Service Manual

C at e r p i l l a r
Service Manual
3204 Engine
S/n 10X1 & up

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF

CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

CT-S-ENG 3204
 FORM NO. SENR2168-01
FOR USE IN SERVICE MANUAL:
215 EXCAVATOR;
FORM NO. SENR2165

,
.,-
I

DISASSEMBLY AND ASSEMBLY

3204 VEHICULAR ENGINE

FOR 215 EXCAVATOR
SERIAL NUMBERS:
1OX-UP

.- --------- --- ---------'-- .--------.-

ENGINE DISASSEMBLY AND ASSEMBLY

INDEX

Acessory Drive ................................................................................................................................. 72-74

Accessory Drive, Disassemble & Assemble ....................................................................................... 75·77
Air Cleaner Housing .. .......... .......... ..................................... ............. ............................... .................. ........ 9
Air Cleaner Housing, Disassemble & Assemble ....................................................................................... 10
Alternator ............................ ................... ...... ..................... ........ ...................... ................ ............. .... ...... 16
Batteries ........................... ... ........... ...... ... ....... ................ ..... ..................................... ....... ..... ........ ... ........ 8
Camshaft ....... ................................................................ ............................. ......... ... ...................... 104,105
Camshaft Bearings ............. ...... ....................... ...................... .......................................... ......... .... ........ 124
Connecting Rod Bearings ................................... .............. .......................................... .... ........ ................ 94
Crankshaft Front Pulley....... ....... ........... ... ....... ... .............. .............. .•............... ................... ................ .... 29
Crankshaft Front Seal ....................... ....................................................... ... ..... ...................................... 29
Crankshaft and Gear ..................................................................................................................... 125,126
Crankshaft Main Bearings ................................................ ............. ........... ............... .......................... 98,99
Crankshaft Rear Seal and Wear Sleeve ............................................................................................... 123
Cylinder Head .........................................•,~:.......................................... ........... ........ ......................... 86,87
Cylinder Head, Disassemble & Assemble ............. ........ .............................. ... .................................... 88,89
Electric Starting Motor ...... ................. ........ ....... ... ..... ......... ...... ........ ............ ............. ... ..... .......... ..... ...... 18
Engine Hoods .............. ......... ...... ....... ......... ........ ................. ........... ..... ................ ........ .... ...... ...... ..... ........ 7
Engine Oil Cooler ........... ....... ....... ........ .... ......... ................ ............. ................. .............. ............. ...... ....•. 38
Engine Oil Cooler, Disassemble & Assemble ........................................................................................... 39
Engine, Pump Drive and Radiator ................................................................................................•. 109-115
Exhaust Manifold ............... ... ........... ...... ... ... ..... ................ ....... ........ ......................... ..... ..... ............ ......•. 40
Fan and Fan Drive ............................................................................................................................ 19,20
Fan Drive, Disassemble & Assemble ................................................................................................. 20-22
Flexible Coupling ..... ...... ......... ............. ........ ....... ..... .......... ........ .......... ..... ..... ........... .... ........... ..... ........ 117
Flywheel .............................................................................................................................................. 118
Flywheel Housing .....................................................................•.................................................... 119-122
Flywheel Ring Gear .............................................................................................................................. 119
Fuel Injection lines ....... ....... ........ .......... ................ .......... ..•.. ..... ...... ...... ......... .......... ....... ...... .......... .... ... 41
Fuel Injection Nozzles .......................................................•.................................................•.............. 81,82
Fuel Injection Nozzles, Disassemble & Assemble .......... ........ .... ...... ...... ....... .... ..•..... ........ ...... ............ 82-85
Fuel Injection Pump Housing, Disassemble & Assemble .........................................•............•............. 68-71
Fuel Injection Pump Housing and Governor .... ....... ................... ............. ......... .... ........ ........ ......... ....... 45·51
Fuel Injection Pumps ........................................................................................•.......... '" ................ .•.. 64·66
Fuel Injection Pumps, Disassemble & Assemble ....................................................... .......................... 66,67
Fuel Pump Drive ............. ......... ...... ....... ..... ... ..................... ...... ...... .... ................. ........ ..... ..... ....... .... ....... 52
Fuel Pump Drive, Disassemble & Assemble .................................................................. ..................... 53,54
Fuel Transfer Pump ................................................... ............................................................................. 42
Fuel Transfer Pump, Disassemble & Assemble ............................................. ..................................... 43,44
Governor, Disassemble & Assemble .................................................................................................. 55-63
Hydraulic Oil Cooler ............................................................................................................................... 13
Muffler ..................................................................................................................................................... 9
Oil Pan ................................................................................................................................................... 90
Oil Pump and Relief Valve ....................................... :......................................................................... 91-93
Pistons .............................................................................................................................................. 95,96
Pistons, Disassemble & Assemble ..................................................................................................... 97,98
Piston Cooling Jets ............................... ,.............................................................................................. 127
Pump Drive and Engine, Separation & Connection ................................................................................ 116
Radiator Core ................................................ ................................................................. .................. 11,12
Radiator and Guard ........................................................................................................................... 14,15
Rocker Shaft, Disassemble & Assemble ....................................... .............. .................... ................... 79,80
Rocker and Push Rods ............ ............ .............. ............... .................. ............................. ............ ..... ... ... 79
Timing Gear Cover .................................................... ,................................................................... 100-103
Timing Gears and Plate ................................................................................................................. 106-108
Turbocharger .................................................................................................................................... 30,31
Turbocharger, Disassemble & Assemble ........................................................................................... 31-37
Valve Covers .......... ...... ............. .................................................. .................. .......... ... ... ........................ 78
Valve lifters ............................................................................................... ... ............ ............................. 90
Water Pump ......... ... ... .................................................................. .............. .............. .............................. 23
Water Pump, Disassemble & Assemble ...................................................... .............. ....... .................. 24-28
Water Temperature Regulator ................................................................................................................ 17

6
ENGINE DISASSEMBL Y AND ASSEMBLY

CRANKSHAFT REAR SEAL AND WEAR SLEEVE

REMOVE CRANKSHAFT REAR SEAL AND
WEAR SLEEVE 1161-11

Tools Needed ABC

1P3075 Puller Assembly
5P7312 Distorter
5P7~38 Ring

start by:
a) remove flywheel
NOTE: When a replacement of the rear seal is made,
a replacement of the wear sleeve is to be made also.
1. Remove the crankshaft rear seal with tool (A).
2. Install tool (C) in the rear seal bore.
3. Install tool (8) between tool (C) and wear
sleeve. Turn tool (8) until the edge of the tool
makes a flat place (crease) in the wear sleeve.
Do this in two or more places until the wear
sleeve is loose.
4. Remove tool (C) and the wear sleeve by hand.
INSTALL CRANKSHAFT REAR SEAL AND
WEAR SLEEVE 1161-12

Tools Needed A
5P7293 Installer TYPICAL EXAMPLE
5P290 Locator
1P5515 Bolt 2
9S8858 Nut 2 ----1:=:AJ~:I.L..L;
~~~____-----3

1. Install the crankshaft rear seal and wear sleeve 4

with tooling (A) as follows:
a) Clean and make a preparation of the wear
sleeve inside diameter and crankshaft out-
side diameter with 6V1541 Quick Cure
Primer. Make an application of 9S3265
Retaining Compound to crankshaft outside
diameter and wear sleeve inside diameter
before the wear sleeve is installed on the
crankshaft.
b) Install locator (3) and the bolts on the rear "....------5
of the crankshaft.
c) Put clean engine oil on the lip of seal (1) and A52504X2

install the seal on wear sleeve (2).
d) Put 7F2770 Cement on the outer metal
surface of the seal.
e) Put the wear sleeve (2) and seal (1) in posi-
tion on locator (3) with the outside dia-
meter bevel of the wear sleeve toward the
outside.
NOTE: Make sure the lip of the seal is toward the
front of the engine before the seal is pushed in posi-
tion as shown.
f) Put installer (5) in position on the locator.
g) Put clean engine oil on the face of nut (4)
and install it on the locator. Tighten the nut
until installer (5) is at bottom.
h) Remove tooling (A) and check the wear
sleeve and seal for the correct position after
installation. The wear sleeve must be even
with the flywheel mounting flange.
end by:
a) install flywheel

123
 3204 VEHICULAR ENGINE SPECIFICATIONS
FOR 215 EXCAVATOR

INTRODUCTION

The specifications given in this book are on the basis can be used again. If the part is equal to or within the
of information available at the time it was written. The specification given, use the part again.
specifications torques, pressures of operation, mea-
surements, adjustments and other items can change at When the word "permissible" is in the description,
any time. These changes can effect the service given to the specification given is the' 'maximum or minimum"
the product. Get the complete and most current infor- tolerance permitted before adjustment, repair and/or
mation before you start any job. Caterpillar Dealers new parts are needed.
have the most current information which is available. A comparison can be made between the measure-
For a list of the most current modules and form numbers ments of a worn part, and the specifications of a new
available for each Service Manual, see the SERVICE part to find the amount of wear. A part that is worn can
MANUAL CONTENTS MICROFICHE REG 1139F. be safe to use if an estimate of the remainder of its
When the words "use again" are in the description, service life is good. If a short service life is expected,
the specification given can be used to determine if a part replace the part.
77200X2

NOTE: For Systems Operation and Testing and Adjusting, make reference
to 3204 VEHICULAR ENGINE FOR 215 EXCAVATOR, Form No.
SENR2137.
I
NOTE: The "C" is an indication of a change from the former issue.

INDEX

AiHnduction and Exhaust System Cooling System

Air Breather. ..................... . ...........•....... 18 Gauge for Water Temperature. . . • . . . . . . . . . . . . . . . . . . . .. 39
Air Cleaner...... ......................•....•......... 18 Pressure Cap . . . . . . . . . • . . . . . . . . . . . . . • . . . . . . . . . . . . . . . •. 24
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . •. 12 Water Pump. . . . .. . . . . . • . . . . . . . . . .. • . . . . . . . . . . . . . . . . .. 24
Cylinder Head........................................ 13 Water Temperature Regulator and Lines •.............. 23
Exhaust Manifold ..................................... 20 V-Belt Tension Chart. . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . .. 23
Exhaust Pipe ..................................•...•.. 20
Muffler.............. ... .....•..... .....•............. 19 Electrical System
Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . •. 11 Alternators ........................................ 35, 36
Turbocharger.... ........ .........................•... 17 Starter Motors ..... . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . .. 37
Valves and Valve Springs.... .......................... 14 Starter Solenoid .......• .-............................. 38
Valve Cover ......•.........•......................... 15 Engine Design ............••............. : . . . . . . . . . . . . . . 5
Valve Rocker Arms and Lifters......................... 16
Fuel System
Valve Seats and Inserts ........ , .... .. .......... .... 15, 16
Accessory Drive...... ..•..... .............•. ......... 10
Basic Engine Components Fuel Filter (Primary) . . . . . . . . . . . . . . . . . . . . . . . . . . .• . . . . . .. 11
Bearing Surface (Journal) for Connecting Rods ........ 29 Fuel Injection... . ... .. ...... ..... .......... .......... 6, 7
Bearing Surface (Journal) for Main Bearings ........... 30 Fuel Injection Lines. . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting Rod ...................................... 27 Fuel Injection Pump Housing... ..................... . . 8
Crankshaft ........................................... 28 Governor............................................. 9
Cylinder Block. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. 25 Governor Housing .................................... 7
Flywheel .......................... :.................. 31 Injection Nozzle ...................................... 7
Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31
Lubrication System
Flywheel Housing Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 33
Gauge for Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 39
Flywheel Housing Runout ............................. 32
Flywheel Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 34 Oil Filter.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21
Pistons and Rings. ..... . ... ... . . . ........... ... ....... 26 Oil Pan ............................................... 23
Timing Gears. . .. .... ... ... . . . .... .. . ....... .......... 11 Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 39
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21. 22

2
Index Valve Cover ................................................................ 14
Valve Cover Base ....................................................... 14
Valve Lifters ................................................................ •
Air Cleaner Housing ................................................... 6
Alternator .................................................................... 6 Water Pump ................................................................ 13
Water Pump, Disassemble & Assemble...... ............... •
Camshaft ..................................................................... • Water Temperature Regulator ..................................... 8
Camshaft Bearings ..................................................... •
Connecting Rod Bearings .......................................... • ·For disassembly and assembly information for these
Crankshaft And Gear ................................................. • components, see 3204 Vehicular Engine, Disassembly
Crankshaft Front Pulley .............................................. 12 And Assembly Manual, Form No. SENR3230.
Crankshaft Front Seal ................................................. •
Crankshaft Main Bearings.......................................... •
Crankshaft Rear Seal And Wear Sleeve .................... •
Cylinder Head Assembly ............................................ • A WARNING
Cylinder Head Assembly, Disassemble &
Assemble ....................................................................• Disconnect batteries before performance of any
service work.
Engine (See D4B & 935B Power Train, Disassembly
And Assembly Manual, form No. SENR3547)
Engine Oil Cooler, Support and Bypass Valve .......... 8
Exhaust Manifold ........................................................ •

Fan And Pulley ........................................................... 12

Flywheel ......................................................................•
Flywheel Housing ....................................................... •
Fuel Injection Lines ..................................................... 15
Fuel Injection Nozzles ................................................. •
Fuel Injection Pump Housing And Governor .............. 16
Fuel Injection Pump Housing, Disassemble &
Assemble .................................................................... •
Fuel Injection Pumps, Disassemble & Assemble ....... •
Fuel Transfer Pump .................................................... 15
Fuel Transfer Pump, Disassemble & Assemble ......... •

Governor, Disassemble & Assemble ......................... •

Hood ........................................................................... 5

Muffler ......................................................................... 7

Oil Pan ........................................................................ 20

Oil Pump And Relief Valve .. ...... .... ................ .... .... ..... •

Pistons And Connecting Rods ................................... •

Pistons And Connecting Rods, Disassemble &
Assemble ....................................................................•
Piston Cooling Orifices ............................................... •

Radiator And Guard ................................................... 10

Rocker Shaft Assembly And Push Rods.................... •
Rocker Shaft, Disassemble & Assemble .................... •

Starting Motor............................................................. 6
Support Bracket (931C) ............................................. 4

Timing Gear Cover ..................................................... 20

Timing Gears And Plate ............................................. •

Engine Supplement 3 Index

 NOTICE
Make sure the vent hole is open, and do not use liquid
gasket material on the gasket. The cylinder head can
be damaged if the vent hole is not open.

7. Put gasket (3) and elbow (2) in position, and install

the bolts that hold it.

8. Put the radiator hose in position on the elbow, and

tighten the clamp.

9. Fill the cooling system with coolant to the correct

level. See the Maintenance Guide.
7. Remove cover (4) and the gasket from core
assembly (5).

Engine Oil Cooler, Support And

Bypass Valve

Remove And Install Engine Oil Cooler,

Support And Bypass Valve 1378 &
1314-010
1. Remove the plate assembly from the right side of
the engine compartment.

2. Drain the coolant from the cooling system.

3. Drain the oil from the oil cooler.

Make note that it is between the fifth and sixth plate.

8. Remove divider (6) from core assembly (5).

4. Loosen the hose clamp, and disconnect hose (1)

from the oil cooler.
Typical Example
5. Remove hose (2) from the oil cooler and the elbow
on the timing gear cover.
9. Remove six bolts (7) and support (8) from the
6. Remove 10 bolts (3), cover (4) and the core engine.
assembly from the oil cooler support.

Engine Supplement 8 Disassembly And Assembly

Index INTRODUCTION
When the words "use again" are in the description, the
Specifications specification given can be used to determine if a part can be
used again. If the part is equal to or within the specification
Air Induction And Exhaust System given, use the part again.
Air Breather ................................................................... 28
Air Cleaner .................................................................... 26 When the word "permissible" is in the description, the
Camshaft ..................... ....... ................ .................. ........ 21 specification given is the "maximum or minimum" tolerance
Cylinder Head ............................................................... 25 permitted before adjustment, repair and/or new parts are
Exhaust Manifold .......................................................... 28 needed.
Mufflers ......................................................................... 28 A comparison can be made between the measurements of a
Turbocharger ................................................................ 26 worn part and the specifications of a new part to find the
Valves ........................................................................... 23 amount of wear. A part that is worn can be safe to use if an
Valve Cover .................................................................. 22 estimate of the remainder of its service life is good. If a short
Valve Rocker Arms And Lifters .................................... 23 service life is expected, replace the part.
Valve Seat And Inserts ..... ................ ........ ................ .... 24
REFERENCE: See 3204 Vehicular Engine, Form No.
Basic Engine Components SENR2137, for Systems Operation, Testing and Adjusting.
Connecting Rod ........................................................... 35
Connecting Rod Bearings ............................................ 40
Crankshaft .................................................................... 39
Crankshaft Seals .......................................................... 41
Cylinder Block .............................................................. 37
Flywheel ........................................................................ 42
Flywheel Housing ......................................................... 42
Flywheel Housing Bore ................................................. 44
Flywheel Housing Runout ..................... ........................ 43
Flywheel Runout ........................................................... 42
Main Bearings .............................................................. 40
Piston And Rings.............. ......... ................. ....... ........... 34
Cooling System
Pressure Cap ................................................................ 32
V -Belt Tension Chart .................................................... 34
Water Pumps ....................... ........ ......... .............. .......... 33
Water Temperature Regulator And Water Lines .......... 33
Electrical System
Alternators And Regulators .......................................... 45
Starter Motors ............................................................... 49
Starter Solenoids .......................................................... 50
Engine Design ........................................................ .......... .... 4.
Fuel System (New Scroll)
Fuel Injection Pump ................................ ............. ......... 4
Fuel Injection Pump Housing ........................................ 6
Fuel Injection Lines ....................................................... 9
Fuel Injection Nozzles (7000 Series) ............................ 9
Governor ....................................................................... 7
Governor Linkage Adjustment ..................................... 12
Timing Gears ................................................................ 10 '
Fuel System
Accessory Drive ........................................................... 21
Fuel Injection ................................................................ 10
Fuel Injection Lines ....................................................... 19
Fuel Injection Pump Housing............................... ......... 18
Governor ....................................................................... 20
Governor Housing ...... ........... ..................... .................. 11
Injection Nozzles .......................................................... 17
Lubrication System
Oil Filter ...................................................... .................. 32
Oil Pan .......................................................................... 32
Oil Pump ....................................................................... 30

3204 Vehicular Engine 3 Index

 Engine Disassembly and Assembly

Index

Camshaft .......................................................... 73 Valve Lifters ..................................................... 60

Camshaft Bearings .......................................... 75
Water Pump ....................................................... 8
Connecting Rod Bearings ............................... 67
Water Pump, Disassemble & Assemble ............ 9
Crankshaft And Gear ....................................... 85
Crankshaft Front Seal ...................................... 14
!his mo?ule contains disassembly and assembly
Crankshaft Main Bearings ............................... 77
Information for 3204 Vehicular Engines. For
Crankshaft Rear Seal And Wear Sleeve ... " .... 83
additional information, see the engine module
Cylinder Head Assembly................................. 54
supplement for the specific vehicle.
Cylinder Head Assembly, Disassemble
& Assemble ...................................................... 57
Exhaust Manifold ""'''''''''''''''''''''''''''''''''''''''''' 22
Flywheel .......................................................... . 80
Flywheel Housing ............................................ . 82
Fuel Injection Nozzles .................................... .. 53
Fuel Injection Pump Housing, A WARNING .
Disassemble & Assemble ................................ 42
Fuel Injection Pumps, Disassemble
& Assemble ...................................................... 48 Disconnect batteries before performance of
Fuel Transfer Pump, Disassemble & any service work.
Assemble ......................................................... 23
Governor, Disassemble & Assemble ............... 25
Oil Pump And Relief Valve .............................. 61
Pistons And Connecting Rods ........................ 69
Pistons And Connecting Rods,
Disassemble & Assemble ................................ 71
Piston Cooling Orifices .................................... 89
Rocker Shaft Assembly And Push Rods ......... 50
Rocker Shaft, Disassemble & Assemble ......... 51
Timing Gears And Plate ................................... 64
Turbocharger, Disassemble & Assemble ........ 15