measure the
top, the middle and the bottom of the cylinder liner. Refer to Table 2 for tolerances of the cylinder
liner.
Table 1
Tolerances of Cylinder Sleeves

Standard at Assembly Repair Limit (1) Service Limit (2)
Inside
102.010 to 102.045 mm (4.0161 to 102.200 mm (4.0236 102.700 mm (4.0433
Diameter
4.0175 inch) inch) inch)
Out of Round
N/A N/A
0.010 mm (0.0004 inch)
Taper N/A N/A

0.015 mm (0.0006 inch)
Repair a part if the repair limit is reached.
Bore the cylinder to the specified oversize dimension if the inside diameter reaches the repair limit
but the inside diameter does not reach the service limit. Refer to Table 3.
Hone the liner to +0.25 mm (+0.010 inch) or +0.50 mm (+0.020 inch) oversize. Hone the liner to an
accuracy within 0.010 to 0.045 mm (0.0004 to 0.0018 inch).
Determine the oversize dimension that is necessary in order to clean up the cylinder if any liner has
uneven wear.
Replace all cylinder liners that are in excess of the service limit.
Note: Refinish all liners to the same oversize dimension. Use a ridge reamer in order to cut the ridge
of the cylinder if the liner is in good condition. Hone the cylinder bore.
Table 2
Oversize Bore Cylinder Bore Size
102.260 mm (4.0260 inch)

0.250 mm (0.0098 inch)
102.295 mm (4.0274 inch)
102.510 mm (4.0358 inch)

0.500 mm (0.0197 inch)
102.545 mm (4.0372 inch)
(5) Service limit of cylinder liner ... 102.700 mm (4.0433 inch)
Note: Replace all cylinder liners that exceed the service limit.
Use the following procedure in order to replace the cylinder liners.

1. Set up a boring machine on the cylinder block. Align the boring machine with the center of the
bottom of the cylinder liner with the least worn area.
2. Bore the liner until the thickness is 0.50 mm (0.020 inch).
3. Remove the remainder of the liner. Be careful not to damage the cylinder block.
4. Install a new liner. Align the liner with the top of the cylinder block.
5. The bore of the cylinder must be 102.000 to 102.035 mm (4.0157 to 4.0171 inch).
Diameter for the main bearing bores ... 95.000 mm (3.7402 inch)
Maximum diameter of the main bearing bores ... 95.022 mm (3.7410 inch)
New height of deck from centerline of crankshaft to deck ... 307.00 0.05 mm (12.086 0.002 inch)
Minimum height from the centerline of crankshaft to deck ... 306.70 mm (12.075 inch)
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Especificaes
i02876647

SMCS - 1202; 1203
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BWW1-UP
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BYM1-UP
S/N - BZF1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - EAX1-UP
S/N - FAL1-UP
S/N - FMH1-UP
S/N - GKS1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - JLG1-UP
S/N - KBD1-UP
S/N - KGF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDT1-UP
S/N - NAS1-UP
S/N - NCM1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PDP1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SBP1-UP
S/N - SBZ1-UP
S/N - SED1-UP
S/N - TAE1-UP
S/N - TGY1-UP
S/N - WFD1-UP
S/N - WGC1-UP
S/N - XCK1-UP
S/N - YDS1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
(2) Dial indicator
Procedure to measure the bore of main bearing journal
1. Put the main bearing caps in position in the cylinder block. Apply clean engine oil on the main
bearing bolts. Install the main bearing bolts and tighten the main bearing bolts to a torque of
137 5 Nm (100 4 lb ft).
2. Measure the main bearing bores with a dial indicator. Subtract the diameter of the crankshaft
journal from the inside diameter of the main bearing in order to determine the bearing
clearance on the main journal. Clearance between the crankshaft journal and the main bearing
is 0.050 to 0.118 mm (0.0020 to 0.0047 inch).
Note: Replace the bearings or refinish the crankshaft to the next undersize bearing if the main
bearing clearance exceeds 0.20 mm (0.008 inch).
Note: The allowable tolerance for main bearing journals that are out of round is 0.010 mm (0.0004
(3) Bolts
(4) Main bearing
(5) Main bearing journal
(3) Torque for bolts ... 137 5 Nm (100 4 lb ft)
Table 1
T ! " # C# $ $ ! % M$ B $ # &
S ' " ! C# $ $ ! % M$ B $ # & J " ( # $ ) B $ # & T
Original size journal

2.477 to 2.490 mm (0.0975 to 0.0980 inch)
Undersize
0.25 mm (0.010 inch) 2.602 to 2.615 mm (0.1024 to 0.1030 inch)
Undersize
Undersize
The diameter of the crankshaft main bearing journal is given in Table 3.
Table 2
M$ B $ # & J " ( # $ )
Original size journal (1)
89.95 to 89.97 mm (3.541 to 3.542 inch)
Undersize journal
89.70 to 89.72 mm (3.531 to 3.532 inch)
0.25 mm (0.010 inch)
Undersize journal
89.45 to 89.47 mm (3.521 to 3.522 inch)
0.50 mm (0.020 inch)
Undersize journal
89.20 to 89.22 mm (3.512 to 3.513 inch)
0.75 mm (0.030 inch)
(1) Regrind the main bearing journals to the next undersize dimension if the repair limit of 89.85 mm (3.537 inch) is
exceeded.
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i02978080
Piston and Rings

SMCS - 1214; 1215
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BWW1-UP
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BYM1-UP
S/N - BZF1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - EAX1-UP
S/N - FAL1-UP
S/N - FMH1-UP
S/N - GKS1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - JLG1-UP
S/N - KBD1-UP
S/N - KGF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDT1-UP
S/N - NAS1-UP
S/N - NCM1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PDP1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SBP1-UP
S/N - SBZ1-UP
S/N - SED1-UP
S/N - TAE1-UP
S/N - TGY1-UP
S/N - WFD1-UP
S/N - WGC1-UP
S/N - XCK1-UP
S/N - YDS1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
(A) Piston diameter
Each piston has markings (1) which are stamped on top of the piston. The markings are used to align
the piston assembly to the camshaft side of the cylinder block.
Table 2 gives the dimensions for pistons that are standard. Table 2 also gives the dimensions for
pistons that are oversize.
Note: Measure the piston diameter along the perpendicular of the piston pin bore.
Table 1
Dimensions for Piston Diameters

Bore Size Standard at Assembly Service Limit (1)
101.915 to 101.945 mm (4.0124 to 4.0136

Standard 101.730 mm (4.0051
inch)
inch)
Oversize
0.25 mm (0.010 inch) 102.165 to 102.195 mm (4.0222 to 4.0234 101.980 mm (4.0150
inch) inch)
8 6 !% 9
5 ' 55 5 ' 5 25 & . / 15 2' 415 " 15 2' 445 4' 5 ( 21 " 4' 5 ( ( ( 15 2' 2( 5 4' 5 248
& . / & . /
1 A$ % " & 4 / . / 7 . 2 % / % 3 0 % 1 ! $ 3 . 2 '
;330 % ! " & 2 < 5 1411629

B D ! " # $ % " & $ & 1 " !
C D ! " # $ % " & $ & ' ' ' ( ( ' 991 " ( ( ' 99* 1' ( ( 82 " 1' ( ( 85 & . /
M % 0 ! / $ % " & $ & 1 " ! 2 ! ' S0 1 ! . / $ % " & $ & 2 ! # ! " / 1 " ! 2 ! ' T/
. 3 ! & . 1 4 & / 1 " ! & 2 $ % " & $ & ' ' ' 5 ' 5 5 5 " 5 ' 5 21 5 ' 5 5 5 2 " 5 ' 5 5 5 8 & . /
Note: T/ % ! 6 . 3 # " ! / . 3 ! & . 1 4 & / $ % " & $ & & 2 / $ % " & $ & 1 " ! % 5 ' 5 55
5 ' 5 5 25 & . / ' R $ 3 . / $ % " & # / . 3 ! & . / % 1 & 7 . 2 2 '
(2) Install the piston rings with the identification mark toward the top.
Note: Each piston ring is marked with an "R" or "T" for an identification mark.
(3) When the top piston ring is installed in a cylinder liner with a bore of 102 mm (4.0 inch), the
clearance between the ends of the top piston ring is the following distance. ... 0.30 to 0.45 mm (0.012
to 0.018 inch)
Note: Replace the top piston rings if the end gap exceeds the maximum tolerance of 1.50 mm (0.060
inch).
(4) When the intermediate piston ring is installed in a cylinder liner with a bore size of 102 mm (4.0
inch), the clearance between the ends of the intermediate piston ring is the following distance. ...
0.30 to 0.45 mm (0.012 to 0.018 inch)
Note: Replace the intermediate piston rings if the end gap exceeds the maximum tolerance of 1.50
mm (0.060 inch).
Note: The position of the end gap of the oil control ring is 180 degrees from the ends of the ring
expander.
(5) When the oil control piston ring is installed in a cylinder liner with a bore of 102 mm (4.0 inch),
the clearance between the ends of the oil control piston ring is the following distance. ... 0.30 to 0.50
mm (0.012 to 0.020 inch)
Note: Replace the oil control piston rings if the end gap exceeds the maximum tolerance of 1.50 mm
(0.060 inch).
Note: Install new piston rings in the ring grooves of the piston. Measure the side clearance of the
ring groove (D) with a straight edge and feeler gauge. Table 3 gives acceptable clearances of the ring
groove.
Table 2
Clearances of the Piston Rings
Width of Ring Side Clearance of Ring

Piston Rings Service Limit (2)
Groove
No. 1 Compression
3.00 mm (0.118 0.080 to 0.120 mm (0.0031 to 0.200 mm (0.0079
Ring
inch) 0.0047 inch) inch)
No. 2 Compression
2.00 mm (0.079 0.080 to 0.120 mm (0.0031 to 0.150 mm (0.0060
Ring
Oil Control Ring 4.00 mm (0.157 0.025 to 0.065 mm (0.0010 to 0.150 mm (0.0060
(2) The piston must be replaced if the piston rings exceed these clearances.
(6) Camshaft side of engine block
(7) End gap for no. 1 ring (top compression ring)
(8) End gap for no. 2 ring (intermediate compression ring)
(9) End gap for oil control ring
Note: Position the piston rings according to Illustration 5.
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Cylinder Head Valves

SMCS - 1105
(A) Diameter of the valve head
Inlet ... 34.5 mm (1.36 inch)

(B) Diameter of the valve stem
Inlet valve ... 6.6 mm (0.26 inch)

Exhaust valve ... 6.6 mm (0.26 inch)
(C) Length of the valve

(D) Width of the valve seat
Inlet ... 1.0 mm (0.039 inch)

(E) Angle of valve seat face
Inlet ... 30 degrees

Exhaust ... 45 degrees
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i02707320
Piston Ring Groove - Inspect

SMCS - 1214-040
Table 1
Required Tools
Part Number Part Name Qty
8H-8581 Feeler Gauge 1
Inspect the Piston and the Piston Rings

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

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

/ llustration 2 g01* 582* 5
' 1( & iston ring
' 2( C% linder ring ridge
' * ( Feeler gauge
1. Clean all carbon from the top of the c% linder bores.
2. & lace each piston ring ' 1( in the c% linder bore ) ust below the c% linder ring ridge ' 2( .
* . + se the 8H-8581 Feeler Gauge ' * ( to measure piston ring end gap. Refer to , pecifications-
. & iston and Rings. for the dimensions.
Note: The coil spring must be removed from the oil control ring before the gap of the oil
control ring is measured.
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Engine Oil Pump - Inspect

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

(1) Driven gear assembly
(2) Drive gear assembly
(3) Oil pump gear
(4) Idler gear assembly
(5) Spindle
NOTICE
Before operation, the pump must be lubricated with clean engine oil
and the pump must turn freely by hand or damage to parts can be the
result.
Note: The minimum acceptable oil pressure at low idle is 48 kPa (7 psi).
Measure the backlash between the oil pump gear and the idler gear.
Note: Replace the gears if the backlash exceeds 0.35 mm (0.014 inch).
Note: The oil pump gear and the drive gear assembly are not serviceable if the oil pump gear is
removed.
(3) Oil pump gear
Note: Do not use a torch.
Heat the oil pump gear to 180 C to 220 C (356 F to 428 F) and support the end of the drive gear
shaft in order to install the oil pump gear. Press the oil pump gear until the oil pump gear is flush
with the end of the shaft.
Measure the difference in the length of the assembly for the oil pump gear. Measure the depth in the
oil pump housing.
Note: Replace the oil pump gear assembly if the clearance exceeds the service limit of 0.150 mm
(0.0059 inch).
Measure the clearance between the oil pump gears and the oil pump housing with a feeler gauge.
Note: Replace the oil pump gear assembly if the clearance exceeds the service limit of 0.100 mm
(0.0039 inch).
(7) Cover
Measure the inside diameters of the bores of the shafts in the cover (7) and the oil pump housing (6) .
Measure the bores of the shafts.
Note: Replace the oil pump gear assembly, the cover, or the oil pump housing if the clearance
exceeds the service limit of 0.150 mm (0.0059 inch).
Note: Replace the drive gear and driven gear as an assembly.

(5) Spindle
(8) Idler gear bushing
Measure the inside diameter of the idler gear bushing.
Measure the diameter of the spindle.
Clean the surface of the oil pump cover (7) . Install the cover to the oil pump housing (6) . Install
bolts for the oil pump cover.
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Cylinder Head - Inspect

SMCS - 1100-040
Table 1
Required Tools
Part Number Part Name Quantity
8S - 6691 Cylinder Head Repair Stand 1
1U - 7234 Feeler Gauge 1
Bolt tightening sequence
1. Remove the cylinder head bolts in the reverse sequence that is shown in Illustration 1.
2. Clean the cylinder head thoroughly. Make sure that the contact surfaces of the cylinder head
and the cylinder block are clean, smooth and flat.
3. Inspect the bottom surface of the cylinder head for pitting, corrosion, and cracks. Inspect the
area around the valve seat inserts and the holes for the fuel injection nozzles.
(1) Cylinder head
(2) Cylinder head repair stand
4. Put the cylinder head (1) on the 8S-6691 Cylinder Head Stand Set (2) .
5. Measure the flatness of the cylinder head with a straight edge (1) and with a feeler gauge (2) .
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Cylinder Block - Inspect

SMCS - 1201-040
Table 1
Required Tools
1P-3537 Dial Bore Gauge Group 1
Inspect the top of the cylinder block for cracks and warpage. Refer to the Specifications Module,
"Cylinder Block" topic for the tolerances.
Inspect each cylinder bore. There should be no scoring, rust or corrosion. Use a 1P-3537 Dial Bore
Gauge Group in order to measure each cylinder bore. Each cylinder bore should be measured at the
top, middle and bottom. Refer to Special Instruction, GMG00981 for the instructions that are needed
to use the dial bore gauge.
If the cylinder bores are out of the service limit, the cylinder block must be bored oversize. Refer to
the Specifications Module, "Cylinder Block" topic for the tolerances.
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Engine Oil Cooler - Inspect

SMCS - 1378-040
(1) Element
(2) Gaskets
(3) Oil cooler cover
Check the element (1) for cracks or other defects. If the element is damaged replace the element. Replace
all gaskets (2) and check the oil cooler cover (3) for cracks. If the oil cooler cover is damaged, replace the
cover.
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Flywheel - Inspect
SMCS - 1156-040
Face Runout (Axial Eccentricity) of the Flywheel

Table 1
Required Tools

8T-5096 Dial Indicator Gp 1
Checking face runout of the flywheel
1. Refer to Illustration 1 and install the dial indicator. Always put a force on the crankshaft in the
same direction before the dial indicator is read. This will remove any crankshaft end clearance.
2. Set the dial indicator to read 0.0 mm (0.00 inch).
3. Turn the flywheel at intervals of 25 mm (1.00 inch) along the outer circumference of the
flywheel face, and record measurements at each point.
4. The difference between two consecutive measurements must not be more than 0.03 mm (0.001
inch), which is the maximum permissible flywheel face runout.
Flywheel Runout
Note: The flywheel housing must be removed in order to perform this runout check.
Illu s tration 2 g 002 95956
C h eck ing f ly w h eel ru nou t
1. R ef er to Illu s tration 2 and ins tall th e dial indicator.
2 . S et th e dial indicator to read 0. 00 m m ( 0. 000 inch ) .
3 . Tu rn th e f ly w h eel at interv als of 90 deg rees and read th e dial indicator.
4. C alcu late th e dif f erence betw een th e low es t m eas u rem ent and th e h ig h es t m eas u rem ent of th e
f ou r locations . Th is dif f erence m u s t not be g reater th an 0. 50 m m ( 0. 0197 inch ) . Th is
dim ens ion is th e m ax im u m perm is s ible dis tance f or th e ou ts ide diam eter ru nou t of th e
f ly w h eel.
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i02965663
Fuel Injection Lines

SMCS - 1252
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
Contact with high pressure fuel may cause fluid penetration and burn
hazards. High pressure fuel spray may cause a fire hazard. Failure to
follow these inspection, maintenance and service instructions may cause
personal injury or death.
(1) Torque for five bolts ... 17 2 Nm (150 18 lb in)
(3) Torque for three bolts ... 34 4 Nm (300 35 lb in)
(4) Torque for four bolts ... 15 2 Nm (130 18 lb in)
(5) Torque for four bolts ... 17 2 Nm (150 18 lb in)

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Finding Top Center Position for No. 1 Piston

SMCS - 1105-531
Note: Refer to the Disassembly and Assembly for your machine for the removal of components.
1. Remove the valve mechanism cover. Rotate the crankshaft in the normal direction of the engine
rotation until the inlet valve of the rear cylinder has just opened and the exhaust valve of the rear
cylinder has not completely closed.
Typical example
2. Align the TC mark on the crankshaft pulley with the pointer on the timing case.
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Valve Mechanism Cover

SMCS - 1107
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(1) Torque for 19 bolts ... 17 2 Nm (150 18 lb in)
(3) Torque for six bolts ... 8.8 1.0 Nm (80 9 lb in)
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Piston Height - Inspect

SMCS - 1214-040
If the height of the piston above the cylinder block is not within the tolerance that is given in the
Specifications Module, "Piston and Rings", the piston and the bearing for the piston pin must be
replaced. If any of the following components are replaced or remachined, the piston height above the
cylinder block must be measured:
z Crankshaft
z Cylinder head
z Connecting rod
z Bearing for the piston pin
z Piston
The correct piston height must be maintained in order to ensure that the engine conforms to the
standards for emissions.
Note: The top of the piston should not be machined. If the original piston is installed, be sure that the
original piston is assembled to the correct connecting rod and installed in the original cylinder.
8T-0455 Liner Projection Tool Group
(1) 1P-2403 Dial indicator
(2) 1P-2402 Gauge body
(3) 1P-5507 Gauge block
1. Use the 8T-0455 Liner Projection Tool Group in order to measure the piston height above the
cylinder block. Use the gauge block (3) to zero the dial indicator (1) on the face of the cylinder
block.
2. Position the gauge block (3) on the cylinder block. Rotate the crankshaft until the piston is at
the approximate top center. Ensure that the flame ring of the cylinder liner does not interfere
with the gauge block or the dial indicator.
Measurement of the piston height
(1) 1P-2403 Dial indicator
(2) 1P-2402 Gauge body
3. Position the gauge body (2) and dial indicator (1) in order to measure the piston height above
the cylinder block. Slowly rotate the crankshaft in order to determine when the piston is at the
highest position. Record this dimension. Compare this dimension with the dimensions that are
given in Specifications, "Piston and Rings".
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i02978080
Piston and Rings

SMCS - 1214; 1215
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BWW1-UP
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BYM1-UP
S/N - BZF1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - EAX1-UP
S/N - FAL1-UP
S/N - FMH1-UP
S/N - GKS1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - JLG1-UP
S/N - KBD1-UP
S/N - KGF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDT1-UP
S/N - NAS1-UP
S/N - NCM1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PDP1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SBP1-UP
S/N - SBZ1-UP
S/N - SED1-UP
S/N - TAE1-UP
S/N - TGY1-UP
S/N - WFD1-UP
S/N - WGC1-UP
S/N - XCK1-UP
S/N - YDS1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
(A) Piston diameter
Each piston has markings (1) which are stamped on top of the piston. The markings are used to align
the piston assembly to the camshaft side of the cylinder block.
Table 2 gives the dimensions for pistons that are standard. Table 2 also gives the dimensions for
pistons that are oversize.
Note: Measure the piston diameter along the perpendicular of the piston pin bore.
Table 1
Dimensions for Piston Diameters

Bore Size Standard at Assembly Service Limit (1)
101.915 to 101.945 mm (4.0124 to 4.0136

Standard 101.730 mm (4.0051
inch)
inch)
Oversize
0.25 mm (0.010 inch) 102.165 to 102.195 mm (4.0222 to 4.0234 101.980 mm (4.0150
inch) inch)
8 6 !% 9
5 ' 55 5 ' 5 25 & . / 15 2' 415 " 15 2' 445 4' 5 ( 21 " 4' 5 ( ( ( 15 2' 2( 5 4' 5 248
& . / & . /
1 A$ % " & 4 / . / 7 . 2 % / % 3 0 % 1 ! $ 3 . 2 '
;330 % ! " & 2 < 5 1411629

B D ! " # $ % " & $ & 1 " !
C D ! " # $ % " & $ & ' ' ' ( ( ' 991 " ( ( ' 99* 1' ( ( 82 " 1' ( ( 85 & . /
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5 ' 5 5 25 & . / ' R $ 3 . / $ % " & # / . 3 ! & . / % 1 & 7 . 2 2 '
(2) Install the piston rings with the identification mark toward the top.
Note: Each piston ring is marked with an "R" or "T" for an identification mark.
(3) When the top piston ring is installed in a cylinder liner with a bore of 102 mm (4.0 inch), the
clearance between the ends of the top piston ring is the following distance. ... 0.30 to 0.45 mm (0.012
to 0.018 inch)
Note: Replace the top piston rings if the end gap exceeds the maximum tolerance of 1.50 mm (0.060
inch).
(4) When the intermediate piston ring is installed in a cylinder liner with a bore size of 102 mm (4.0
inch), the clearance between the ends of the intermediate piston ring is the following distance. ...
0.30 to 0.45 mm (0.012 to 0.018 inch)
Note: Replace the intermediate piston rings if the end gap exceeds the maximum tolerance of 1.50
mm (0.060 inch).
Note: The position of the end gap of the oil control ring is 180 degrees from the ends of the ring
expander.
(5) When the oil control piston ring is installed in a cylinder liner with a bore of 102 mm (4.0 inch),
the clearance between the ends of the oil control piston ring is the following distance. ... 0.30 to 0.50
mm (0.012 to 0.020 inch)
Note: Replace the oil control piston rings if the end gap exceeds the maximum tolerance of 1.50 mm
(0.060 inch).
Note: Install new piston rings in the ring grooves of the piston. Measure the side clearance of the
ring groove (D) with a straight edge and feeler gauge. Table 3 gives acceptable clearances of the ring
groove.
Table 2
Clearances of the Piston Rings
Width of Ring Side Clearance of Ring

Piston Rings Service Limit (2)
Groove
No. 1 Compression
3.00 mm (0.118 0.080 to 0.120 mm (0.0031 to 0.200 mm (0.0079
Ring
No. 2 Compression
2.00 mm (0.079 0.080 to 0.120 mm (0.0031 to 0.150 mm (0.0060
Ring
Oil Control Ring 4.00 mm (0.157 0.025 to 0.065 mm (0.0010 to 0.150 mm (0.0060
(2) The piston must be replaced if the piston rings exceed these clearances.
(6) Camshaft side of engine block
(7) End gap for no. 1 ring (top compression ring)
(8) End gap for no. 2 ring (intermediate compression ring)
(9) End gap for oil control ring
Note: Position the piston rings according to Illustration 5.
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C4.2 Engine
Especificaes
i02986420
Crankshaft Pulley
SMCS - 1205
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(1) Torque for the crankshaft pulley nut ... 706 59 Nm (520 45 lb ft)
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Especificaes
i02976008
Fan Drive
SMCS - 1359
S/N - BYK1-UP
S/N - CJN1-UP
S/N - DAY1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - NCM1-UP
S/N - TGY1-UP
(1) Torque for four bolts. ... 58 6 Nm (43 4 lb ft)
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C4.2 Engine
Especificaes
i02974181
Engine Oil Pressure Sensor

SMCS - 1924
(1) Final installation torque for the pressure sensor group ... 10 2 Nm (90 18 lb in)
Operating temperature ... -40 to 125 C (-40 to 257 F)
Operating voltage ... 5.0 0.5 VDC
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Especificaes
i02974301
Boost Pressure Sensor

SMCS - 1917
(1) Final installation torque for the pressure sensor group ... 12 Nm (105 lb in)
Operating temperature ... 40 to 125 C (40 to 257 F)
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Especificaes
i02973716
Fuel Pressure Sensor

SMCS - 1718
Contact with high pressure fuel may cause fluid penetration and burn
hazards. High pressure fuel spray may cause a fire hazard. Failure to
follow these inspection, maintenance and service instructions may cause
personal injury or death.
Refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel
Lines" before adjustments and repairs are performed.
Note: Refer to Systems Operation, Testing and Adjusting, "Cleanliness of Fuel System
Components" for detailed information on the standards of cleanliness that must be observed
during ALL work on the fuel system.
Ensure that all adjustments and repairs are performed by personnel that have had the correct training.
(1) Final installation torque for the pressure sensor group ... 34 6 Nm (25 4 lb ft)
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Especificaes
i02974360
Speed/Timing Sensor
SMCS - 1907; 1912
(1) Final installation torque for the speed sensor group ... 18 Nm (13 lb ft)
Operating voltage ... 4 to 24 VDC
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Especificaes
i02974322

SMCS - 1917

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C4.2 Engine
Especificaes
i02974280

SMCS - 1917
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C4.2 Engine
Especificaes
i02974120

SMCS - 1718
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C4.2 Engine
Especificaes
i02973719

SMCS - 1718
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Especificaes
i02974240

SMCS - 1924

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C4.2 Engine
Especificaes
i02974220

SMCS - 1924
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Especificaes
i02973696
Coolant Temperature Sensor

SMCS - 1906
(1) Final installation torque for the temperature sensor group ... 20 3 Nm (15 2 lb ft)
Output type ... Passive
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Especificaes
i02973696
Coolant Temperature Sensor

SMCS - 1906
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Especificaes
i02973702
Fuel Temperature Sensor

SMCS - 1922
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Teste e Ajustes
i02867135
Fuel Injection Timing - Check

SMCS - 1251-036
(1) Fuel injection pump drive gear
(2) Idler gear
(3) Camshaft gear
(4) Crankshaft gear
1. Set the number one piston at the top center on the compression stroke. Refer to Testing and Adjusting,
"Finding Top Center Position for the No. 1 Piston" for the correct procedure.
2. Align the marks of each gear to the idler gear.
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Especificaes
i02966780
Valve Mechanism Cover

SMCS - 1107
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - FMH1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - KBD1-UP
S/N - NCM1-UP
S/N - PDP1-UP
S/N - SBP1-UP
S/N - TGY1-UP
(3) Torque for six bolts ... 8.8 1.0 Nm (80 9 lb in)
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C4.2 Engine
Teste e Ajustes
i02725129
Engine Oil Pressure - Test

SMCS - 1304-081
Table 1
Tools Needed
1U-5470 Engine Pressure Group 1
An oil pressure gauge that has a defect can indicate low oil pressure.
The 1U-5470 Engine Pressure Group can be used to check engine oil pressure.
1U-5470 Engine Pressure Group
The 1U-5470 Engine Pressure Group has a gauge that measures the oil pressure in the engine. Refer
to Special Instruction, SEHS8907 for more information on using the 1U-5470 Engine Pressure
Group. The information is included in the tool group.
1. Ensure that the engine is filled to the correct oil level.
2. Connect the 1U-5470 Engine Pressure Group to the sender for the engine oil or the sensor for
the engine oil.
3. Operate the engine. Allow the engine to obtain normal operating temperature.
4. Keep the oil temperature constant with the engine at the rated rpm. Read the pressure gauge.
5. Refer to Table 2 in order to determine if the engine oil pressure is in tolerance.
Table 2
Oil Pressure (1)
Oil Pressure at 1500 rpm

145 kPa (21 psi)
Oil Pressure at Idle (2)

48 kPa (7 psi)
(1) The oil temperature must be 60 to 70C (140 to 158F).
(2) Idle rpm is 900 20 rpm.
Find the cause of the problem and correct the problem if the results of the test do not fall within the
pressure range in Table 2. Engine failure or a reduction in engine life can be the result if engine
operation is continued with oil pressure outside this range.
Note: A record of engine oil pressure at regular intervals can be used as an indication of possible
problems of the engine. A record of engine oil pressure at regular intervals can also be used as an
indication of possible damage to the engine. The engine should be inspected and the problem should
be corrected if there is a sudden increase or a sudden decrease of 70 kPa (10 psi) in oil pressure.
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Especificaes
i02976074
Gear Group (Front)

SMCS - 1206
(1) Fuel injection pump drive gear
(2) Idler gear
(3) Camshaft gear
(5) Crankshaft gear
(4) Torque for nut ... 90 6 Nm (65 4 lb ft)

Note: Ensure that the marks on the timing gears are in alignment.
Install a dial indicator and rotate the idler gear (2) back and forth in order to measure backlash.
Replace the idler gear if the backlash exceeds the service limit. Refer to Table 2.
Table 1
Item Standard at Assembly Service Limit (1)
Backlash of idler gear 0.03 to 0.17 mm (0.001 to 0.007 0.25 mm (0.010

inch) inch)
End play of idler gear 0.05 to 0.20 mm (0.002 to 0.008 0.35 mm (0.014
inch) inch)
Clearance between idler gear bushing 0.019 to 0.100 mm (0.0007 to 0.120 mm (0.0047
and shaft
0.0039 inch) inch)
(1) Replace the idler gear if the service limit is exceeded.
Note: Measure the end play of the idler gear with a feeler gauge. Refer to Table 2.
(7) Torque for bolts that holds the front plate ... 29 to 41 Nm (21 to 30 lb ft)
(A) Inside diameter of idler gear bushing
(8) Idler gear shaft
Replace the bushing if the clearance between the idler gear bushing and the idler gear shaft exceeds
the service limit. Refer to Table 2.
Torque for bolts of the timing gear cover ... 29 to 41 Nm (21 to 30 lb ft)
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Especificaes
i02972680
Engine Oil Bypass Valve

SMCS - 1306-BV
(1) Torque for nut ... 44 5 Nm (32 4 lb ft)
(2) Torque for relief valve assembly ... 49 5 Nm (36 4 lb ft)

The valve opens at the following pressure. ... 350 50 kPa (51 7 psi)
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Especificaes
i02972952
Water Temperature Regulator

SMCS - 1355
Start to open temperature of the water temperature regulator ... 71 2 C (160 4 F)
The valve lifts more than 10 mm (0.4 inch) at the following temperature. ... 85 C (185 F)
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i02967360
Cylinder Head Valves

SMCS - 1105
(A) Diameter of the valve head
Inlet ... 34.5 mm (1.36 inch)

(B) Diameter of the valve stem

(C) Length of the valve

(D) Width of the valve seat
Inlet ... 1.0 mm (0.039 inch)

(E) Angle of valve seat face
Inlet ... 30 degrees

Exhaust ... 45 degrees
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Especificaes
i02978042
Flywheel
SMCS - 1156
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BWW1-UP
S/N - BYJ1-UP
S/N - BYK1-UP
S/N - BYM1-UP
S/N - BZF1-UP
S/N - BZH1-UP
S/N - CJN1-UP
S/N - CLA1-UP
S/N - DAY1-UP
S/N - DDW1-UP
S/N - EAW1-UP
S/N - EAX1-UP
S/N - FAL1-UP
S/N - FMH1-UP
S/N - GKS1-UP
S/N - HCW1-UP
S/N - JBC1-UP
S/N - JLG1-UP
S/N - KBD1-UP
S/N - KGF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDT1-UP
S/N - NAS1-UP
S/N - NCM1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PDP1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SBP1-UP
S/N - SBZ1-UP
S/N - SED1-UP
S/N - TAE1-UP
S/N - TGY1-UP
S/N - WFD1-UP
S/N - WGC1-UP
S/N - XCK1-UP
S/N - YDS1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
(1) Place the flywheel on a surface plate in order to measure the flatness of the flywheel. Use a dial
indicator to measure the flatness of the flywheel.
Standard at assembly of flywheel ... 0.15 mm (0.006 inch)

Repair limit of flywheel ... 0.50 mm (0.020 inch)
Note: Refinish the flywheel if the repair limit is exceeded.

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Manual Oficina c4.2 c6.4 Caterpilla

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Tela anterior

(B) Inlet valves

Bore ... 102 mm (4.02 inch)

Stroke ... 130 mm (5.12 inch)

Displacement ... 4.2 L (256 cu in)

Cylinder arrangement ... In-line

Valves per cylinder ... 4

Engine valve lash

Inlet ... 0.25 mm (0.010 inch)

Type of combustion ... Direct injection

Firing order ... 1-3-4-2

Engine Valve Lash - Inspect/Adjust

Be sure the engine cannot be started while this maintenance is being

Valve Lash Setting with Stopped Engine (Cold)

Inlet ... 0.25 mm (0.010 inch)

Adjustment of the Height of the Valve Bridge

1. Push the rocker arm onto the bridge.

4. Turn adjustment screw (1) an additional ten degrees.

5. Tighten locknut (2) to 4 1 Nm (35 9 lb in).

Valve Lash Check

Inlet Valves Exhaust Valves

Valve Lash (Stopped Engine)

TC Exhaust Stroke (1) 3-5-6 2-4-6

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

Valve Lash Adjustment

TC Compression Stroke Inlet Valves Exhaust Valves

2. Adjust the valve lash according to Table 3.

3. Loosen the adjustment locknut (3) .

TC Exhaust Stroke Inlet Valves Exhaust Valves

Cylinders 3-5-6 2-4-6

7. Adjust the valve lash according to Table 4.

8. Loosen the adjustment locknut (3) .

z Worn camshaft and tappets

z Worn rocker arms

z Loose adjustment screws for valve lash

z Broken socket on the upper end of pushrod

(A) Diameters of camshaft journals

Number of Journal Standard Diameter Service Limit (1)

(2) Torque for two bolts ... 12 2 Nm (105 18 lb in)

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Number of Journal Standard Diameter Repair Limit (1)

Note: The maximum repair limit is 0.300 mm (0.0118 inch).

Dimensions for Grinding of Crankshaft

Oversize Thrust Oversize (front or Oversize (front or

Fuel Injection Nozzles

(3) O-ring seal

(1) Torque for the bolt ... 29 3 Nm (21 2 lb ft)

(1) Torque for four bolts ... 108 5 Nm (80 4 lb ft)

(2) Torque for the bolt ... 58 6 Nm (43 4 lb ft)

Resurface the top of the block if the repair limit is reached.

Tolerances of Cylinder Sleeves

Taper N/A N/A

Oversize Bore Cylinder Bore Size

102.260 mm (4.0260 inch)

102.510 mm (4.0358 inch)

(5) Service limit of cylinder liner ... 102.700 mm (4.0433 inch)

Use the following procedure in order to replace the cylinder liners.

2. Bore the liner until the thickness is 0.50 mm (0.020 inch).

Fuel Injection Pump

(1) Torque for solenoid valve group ... 70 5 Nm (50 4 lb ft)

(2) Torque for two plugs ... 60 6 Nm (44 4 lb ft)

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3 T ! " # $ % & ' ' ' 13( ) * N+ , 100 ) . $ # " %

= 16 14 2 $ & 1> ! 7 4 2 $

T/ ! 0 1 2 , ! % ! " % / ! 3 2 4 5 & / 2 " % , 2 1 4 # ! 2 1 4 6 7 4 2 $ 1 & 6 1 8 ! 4 1 4 T2 # $ ! 3'

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