RENR1230-02 May 2004
Engine Design
3116 3116 & 3126 HEUI Diesel Diesel Truck Engine
3116 & 3126 HEUI Diesel Truck Engine Specifications Cylinders and Arrangement Bore 3116 Bore 3126 Stroke Firing Order Rotation (viewed from flywheel)
6 In-Line 105 mm (4.1 inch) 110 mm (4.3 inch) 127 mm (5.0 inch) 1-5-3-6-2-4 Counterclockwise Counterclockwise
In-Frame Overhaul verhaul Procedure ro cedure Q-De Q-Denotes notes Criti cal Checkpoin t
Form No. SEBF8211 SELD0018 SENR6553 SENR6558
SENR6557 SEBF8167 SEBF8167 SEBF8261
Title 3116 Reuse & Salvage Guidelines Reference Manual Core Acceptance -Cylinder Heads 3100 HEUI Diesel Truck Engine Disassembly & Assembly Manual Manual (8WL, 1WM, 4ES, 2CW, 8HW, 8HW, 7LZ) 3100 HEUI Diesel Truck Engine Systems Operation Testing & Adjusting (8WL, 1WM, 4ES, 2CW, 8HW, 7LZ) 3100 HEUI Diesel Truck Engine Specificati ons (8WL, 1WM, 4ES, 2CW, 8HW, 7LZ) Reconditioning Reconditioning Procedures 3114 and 3116 Engines (Part of SEBF8211) Installing a 7C-6208 Cylinder Sleeve in 3114 and 3116 Engines
Initial Disassembly Note: EXTRA ATTENTION should be given to cleanliness, as built in dirt is a major cause of engine failure following rebuild. Steps 1 2 3 4
Steps Q – 21
Literature References References
Procedures Steam clean engine. Disconnect batteries. Drain engine oil Drain coolant.
main bearing top halves, halves, both the Note: When removing the main center and two end crankshaft main journals have no oil hole. To remove these upper main bearing halves, put a thin piece of soft material (that will not damage the crankshaft journal) against the end of the bearing half, opposite the tab. Tap the bearing with the soft material until the tab of the bearing half is free from the groove in the cylinder cylinder block. When removing the remaining four bearing halves using the 2P-5518 Bearing Removal & Installation tool, if the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and the cylinder block. This can cause damage damage to either or both the crankshaft and cylinder block. Q – 22 Q – 23
9 10
Remove fan drive. Remove water temperature regulator. Remove valve cover. Remove fuel jumper tubes, seals and loose seat from fuel injection pump. Disconnect wiring harness plug from fuel injectors. Remove rocker arm assemblies and pushrods.
injection solenoid Note: DO NOT pry on the hydraulic fuel injection assembly. Pry only on the fuel injector body using the 1U-7587 Removal Service Tool. Tool. Damage to the fuel injector can occur. 11 12 13 14 15 16 17 18 Q – 19
Remove fuel injectors. Remove inlet manifold. Remove the turbocharger and the exhaust manifold. Remove cylinder head and cylinder head gasket. Remove crankshaft damper and pulley. Check alignment marks on damper. Replace if necessary. necessary. Remove crankshaft seal (front) and install new seal with shipping sleeve in position. Remove engine oil pan. Remove oil discharge tube, oil pump and piston cooling jets. Mark connecting connecting rods, rod rod caps and main bearing bearing caps before removing. During assembly it is mandatory mandatory that all rod and main caps be installed in the same location as removed.
Note: To protect the crankshaft journals from the threaded portion of the connecting rod bolts, cut short pieces of rubber hose and install them over the connecting rod bolt threads. Q – 20
Remove piston and rod assemblies. Take care care to prevent damaging the crankshaft journals.
Q – Measuring Measuring Cylinder Bores Refer to Guideline For Reusable Parts and Salvage Operations, SEBF8211, for information and procedures. Measure all cylinder bores with the 4C-4377 Stress Plate Group and a cylinder head gasket over each cylinder to simulate accurate bore conditions. The crosshatch remaining and bore diameter determines if honing or installing sleeves is required. Refer to SEBF8261, “Guideline “Guideline for Reusable Parts and Salvage Operations for additional additional information. The 4C-4377 Stress Plate Group is ONLY used when measuring the bores and honing. It is NOT used when boring the cylinders. Cylinder bores which show at least 75% of crosshatch pattern and have only light vertical scratches can be restored by flexible honing. Refer to SEBF8167, Guideline Guideline for Reusable Parts and Salvage Operations for additional information. Cylinder bores with less than 75% should be reconditioned with a rigid hone. Bores larger than maximum dimensions require sleeving. Maximum Cylinder Bore Size As Measured With Stress Plate Installed:
Q – 24
Q – 25
Install upper halves halves of No. 2 and 6 main bearings. bearings. Install lower halves in main bearing caps and install No. 2 and 6 caps. This will provide support support for crankshaft during main bearing replacement. replacement. No. 6 main bearing is thrust. thrust. Install thrust bearing at this location. Put clean engine oil on bolt threads and washer washer contact face. Torque No. 2 and 6 main main bearing bolts to a torque of 54 ± 7 N·m (40 ± 5 lb ft). Tighten bolts an additional 90 ± 5 degrees (1/4 turn). Remove No. 1 and and 7 main bearing caps and bearings. These two journals do not have oil holes, so it will be necessary to tap the top bearing halves out with a soft material.
Q – Note: Note: Lubricate journal surface of bearing ONLY. Q – 26 Q – 27 Q – 28 Q – 29 Q – 30 Q – 31
Install upper upper halves halves to No. 1, 3, 4, 5 and 7 main bearings. Install main bearing caps. Put clean clean engine oil on bolt threads threads and washer contact face. face. Install bolts and washers. Tighten bolts bolts of each main main bearing bearing cap to a torque of 54 ± 7 N·m (40 ± 5 lb ft). Tighten main bearing bearing bolts bolts an additional 90 ± 5 degrees degrees (1/4 turn). Check end play play of of crankshaft crankshaft with with a dial indicator. indicator. End play play must be 0.07 to 0.32 mm (0.003 to 0.013 inch). Check clearance between ends of piston piston rings. See topic, “Piston and Rings” in the Specification Manual, SENR6557. SENR6557.
Q – Note: Note: The oil ring is to be installed over the spring with the end gap 180 degrees from the oil spring joint. After installing of all three piston rings, put the piston rings in position so the end gaps are 120 degrees apart. Q – Note: Note: The connecting rods were marked with the number of the cylinder they were removed from. Reinstall the rod and piston in the same location as removed. Be sure the short pieces of rubber hose are installed on the rod bolt threads to protect the journals from damage. Q – Note: Note: Engines using one piece pistons have the word “FRONT” on the crown. The word “FRONT” must be be facing toward the front of the engine. The two piece piston is not stamped with the word “FRONT”. The piston orientation to the rod is not necessary on the two piece piston. Q – 32 Q – 33 Q – 34
Q – 35
Q – 36
Q – 37
Q – 38
Q – 39
3116 Engine 105 mm (4.134 inch) 8WL 3126 Engine 110 mm (4.331 inch) 1WM
Remove main bearing bearing caps and bearings bearings from No. 2, 3, 4, 5 and 6. No. 4 will not have have a hole in the journal. journal. Clean No. 2, 3, 4, 5 and 6 main bearing journals and caps. caps.
Q – Note: Note: Lubricate journal surface of main bearing ONLY. DO NOT put oil on back side of bearings. Q – Note: Note: Ensure main bearing caps are installed correctly. Install main bearing caps with sequence number facing towards turbocharger side.
Disassembly 5 6 7 8
Procedures Remove side covers covers and lifter assemblies assemblies as a unit. Inspect lifter assemblies and camshaft for reuse.
Q – 40
Install ring compressor tool group. With number one crankshaft throw at bottom center, carefully install piston and connecting rod assembly into cylinder block. Put connecting rod in alignment with crankshaft journal. Using a rubber mallet, tap piston into cylinder bore until ring compressor comes off piston. Before connecting rod comes in contact with crankshaft, install upper half of rod bearing. Be sure bearing tab engages with groove in connecting rod. Apply clean engine oil on JOURNAL SURFACE ONLY of upper rod bearing. Continue tapping piston piston down, guiding connecting connecting rod onto crankshaft. Position lower half of rod rod bearing bearing in corresponding corresponding numbered rod bearing cap. Be sure bearing tab engages with groove groove in rod bearing cap. Apply clean engine oil on JOURNAL SURFACE ONLY of lower bearing surface. Install rod bearing cap on connecting connecting rod with number on bearing cap on same side and same number as on connecting rod. Apply clean engine engine oil on bolt bolt threads threads and all surfaces surfaces that that make contact between bolts and caps. Tighten each rod cap nut to a torque of 54 ± 5 N·m (40 ± 4 lb ft). Put a reference mark on each each rod cap nut. Tighten each nut an additional additional 60 ± 5 degrees (1/6 turn). Install remainder of pistons pistons and connecting rod assemblies assemblies using above procedures and torques.
Steps Q – 41
Q – 42
Procedures Check the piston cooling jets and then install them. Tighten the cooling jet bolt to a torque of 28 ± 7 N·m (21 ± 5 lb ft). Install the oil pump. If new or exchange exchange cylinder head is being being installed, installed, transfer all components to replacement head.
Piston Coolin g Jets for 3116 3116 HEUI HEUI a. 120.6 ± 0.3 mm (4.75 ± 0. inch) b. 110.2 ± 0.3 mm (4.34 ± 0.010 inch) c. 114.1 ± 0.3 0.3 mm (4.49 inch) inch) d. 120.3 ± 0.3 mm (4.74 ± 0.010 inch) e. 22.6 ± 0.3 mm (0.890 ± 0.010 inch) f. 9.7 ± 0.3 mm (0.382 ± 0.010 inch) g. 41.5 mm (1.63 inch)
Steps Q-50
Q – 51
Procedures Install gasket and turbocharger. Apply 5P-3931 Anti-Seize Compound to turbocharger studs. Install locknuts. locknuts. Tighten locknuts to a torque of 54 ± 5 N·m (40 ± 4 lb ft). Make sure sure mating surface of cylinder head and and cylinder cylinder block are thoroughly clean.
Note: To prevent damage to the two cylinder head-to-cylinder block dowels, keep the cylinder head assembly level during installation. Q – 52
Put new cylinder head gasket in position on cylinder block. Be sure head gasket is DRY. Fasten hoist to cylinder head, and put in position on cylinder block.
Note: Dimensions b, d and e are for the spray for one orifice; dimensions a, c and f are for the other orifice’s spray.
Cylinder head bolt tightening sequence Q – 53 Q – 54 Q – 55 Q – 56 Q – 57
Piston Coolin g Jets for 3126 3126 HEUI HEUI a. b. c. d. e.
108.01 ± 0.25 mm (4.25 (4.25 ± 0.010 inch) 121.30 ± 0.25 mm (4.78 (4.78 ± 0.010 inch) 38.5 mm (1.52 (1.52 inch) 24.32 ± 0.25 mm (0.957 ± 0.010 inch) 121.30 ± 0.25 mm (4.78 (4.78 ± 0.010 inch)
Q –58 Q – 59 Q – 60 Q – 61
Tighten bolts bolts 1 thru 14 in in number sequence sequence to a torque torque of 300 ± 15 N·m (220 ± 11 lb ft). Loosen bolts bolts 1 thru 14 to a torque of 0 N·m (0 lb lb ft). Tighten bolts bolts 1 thru 14 in in number sequence sequence to a torque torque of 130 ± 15 N·m (95 ± 11 lb ft). Retorque bolts bolts 1 thru 14 in number sequence sequence to a torque torque of 130 ± 15 N·m (95 ± 11 lb ft). Turn bolts 1 thru 14 by a numerical sequence sequence an additional additional 90º (1/4 turn). Apply 4C-5593 Anti-Seize Compound on the threads and under under bolt head of bolts 15 thru 20. Tighten bolts bolts 15 thru 20 in number sequence sequence to a torque torque of 55 ± 7 N·m (41 ± 5 lb ft). Install HEUI HEUI Injectors as shown in Disassembly Disassembly & Assembly Manual, SENR6553. Adjust valves valves according according to procedures procedures listed listed in System System Operation Operation Testing & Adjusting , SENR6558.
Cylinder and valve location
Crankshaft Positions For Valve Lash Setting SAE Standard (Counterclockw (Counterclockw ise) Rotation Engines As Viewed From the Flywheel End Exhaust Manifold
Typical example of a three-piece exhaust manifold
NOTICE If 2P-2333 Sealer is left on the inside of the exhaust manifold after assembly, it may cause damage to the turbocharger. Q – 43 Q – 44
Q – 45
Coat inside diameter of female female ends of manifold manifold with clean engine oil. Apply thin coat coat of 2P-2333 Sealer to outside outside diameter diameter of male ends of manifold before assembly. assembly. Remove excess sealer from assembled joint. Continue with procedure given for one-piece exhaust manifold.
Check/Adjust With No.1 Piston On Inlet Valves Exhaust Valves Check/Adjust Check/Adjust With No. 1 Piston On Inlet Valves
TC Compression Stroke* 1-2-4 1-3-5 TC Exhaust Stroke* 3-5-6
Exhaust Valves Firing Order
2-4-6 1-5-3-6-2-4
*Put No. 1 piston at top center (TC) position and make identification for the correct stroke. Make reference to Finding Top Center Center Position For No. 1 Piston in 3100 HEUI Diesel Truck Engine Systems Operation Testing & Adjusting, SENR6558. SENR6558. After top center position position for a particular stroke is found and adjustments are made for the correct cylinders, remove the top center (TC) bolt and turn the flywheel counterclockwise counterclockwise 360 degrees. This will put No. 1 piston at top center (TC) position on the other stroke. Install the top center (TC) bolt in the flywheel and complete the adjustments for the cylinders that remain.
Valve Lash Setting: Setting: Engine Stopped Inlet Valves 0.38 ± 0.08 mm (0.015 ± 0.003 inch) Exhaust Valves 0.64 ± 0.08 mm (0.025 ± 0.003 inch) Note: After setting valve lash, tighten adjusting screw locknut to 30 ± 7 N·m (22 ±5 lb ft). Q – 62 Q – 63 Q – 64
Finish assembling engine components. Fill engine with oil. Fill engine with coolant.
Q – 65 Q – 66 Q – 67
Connect batteries. Start engine and check all operating systems. Check for fuel fuel and and oil leaks before road testing vehicle.
Typical example of a one-piece manifold Q – 46 Q – 47 Q – 48
Q – 49
Check condition of exhaust exhaust manifold gaskets. If gaskets gaskets are are damaged, replace with new parts. Apply 5P-3931 Anti-Seize Compound on threads threads of bolts that that hold exhaust manifold in position. Put gaskets gaskets and exhaust manifold manifold in in position position on cylinder head assembly. Install locks and bolts that hold it. Tighten bolts bolts 1 thru 12 in numerical sequence shown to an initial torque of 4 ± 1 N·m (3 ± 1 lb ft). Tighten bolts 1 thru 12 in numerical sequence to a final torque of 45 ± 5 N·m (33 ± 4 lb ft). Bend lock tab over flat of each bolt head. If necessary, loosen to tighten bolt to align flat of bolt head with lock tab. If four turbocharger mounting studs were were removed removed from from exhaust exhaust manifold, apply 5P-3931 Anti-Seize Compound on studs, install, and tighten to a torque of 35 ± 5 N·m (26 ± 4 lb ft).
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