Ia Caterpillar Specifications 3304 VehicularEngine Text

CATERPILLAR
FORM
NO. SENR7590-01
IN
I
FOR USE
SERVICE MANUALS:
VOLUME SPECIFICATIONS, REG01312

D4 TRACTOR, REG00632 D4E TRACTOR, SENR7624 D4 SA TRACTOR, REG00784 D4E SA TRACTOR, SENR7636 NO. 112F MOTOR GRADER, REG00885 120G MOTOR GRADER, REG01654 130G & 140G MOTOR GRADERS, REG01652 225 EXCAVATOR, REG01578 518SKIDDER, REG00971 920 & 930 WHEEL LOADERS, REG00514 941 TRACK-TYPE LOADER, REG00527 950 WHEEL LOADER, REG00548 951 TRACK-TYPE LOADER, REG00783 955 TRACK-TYPE LOADER, REG00634 955L TRACK-TYPE LOADER, SENR7364 955L TRACK-TYPE LOADER, SENR7672
p(iDiiifeira
3304 Vehicular Engine
7Z1-UP
3304
VEHICULAR ENGINES
SPECIFICATIONS
INTRODUCTION
book are on the basis it was written. The specifications torques, pressures of operation, measurements, adjustments and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information which is available. For a list of the most current modules and forni numbers available for each Service Manual, see the SERVICE
specifications given in this
at the
'^
If the part is
The
can be used again.
equal to or within the
of infoniiation available
time
specification given, use the part again.
When
the
word "permissible"
is
"
is in
the description,
the specification given
the
"maximum or minimum"
tolerance permitted before adjustment, repair and/or
new
parts are needed.
MANUAL CONTENTS MICROFICHE REG

When
the
139F.
words "use again" are
in the
description,
if
A comparison can be made between the measurements of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the remainder of its service life is good. If a short service life is expected,
replace the part.
the specification given can be used to determine
apart
77200X2
NOTE: For Systems

3304
VEHICULAR ENGINES, Form
Operation and Testing and Adjusting, make reference to No. SENR7591.
ENGINE DESIGN
Bore
Stroke
4.75
6.0
of Cylinders
in.
(120.7
in.
(152.4
mm) mm)
4
Number
Firing
Cylinder Arrangement
'in-line
1, 3, 4,
Order (Injection Sequence)
Direction of Rotation
(when seen from flywheel end) *No. 1 Cylinder Is Opposite Flywheel End.
EXHAUST VALVES
Counterclockwise
2
INTAKE VALVES
CYLINDER AND VALVE IDENTIFICATION
NOTE: This book has been completely changed from
the former issue.
3304
VEHICULAR ENGINES
SPECIFICATIONS
INDEX
Air Inlet
and Exhaust System

43 37 42
41
Engme Design
Engine Mounting Bolts
Fuel
Air Cleaner
2 76
Camshaft Cylinder Head
Glow Plug Positioning

Exhaust Manifold Exhaust Pipe and Muffler Turbocharger Turbocharger Impeller Installation
Valves (Dl)
Valves (PC)
Valve Cover Valve Rocker Ar'ms and Lifters
43 43
46-51
44, 45
System System Timing Fuel System Usage Chart Service Meter Tachometer Drive Fuel System Scroll (Dl)
Fuel
6
6
7
7
31
Fuel Injection
Fuel Injection
32
40 38, 39 42 37
Fuel Transfer
Pump Housing Pump
31
Governor Governor Housing

Injection Nozzle
35 34
Basic Engine
Components
69 68 66 67 70
60
61
Fuel System
Scroll (PC)
Bearing Surface (Journal)
Fuel Bypass Valve Fuel Injection Equipment Fuel Transfer
Connecting Rods Main Bearings Connecting Rod

Crankshaft Crankshaft Hub Cylinder Block
Pump
33 33 27 30 27 30
28
Counterbored Block Spacer Plate Block

Cylinder Liner Cylinder Liner Projection
Governor (Earlier) Governor (Later) Fuel System Scroll {PC & Dl) Timing Gears Fuel System Sleeve Metering Fuel Injection Equipment
29
36 36
(Dl)
18 18-20
21
21
62
62 63
71 76, of the
Fuel Ratio Control Fuel Transfer
Pump
Counterbored Block Spacer Plate Block Fan Drive Flexible Drive Coupling Checking and Adjusting Alignment Flexible Drive Coupling
Flywheel Flywheel Housing Flywheel Housing Bore Flywheel Housing Tightening
77 78 73 74 75 72 72 70 64 65
Governor Governor Governor Governor

Fuel System
Control {D4E) Control (120G & 130G) Control (225) Control (518)
23 22 24
24
21
Injection Nozzle
Sleeve Metering (PC)
Fuel Injection Equipment Fuel Ratio Control Fuel Transfer
8-12
13
13 14
Pump
Flywheel Ring Gear Main Bearing and Connecting Rod Bearings Pistons and Rings
Keystone
Straight Side
Cooling System Coolant Flow Switch Fan Drive

Radiator
V-Belt Tension Chart
Governor Control (920 & 930) Governor Control (950) Governor Control (951) Governor Control (955L) Fuel System Sleeve Metering (PC & Timing Gears Water Separator
16 17 15
Dl)
25
26 25
59
71
Gauges
Converter Oil Temperature Indicator Fuel Pressure Indicator Oil Pressure Indicator
97
58
57
Water Pump Water Temperature Regulator

Electrical
96 97
57 59
Water Temperature Indicator

General Tightening Torques
Lubrication System
96
4
System
79-82
Alternators
Engine
Oil
Oil Pressure
Alternator Regulator
83
85-87
84, 85
Breather
Cap
55,
55 56
Generator Regulators Generators

Starter Magnetic Switches Starter Motors Starter Solenoids
Oil Filter Oil Oil
56
97
Pump
Pressure Switch
for Flared
52-54
92 88-92 93-95
Torque
and O-Ring
Fittings
3304
VEHICULAR ENGINES
SPECIFICATIONS
GENERAL TIGHTENING TORQUE FOR
3304
VEHICULAR ENGINES
SPECIFICATIONS
TORQUE FOR FLARED AND 0-RING

The torques shown
in the chart that
FITTINGS
follows are to be used on the part of 37 Flared, 45 Flared and
Inverted Flared fittings (when used with steel tubing), O-ring plugs and O-ring fittings.
E^fe^&a E^^gp
45
^^^p^^^r^^^^vsss)
oaa
FLARED
12.70
.500
3/4
PB
O-RING FITTING - PLUG
INVERTED FLARED
37
FLARED
45
SWIVEL NUTS
TUBE
SIZE
(O.D.)
3.18
.125
4.78
.188
6.35
.250
7.92 .312
1/2
9.52
.375
TUBE
SIZE
(O.D.)
15.88
.625
7/8
1
19.05
.750
1
22.22
.875
25.40
1.000
1
31.75
1.250
1
38.10
1.500
1
50.80 2.000
2 1/2
THREAD
SIZE
(in.)
5/16
5
1
3/8
11
7/16
9/16
5/8
THREAD
SIZE
(in.)
1/16
3/16
1
1/4
5/16
5/8
7/8
TORQUE
N-m
16
+1
2
145 20
20 2
175
30 2
TORQUE
Nm
TORQUE
lb
.ft.
50 5
35 3
55 7
75 7
55 5
90
7
110 +7
135 15
160 15
310 30
230 20
TORQUE
Ib.in.
45 10
100
10
20
265 25
40 5
65 5
80 5
100 10
120 10
ASSEMBLY OF FITTINGS WITH STRAIGHT THREADS AND O-RING SEALS

1.
Put locknut (3), backup washer (4) and O-ring

seal (5) as far back on fitting body (2) as possible. Hold these components in this position. Turn the fitting into the part it is used on, until backup washer (4) just makes contact with the face of the
part
it
is
used on.
NOTE:
To
If the fitting is a
connector (straight
fitting)
or
plug, the hex on the body takes the place of the locknut.
install this
type fitting tighten the hex against the

it
face of the part

2.
goes
into.
its
To
put the fitting assembly in
correct position
turn the fitting
maximum
torque
(2) out (counterclockwise) a of 359. Tighten locknut (3) to the

in the chart.
1.
body
ELBOW BODY ASSEMBLY

End
3.
shown
of fitting t>ody (connects to tube). 2.
Fitting
body.
Locknut.
A71009X2
End
of fitting that
Backup washer. 5. 0-rlng goes Into other part.

4.
seal. 6.
3304
VEHICULAR ENGINES
SPECIFICATIONS
FUEL SYSTEM USAGE CHART
3304
VEHICULAR ENGINES
SPECIFICATIONS
SERVICE METER
(EARLIER MODELS)
(II
Torque
for bolts
for service
which hold service meter or adapter meter drive 96 24 lb. in. (10.9
for cable nut
2.8
Nm)
N-m)
AI756axl
NOTE: Torque
50
lb. in.
(5.7
ELECTRIC SERVICE METER (LATER MODELS)
6N5906
Polarity
is
negative ground.
Operating voltage
24V DC only
TACHOMETER DRIVE
(1)
Torque
for cable nut
100
20
lb. in.
(11.3 + 2.3 N-m)
(2)
Tighten bolts which hold adapter for tachometer drive to 96
24
lb. in
10.9 2.8
Nm)
3304
VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM
SPECIFICATIONS
PC)
FUEL INJECTION EQUIPMENT
VIEW A-A
Firing order (injection
sequence)
1,3,4,2
Injection timing before
TC
(top center):
to 044,
Fuel
Fuel
pump pump
serial
numbers
899
12 30' + 13 30'
serial
numbers, 044, 900 and up
Torque
for bolt in tiole for
timing pin
108 36
lb. in.
(12.2
4.1
Nm)
(3)
Torque for bolts that hold governor tocamshaft

(1)
vi/eight carrier
End play for camshaft with sleeve installed (new) 023 .018
installing sleeve
in.
(0.58
0.46
mm)
90 101b.
in.
(10.2
1.1
Nm)
mm)
NOTE: When
Diameter of rear bearing surface

(new)
(journal) of the
camshaft
shaft to prevent
damage
to
on end of camshaft, support the camparts inside of injection pump and
2.3720
.0005
in.
(60.249
0.013
governor housing.
(4)
Bore in the rear bearing for the camshaft (new) 2.3750 .0005
Governor spring:
in.
(60.325
0.013
mm)
(5)
Make
reference to the chart

valve:
"GOVERNOR SPRINGS."
"BYPASS VALVE SPRINGS."
permissible clearance between the bearing and the camshaft bearing surface (journal)
(worn)
(2)
Maximum
Bypass
006
fuel control shaft
in.
(0.15
mm)
(6)
Make
Diameter of
(new)
3530 .0003
In
in.
(8.966
0.008
mm)
Diameter of front bearing surface (journal) of the camshaft (new) 9990 .0005 in. (25.375 0.013
mm)
mm)
Bore
(new)
the housing for fuel control shaft 3543 .0005
Bore
in.
in
(8.999
0.013 mm)
(new)
the front bearing for the camshaft 1 .0005 .0005 in. (25.413 0.013
Maximum
in
permissible clearance between the bore the housing and the fuel control shaft
(worn)
003
in.
(0.08
mm)
permissible clearance between the bearing and the camshaft bearing surface (journal) (worn) 003 in. (0.08
Maximum
mm)
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
3304
VEHICULAR ENGINES
SPECIFICATIONS
PC)
Fuel Injection
Equipment (Cont.)
GOVERNOR SPRINGS
3304
VEHICULAR ENGINES
SPECIFICATIONS
PC)
Fuel Injection Equipment (Cont.)
((.OF
LIFTER
A98051X1
Install
guide pin
(A) to deptti (B) [.642
.003
in.
(16.31
0.08 mm)].
lifter.
Slot in guide pin (A)

(7) (8)
must be
in
area shown from center of
Torque
for
bushing
for injection
70 5
lb. ft.
(95
Nm)
mm)
4N4318 Spring
pump:
1
Length under test force

Test force
12.5
.35
in.
(34.3
1.3
lb.
(55.5
in.
5.8 N)
Free length after test
1.566
(39.78 (18.49
mm) mm)
Outside diameter
(9)
728
in.
Torque
for bolt holding sleeve
on
24 2
fuel lines
lb. in. (2.8
control shaft
(10)
0.2
Nm)
Nm)
7 N)
Torque for the nuts that hold the (Use 5P144 Fuel Line Socket) Torque
for the
30 5
lb. ft.
(40
(11)
nuts that hold 105
the nozzles
(12) (13)
lb. ft.
(142
Body.
Put 5P3931 Anti-Seize
Compound on
120
threads of glow plug
and tighten
(14)
(15)
to
24
lb. in.
(13.6
2.8 N-m)
Tighten nozzle finger tight on body.
Torque for precombustion chamber (put 5P3931 Anti-Seize Compound on threads) 150 10
Positioning.
lb. ft.
(205
14
Nm)
NOTE: See Glow Plug
10
3304
VEHICULAR ENGINES
SPECIFICATIONS
PC)
TYPICAL ILLUSTRATION
(16)
Torque
tor bolts holding
clamps on
tuel Injection lines;
With rubber damper Without damper

(17) (18)
84 24 lb. in. (9.6 2.8 Nm) 108 36 lb. in. (12.2 4.1 N-m)
Lever assembly.
Clearance between lever assembly (17) and governor housing when shatt assembly (19) is pulled against 437 in. (1 the governor housing
.10
mm)
(20)
Spring for the terminal shaft. Install the spring (20) for the terminal shaft so that the end of the spring is in the 30 range as
fet^^-^ZZZZ^
shown.
9S8597 Spring
for terminal shaft:

1
Color code (stripes)
white
Length under
Test force
test force
584
in.
(14.83
lb.
mm) mm) mm) mm)

AI0Z90X1
1
56.3
1.21
in. in.
(251 N)
(30.7
Outside diameter
1.635
(41.53
(3.43
Diameter of wire
135
in.
2P726 Spring
for terminal shaft:
red
Length under
Test force
test force
584
in.
(14.83
lb.
mm)
109
1
(485 N)
.04
in.
(26.4
mm) mm)
mm)
mm)
Outside diameter
1.635
in,
(41,53
(3.96
Diameter of wire
156
in.
4N4366 Spring
Length under
Test force
for terminal shaft:
test force
584
in.
(14.83
lb.
156
1,016
1-638
in.
in,
(692 N)
(25,81 (41,61
mm) mm) mm)
Outside diameter
Diameter
of wire
for terminal shaft:
168
in.
(4,27
9L6508 Spring

Put a load on spring of
5.00
lb.
yellow
(22,2 N)
Then make spring shorter by

Total test force
700
in,
(17,78
mm) mm) mm)
1970
1
,52
lb.
in,
(87.63 2.31 N)
(44,2 0,5
in.
.74 ,02
Outside diameter
1,518
(38,56
11
3304
VEHICULAR ENGINES
SPECIFICATIONS
PC)
-^r-n
(21)
9S8632 Low
Idle Spring: test force

1
Length under
Test force
.20
In.
(30.5
mm)
mm) mm)
40 4
lb. ft.
(180 18 N)
in.
Free lengttn after test
2.00
(50.8
Outside diameter
880
in.
(22.35
12
3304
VEHICULAR ENGINES
SPECIFICATIONS
PC)
FUEL TRANSFER PUMP
(1)
Diameter of shaft
(new)
for idler
gear 4914 .0003
in.
(12.482
0.008 mm) 0.008 mm) 0.008 mm) 0.013 mm)
Bore
(new)
(2)
in idler
gear
4926 .0003
in.
(12.512
Thickness of gears
(new)
3736 .0003
in.
(9.489
Depth of counterbore
(new)
3750 .0005
in.
(9.525
Clearance between end of gears and surface of pump body 0006 to .0022 in. (0.01 5 to 0.056 mm) (new)
FUEL RATIO CONTROL
SPRINGS FOR FUEL RATIO CONTROL
3304
VEHICULAR ENGINES
SPECIFICATIONS
PC)
GOVERNOR CONTROL
(920 & 930 Wheel Loaders)
OFF
L>nCIZI3-e,
B41 448X1
LINKAGE ADJUSTMENT PROCEDURE:

1
With the governor in the OFF position, install lever (1) at angle (B). Adjust the length of rod (6) by turning rod ends (2) and (3) so lever (4) is at angle (C).
3.
Tighten nuts on rods
(6)
and
(8). 19'"
Angle A Angle B Angle C
is
is is
Move
lever (1) to
HIGH IDLE
(7)
position and adjust rod

(5) is at
(8)
by
20 + 5"
turning rod ends
and
(9)
so pedal
angle
(A).
30
5''
14
3304
VEHICULAR ENGINES
SPECIFICATIONS
PC)
GOVERNOR CONTROL
(955L Track-Type Loader)

3.
1
With lever
(5)
in
Put the governor control (2) in the OFF position (approximately .47 in. (12 mm) from the end of slot in the guide. Adjust length of rod (3) so lever engine. Tighten nuts (4) on rod
(5) is in
(3).
force needed to (65 4 N).
move governor
the center between discs, tighten nut (6) so control lever (2) is 14.6 .9 lb.
2.
the
OFF
position at the
Angle A
control
for lever (1)

(2) is
and governor
102 5
15
3304
VEHICULAR ENGINES
SPECIFICATIONS
PC)
GOVERNOR CONTROL
(950 Wheel Loader)
B41 450X1
4.
Adjust length of rod

rods.

1.
(3)
and
install pin (6).
Tighten locknuts on
37
6
11"
With lever
Adjust rod
(1) in
(2)
OFF
OFF
position.
(5) is at
Angle A
angle (C).
is
2.
so lever
Angle B Angle
is
3.
Put pedal
(4) in
position.
is
16
3304
VEHICULAR ENGINES
SPECIFICATIONS
PC)
GOVERNOR CONTROL
(951
Track-Type Loader)
B41451X1

1.
3.
is
Make an adjustment
(71 6.3
3.
mm)
28.20 .12 in. at center of pins. Tighten nuts on rod and install
to rod (4) so length of rod
4.
Adjust length of rod (5) so lever position. Tighten nuts on rods.
(6) at
the engine
is in
the
OFF
rod on machine.
2.
Tighten nut
Distance
(3)
is
so force on knob
(1) is
13
lb.
(58
4 N).
Put governor control lever (2) in the LOW IDLE position, approximately .25 in. (6.4 mm) from end of slot in guide.
A
is
28.20
.12 in. (716.3
3.0
mm)
15"
Angle B
17
3304
VEHICULAR ENGINES
SPECIFICATIONS
Dl)
VIEW
A-
sequence)
1, 3, 4,
(3)
TC
(top center):
End play for camshaft with sleeve installed (new) 023 .018
installing sleeve
in.
(0.58
0.46
mm)
cam-
Direct Injection Engines with turbocharger

Direct Injection Engines
NOTE: When
23
1
on end
of camshaft, support the
shaft to prevent
damage
to parts inside of injection
pump and
gover-
nor housing.
without turbocharger
29
Torque for bolts that hold governor weight carrier to camshaft
(4)
Governor spring:
10
lb. ft.
(14
Nm)
(5)
Make

valve:
"GOVERNOR SPRINGS."
Make a mark
(stake) the governor weight cover apart directly over the groove in the camshaft.
(1)
in
four places 90
Bypass
4N605 Bypass Valve
Spring:
Diameter of rear bearing surface (journal) of the camshaft

(new)

in.
880
3.53
in.
(22.35
mm)
2.3720 .0005
in
(60.249
0.013
mm) mm)
Test force
.18
lb.
(15.7
in.
0.8 N)
Bore
(new)
the rear bearing for the camshaft 2.3750 .0005 in. (60.325

0.013
1.73
(43.9
mm) mm)
Outside diameter
Pressure of fuel
fuel injection
in
527
in.
(13.39
permissible clearance between the bearing and the camshaft bearing surface
(journal) (worn)
(2)
Maximum
housing
for
pumps,
30 5 psi (205 35 kPa)
006
in.
(0.15
mm)
(6)
(Full
Load)
Diameter of sleeve control shaft (new) 3530 .0003 Bore

(new)
in
in.
(8.966
0.008 mm)
the housing for the
Diameter of front bearing surface Oournal) of the camshaft (new) 9990 .0005
in.
(25.375
0.013
mm)
mm)
fuel control shaft
Bore 3543
.0005
in.
in
(8.999
0.013
mm)
(new)
the front bearing for the camshaft 1.0005 .0005 in. (25.413
0.013
permissible clearance between the bore in the housing and the sleeve
control shaft (worn)
Maximum
permissible clearance between the bearing and the camshaft bearing surface
Maximum
003
in.
(0.08
mm)
(journal) (worn)
002
in.
(0.05
mm)
18
NOTE: FOR TOROUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
3304
VEHICULAR ENGINES
SPECIFICATIONS
Dl)
GOVERNOR SPRINGS
3304
VEHICULAR ENGINES
SPECIFICATIONS
Dl)
^lOF lifter
Install
guide pin
(A) to
depth
(B) [.642
in
.003
in.
(16.31
0.08 mm)].
lifter.
Slot in guide pin (A)

(7)
must be
area shown from center of
Torque
for
bushing
for injection
70 5
lb. ft.
(95
+ 7
Nm)
mm) mm) mm)
(8)
9N5862 Spring
pump:
1.38 12.5
in.

Test force
(35.1
1.4 lb. (56.7
6.6 N)
1.61
in.
(40.9
Outside diameter
(9)
728
in.
(18.49
Torque
shaft
for bolts that
hold sleeves on control
24 2
for
lb. in. (2.8
0.2
Nm)
(10)
Torque
the nuts that hold the fuel lines (use 5P144 Fuel Line Socket)
30 5
lb. ft.
(40
7 N-m)
(11)
Spring for the terminal shaft. Install the spring (1 1) for the terminal shaft so that the end of the spring is in the 30 range as
shown.
SPRINGS FOR TERMINAL SHAFT
3304
VEHICULAR ENGINES
SPECIFICATIONS
Dl)
FUEL RATIO CONTROL
SPRINGS FOR FUEL RATIO CONTROL
3304
VEHICULAR ENGINES
SPECIFICATIONS
Dl)
GOVERNOR CONTROL
(120G and 130G Motor Graders)

NOTE: DO NOT use
To shut engine OFF,
1.
control lever
pull
(2) to
shut
OFF
the engine.
(11).
8.
up on accelerator treadle
Tighten nut (A) just enough so position of control lever (2) is not affected by the operation of the accelerator treadle (11) and decelerator treadle (9).
With the parking brake
Loosen locknut (14) and adjust length of rod so top of decelerator treadle (9) is .19 in. (4.8 mm) above floor plate (10)
as shown. If machine is equipped with a thick floor insulation pad, (used with enclosed cab), adjust decelerator treadle (9) so top of treadle is .38 in. (9.7 mm) above top of floor plate and tighten locknut (14).
2.
ON
and engine stopped, BE
SURE
dis9.
connect
3. 4.
sw/itch
is
OFF.
Move
control lever
(2) to
HIGH IDLE
it
position.
(12)
Remove
pin (4).
10.
Loosen LOW IDLE stop do not touch lever (12).

tvlove control lever (2) to
Turn HIGH IDLE stop

locknut
(6).
(5) until
touches lever
and lighten
(7)
and HIGH IDLE stop
(5)
so they
11.
5. 6.
LOW
IDLE
it
position.
(12)
Turn
LOW
(8).
IDLE stop
(7) until
touches lever
and tighten
12.
Loosen locknut (16) and adjust accelerator treadle (11) so that distance from bottom of plate on treadle to top of floor plate (10) is 2.38 .12 in. (60.5 + 3.0 mm) as shown.
locknut
7.
Move
rod
(1)
Adjust length of rod (13) so distance from top of lever (15) to bottom of floor plate (10) is 1.50 m. (38.1 mm) as shown
lever (3) to HIGH IDLE position so pin (4) can be installed.
and adjust length
of
13.
Install pin (4).
22
3304
VEHICULAR ENGINES
SPECIFICATIONS
Dl)
GOVERNOR CONTROL
(D4E Tractor)
A48074X2
NOTE: With
shaft
in full
is
on
control lever in high idle position and governor control position, put lever (4) on shaft at angle (D).
40'
1.
With pin removed from lever

(rearward),
(4)
move
lever
(4)
to high idle position
Angle (D)
2.
Move
in. (5
lever (Y) rearward until interference
occurs
in
linkage.
.2
Dimension
Tighten nut
(A) (approximately)
(1) to
14.2
in.
(361
mm)
N-m)
3.
18
lb.
ft.
(24
in.
Adjust rod end (Z) to position holes short of alignment [approx. mm)] with hole in lever (4).
f^
Dimension
(B) (approximately)
(2) to
19.2
(488
mm)
N>m)
4.
Tighten nuts
18 5
lb. ft.
(24
in.
Dimension (C) (approximately)

Tighten nut
(3) to
18.7
(475
mm)
5.
lever (4) to shutoff position and lever (Y) forward until interference occurs. Holes In rod end (Z) must be forward of hole in lever (4). If additional adjustment is required repeat Step 3, [.2 in. (5 mm) dim. may be decreased],
t\/love
18 + 5
lb, ft.
(24
7 N-m)
Install pin
and
cotter.
23
3304
VEHICULAR ENGINES
SPECIFICATIONS
Dl)
GOVERNOR CONTROL
(518 Skldder)
B42382X1

1
Move governor
(2)
shaft (3) to
SHUT OFF
(4)
position
and
install lever
on shaft
(3) at
angle
(A).
2.
Adjust length of rod (5) so stop (B) from the floor plate.
on pedal
(1
is at
dimension
28 + 5
Angle (A)
is
Dimension
(B)
is
2.25
.03
in.
(57.2
0.8
mm)
GOVERNOR CONTROL
(225 Excavator)
B41452X1

Adjust distance (A) to 2.50
to
in.
(63.5
mm)
back edge of governor control handle 1400 t 50 rpm.
from inlay mounting holes with engine running at (1

)
24
3304
VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM - PC &
Dl)
SPECIFICATIONS
AS7414X1
WATER SEPARATOR
(1)
Torque
(3),
for bolt
9 3
lb. ft.
(12
4 N-m)
(2),
(5)
and
(6)
tighten to 12
(4)
Put 8M8058 Sealant on plug and fittings and lb. ft. (17 + 5 N-m)
17
Torque
for bolts
lb. ft.
(23
Nm)
3304
VEHICULAR ENGINES
SPECIFICATIONS
PC &
Dl)
TIMING GEARS
Tighten bolts which fasten into

front plate to
17 3
lb. ft,
(23
4 N-m)
Tighten nuts holding cover for fuel pump drive gear to

(1)
20 + 5
lb. ft.
(25
7 N-m)
With the timing pin and timing bolt correctly installed, put a clockwise force of 50 lb. ft. (70 N-m) on the drive gear
for the fuel
pump and
tighten
bolt (1) to
(2)
110 5
lb. ft.
(149 + 7 N-m)
End play
for the idler
gear (new)
004
to .016
. .
in.
(0.10 to 0.41
mm) mm)
mm)
A4SIS8X2
Maximum
permissible end play (worn)

for the idler
.034
in.
(0.86
Bore in bearing gear (new)
1.3781
idler
.0019
in.
(35.004 0.048
Diameter of shaft for gear (new)
1.3741
.0005
in.
(34.902
0.013 mm)
Clearance between shaft and bearing (new) 0016
to .0064
in.
(0.041 to 0.163
mm)
mm)
permissible clearance between shaft and bearing (worn) 009

(3) (4) (5)
Maximum
in.
(0.23
Camshaft gear.
Crankshaft gear.
End play for the balancer shafts (new) 0035 to .0075
in.
(0.089 to 0.191
.
mm) mm)
Maximum
.017
in.
(0.43
Diameter of balancer shaft

bearing surface (journal) (new) 2.0825 .0005
in.
(52.896 0.013
mm) mm)
bearing for balancer shaft (new) 2.0886 .0024

in
Bore
in.
(53.050 0.061
Maximum
permissible clearance
between balancer shaft and

bearing (worn)
(6) (7)
010
in,
(0.25
mm)
Idler
gear for
oil oil
pump.
pump.
Drive gear for
26
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES
3304
VEHICULAR ENGINES
(SCROLL FUEL SYSTEM
SPECIFICATIONS
PC)

sequence)
3, 4,
1

(1)
TO
(top center)
lb. ft.
13 30'
Torque
for
bushing 130 +10 or -5
(177 +14 or -7 N-m)
(2)
Thickness of spacers:
9N6496 Spacer
9N6495 Spacer
161
in.
(4.12 (4.22 (4.32

(4.42 (4.52 (4.62 (4.72
mm) mm) mm)

mm) mm) mm) mm)
166 170 174 178 182 186 190

194
in.
5M2697 Spacer
in.
2M4208 Spacer
2fv14209
in.
Spacer
in.
2M4210 Spacer
2M421
1
in,
Spacer
in.
2M4212 Spacer
5tV12691
in.
(4.83 (4.93 (5.03 (5.16

(5.26
mm) mm) mm) mm)

mm)
Spacer
in.
5S7189 Spacer
198
in.
4N9839 Spacer 4N9840 Spacer

(3)
203
207
in.
in.
1S206 Spring;
Test force
15.4 1.39
in.
(35.3
mm)
.8 lb.
(68.5
in.
3.6 N)
1.59
(40.4
mm) mm)
Outside diameter
979
for the fuel injection
in.
(24.87
(4)
Timing dimension
pumps;
(108.395
0.051
OFF Engine Gauge
with 5P4158 or 8S7167 4.2675 .0020
in.
mm) mm)
mm) mm)
A-5P4158 GAUGE ILLUSTRATED
ON
(5)
Engine with 5P4158 or 8S7167

4.2216 .0020
in.
Gauge
Length of pump plunger (new)
(107.229
0.051
2,5934 .0015
in.
(65.872
in.
0.038
Minimum
(6)
permissible length (worn)
2.5869
(65.707
Bore
in
the bearings for the rack:
Bearing at the rear Bearing at the front
5018 ,0018 5023 ,0015 4985 .0002
in,
(12,746
0,046 mm) 0.038 mm) 0.005 mm)
in,
(12,758 (12.662
Diameter of
fuel rack
in.
fvlaximum permissible clearance between rack and bearings (worn)

(7)
005
in.
(0.13
mm)
Bore
in
bearings for the

1.8755 .0005
in,
camshaft
(47,638
0.013 mm)
0.013
Diameter of bearing surfaces (journals) of the 1.8730 .0005 in. (47.574 camshaft (new)
mm)
fâximum permissible clearance between the bearings and the camshaft bearing surfaces
(journals) (worn)
(8)
010
fuel lines (use
in.
(0.25
mm)
Torque for the nuts that hold the 5P144 Fuel Line Socket) Torque
for
30 5
lb. ft.
(40
Nm)
(9)
the nuts that hold
the nozzles
(10) (11)
105 5
lb. ft.
(142 7
Nm)
Put 5P3931 Anti-Seize Compound on threads of precombustion chamber and 150 10 tighten to
Positioning.
Body.
Put 5P3931 Anti-Seize threads of glow plug and 120 24 tighten to
(13
Compound on
(12)
lb. in.
(13.6
2.8
Nm)
lb. ft.
(205
14
Nm)
Tighten nozzle finger tight on body.
NOTE: See Glow Plug
27
3304
VEHICULAR ENGINES
(SCROLL FUEL SYSTEM
SPECIFICATIONS
PC)
GOVERNOR
(EARLIER)
(1)
(2)
Torque for nut
9
for speed limiter:
lb. ft.
(12 4
Nm)
mm)
1S9312 Spring
Length under
Test force
test force
86
2.38
in.
(21 .8
.19
lb.
(10.52
in.
0.76 N)
2.62
(66.5
mm) mm)
Outside diameter
(3)
67
in.
(17.0
9M3160
Spring for governor:

(stripes)
1
Color code
blue
Put force on spring of
5.0
lb.
(22 N)
Then add more

shorter by
force to
make
spring
900
19.4
in.
(22.86
mm)
Total test force
.5 lb.
(86.6 2 N)
2.34
.03
in.
(59,4 0.8
in,
mm) mm)
Outside diameter
(3)
1.39
(35.3
9L3617 Spring For Governor;

1
blue,
white
(27 N)
6,0
lb,
Then add more force

shorter by
to
make
spring
900
22.2
in.
(22.86
+
mm)
2 N)
Total test force
.5 lb.
in.
(100.8
2.34
.03
(59.4 0.8
.39
in.
mm)
mm)
Outside diameter
(3)
(35.3
8IV19140 Spring for governor:
Color code
(stripes)
green
(18 N)
4.0
to
lb.
Then add more force

shorter by
make
spring
900
16.6
in.
(22.86
mm)
Total test force
.3 lb.
in.
(74.0 1.3 N)
2.34 .03
(59.4 + 0.8
.38 in. (35.1
mm)
Outside diameter
mm)
28
3304
VEHICULAR ENGINES
(SCROLL FUEL SYSTEM
SPECIFICATIONS
PC)
GOVERNOR
(LATER)
(1)
(2)
Torque
for nut
lb. ft.
(12 4
Nm)
8M9140
Spring for governor:

(stripes)
1
Color code
green (18 N)
4.0
to
lb.
Then add more force

shorter by
make
spring
900
16.6 +
.3 lb.
in.
in.
(22.86
1
mm)
.3
Total test force
(74.0
N)
2.34
.03
(59.4 0.8
in.
mm) mm)
Outside diameter
(3) (4)
1.38
(35.1
Collar for spring.
2S7235
Spring:
test force
Length under
Test force
375
39
in.
(9.53
+
mm)
IM)
.03
lb.
(1.75
in.
0.13
68
425
(17.3
mm)
Outside diameter
(5)
in.
(10.80
mm) mm)
mm) mm)
9M6303
Spring for over-fueling;

test
Length under
Test force
force
180
10.0 + .5
in.
(4.57
+
lb.
(45
2.2 N)
Free length after test (approximate)
344
in.
(8.74
Outside diameter
480
in.
(12.19
29
3304
VEHICULAR ENGINES
(SCROLL FUEL SYSTEM
SPECIFICATIONS
PC)
FUEL TRANSFER
PUIVIP
Pressure of fuel to injection
pump
(1)
25 to 32
. ,
psi
(170 to 220 kPa)
Bore of bearing (new)
.4953
.0003
in.
(12.581
0.008
mm) mm)
(2)
Depth of bore
(new)
in
body 3750
. .
.0003
in.
(9.525
0.008 0.008
Thicl<ness of gear (new)

(3)
(4)
.3730
.0003
in.
(9.474
5
lb. ft.
mm)
Torque
for nut
22
(28
Nm)
mm)
mm)
Clearance between gear and cover (new)
0014
to .0026
in.
(0.036 to 0.066
permissible clearance between gear and cover (worn)

(5)
Maximum
0035
in.
(0.089
Shaft diameter (new)
.4937
.0001
in.
(12.540
0.003
mm) mm)
Bore in shaft bearing (new)
4953
.0003
in.
(12.581
0.008
permissible clearance betv\en shaft and bearing (worn)

(6)
Maximum
8M3210
003
in.
(0.08
mm)
Spring:

Test force Free length after test
1.212
5.36
in.
(30.78
+
mm)
.13
lb.
(23.8
in.
0.58 N)
.82
(46.2
mm)
mm)
Outside diameter
(7)
41
gasket:
in.
(10.4
Torque
for plug
when used with

(copper)
(plastic)
2A1913 Gasket
4IM7465 Gasket
110
15
+
1b. ft.
(149
20
Nm)
27
lb. ft.
(38 4
Nm)
Put a thin layer of 8S6747 Sealer on face of pump body before installing pump cover. Do not let any of 8S6747 Sealer get into the
NOTE:
pump.
FUEL BYPASS VALVE
C^TO
psi
pump
(1)
25 to 32
for bypass valve:
(170 to 220 kPa)
4S6526 Spring
Length under
Test force
test force
1.04
in.
(26.4
mm)
3.16
.16
lb.
(14.1 0.71 N)
in. in.
.88
(47.8
(17.8
(1.3
mm) mm)
mm)
Outside diameter
70
Diameter of wire
05
in.
30
3304
VEHICULAR ENGINES
(SCROLL FUEL SYSTEM
SPECIFICATIONS
Dl)
3304
VEHICULAR ENGINES
(SCROLL FUEL SYSTEM
SPECIFICATIONS
Dl)
FUEL INJECTION
A-5P4158
GAUGE
TYPICAL EXAMPLE
sequence)
3, 4,
TC
(top center):
Direct Injection Engines
without turbocharger
(1)
27
154
11
lb. ft.
Torque
for
bushing
(205
15 N-m)
PUMP ASSEMBLY SPRINGS
3304
VEHICULAR ENGINES
(SCROLL FUEL SYSTEM
SPECIFICATIONS
Dl)
INJECTION PUMP & TIMING DIMENSION
Fuel Injection (Cont.)

(7)
Bore
(new)
in
the bearings for the camshaft

1.8765
.0010
in.
(47.663
0.025 mm)
Diameter
(new)
of bearing surfaces of the
camshaft
in.
1.8730
.0005
(47.574
in.
0.013
mm) mm)
Maximum
permissible clearance between the bearings
and the camshaft
010
(0.25
3304
VEHICULAR ENGINES
(SCROLL FUEL SYSTEM
SPECIFICATIONS
Dl)
GOVERNOR
A81478X1
INSTALL SPRING
WASHERS AS SHOWN
B14464X1
(1)
(2)
Torque
for nut
9 3
lb. ft.
(12
4 Nm)
(4)
4N6681 Spring
tor governor-
3P131 Spring:
Test force
21
2 purple
4.0
to
lb.
430
in.
(10.92
mm)
N)
(18 N)
.02
lb.
(0.95
0.09
(21.6 (9.40
Then add more force

shorter by
Total test force
make
spring
Free length
after test
90
14.8
in.
(22.9
mm)
85
in.
in.
mm) mm)
.48
lb.
(67
2 N)
Outside diameter
(3)
370
Free length
after test
Seat. Install a spring washer, flat washer and spring washer between seat (3) and spring (4) as shown.
2.24
.03
in.
(56.9
in.
0.8 mm)
(34.87
Outside diameter
(5)
1.373
mm)
(4)
9L6446 Spring
for governor:
1
4N5549 Spring
for over-fueling:

blue,
green
(18 N)

Test force
209
65 .03
lb.
in.
(5.31
mm)
4.0
to
lb.
(2.9
in.
in.
0.1 N)
Then add more force

shorter by
Total test force
make
spring
80
12.4
in.
(20.3
mm)
Outside diameter
1
859
429
(21.82
mm)
mm) mm)
.24
lb.
(55
0.8
(10.90
N)
(6)
Free length
after test
Diameter
(new)
of the outer
2.24
.03
in.
(56.9
In.
mm)
Bore
in
surface of the cylinder 1.2172 .0005 in. (30.917 0.013
the gear
Outside diameter
1.371
(34.82
mm)
(new)
1.2192 .0005
in.
(30.968
0.013 mm)
NOTE: Governor weights must
pivot freely.
34
3304
VEHICULAR ENGINES
(SCROLL FUEL SYSTEM
SPECIFICATIONS
Dl)
FUEL TRANSFER PUMP

(4N4864)
pump
(1) (2)
25to32psi(170to220kPa)
.
. .
Bore of bearing (new)

Deptti of bore
In
.4953
.0003
In.
(12.581
0.008 mm) 0.008 mm) 0.008 mm)

(28
body
3750 .0003
.
.
(new)
in.
(9.525 (9.474
lb. ft.
Tfilcknessof gear(new)
(3) (4)
.3730
.0003
in.
Torque
for nut
22 5
7 N-m)
Clearance between gear and cover (new) 0014 to .0026

permissible clearance between gear and cover (worn)
in.
(0.036 to 0.066
mm)
Maximum
0035
(12.540
In.
(0.089
mm)
(5)
Shaft diameter (new)
4937 .0001
In.
0.003 mm) 0.008 mm)

In.
Bore
(new)
In
shaft bearing
4953 .0003
In.
(12.581
fvlaxlmum permissible clearance between shaft and bearing (worn)

(6)
003
(0.08
mm)
8M3210
Spring:
1.212
5.36
In.

Test force
(30.79
mm) mm) mm)
.13
lb.
(23.8
in.
0.58 N)
.82
(46.23
(10.4
Outside diameter
(7)
41
In.
Torque
for plug
when used
with gasket:
. . .
4N7465 Gasket
27 3
lb.
ft.(38
Nm)
NOTE: Put a
Installing
8S6747 Sealer on face of pump body before pump cover. Do not let any of 8S6747 Sealer get Into the
thin layer of
pump.
35
3304
VEHICULAR ENGINES
(SCROLL FUEL SYSTEM
SPECIFICATIONS
PC &
Dl)
TIMING GEARS
Torque
for
two bolts that hold front

17
cover to plate
+ 3
lb. ft.
(23
4 N-m)
7
Torque
for nuts holding
cover for
accessory drive gear

(1)
20 5
lb. ft.
(27
N-m)
N'Oi)
Torque
for nut holding
accessory drive gear

(2)
100 10
lb. ft,
(135
14
End play
(new/)
for the cannshaft
007 .003
of
in.
(0.18
0.08 mm)
(0.64
Maximum
Diameter
025
in.
mm)
mm) mm)
camshaft bearing surface

2.3110 .0005
in.
(journal) (new)
(58.699 0.013
Bore
(new)
in
bearing for camshaft 2.3150 .0024
in.
(58.801
0.061
and bearing surface

(3)
IVIaximum permissible clearance between bearing (journal) (worn) 008 in. (0.20
mm) mm)
mm)
End play
(new)
for the idler
gear
004
to .016
.
in.
(0.10 to 0.41
Maximum

idler
1
034
in.
(0.86
Bore in bearing for the gear (new)

Diameter of shaft gear (new)
.3781
.0019
in.
(35.004 0.048
mm) mm) mm)
for idler
1.3741
.0005
in.
(34.902 0.013
permissible clearance between shaft 009 and bearing (worn)

(4)
Maximum
in.
(0.23
Balancer shafts:
Diameter of balancer shaft bearing surface 2.0825 + .0005 in. (52.896 0.013 (journal) (new)
bearing for balancer 2.0886 .0024 shaft (new)
mm)
mm)
Bore
in
in.
(53.050 0.061
Maximum
shaft
permissible clearance between balancer
and bearing (worn)

for the
010
in.
(0.25
mm)
End play
(new)
balancer shaft
0035
to .0075 in. (0.089 to 0.191
mm) mm)
Maximum
(5)
017
in.
(0.43
Distance from front face of bushing to rear

face of cover
2.56
in.
(65.02
36
FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
CAMSHAFT
NOTE: Put a
installing.
(1)
layer of graphite
grease on lobes of camsfiaft wfien
Width of groove
(new)
in
cannshaft for thrust washer 190 .002 in. (4.83
0.05
mm)
Thickness of thrust washer

(new)
183 .001
of the
in.
(4.65
0.03
mm)
mm) mm)
End play
(new)
camshaft
007 .003
in.
(0.18
in.
0.08
(0.64
Maximum
(2)

(journal)
in.
025
Diameter of camshaft bearing surface

(new)
2.3110
in
.0005
(58.699
0.013 mm)
(3)
Bore
(new)
bearing for camshaft 2.3150 .0024
in.
(58.801
0.061
mm) mm)
Clearance between bearing and bearing surface (journal) (new) 002 to .006 in. (0.05 to
0.1
permissible clearance between bearing and bearing surface (journal) (worn) 008 in. (0.20 mm)
Maximum
NOTE; Make reference

sions.
(5)
to
CYLINDER BLOCK
for installation
dimen-
Height of camshaft lobes.
To
A.
B.
find lobe
lift,
use the procedure that follows;

(5).
Measure camshaft lobe height

Measure base
base
is
circle
circle
(6).
C. Subtract
(STEP
B)
from lobe height (STEP
A).
The
difference
D.
actual lobe
lift (4).
Specified camshaft lobe
lift
(4) is
3300
in.
(8.382
mm) mm)
74239- 1X1
Maximum
permissible difference between actual lobe and specified lobe lift (STEP D) is 010
lift
(STEP C)
(0.25
in.
VALVE ROCKER ARMS AND LIFTERS

(1)
Bore
(new)
in
bearing for shaft
7263 .0005
in.
(18.448
0.013 mm) 0.013 mm)

in.
Diameter of shaft
(new)
7245 .0005
in.
(18.402
Maximum
(worn)
(2)
permissible clearance between bearing and shaft
008
for locknut
(0.20
mm)
Torque screw
on valve adjustment
21
lb. ft.
(26
Nm)
mm) mm)
A156S6XI
(3)
Clearance
for valves;
Intake valves
015
025
lifter
in. in.
(0.38
(0.64
Exhaust valves
(4)
Diameter of valve
(new)
1.3105
in
.0005
in.
(33.287
0.013
mm)
Bore
(new)
block for valve
lifter
1.3145
.0010
in.
(33.388
0.025 mm)
permissible clearance between for valve lifter (worn)
Maximum
lifter
and bore 012 in. (0.30
mm)
37
3304
VEHICULAR ENGINES
SPECIFICATIONS
VALVES
(PC)
NOTE: GUIDELINE FOR REUSABLE PARTS: VALVES AND VALVE SPRINGS, Forms SEBF8002 and SEBF8034 have the procedure and
specifications necessary for checking used valves and valve springs.
(1)
7S7144 Spring
for valves (new):

Test force
57.7
1.766
in,
(44.86
mm)
N)
4.5
lb.
(256
20
Use again minimum

test force
load at length under

46.5
1.271
.
lb.
(207 N)
Length of spring at valve open position
in.
(32.28
lb.
mm)
Use again minimum load

at valve
open position.
144
in.
(640 N)
2.05
(52.1
mm) mm)
Outside diameter
Spring must not be bent more than
(2)
1.386
in.
(35.20
.83
072 875
in. (1
mm) mm)
mm) mm)
Height to top of valve guide
in.
(22.23
(3)
Diameter of valve stem

(new)
3717 .0003
in.
(9.441
in.
0.008
(9.408
Use again minimum diameter

valve guide with guide installed in the head
3704
Bore
in
(new)
3733 .0010
in,
(9.482
in.
0.025
(9.578
mm)
râximum permissible bore (worn)

(4)
3771
mm)
Valve
lip
thicl<ness:
8N875 & 5S7232 Exhaust Valve Use again minimum

5S6449 Exhaust Valve Use again minimum 5S6452 Intake Valve Use again minimum
(5)
106
in.
(2.69
mm)
096
in.
(2.44
mm)
mm) mm) mm)
096
in.
(2.44
Diameter of valve head:
Exhaust valve
Intake valve
(6)
1.896 .005
in.
(48.16 0.13
(51.31
2.020 .005
in.
0.13
Angle
of valve face
29 1/4"
38
FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
Valves (Cont.)
(PC)
(7)
Depth
of
bore
in
head
for valve seat insert:
Exhaust (5S7221 & 1P6837)

Intake:
Earlier (5S7218)
449 .005
in.
(11.40 0.13
mm)
449 .005
in.
(11.40 0.13
(8.86
mm)
mm)
Later (7N4448)
(8)
349 .005
in.
0.13
Diameter
of valve seat insert:
Exhaust (5S7221 & 1P6837)

Intake:
Earlier (5S7218)
. . .
2.0035
.0005
in.
(50.889
+ 0.013 mm)
2.1285 .0005
in. in.
(54.064 (52.032
0.013 mm) 0.013 mm)
Later (7N4448) .... 2.0485
.0005
Bore
in
head
for valve seat insert:
Exhaust (5S7221 & 1P6837)

Intake: Earlier (5S7218)
.
.
.
2.0005 .0005
in.
(50.813
0.013 mm)
2.1255 .0005
in. in.
(53.988
(51.961
0.013 mm)
0.013
Later (7N4448) .... 2.0457

(9)
.0005
mm)
30
Angle of face of valve seat
insert
(10)
Maximum
(intake
permissible width of valve seat
and exhaust) and exhaust)
076
in.
(1.93
mm)
mm)
I\înimunn permissible width of valve seat
(intake
(11)
045
in,
(1.14
Dimension from top
of closed valve to face of head:
Iviaximum permissible dimension for 5S6449 or
5S7232 Exhaust Valves
140
for
in.
(3.56
mm) mm)
Minimum permissible dimension

5S7232 Exhaust Valves
5S6449 or
056
in.
(1.42
Maximum
Minimum
permissible dimension for Exhaust Valve

permissible dimension for
8N875
163
in.
(4.14
mm) mm) mm) mm)
8N875
079
in.
Exhaust Valve
(2.01
Maximum
Minimum
permissible dimension for 5S6452 Intake Valve 140
in.
(3.56
permissible diameter for 5S6452 Intake Valve
066
in.
(1.68
(12)
Outside diameter of the face of the valve seat or valve seat

insert:
Exhaust seat
1.810
1.860 1.934
in.
(45.97
(47.24
mm)
Maximum Maximum
(13)
permissible, exhaust seat
in.
mm) mm) mm)

15
Intake seat
permissible, intake seat
in. In.
(49.12 (50.39
1.984
Angle to grind seat face of the insert to get a reduction of maximum seat diameter
39
3304
VEHICULAR ENGINES
SPECIFICATIONS
VALVES
(Dl)
NOTE: GUIDELINE FOR REUSABLE PARTS: VALVES AND VALVE SPRINGS, Forms SEBF8002 and SEBF8034 have the procedure and specifications necessary for checking used valves and valve springs.
(1)
7S7144 Spring
for valves {new):

Test force
57.7
at length
1.766
in.
(44.86
mm)
N)
4.5
lb.
(256.7
20
Use again minimum load

test force
under
46.5
lb.
(207 N)
Length of spring at valve open

position
1.271
at valve
in.
(32.28
mm)
Use again minimum load open position

144.4
lb.
(642 N)
2.05
in.
(52.1
mm)
Outside diameter
Spring must not be bent more than
(2)
1.386
in.
(35.20 mm)
.83
072
in. (1
mm)
mm)
B9217X1
Height to top of
valve guide
875
in.
(22.23
(3)
Diameter of valve stem

(new)
3717 .0003
in.
(9.441
in.
0.008
(9.408
mm) mm)
Use again minimum diameter

Bore
in
3704
in
valve guide with guide installed
the head.
Minimum permissible (new)
3723 3772
in.
(9.456
(9.581
mm)
Maximum
(4)
permissible (worn)
in.
mm)
Valve
lip
thickness:
Valve.
6N9916 Exhaust
Use again minimum
106
Valve.
in.
(2.69
mm)
B9216X1
6N9915 Intake Valve and 7N573 Exhaust

Use again minimum
(5)
096
in.
(2.44
mm)
Diameter of valve head:
Exhaust
valves
Intake
valve
(6)
(7)
1.896
.005
in.
(48.16
0.13
mm)
2.020
.005
in.
(51.31
0.13
mm)
Angle of valve face
29 1/4
for valve seat
Depth of bore
insert
in
head
488 .005
for
in.
(12.41
0.13
mm)
(8)
Diameter of valve seat insert

valve
exhaust
2.0035
in
.0005
in.
(50.889
0.013
mm)
(11)
Dimension from top
of closed valve to face of head:
Bore
valve
head
for valve seat insert for
exhaust
in.
2.0005
.0005
(50.813
0.013
mm)
Minimum Minimum
permissible dimension for 7N573 and
6N9916 Exhaust Valve

Diameter of valve seat
insert for intake
026
in.
(0.66
mm)
mm)
permissible dimension for

.
valve
2.0485
in
.0005
in.
(5.032
0.013
mm)
(12)
6N9915 Intake Valve
006
in.
(0.15
Bore
valve
(9)
head
for valve seat
Outside diameter of the face of the valve seat
insert:
in.
insert for intake
2.0455
.0005
in.
(51.956
0.013 mm)
30
Exhaust seat
1.812
1.862 1.940
(46.02
mm)
mm) mm) mm)
15
Maximum
permissible, exhaust seat
in.
(47.29 (49.28 (50.55
Angle of face of valve seat insert

permissible width of valve seat (intake and exhaust)
(10)
Maximum
Intake seat
in.
076
in.
(1.93 mm)
(13)
Maximum
permissible, intake seat
1.990
in.
Minimum permissible width

(intake
of valve seat
and exhaust)
045
in.
(1.14
mm)
Angle to grind seat face of the insert to get a reduction of maximum seat diameter
40
FOR TOROUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS- FOR GENERAL TIGHTENING TOROUES
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
GLOW PLUG POSITIONING
Cyl. Nos. Cyl. Nos.
1, 2, 1
and 33304*
Cyl. No.
43304*
thru
43304"
'Engines with counterbored **Engines with spacer plate.
blocl(.
(A) Correct
range for glow plug opening.
Put 5P3931 Anti-Seize bustion chamber.

Put
Compound on
it,
the threads of the precom-
5M2667 Gasket, with "2C" on on the precombustion champrecombustion chamber in the cylinder head and tighten to 150 10 lb. ft. (205 14 N-m)
ber. Install the
NOTE:
If the hole for the glow plug is not in range precombustion chamber. Remove the gasket.
(A),
remove the
If the hole was in range (B) install 2S8959 Gasket, with "2S" on it, on the precombustion chamber. Install the precombustion chamber in the cylinder head and tighten to 150 10 lb. ft. (205 14 N-m)
If
the hole
was
in
range (C)
install
on the precombustion chamber. in the cylinder head and

tighten to
Install
2S8960 Gasket, with "2X" on it, the precombustion chamber

150 10
lb. ft.
(205 i 14 N-m)
41
3304
VEHICULAR ENGINES
SPECIFICATIONS
CYLINDER HEAD
Thickness of cylinder head

(new)
Step
3.938
2.
Again tighten
all
bolts
in
number
185
.030
in.
(100.03
0.76
mm)
Step
3.
sequence sequence
Step
4.
to
all
13
lb. ft.
(250
17 N-m)
NOTE: Dimension from top of closed valve to face of cylinder head must be according to the specifications in VALVES.
Again tighten
to
bolts in
number
185 13
lb. ft.
(250
17
Nm) Nm)
Compound on
bolts
in
threads and tighten bolts
in
the
Step sequence that
follov/s:
all
Tighten all bolts in letter sequence (hand torque only) to 32 5
lb. ft.
(43
Step
1.
Tighten
number
1
sequence
to
15
lb. ft.
(155
Nm)
0^
03
02
06
11
10
.0
VALVE COVER
77077X
I
VIEW FROM RIGHT SIDE OF ENGINE
Put 5H2471
Cement on
the face of valve cover and top side of gasket.
Tighten bolts by number sequence show/n to
96
24
1b. in.
(10.9
2.8
Nm)
42
3304
VEHICULAR ENGINES
SPECIFICATIONS
EXHAUST MANIFOLD

(1) (2)
Compound on
all
threads.
Torque
for for
studs
nuts holding exhaust
20 3
lb. ft.
(25
Nm)
Nm)
Torque
manifold
32 5
lb. ft.
(43
EXHAUST PIPE AND MUFFLER

Put 5P3931 Anti-SeIze
of bolts for
Compound on
threads 20 5
lb. ft.
clamps and
(25
tighten to
7 N-m)
AIR
(1)
CLEANER
20
Tighten nuts that hold

to
air filter
elbow
lb. ft.
(25
Nm) Nm)
(2)
Tighten wing nuts to
35 5
lb. in. (4.0
0.6
43
3304
VEHICULAR ENGINES
SPECIFICATIONS
TURBOCHARGER IMPELLER INSTALLATION

Schwitzer
Installation
A. Put
ONLY
Procedure Chart
if
6V1541 Quick Pure Primer on the nut and the shaft threads to clean them,
necessary.
B.
Put a small amount of 9S3265 Retaining
Compound on
the nut and shaft threads.
CAUTION
Do
not
let
it
the retaining
compoun
because
can make removal
of the
get into the compressor wheel bore on the shaft, compressor wheel difficult during future turbo-
charger disassembly.
C. Put a small
amount of lubricant, such as Lubriplate, on the nut seat area on the compressor. Do not put lubricant on the threads.
wheel
44 2
lb. ft.
D. Tighten the compressor retainer nut to
(60
3 N-m)
NOTE: Do
not bend or add stress to the shaft
when
the nut
is
tightened.
44
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
TURBOCHARGER IMPELLER INSTALLATION

(AIResearch
ONLY)
TEST FOR TYPE OF IMPELLER INSTALLATION

1.
Install the proper thrust collar and seal carrier spacer on the shaft-wheel assembly to be used. Install
2.
impeller on shaft by hand.

at the
3.
point
4.
If
Measure the distance between impeller and seal carrier where impeller no longer moves freely on shaft.
the distance
is:
(a)
more than
.31 in. (7.9
.31
in.
(7.9
mm), use heat
for installation.*
(b)
mm)
or less, use
room temperature
installation."
3304
VEHICULAR ENGINES
SPECIFICATIONS
TURBOCHARGER
(AiResearch T04B91)
46923-1X3
Make reference
No. FEG45138.
to
ANALYZING TURBOCHARGER FAILURE, Form
to GUIDELINES FOR REUSEABLE PARTS TURBOCHARGERS, Form Nos. SEBF8018 & SEBF8019.
Make reference
(1)
Torque
for
impellernut
20
lb. in.
(2.3
N-m)
100
Tighten nut an added
NOTE: Do
(2)

for bolts holding
when
in.
nut
is
tightened.
(7)
Radial play for shaft:
Torque
back plate
(3)
75 to 90
lb,
(8.5 to 10.2
N-m)
Minimum
permissible radial play
003
in.
(0.08 (0.15
mm)
mm)
Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding compressor housing to center 115 15 lb. in. (13 1.7 N-m) section to Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding turbine housing to center section to 115 15 lb. in. (13 1.7 N-m)
Maximum
(8)
permissible radial play
006
in.
Bore
in
the
bearing
4010
to .4014
in.
(10.185 to 10.196
mm)
mm)
(4)
for the bearing

(9)
Diameter of surface on shaft (journal) 3997 to .4000 in. (10.152
to
10.160
Bore
in
housing...
.6220 to .6223
in.
(15.799 to 15.806
mm)
mm)
(5)
Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding turbocharger to 40 4 lb. ft. (55 manifold to
N-m)
(10)
Outside diameter of the 6182 to .6187 bearing
in.
(15.702 to 15.715
(6)
End play
for shaft:
Clearance between ends of

seal ring
oil
008
of
to .015
in.
(0.20 to 0.38
mm)
mm)
Minimum
permissible end play permissible end play
001
in.
(0.03 (0.10
mm)
Diameter
seal ring
bore for
oil
Maximum
004
in.
mm)
709
to .71
in.
(18.01 to 18.06
46
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
TURBOCHARGER
(AIResearch T0490)
Make
reference to No. FEG45138.

GUIDELINES FOR REUSABLE PARTS TURBONos. SEBF8018 & SEBF8019.
20
lb.
Make reference
Torque
to
CHARGERS, Form
(1)
for impeller nut
in.
(2.3
N-m)
(6)
End play
for shaft
001 to .004
in,
(0.03 to 0.10 (0.08 to 0.18
mm) mm) mm) mm) mm)
Tighten nut an added
100
(7)
Radial play for shaft
003
to .007
in.
NOTE: Do
(2)

for bolts holding
when
lb. in.
nut
is
tightened.
Bore
in
the
Torque
plate
back
50 10
(5.7
bearing
4010
to .4014
in.
(10.185 to 10.196
1.1
N>m)
(3)
Put 5P3931 Anti-Seize Compound on threads and tighten bolt holding band clamp to 60 10 lb.
Diameter of surface on shaft (journal) for the bearing 3997 to .4000 in. (10.152
(8)
to 10.160
in.
(6.8
1.1 N-m)
Bore
in
housing
.6220 to .6223
in.
(15.799 to 15.806
(4)
Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding turbine housing to 115 15 lb.
Outside diameter of the bearing 6182 to .6187

in.
in.
(15.702 to 15.715
mm)
mm)
mm)
(13 1.7 N-m)
(9)

seal ring
oil
(5)
Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding turbocharger to manifold to 40 4 lb. ft. (55 5 N-m)
008
oil
to .015
in.
(0.20 to 0.38
(10)
Diameter of bore for

seal ring
709
to ,71
in.
(18.01 to 18.06
47
3304
VEHICULAR ENGINES
SPECIFICATIONS
TURBOCHARGER
(AIResearch T1210 and T1224)
T98428X4
Make

Make reference
to
CHARGERS, Form
(5)
Compound on
threads
lb. in.
Put 5P3931 Anti-Seize elbow.
Compound on
tfireads of plug for exfiaust
of bolts holding turbocharger to
manifold and tighten to

(6)
40 4
(55 5
N-m)
Put 5P3931 Anti-Seize Compound on bolts holding support for exhaust and
tighten to
(1) (2)
End play
(new)
for shaft
006
in
to .011
in.
(0.15 to 0.27
mm) mm)
mm) mm) mm)
45 5
lb. ft.
(60
N-m)
(7)
Bore
the
See
TURBOCHARGER IMPELLER INSTALLATION.

for bolts
bearing
6268
of surface
to .6272
in.
(15.921 to 15.931
Torque
plate
holding thrust
Diameter
35 4
lb. in.
(4.0
0,5 N-m)
(8)
the bearing
on shaft (journal) for 6250 to .6254 in. (15.875

.9827 to .9832
in.
to
15.885
(3)
Tighten bolt holding band
Bore
in
housing
(24.961 to 24.973
clamp
(4)
to
120 10
lb. in.
(13.6 1.1
N-m)
Put 5P3931 Anti-Seize Compound on threads of bolts holding turbine housing and tighten to 175 15 lb. in. (19.8 1.7 N-m)
Outside diameter of the bearing 9780

(9)
to .9785
oil
in.
(24.841 to 24.854

seal ring
008
to .015
in.
(0.20 to 0.38
mm)
48
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
TURBOCHARGER
(Schwitzer 3LK)
73113X2
Make

0045 .0015
In.
Make
(1)
reference to
(5)
Maximum
measured
permissible gap of
in
oil
seal ring,
CHARGERS, Form
End play
(new)
bore of housing
007
in,
(0,18
mm)
for stiaft
(6)
See
TURBOCHARGER INSTALLATION,
75025 ,00025
in,
(0.114
.008
0.038 mm)
(7)
in,
Maximum
(2)
(0.20
mm)
mm) mm)
(8)
Bore in housing
(19,0564 0,0064
mm)
mm)
Thickness of thrust
bearing
21
of surface
1
.001
in.
(5.36
0.03
Outside diameter of the bearing 74625 ,00025
in,
(18,9548 0,0064
(3)
Diameter
the bearing
on shaft (journal) for 44015 .00015 in. (11.1798 0.0038

44165 .00015
(11.2179 0.0038
Maximum
permissible clearance between

in
bearing and bore
housing
1005 ,0005
0045
in,
(0,114
mm)
mm)
N-m)
Bore
in
the
in.
Thickness of each thrust

ring
in,
bearing
mm)
(9)
(2,553 + 0,013
Maximum
(4)
Torque
for bolts holding
bearing and shaft
0018
in.
(0.046
mm)
(10)
impeller housing
60
lb, in,
(6,8
Put 5P3931 Anti-Seize Compound on threads and tighten bolt holding band
Put 5P3931 Anti-Seize Compound on threads of bolts holding turbocharger to manifold
clamp
to
120
lb. in.
(13,6
N-m)
and tighten
to
40 4
lb, ft,
(55
5 N-m)
49
3304
VEHICULAR ENGINES
SPECIFICATIONS
TURBOCHARGER
(Schwitzer 3LM)
A22019X2
Make Make
reference to No. FEG45138, reference to

(6)
Thickness of thrust
bearing
107 to .108
in.
GUIDELINES FOR REUSABLE PARTS TURBOCHARGERS, Form Nos. SEBF8018 & SEBF8019.
(1)
(2.72 to 2.74
mm)
(7)
Bearing:
End play
for shaft (new)
002 to ,005
in.
(0.05 to 0.13
mm)
Bore
in
housing
7500 to .7505
in.
(2)
Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding impeller housing to 60 lb. in. (6.8
for bearing
(19.050 to 19.063
mm)
mm)
Nm)
(3)
Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding turbine housing to 11 to 12 lb.
permissible gap of measured in bore of housing
for
Diameter of surface of bearing housing 7460 to .7465 Diameter of surface of
in.
(18.948 to 18.961
ft.
(15 to 17
Nm)
mm)
bearing for shaft
4415 to .4418
in.
(11.214 to
11.222mm)
(4)
Maximum
oil
seal ring,
007
in.
(0.18
Diameter of surface of shaft for bearing (journal) 4400 to .4403
in.
(11.176 to 11.184
in.
mm)
(5)
See
TURBOCHARGER
IIVIPELLER INSTALLATION.
Length
of bearing
2.425 to2.426
(61.60 to61.62
mm)
50
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
TURBOCHARGER
(Schwitzer F444, 4LF504 and E Models)
T97594X1
Make
(4)
Put 5P3931 AntiSelze

tighten bolt holding
Compound on
to
oil
band clamp
threads and 120 lb.
in.
(13.6
N-m)
Make
reference to
CHARGERS, Form
(5)
permissible gap of measured In bore of housing
Maximum
seal ring,
009
in.
(0.23
mm)
(6)
See
TURBOCHARGER IMPELLER
In
INSTALLATION.
(22.255 to 22.268
(1)
End play for stiaft (new)
(7)
Bore
(new)
housing
0045 .0015
in.
(0.114
0.038 mm)
In.
8762 to .8767
In.
mm)
mm)
mm)
Maximum
(2)
(3)

...
008
(0.20
mm)
mm) mm)
(8)
Outside diameter of the bearing (new) 8718 to .8722
in.
(22.144 to 22.154
Thickness of thrust bearing
.211
.001
in.
(5.36
0.03
Maximum
bore
In
permissible clearance between bearing and
Diameter of surface on shaft (journal) for the bearing (new) 5612 to .5615 in. (14.254 to 14.262
housing (worn)
006
1005 .0005
in.
(0.15
Thickness of each thrust

ring
in.
Bore
(new)
in
the bearing
(2.553
0.013
mm)
5627 to .5630
in.
(14.293 to 14.300
mm)
(9)
Maximum permissible clearance between bearing and shaft (worn) 003 in. (0.08
mm)
Put 5P3931 Antl-Seize Compound on threads and tighten bolts holding turbocharger to manifold to 40 4 lb. ft. (55
5 Nm)
51
3304
VEHICULAR ENGINES
SPECIFICATIONS
OIL
PUMP
(2P7830, 5S3876 & 7S9840)
(1)
Diameter of the drive

shaft (new)
7407 .0003
in.
(18.814
0.008 mm) 0.013 mm)

0.020
the bearings for the 7425 .0005 drive shaft
Bore
in
in.
(18.860
Clearance between drive shaft and bearing (new) 0018 .0008
in.
(0.046
mm) mm)
Maximum
shaft
(2)
and bearing (worn)

2.9955 .0005
in.
005
(76.086
in.
(0.13
Length of gear
0.013 mm) 0.020 mm)

0.033
Depth of counterbore
for
gear
3.0008 .0008
of gear
in.
(76.220
Clearance between end cover (new)

(3)
and 0053 .0013
in.
(0.135
mm)
Length of gear
.9975 .0005
in.
(50.737
0.013 mm)
Depth
for
of
counterbore
2,0008 .0008
of
in.
gear
(50.820 0.020
mm)
Clearance between end cover (new)

(4)
gear and 0033 .0013
in.
(0.084
0.033 mm)
Diameter of the shaft for the drive idler gear (new) 1.1225 1 .0005 in. (28.512 0.013
mm) mm) mm)
Bore
(new)
in
bearing of gear
1.1260 .0019
in.
(28,600 0.048
Clearance between shaft and bearing (new) 0035 .0024
in.
(0.089
0.061

(5)
Maximum
in.
(0.20
mm) mm) mm) mm)

mm) mm) mm)
1S3921 Spring for pressure Length under

Test force
test force
relief
valve (engine
oil):
in.
3.25 39.8
(82.6
3.2
lb.
(177.5
in.
+ 14.0 N)
(90.7
3.57
Outside diameter
(6)
77
in.
(19.6
Diameter of the shaft for the idler gear (clutch pump) (new) 7407 .0003 in. (18.814 0,008
Bore
in
the bearing
7425 .0005
in,
(18,860 0,013
Clearance between shaft and bearing (new) 0.0018 .0008
in.
(0.046 0.020

(7)
Maximum
in.
(0.20
mm)
mm)
Diameter of the shaft
for the idler
pump) (new)
Bore
idler
in
gear (scavenge 7407 .0003 in. (18.814 0.008
the bearing of the
gear
7425 .0005
in.
(18.860 0.013
mm)
(8)
4J4790 Spring
Length under
for pressure relief valve (clutch oil):

test force
Clearance between shaft and 0018 .0008 bearing (new)
1.548
in.
(39.32
lb.
mm)
mm) mm)
N-m)
in.
(0.046
0.020 mm)
Test force Free length after test
12.27
(54.6 N)
Maximum
in.
(0.20
mm)
(9)
2.163
in.
(54.94
(18.3
Length of gear
9975 .0005
1.0008 .0008
in.
(25.337
0.013 mm)
Outside diameter
72 60
pin.
in.
Depth
for
of
counterbore
in.
Torque
for nut holding drive gear
lb. ft.
(80
gear
(25.420 0.020
mm)
Tighten farther to get alignment for cotter
52
3304
VEHICULAR ENGINES
SPECIFICATIONS
OIL
PUMP
(781849 & 7S9461)
(1)
Diameter of the drive shaft 8747 .0002 (new)

the bearings for the 8763 drive shaft
in.
(22.217
0.005 mnn) 0.008 mm)

0.013
(0.13
Bore
in
.0003
in.
(22.258
Clearance between drive shaft and 0016 .0005 bearings (new)
in.
(0.041
mm) mm) mm)
Maximum
(2)
permissible clearance between shaft
and bearing (worn)

Diameter gear (new)
of the shaft for the drive idler
005
in.
1.1225
.0005
in.
(28.512 + 0.013
Bore
in
the
bearing
1.1260 .0019
in.
(28.600
0.048 mm)
in.
in.
(0.089
0.061
mm) mm)
Maximum
(3)
permissible clearance between shaft
and bearing (worn)

Diameter of the shaft for the 8747 .0002 idler gear (new)
008
(0.20
in. in.
(22.217
0.005 mm)
Bore
in
the bearing.
.8763
.0003
(22.258 0.008
mm)
in.
(0.041
0.013 mm)
in.
permissible clearance between shaft and bearing (worn)

(4)
Maximum
008
(0.20
mm) mm) mm) mm)
1S3921 Spring for pressure

Length under
Test force
test force
relief valve:
3.25
in.
(82.6
39.8
3.2
lb.
(177.5
in.
in.
14.0 N)
3.57
(90.7
Outside diameter
(5)
77
1
(19.6
Length
of
gear
.4988
.0010
in.
(38.070
0.025 mm) 0.020 mm) 0.046 mm) 0.025 mm) 0.020 mm) 0.046 mm)
(80
for
Depth of counterbore gear
1.5038 .0008
in.
(38.197
Clearance between end of gear 0050 .0018 and cover (new)

(6)
in.
(0.127
Length of gear
2.0003
.0010
in.
(50.808
Depth
of
counterbore
2.0053 .0008
in.
for gear
(50.935
Clearance between end of gear 0050 .0018 and cover (new)

(7)
in.
(0.127
Torque
for nut holding drive gear
60
pin.
lb. ft.
N-m)
Tighten farther to get alignment for cotter
53
3304
VEHICULAR ENGINES
SPECIFICATIONS
OIL
PUMP
(2P1785 and 6N2642)
a-.^j.^
(1)
Bore
gear
in
bearing of idler
1
.1260 .0024
in.
(28.600 0.061
mm)
Diameter of shaft for idler gear
thie
1.1255 .0005
in.
(28.588
0.013 mm)
0.074
I80o)
stiaft
(2)
Clearance between bearing and 0035 + .0029
in.
(0.089
mm) mm) mm) mm) mm)

mm)
Clearance between gears and body of pump 002 to .026

Diameter of shafts
for
in.
(0.05 to 0.66
(3)
pump
Bore
in
8747 .0002
bearings for
in.
(22.217 0.005
shafts
8763 .0003
in.
(22.258 0.008
Clearance between shafts and bearings 0016 .0005

(4)
in.
(0.041
0.013
Length
of of
gears
2.0003 .0010
in.
(50.808 0.025
Depth
gears
bore
in
pump body
of
for
in.
2.0053 .0008
(50.935 0.020
mm)
mm) mm) mm)
Clearance between end
pump body
(5)
gears and 0050 .0018
in,
(0.127 0.046
Length of gears
.4988 .0010
for
in.
(38.070 0.025
Depth of bore
gears
in
pump body
of
1.5038 .0008
in.
(38.197 0.020
Clearance between end
pump body
(6)
gears and 0050 .0018
in.
(0.127 0.046
mm)
N-m)
Torque
for bolt holding drive
gear to 32 5
lb. ft.
drive shaft
(43 7
54
3304
VEHICULAR ENGINES
SPECIFICATIONS
ENGINE OIL PRESSURE
All
steps of this procedure must be followed for the pressure findings
Step
3.
Run
the engine to get the
oil
temperature
at
210 F (99 C).
to
be usable.
1.
NOTE: A
that the
Step
Besure
SAE
10 or SAE information in not apply.
engine is filled to thecorrect level with either 30 oil. If any other viscosity of oil is used, the the ENGINE OIL PRESSURE CHART does
psi (7
4.
5 F (3 C) increase in oil temperature gives approximately kPa) decrease in oil pressure.
Step
the
Keep the engine oil temperature constant. With the engine at rpm from the chart, read the pressure gauge.
Step
2.
Find a location on the engine oil manifold to install a tee. The easiest method is to remove the sending unit for the present gauge and install a tee at this location. Install a probe from the 9S9102 Thermistor Thermometer Group in one side of the tee. Connect a 8M2744 Gauge from the 5P6225 Hydraulic
Test Box to the other side of the
tee.
Make a comparison between the pressure reading on the test gauge and the minimum permissible pressure from the ENGINE OIL PRESSURE CHART. If the pressure reading on the test gauge is below the minimum permissible pressure, find the cause and correct it. Operation of the engine with low oil pressure can be the cause of engine failure or of a reduction in engine life.
ENGINE OIL PRESSURE CHART
3304
VEHICULAR ENGINES
SPECIFICATIONS
OIL FILTER
(7S6638, 7S6639
&
9S1806)
(1
Torque
for the bolt
20
+ 5 lb.
ft.
(25 7
Nm)
mm)
(2)
6F8007 Spring
Length under
Test force
for oil filter bypass valve:
test force
2.43
5.2 to 6.1
in.
(61 .7
lb.
(23 to 27 N)
(91.7
3.61
in.
mm)
Outside diameter
81
in.
(20.6
mm)
7S6638
(3)
Filter only:
6F8007 Spring
Length under
Test force
for oil cooler bypass valve:
test force
2.43
5.2 to 6.1
in.
(61 .7
mm)
lb.
(23 to 27 N)
(91.7
3.61
In. in.
mm)
Outside diameter
81
(20.6
mm)
OIL
BREATHER CAP
(1)
Torque
for bolt holding
breather cap
120+ 24
1b. in.
(13.6
2.8 N-m)
56
3304
VEHICULAR ENGINES
SPECIFICATIONS
WATER PUMP
(1)
Oil seal. Put engine toward the bearings.
oil
on the seal
lip.
Assemble with the
lip
(2)
Water seal and

a.
ring.
Put water on the seal. the seal and ring together shiny face of the ring outside.
Install
in
b.
the housing bore, with the
(3)
Seal assembly.
a.
b.
c.
Remove
the spring from the seal.
Put water inside the seal assembly.

Install the seal
assembly around the

is
Installation Tool, (the tool
bon face makes

d.
(4)
shaft, with the 7N7843 with the seal group) until the carcontact with the shiny face of the ring (2).
Install
the spring.
Torque
for the bolt that
holds the
impeller
(5)
28
holds the 32
lb. ft.
(39
Nm)
Torque gear
for bolt that
51b.
ft.
(43
7Nm)
V-BELT TENSION CHART
3304
VEHICULAR ENGINES
SPECIFICATIONS
RADIATOR
T93973
TOP TANK WITH
5S1218 PRESSURE RELIEF VALVE
A59222XI
TIGHTENING PROCEDURE FOR TYPICAL TWO-ROVI/ TANK
Clean the threads

stalling
(1)
of the studs with 8M8060 Quick Cure Primer. Then put 9S3265 Retaining Compound on the threads before in-
them.
for the
filler
Torque for stud cap
40 l 5
Relief Cap:
lb. ft.
(55 7
N-m)
(2)
2S3080 Pressure
Pressure valve must not leak at Pressure valve must be open

at at a
11 .9 psi (82
kPa)
15 psi (105 kPa)
Vacuum
valve must be
of
open
pressure below
0.6 psi (4 kPa)
atmospheric
or 1.22 or 16.6
(2)
in. in.
Hg
(31.0
Hs (422
mm Hg) mm HjO)
321464 Pressure Relief Cap:
Cap must
not leak at
at
6.5 psi (45 kPa)
Cap must be open

(2)
8 psi (55 kPa)
5S1218 Pressure
Relief Valve:
o o o
Vacuum relief at a maximum

Pressure Pressure
(3)
valve to
of
open
1
psi (7
kPa)
relief relief
valve must not leak at
14 psi (95 kPa)
valve must be
open
i^
at
5O
18 psi (125 kPa)
-I Oo
Torque for bolts and shields
that hold baffles
15 5
lb. ft.
(20 7
N-m)
(4)
Bolt torque sequence for radiator tanks. not required on the bottom tank.
Sequence 5 and 6 are
TIGHTENING PROCEDURE FOR TYPICAL THREE-ROW TANK
58
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
WATER TEMPERATURE REGULATOR
7N208 Regulator:
Temperature when completely open
195= F (90
"
C)
77719X1
Minimum open
distance
375
in.
(9.53
mm)
9S3808 and 4H1991 Regulator:

Temperature when completely open
185 F (85 C)
Minimum open distance
310
in.
(7.87
mm)
85312X1
COOLANT FLOW SWITCH
4N9072 SWITCH (John W. Hobbs Number 22258)

(1)
Terminal connected to insulated contact. The other contact is connected to the body of the switch. Switch contacts are normally closed.
With paddle
in vertical
(2)
position,
(2)
the force (F) on rivet head
necessary
switch
(3)
to
open contacts
of
1
.2
.1
oz. (34
3 grams)
(65.5
Length
of
paddle
the switch
is
2.58
in.
mm)
installed in engine cooling system, the flow of coolant at cranking speed of the engine does not have enough force to activate the switch. When the engine is running at low idle the flow of coolant has enough force to activate the switch.
NOTE: When
59
3304
VEHICULAR ENGINES
SPECIFICATIONS
CYLINDER BLOCK
(Counterbored Block)
(1)
Depth
of bore in block
for liner
401 .001 top of block
in.
'10.19
0.03
mm)
CYL-
NOTE: For fieighit of liner over INDER LINER PROJECTION.

(2)
make
reference to
Camshaft bearing bore

installed
2.3150 .0020
in.
(58.801
0.051 mm)
Bore
in block for
camshaft
2.5630:
.0010
in.
bearings
(65.100
0.025 mm)
Depth to
install
bearings at block
camshaft both ends of

...
.06
.02
in.
(1.5
0.5
mm)
in-
NOTE: The camshaft bearing

within
(3)
at the front of the
block must be
joint at the
stalled with oil holes in a horizontal position
and
top
15 from
vertical.
Bore in block for main bearings

(standard size)
3.8160:
.0005
in.
(96.926
0.013 mm)
block for main bearings .020 in. (0.51
Bore
in
mm
3.8360 .0005
of
in.
oversize)
(4)
(97.434
0.013 mm)
Dimension from center
main
in.
bearing bore to top of cylinder 15.5000 .0065 block (new)

(5)
(393.700
0.165
mm)
Dimension from center of main bearing bore to bottom of cylinder 6.0625 .0040 block (new)
Clearance between
bearing cap
slot in
in.
(153.988
0.102 mm)
(6)
block and
0017
in.
.0013
(0.043 mm) loose to in. (0.033 mm) tight
Main bearing cap

width
6.4998 .0008
in.
'165.095
0.020 mm)
0.018
Width of cylinder block for main bearing 6.5000 .0007 in. (165.100 cap
(7)
mm)
block for balancer bearing
Bore
in
2.2776 .0010
in.
(57.851
0.025 mm)
(8)
Torque
a.
for bolts holding bearing

oil
caps
for
main bearings:
Put engine
on threads and washer
face.
lb. ft.
b.
c.
Tighten
all
bolts to
bolt
30 3
(40
N-m)
Put a mark on each
and cap.
90
d.
Tighten
Install
all
bolts from
mark
of the engine.
bearing caps with the part Be sure that the mark (number) on the bearing cap next to the bolt hole is in agreement with the mark in the cylinder
block.
NOTE:
number toward
the front
CAUTION
the bores for the main bearings, between cylinders 1 and 2, and 3 and 4 for piston cooler orifices. These holes must have either orifices (10) or plugs (9) installed.
There are holes
in
NOTE: NOTE:
(11)
If
a turbocharger
is
installed
oil
on the engine, be sure
to install
orifices (10)
If
and an engine
cooler.
oil
the engine has an engine

install orifices (10).
cooler and no turbocharger,
be sure to
Distance to install dowels from top of block
38
.02
in.
(9.7
0.5
mm)
(12) Distance to install stud from face of block

(13)
62
.02 in. (15.7
0.5 mm)
0.5
Llfir/A261 07-1X3
Distance to
install
dowels from
88
.02 in. (22.4
front face of block
mm)
60
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
CYLINDER BLOCK
(1)
Thickness of spacer plate

Thickness of spacer plate gasket
(With Spacer Plate) r /

\
3925 .0010
.0082
in.
(9.970 0.025
mm)
.0010
in.
(0.208
0.025 mm)
reference to
NOTE: For
(2)
height of liner over top of spacer plate
make
CYLINDER LINER PROJECTION.

Camshaft bearing bore
(installed)
2.3150 .0020
in.
(58.801
0.051
mm)
Bore
in block for camshaft bearings 2.5630 .0010
in.
(65.100
0.025 mm)
Depth
to install
bearings at block
camshaft both ends of

06 .02
at
in.
(1.5
0.5
mm)
NOTE: The camshaft bearing

stalled with
oil
holes
in
the front of the block must be ina horizontal position and joint at top within
15 from vertical.
(3)
Bore in block for main bearings (standard

size)
3.8160
in
.0005
in.
(96.926 0.013
mm)
Bore
block for main bearings .020 in. (0.51

oversize)
(4)
mm
3.8360 .0005
of
in.
(97.434 0.013
mm)
Dimension from center
main
bearing bore to top of cylinder block (new) 15.099

(5)
.006
in.
(383.51
0.15 mm)
Dimension from center bearing bore to bottom

block (new)
of
main
6.063
of cylinder
.004
in.
(154.00
0.10 mm)
(6)
Clearance between bearing cap
slot in block
and 0017
in.
.0013
(0.043 mm) loose to in. (0.033 mm) tight
Main bearing cap

width
6.4998 .0008
in.
(165.095 0.020
mm)
mm) mm)
B4 2697 XI
Width of cylinder block for main bearing cap 6.5000 .0007 in. (165.100 0.018
(7)
Bore
in
bearing
(8)
block for balancer 2.2776 .0010

for bolts holding bearing
oil
in.
(57.851
0.025
Torque
a.
caps
for
main bearings:
Put engine
on threads and washer
face.
lb. ft.
b.
c.
Tighten
all
bolts to
30 3
(40
N-m)
Put a mark on each bolt and cap.
d.
Tighten
all
bolts from
mark
90
NOTE: Install bearing caps with the part number toward the front of the engine. Be sure that the mark (number) on the bearing cap next to the bolt hole is in agreement with the mark in the cylinder block,
CAUTION
Ttiere are holes in the bores for the main bearings, between cylinders 1 and 2, and 3 and 4 for piston cooler orifices. These holes must have either orifices (10) or plugs (9) installed.
NOTE:
If
orifices (10)
turbocharger is installed on the engine, be sure to and an engine oil cooler.
install
NOTE:
(11)
If
the engine has
an engine
oil
cooler and no turbocharger
be sure to
install orifices (10).
Distance to install dowels from top of block 780 .020
in.
(19.8
0.5
mm)
mm) mm)
(12)
Distance to install stud from face of block Distance to

install
62 .02
in.
(15.7
0.5
Lltrr/J
A261 07-1X3
(13)
dowels from
front face of block
.02 in. (22.4
0.5
61
3304
VEHICULAR ENGINES
SPECIFICATIONS
CYLINDER LINER
NOTE: Make reference
to
GUIDELINE FOR REUSABLE PARTS:
PISI
TONS AND CYLINDER

(1)
LINERS, Form No. SEBF8001.

I
Bore
(new)
in liner
4.751
.001
in.
(120,68
0.03
mm)
Use again maximum bore when measured near upper end of tfie 4.755 in. (120.78 mm) wear surface of tfie cylinder liner
(2)
Ttiickness of flange
on
(3)
liner
.4048
.0008
in,
(10.282
0,020
mm)
Filler
band.
Cylinder Liner Installation

Put liquid soap on bottom liner bore in block, on grooves in lower and on 0-rings. Install 0-rings on liner. Put filler band (3) in
oil for a moment and install on cylinder block (before expansion of
liner,
engine
in
liner.
filler
Immediately
band).
install liner
T8832I
-
1X1
CYLINDER LINER PROJECTION

(Counterbored Block)
IVIake reference to CYLINDER LINER Adjusting for tfie complete procedure.
1.
PROJECTION
(1)
in
Testing and
A34793Xt
Install tooling
as sfiown. Tighten bolts
evenly
in
four steps:
lb. ft. (7
1st step
N-m)
2nd step
3rd step 4th step
2,
15
lb. ft.
(20 (35 (70
Nm) Nm) Nm)
25 50
lb. ft.
lb. ft,
fvleasure cylinder liner projection with dial indicator

in
(7)
clamped
1P2402 Gauge Body (6) as shown, IVIeasure at four places around each cylinder liner near the clamped area.
Cylinder liner projection
liner
measurement
for
any cylinder
in.
must be
0020 to .0056
(0.051 to 0,142
mm)
mm)
IVIaximum permissible difference between
all
four
measurements
002
in,
(0,05
permissible difference between average projection of any two cylinders next to 002 each other
Maximum
in,
(0.05
mm)
Maximum
permissible difference between average projection of all cylinder liners under one
cylinder head
003
in,
(0,08
mm)
NOTE: If liner projection is not correct, turn the liner to a new position within the bore. If projection can not be corrected this way, move the liner to a different bore. If the projection can not be corrected this way, make reference to Special Instruction, Form No, FM055228 for complete instructions on the use of 8S3140 Counterboring Tool
Arrangement,
(1) (2) (3) (4) (5) (6) (7)
Bolts [5/8" NC, 5.5 in, (140 mm) long). Crossbar (from 8B7548 Push-Puller)
SHIM THICKNESS, COLOR CODE, AND PART NUMBER
4B4281 Washers 1 P2394 Adapter Plate
3H465 Plates
P2402 Gauge Body 1P2403 Dial Indicator
1
3304
VEHICULAR ENGINES
SPECIFICATIONS
CYLINDER LINER PROJECTION

(With Spacer Plate)
Make reference to CYLINDER LINER Adjusting for the complete procedure.

1.
PROJECTION
in
Testing and
Install
Wasfiers. Tighiten bolts

1st step
gasket and spacer plate (2) witti bolts (3) and two 1S379 (3) evenly in four steps:
10
lb. ft.
(14 (35
Nm)
Nm) Nm) Nm) Nm)
N-m)
2nd step
3rd step
25
lb. ft.
50 70 as shown. Tighten bolts

(4)
lb. ft.
(70 (95
4th step
2.
lb. ft.
Install tools
evenly
In
four steps:
1st step
5
15
lb. ft. (7
2nd step
3rd step
lb. ft.
(20
25 50
lb. ft.
lb. ft.
(35
(70
Nm) Nm)
4th step
3.
Measure cylinder liner projection with dial indicator (6) in 1P2402 Gauge Body (8) as shown. Measure at four places around each cylinder liner near the clamped area.
Cylinder liner projection
liner
measurement
for
any cylinder
in.
must be
00 13 to .0069
(0.033 to 0.1 75
mm) mm)
Maximum
four
permissible difference between
all
measurements
002
In.
(0.05
Maximum
of
any two cylinder each other
permissible difference between average projection liners next to
002
in.
(0.05
mm)
Maximum permissible difference between average projection of all cylinder liners under one cylinder head 003 in. (0.08
mm)
NOTE; If liner projection is not correct, turn the liner to a new position within the bore. If projection can not be corrected this way, move the liner to a different bore. If the projection can not be corrected this way, make reference to Special Instruction, Form No. FM055228 for complete instructions on the use of 8S3140 Counterboring Tool
Arrangement.
SHIM THICKNESS, COLOR CODE, AND PART NUMBER
3304
VEHICULAR ENGINES
SPECIFICATIONS
PISTONS AND RINGS
Make
reference to
GUIDELINE FOR REUSABLE PARTS; PISTONS
AND CYLINDER
LINERS, Form No. SEBF8001.
PISTONS AND PISTON RINGS
3304
VEHICULAR ENGINES
SPECIFICATIONS
PISTONS AND RINGS

Make reference
to
GUIDELINE FOR REUSABLE PARTS: PISTONS AND CYLINDER LINERS. Form
No. SEBF8001.
3304
VEHICULAR ENGINES
SPECIFICATIONS
CONNECTING ROD
(1)
Bore
in
bearing for piston pin (new):

1
5S6360 Rod 5S2793 Rod
5017 .0003
in.
(38.143 + 0.008 (43.210 + 0.008
mm) mm)
1.7012 .0003
in.
8N1984 Rod
(tapered)
1.5017
.0003
in.
(38.143
0.008 mm)
8N1721 Rod
(tapered)
1.7012 .0003
in.
(43.210 + 0.008
mm)
mm)
mm)
Maximum
(2)
permissible clearance between bearing
and piston pin (worn)

Bore
in
003
for
in.
(0.08
connecting rod
bearing
(3)
3.2500
.0005
in.
(82.550
0.013
Distance between center of piston pin and center of crankshaft bearing

(new)
9.595
.001
in.
(243.71
0.03
mm)
(4)
Diameter of piston pin (new):
9H4016
7N9804
Pin Pin
1.5003
.0002
.0002
in.
(38.108
(38.108 (43.175
0.005 mm) 0.005 mm)
1.5003
1.6998 1.6998
in.
8r^6487 Pin
.0002
in.
0.005
0.005
mm)
mm)
7N9805
(5)
Pin
.0002
in.
(43.175
Clearance between connecting rod bearing
and crankshaft bearing surface

(journal)
0030 to .0066
in.
(0.076 to 0.168
mm) mm)
Maximum
(worn)
(6)
permissible clearance between bearing and crankshaft
010
for
oil
in.
(0.25
Torque on nut
a.
connecting
rod:
Put engine
on threads and nut
seat.
b. c.
Tighten both nuts to
30
of bolt.
lb. ft.
(40
4 Nm)
B09139X2
Mark each nut and end
d.
Again tighten both nuts (from mark)

slot for the
90
bearing tab
Install the connecting rod in the piston with the on the same side as the V mark on the piston.
Make reference to Special Instructions, Form No. GMG02394 and SMHS7366 for information about checking and reconditioning connecting rods.
66
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
CRANKSHAFT
)
(1)
Thickness of thrust plates (new):

Without tabs
6N8940
9S3037
with tabs:
1850 .0015
in.
(4.699
(5.894
0.038 0.038
mm) mm)
2320 .0015
in.
7N9342
2150 .0015
2620 .0015
to
in.
(5.461
0.038 0.038
mm)
mm)
7N9343
in.
(6.655
NOTE: Make reference
THRUST PLATE USAGE CHART
for the
correct thrust plate to use.

(2)
THRUST PLATE USAGE CHART
Make reference to MAIN BEARINGS and BEARING SURFACE (JOURNAL) FOR MAIN BEARINGS. Make reference to CONNECTING ROD BEARINGS and BEARING SURFACE (JOURNAL) FOR CONNECTING RODS.
Tighten plugs to
17
(3)
(4)
lb. ft.
(23
Nm)
Then "stake" the crankshaft to hold plugs in place. "STAKE" use a center punch and a hammer to change the shape of the hole as shown.
(5)
Crankshaft gear:
Do
(6)
not heat gear to

for
more than 600F
(316C).
End play
(new)
crankshaft
0025 to .0145
in.
(0.064 to 0.368
mm)
Maximum
(worn)
(7)
permissible end play for crankshaft
025
seal installation:
in.
(0.64
mm)
Wear sleeve and
seal into position with correct tooling. reference to Special Instruction, Form No. SMHS7100 for instructions and the correct tooling for installing wear sleeves
Push wear sleeve and
Make
and
seals.
3304
VEHICULAR ENGINES
SPECIFICATIONS
BEARING SURFACE (JOURNAL)
FOR MAIN BEARINGS
A06090X1
BEARING SURFACE (JOURNAL) FOR MAIN BEARINGS
3304
VEHICULAR ENGINES
SPECIFICATIONS
BEARING SURFACE (JOURNAL)
FOR CONNECTING RODS
A06090X1
BEARING SURFACE (JOURNAL) FOR CONNECTING RODS
3304
VEHICULAR ENGINES
SPECIFICATIONS
MAIN BEARINGS AND CONNECTING ROD BEARINGS
Make
reference to
GUIDELINE FOR REUSABLE PARTS; MAIN BEARINGS AND CONNECTING ROD BEARINGS, Form No. SEBF8009.
CONNECTING ROD BEARINGS
3304
VEHICULAR ENGINES
SPECIFICATIONS
FAN DRIVE
(1)
Fill
chamber between bearings
half
full
of
1P808 Grease before
V///
bolts are tightened.
71
3304
VEHICULAR ENGINES
SPECIFICATIONS
FLYWHEEL RING GEAR
(1)
(2)
Ring gear.
Flywheel.
Pilot
(3)
bearing bore.
of ring gear
(1).
(4)
Chamfer side
Install ring
gear
(1) is
gear (1) on flywheel as shown.

ring
(2)
so that the chamfer side
(4)
of ring
CAUTION: Do not heat

installing
gear to more than 600F (316C) before
on the flywheel.
FLYWHEEL HOUSING
TIGHTENING
Tighten bolts
to
in
number sequence
75 10
lb.
ft.
(100 14 N-m)
(A)
Timing
bolt hole.
NOTE: On some engines
the timing bolt hole
is
below the
starter.
TYPICAL ILLUSTRATION
72
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES
3304
VEHICULAR ENGINES
SPECIFICATIONS
FLYWHEEL
Face Runout
1.
(axial eccentricity) of the Flywheel:
the dial indicator as shown. Put a force on the flywheel toward the rear.
Install
2. 3.
Set the dial indicator to read .000
in.
(0.0
mnn)
Turn the flywheel and read the indicator every 90. Put a force on
the flywheel to the rear before each reading.
4.
The difference between the lower and higher measurements taken at all four points must not be more than .006 in. (0.15 mm), which is the maximum permissible face runout (axial eccentricity)
of the flywheel.
CHECKING FACE RUNOUT OF THE FLYWHEEL
CHECKING FLYWHEEL BORE
Bore Runout
1.
(radial eccentricity) of the Flywheel:

(3)
it
Install
the dial indicator
versal
2. 3. 4.
attachment
(4)
so
and make an adjustment makes contact as shown.

in.
of the uni-
Set the
dial indicator to
read .000
(0.0
mm)
Turn the flywheel and read the indicator every 90.
The difference between the lower and higher measurements taken at all four points must not be more than .006 in. (0.15 mm),
which
ity)
is
the
maximum
permissible bore runout (radial eccentric-
of the flywheel.
for the fly-
5.
Runout (eccentricity) for the bore for the pilot bearing wheel clutch, must not exceed .005 in. (0.13 mm)
CHECKING FLYWHEEL CLUTCH PILOT BEARING BORE
73
3304
VEHICULAR ENGINES
SPECIFICATIONS
FLYWHEEL HOUSING
8S2328 DIAL INDICATOR
GROUP INSTALLED
Face Runout
1.
(axial eccentricity) of the
Flywheel Housing:
Fasten a dial indicator to ttie cranl<shaft flange so the anvil of the indicator will touch the face of the flywheel housing.
Put a force on the crankshaft toward the rear before reading the
indicator at
2.
each
point.
in.
3.
With
dial indicator set at .000
(0.0
mm)
at location (A), turn the

(B), (C)
crankshaft and read the indicator at locations

4.
and
(D).
The difference between lower and higher measurements taken all four points must not be more than .012 in. (0.30 mm), which is
the maximum permissible face runout (axial eccentricity) of the flywheel housing.
C (TOP)
A (BOTTOM)
74
3304
VEHICULAR ENGINES
SPECIFICATIONS
C (TOP)
FLYWHEEL HOUSING BORE

NOTE: Write the dial indicator measurements with and negative (-) notation (signs). This notation making the calculations in the chart correctly.
1.
their positive
is
+
for
necessary
With the
dial indicator in position at (C),
adjust the dial indicator
to "0" (zero).
(C).
Push the cranl<shaft up against the top bearing. Write the measurement tor bearing clearance on line 1 in column
2.
Divide the
line
1
in
measurement from Step columns (B) & (D).
by
2.
Write this number on
3.
Turn the crankshaft to put the

indicator to "0" (zero).
dial indicator at (A).
Adjust the dial
4.
Turn the cranl<shatt counterclocl<wise to put the (B). Write the measurement in the chart. Turn the cranl<shaft counterclockwise to put the (C). Write the measurement in the chart. Turn the crankshaft counterclockwise to put the (D). Write the measurement in the chart.
dial indicator at
5.
dial indicator at
6.
dial indicator at
7.
Add
lines
&
II
by columns.
8.
Subtract the smaller number from the larger number in line III in columns (B) (D). The result is the horizontal "eccentricity" (out of round). Line III, column (C) is the vertical eccentricity.
CHART FOR DIAL INDICATOR MEASUREMENTS
3304
VEHICULAR ENGINES
SPECIFICATIONS
ENGINE MOUNTING BOLTS
NOTE: Use a torque wrench to get the correct torque mounting bolts.
The chart
for
for
all
the engine
GENERAL TIGHTENING TORQUES

all
has the correct

list
tightening torque for
the bolts except those
in
the
that follows.
D4
Tractor
941-951 Track Type Loaders

Tighten the bolts which hold the front support to the frame to 460 50
Solid rear brackets only:
lb. ft.
(540
55 N
lb. ft.
(624
70
Nm)
Tighten the bolts which hold the rear brackets together to Tighten the bolts which hold the rear brackets to the frame to
Tighten the bolts which hold thB block on the flywheel housing to the frame to 460 50 lb. ft. (624
70 N-m)
400
225
40
lb. ft.
(540
55 N
35 N m)
955 Track Type Loader

25
lb. ft.
(300
lb. ft.
(624
70
Nm)
225 Excavator
Tighten the bolts which hold the support for the hydraulic pump drive housing to the frame to 350
35
lb. ft.
(470
45 N
FLEXIBLE COUPLING DRIVE

(6P3983, 6P3984, 6P5020)
(1)
Torque
for bolts
for bolts
80 95
5 lb.
ft. (1
10 7 N-m)
(2) (3)
Torque
lb. ft.
(130
Nm)
Maximum
permissible out of square of the face of
flange in relation to the input shaft of the
torque converter
(4)
026
in.
(0.66
mm)
Maximum
permissible out of round of output flange
in
relation to the input shaft of the
torque converter
080
in.
(2.03
mm)
NOTE:
Fill
the grease lines and the area between the seals with
grease before installing in the vehicle.
76
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
FLEXIBLE DRIVE COUPLING (Earlier; Two Piece Front Flange)
TO413
(1)
Torque
tor bolts
80
160
lb. ft. (1
10 7
Nm)
Nm)
mm)
(2)
Torque for bolt holding flange

to drive
10
lb. ft.
(219
14
(3)
Maximum
Maximum
permissible "runout" axial alignment of face
(total indicator readingi

(4)
026
in.
(0.66
permissible "eccentricity" radial off
center of flywheel output flange rim to torque converter shaft (total indicator reading)
080
in.
(2.03
mm)
FLEXIBLE DRIVE COUPLING

(Earlier;
One
Piece Front Flange)
(1
Torque
for bolts
80
lb. ft. (1
10 7
Nm)
mm)
(2)
Maximum
permissible "runout" axial alignment of face
(total indicator reading)

(3)
026
in.
(0.66
Maximum
permissible "eccentricity" radial off
center of flywheel output flange rim to torque converter shaft (total indicator reading)
080
in.
(2.03
mm)
77
3304
VEHICULAR ENGINES
SPECIFICATIONS
CHECKING AND ADJUSTING ALIGNMENT OF THE FLEXIBLE COUPLING DRIVE
A09406- 1X1
Remove
the bolts, joints and torque converter flange.
2.
Fasten a 3/8 in. (9.5 mm) diameter rod 3 in. (76.2 mm) long to the torque converter input shaft with a 1J9778 Hose Clamp. Install a
7H1948 Snug onto
the rod. Assemble a
7H1942
Indicator (with a
into the
7m940
3.
Universal Attachment),
and 7H1945 Holding Rod
7H1948Snug.
Put the universal attachment on the outside diameter of the engine output flange. Rotate the indicator until it stops on "0". Turn the torque converter input shaft 360. Record the indicator measurement at each 90of rotation.
4.
The total indicator reading through 360 of rotation must not be more than .080 in. (2.03 mm). The alignment can be made correct by loosening the engine rear bolts and moving the engine from side to side. If the alignment up and down is not correct, install or remove shims under the engine rear supports.
If the holes for the support bolts have become larger because of wear, dowels should be installed after the engine has been fastened down. [See Step (8)1
.
5.
6.
Remove
the universal attachment. Put the face of the
7H1942
Indicator rod against the engine flange between the bolt
holes and
outside diameter of the flange. Turn the indicator to "0".

7.
Turn the torque converter input shaft 360. Record the indicator measurement at each 90 of rotation. The total indicator reading through 360 of rotation must not be more than .026 in. (0.66 mm). The alignment can be made correct by loosening the engine front support bolts and moving the front of the engine side to side. Check the vertical and horizontal alignment again. When the ment is correct, tighten the engine mount bolts:
align-
8.
A09407- X
1
Make
reference to
ENGINE MOUNTING BOLTS
for the correct
torque for the bolts that hold the engine to the frame.
NOTE:
If
is
is off by a large amount, inspect for the cause. can be straightened. If the engine front support badly worn, a replacement is needed.
If
the alignment
is
the frame
bent,
it
78
3304
VEHICULAR ENGINES
SPECIFICATIONS
ALTERNATORS
7S5897 24V 19A
(Prestolite (Prestolite
Number ANB6001)
9S4070 24V 19A

Polarity
is
Number ANB7001
)*
negative ground.
at
Rated output
28V
19
1
Output
at
500 rpm and 28V

18 to 20
Resistance of the rotor at 77 F (25 C)
ohm
.3
Current consumption (draw)
at
77 F (25 C)
1
and 24V
(1
)
.2
to
Torque
for nut holding pulley for bolts

for screws
85 to 90
lb. ft. (1 lb. in.
15 to 120
Nm)
Nm)
N-m)
(2)
(3)
(4)
Torque
Torque
25 to 30
10 to 15
(2.8 to 3.4
.1
lb. in. (1
to
.7
Torque Torque
for terminal nuts for bolts holding the
30 to 35
lb. in.
(3.4 to 4.0
Nm)
Nm)
(5)
regulator
45
to
50
lb. in. (5.1
to 5.7
Including the
9S2329 Regulator (Prestolite
Number VSH6401)
2P1698 24V 19A
Number ANB6002 Number ANB7002
or
ANB6004)
ANB7004)*
2P1204 24V 19A

Polarity
is
or
negative ground.
at
Rated output
28V
(21 C)
19
Output
at
6000 rpm, 28V and 70 F
25
to
30
Resistance of the rotor at 77 F (25 C)
18 to 20 ohms
Current consumption (draw) at 77 F (25 C) and 24V

(1) (2)
.20 to
.33
Torque
for nut holding pulley

field
75
lb. ft.
(100
Nm)
N-m)
Torque for nuts for ground terminals Torque
and
25 to 30
lb. in.
(2.8 to 3.4
(3)
for screws holding
terminal plate
(4)
10 to 15
lb. in. (1
lb. in.
.1
to 1.7
Nm)
Nm) Nm)
Torque
for bolts for bolts holding
25 to 30
(2.8 to 3.4
(5)
Torque
regulator
(6)
45 to 50
45
to
lb. in. (5.1
to 5.7 to 5.7
Torque Torque
for nut for terminal
50
lb. in. (5.1
Nm)
Nm)
(7)
for nut for positive
terminal
225
to
250
lb. in.
(25.4 to 28.3
(Prestolite
Including 2P1699,
4N5938 or 6N3821 Regulator VSH-6401A, VSH-6401B or VSH-6401C).
Number
79
3304
VEHICULAR ENGINES
SPECIFICATIONS
Alternators (Cont.)
6N9294 24V 35A (Delco-Remy Number 1117640)

Rotation can be either direction.
Polarity
is
negative ground-
Output
at at
28V and 2600 rpm 28V and 6500 rpm
15
Output
35 A 35 A
(27
Rated output, hot

Field current at
(1) (2)
24V and 80 F
C) 75 5 20 5
...
lb.
ft.
2.5 to 3.2
Torque
for nut
holding pulley
(100 7 N-m)
(2.3
Torque Torque
for
for
cover screws
output (POS) terminal
lb. in.
0.6 N-m)
(7
lb. ft.
N-m)
80
NOTE:
3304 VEHICULAR
ENGINES
SPECIFICATIONS
Alternators (Cont.)
5S9088 24V 50A (Delco-Remy Number 1117226)

Polarity
is
negative ground
Circuit
B
testing
Speed for
5000 rpm
Output when cold:

Fasten carbon pile to battery to get
maximum
output
54
Rated output, hot

Field current at
50 A
F (27 C)
24V and 80
2.5 to 2.9
Voltage regulator: Voltage setting range

Adjust voltage setting to
26 to 30 28
V
V
then Increase speed to get maximum output

(1)
(2)
50
75

Torque
for nut holding pulley
lb. ft.
(100 7
(14
+
1
Nm)
Torque for output terminal
10
lb. ft.
Nm)
3P77 24V (Delco-Remy Number 1102398)

Polarity
is
negative ground.
Output
at
at
26V and 2600 rpm

26V and 7000 rpm
(cold) (cold)
25 A
41
Output
Rated output (hot)

(1)
40 A
25 to 40
Torque
for stud nut for battery

lb. in.
connection
(2)
(2.8 to 4.5
ft.
Torque for pulley nut
60
+ 5 lb.
(80 7
Nm) Nm)
81
3304
VEHICULAR ENGINES
SPECIFICATIONS
Alternators (Cont.)
5A8908 24V 20A

Rotation
Polarity
is
(Mitsubishi
Number AR4020A)
clocl<wise
when
seen from drive end.
is
negative ground.
at
Rated output
24V
1150 rpm
20 28
A
V
No
load output at speed below

at
Loaded output
speed below 2500
rpm and 28 V
29.5
1 1
20 A
Resistance of field coil at 68 F (20 CI
ohms
Tension of brush spring
to 14 oz. (3.1 to 3.9 N)
Minimum
permissible tension of spring
7.4 oz. (2.1 N)
Brush length
75
in.
(19.0
(6.4
mm)
Minimum
permissible brush length
25 75
to
in.
mm)
Torque for nut holding pulley Torque for nut holding

slip rings
90
lb. ft.
(100 to 120
Nm)
35
lb. ft.
(45 IMm)
3A1997 24V 19A (Paris-Rhone Number A13RH3T)

Polarity
is
negative ground.
Rotation
is
clockwise
when
Output Output
(1)
(2) (3) (4)
at
at
4,000 rpm (hot)

1,180 rpm (hot)
19
A
V
28
Torque for pulley nut

75 to 90
lb. ft.
(100 to 120
lb.
Nm)
mm) mm) mm)
2.25 to 2.75
(10 to 12 N)
(11.2
Minimum brush
Diameter of
length
44
1.65 1.57
lb. ft.
in.
slip ring
(new)
in.
in.
(42,0
(40.0
Minimum
(5)
permissible slip ring diameter
Torque
for slip ring nut
18 to 22
(24 to 28
Nm)
82
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
ALTERNATOR REGULATOR
6N3821 24V
(Prestolite
(Prestolite
Number VSH-6401C)
4N5938 24V
2P169g 24V
Number VSH-6401B)
Number VSH-6401A) Number VSH-6401)
9S2329 24V
Polarity
is
negative ground.
at
Voltage setting range

(1)
70 F (21C)
27.3 to 28.7
Adjustment screw and washer.

With voltage adjustment screw (Din position "N" (center). When screw (II is in position "L", voltage will be 0.5V less. When screw (1 is in position "H", voltage will be 0.5V higher.
5A9131 24V
Voltage range
(Mitsubishi
at
Number RM4140G)
28 to 31
3000 rpm
83
3304
VEHICULAR ENGINES
SPECIFICATIONS
GENERATORS
4M9102 24V 20A (DelcoRemy Number 1106971)
Rotation
Circuit
is
clocl<wlse
when
seen from
tlie
drive end.
A
for testing
1
Speed
720 rpm
Field current at
24V and 80
F (27 C)
83 to .89 A 20 A
26 V
Output
at
720 rpm and 26V wfien cold
Output wtien cold

(1
Tension of brusfi spring
20 83
oz. (5.6 N)
(2)
Torque
pulley
for nut holding
lb. ft.
(114
11
Nm)
1^
1S151 24V 15A (DelcoRemy Number 1105241)

Rotation
Circuit
is
clockwise
when seen from
the drive end.
A
1800 rpm
F (27 C)
Speed for testing

Field current at
24V and 80
94
to
.02
A A
V
Output
at
1800 rpm and 28.5V when cold
15
28.5
e a _
Output when cold

(1
16 oz. (4.4 N)
(2)
Torque
pulley
for nut holding
83
lb. ft. (1
14
1 1
IMm)
1S5134 24V and 25A (Oelco-Remy Number 1106887)

Rotation
Circuit
is
clockwise
when
seen from the drive end.
A
for testing
Speed
1700 rpm
F (27 C)
Field current at
24V 80
83 to.89
Output
at
700 rpm and 26V when cold
20 A
26 V
Output when cold

(1)
20 60
10
oz. (5.6
N)
(2)
Torque for nut holding

pulley
lb. ft.
(80 14
Nm)
3304
VEHICULAR ENGINES
SPECIFICATIONS
Generators (Cont.)
5A3033 & 5A6539

Rotation
is
(Mitsubishi
Number DR 350/24MR)
clockwise
when
Speed for testing with
a load (less than)
2000 rpm
28.5
1
Output with Output

at
a load
V A
below 2000 rpm and 28.5V

(less
Speed for testing with no load
than)
1550 rpm
28.5
Output with no load (zero Amps)

77
lb. (3.4
N)
5A7375
Rotation
(Mitsubishi
is
Number DT 600/24 ZR)

when
clockwise
Speed
for testing with a load (less than)

a load
1600 rpm
28
Output with Output

Speed
at
V A
below 1600 rpm and 28\/
25
for testing with
no load
(less
than)
1450 rpm
28 V
Output with no load (zero Amps)

93
lb.
(4.2
N)
GENERATOR REGULATORS
2M6497 24V 15A (Delco-Remy Number 1119626)

Polarity
is
negative ground or insulated.
Circuit
(1)
A
relay:
Cutout
Air gap between armature and core
01 7
in.
in.
(0.43
(0.81
mm)
Point gap
032
mm)
V
Voltage closing range

(2)
22.8 to 25.2
Current regulator:
068
to .082
in.
(1.73 to 2.08
mm)
A
Current setting range

(3)
14 to 16
Voltage regulator:
067
in. (1 in.
.70
mm)
mm) V
Point gap
016
at
(0.41
85 F (29 C):
27.4 to 29.4
Upper contacts
'
Lower contacts
(4)
2 to .6V less than upper contacts
Torque
for bolt
36
lb. in. (4.1
0.7
N-m)
85
3304
VEHICULAR ENGINES
SPECIFICATIONS
Generator Regulators (Cont.)
4M9349 24V 20A (Delco-Remy Number 1119653)

Polarity
Circuit
(1)
is
negative ground or insulated.
A
relay:
Cutout
Air gap
between armature and
core
015
to .019
in.
(0.38 to 0.48
mm)
Point gap
032
in.
(0.81
mm)
V

(2)
22.8 to 25.2
Current regulator:
Air gap between armature and
core
068
to .082
in. (1
.73 to 2.08
mm)
A

(3)
19 to 21
Voltage regulator:
067
in. (1
.70
mm)
Point gap
016
at
in.
(0.41
mm) V
85 F (29 C):
27.4 to 29.4
Upper contacts Lower contacts

(4)
2 to .6V
less
than upper contacts

0.7
Torque
for bolt
36
lb. in. (4.1
Mm)
3S5028 24V 25A (DelcoRemy Number

Polarity
Circuit
(1)
is
11
19306 and 1119306-E)
negative ground.
A
relay:
Cutout
core
Point gap
015
to .019
in.
(0.38 to 0.48
mm)
032
in.
(0.81
mm)
V

(2)
24
to 27
Current regulator:
core
068 to .082
in. (1
.73 to 2.08
mm)
27

(3)
23
to
Voltage regulator:
060
in. (1
.52
mm)
V
Voltage setting range at 85 F (29 C)

(4)
27.5 to 29.5
Torque
for bolts
36
lb. in. (4.1
0.7
Nm)
86
3304
VEHICULAR ENGINES
SPECIFICATIONS
Generator Regulators (Cont.)
3A1874 24 V
(1)
(Paris-Rhone
Number 2T216)
Cutout relay:
027
031
in. in.
(0.69
(0.79
mm) mml
V
Point gap
Closing range
(2)
when
cold
24.0 to 26.0
Current regulator:
039
In.
(0.99
mm) A

(3)
14 to 15
Voltage regulator:
043
in. (1
.09
mm) V
Voltage setting range at 85 F (29 C)

(4)
26.8 to 28.2
Torque for bolts
36
lb. in.
(4.1 + 0.7
N-m)
5A3061
(Mitsubishi
Number RW-3B)
Cutout relay:
core
043 030 020
to .055 in. (1.09 to 1.40
mm)
Back gap
Point gap
to .047
in. in.
(0.76 to
.19
mm)
mm)
1
to .032
(0.51 to 0.81
Switch
in
24.5
(less
V A
Reverse current
than)
Voltage regulator:
core
039 to .047
in.
in.
(0.99 to 1.19
mm)
Back gap
Regulator setting (no load)
Current regulator:
Air gap
at
029 to .043 3000 rpm
(0.74 to 1.09
.
mm)
27.5 to 29.5
core
047
to .055 to .043
in. in.
(1.19 to 1.40
mm)
Back gap
Current limiter setting range
at
029
(0.74 to
.09
mm)
A
3000 rpm
14 to 16
5A7385
(Mitsubishi
Number RT4342E)
Cutout relay:
051
in.
in.
(1.30
mm) mm)
V
Point gap
016 to .024
(0.41 to 0.61
Switch
in
26
(less
to 27
Reverse current Voltage regulator:
than)
10
079 to .087
in.
(2.01 to 2.21
mm)
V
Regulator setting (no load)
at
3000 rpm
28 to 29
Current regulator:
Air gap

051 to .069
at
in. (1
core
.30 to
.75
mm) A
Current limiter setting range
4000 rpm
24
to 26
87
3304
VEHICULAR ENGINES
SPECIFICATIONS
STARTER MOTORS
9M1662 24V (Delco-Remy Number 1113967)

4N3182 24V (Delco-Remy Number 1114711)
Rotation
is
clockwise when seen from drive end.

with no load with no load
at
Minimum speed
5500 rpm
Maximum speed
7500 rpm
no
load:
Minimum
with solenoid at with solenoid at
20V 20V
36
75
Maximum
95 A
Clearance between pinion and housing

(pinion clearance)
(1) (2)
in. (9.1
mm)
56 oz. (15.6 N)
Torque
to lever
for
screws holding nose housing housing 13 to 17

20
to
lb. ft.
(18 to 23 (25 to 35
N-m) N-m)
(3)
Torque
for terminal nuts
25
lb.
ft.

Rotation
is

at
Minimum speed
5500 rpm
7500 rpm
load:
Maximum speed
no
Minimum
with solenoid at 20V

with solenoid at
85
Maximum
20V
36
112 A
Clearance between pinion and housing

(pinion clearance)
(1)
(2)
in. (9.1
mm)
Tension of brush spring'
36
to
40 oz. (10.0
to
to 11.1 N)
Torque for screws holding nose housing lever housing
8
lb.
ft.
lb.
ft.
(11
N-m)
N-m)
(3)
Torque
for terminal nuts
20
to
25
(25 to 35
"Minimum
for leaf springs
80 oz. (22 N)

Rotation
is
3T2772 24V (Delco-Remy Number 1113540)

Rotation
is
clockwise
when seen from
drive end.

at
Minimum speed
with no load
with
5500 rpm
Minimum speed
5500 rpm
7500 rpm
load:
Maximum speed
no load
at
7500 rpm
load:
Maximum speed
no
no
Minimum

1
85 A
12
Minimum

with solenoid at
60 A 120 A
Maximum
Maximum
20V
to .39 to
Clearance between pinion and housing 010 to .140 (pinion clearance)

(1)
in.
(0.25 to 3.56
mm)
Clearance between pinion and housing (pinion clearance) 33

(1)
in.
(8.3 to 9.9
mm)
36
to
40 oz. (10.0 to 11.1 N)
36
40 oz. (10.0
to 11.1 N)
(2)
Torque
screws holding nose housing to lever housing 13

for
for terminal nuts
(2)
Torque
housing
for
to
to 17
lb. ft.
(18 to 23 (25 to 35
N-m) N-m)
(3)
screws holding nose lever housing 13
to 17
lb. ft.
(18 to 23
(25 to 35
N-m)
(3)
Torque
20
to
25
lb. ft.
Torque
for terminal nuts
20 to 25
lb.
ft.
N-m)
88
3304
VEHICULAR ENGINES
SPECIFICATIONS
Starter
Motors (Cont.)
drive end.

Rotation
is
clockwise
when seen from

no load
iVIInimum speed
witii
5500 rpm
Maximum speed
with no load
9000 rpm
Current consumption (draw) at no load:
Minimum

with solenoid at
70
Maximum
28V
110 A
Clearance between pinion and housing (pinion clearance) 33

(1)
to .39
in.
(8.3 to 9.9
mm)
N-m) N-m)
Torque
for terminal nuts for
20 to 25
lb. ft.
(25 to 35
(2)
Torque
to
screws holding nose housing lever housing 13 to 17
lb. ft.
(18 to 23

Rotation
is
clockwise
when seen from
drive end.
Minimum speed
5500 rpm 7500 rpm
Maximum speed
Minimum

with solenoid at
60
80
A
A
Maximum
20V
Clearance between pinion and housing (pinion clearance) 33 to .39

(1) (2)
in.
(8.3 to 9.9
mm)
N-m)
Torque
Torque
for terminal nuts
20 to 25
lb. ft.
(25 to 35
for screws holding nose housing to lever housing 13
to 17 lb.
ft.
(18 to 23
N-m)
7S5900 and 2P2501 24V

3P6 24V
(Prestolite
(Prestolite
Number MFY
6201 K)
Number MFY 6401 K)
4N7901 24V
Rotation
is
(Prestolite
Number MFY 6401 L)
clockwise when seen from the drive end.

load speed
Minimum no
5000 rpm
Maximum
(1) (2)
at
20V
65
52 to 65 oz. (14.5 to 18.1 N)

8
lb. ft.
Torque
for bolts for terminal nuts

for the pinion
. .
.
(11
N-m) N-m)
(3)
(4)
Torque
20
to
25
lb. ft. in.
(25 to 35
1
Clearance
.020 to .050
(0.51 to
.27
mm)
7S2234 and 1P7839 24V
(Prestolite
Number MES6101K)
4N7752 24V
2P6162 24V
(Prestolite
Number MES6404K)
Number MES6301K) Number MES6601K)
9G4338 24V
Rotation
is

with no load
Minimum speed
5000 rpm
Current consumption (draw) with no load:
Maximum
(1) (2)
(3)
at
20V
80
to
77
90 oz. (22.2 to 25.0 N)

8
lb.
ft.
Torque Torque
for housing bolts

for terminal nuts
(1
N-m) N-m)
20
to
25
lb. ft.
(25 to 35
(4)
Clearance between pinion and housing (pinion clearance) 020 to .050
in.
(0.51 to
.27
mm)
89
3304
VEHICULAR ENGINES
SPECIFICATIONS
Starter Motors (Cont.)
9G4337 24V
Rotation
Is
(Presfolite
Number MFY6601K)
ttie
clockwise when seen from

load speed
at
drive end-
Minimum no
5000 rpm
no
load:
Maximum
(1) (2)
at
207
8 20 to 25
. .
65 A
lb.
ft.
Torque Torque
for bolts tor terminal nuts

ttie
(11
N-m)
lb, ft.
(25 to
35 N-m)
(3)
Clearance for
pinion
.020 to .050
in.
(0.51 to 1.27
mm)
3T6305 24V (Robert Bosch Number 0-001-430-03)

Rotation
is
clockwise wtien seen from

load speed
at
ttie
drive end.
Minimum no
5500 rpm no load:

140 A
Minimum
Permissible clearance between pinion and ring gear
(1
06 to .22 20 to 24
in.
(1.5 to 5.6
mm)
N-m)
Torque
for terminal nuts
lb. ft.
(27 to 33
(2)
Minimum
thie
permissible lengtti of brusties permissible diameter of
69
in.
(17.5
mm)
(3)
Minimum
commutator
1.9 in. (48
mm)
90
3304
VEHICULAR ENGINES
SPECIFICATIONS
Starter
Motors (Cont.)
3A2035 24V
(Paris-Rhone
Number D13 E76) Number D13 E77)

at
3A 1872 24V
Rotation
is
(Paris-Rhone
clocl<wise
when
iVIaximum speed with no load
20 V
6000 rpm
Maximum
Minimum
commutator
with solenoid
at
20 V and 6000 rpm
75
permissible diameter of the
2.05
in.
(52.1
mm)
mm)
Clearance between pinion and support

(pinion clearance)
(1) (2)
039
.020 in. (1.00 + 0.51
53.3 5.3 oz. (14.8
1.5 N)
Torque
for screws holding
support to
lever housing
(3)
15
lb. ft.
(20 3
Nm)
Torque
for terminal nuts
20
to
25
lb. ft.
(25 to 35 IMm)
3A1529 24V (Paris-Rhone Number D13 E68)

3A1531 24V (Paris-Rhone Number D13 E75)
flotation
is
clockwise
when

at
Maximum
speed with no load
20 V
6000 rpm
Current consumption (draw) with no load:
Maximum
with solenoid at 20
and 6000 rpm
75
r^
Minimum
commutator
Clearance between pinion and thrust washer
(pinion clearance)
(1)
(2)
2.05
in.
(52.1
mm)
039
.020
in.
(1.00 + 0.51
mm)
53.3 5.3 oz. (14.8

to
1.5 N)
Torque for screws holding support

lever housing
15
lb. ft.
(20
3 N-m)
(3)
Torque
for terminal nuts
20 to 25
lb. ft.
(25 to 35
Nm)
5A6492 and 5A3031
(IMitsubishi
Number Number
MX MT
10/24 ZR)
5A6494 and 5A3196

Rotation
is
(Mitsubishi
10/24 YR)
clockwise
when
Minimum
speed with no load
6000 rpm
Maximum
Stall
at
23V
110
torque
test:
Maximum
Stall
(1
current consumption (draw) at
9V
1500 A
79.6
lb. ft.
(maximum)
torque at
9V (minimum)
(108.1
Nm)
mm)
Minimum
commutator
(2)
2.01
in.
(51.1
2.29
.34
lb.
(10.2 1.50 N)
in,
(3)
(4)
Minimum
permissible length of brushes
55
(14.0
mm) mm)
Clearance between pinion and housing (pinion clearance) 1 18 to .138
in.
(2.99 to 3.51
91
3304
VEHICULAR ENGINES
SPECIFICATIONS
Starter Motors (Cont.)
5A6522 5A6495
(Mitsubishi
(IVIitsubishi
(IVIitsubishi
is
Number
Number Number
when
MRA 7
MTR
5/24 ER or IV1OO7T03774)
IVIRE 7 5/24
ER)
5A5744
Rotation
7 5/24
YR)
clockwise
Minimum speed with no
load
6000 rpm
Maximum
Stall
at
23V
10
torque
test:
Maximum
Stall
(1)
current consumption (draw) at
9V
1500
(maximum)
torque at
9V (minimum)
80
lb. ft. (1
10 N-m)
Minimum

2.01
in.
commutator
(2)
(3)
(51.1
mm)
4.6
.7 lb.
(20.5 3.1 N)
in.
Minimum
permissible length of brushes
55
(14.0
mm) mm)
(4) Clearance between pinion and housing 1 18 to .138 (pinion clearance)
in.
(2.99 to 3.51
STARTER MAGNETIC SWITCHES

7N3621 24V
7M4291 24V (Delco-Remy Number 1119866)

Current consumption (draw) at 20
(1)
3.5 to 3.9
7M7553
Spring:
test force
Length under
Test force
278
7.6 to 8.4
in.
(7.06
mm)
lb.
in.
(33 to 38 N)
657
(16.69 (13.06
mm) mm)
Outside diameter
(2)
514
in.
7M7622
Spring:
test force
Length under
Test force
56
2.65 to 3.25
lb. (1
1
in.
(14.2
mm)
.60 to 14.00 N)
in.
874
(22.20
mm) mm)
Outside diameter
434
in.
(11.02
9F3099 24V (Delco-Remy Number 0001481)

Current consumption (draw) both windings at 24 V
(1)
83
.
to .89
Torque
for large terminal nuts ..
30
to
40
lb. in.
(3.4 to 4.5
Mm)
5L5886 12V (Delco-Remy Number 0001486)

302266 or 9N964 12V (Delco-Remy Number 1119828)
Rating
12
V
A
Current consumption (draw) hold-in windings at 8 V

(1)
2.1 to 2.4
Torque
nuts
for large terminal
30 to 40
lb. in.
(3.4 to 4.5
Nm)
92
NOTE: FOR TOROUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
3304
VEHICULAR ENGINES
SPECIFICATIONS
STARTER SOLENOIDS
4M1812 24V (Delco-Remy Number 1119832

Current consumption (draw):
Current
pull in
pull in
in
or 1119848)
windings windings
winding
at
5V
20 20
to
10 to 11.5
Current
at at
24V 24V
40
to 55.2 of 8.2
A A
Current hold
(1)
to
Maximum
4M1815 Spring
Length under
Test force
for contact release:
test force
42
8.5 to 9.5
lb.
in.
(10.7
mm)
(37.8 to 42.3 N)
83 .015
375 .010
in. in.
(21.1
0.38 mm) 0.25 mm)
Outside diameter
(2)
(9.53
9M7609
or
8M1856 Spring
test force
to return the clutch lever:
Length under
Test force
1.56
in.
(39.6
mm) mm)
14
.5 lb.
(62 2.2 N)
(70.9
2.79
in.
Outside diameter
(3)
1.393
.015
in.
(35.38
0.38 mm)
N-m)
Torque
for terminal
screws
16 to 30
lb. in.
(1.8 to 3.4
6NS123 24V (Delco-Remy Number 1115544)

Current at 20V Current at 20 to 24V

(1)
40 to 45.5 A 40 to 54.6
4M1815 Spring
Length under
Test force
for contact release:

.
test force
42
lb.
in.
(10.7
mm)
8.5 to 9.5
(38.0 to 42.5 N)
83 .015
in.
in.
(21.1
0.38 mm)
0.25
Outside diameter
(2)
375 .010
(9.53
mm)
9M7609 Spring
Length under
Test force
test force
1.56
in.
(39.6
mm) mm)
mm)
N-m)
14
.5 lb.
(62
2.2 N)
2.79
in.
(70.9
Outside diameter
(3)
1.393 .015
in.
(35.38 0.38
to 3.4
Torque
for terminal
screws
16 to 30
lb. in. (1 .8
93
3304
VEHICULAR ENGINES
SPECIFICATIONS
Starter Solenoids (Cont.)

Current Current
(1)
at
20V
40 to 45.5 A
to
at
20V
24V
40 to 54.6 A
4M1815 Spring
for contact release;

Test force
8.5 to 9.5
lb.
42
in.
(10.7
mm) mm)
mm)
(37.8 to 42.3 N)
83 .015
in.
in.
(21.1
0.38
Outside diameter
(2)
375 .010
(9.53 0.25
9M7609 Spring
Length under
Test force
test force
1.56
in.
(39.6
mm)
14 +
.5 lb.
(62 2.2 N)
(70.9
2.79
in.
mm)
Outside diameter
(3)
1.393 .015
in.
(35.38
0.38 mm)
N-m)
Torque
for terminal
screws
16 to 30
lb. in.
(1.8 to 3.4

Pull in
winding winding
for nuts
at at
5V
9 to 11.5
6.8
B38473X1
Hold
(1)
in
20V
20 to 25
lb. ft.
A IVIaximum
N-m)
Torque
(27 to 33
94
NOTE:
3304
VEHICULAR ENGINES
SPECIFICATIONS
Starter Solenoids (Cont.)
3T868 24V (Robert Bosch Number 0331 410 002)

Resistance:
Pull in
winding
513 to .567
ohm
B38474X1
Resistance:
Hold
in
winding
3.28 to 3.62
ohm
r^
3T3369 24V
9S7976 24V
(Presfolite
(Preslolite
Number SAT-4105) Number SAT-4103) Number SAT-4101)
8S1529 24V
(Prestolite
Current consumption (draw): Current pull

Current pull
in in in in
if=
23.2 to 26.6
windings windings
at at
12
V
to
20
24 V
38.6 to 52.4
4.1 to 4.8
A A A
Current hold Current hold
windings at 12
V V
windings at 20 to 24
6.8 to 9.6
3A1555 24V (Paris-Rhone Number CED65I

Current Consumption (draw):
Current both windings at Current hold

(1)
in
20V
at
70
A
A
windings
20V
11.2
1.2
Spring for contact release:
Length under
Test force
test force
295
18.7
in.
(7.49
mm)
N)
1.9 lb. (83.0 8.5

in.
433
.010
(11.00
0.25
(9.4
mm) mm) mm)
Outside diameter
(2)
37
in.
Spring to return the clutch lever:
Length under
Test force
test force
2.4
in. (61 .0
13.2
1.3
lb.
(58.5
in. (1
5.8 N)
Outside diameter
45
1.4
mm)
95
3304
VEHICULAR ENGINES
SPECIFICATIONS
FUEL PRESSURE INDICATOR
6N3272
Indicator (Frank
W. Murphy Mfr.
Inc.)
Gauge with color code.
CALIBRATIOIM CHART
3304
VEHICULAR ENGINES
SPECIFICATIONS
OIL
PRESSURE INDICATOR
5M1065
Indicator (Stewart Warner Corp.
Number 342-FR)
Gauge with color code.
CALIBRATION CHART
o
CITERPILLAR
o.
SENR7590-01
Printed
In
U.S.A. (10/81)

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CATERPILLAR

VOLUME SPECIFICATIONS, REG01312

can be used again.

equal to or within the

specification given, use the part again.

the specification given

tolerance permitted before adjustment, repair and/or

parts are needed.

MANUAL CONTENTS MICROFICHE REG

words "use again" are

the specification given can be used to determine

NOTE: For Systems

VEHICULAR ENGINES, Form

Operation and Testing and Adjusting, make reference to No. SENR7591.

Order (Injection Sequence)

CYLINDER AND VALVE IDENTIFICATION

NOTE: This book has been completely changed from

the former issue.

and Exhaust System

Camshaft Cylinder Head

Glow Plug Positioning

Pump Housing Pump

Governor Governor Housing

Bearing Surface (Journal)

Fuel Bypass Valve Fuel Injection Equipment Fuel Transfer

Connecting Rods Main Bearings Connecting Rod

Counterbored Block Spacer Plate Block

Fuel Ratio Control Fuel Transfer

Governor Governor Governor Governor

Sleeve Metering (PC)

Fuel Injection Equipment Fuel Ratio Control Fuel Transfer

Cooling System Coolant Flow Switch Fan Drive

Water Pump Water Temperature Regulator

Water Temperature Indicator

Generator Regulators Generators

Oil Filter Oil Oil

GENERAL TIGHTENING TORQUE FOR

TORQUE FOR FLARED AND 0-RING

follows are to be used on the part of 37 Flared, 45 Flared and

ASSEMBLY OF FITTINGS WITH STRAIGHT THREADS AND O-RING SEALS

Put locknut (3), backup washer (4) and O-ring

type fitting tighten the hex against the

face of the part

put the fitting assembly in

turn the fitting

(2) out (counterclockwise) a of 359. Tighten locknut (3) to the

ELBOW BODY ASSEMBLY

of fitting t>ody (connects to tube). 2.

Backup washer. 5. 0-rlng goes Into other part.

FUEL SYSTEM USAGE CHART

ELECTRIC SERVICE METER (LATER MODELS)

for cable nut

(11.3 + 2.3 N-m)

Tighten bolts which hold adapter for tachometer drive to 96

FUEL INJECTION EQUIPMENT

Firing order (injection

Injection timing before

numbers, 044, 900 and up

for bolt in tiole for

Torque for bolts that hold governor tocamshaft

Diameter of rear bearing surface

on end of camshaft, support the camparts inside of injection pump and

reference to the chart