3208 TRUCK ENGINE Caterpillar


Reconditioning Procedures

Usage:

General Information

The 4.5" Bore, V8 (Direct Injection) Engine can be reconditioned to provide performance characteristics comparable to a new engine. The reconditioned engine will operate satisfactorily if certain reconditioning precautions are observed.

Performance and oil control comparable to a new engine can be obtained only if the necessary machining is done to the required Specifications. Cylinder block reconditioning requires an automatic honing machine to control size, surface finish, and crosshatch pattern of the cylinder bores. A manually operated hone does not give satisfactory results and is not recommended.

To facilitate reconditioning, pistons and rings are available .020 in. (0.51 mm) and .040 in. (1.02 mm) oversize.

Connecting rod and main bearings are available .010 in. (0.25 mm) and .020 in. (0.51 mm) undersize.

Main bearings are available with a .010 in. (0.25 mm) oversize outside diameter. These bearings are for cylinder blocks that have had the bore for the main bearings bored oversize.

Basic Block

Cylinder Block Honing

The following preliminary check is essential to determine if honing is necessary, and if so, the size to hone.

Measure all cylinder bores during disassembly using the 1P3537 Bore Gauging Group. This group includes a 1P3535 Dial Bore Gauge Group and a 1P3536 Size Setting Fixture Group. The bore gauging group provides more accurate measurements than other methods, such as inside micrometers. When setting the gauge, always be sure the gauge pin has sufficient travel to measure the points of maximum wear in the bore. In a cylinder bore, maximum wear is usually across the diameter perpendicular to the crankshaft centerline, either at the top or bottom of ring travel. Normal wear usually will not exceed .020 in. (0.51 mm); however, if bore wear is greater than .020 in. (0.51 mm), hone the block .040 in. (1.02 mm) oversize. The fact that the block can be honed both .020 in. (0.51 mm) and .040 in. (1.02 mm) oversize will allow a block to be reconditioned twice under normal wear conditions. The standard bore size is 4.5000 to 4.5015 in. (114.300 to 114.338 mm).


1P3537 BORE GAUGING GROUP

When reconditioning an engine, the bore size is the determining factor as to the necessity of honing the bores. If bores are worn .006 in. (0.15 mm) more than the standard size, the block should be honed. However, additional service may b obtained without honing if wear does not exceed the maximum wear limit of .0085 in. (0.216 mm).

Before honing, inspect the bottom of each cylinder bore adjacent to the main bearing saddle or web. Some of the saddles may overlap the edge of cylinder bores enough to interfere with honing. Where overlap exists, machine a relief in the saddle to provide clearance for the honing tool. The radius of the relief must be concentric with the cylinder bore and .030 ± .005 in. (0.76 ± 0.13 mm) larger than the bore radius. The relief extends .62 in. (15.7 mm) beyond the bottom of the bore, as shown. This provides adequate clearance for honing.


RELIEF IN SADDLES and CHAMFER AFTER HONING

When honing, check bore size at several locations in the length of the bore and around the circumference. Specifically measure at points perpendicular to the crankshaft centerline at locations .25 in. (6.4 mm) from each end and at center of bore. These three specific locations are primary gauge points during and after honing.


PRIMARY GAUGING POINTS

When honing cylinder blocks, maintain the specified dimensional surface finish and crosshatch tolerances to obtain satisfactory oil control. The tolerances specified are virtually the same as those used for original bore finish at the factory, and can be obtained with an automatic honing machine such as the Sunnen CK-10. This machine has been evaluated and found to give satisfactory results.

The Sunnen CK-10 machine is available from Sunnen Products Company, 7910 Manchester Avenue, St. Louis, Missouri, 63143.

Due to the cost of suitable honing equipment, it may be more expedient to have the honing done by a shop equipped with a Sunnen CK-10 or equivalent. A list of these shops appears at the back of RECONDITIONING PROCEDURES section of this service manual.

Transit Preparation

The following Steps can prevent damage to the block in transit to a shop.

1. Completely disassemble, but do not clean block. The residual oil on the surface will prevent rust.

2. Enclose the block in an industrial plastic bag and position it with the oil pan surface on a suitable wood pallet or equivalent. Dimensions of a suitable wood pallet are shown.


TRANSPORTING PALLET

3. Cover the block with 1/2 in. (12.7 mm) thick plywood or equivalent, and band block to the pallet.

4. Follow similar instructions when block is returned. To prevent rust, the block should not be cleaned after honing, the film of honing oil provides ample protection from rusting.

NOTE: If blocks are to be stored for any length of time, clean and anti-rust after honing.

Cleaning Procedure

After honing is completed, and before assembling the engine, the cylinder block must be cleaned and prepared according to the following instructions.

1. If not previously removed, the camshaft bearings must be removed to permit thorough cleaning of the oil passages. To remove the bearings, see the topic CAMSHAFT BEARINGS REMOVAL AND INSTALLATION.

2. Using the 1P3565 Chamfering Group, remove the sharp corner at the bottom of the cylinder bores as shown. This is essential to prevent scuffing the piston skirts. The chamfer should be approximately 10° × .09 in. (10° × 2.3 mm).


CHAMFERING BORE


NOTICE

Avoid damage to the cylinder bore surface or any other parts.


3. Using the 1P5580 Brush Group and a strong detergent and water solution, clean the following areas of the block.

A. Main oil gallery and supply passage. Use the 1P5572 or 1P5573 Brush and stroke several times while rotating the brush.

B. Camshaft bearing oil passages. Use the 1P5571 Brush and stroke several times while rotating the brush.

C. Cylinder bores. Use the 1P5574 Brush and stroke each bore for one minute while rotating the brush at 1000 rpm.


NOTICE

Incomplete cleaning will result in piston seizure or rapid wear of cylinder bores, pistons and rings. Only thorough rotary brushing with a strong detergent and water solution satisfactorily removes abrasive particles.



1P5580 BRUSH GROUP

4. Thoroughly clean the cylinder block in an agitator-type cleaning tank. This type of cleaning should follow the brushing of the cylinder bores but is not sufficient by itself for cleaning.

5. Coat all machined surfaces immediately after cleaning with engine oil (SAE 30). Keep the block covered to exclude dirt until assembled.

Main Bearing Bores

With main bearing caps installed and tightened to the torque given in the chart TIGHTENING PROCEDURE FOR THE BOLTS FOR MAIN BEARING CAPS. Check main bearing bore size using the 1P3537 Gauging Group. If the main bearing bore is not within 3.7075 ± .0015 in. (94.171 ± 0.038 mm), replace the main bearing cap. It is necessary to line bore the replacement service caps. See the topic LINE BORING MAIN BEARING CAP.

When installing main bearing caps on a reconditioned engine, use new main bearing cap bolts and washers.

Main Bearing Cap Guide Width

Check the width of the main bearing cap guide. The guide width of a new cap is 6.5600 ± .0007 in. (116.624 ± 0.018 mm). Replace main bearing caps that are less than the minimum width of 6.5580 in. (116.573 mm). It is necessary to line bore the replacement service caps. See the topic LINE BORING MAIN BEARING CAP.

When installing main bearing caps on a reconditioned engine, use new main bearing cap bolts and washers.

Line Boring Main Bearing Cap

When reconditioning a block, and one main bearing cap is replaced, line bore the replaced cap. If it is necessary to replace more than one cap, it is recommended that all of the main bearing bores be line bored. See the topic LINE BORING MAIN BEARING BORES.

Clean bearing caps and saddles. Remove all nicks from pan rail. Plug oil holes in block with grease to prevent chips from entering oil passages.


CENTERING RINGS IN BLOCK
1. 1P2344 Centering Rings. 2. Oiler.

Place 1P2344 Centering Rings (1), with oiler (2) up, on each side of the cap being replaced. For an end cap, place 1P2344 Centering Rings (1) in the second and fourth main bearing bores.

Mark new cap to correspond with number on saddle and install the new unbored cap (5). Mark cap and saddle "OS" for oversize next to location number. Tighten the unbored cap bolts (4) to the torque shown in the chart TIGHTENING PROCEDURE FOR THE BOLTS FOR MAIN BEARING CAPS. Place the original bearing caps (3) over the centering rings (1). Tighten the original bearing cap bolts (6) hand tight.


CENTERING RINGS INSTALLED
1. 1P2344 Centering Rings. 3. Original bearing caps. 4. Bolts (two). 5. Unbored cap. 6. Bolts (four).

Oil boring bar (7) and insert it through centering rings (1). Tighten bolts (6) to a minimum of 20 lb. ft. (25 N·m) and a maximum of 50 lb. ft. (70 N·m) while spinning boring bar (7) to check for binding. Centering rings (1) must be seated in bearing saddles after tightening.


INSTALLING BORING BAR
6. Bolts (four). 7. 1P2352 Boring Bar.

Bolt torsion bar assembly (8) loosely to opposite end of block from which boring bar will be driven. Install feed assembly (10) into boring bar and tighten setscrew (9). Slide feed assembly (10) onto torsion bar assembly (8) and tighten bolt (11). Tighten bolt (12) finger tight. Boring bar must slide in and out freely after these tightening operations. Tighten thumbscrew (13).


FEED ASSEMBLY INSTALLED
8. 1P2369 Torsion Bar Assembly. 9. Setscrew. 10. 1P2365 Feed Assembly. 11. Bolt. 12. Bolt. 13. Thumbscrew.

To set tool in tool holder. Set micrometer (15) to 3.7075 in. (94.171 mm). Place centering ring (1) on 1P2370 Micrometer Bracket Assembly. Move micrometer (15) until spindle (14) contacts centering ring (1). Tighten bolt (16). Back off micrometer thimble and recheck micrometer setting. Repeat above steps until micrometer setting is accurate.


SETTING MICROMETER
1. 1P2344 Centering Ring. 14. Micrometer spindle. 15. Micrometer. 16. Bolt.

Place tool holder (17) on the 1P2370 Micrometer Bracket Assembly. Align mark on tool holder (17) with hole in shaft (18). Place tool bit (20) in tool holder (17) and set the micrometer .070 in. (1.78 mm) less than the finish bore diameter of 3.7175 ± .0005 in. (94.425 ± 0.013 mm). Turn the bracket assembly arm until micrometer spindle aligns with tool bit (20). Adjust tool bit (20) by pushing it with the 9S8521 Rod (19) until tip of tool bit (20) touches micrometer spindle.


NOTICE

Do not sweep micrometer spindle across tool bit.



SETTING TOOL BIT
17. 1P2366 Tool Holder Assembly. 18. Shaft. 19. 9S8521 Rod. 20. Tool bit.

Use a maximum of .025 in. (0.64 mm) rough cuts and .010 in. (0.25 mm) finish cuts.

Wipe boring bar and tool holder clean. Place tool holder on the boring bar, with tool bit cutting edge facing the direction of rotation. Assemble the tool holder by placing lower half over the bolts, slide into slot and tighten bolts. Slide boring bar in until tool is approximately .12 in. (3.0 mm) from the bore. Compare tool cutting tip with bore surface while turning boring bar by hand, to insure correct tool setting.

Set feed mechanism into feed by turning knob (23) until pin (22) drops into slot (21).


FEED ENGAGED
21. Slot. 22. Pin. 23. Knob.

NOTE: To set the feed mechanism into feed on later units, turn lever (A) up (the direction of arrow).


LATER FEED MECHANISM
A. Lever.

Place adapter (24) into boring bar and tighten setscrew (25).


ADAPTER INSTALLED
24. 1P2364 Adapter. 25. Setscrew.

Apply layout bluing to the bearing cap and bearing bore. Oil the centering rings. Do not use lubricant on the cutter. Use a one-half inch electric drill with universal joint (26) to feed tool through the bore. Service main bearings with .010 in. (0.25 mm) oversize outside diameter are available to permit the bore to be bored oversize. Bore the bore to 3.7175 ± .0005 in. (94.425 ± 0.013 mm).


BORING BEARING BORE
26. 1P2363 Universal.

NOTE: If you use the later feed mechanism, the tool can be driven from either the boring bar or the feed mechanism.


DRIVING THROUGH FEED MECHANISM (Typical Example)
26. 1P2363 Universal.

The bluing applied to the bearing bore indicates the condition of the bore at the correct bore size. If bluing shows an out of round condition, check the largest diameter (indicated by remaining bluing) in relation to the smallest diameter (indicated by lack of bluing). The difference of the two must not exceed .0010 in. (0.025 mm).

If bluing indicates a step in the joint face, measure the diameter at the step in relation to the smallest diameter. A step of .0005 in. (0.013 mm) on one or both sides is permissible. A maximum of .0010 in. (0.025 mm) over the nominal finish bore diameter is permissible if within the described limits.

To check the bore diameter, set the 1P3535 Dial Bore Gauge to 3.7175 in. (94.425 mm).


CHECKING BORE (Typical Example)

Line Boring Main Bearing Bores

Line bore all main bearing bores if bearing caps or saddles are distorted.

Clean bearing caps and saddles. Remove all nicks from pan rail. Plug oil holes in block with grease to prevent chips from entering oil passages.

Place 1P2344 Centering Rings (1), with oiler (2) up, at each end of block. If an end bore is distorted, use the next good bore.

NOTE: There must be two good bores for locating centering rings.


CENTERING RINGS IN BLOCK
1. 1P2344 Centering Rings. 2. Oiler.

Place original bearing caps (4) over the centering rings (1). Tighten bolts (3) hand tight.


CENTERING RINGS INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 4. Bearing caps.


BORING BAR INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 5. 1P2352 Boring Bar.

Oil boring bar (5) and insert it through centering rings (1). Tighten bolts (3) to a minimum of 20 lb. ft. (25 N·m) and a maximum of 50 lb. ft. (70 N·m) while spinning boring bar (5) to check for binding. Centering rings (1) must be seated in bearing saddles after tightening.

Slide boring bar (5) out of one end of block and install bearing assemblies (6) on boring bar (5). Slide boring bar (5) back through centering ring. Adjust bearing by tightening bolt (7) until bar begins to bind, then back off until boring bar (5) spins easily.


INSTALLING BEARING ASSEMBLIES
5. 1P2352 Boring Bar. 6. 1P2373 Bearing assembly (two). 7. Bolt.

Install bridge assemblies (8) over bearing assemblies (6). Position bridge assemblies (8) on block as shown with thicker portion up.

NOTE: Bridge assemblies must be on block as shown for tool holder clearance at each bore.


BRIDGE ASSEMBLIES INSTALLED
6. 1P2373 Bearing Assembly (two). 8. 1P2343 Bridge Assembly (two).

Tighten bolts (9) finger tight. Tighten bolt (10) lightly. Tighten bolt (11). Loosen, then tighten bolts (9) and bolt (10). Spin boring bar (5) during all tightening operations. Repeat above procedure if boring bar (5) binds.


BOLT LOCATION
9. Bolts (two). 10. Bolt. 11. Bolt.

Remove original bearing caps and centering rings. Mark new caps to correspond with numbers on saddle and install new service caps. Mark caps and saddles "OS" for oversize next to location number.

Be sure to install new bolts. Put crankcase oil on bolt threads and washer face. Tighten bolts in number sequence shown to 30 ± 3 lb. ft. (40 ± 4 N·m), put a mark on each bolt and cap. Tighten all bolts by number from mark an added 120° ± 5°.


(Typical Example) BOLT TIGHTENING SEQUENCE

Bolt torsion bar assembly (12) loosely to opposite end of block from which boring bar will be driven. Install feed assembly (14) into boring bar and tighten setscrew (13). Slide feed assembly (14) onto torsion bar assembly (12) and tighten bolt (15). Tighten bolt (16) finger tight. Boring bar must slide in and out freely after these tightening operations. Tighten thumbscrew (17).


FEED ASSEMBLY INSTALLED
12. 1P2369 Torsion Bar Assembly. 13. Setscrew. 14. 1P2365 Feed Assembly. 15. Bolt. 16. Bolt. 17. Thumbscrew.

Place adapter (18) into boring bar and tighten setscrew (19).


ADAPTER INSTALLED
18. 1P2364 Adapter. 19. Setscrew.

To set tool in tool holder. Set micrometer (21) to 3.7075 in. (94.171 mm). Place centering ring (1) on the 1P2370 Micrometer Bracket Assembly. Move micrometer (21) until spindle (20) contacts centering ring (1). Tighten bolt (22). Back off micrometer thimble and recheck micrometer setting. Repeat above steps until micrometer setting is accurate.


SETTING MICROMETER
1. 1P2344 Centering Ring. 20. Micrometer spindle. 21. Micrometer. 22. Bolt.

Place tool holder (23) on the 1P2370 Micrometer Bracket Assembly. Align mark on tool holder (23) with hole in shaft (24). Place tool bit (26) in tool holder (23) and set the micrometer .070 in (1.78 mm) less than the finish bore diameter of 3.7175 ± .0005 in. (94.425 ± 0.013 mm). Turn the bracket assembly arm until micrometer spindle aligns with tool bit (26). Adjust tool bit (26) by pushing it with the 9S8521 Rod (25) until tip of tool bit (26) touches micrometer spindle.


NOTICE

Do not sweep micrometer spindle across tool bit.



SETTING TOOL BIT
23. 1P2366 Tool Holder Assembly. 24. Shaft. 25. 9S8521 Rod. 26. Tool bit.

Use a maximum of .025 in. (0.64 mm) for rough cuts and .010 in. (0.25 mm) for finish cuts.

Wipe the boring bar and tool holder clean. Place tool holder on the boring bar, with tool bit cutting edge facing the direction of rotation. Assemble the tool holder by placing lower half over the bolts, slide into slot and tighten bolts. Slide boring bar in until tool is approximately .12 in. (3.0 mm) from the bore. Compare tool cutting tip with bore surface while turning boring bar by hand, to insure correct tool setting.


FEED ENGAGED
27. Slot. 28. Pin. 29. Knob.

Set feed mechanism into feed by turning knob (29) until pin (28) drops into slot (27).

NOTE: To set the feed mechanism into feed on later units, turn lever (A) up (the direction of arrow).


LATER FEED MECHANISM
A. Lever.

Oil the bearing assemblies. Do not use lubricant on the cutter. Use a one-half inch electric drill with universal joint (30) to feed the tool through the bores. Service main bearings with .010 in. (0.25 mm) oversize outside diameter are available to permit bores to be bored oversize. Bore block to 3.7175 ± .0005 in. (94.425 ± 0.013 mm).


BORING BLOCK
30. 1P2363 Universal.


DRIVING THROUGH FEED MECHANISM (Typical Example)
30. 1P2363 Universal.

NOTE: If you use the later feed mechanism the tool can be driven from either the boring bar or the feed mechanism.

When boring, if bearing assemblies interfere or tool does not reach next bore, reposition tool holder on boring bar.


POSITIONING TOOL HOLDER

To check bores, set the 1P3535 Dial Bore Gauge to 3.7175 in. (94.425 mm).


CHECKING BORE

Cylinder Head And Valve Components

Cylinder Head And Valve Components

Check cylinder head for cracks before reconditioning.

Flatness of the cylinder head should be within .006 in. (0.15 mm) total, and a maximum of .003 in. (0.08 mm) for any 6 in. (152.4 mm) span. A maximum stock removal of .010 in. (0.25 mm) is permissible when resurfacing the head.

Always check the thickness of a cylinder head before resurfacing. The cylinder head may have been resurfaced before and would not have enough stock to be resurfaced again.

To check the thickness of a cylinder head, measure through the fuel injection nozzle holes at each end of the cylinder head. For the correct thickness of the cylinder head, see the topic CYLINDER HEAD in the SPECIFICATIONS.

The exhaust valve seats have replaceable inserts. To remove, use the 8S7170 Valve Seat Insert Puller Group.


REMOVING EXHAUST VALVE SEAT INSERT

Freeze the exhaust valve seat inserts or use the 8S7170 Valve Seat Insert Puller Group to install inserts into head. Be sure bores are clean, free of burrs, and the insert has a good press fit into the bore.

After inserts are installed, grind the seat face of the insert to be sure it is flat, has the correct angle, and is in alignment with the bore in the valve guide. For specifications, see VALVE GRINDING SPECIFICATIONS CHART.

NOTE: Replace exhaust valve seat inserts when valve seat width or valve head-to-cylinder head face cannot be machined to the correct specification. For specifications, see VALVE GRINDING SPECIFICATIONS CHART.

A 2N8943 Valve Seat Insert for the intake valve is available. This insert can be used in the repair of cylinder heads which have an intake valve seat with damage. Before, damage to an intake valve seat made replacement of the cylinder head assembly necessary.

To use a 2N8943 Valve Seat Insert, the inlet port of the cylinder head must be machined to a diameter of 2.1470 ± .0005 in. (54.534 ± 0.013 mm) and to a depth of .442 ± .002 in. (11.23 ± 0.05 mm).

To install a 2N8943 Valve Seat Insert into the cylinder head, freeze the insert or use a 2P2343 Extractor with the 8S7170 Valve Seat Insert Puller Group. After an insert is installed, grind the seat face of the insert to be sure it is flat, has the correct angle, and is in alignment with the bore in the valve guide. For specifications, see VALVE GRINDING SPECIFICATIONS CHART.

Clean valve guides of all carbon and oil, using the 5P5176 Brush and a solvent.

The valve guides are cast in the cylinder heads. Check each valve guide bore size 3/4 in. (19.1 mm) deep from each end. The bore size is .3745 ± .0005 in. (9.512 ± 0.013 mm) and the maximum size worn is .3760 in. (9.550 mm). Valve guides worn more than the maximum wear size, can be restored to original tolerances through knurling.

Use the 5P3536 Valve Guide Gauge Group to check the bore of the valve guides. Special Instructions GMG02562 gives complete and detailed instruction for use of the 5P3536 Valve Guide Gauge Group.


USING 5P3536 VALVE GUIDE GAUGE GROUP

NOTE: If valve guide bore is larger than .381 in. (9.68 mm), knurling may not restore the guide to original tolerances.

The following procedure can be used to knurl valve guide bores using the 5P5170 Knurling Group:


5P5170 KNURLING GROUP
1. 5P5178 Lubricant. 2. 5P5187 Tap Wrench. 3. 5P5177 Speed Reducer (7 to 1). 4. 5P5176 Brush. 5. 5P5175 Knurling Arbor. 6. 5P5171 Reamer (.371 in.). 7. 5P5172 Reamer (.372 in.). 8. 5P5173 Reamer (.373 in.). 9. 5P5174 Reamer (.374 in.).

1. Clean and buff head, guides and valves. Check valve stem diameter. The intake valve stem diameter is .3725 ± .0005 in. (9.462 ± 0.013 mm) and the minimum size worn is .3710 in. (9.423 mm). The tapered stem exhaust valve has a stem diameter of .3715 ± .0005 in. (9.436 ± 0.013 mm) at the keeper end of the stem, and .3705 ± .0005 in. (9.411 ± 0.013 mm) at the head end of the stem. The minimum size worn is .3690 in. (9.373 mm).

2. Place head on the FT806 Cylinder Head Bench or 8S6691 Cylinder Head Stand with rocker arm side toward you.

NOTE: Use FT967 Adapter Plates to mount head on FT806 Cylinder Head Bench.

3. Dip the 5P5176 Brush (4) into the 5P5178 Lubricant (1) and run the brush through the guide.

NOTE: The 5P5178 Lubricant is specially formulated for knurling cast iron guides and will prolong arbor life. If not available, use only Black Sulfur cutting oil or parafin base oil.

4. Dip the 5P5175 Knurling Arbor (5) into the 5P5178 Lubricant just prior to knurling. Use the 5P5177 Speed Reducer (3) and a 1/4 inch electric drill (1200 to 1600 rpm recommended) to drive the arbor. Hold the speed reducer and drill firmly during knurling. Do not push or guide arbor during knurling.


KNURLING GUIDE
3. 5P5177 Speed Reducer. 5. 5P5175 Knurling Arbor.

5. Select the reamer that is closest to the size of the valve stem that is to be used and ream the guide using the speed reducer and 1/4 inch electric drill. Push firmly to ream.


REAMING GUIDE

NOTE: It is not necessary to use lubricant for reaming.

6. Clean the valve guides with brush and solvent. Dry the guides.

7. Install the valve. It is permissible to use a maximum force of 6 lbs. (27 N) with no oil to install the valve. Should valve not fit, use next size larger reamer and ream as in Step 5.

8. Thoroughly clean the valve guide bores after knurling.

The following procedure may be used to knurl valve guide bores using the United Tool Process.

1. Clean and buff head, guides, and valves. Check valve stem diameter. The intake valve stem diameter is .3725 ± .0005 in. (9.462 ± 0.013 mm) and the minimum size worn is .3710 in. (9.436 ± 0.013 mm) at the keeper end of the stem, and .3705 ± .0005 in. (9.411 ± 0.013 mm) at the head end of the stem. The minimum size worn is .3690 in. (9.373 mm).

2. Place head on the FT806 Cylinder Head Bench or 8S6691 Cylinder Head Stand with spring end of valve guides toward you.

NOTE: Use FT967 Adapter Plates to mount head on FT806 Cylinder Head Bench.

3. Select the drill jig that corresponds in size to the valve guide. Use the 3/16 in. drill and stop in a slow speed drill. Drill an offset hole in guide 1/8 in. to 3/16 in. (3.2 to 4.8 mm) deep (hole to be drilled on exhaust manifold side of guide).

4. Using the proper size knurling tool and wheel, insert tool into guide and place wheel edge in offset notch. Place one drop of lubricant in each offset notch before knurling, and one drop on wheel after installing wheel in knurling tool. Use straight hex blade provided to match knurling tool and adapter in speed reducer. Hold outer shell of reducer from turning and start drill. Follow the rotating tool with slight pressure through the guide.


NOTICE

Use the mechanical speed reducer for all knurling and reaming as excessive speed and torque destroys tools. If possible, use a drill with a no load speed of 600 rpm.


5. After knurling all guides, and before reaming, try valves in each end of guides. They should not fit into guides. If valves will go in either end of guides, the guides must be knurled again using the next size wheel. Ream the guides with a .374 in. reamer before knurling. Repeat knurling and reaming process until valves will not fit into guides.

6. Ream valve guide bores to .3745 ± .0005 in. (9.512 ± 0.013 mm). To ream valve guide bores use a .374 in. reamer. The reamer will ream the bore .0005 to .0008 in. (0.013 to 0.020 mm) over the size marked on the reamer.

7. After reaming, clean guides thoroughly before checking valve guide bore size.

8. Before installing valves, clean valve guide bores with the 1P5571 Brush and a strong detergent. Stroke each bore several times with the brush rotating to remove all dirt and loose chips.

After the valve guides are knurled, the valves and valve seats must be ground to provide proper sealing. For valve grinding specifications, see VALVE GRINDING SPECIFICATIONS CHART.


GRINDING VALVE SEATS

Valve Springs

Check valve springs with the 8S2263 Valve Spring Tester. Springs not meeting Specifications should be replaced.

Connecting Rod

Connecting Rod

Use the 2H6782 Connecting Rod Boring Machine to recondition connecting rods and to check for connecting rod distortion.

NOTE: The 5P2009 Rework Group is available for the 2H6782 Connecting Rod Boring Machine. To install the rework group see Special Instruction GMG02394.

Press a new piston pin bushing into the connecting rod. Assemble new rod bearings and the expansion sleeve. Tighten rod bolt nuts in the following step sequence.

1. Put crankcase oil on bolt threads and seating faces of cap and nut.

2. Tighten both nuts to 30 ± 3 lb. ft. (40 ± 4 N·m).

3. Put a mark on each nut and cap.

4. Tighten each nut 60° from the mark.

Clean spindle and slide the expansion sleeve and connecting rod into place. Install and tighten nut hand tight.

Adjust the carrier to the distance between center of the bores, [center-to-center distance is 7.900 ± .001 in. (200.66 ± 0.03 mm)]. Position the locating rods .25 in. (6.4 mm) from the connecting rod. Install front bushing in bracket and insert locating arbor through front bushing. Slide the centering sleeve over the end of the locating arbor. Slide the locating arbor through the rear bushing, centering sleeve, and into the connecting rod. Tighten knobs until locating rods lightly contact the connecting rod. Lock the locating rods and carrier.

To check connecting rod distortion, slide locating arbor in and out of rear bushing. If the locating arbor does not slide freely, recheck horizontal location. If the locating arbor still binds, loosen the carrier clamp and raise or lower the carrier until the locating arbor slides freely. Read the vernier scale and note the variation from the nominal dimension. If the variation exceeds .010 in. (0.25 mm) the rod is distorted and should be replaced.

NOTE: Mark replacement rods for cylinder identification on bearing tab slot side of rod and cap.

With the center-to-center distance set to the nominal dimension, set tool in boring bar and insert the boring bar and front bushing. Connect boring bar to the feed mechanism and engage the feed lever. Install the hand crank or an electric drill and flexible adapter and bore the bushing. Use a slow feed rate. Check the bore size. The size is 1.5010 ± .0003 in. (48.125 ± 0.008 mm).

NOTE: A 5P2050 Connecting Rod Checking Fixture is available for checking connecting rods. For instructions for the use of the checking fixture see Special Instruction GMG02395.

Install connecting rod into piston with boss on rod on same side as crater in piston crown.


CONNECTING ROD AND PISTON

Oil Pump

Oil Pump

Check oil pump end clearance. End clearance is .004 ± .002 in. (0.10 ± 0.05 mm).


CHECKING END CLEARANCE

Remove oil pump cover mounting bolts (1). Remove oil pump cover (2).


OIL PUMP
1. Bolts (four). 2. Oil pump cover.


CHECKING ROTOR TIP CLEARANCE

Check oil pump rotor tip clearance. Rotor tip clearance is .004 ± .002 in. (0.10 ± 0.05 mm). Maximum rotor tip clearance is .009 in. (0.21 mm).

Remove outer rotor (5) and inner rotor (3). Check size of bearing (4). Size of bearing (4) is 2.8041 ± .0022 in. (71.244 ± 0.056 mm). Replace bearing if necessary. Use an 8S2285 Driver (6) to install the bearing. For the correct location of bearing junction, see the topic OIL PUMP in the SPECIFICATIONS.


ROTORS REMOVED
3. Inner rotor. 4. Bearing. 5. Outer rotor.


INSTALLING BEARING
6. 8S2285 Driver.

Clean all parts thoroughly before installing. Oil all component parts before installing. Install inner rotor (3), outer rotor (5), cover (2), mounting bolts (1) and locks. Tighten bolts to 18 ± 5 lb. ft. (24 ± 7 N·m) and secure with locks.

Crankshaft

Crankshaft

Reconditioning of these crankshafts can be done by grinding the "journals" (bearing surface on the crankshaft for the connecting rod bearings and main bearings) .010 in. (0.25 mm) or .020 in. (0.51 mm) "undersize" (smaller than the original size).

The diameter of the "journals" for the connecting rod bearings is 2.7496 ± .0006 in. (69.840 ± 0.015 mm). The diameter of the "journals" for the main bearings is 3.4995 ± .0005 in. (88.887 ± 0.013 mm). The minimum permissible diameter of the "journals" for the connecting rods is 2.7486 in. (69.814 mm). The minimum permissible diameter of the "journals" for the main bearings is 3.4985 in. (88.862 mm). Measure each "journal" in several places around the diameter to find the maximum wear point. If the diameter of any "journal" is smaller than the minimum permissible diameter, grind all of the "journals." Before grinding a crankshaft, check the crankshaft for being straight. To check a crankshaft for being straight, support each end main bearing "journal" in V-blocks. Using a dial indicator, position the indicator at the zero reading then measure the total indicator reading at the other three main bearing "journals." The maximum total indicator reading is .008 in. (0.20 mm) at the center main bearing "journal" and .004 in. (0.10 mm) at the other two main bearing "journals." If total indicator reading is more than that given but less than .030 in. (0.76 mm) the crankshaft can be "straightened" (made straight). Before "straightening" (making straight) a crankshaft, get temperature of the crankshaft to 400° F (204° C). For the specifications for grinding a crankshaft, see the topic CRANKSHAFT GRINDING SPECIFICATIONS.

With the crankshaft installed in the cylinder block, check the end play for the crankshaft. End play for the crankshaft is .006 ± .003 in. (0.15 ± 0.08 mm). Maximum permissible end play for the crankshaft is .014 in. (0.36 mm).

NOTE: If end play for the crankshaft is more than the maximum permissible end play, check the crankshaft thrust bearing.

Crankshaft Grinding Specifications


DIMENSIONS FOR GRINDING
A. Diameter of connecting rod bearing journals. B. Radius on connecting rod bearing journals. C. Width to grind journals for the connecting rods. D. Diameter of main bearing journals. E. Radius on main bearing journals. F. Width to grind journals for the main bearings.

The dimensions and finish for grinding crankshafts are as follows:

Diameter (A) for connecting rod bearing journals is;

.010 in. (0.25 mm) Undersize ... 2.7396 ± .0006 in.(69.586 ± 0.015 mm)

.020 in. (0.51 mm) Undersize ... 2.7296 ± .0006 in.(69.332 ± 0.015 mm)

Surface finish must be 10 micro inches (0.25 micrometers) or less.

Radius (B) must be .100 ± .010 in. (2.54 ± 0.25 mm).

Surface finish must be 63 micro inches (1.6 micrometers) or less.

The radius must blend smoothly with the newly machined journals.

Width (C) is 2.314 +.006 -.003 in. (58.77 +0.15 -0.08 mm).

Diameter (D) for main bearing journals is;

.010 in. (0.25 mm) Undersize ... 3.4895 ± .0005 in.(88.633 ± 0.013 mm)

.020 in. (0.51 mm) Undersize ... 3.4795 ± .0005 in.(88.379 ± 0.013 mm)

Surface finish must be 10 micro inches (0.25 micrometers) or less.

Radius (E) must be .095 ± .010 in. (2.41 ± 0.25 mm).

Surface finish must be 63 micro inches (1.6 micrometers) or less.

The radius must blend smoothly with the newly machined journals.

Width (F) is 1.258 +.004 -.002 in. (31.95 +0.10 -0.05 mm) for number 4 main bearing journal. Surface finish on the thrust faces of the number 4 main must be 30 micro inches (0.75 micrometers) or less.

Width (F) is 1.268 +.020 -.010 in. (32.21 +0.51 -0.25 mm) for number 2, 3, and 5 main bearing journals.

There is no width (F) for number 1 main bearing journal.

When grinding a crankshaft, no material can be removed from the crankshaft webs or counterweights.

Crankshaft Gear Removal

Remove the gear using an 8B7548 Push Puller, 8B7551 Bearing Pulling Attachment, 8B7561 Step Plate, and 8H684 Ratchet Box Wrench.


PULLING CRANKSHAFT GEAR

The 1P820 Hydraulic Puller Group can also be used to pull gear from crankshaft. Tools required are 1P820 Hydraulic Puller Group, 8B7551 Bearing Pulling Attachment, 8B7549 Puller legs (two), 8B7561 Step Plate, 3H465 Plate (four), 1B4207 Nut (two), and 9S5800 Pump Group.


USING HYDRAULIC PULLER

Crankshaft Gear Installation

1. Install the key in keyway of crankshaft. Remove all burrs from key and keyway inside of crankshaft gear.

2. Heat gear to 500° F. (260° C) maximum.

3. Install gear on crankshaft with timing mark on gear facing front of crankshaft.

Crankshaft Wear Sleeve Removal

Use the 1P3075 Puller Group to remove the crankshaft rear seal.


REMOVING WEAR SLEEVE

Crankshaft Wear Sleeve Installation


WEAR SLEEVE INSTALLATION TOOLS
1. 5P290 Pilot. 2. 5P286 Ring. 3. 9S8858 Nut. 4. 1P5515 Bolts. 5. 9S8864 Pusher Plate.

To install the wear sleeve, use the following procedure:

1. Install 5P290 Pilot (1) on the end of the crankshaft. Install 1P5515 Bolts (4) and tighten just enough to hold pilot (1) yet allow some side movement. Put the wear sleeve on pilot (1) with the chamfer toward the rear of the engine. Push the wear sleeve on the crankshaft to put pilot (1) in the center, then tighten bolts (4).

2. Put 5P286 Ring (2) on 9S8864 Pusher Plate (5) and place this assembly on the stud of pilot (1). Install 9S8858 Nut (3) and tighten nut to push wear sleeve on to the crankshaft.

Crankshaft Rear Oil Seal Removal

Use the 1P3075 Puller Group to remove the crankshaft rear seal.


REMOVING REAR OIL SEAL (Typical Example)

Crankshaft Rear Oil Seal Installation


REAR OIL SEAL INSTALLATION TOOLS
1. 5P290 Pilot. 2. 1P5515 Bolts. 3. 5P285 Ring. 4. 9S8858 Nut. 5. 5P288 Ring. 6. 9S8864 Pusher Plate.

To install the crankshaft rear oil seal, use the following procedure:

1. Install 5P290 Pilot (1) on the crankshaft with 1P5515 Bolts (2). Install 5P288 Ring (5) on pilot (1).

2. Put 7F2770 Cement on the outer diameter of the seal metal shell. Put engine oil on the lip of the seal. Install the seal on the pilot with the lip of the seal toward the front of the engine.

3. Install 9S8864 Pusher Plate (6) and 5P285 Ring (3) over pilot (1). Install 9S8858 Nut (4). Tighten nut (4) until ring (5) makes contact with the flywheel housing.

NOTE: To prevent possible oil leakage, install a new wear sleeve each time the rear oil seal is replaced.

Crankshaft Front Oil Seal Removal


REMOVING FRONT OIL SEAL (Typical Example)

Remove the crankshaft front pulley. Use the 1P3075 Puller Group to remove the crankshaft front oil seal.

Crankshaft Front Oil Seal Installation

1. Put the seal over the short end of 5P4194 Installer Assembly (A). Put 7F2770 Cement on the outer diameter of the seal metal shell. The lip of the seal must be toward the inside of the engine.

2. Put the seal and installer assembly (A) in position on the end of the crankshaft. Install bolt (1) and washer (2) that hold the crankshaft pulley in place. Tighten bolt (1) until the installer assembly (A) makes contact with the crankshaft gear.

NOTE: If a new wear surface for the front seal is needed, put the 5P4230 Spacer between the seal and flange of the installer assembly.


INSTALLING FRONT OIL SEAL
1. Bolt. 2. Washer. A. 5P4194 Installer Assembly.

3. Put engine oil on the lip of the seal before installing the pulley.

Crankshaft Pulley Removal

1. Remove pulley retaining bolt and washer.

2. Remove the pulley using a 5F7465 Puller Assembly, 8B7560 Step Plate, two 5M2894 Washers, and two S1571 Bolts.


PULLEY REMOVAL (Typical Example)

Crankshaft Pulley Installation

1. Lubricate lip of crankshaft front oil seal and the sealing surface of crankshaft pulley with engine oil (SAE 30).

2. To install pulley, start pulley on crankshaft. Put screw (4) from the 8B7548 Push Puller into the crankshaft until it bottoms out. Put crossbar (1) from the 8B7548 Push Puller onto screw (4). Install washer (2) and nut (3) on screw (4). Hold screw (4) and turn nut (3) to press pulley onto crankshaft. When installed, the pulley hub will contact the crankshaft gear.


INSTALLING PULLEY
1. Crossbar. 2. Washer. 3. Nut. 4. Screw.

3. Remove the tool setup. Install the pulley retaining bolt and washer. Tighten the pulley retaining bolt to 460 ± 60 lb. ft. (624 ± 80 N·m).

Camshaft

Camshaft

When reconditioning an engine, check the diameter of the camshaft bearing journals and the camshaft lobe height.

Camshaft bearing journals have a diameter of 2.5000 ± .0005 in. (63.500 ± 0.013) and the minimum diameter worn is 2.4970 in. (63.424 mm).

To measure height (B) of camshaft lobes, use the following procedures:

1. Measure base circle (C) of one exhaust and one intake lobe. Make a record of each dimension.

2. Add lobe lift dimension (A) to each base circle measurement. The lobe lift dimension (A) is .3071 in. (7.800 mm) for the exhaust lobe and .3077 in. (7.816 mm) for the intake lobe.

3. The minimum height of lobe (B) is .010 in. (0.25 mm) less than the dimension found in Step 2.

Example of finding the height of a lobe:


CAMSHAFT LOBE
A. Lobe lift. B. Lobe height. C. Base circle.

With camshaft installed in the cylinder block, check end play. End play with new components should be .007 ± .003 in. (0.18 ± 0.08 mm). The maximum permissible end play is .020 in. (0.51 mm).

Camshaft Followers

Use an 8S2293 Magnet to remove the cam followers.


REMOVING CAM FOLLOWERS

Cam followers establish a wear pattern with the camshaft lobes. Identify and reinstall the followers in the same location from which they were removed. Dishing or circular wear pattern is allowed on the cam follower face, providing the wear face keeps a polished appearance. Replace the follower if the wear face is rough or shows signs of scuffing. A new follower can be used with an old camshaft, providing the lobe is in good condition. Put engine oil on the cam followers and the camshaft lobes before installing the cam followers.

NOTE: Use new cam followers with a new camshaft.

Camshaft Gears

1. Remove screw (1) and washer (2) from end of camshaft.


REMOVING TIMING ADVANCE RETAINING SCREW
1. Screw. 2. Washer.

2. Remove timing advance unit from the camshaft.

3. Install puller (A), with spacer (C) over the shaft in the camshaft and spacer (B) on spacer (C) as shown and remove the gear from the camshaft.


REMOVING GEAR (Typical Example)
A. 1P2321 Puller. B. 8S5579 Spacer. C. 9S9155 Spacer.

To install the gear use the following procedure:

1. Heat the gear to a temperature of approximately 400° F (204° C) before installing on the camshaft.


NOTICE

Do not heat the gear with a torch. Do not heat the gear to a temperature of more than 600° F (315° C). Heating the gear with a torch or to a temperature of more than 600° F (315° C) may cause the two drive dowels for the automatic timing advance to loosen and come out of the gear.


2. Align slot in gear hub with the pin in the camshaft. Install the gear on the camshaft with timing mark on gear aligned with timing mark on crankshaft gear. Be sure the gear is completely seated against the shoulder of the camshaft.


NOTICE

Do not drive the gear on the camshaft.


3. Align holes in weights with dowels in gear and install the automatic timing advance.

4. Align pin (3) in washer with hole (4) in camshaft and install washer (2).

5. Install screw (1) and tighten to 70 ± 5 lb. in. (7.9 ± 0.6 N·m). Stake screw in two places.


INSTALLING WASHER
2. Washer. 3. Pin. 4. Hole.


NOTICE

Stake screw (1) carefully. Heavy blows on washer or screw can force the shaft extension too far into the camshaft and eliminate all end clearance.


6. After screw (1) is staked, the gear and weight assembly requires .003 to .037 in. (0.08 to 0.94 mm) end clearance to prevent binding against the washer, camshaft end, or camshaft gear.


STAKING SCREW
1. Screw.

Camshaft Bearings Removal And Installation

Remove camshaft bearings using the 1P5544 Washer (1) and S509 Bolt (2), from the 1P5545 Adapter Group, in conjunction with the 8S2241 Camshaft Bearing Removal and Installation Group, and the 8H684 Ratchet Box Wrench.


INSTALLING WASHER
1. 1P5544 Washer. 2. S509 Bolt.

With removal tools installed on cylinder block, remove bearings.


REMOVING CAMSHAFT BEARINGS

Install camshaft bearing using the 1P5545 Adapter Group in conjunction with the 8S2241 Camshaft Bearing Removal and Installation Group, and the 8H684 Ratchet Box Wrench.


INSTALLING CAMSHAFT BEARINGS

The 1P5545 Adapter Group pilots in the camshaft bearing bore and also pilots the bearing into the bore. This insures bearing alignment. Install bearings from chamfered side of the bores and align oil hole in bearings with oil holes in the cylinder block.

To install the camshaft front bearing, it is necessary to machine a notch in the 8S8289 Tube (3) for clearance of the boss that projects above the camshaft bearing bore. Machine the notch 1 1/2 in. (38.1 mm) wide, 3/8 in. (9.5 mm) deep, with a 1/8 in. (3.2 mm) radius or chamfer in the corners and on the edges.


NOTCH IN TUBE
3. 8S8289 Tube. 4. 8S8288 Cone. 5. Notch.

Invert the 8S8288 Cone (4) and install it in the 8S8289 Tube (3) for installation of the camshaft front bearing.


INSTALLING CAMSHAFT FRONT BEARING
3. 8S8289 Tube. 4. 8S8288 Cone.

Engine Test Procedure

Lubrication For A Rebuilt Engine

It is very important for a rebuilt engine to have "adequate" (needed) lubrication during the first seconds of operation. A "dry start" (without needed lubrication) on a rebuilt engine can cause bearing damage.

When an engine is rebuilt with new parts, oil is put on each part as it is installed. This is generally enough lubrication for engine start-up. However, this lubrication may not be enough or may be lost if the rebuilt engine is placed in storage for any length of time.

When a factory assembled short block assembly is installed, the oil used at the factory has to give this needed lubrication. However, the factory oil application can flow off the parts in a short block during storage or shipment. As a result, the parts in a rebuilt engine will not have "adequate" lubrication at start-up.

To prevent the possibility of a "dry start" and bearing damage during the first seconds of running, use the 1P540 Flow Checking Tool Group, and shop air pressure to pressure lubricate (fill the main oil passage with oil under pressure) all rebuilt engines.

Procedure for Pressure Lubrication

1. Clean the tank of the 1P540 Flow Checking Tool Group thoroughly, and set the pressure regulator to 35 ± 5 psi (240 ± 35 kPa).

------ WARNING! ------

Air pressure should not be more than 50 psi (345 kPa) at any time.

--------WARNING!------

2. Put approximately one gallon of engine oil in the tank.


PRESSURE LUBRICATION (Using the 1P540 Flow Checking Tool Group)

3. Connect the tooling to the engine as shown. The tap shown is connected to the main oil passage.

4. Add air pressure to the tank, with the regulator set at 35 ± 5 psi (240 ± 35 kPa). Although the tank does have a hand pump, it is difficult to get enough air pressure to do the job with the hand pump. Therefore, use of shop air is recommended.

5. Let the one gallon of engine oil flow into the oil passage under pressure.

When filling the crankcase, put in one gallon of oil less than the recommendation in the Lubrication and Maintenance Guides, if engine has received this pressure lubrication application. Also, if the engine is not going to be used for a long time, do the above procedure again before the first starting.

If shop air is not available for charging the tank, the hand pump may be used to get the minimum required pressure.


NOTICE

Do not use the same 1P540 Flow Checking Tool Group for both "pressure lubrication application" and for checking fuel flow. Incorrect cleaning is probable if the tool is used for both fuel and lube oil. Even a minute amount of dirt in the fuel system can cause fuel nozzle failure.


Dynamometer Test Precaution

To avoid possible engine damage while testing on a dynamometer, the thermostats must be installed and the shunt line connected as shown.


SHUNT LINE CONNECTED TO ENGINE

Initial Operation After Engine Reconditioning

The quality of oil control components used in Caterpillar engines is such that, following engine reconditioning (with Caterpillar Service Parts), only an initial operational check is necessary before continued operation in normal service.

The purpose of this initial operational check is to: insure that the engine has been assembled properly; determine if proper pressures and temperatures are maintained in the lubrication, cooling and fuel systems; correct any leaks; perform necessary adjustments (such as valve clearance, governor high and low idle speeds, etc.); check the power setting of the engine.

To provide a safe, uniform initial operational check, the following procedure is recommended:

1. Motor engine at cranking speed until oil pressure is observed.

2. Operate engine for 10 minutes at low idle.

3. Operate engine for 15 minutes at half-load and 3/4 rated speed.

4. Operate engine for 30 minutes at rated load and speed.

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