Thermo King TK 2.44 Bedienungsanleitung

Overhaul Manual

TK 2.44, 2.49, 3.66,

3.74, 3.88 and 3.95

TK 8312-2 (Rev. 1/97)

Printed in U.S.A.

This manual is published for informational purposes only and the information so provided should not be considered

as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation should be

consulted.

Sale of product shown in the Manual is subject to Thermo King’s terms and conditions including, but not limited to,

the Thermo King Limited Express Warranty. Such terms and conditions are available upon request.

Thermo King’s warranty will not apply to any equipment which has been “so repaired or altered outside the manu-

facturer’s plants as, in the manufacturer’s judgment, to effect its stability.”

No warranties, express or implied, including warranties of fitness for a particular purpose or merchantabil-

ity, or warranties arising from course of dealing or usage of trade, are made regarding the information, rec-

ommendations, and descriptions contained herein. Manufacturer is not responsible and will not be held

liable in contract or in tort (including negligence for any special, indirect or consequential damages,

including injury or damage caused to vehicles, contents or persons, by reason of the installation of any

Thermo King product or its mechanical failure.

Specifications 1

Engine Disassembly 2

Inspection and Reconditioning 3

Engine Assembly 4

Lubrication System 5

Fuel System 6

Electrical 7

Run In 8

Table of Contents

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TK 2.44 & TK 3.66 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

TK 2.49 & TK 3.74 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

TK 3.88 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

TK 3.95 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Torque Values for TK 2.44 & TK 3.66 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Torque Values for TK 2.49 & TK 3.74 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Torque Values for TK 3.88 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Torque Values for TK 3.95 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Inspection and Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Inspection and Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Connecting Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Valve Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Valve Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Valve Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Push Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Rocker Arm Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Wrist Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Assembly Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Table of Contents (Continued)

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Bleeding Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Major Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Delivery Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Fuel Control Rack And Pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Plunger Barrel Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Plunger and Plunger Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Plunger Guide Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Fuel Limit Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Individual Cylinder Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Timing Injection Pump To Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Maximum Speed Stop Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Fuel Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Fuel Solenoid Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Gears and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Major Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

No Load Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Run In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Dynamometer Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Run In Procedure Without Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Three Cylinder Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Two Cylinder Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Specifications 1

Table of Contents . . . . . . . . . . . . . . . . . . . . . 1

TK 2.44 & TK 3.66 Diesel Engine Specifications . . . . . 3

TK 2.49 & TK 3.74 Diesel Engine Specifications . . . . . 8

TK 3.88 Diesel Engine Specifications . . . . . . . . . . 13

TK 3.95 Diesel Engine Specifications . . . . . . . . . . 18

Torque Values for TK 2.44 & TK 3.66 Engines . . . . . 23

Torque Values for TK 2.49 & TK 3.74 Engines . . . . . 24

Torque Values for TK 3.88 Engine . . . . . . . . . . . . 25

Torque Values for TK 3.95 Engine . . . . . . . . . . . . 26

TK 2.44 & TK 3.66 Diesel Engine

Specifications

The TK 2.44 is a two cylinder engine. The TK 3.66 is a three cylinder engine. Unless it is otherwise noted, the specifications

for both of these engines are the same.

General TK 2.44 TK 3.66

Model 2TN66 3TN66

Type Four Stroke Cycle

Water Cooled

Four Stroke Cycle

Water Cooled

Number of Cylinders 2 3

Bore 2.60 in. (66.0 mm) 2.60 in. (66.0 mm)

Stroke 2.53 in. (64.2 mm) 2.53 in. (64.2 mm)

Displacement 26.8 cu. in. (439 cc) 40.2 cu. in. (658 cc)

Power Rating 8.2 hp (6.0 kW) 11.2 hp (8.2 kW)

Compression Ratio 23 to 1 23 to 1

Direction of Rotation Counterclockwise

(Viewed from Flywheel)

Counterclockwise

(Viewed from Flywheel)

Firing Order 1, 2 1, 3, 2

Fuel Injection Timing 14 Degrees BTDC 14 Degrees BTDC

Nozzle Injection Pressure 1707 psi (11768 kPa) 1707 psi (11768 kPa)

Oil Pressure 18.5 psi (127 kPa) Minimum

@ 230 F (110 C) & 1600 rpm

18.5 psi (127 kPa) Minimum

@ 230 F (110 C) & 1600 rpm

Valve Train Standard Dimensions Wear Limit

Valve Spring

Free Length 1.10 in. (28.0 mm) 0.99 in. (25.2 mm)

Inclination .03 in. (0.8 mm)

Valve Guide Inside Diameter

Intake .2165-.2171 in. (5.500-5.515 mm) .2197 in. (5.580 mm)

Exhaust .2165-.2171 in. (5.500-5.515 mm) .2197 in. (5.580 mm)

Valve Stem Outside Diameter

Intake .2150-.2156 in. (5.460-5.475 mm) .2126 in. (5.400 mm)

Exhaust .2144-.2150 in. (5.445-5.460 mm) .2126 in. (5.400 mm)

Valve Depth

Intake .016 in. (0.40 mm) .039 in. (1.00 mm)

Exhaust .033 in. (0.85 mm) .039 in. (1.00 mm)

Valve Guide Projection

Intake .276 in. (7.00 mm)

Exhaust .276 in. (7.00 mm)

Valve Stem to Rocker Arm Clearance

Intake .008 in. (0.20 mm)

Exhaust .008 in. (0.20 mm)

Valve Seat Angle

Intake 30 Degrees

Exhaust 45 Degrees

TK 2.44 & TK 3.66 Diesel Engine Specifications (Rev 1/97)

Valve Train (continued) Standard Dimensions Wear Limit

Valve Seat Width

Intake .045 in. (1.15 mm) .065 in. (1.65 mm)

Exhaust .056 in. (1.41 mm) .075 in. (1.91 mm)

Push Rod Length 4.488-4.528 in. (114.00-115.00 mm)

Rocker Arm Bushing Inside Diameter .3937-.3945 in. (10.000-10.020 mm) .3972 in. (10.090 mm)

Rocker Arm Shaft Outside Diameter .3925-.3933 in. (9.970-9.990 mm) .3919 in. (9.955 mm)

Rocker Arm Bushing to Rocker Arm

Shaft Clearance .0004-.0020 in. (0.010-0.050 mm) .0053 in. (0.135 mm)

Tappet Outside Diameter .7067-.7074 in. (17.950-17.968 mm) .7059 in. (17.930 mm)

Tappet Bore Inside Diameter .7087-.7094 in. (18.000-18.018 mm) .7106 in. (18.050 mm)

Tappet To Tappet Bore Clearance .0013-.0027 in. (0.032-0.068 mm)

Camshaft

Cam Lobe 1.1799-1.1823 in. (29.970-30.030 mm) 1.1713 in. (29.750 mm)

Camshaft Journal

Timing Gear End 1.4150-1.4157 in. (35.940-35.960 mm) 1.4114 in. (35.850 mm)

Middle 1.4138-1.4148 in. (35.910-35.935 mm) 1.4114 in. (35.850 mm)

Flywheel End 1.4150-1.4157 in. (35.940-35.960 mm) 1.4114 in. (35.850 mm)

Camshaft Bearing Inside Diameter

Timing Gear End Bearing Insert 1.4173-1.4199 in .(36.000-36.065 mm) 1.4213 in. (36.100 mm)

Middle Bearing 1.4173-1.4183 in. (36.000-36.025 mm) 1.4213 in. (36.100 mm)

Flywheel End Bearing 1.4173-1.4183 in. (36.000-36.025 mm) 1.4213 in. (36.100 mm)

Camshaft Journal to

Camshaft Bearing Clearance

Timing Gear End .0016-.0049 in. (0.040-0.125 mm)

Middle .0026-.0045 in. (0.065-0.115 mm)

Flywheel End .0016-.0033 in. (0.040-0.085 mm)

Camshaft Deflection .001 in. (0.02 mm)

Camshaft End Play .002-.006 in. (0.05-0.15 mm) .016 in. (0.40 mm)

Piston, Piston Rings, and Wrist Pin

Piston Outside Diameter Measuring

Point (From Bottom of Piston) .20 in. (5.0 mm)

Piston Outside Diameter

Standard 2.5956-2.5967 in .(65.927-65.957 mm) 2.5925 in .(65.850 mm)

1st Oversize 2.6054-2.6066 in .(66.177-66.207 mm) 2.6024 in. (66.100 mm)

2nd Oversize 2.6152-2.6164 in .(66.427-66.457 mm) 2.6122 in. (66.350 mm)

Piston to Cylinder Wall Clearance .0017-.0041 in .(0.043-0.103 mm)

TK 2.44 & TK 3.66 Diesel Engine Specifications (Rev 1/97)

Piston, Piston Rings, and Wrist Pin (continued)

Piston Ring Groove Width

Top Ring Groove .0612-.0618 in .(1.555-1.570 mm)

Middle Ring Groove .0598-.0604 in. (1.520-1.535 mm)

Bottom Ring Groove .1382-.1388 in. (3.510-3.525 mm)

Piston Ring Width

Top Ring .0579-.0587 in. (1.470-1.490 mm)

Middle Ring .0579-.0587 in. (1.470-1.490 mm)

Bottom Ring .1366-.1374 in. (3.470-3.490 mm)

Piston Ring to Ring Groove Clearance

Top .0026-.0039 in. (0.065-0.100 mm) .0079 in. (0.200 mm)

Middle .0012-.0026 in. (0.030-0.065 mm) .0079 in. (0.200 mm)

Bottom .0008-.0022 in. (0.020-0.055 mm) .0079 in. (0.200 mm)

Piston Ring End Gap

Top Ring .006-.014 in. (0.15-0.35 mm) .059 in. (1.50 mm)

Middle Ring .010-.016 in. (.025-.040 mm) .059 in. (1.50 mm)

Bottom Ring .006-.014 in. (0.15-0.35 mm) .059 in. (1.50 mm)

Wrist Pin Bore Inside Diameter .7874-.7877 in .(20.000-20.008 mm) .7882 in. (20.020 mm)

Wrist Pin Outside Diameter .7870-.7874 in .(19.991-20.000 mm) .7864 in. (19.975 mm)

Wrist Pin to Wrist Pin Bore Clearance 0-.0007 in. (0-.017 mm) .0018 in. (0.045 mm)

Connecting Rod

Wrist Pin Bushing Inside Diameter .7884-.7889 in .(20.025-20.038 mm) .7913 in. (20.100 mm)

Wrist Pin to Wrist Pin Bushing

Clearance .0010-.0019 in .(0.025-0.047 mm) .0043 in (0.110 mm)

Side Clearance (Crank to Rod) .008-.016 in .(0.20-0.40 mm) .022 in. (0.55 mm)

Twist per 4 in. (100 mm) .002 in. (0.05 mm) .003 in. (0.08 mm)

Parallelism per 4 in. (100 mm) .002 in. (0.05 mm) .003 in. (0.08 mm)

Crankshaft and Crankshaft Bearings

Main Journal Outside Diameter

Standard 1.5736-1.5740 in. (39.970-39.980 mm) 1.5717 in. (39.920 mm)

Undersize 1.5638-1.5642 in. (39.720-39.730 mm) 1.5618 in. (39.670 mm)

Main Bearing Inside Diameter

Standard 1.5748-1.5765 in. (40.000-40.042 mm) 1.5776 in. (40.070 mm)

Undersize 1.5650-1.5666 in. (39.750-39.792 mm) 1.5677 in. (39.820 mm)

Main Bearing Clearance .0008-.0028 in .(0.020-0.072 mm) .0059 in. (0.150 mm)

Rod Journal Outside Diameter

Standard 1.4161-1.4165 in. (35.970-35.980 mm) 1.4142 in. (35.920 mm)

Undersize 1.4063-1.4067 in. (35.720-35.730 mm) 1.4043 in. (35.670 mm)

TK 2.44 & TK 3.66 Diesel Engine Specifications (Rev 1/97)

Crankshaft and Crankshaft Bearings (continued)

Rod Bearing Inside Diameter

Standard 1.4173-1.4190 in. (36.000-36.042 mm) 1.4201 in. (36.070 mm)

Undersize 1.4075-1.4091 in. (35.750-35.792 mm) 1.4102 in. (35.820 mm)

Rod Bearing Clearance .0008-.0028 in. (0.020-0.072 mm) .0059 in .(0.150 mm)

End Play .0037-.0105 in. (0.095-0.266 mm) .0130 in .(0.330 mm)

Deflection .0008 in. (0.020 mm)

Cylinder Block

Cylinder Inside Diameter

Standard 2.5984-2.5996 in. (66.000-66.030 mm) 2.6063 in. (66.200 mm)

1st Oversize 2.6083-2.6094 in. (66.250-66.280 mm) 2.6161 in. (66.450 mm)

2nd Oversize 2.6181-2.6193 in. (66.500-66.530 mm) 2.6260 in. (66,700 mm)

Cylinder Roundness 0-.0004 in. (0-0.010 mm) .0008 in. (0.020 mm)

Deck Distortion .002 in. (0.05 mm)

Cylinder Head

Distortion 0-.002 in. (0-0.05 mm) .006 in. (0.15 mm)

Timing Gears

Timing Gear Lash

Crankshaft Gear to Idler Gear .0016-.0047 in. (0.040-0.120 mm) .0079 in. (0.200 mm)

Crankshaft Gear to Oil Pump Gear .0043-.0075 in. (0.110-0.190 mm) .0079 in. (0.200 mm)

Idler Gear to Camshaft Gear .0016-.0047 in. (0.040-0.120 mm) .0079 in. (0.200 mm)

Idler Gear to Fuel Injection Pump

Gear .0016-.0047 in. (0.040-0.120 mm) .0079 in. (0.200 mm)

Idler Gear Bushing Inside Diameter .7874-.7882 in. (20.000-20.021 mm) .7906 in .(20.080 mm)

Idler Gear Shaft Outside Diameter .7858-.7866 in. (19.959-19.980 mm) .7846 in. (19.930 mm)

Idler Gear Shaft to Idler Gear Bushing

Clearance .0008-.0024 in. (0.020-0.062 mm) .0059 in. (0.150 mm)

Oil Pump

Type Trocoid

Outer Rotor to Pump Body Clearance .0039-.0063 in. (0.100-0.160 mm) .0098 in. (0.250 mm)

Inner Rotor Tip to Outer Rotor Lobe

Clearance .0059 in. (0.150 mm)

Rotor Plate to Rotor Clearance .0012-.0035 in. (0.030-0.090 mm) .0051 in. (0.130 mm)

Rotor Shaft to Rotor Shaft Bore

Clearance .0006-.0019 in. (0.015-0.048 mm) .0079 in. (0.200 mm)

Pressure Control Valve Setting 42.7-56.9 psi (294-392 kPa)

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