FORM NO.

REG01254-04
FOR USE IN S E R V IC E M A N U A L S :
D3 TRACTOR, R E G 01357
D3B TRACTO R, SENR7911
9 1 0 W HEEL LO ADER, R E G 0 1 3 3 0
9 1 0 W H E EL L O A D E R , S E N R 7 9 8 2
9 3 1 T R A C K -T Y P E LO A D E R ,
REG 01387
931 B T R A C K -T Y P E L O A D E R ,
SENR7925
V O L U M E I S P E C IF IC A T IO N S .
R EG 01312

SPECIFICATIONS
FOR

3204 VEH IC U LAR E N G IN E

ENGINE SERIAL NUMBERS

45V1-UP

From the library of Barrington Diesel Club

3204 V E H IC U LA R ENGINE SPECIFICATIONS

IN T R O D U C T IO N

The specifications given in this book are on the basis can be used again. If the part is equal to or within the
o f information available at the tim e it was written. The specification given , use the part again.
specifications torques, pressures o f operation, m ea­
surements, adjustments and other items can change at When the word “ perm issible” is in the description,
any tim e. These changes can effect the service given to the specification given is the “ maxim um or m inim um ”
the product. Get the com plete and m ost current infor­ tolerance permitted before adjustment, repair and/or
mation before you start any job. Caterpillar Dealers new parts are needed.
have the m ost current information w hich is available.
A com parison can be made between the measure­
For a list o f the m ost current m odules and form numbers
ments o f a worn part, and the specifications o f a new
available for each Service M anual, see the SERVICE
part to find the amount o f wear. A part that is worn can
M A N U A L C O NTENTS M ICROFICHE R E G 1139F.
be safe to use if an estim ate o f the remainder o f 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

N O T E : The " C " is an in d ic a tio n o f a change fro m the fo rm e r issue.

NOTE: F or S y stem s O peration and T esting and A djusting, m ake referen ce to

the 3 2 0 4 V eh icu lar E ngine, F orm N o . R E G 0 1 2 2 2 .

IN D E X

A cce s s o ry D rive G e a r ....................................................................... 15 E le ctrica l System

A ir In d u c tio n and E xhaust System A lte rn a to rs ....................................................................................... 39
A ir C le a n e r ....................................................................................... 17 A lte rn a to r In s ta lla tio n ................................................................... 38
C a m s h a ft............................................................................................ 16 A lte rn a to r R e g u la to r .................................................................... 40
C y lin d e r Head G lo w Plug C o n n e c tio n ................................................................ 6
D l ...................................................................................................... 23 Pressure S w itch ............................................................................. 25
P C .................................................................................................... 22 S ta rte r S o le n o id .......................................................................... 41, 42
M u f f le r ................................................................................................ 24 S ta rte r M o t o r ................................................................................... 41
T im in g G e a r s ................................................................................... 16 Vee B e lt s ........................................................................................... 42
Valve C o ve r ..................................................................................... 21 E ngine D e s ig n ..................................................................................... 5
Valve R o cke r A rm s and L if t e r s .................................................. 17
Valves and Valve S p r in g s ............................................................ 18 Fuel System
Valve Seats and Inserts Fuel In je c tio n 7, 8
D l ................................................................................................ 20, 21 Fuel In je ctio n L in e s ....................................................................... 9
P C .................................................................................................... 19 Fuel In je c tio n Pum p H o u s in g .................................................... 6
Fuel T ra n s fe r P u m p ....................................................................... 11
Basic E ngine C o m p o n e n ts G o v e rn o r ........................................................................................... 10
C o n n e c tin g Rod ............................................................................. 29 G o ve rn o r C o n tro l L in k a g e ..........................................11, 12, 13, 14
C ra n k s h a ft ....................................................................................... 31 N ozzles
B e aring S urface (J o u rn a l) — C o n n e ctin g R o d s 32 D l ...................................................................................................... 8
B e aring S urface (J o u rn a l) — M a in s .................. 33 P C .................................................................................................... 8
C y lin d e r B lo c k ................................................................................. 28
E ngine S u p p o r ts ............................................................................. 34 L u b ric a tio n System
Flyw heel ............................................................................................ 34 O il F ilte r .............................................................................................. 25
F lyw h ee l H o u s in g ........................................................................... 34 O il P a n ................................................................................................ 25
Flyw heel H o u sin g B o r e ................................................................ 35 O il Pressure G a u g e ....................................................................... 25
Flyw heel H o u sin g R u n o u t .......................................................... 36 O il Pressure S w itc h ....................................... 25
Flyw heel R u n o u t............................................................................. 37 O il P u m p ........................................................................................... 24
Pistons and R in g s ........................................................................... 30
T o rq u e fo r Flared and O -rin g F it t in g s ....................................... 4
C o o lin g System
Pressure C a p ................................................................................... 27
W ater P u m p s ................................................................................... 26
W ater T e m p e ra tu re G auges ...................................................... 27
W ater T e m p e ra tu re R e g u la tors (T h e rm o sta t) ..................... 27
Vee B e lt s ............................................................................................ 42

2
3204 V E H IC U LA R ENGINE SPECIFICATIO NS

G E N E R A L T IG H T EN IN G TORQUE FOR
BOLTS, NUTS A N D T A P ER LO C K STUDS
The follow ing charts give the standard torque values fo r bolts, nuts
and taperlock studs o f SAE Grade 5 or better quality. Exceptions are
given in other sections of the Service Manual where needed.

THREAD DIAM ETER STANDARD TORQUE

inches m illim e te rs lb. ft. Nm*

Standard thread
nmirnmnw Use these torques fo r bolts and nuts w ith stan­
dard threads (conversions are approximate).

1/4 6 .3 5 9 ±3 12 ± 4
5/16 7 .9 4 18 ± 5 25 ± 7
3/8 9 .5 3 32 ± 5 45 ± 7
7/16 11.11 50 ± 10 70 ± 15
1/2 12.70 75 + 10 100 + 15
9/16 14.29 110 ± 15 150 ± 2 0
5/8 15.88 150 ±2 0 200 ± 2 5
3/4 19.05 265 + 35 360 ± 5 0
7/8 22 .23 420 ± 6 0 5 70 ± 80
1 2 5 .4 0 640 ± 8 0 875 ± 100
i i/s 28.58 800 ±100 1100 ± 150
1 1/4 3 1 .75 1000 ±120 1350 + 175
1 3/8 3 4 .9 3 1200 ± 1 5 0 1600 ±200
1 1/2 3 8 .1 0 1500 ±200 2000 ± 275

Use these torques fo r bolts and nuts on

hydraulic valve bodies.

5/16 7.94 13 ± 2 20 ± 3
3/8 9.5 3 24 ± 2 35 ± 3
7/16 11.11 39 ± 2 50 ± 3
1/2 1 2 .70 60 ± 3 80 ± 4
5/8 15.88 118 ± 4 160 + 6

Taperlock stud

Use these torques fo r studs w ith Taperlock threads.

i i i i

1/4 6.35 5 ±2 7 ± 3
5/16 7.9 4 10 ± 3 15 ± 5
3/8 9.53 20 ± 3 30 ± 5
7/16 11.11 30 ± 5 4 0 ± 10
1/2 1 2 .70 40 ± 5 5 5 ± 10
9/16 1 4 .29 60 ± 10 8 0 ± 15
5/8 15.88 75 ± 10 100 ± 15
3/4 19.05 110 ± 15 150 ± 20
7/8 2 2 .2 3 170 ± 2 0 2 3 0 ± 30
1 2 5 .4 0 2 6 0 ± 30 3 5 0 ± 40
1 1/8 2 8 .58 3 2 0 ± 30 4 0 0 ± 40
1 1/4 3 1 .75 4 0 0 ± 40 5 5 0 ± 50
1 3/8 3 4 .9 3 4 8 0 ± 40 6 5 0 + 50
1 1/2 3 8 .1 0 5 50 ± 50 7 5 0 ± 70

*1 newton meter (N m) is approximately the same as 0.1 mkg. T95416-7

3
3204 V E H IC U L A R ENGINE SPECIFICATIONS

TORQUE FOR FLARED AND O-RING FITTINGS

The torques show n in the chart that fo llow s are to be used on the part o f 37° Flared, 45° Flared and
Inverted Flared fittings (w hen used with steel tubing), O-ring plugs and O-ring fittings.

~7~7~Z

SEP
t
? e pa
IN V E R TE D O-RING
45° F LA R E D 37 F LA R E D 45 F LA R E D F IT T IN G - PLUG SW IV EL NUTS

TUBE 3.18 4.78 6.35 7.92 9.52 TUBE 12.70 15.88 19.05 22.22 25.40 31.75 38.10 50.80
SIZE SIZE
(O.D.) .125 .188 .250 .312 .375 (O.D.) .500 .625 .750 .875 1.000 1.250 1.500 2.000
THREAD 9 /1 6 THREAD 1 3/16
5/16 3/8 7/16 1/2 3/4 7/8 1 1/16 1 5/16 1 5/8 1 7/8 2 1/2
SIZE (in.) 5/8 SIZE (in.) 1 1/4
TOR QU E 5 11 16 20 25 TORQUE 50 75 100 120 135 180 225 320
N-m ±1 ±1 ±2 ±2 ±3 N-m ±5 ±5 ±5 ±5 ±10 ±10 ±10 ±15
TORQUE 45 100 145 175 225 TORQUE
35 ± 4 55 ± 4 75 ± 4 9 0 ± 4 100 ± 7 135 ± 7 165 ± 7 235 ± 10
Ib.in. ±10 ±10 ±20 ±20 ±25 Ib .ft.

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.
H old these com ponents in this position. Turn the
fitting into the part it is used on, until backup
washer (4) just m akes contact with the face o f the
part it is used on.

NOTE: If the fitting is a connector (straight fitting) or

plug, the hex on the body takes the place o f the locknut.
To install this type fitting tighten the hex against the
face o f the part it goes into.

2. T o put the fitting assem bly in its correct position

turn the fitting body (2) out (counterclockw ise) a
m axim um o f 359°. Tighten locknut (3) to the ELBOW BODY ASSEMBLY
torque show n in the chart. 1. End o f fittin g body (connects to tube). 2. Fitting
body. 3. Locknut. 4. Backup washer. 5. O -ring seal. 6.
A 7 1009X3 End o f fittin g that goes into other part.

4
3204 V E H IC U L A R ENGINE SPECIFICATIONS

E N G IN E D ESIG N

B o re ........................................................................................................... 4.5 in. (114.3 mm)

Stroke ....................................................................................................... 5.0 in. (127.0 mm)
Number and Arrangement of Cylinders ..................................................................4, in line
Firing Order (Injection Sequence) ........................................................................... 1,3, 4, 2
Rotation of Crankshaft (when seen from flywheel e n d ) ........................ Counterclockwise
Rotation of Fuel Pump Camshaft (when seen from pump drive end) . . Counterclockwise
NOTE: Front end of engine is opposite to flywheel end. No.1 cylinder is the fron t cylinder.

IN T A K E EXH AU ST
.015 in. (0.38 mm) .025 in. (0.64 mm)
41385-1X1

C Y L IN D E R A N D V A L V E LO C ATIO N
(D l ENGINE)

IN T A K E EXH AU ST
.015 in. (0.38 mm) .025 in. (0.64 mm)

C Y L IN D E R A N D V A L V E LO CATIO N
(PC ENGINE)

----

5
3204 V E H IC U LA R ENGINE SPECIFICATIONS

FUEL INJECTION PUMP HOUSING

(1) Install dow el to get a d im ension from ce n te rlin e of (4) Install rear rack bearing to
fu e l in je ctio n pum p bore to dow el (seal dow el hole a depth of ........................................ 195 ± .005 in. (4.95 ± 0.13 mm)
w ith a lu m in u m b a ll) ............... 58 4 ± .002 in. (14.83 ± 0.05 mm)
NOTE: Small holes in bearing must be positioned as shown (parallel to
(2) Rack bearing a lig n m e n t — the ce n ter of th e rack bearing tab the vertical centerline th ru the pum p).
m ust be w ith in .002 in. (0.05 mm) of a vertical line that:
(5) Bore in bearings fo r the .
(a) goes through the center of the rack bearing. camshaft (new) 1.8775 ± .0005 in. (47.638 ± 0.013 mm)
(b) is parallel to the vertical centerline th ru the injection pump Diameter of bearing surfaces o f the
bores and camshaft bearing bores. camshaft (new) 1.8730 ± .0005 in. (47.574 ± 0.013 mm)
NOTE: The fo llo w in g tools are available to position the rack bearings M aximum permissible clearance between the
correctly: 5P1665 Alignm ent Plate and 9S6329 Driver. bearings and the c a m s h a ft........................................010 in. (0.25 mm)
The correct bearing depth is controlled when driver is stopped by plate. (6) Install camshaft bearings flush w ith fro n t and rear face of housing.
(3) Install pins un til they contact b o ttom o f housing casting. (7) Camshaft bearing oil hole. Position fro n t bearing w ith oil hole in
alignment w ith drilled oil passages in block.

GLOW PLUG CONNECTION

(PC ENGINES)

(1) Torque fo r the glow plugs (put 9M 3710 Anti-Seize

Compound on threads) .............. 120 ± 24 lb. in. (13.6 ± 2.8 N-m)
(2) T o rq u e fo r the plug fo r e le ctrica l co n n e ctio n (pu t 5P3931 A n ti­
Seize C o m p o u n d on threads):
Step 1. T ig h te n the plug by hand.

Step 2. T ig h te n the plug 2!4 to 2% tu rn s beyond hand tig h t.

N O TE: FOR TORQUE V A LU E S N O T G IV E N , SEE THE FIRST

6 PAGE OF SPEC IFIC ATIO N S FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U L A R ENGINE SPECIFICATIONS

FUEL INJECTION

A —8S7167 GAUGE B -5 P 4 1 5 8 GAUGE

(4) SPACER C H A R T

T h ickn e ss

Part No. in. mm

A53167X1
9N6496 .162 4.22
9 N 6495 .166 ■ 4.11
5M2697 .170 4.32
Rotation of Fuel Pump C am shaft (w hen 2M 4208 .174 4.42
seen from pum p d rive end) .......................................... C o u n terclockw ise 2M4209 .178 4.52
Firing order (injection sequence) ............................................ 1, 3, 4, 2 2M4210 .182 4.62

Injection tim in g before TC (top center): 2M4211 .186 4.72

2M4212 .190 4.83
Precombustion Chamber (PC) 20 ± 1°
5M2691 .194 4.93
Direct Injection (D l) 20 t 1°
5S7189 .198 5.03
(1) Torque fo r bushing 150 ± 10 lb. ft. (205 ± 14 N m)
4N9839 ,203 5.16
4N9840 .207 5.26
PUMP ASSEM BLY SPRINGS
(5) Bore fo r the rack and diam eter o f the rack:
(2) Check Valve Spring (3) L ifte r Spring Bearing at th e rear
(n e w ) 5020 ± .0016 in. (12.751 t 0.041 mm)
Type PC Dl PC 8< Dl
Bearing at the fro n t
Part No. 3F303 9S97 1S206 (n e w ) 5023 ± .0015 in. (12.758 ± 0.038 mm)
Diameter of fuel rack
Length under .308 in. .265 in. 1.390 in.
(n e w ) 4985 ± .0002 in. (12.662 ± 0.005 mm)
test force (7.52 mm) (6.83 mm) (35.30 mm)
M axim um permissible clearance between rack
Test force 1.5 ± .1 oz. .24 ± .01 lb. 15.4 + .8 lb. and bearings ( w o r n ) 005 in. (0.13 mm)
(0.40 ± 0.03 N) (1.1 ± 0.04 N) (68.8 ± 3.6 N)
(6) Bore in bearings fo r the
camshaft (new) 1.8775 ± .0005 in. (47.638 ± 0.013 mm)
Free length .37 in. .39 in. 1.59 in.
after test (9.4 mm) (9.9 mm) (40.3 mm) Diameter o f bearing surfaces of the
camshaft (new) 1.8730 ± .0005 in. (47.574 ± 0.013 mm)
Outside .332 in. .420 in. .979 ± .005 in.
diameter (8.43 mm) (10.67 mm) (24.86 ± 0.13 mm) M axim um permissible clearance between the
bearings and the c a m s h a ft 010 in. (0.25 mm)

7
3204 V E H IC U LA R ENGINE SPECIFICATIONS

Fuel Injection (Cont.)

INJECTION PUMP & T IM IN G DIM ENSIONS

PC Dl

Length 2.5934 t .0015 in. 2.5934 ± .0015 in.

(new) (65.872 ± 0.038 mm) (65.872 ± 0.038 mm)
(7) Pump Plunger
Min. Permissible 2.5869 in. 2.5869 in.
Length (65.707 mm) (65.707 m m)

Tim ing dimension On 4.1903 ± .0020 in. 4.1640 ± .0020 in.

fo r fuel injection Engine (106.433 ± 0.051 mm) (105.766 ± 0.051 m m)
(8) pumps w ith 8S7167
Gauge (A) o r 5P4158 O ff 4.2675 ± .0020 in. 4.2675 ± .0020 in.
Gauge (B) Engine (108.395 ± 0.051 mm) (108.395 ± 0.051 mm)

PR E CH A MB ER NOZZLE

(1) T o rq u e fo r g lo w p lu g s (p u t 5P3931 A n ti-S e ize

C o m p o u n d on th r e a d s ) 120 ± 24 lb. in. (13.6 ± 2.8 N-m)
(2) Torque fo r all nuts th a t hold
the fuel lines ............................................. 30 ± 5 lb. ft. (40 ± 7 N-m)
(3) Torque fo r the nuts th a t hold
the no zzle s .................................................. 55 ± 5 lb. ft . (75 ± 7 N-m)
(4) Body.
(5) Rubber ring. Put liq u id soap on rubber ring and in bore in cylinder
head.
(6) Nozzle. Tighten nozzle finger tig h t on body (4).
(7) T orque for precom bustion
cham ber 150 ± 10 lb. ft. (205 ± 14 N-m)

c INJECTION NOZZLE

Bench test nozzles using clean SAE J9 6 7 C a libration oil

at a te m p e ra tu re o f .......................................... 65 to 70 ° F (18 to 2 0 ° C)
Nozzle se ttin g pressures (valve lift a d ju stm e n t screw tu rn e d 3 / 4 ±
1 / 8 tu rn from closed position):

9 L 6 9 6 9 Nozzle:
Used n o z z le ................. 1 900 to 2 9 0 0 psi (13 0 9 0 to 19 9 8 0 kPa)
Used, adjusted
nozzle 2 7 0 0 to 2 900 psi (18 6 00 to 19 980 kPa)

9 N 3 9 7 9 and 1W 5 8 2 9 Nozzles:
Used n o z z le ................. 1 500 to 2 6 0 0 psi (10 300 to 17 6 9 0 kPa)
Used, adjusted
nozzle 2 4 0 0 to 2 6 0 0 psi (16 5 45 to 17 6 9 0 kPa)
Return oil leakage te st 9 N 3 9 7 9 and 1 W 5 8 2 9 Nozzles:
p re s s u re ................................. 1400 to 1600 psi (96 3 0 to 11 0 4 5 kPa)
M axim um tip leakage is 20 drops in 15 seconds w ith a pressure
Leakage in 1 5 seconds ( 9 L 6 9 6 9 ) ................................... 2 to 30 drops of 2 00 psi (1 3 8 0 kPa) less th a n opening pressure.
Leakage in 15 seconds (9N 3979 & 1W 5829). NO m in im u m or (1) Torque fo r valve lift
m axim um . locknut ............................................ 35 to 45 lb. in. (4.0 to 5.1 N-m)
9 L 6 9 6 9 Nozzle: (2) Torque fo r pressure scre w
lo ckn u t ............................................ 70 to 80 lb. in. (8.0 to 9.1 N-m)
M axim u m tip leakage is 10 drops in 15 seconds w ith pressure
2 0 0 psi (1380 kPa) less th a n opening pressure. (3) Torque fo r c a p ................... 1 10 to 120 lb. in. (12.4 to 13.6 N-m)

NOTE: FOR TORQUE V A LU E S N O T G IV E N , SEE THE FIRST

8 PAGE OF SPEC IFIC ATIO N S FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U L A R ENGINE SPECIFICATIO NS

F UE L INJECTION LINES
(D l ENGINE)

(1) 90° Adapter. Before tightening fuel injection nozzle

nut (2), hold adapter in a vertical position w ith in ................... ±2°
(2) Torque fo r the fuel injection nozzle
n u ts 30 ± 5 lb.ft. (40 ± 7N-m)
A73319X1

(3) Torque fo r the fuel injection

line n u ts 30 ± 5 lb.ft. (40 ± 7N-m)
(4) Torque fo r the valve cover studs . . . . 11 ± 3 lb. f t . (15 ± 4 N-m)

Torque fo r n u ts on studs 6 ± 1 lb.ft. (8 ± 1 N-m)

(5) Fuel lines m u s t not co n tact o th e r fu e l lin e s or eng in e co m p o ­
n e n ts except at fittin g s and clam ps.

FUEL INJECTION LINES

(PC ENGINE)

(1) Torque fo r fuel injection line

n u ts 30 ± 5 lb. ft. (40 ± 7 N-m)
(2) Adapter.

(3) Fuel lines must not contact other fuel lines or engine components
except at fittin g s and clamps.

9
3204 V E H IC U L A R ENGINE SPECIFICATIONS

GOVERNOR

(1) Torque fo r nut 9 ± 3 lb. f t . (12 ± 4 N-m)

(2) 9L6449 Spring fo r governor:

Color code (s trip e s ) 1 brow n, 1 green
Put force on spring o f ...................................................... 5.0 lb. (22 N)

Then add more force to make spring

shorter by ...................................................... -90 in. (22.9 mm)
60414X7
T otal test force ............................................. 19.4 ± .4 lb. (87 ± 2 N)
Free length a fte r t e s t ....................... 2.24 ± .03 in. (56.9 ± 0.8 mm)
Outside d ia m e te r................................................ 1.387 in. (35.23 mm)

(2) 9M 3160 Spring fo r governor:

C olor code (s trip e s )....................................................................... 1 blue
Put force on spring o f ...................................................... 5.0 lb. (22 N)
Then add more force to make spring
shorter by ..................................................................900 in. (22.86 mm)
T otal test force 19.40 ± .52 lb. (86.8 ± 2.3 N)
Free length after t e s t ....................... 2.34 ± .03 in. (59.4 ± 0.8 mm)
Outside d ia m e te r 1.391 in. (35.33 mm)
(3) 4N 5549 Spring fo r over-fueling:

Length under test f o r c e .............................................209 in. (5.31 mm)

Test force ......................................................65 ± .03 lb. (2.9 ± 0.1 N)

Free length after test (approxim ate) ...................859 in. (21.82 mm)

Outside d ia m e te r 429 in. (10.90 mm)

(4) Diameter o f the outer surface o f the

cylinder ( n e w ) ........ 1.2172 ± .0005 in. (30.917 ± 0.013 m m)

Bore in the gear (new) . 1.2192 ± .0005 in. (30.968 ± 0.013 m m)

(5) Bore in th e bearings
( n e w ) ................................. 6 2 3 0 ± .0 0 05 in. (1 5 .8 2 4 ± 0 .0 1 3 mm)

D ia m e te r of th e shaft A65353X1

( n e w ) .................................6 1 8 8 ± .0 0 05 in. (1 5 .7 1 8 ± 0 .0 1 3 mm)

(6) D istance betw een th e bearings fo r th e governor

co n tro l s h a f t ......................... 2 .3 8 5 ± .005 in. (60.58 ± 0 .1 3 mm)

(7) D istance fro m th e center line of the

co n tro l group bolt holes to th e
end of th e bearing fo r th e governor
co n tro l s h a f t ....................... 1.073 ± .0 1 0 in. (2 7 .3 0 ± 0.2 5 mm)

(8) Install seal w ith lip to th e inside.

N O TE: FOR TORQUE V A L U E S N O T G IV E N , SEE THE FIRST

10 PAGE OF SPECIFICATIO NS FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U LA R ENGINE SPECIFICATIONS

FUEL T R A N S F E R PUMP
(4N6835)

(1) Torque fo r o u tle t valve 18 to 22 lb. ft. (25 to 28 N m)

(2) Torque fo r in le t valve 18 to 22 lb. ft. (25 to 28 N-m) A23805- ix t

O u tle t fuel pressure fro m the

fuel transfer p u m p 30 to 50 psi (205 to 345 kPa)

GO V ER N OR CONTROL L I NK AG E
(GOVERNOR CONTROL, D3 TRACTOR
& 931 TRACK-TYPE LOADER)

(1) Force to move co n tro l lever (a p p ro x im a te )............ 11 lb. (49 N)

(2) Guide plate.
(3) F rictio n disc. Put new disc in kerosene fo r 24 hours before
installation.
(4) Tighten nut only so co n tro l lever (1) does not slide when the
engine is at high idle.
(5) Cable end.
(6) Governor lever.
(7) Cable end.
Cable adjustment procedure:
Step 1. Put the governor lever (6) in "sh ut o f f " position.
Step 2. A djust the cable ends (5 and 7) so the co n tro l lever (1) is also
in " s h u t-o ff" position [approxim ately .5 in. (12 mm) from end
o f slot in guide plate ( 2 ) ].

11
3204 V E H IC U L A R ENGINE SPECIFICATIONS

G O V E R N O R CONTROL LI NKAGE
(FOR 910 WHEEL LOADER)

. : V

A djustm ent procedure:

(1) G overnor lever, in high idle position.
Step 1. A djust the stop b o lt (5) so the pedal stops at the correct high
(2) Interm ediate levers (tw o levers on same shaft).
idle angle (6).
(3) Ends fo r the pedal rod.
Step 2. Disconnect the pedal rod and adjust the pedal rod ends (3) to
(4) C ontrol pedal. the correct distance (8). Install the pedal rod.

(5) Pedal stop b o lt fo r the high idle position. Step 3. Disconnect the governor rod.

(6) Angle between the pedal and the flo o r plate: Step 4. Put the governor lever (1) and the co n tro l pedal (4) in high idle
position. A d ju st the rod ends (7) so the rod w ill f it correctly in
Pedal in high idle p o s itio n .............................................................. 28° the governor lever (1) and in the longer interm ediate lever (2).
Pedal in fuel o ff p o s itio n ................................................................ 65°
Step 5. Tighten the locknut o f all rod ends.
(7) Ends fo r the governor rod.
Step 6. If necessary, adjust the pedal stop b o lt (5) again. A djust so the
(8) Distance between centers pedal stops when the governor lever (1) is in high idle position.
o f p in s 44.49 ± .06 in. (1130.0 ± 1 .5 mm) Tighten the locknut fo r the stop b o lt.

NO TE: FOR TORQUE V A L U E S N O T G IV E N , SEE THE FIR ST

12 PAGE OF SPECIFICATIO NS FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U L A R ENGINE SPECIFICATIONS

GOVERNOR CONTROL LINKAGE

(6 S 7 0 7 1 )
(GOVERNOR A N D TR A N S M IS S IO N CONTROL,
AN ATTAC H M EN T FOR D3 TRACTOR &
931 TRACK-TYPE LOADER)

(1) Distance between ball jo in t c e n te r s ................ 5.32 in. (135.0 mm)

(2) Rear interm ediate lever.

(3) Handle shaft lever.

(4) Torque fo r locknuts of

ball jo in t s ........................................... 30 ± 5 lb. in. (3.4 ± 0.6 N-m)
(5) Angle between the rear interm ediate lever (2) and
a vertical line, in "s h u t o f f " p o s itio n ........................................... 45°

(6) F ro n t interm ediate lever.

(7) Distance between bracket and end o f cable ball
jo in t, in "s h u t o f f " p o s itio n ............................ 7.84 in. (199.0 mm)

(8) Control handle in " o f f " position.

(9) C ontrol handle in "h ig h id le " position.

NOTE: When the governor lever is in m axim um "sh u t o f f " position, the
interm ediate levers (2 and 6) and the co n tro l handle (8) must also be in
"sh u t o f f " position as shown. mm-m

13
3204 V E H IC U L A R ENGINE SPECIFICATIO NS

GOVERNOR CONTROL LINKAGE

(5G 2 25 7 )
(GOVERNOR A N D T R A N S M IS S IO N CONTROL,
AN ATTAC H M EN T FOR D3B TRACTOR &
931 B TRACK-TYPE LOADER)
A93718X1

CAUTION
Be sure o p e ra to r c a n s h u t th e e n g in e o ff w h e n h a n d le (5)
is tu rn e d c o u n te rc lo c k w is e .

1. Disconnect g o ve rn o r cable (3) at th e ta n k end.

2. Put governor lever (4) in lo w idle position as show n.

3. A d ju s t length o f rod (2) so distance betw een

center o f pins fo r th e rod i s ................................... 0.5 in. (127 mm)
4. W ith lever (4) and handle (5) in th e p o sition sh o w n , a d ju st the
clevis on cable (3) and connect th e clevis to th e lever.

N O TE: FOR TORQUE V A L U E S N O T G IV E N , SEE THE FIRST

14 PAGE OF SPECIFICATIO NS FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U L A R ENGINE SPECIFICATIO NS

AC C ES SO R Y D R I V E GEAR

(1 1 Torque fo r the b o lt that holds the accessory drive gear:

PC [w ith tw o washers (2) and

sleeve ( 4 ) ] ................................. 75 ± 10 lb. ft. (100 ± 14 N m)

D l (w ith one washer (2) and

no sleeve) ................................... 110 ± 5 lb. ft . (149 ± 7 N-m)

(2) Washer
P C ...................................................................................................... tw o

D l .................................................................................................... one

(3) Bore in the bearing fo r the

idler gear ( n e w ) 1.0059 ± .0019 in. (25.550 ± 0.048 mm)
Diam eter o f the shaft fo r
the idler g e a r 1.0019 ± .0005 in. (25.448 ± 0.013 mm)

(4) Sleeve (PC o n ly).

15
3204 V E H IC U L A R ENGINE SPECIFICATIONS

TIMING GEAR S

(1) Accessory drive gear.

(2) T orque fo r b o lt. See the Subject ACCESSORY DR IVE GEAR.

(3) Idler gear.

(4) Crankshaft gear.
(5) Camshaft gear.

C AM SH A FT

(1) Diameter o f the bearing surface (journal)

o f c a m s h a ft................... 2.5000 ± .0005 in. (63.500 ± 0.013 m m)

Clearance between bearings and bearing

surfaces ( jo u r n a ls ) .................0035 ± .0020 in. (0.089 ± 0.051 mm)

M axim um permissible clearance between bearings

and bearing surfaces (jo u rn a ls ).................................010 in. (0.25 m m)
(2) End play fo r the c a m s h a ft 007 ± .003 in. (0.18 ± 0.08 mm)
M axim um permissible end p l a y .............................. 025 in. (0.64 mm)

(3) T ig h t f it between the gear

and c a m s h a ft......................... 0012 to .0028 in. (0.030 to 0.071 mm)

M axim um permissible temperature

o f the gear fo r installation on
the camshaft (do n o t use a torch) ............................ 600° F (315° C)
NOTE: When gear is installed, tim in g m ark m ust be to the outside
(away from camshaft).
(4) Tighten stud to a torque o f ................. 11 ± 2 lb. ft . (15 ± 3 N-m)
(5) Height o f camshaft lobes.

To fin d lobe lif t , use the procedure that fo llo w s:

A. Measure camshaft lobe height (5).

B. Measure base circle (7).

C. Subtract base circle (STEP B) fro m lobe height (STEP A ). The

difference is actual lobe lift (6).

D. Specified camshaft lobe lif t (6) is:

a. Exhaust lobe 3071 in. (7.800 mm)

b. Intake lo b e 3077 in. (7.816 m m)

M axim u m p e rm issib le d iffe re n ce betw een actual lobe lift (STEP C)

and specified lobe lift (STEP D) is .0 1 0 in. (0.25 mm).

NOTE: For in s ta lla tio n of ca m sh a ft, th e tim in g m ark on th e ca m sh a ft

gear to o th space m ust be in a lig n m e n t w ith th e tim in g m ark on the
tooth of th e cra n ksh a ft gear.

N O TE: FOR TORQUE V A L U E S N O T G IV E N , SEE THE FIRST

16 PAGE OF SPEC IFIC ATIO N S FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U L A R ENG INE SPECIFICATIONS

V A L V E R OC KE R A R M S AND LI FT E R S

(1) Valve clearance setting w ith engine stopped:

Intake v a lv e 015 in. (0.38 mm)
Exhaust v a lv e 025 in. (0.64 mm)

(2) Torque fo r lo ckn u t on valve

adjustm ent s c re w 24 ± 5 lb. ft. (30 ± 7 N m)

(3) Bore in rocker arm

( n e w )...................................... 8603 ± .0008 in. (21.851 ± 0.020 mm)

Shaft diameter (new) . . . .8584 ± .0004 in. (21.803 ± 0.010 mm)

M aximum permissible clearance between

bearing and shaft (worn) .......................................... 005 in. (0.13 mm)

(4) Diameter o f valve

lifte r 1.1589 ± .0004 in. (29.436 ± 0.010 mm)

Bore in cylinder b lo ck fo r valve

lifte r 1.1624 ± .0006 in. (29.524 ± 0.015 mm)

M aximum permissible clearance between valve

lifte r and cylinder b lo ck 008 in. (0.20 mm)

A I R C L E A NE R

(1) Torque fo r wing nuts th a t hold the

element assemblies............................ 33 ± 3 lb. in. (3.7 ± 0.3 N-m)

17
3204 V E H IC U L A R ENGINE SPECIFICATIONS

V A L V E S A N D V A L V E SPRINGS

NOTE: GUIDELINE FOR REUSABLE PARTS: VALVES AND VALVE

SPRINGS, Form SEBF8002 and SEBF8034 have th e procedure and
s p e cific a tio n s necessary fo r checking used valves and valve springs.

(1) Springs fo r valves (ne w ):

9L9 19 0 , 9N 3617, 9N3387
Length under test f o r c e .................................... 1.655 in. (42.04 mm)
Test force ...................................................... 50 ± 5 lb. (220 ± 22 N)

Use again m inim um load at length

under test f o r c e .............................................................. 35 lb. (155 N)

Length o f spring at valve open

p o s it io n ................................................................ 1.167 in. (29.64 mm)

Use again m inim um load at valve open

p o s it io n ....................................................................... 154.5 lb. (687 N)

Free length after t e s t ........................................ 1.854 in. (47.09 mm)

Outside d ia m e te r............................................... 1.440 in. (36.58 mm)
54651 1 X 3
Spring m ust not be bent more t h a n 065 in. (1.65 mm)

V A L V E CHART

PC Dl

IN T A K E EXHAUST IN T A K E EX H AU S T
9L7682
9N180 9N185 9 L 7683
8N 5645

(2) Diameter o f valve stems:

.3725 ± .0005 in. .3725 ± .0005 in.

Straight New (9.462 ± 0.013 mm) (9.462 ± 0.013 mm)
Stem
Use again m inim um diameter .371 in. (9.42 mm) - .371 in. (9.42 mm) -

.3705 ± .0005 in. .3705 ± .0005 in.

Head end _ (9.411 ± 0.013 m m) (9.411 ± 0.013 mm)
New
.3715 ± .0005 in. .3715 ± .0005 in.
Tapered Lock end - (9.436 ± 0.013 mm) - (9.436 ± 0.013 m m)
Stem:
Use again Head end - .369 in. (9.37 m m) - .369 in. (9.37 mm)
m inim um
diameter Lock end - .370 in. (9.40 m m) - .370 in. (9.40 mm)

Diameter o f valve guide bores (new): .3745 ± .0005 in. .3745 ± .0005 in.
(9.512 ± 0.013 mm) (9.512 ± 0.013 mm)

M axim um permissible diameter

measured .75 in. (19.0 mm) deep in .3760 in. .3760 in.
both ends o f guide bores: (9.550 mm) (9.550 m m)

(3) Distance from the end o f the valve 2.147 ± .020 in. 2.063 ± .015 in.
to the valve spring spacer seat: (54.53 ± 0.51 m m) (52.40 ± 0.38 mm)

(4) Thickness of New .080 in. (2.03 mm) .063 in. (1.60 mm) .091 in. (2.31 mm) .063 in. (1.60 m m)
valve lip :
Use again m inim um
thickness .059 in. (1.50 mm) .043 in. (1.09 m m) .070 in. (1.78 mm) .043 in. (1.09 mm)

(5) Angle o f valve face: 30° ± 15’ 45° ± 15' 30° ± 15' 45° ± 15'

(6) Diameter o f valve head: 1.895 ± .005 in. 1.804 ± .005 in. 2.094 ± .005 in. 1.804 ± .005 in.
(48.13 ± 0.13 mm) (45.82 ± 0.13 mm) (53.19 ± 0.13 mm) (45.82 ± 0.13 mm)

N O TE: FOR TORQUE V A L U E S N O T G IV E N , SEE THE FIRST

18 PAGE OF SPECIFICATIONS FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U L A R ENGINE SPECIFICATIONS

V A L V E S EAT S AN D INSERTS
(FOR PC ENGINES)

EXHAUST VA LV E

(1) Distance from the end o f the valve to the valve

spring washer seat 2.147 ± .020 in. (54.53 ± 0.51 mm)
(2) Depth o f bore in head fo r valve
seat insert .............................. 3420 ± .0035 in. (8.686 ± 0.088 mm)

(3) Diameter o f valve seat

in s e r t ...... 1.9120 ± .0005 in. (48.565 ± 0.013 mm)

Bore in head fo r valve seat

in s e r t ..... 1.9090 ± .0005 in. (48.489 ± 0.013 mm)

(4) M axim um permissible w id th o f the face o f

the valve seat insert 105 in. (2.67 m m)

(5) Angle o f the face o f the valve seat in s e r t ................ 45%° ± Vi°
(6) Outside diameter o f the face o f the valve
seat insert ......................................................... 1.735 in. (44.07 mm)
M aximum permissible ................................... 1.760 in. (44.70 mm)

(7) Angle to grind face o f seat insert (to get a reduction

of m axim um seat diameter) ......................................................... 15°

(8) Distance fro m head o f the valve to cylinder

head face 040 in. (1.02 mm)

M aximum permissible (valve closed) 050 in. (1.27 mm)

M inim um permissible (valve closed) 015 in. (0.38 mm)

INTAKE VA LV E

(1) Distance fro m the end o f the valve to the valve

spring washer seat 2.147 ± .020 in. (54.53 ± 0.51 mm)
(2) M axim um permissible w id th o f the face
o f the valve seat 120 in. (3.05 mm)

(3) Angle o f the face of the valve s e a t 30’/2° ± Vi°

(4) Outside diameter o f the valve seat ............ 1.858 in. (47.19 mm)
M aximum permissible .................................... 1.878 in. (47.70 mm)
(5) Diameter o f the bore 2.00 in. (50.8 mm)

(6) Distance fro m head o f valve to cylinder

head face 050 in. (1.27 mm)

M axim um permissible (valve closed) 060 in. (1.52 mm)

M inim um permissible (valve closed) 025 in. (0.64 mm)

(7) M axim um permissible depth o f the bore to make

the face o f the valve seat s m a lle r 062 in. (1.57 mm)

19
3204 V E H IC U L A R ENGINE SPECIFICATIONS

V A L V E S EAT S A N D INSERTS
(FOR Dl ENGINES)

INTAKE VA LV E (w ithout valve seat insert)

(1) Distance from head o f valve to cylin d e r head face:

M axim um permissible (valve closed) 068 in. (1.73 mm)

M inim um permissible (valve c lo s e d ) 036 in. (0.91 mm)

(2) M axim um permissible w id th o f the face

o f the valve s e a t 120 in. (3.05 mm)

(3) Outside diameter o f the valve

seat 2.045 ± .005 in. (52.23 ± 0.13 mm)
M axim um permissible 2.065 in. (52.45 mm)

(4) Angle o f the face o f the valve s e a t 30/4 ± 14°

(5) Diam eter o f the b o r e ........................................ 2.150 in. (54.61 mm)

(6) M axim um permissible depth o f the bore to make the

face o f the valve seat s m a lle r 170 in. (4.32 mm)

INTAKE VA LV E (with valve seat insert)

(1) Diameter o f the valve seat
in s e r t 2.1500 ± .0005 in. (54.610 ± 0.013 mm)

(2) Bore in head fo r valve seat

in s e r t 2.1470 ± .0005 in. (54.534 ± 0.013 mm)
Depth o f bore in head fo r valve
seat insert 442 ; .002 in. (11.23 ± 0.05 mm)
(3) M axim um permissible w id th o f the face
o f the valve seat in s e r t 120 in. (3.05 mm)
(4) Distance from head o f valve to cylinder head face:
M axim um permissible (valve closed) 068 in. (1.73 m m)
M inim um permissible (valve c lo s e d ) 036 in. (0.91 mm)
(5) Angle o f the face o f the valve seat in s e r t 3054 ± 54°

(6) Outside diameter o f the face of the

valve seat in s e r t 2.045 ± .005 in. (52.23 ± 0.13 mm)
M axim um permissible 2.065 in. (52.45 mm)
(7) Angle to grind face o f seat insert (to get a reduction
o f m axim um seat d ia m e te r).............................................................. 15°

N O TE: FOR TORQUE V A L U E S N O T G IV E N , SEE THE FIRST

20 PAGE OF S PEC IFIC ATIO N S FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U L A R ENGINE SPECIFICATIONS

Valve Seats and Inserts

(For Dl Engines) (Cont.)

EXHAUST VALVE

(1) Depth o f bore in head fo r valve

seat insert ..................... 442 ± .005 in. (11.23 ± 0.13 mm)
(2) Diameter o f valve
seat insert ....................... 1.9120 ± .0005 in. (48.565 ± 0.013 m m)
(3) Bore in head fo r valve
seat insert ........................ 1.9090 ± .0005 in. (48.489 ± 0.013 mm)

M aximum permissible w id th of the face

o f the valve seat in s e r t 105 in. (2.67 mm)
(4) Distance from head of valve to cylinder head face:

M aximum permissible (valve closed) 085 in. (2.16 mm)

M inim um permissible (valve c lo s e d ) 050 in. (1.27 mm)
(5) Angle o f the face o f the valve seat in s e r t 45V4 ± !4°
(6) Outside diameter o f the face o f the
valve seat in s e r t ..................... 1.735 ± .005 in. (44.07 ± 0.13 mm)
M axim um permissible ...................................... 1.760 in. (44.70 mm)
(7) Angle to grind face o f seat insert (to get a reduction
o f m axim um seat d ia m e te r).............................................................. 15°

V A L V E COVER

5 4

A50698X1

T IG H T E N IN G SEQUENCE FOR D l ENGINE

T IG H T E N IN G SEQUENCE FOR PC ENGINE

T ig h te n b o lts in se q u en ce show n
to a to rq u e o f ...................................... 10 ± 2 lb. ft. (14 ± 3 N-m )
3204 V E H IC U LA R ENGINE SPECIFICATIONS

C Y L I N D E R HEAD
(PC ENGINE)

(1) Put 5P3931 A n ti-S e iz e C o m p o u n d on b o lt threads and tig h te n

b o lts a c c o rd in g to th e H EA D B O LT C H A R T th a t fo llo w s:

HEA D BO LT C H A R T
A50901X1 DASH M ARKS

‘ E A R L IE R BOLTS ♦LATER BOLTS

Tightening Procedure (w ith six dash marks) (w ith seven dash marks)

Step 1. Tighten bolts 1 th ru 18 in 60 ± 10 lb. ft. 60 ± 10 lb. ft.

number sequence to: (80 ± 14 N m) (80 + 14 N-m)

Step 2. Tighten bolts 1 thru 18 in 95 ± 5 lb. ft. 110 ± 5 lb. ft.

number sequence to: (130 ± 7 N-m) (150 ± 7 N-m)

Step 3. Again tighten bolts 1 thru 18 95 ± 5 lb. ft. 1 1 0 + 5 lb. ft.

in number sequence to: (130 ± 7 N-m) (150 ± 7 N-m)

*See BOLT HEAD IDENTIFICATION p ictu re s for EARLIER E A R LIE R LATER

and LATER id e n tifica tion . (six dash marks) (seven dash marks)

Torque for head bolts 19 th ru 22 32 ± 5 lb. ft. BOLT H E A D ID E N T IF IC A T IO N

(tighten in num ber sequence to) (43 ± 7 N-m)

(2) Seat fo r valve spring.

(3) Thickness o f cylinder head from b o tto m of valve spring seat (2):

N e w ........................................... 3.740 ± .005 in. (94.30 ± 0.13 mm)

M inim um permissible th ic k n e s s ..................... 3.724 in. (94.59 mm) 3

SECTION A -A

NO TE: FOR TORQUE V A L U E S N O T G IV E N , SEE THE FIRST

22 PAGE OF SPECIFICATIO NS FOR G E N E R A L T IG H T E N IN G TORQUES
 3204 V E H IC U LA R ENGINE SPECIFICATIONS

C Y L I N D E R HEAD
(Dl ENGINE)

2
HEA D BO LT LO C ATIO N AN D T IG H T E N IN G SEQUENCE

* ------L --------H
HEAD BOLT
LOCATION CHART u iiiiiiil!)
B o lt Length " L "
Dia. Part No. Location (B o lt No.)
in. mm
1D 4572 5, 2, 4, 10 5.50 139.7
2H 6488 7, 9, 3, 1, 6, 8 5.00 127.0
1 /2 "
L1329 16, 14, 12, 17 3.00 76.2
(1) Put 5P3931 A n ti-S e ize C o m p o u n d on b o lt th re a d s and tig h te n 2B947 18, 11, 13, 15 2.25 57.2
b o lts a c c o rd in g to th e p ro ce d u re th a t fo llo w s: 5B9603 20,21 5.00 127.0
Step 1. Tighten bolts 1 th ru 18in 3 /8 ” 1A5964 19 4.50 114.3
number sequence t o 60 ±10 lb. ft . (80 ±14 N-m) S1571 22 1.75 44.5
Step 2. Tighten bolts 1 th ru 18 in
number sequence t o 110 ± 5 lb. ft. (150 ± 7 N-m)
Step 3. Again tighten bolts 1 th ru 18 in
number sequence t o 110 ± 5 lb. f t . (150 ± 7 N-m)

Step 4. Tighten bolts 19 th ru 22 in

number sequence t o 32 ± 5 lb. ft. (43 ± 7 N-m)

(2) Holes fo r fuel injection nozzles.

C (3) T h ic k n e s s o f c y lin d e r head [m easure th ro u g h th e fuel in je ctio n

nozzle holes at each end o f the c y lin d e r head].
N e w .......................................... 3.785 ± .006 in. (96.14 ± 0.15 m m)

M in im u m p e rm is sib le th ic k n e s s 3.774 in. (95.86 m m)

SECTION A -A

EXHAUST MANIFOLD

(1) A t assem bly, put 5P3931 A n ti-S e ize Com pound on m anifold
m o u n tin g bolts.
3204 V E H IC U LA R ENGINE SPECIFICATIONS

MUFFLER

(1) M u ffle r o u tle t.

NOTE: Do not tighten clamp bolts (2) u n til head is installed and
m u ffle r o u tle t is positioned in center o f opening in hood.

(2) Tighten to a torque o f 18 ± 5 lb. ft. (24 ± 7 N-m)

OIL PUMP
(1) C le a ran ce o f o il p u m p gear
ro to r tip .........................................002 to .008 in. (0.05 to 0.20 m m)

M axim u m p e rm is s ib le cle a ra n ce o f oil

pu m p gear ro to r tip .............................................. 011 in. (0.28 m m)
(2) 9L9243 Spring fo r relief valve:

Length under test f o r c e 2.529 in. (64.24 mm)

Test force ......................................................... 39 ± 2 lb. (175 ± 9 N)

Free length after t e s t ............................................. 3.50 in. (88.9 mm)

Outside d ia m e te r......................................................875 in. (22.23 mm) VIEW A -A OF

.ROTOR O IL PUMP
Oil pressure measured at oil m anifold [SAE 30 oil at 200 ± 10° F (93
± 6° C)] :

H igh idle .................................................. 70 ± 10 psi (480 ± 70 kPa)

Low idle m inim um 15 psi (105 kPa)
(3) F ro n t housing assembly.
(4) Oil pump cover assembly.

(5) D iam eter of bearing for

roto r ( n e w ) 2.8041 ± .0 0 22 in. (7 1 .2 2 4 ± 0 .0 5 6 mm)
D iam eter of rotor
( n e w ) ........................... 2 .7 9 8 0 ± .0 0 05 in. (71 .0 6 9 ± 0 .0 1 3 mm)
(6) W id th of o il pum p rotors
( n e w ) ....................................8 7 3 0 ± .0 0 03 in. (2 2 .1 7 4 ± 0 .0 0 8 mm)
Depth ofco u n te rb o re in fro n t
housing ( n e w ) .878 ± .001 in. (22 .3 0 ± 0 .0 3 mm)
(7) M axim u m p e rm issible end clearance of oil pump
gears w h e n m easured w ith oil pum p in sta lle d to
fro n t c o v e r 0 0 6 in. (0.15 mm)

NOTE: FOR TORQUE V A L U E S NOT G IV E N , SEE THE FIR ST

PAGE OF SPECIFICATIO NS FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U LA R ENGINE SPECIFICATIONS

O IL F IL T E R B55821X1
(1 N 3 2 2 4 )

(1) 1N4425 S p rin g fo r bypass valve:

Length u n d e r te st f o r c e ................................... 1.9 in. (48.3 m m )

Test f o r c e .................................................. 4.6 ± .4 lb. (20.4 + 2 N)
Free le n g th a fte r t e s t ....................................... 2.20 in. (55.9 m m )
O u tsid e d ia m e t e r 457 in. (11.61 m m)

OIL PAN

(1) Torque fo r p lu g 50 ± 10 lb. ft. (70 ± 14 N-m)

GAUGE FOR OIL PRESSURE

5M1065 G auge:

O il pressure o f p o in te r p o sitio n s:

1 10 ± 2 psi (70 ± 14 kPa)

C h e ck
P oints 2 20 ± 2 psi (140 ± 14 kPa)

1W705 G auge:

O il p ressure o f p o in te r p o sitio n s:

1 10 ± 1 psi (70 ± 7 kPa)

C heck
P oints 2 20 ± 1 psi (140 ± 7 kPa)

OIL PRESS URE SWITCH

6N2466 Pressure Switch:

W ith an increase in pressure, switch

closes a t 21 ± 4 psi (145 ± 25 kPa)

W ith a decrease in pressure, switch

opens a t ............................................... 13 + 4 psi (90 ± 25 kPa) 9261 s x t
3204 V E H IC U LA R ENGINE SPECIFICATIONS

W ATER PUMP
(2W 12 23 )

(1) C le a ran ce betw een fro n t h o u sin g and

im p e lle r face v a n e s ....................011 to .033 in. (0.28 to 0.84 m m)
(2) T o rq u e fo r n u t w ith 9S3263 c o m p o u n d
on th r e a d s ....................................... 125 ± 11 lb. ft. (170 ± 15 N-m)

(3) D ista n ce fro m m o u n tin g face o f th e w a te r pum p

to gage d ia m e te r (A) on im p e lle r
v a n e s .......................................... 1.990 ± .005 in. (50.55 ± 0.13 m m )
G age d ia m e te r (A) ......................................... 3.000 in. (76.20 m m)

WATER PUMP
(7N 9001 and 8 N 8 2 7 0 )

(1) Clearance between fro n t housing and

im peller face vanes....................... 011 to .033 in. (0.28 to 0.84 mm)

(2) Distance from endo f housing to end o f seal

(w orking height) ..........................505 ± .005 in.(12.83 ± 0.13 mm)

(3) Torque fo r b o l t 55 ± 5 lb. f t. (75 ± 7 N-m)

(4) Distance from m ounting face o f the water pum p

to gage diameter (A) on impeller
vanes 1.990 ± .005 in. (50.55 ± 0.13 mm)
Gage diameter (A) ............................................. 3.000 in. (76.20 mm)

WA T ER PUMP
(4 N 4 5 5 )

(1) Clearance between fro n t housing and im peller

face vanes .......................................011 to .035 in. (0.28 to 0.89 mm)

(2) Distance from m ounting face o f the

water pump to gagediameter (A) on
im peller vanes 1.990 ± .010 in. (50.55 ± 0.25 mm)
Gage diameter ( A ) ............................................. 3.000 in. (76.20 m m)

NOTE: See Special Instruction Form SMHS7090 fo r water pum p

reconditioning procedures.

N O TE: FOR TORQUE V A L U E S NOT G IV E N , SEE THE FIRST

26 PAGE OF SPECIFICATIO NS FOR G E N E R A L T IG H T E N IN G TORQUES
 3204 V E H IC U LA R ENGINE SPECIFICATIONS

C GAUGES FOR WA T ER T EM PE R A T U R E
(7M7866 for 910)
(1S1161 for D 3 & 931)

7M5827 fo r L a ter 910:

7M5828 fo r D3B & 931B:

W afer te m p e ra tu re at p o in te r p o sitio n s:

1 149 to 171° F (65 to 77° C)

C h e ck
P oints 2 255 to 258° F (124 to 126° C)

7M7866 fo r 910:
1S1161 fo r D3 & 931:

W ater te m p e ra tu re at p o in te r p o sitio n s:

1 151 to 162° F (66 to 72° C)

C h e ck
P oints 2 219 to 226° F (104 to 108 C)

WA TER T E M P E R A T U R E R EG U LA TO R
AND WA T ER LINES

(1) 4N236 Water Temperature Regulator (Therm ostat):

Temperature when com pletely open ........................ 192° F (89° C)

M inim um opening distance ......................................260 in. (6.60 mm)

NOTE: Install regulator w ith vent hole at top.
(2) Torque fo r c la m p ............................... 52 ± 5 lb. in. (5.9 ± 0.6 N m)

NOTE: Install clamp w ith adjusting screw toward the to p and

approxim ately 45° to the right o f vertical (as seen from the fro n t o f the
engine).
NOTE: Seal must be installed all the way in to the counterbore before
clamp is tightened.

COOLING S Y S TE M PR ESS UR E CAP

Cap must not leak at 6.5 psi (45 kPa)

Cap must be open a t 8 psi (55 kPa)

27
3204 V E H IC U L A R ENGINE SPECIFICATIONS

C Y L I N D E R BLOCK

N O TE: T h is e n g in e does n o t use p isto n c o o lin g jets. If a re p la ce ­

m en t e n g in e has p isto n c o o lin g jets, rem ove the jets and insta ll
fo u r 7M 4593 Plugs.

( 1) Bore in the camshaft bearings M aximum permissible wear of cylinder bores (replacement
( n e w ) ............................ 2.5035 ± .0015 in. (63.589 ± 0.038 mm) o f the cylinder b lo ck is necessary) 4.548 in. (115.52 mm)

(2 ) NOTE: See numbers 7 and 8 before installing camshaft bearings. (7) Bearing ju n ctio n .
Install bearings to the fo llo w in g positions from fro n t face o f (8) O il hole in camshaft bearing. Bearings must be positioned as
block: shown w ith bearing ju n ctio n above horizontal and oil hole to the
A ................................................................ 03 ± .03 in. (0.8 ± 0.8 mm) le ft and 30° below horizontal centerline.

B 1.12 ± .03 in. (28.4 ± 0.8 mm) (9) Bore in the block fo r the main bearings:

C .................................................. 11.32 ± .03 in. (288.6 ± 0.8 mm) Standard, original size
( n e w ) ............................ 3.7075 : .0005 in. (94.171 ± 0.013 mm)
D 21.92 ± .03 in. (557.8 ± 0.8 mm)
.010 in. (0.25 mm) larger than
(3) Bore in block fo r camshaft original s iz e ................. 3.7175 ± .0005 in. (94.424 0.013 mm)
b e a rin g s........................ 2.6525 ± .0005 in. (67.373 ± 0.013 mm)
(10) Distance from centerline of crankshaft
(4) Torque fo r stud fo r o il filte r 50 10 lb. ft. (70 ± 14 N-m) to pan rails (n e w ) ................. 3.750 ± .004 in. (95.25 ± 0.10 mm)

(5) Distance from centerline o f crankshaft to top (11) C le arance betw een m ain bearing caps and
o f block (new) . . . . 12.7030 ± .0065 in. (322.656 ± 0.165 mm) c y lin d e r b lo ck 0008 in. (0.020 m m) tig h t to
Measure wear o f the cylinder bore at the top and b o tto m o f .0012 in. (0.030 m m ) loose
(6 )
piston ring travel. (12) T o rq u e fo r b o lts h o ld in g caps fo r m ain bearings:
Cylinder bore [standard, original Install the m ain b e aring caps w ith the pa rt n um bers to w a rd the
size] ..................................... 4.501 ± .001 in. (114.32 ± 0.03 mm) fro n t o f th e e ngine. In sta ll each cap in the c o rre c t p o s itio n by
The recommendation is made to make the p u ttin g the n u m b e r stam ped on the b o tto m o f th e cap to w a rd
cylinder bore the next size larger when the c o rre s p o n d in g n u m b e r on the c y lin d e r block.
the size o f the bore i s .................................... 4.506 in. (114.45 mm) a. Put 2P2506 T hre a d L u b ric a n t on th e th re a d s o f th e bolts.
Cylinder bore must be made the next size b. T ig h te n th e b o lts firs t on th e tab
larger when the size o f the bore i s ............ 4.508 in. (114.50 mm) side o f th e cap to 45 ± 4 lb. ft. (61 ± 6 N-m)
C ylinder bore [.020 in. (0.51 m m) larger than the c. T ig h te n th e b o lts on the
original size] ....................... 4.521 ± .001 in. (114.83 ± 0.03 mm) o p p o s ite sid e t o 45 ± 4 lb. ft. (61 ± 6 N-m)

The recommendation is made to make the d. Put a m ark on each b o lt and cap as show n.
cylinder bore the next size larger when the
e. T ig h te n th e b o lts on th e o p p o s ite side,
size o f the bore i s 4.526 in. (114.96 mm)
fro m th e m a r k .................................................................. 60° ± 5°
C ylinder bore must be made the next size larger when
f. T ig h te n th e b o lts on th e tab side of
the size o f the bore i s 4.528 in. (115.01 mm)
th e cap, fro m th e m ark ......................................... 60° ± 5°
C ylinder bore [.040 in. (1.02 mm) larger than the original
size] ................................... 4.541 ± .001 in. (115.34 ± 0.03 mm)

N O TE: FOR TORQUE V A LU E S N O T G IV E N , SEE THE FIRST

28 PAGE OF SPEC IFIC ATIO N S FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U LA R ENGINE SPECIFICATIONS

CONNECTING ROD

Dl CO NNECTING ROD WITH

(1) Bore in connecting rod fo r piston
TAPERED PIN END
pin b e a rin g ..................... 1.6255 ± .0005 in. (41.288 ± 0.013 mm)

T igh t f it between connecting rod eye

and piston pin bearing . . .0025 to .0045 in. (0.064 to 0.114 mm)
NOTE: Connecting rod must be heated fo r installation o f piston pin
bearing. Do not use a torch.

Heat connecting rod to

temperature of (m a x im u m )...................................... 400° F (215° C)
NOTE: Piston pin bearing ju n ctio n and locating notch must be
assembled in the top half o f rod eye. Bearing ju n ctio n can be located at
either position " A " above centerline.
Make reference to Special Instruction Form SMHS7295 fo r use o f pin
bearing removal and installation tools and procedure.
(2) Bore in connecting rod fo r bearing w ith nuts tightened to
specifications ( 6 ) ......... 2.9418 ± .0005 in. (74.721 ± 0.013 mm)

(3) Distance between center o f

b e a rin g s 7.900 ± .001 in. (200.66 ± 0.03 mm)

(4) Bore in bearing fo r piston

pin ( n e w ) ........................ 1.5010 ± .0003 in. (38.125 ± 0.007 mm)
PC CO NNECTING ROD WITH
Diameter o f piston pin • S T R A IG H T PIN END
( n e w ) ............................... 1.4999 ± .0002 in. (38.097 ± 0.005 mm)

Maximum permissible clearance between

bearing and piston pin ( w o r n ) 003 in. (0.08 mm)

(5) Bore in bearing fo r crankshaft bearing surface

(journal) ................................. 2.753 ± .001 in. (69.97 ± 0.03 mm)

Clearance b etw een bearing and cra n ksh a ft bearing

surface (jo u rn a l) .............. 0 0 1 8 to .0 0 54 in. (0.046 to 0 .1 3 7 m m)
M aximum permissible clearance between bearing
and crankshaft bearing surface (journal) 007 in. (0.18 mm)

(6) T ig h te n in g p ro c e d u re fo r co n n e c tin g rod bolts:

a. Put 2P2506 T hread L u b ric a n t on b o lt thre a d s and c o n ta c t
su rfa ce s o f nut and cap.
b. T ig h te n both nuts t o 30 ± 3 lb. ft. (40 ± 4 N-m)

c. Put a m ark on each n u t and end of bolt.

d. T ig h te n each nut fro m m ark ....................................... 60° ± 5°

Make reference to Special Instruction Form Nos. G M G02394 &
GMG02395 fo r info rm a tio n about checking and reconditioning con­
necting rods.

29
3204 V E H IC U L A R ENGINE SPECIFICATIO NS

PISTONS AN D RINGS

(1) Clearance between to p ring

and g ro o v e 0030 to .0055 in. (0.076 to 0.140 mm)
Replacement needed a t .............................................. 011 in. (0.28 mm)
M aximum permissible clearance............................... 014 in. (0.36 m m)

(2) Clearance between oil ring

and g ro o v e 0015 to .0035 in. (0.038 to 0.089 mm)
Replacement needed a t ..............................................006 in. (0.15 m m)
M axim um permissible clearance............................... 008 in. (0.20 mm)

(3) Bore in piston

fo r p i n ..................... 1.5005 to 1.5009 in. (38.113 to 38.123 mm)

M axim um permissible clearance between

piston pin and bore in p is to n 003 in. (0.08 mm)

(4) Top ring:

Clearance between ends of
piston r i n g ............................... 0225 ± .0075 in. (0.572 ± 0.191 mm)

Ring needs replacement when clearance i s 045 in. (1.14 mm)

M aximum permissible clearance

(replacement o f ring necessary) 055 in. (1.40 mm)
NOTE: Clearance is measured between ends o f piston ring w hile piston
ring is installed in the part o f the cylinder bore th a t has no wear.

(5) Oil ring: TOP V IE W OF PISTON

Clearance between ends o f (D l ENGINE)
piston r i n g ........................................ 020 ± .010 in. (0.51 ± 0.25 mm)

Ring needs replacement when clearance i s 038 in. (0.97 mm)

M axim um permissible clearance

(replacement of ring n ecessary) 045 in. (1.14 mm)

(6) Installation o f piston to connecting rod:

Dl Engine:
Bearing tab slots (6) o f connecting rod m ust be on same
side as piston crater (7).

PC Engine:
Bearing tab slots (6) o f connecting rod m ust be on same
side as piston valve pockets (8).

(7) Installation o f piston and connecting rod group in engine:

Dl Engine:
Craters (7) o f pistons m ust be installed tow ard camshaft
side o f engine. A 7 3 3 1 5X1
PC Engine:
TOP VIEW OF PISTON
Valve pockets (8) o f pistons must be installed toward (PC ENGINE)
camshaft side o f engine.

N O TE: FOR TORQUE V A LU E S N O T G IV E N , SEE THE FIRST

30 PAGE OF SPECIFICATIO NS FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U LA R ENGINE SPECIFICATIONS

CRANKSHAFT

gear to install. Do not heat to a tem perature o f more than 600° F

3 * 5= C l.
End play fo r the
c ra n k s h a ft 0025 to .0190 in. (0.064 to 0.483 mm)

V ;< im u m permissible end play for

■e c r a n k s h a ft............................................................. 035 in. (0.88 mm)
Tn ckness o f th ru s t plates (new):

W ith o u t tabs
6 N 8 9 4 0 ................................1850 ± .0015 in. (4.699 ± 0.038 m m)

W ith tabs
7 N 9 3 4 2 ................................2150 ± .0015 in. (5.461 ± 0.038 m m)
1 D ameter of the surfaces (journals) fo r the connecting rod bearings:

Standard, original size

new) 2.7497 ± .0008 in. (69.842 ± 0.020 mm)

- or bearings .010 in. (0.25 mm) smaller than

or ginal s iz e 2.7397 ± .0008 in. (69.588 ± 0.020 mm)

Fof bearings ,020 in. (0.51 m m) sm alle r than

o riginal s iz e ............... 2 .7 2 9 7 ± .0 0 0 8 in. (6 9 .3 3 4 ± 0 .0 2 0 m m)

a r t 'eference to G U ID E L IN E S FOR REUSABLE PARTS: M A IN

S E -= iN G S AN D CO NNECTING ROD BEARING S, Form No.
5£5F8009.
I 3 s n e te r o f the surfaces (journals) fo r the main bearings:

Standard, original size

new) 3.4992 ± .0008 in. (88.880 ± 0.020 mm)
-z- bearings .010 in. (0.25 mm) smaller than
cnginal s iz e 3.4892 ± .0008 in. (88.626 ± 0.020 mm)

- 0 ’ bearings .020 in. (0.51 m m) smaller than

c-g in a lsize ................... 3.4792 ± .0008 in. (88.372 ± 0.020 mm)

Clearance between main bearings and

r-s -k s h a ft ( n e w ) 0030 to .0066 in. (0.076 to 0.167 mm)

'.'axim um permissible clearance between

— s m bearings and c ra n k s h a ft................................... 010 in. (0.25 mm)

a-e reference to Special Instruction Form No. SEHS6713 fo r

see-; ■ cations fo r crankshaft reconditioning, and Guideline fo r Reusable
- a - i ; crm No. SEBF8030 fo r procedure to measure bent crankshafts.

A c ear wear sleeve:

= *move wear sleeve w ith 5P7318 D istorter Group,

install rear wear sleeve as follow s:

a Clean the inner surface of the sleeve and the outer surface of
the crankshaft w ith 8M 8060 Q uick Cure Primer.

c Put 9S3265 Retaining Compound on the cleaned surfaces.

c. Install the sleeve on the crankshaft, w ith the chamfer on the
outside.
VC TE See Special In stru ctio n Form SMHS7100 fo r the necessary
- :o e and complete procedure fo r installation of rear wear sleeve and
fro n t and rear seals.

31
3204 V E H IC U LA R ENGINE SPECIFICATIONS

BEARING S UR F A C E (JOURNAL)
FOR CONNECTING RODS

BEARING SURFACE (JOURNAL) FOR CONNECTING RODS

O R IG IN A L .0 1 0 in. (0 .2 5 m m ) .0 2 0 in. (0.5 1 m m )

SIZE U N D E R S IZ E U N D E R S IZ E
(S M A L L E R ) (S M A L L E R )
JO U R N A L JO U R N A L

(A) Diameter o f crankshaft 2.7497 ± .0008 in. 2.7397 ± .0008 in. 2.7297 ± .0008 in.
journal (bearing surface) (69.842 ± 0.020 mm) (69.588 ± 0.020 mm) (69.334 ± 0.020 m m)
fo r connecting rod.

Surface finish on 10 m icro inches or smoother

diameter o f journal (0.25 m icrom etre)

*(B) Radius .200 ± .008 in.

(5.08 ± 0.20 mm)

Surface finish 63 m icro inches or smoother

in radius (1.6 micrometres)

(C) W idth o f journal 1.660 ± .003 in.

(42.16 ± 0.08 mm) -

'R adius (B) must blend sm oothly (have no sharp edges) w ith the machined surfaces o f the journals.

NOTE: FOR TORQUE V A L U E S N O T G IV E N , SEE THE FIRST

32 PAGE OF SPECIFICATIO NS FOR G E N E R A L T IG H T E N IN G TORQUES
2204 V E H IC U LA R ENGINE SPECIFICATIONS

BEAR IN G S U R F A C E (JOURNAL)
FOR M A I N BEAR IN GS

BEARING SURFACE (JOURNAL) FOR MAIN BEARINGS

O R IG IN A L .0 1 0 in. (0 .2 5 m m ) .0 2 0 in. (0 .5 1 m m )
SIZE U N D E R S IZ E U N D E R S IZ E
JO U R N A L (S M A L L E R ) (S M A L L E R )
JO U R N A L JO U R N A L

(D) Diameter of 3.4992 ± .0008 in. 3.4892 ± .0008 in. 3.4792 ± .0008 in.
all journals (88.880 ± 0.020 mm) (88.626 ± 0.020 mm) (88.372 ± 0.020 mm)

Surface
finish 10 m icro inches or smoother
on diameter (0.25 m icrom etre)
o f journal

*(E) Radius .200 ± .008 in.

(5.08 ± 0.20 mm)

Surface finish 63 m icro inches or smoother

in radius (1.6 micrometres)

(F) W idth o f all journals 1.4600 ± .0025 in.

(37.080 ± 0.064 mm)

| Surface finish 18 m icro inches or smoother

on th ru st faces (0.46 m icrom etre)
o f center journal

'R adius must blend sm oothly (have no sharp edges) w ith the machined surfaces o f the journals.

33
3204 V E H IC U LA R ENGINE SPECIFICATIONS

ENGINE SUPPORTS

(11 Torque fo r three bolts in A25577X1

each support 90 ± 10 lb. ft . (120 ± 14 N-m)

FLYWHEEL
[4 N 1 8 4 and 7 N 6 9 3 7 )

Maximum temperature of ring gear,

fo r installation 400° F (204° C)

Install gear w ith part number to outside.

(1) M axim um permissible "e c c e n tric ity " (change
in distance from center o f bore) during one
ro ta tio n (total indicator re a d in g )............................006 in, (0.15 mm)

(2) Torque fo r the bolts th a t hold the flywheel

to the c ra n k s h a ft 55 ± 5 lb. ft. (75 ± 7 N-m)

(3) M aximum permissible "e c c e n tric ity " (change

in distance from center o f bore) during one
rota tio n (total indicator re a d in g )............................005 in. (0.13 mm)

(4) M axim um permissible face "ru n o u t" (change

from an exact vertical face) during one rotation
(total indicator re a d in g )............................................ 006 in. (0.15 mm)

FLYW HEEL H O U SIN G

A25783X1

4N183 H o u sin g 7N6344 H ousing

(1) T o rq u e fo r bolts:
4N183 H o u sin g 10 b o l t s
7N6344 H o u s in g 12 b o lt s
(2) M axim u m p e rm issib le face "ru n p u t" (cha n g e from
an e xa ct v e rtica l face) at 4 p o in ts (to ta l in d ic a to r
41 ± 4 lb. ft. (55 ± 5 N-m )
r e a d in g ) .'........................... 012 in. (0.30 m m)
65 ± 11 lb. ft. (90 ± 1 5 N-m )

NO TE: FOR TORQUE V A LU E S N O T G IV E N , SEE THE FIRST

34 PAGE OF SPECIFICATIO NS FOR G E N E R A L T IG H T E N IN G TORQUES
; : : 4 V E H IC U LA R ENGINE S PECIFICATIO NS

C (T O P )

FL Y WH EE L HOUSING BORE

•.7TE Write the dial indicator measurements w ith th e ir positive (+)

n -egative (—) no tatio n (signs). This no tatio n is necessary fo r making
—e calculations in the chart correctly.
' A ith the dial indicator in position at (C), adjust the dial indicator
to " 0 " (zero). Push the crankshaft up against the to p bearing. W rite
the measurement fo r bearing clearance on line 1 in colum n (C).
I Divide the measurement fro m Step 1 by 2. W rite this number on A (B O T T O M )
•re 1 in columns (B) & (D).
I " j r n the crankshaft to p u t the dial indicator at (A). Adjust the dial
-d ic a to r to " 0 " (zero).
± _ jr n the crankshaft counterclockwise to put the dial indicator at
5 W rite the measurement in the chart.
: ~ jr n the crankshaft counterclockwise to p u t the dial indicator at
C)_. W rite the measurement in the chart.
z ~ jr n the crankshaft counterclockwise to put the dial indicator at
2 W rite the measurement in the chart.

7 Add lines I & II by columns.

3 Subtract the smaller number from the larger number in line III in
columns (B) & (D ). The result is the horizontal "e c c e n tric ity ” (out
-ound). Line III, colum n (C) is the vertical eccentricity.

C HAR T FOR D IA L IN D IC A TO R M EASUREM ENTS

Position o f
dial indicator

Line
No. A B C D

C orre c tion fo r bearing clearance 1 0

D ia l In d ic a to r R e a d in g II 0

■'otal o f L in e 1 & 2 III 0 » **

•T otal V ertical eccentricity (ou t o f ro u n d !.

• • Su b tra ct the sm aller N o. fro m the larger No. T h e difference is
:ne total h o rizo n ta l eccentricity.
A10234X1

} the graph fo r to ta l eccentricity fin d the p o in t o f intersection of

••*= nes fo r vertical eccentricity and horizontal eccentricity.

' Z ■ •~e p o in t o f in te rs e c tio n is in th e range m arked "A c c e p ta b le ”

••e bore is in a lig n m e n t. If th e p oint of in te rse ctio n is in the
-e-'ge m arked "N o t A c c e p ta b le " th e fly w h e e l hou sin g m ust
be changed
(0 .0 5 ) (0 .1 0 ) (0 .1 5 ) (0 .2 0 ) (0 .2 5 ) (0.301 mm
3204 V E H IC U L A R ENGINE SPECIFICATIONS

FL Y WH EE L HOUSING RUNOUT 8S2328 D IA L IN D IC A T O R GROUP IN S T A L L E D

C (T O P )

Face Runout (axial eccentricity) o f the Flywheel Housing:

1. Fasten a dial indicator to the crankshaft flange so the anvil of the

indicator w ill touch the face o f the flyw heel housing.

2. Put a force on the crankshaft to w a rd the rear before reading the

indicator at each po in t.

3. W ith dial indicator set at .000 in. (0.00 m m) at location (A ), tu rn

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

4. The difference between lower and higher measurements taken at all

fo u r points must not be more than .008 in. (0.20 m m ), which is the
m axim um permissible face run o u t (axial e ccentricity) o f the
flyw heel housing.

NO TE: FOR TORQUE V A L U E S N O T G IV E N , SEE THE FIR ST

36 PAGE OF SPECIFICATIO NS FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U L A R ENG INE SPECIFICATIONS

F L YWHE EL RUNOUT

Face Runout (axial e ccentricity) o f the Flywheel:

1. Install the dial indicator as shown. Put a force on the flywheel

tow ard the rear.

2. Set the dial indicator to read .000 in. (0.00 m m).

3. Turn the flyw heel and read the indicator every 90°. Put a force on
the flyw heel to the rear before each reading.

4. The difference between the lower and higher measurements taken

at all fo u r points m ust not be more than .006 in. (0.15 m m), which
is the m axim um permissible face runout (axial e ccentricity) o f the
flyw heel. C HECKING FACE RUNO UT OF THE FLY W H EE L

CHECKING FLY W H E E L BORE

Bore Runout (radial e ccentricity) o f the Flywheel:

1. Install the dial in d ica to r (3) and make an adjustment o f the

universal attachm ent (4) so it makes contact as shown.

2. Set the dial indicator to read .000 in. (0.00 m m ).

3. T urn the flyw heel and read the indicator every 90°.

4. The difference between the lower and higher measurements taken

at all fo u r points must n o t be more than .006 in. (0.15 m m ), which
is the m axim um permissible bore run o u t (radial e ccentricity) o f the
flyw heel.

5. Runout (eccentricity) o f the bore fo r the p ilo t bearing fo r the CHECKING FLY W H E E L CLUTCH
flyw heel clutch, must not exceed .005 in. (0.13 m m ). P ILO T B E A R IN G BORE

37
3204 V E H IC U L A R ENGINE S PECIFICATIO NS

A L T E R N A T O R IN S T A L L A T IO N
(4 N 4 5 4 0 a n d 7N 6118 A lte rn a to rs )

(1) T o rq u e fo r n u t h o ld in g
p u lle y 25 to 36 lb. ft. (35 to 46 N-m )

(2) T o rq u e fo r a d ju s tm e n t b o lt
( s ta n d a r d ) .............................................. 18 ± 5 lb. ft. (24 ± 7 N-m )

(3) T o rq u e fo r stra p s u p p o rt b o lt
(stan d a rd) .............................................. 32 ± 5 lb. ft. (43 ± 7 N-m )

(4) T o rq u e fo r leg bolts

(fina l, s ta n d a r d ) .................................... 32 ± 5 lb. ft. (43 ± 7 N-m)

(5) T o rq u e fo r s u p p o rt b o lts
( s ta n d a r d ) .............................................. 18 ± 5 lb. ft. (24 ± 7 N-m )
P ro ce d u re fo r a lte rn a to r in s ta lla tio n and co rre c t a lig n m e n t:

Step 1. Install a lte rn a to r and hardw are, but do n o t tig h te n bolts.

Step 2. Let the a lte rn a to r w e ig h t push all h a rd w a re dow n, and
tig h te n th e tw o s u p p o rt b o lts (5) and nuts.

Step 3. T ig h te n th e tw o leg b o lts (4) and nuts

to a p p ro x im a te ly .......................................... 15 lb. ft. (20 N-m )

Step 4. M ove th e a lte rn a to r to a d ju st the fan belt, and tig h te n the

tw o b o lts (2 and 3).
Step 5. T ig h te n th e tw o leg b o lts (4) and nuts at a lte rn a to r legs.

A L T E R N A T O R IN S T A L L A T IO N
(6 N 5 4 6 0 a n d 7N 47 84 A lte rn a to r)

(1) T o rq u e fo r n u t h o ld in g
p u lle y .................................................. 35 ± 10 lb. ft. (45 ± 1 4 N-m)

(2) T o rq u e fo r a d ju s tm e n t b o lt
(stan d a rd) .............................................. 18 ± 5 lb. ft. (24 ± 7 N-m)

(3) T o rq u e fo r strap s u p p o rt b o lt
(stan d a rd) .............................................. 32 ± 5 lb. ft. (43 ± 7 N-m )

(4) T o rq u e fo r leg bolts

(fina l, s ta n d a r d ) ................................... 32 ± 5 lb. ft. (43 ± 7 N-m )

(5) T o rq u e fo r s u p p o rt b o lts
(stan d a rd) .............................................. 18 ± 5 lb. ft. (24 ± 7 N-m )

P ro ce d u re fo r a lte rn a to r in s ta lla tio n and c o rre c t a lig n m e n t:

Step 1. Install a lte rn a to r and hardw are, but do n o t tig h te n bolts.
Step 2. Let th e a lte rn a to r w e ig h t push all hardw are dow n, and
tig h te n th e tw o s u p p o rt b o lts (5) and nuts.

Step 3. T ig h te n th e tw o leg b o lts (4) and nut

to a p p ro x im a te ly ......................................... 15 lb. ft. (20 N-m )
Step 4. M ove th e a lte rn a to r to a d ju st the fan belt, and tig h te n the
tw o b o lts (2 and 3).
Step 5. T ig h te n th e tw o leg b o lts (4) and n u t at a lte rn a to r legs.

N O TE: FOR TORQUE V A L U E S N O T G IV E N , SEE THE FIRST

38 PAGE OF SPECIFICATIO NS FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U L A R ENGINE SPECIFICATIONS

ALTERNATOR

A lte rn a to rs (N ip p o n d e n so )
V o lta g e R ating 12V
C a te rp illa r N u m be r 4N4540 '6 N 5 4 6 0 7N6118 "7 N 4 7 8 4
N ip p o n d e n s o N u m b e r 0210003030 0210004970 1002110010 1002110230
P o la rity N egative g ro u n d
R o ta tio n as seen fro m d rive end C lo ckw ise
at 1500 rpm 22.5A 17.5A 22.5 A
N o m in al O u tp u t
at 2500 rpm 33.0A 34.0A 30.0
(ho t) at 14V
at 3500 rpm 37.5A 38.5A 36.5
R esistance o f Field C o il
4.0 ohm s 6.4 ohm s 4.0 ohm s
(ro to r) at 68° F (20° C)
1 to 1.2 lb.
(1) T en sio n o f B rush S p ring
(4.4 to 5.3 N)
Standard .492 in.
(2) Brush Length (12.50 mm)
Length Service .217 in.
L im it (5.51 mm)
435 to 652.5 lb. in. 435 to 565.5 lb. in.
(3) T o rq u e P u lle y N ut
(49.2 to 73.7 N*m) (49.2 to 63.9 N-m)
S tandard 1.28 in. 1.654 in. 1.28 in.
D im e n sio n (32.5 mm) (42.01 m m) (32.5 m m)
(4) S lip Ring
O.D. Service 1.264 in. 1.638 in. 1.264 in.
L im it (32.11 mm) (41.61 m m ) (32.11 mm)

'U s e in place o f 4N 4540 w hen c o rro sive s are present.

" U s e in place o f 7N6118 w hen co rro sive s are present.

N O TE: Do n o t a tta ch c o n n e c to r fro m harness assem bly to a lte rn a to r
e x c e p t fo r a lte rn a to r te s tin g u n til ch a rg e d b a tte ry is in stalled.

39
3204 V E H IC U LA R ENGINE SPECIFICATIONS

ALTER N ATO R REGULATOR

R e g u la to rs fo r A lte rn a to rs (N ip p o n d e n so )

C a te rp illa r N ip p o n d e n so Voltage V o ltage Range

N um ber N u m be r R ating P o la rity at 3000 rpm

N egative
4N 5110 026000-2380 12V 13.5 to 14.5 V
g ro u n d

99763X 1

R e g u la tors fo r A lte rn a to rs (N ip p o n d e n so )

C a te rp illa r
N u m be r
N ip p o n d e n so
N u m be r
Voltage
R ating P o la rity Voltage Range* -H r hnJ,q -
7N5961 126000-0020 12V

*U se c o n s ta n t c u rre n t so u rce to test.

N egative
gro u n d
13.5 to 14.5 V
]
B12750X1

N OTE: FOR TORQUE V A L U E S NOT G IV E N , SEE THE FIRST

40 PAGE OF SPECIFICATIONS FOR G E N E R A L T IG H T E N IN G TORQUES
3204 V E H IC U LA R ENGINE SPECIFICATIONS

STARTER MOTOR

12 V o lt S ta rte r M o to rs (N ip p o n d e n so )
(1) (2) (3) (4) (5) (6)
N o Load C learance T o rq u e
C u rre n t T o rq u e T o rq u e betw een fo r b o lts T orq u e
R ota­ Con­ te rm in a l fo r Com ­ Brush p in io n & fo r nose fo r
tio n su m p tio n nut large m u ta to r le n g th p in io n h o u sin g brush
as seen (D ra w ) at m arked stud service service sto p to lever h o ld e r
N ip p o n ­ from M in. 11.7V w ith “ ST" nuts lim its lim it c o lla r h o u sin g bolts
C a te rp illa r denso d rive Speed mag. sw. lb. ft. lb. ft. in. in. in. lb. ft. lb. ft.
N u m be r N u m be r end (rp m ) rem oved (N -m ) (N -m ) (m m ) (m m ) (m m ) (N -m ) (N -m )

028000 12 to 18 5 to 10 1.81 .63 .004 to .157 8 to 12 8 to 12

4N241
-5 9 6 0 CW 3100 110A (1.4 to (6.6 to (46) (16) (0.1 to (10.8 to (10.8 to
2.0) 13.4) 4.0) 16.3) 16.3)

S T A R T E R S O L E N O ID (S W IT C H )

4N6938 12V (N ip p o n d e n s o N u m b e r 053400-1720; 053400-2870)

C u rre n t c o n s u m p tio n (draw ):

Both w in d in g s at 12 V 164 A
P u ll-in w in d in g s at 12 V 152 A

H o ld -in w in d in g s at 12 V ............................................................ 12A A 08439 X 1

41
3204 V E H IC U LA R ENGINE SPECIFICATIONS

Starter Solenoid (Switch)

(Cont.)

B12739X1

8N410 12 V (N ip p o n d e n s o N u m b e r 053400-3531)
C u rre n t c o n s u m p tio n (draw ) at 8 V 3 A

V -B E LT TENSIO N C H ART

B E LT TENSION BE LT TENSION
WIDTH TOP
“ IN IT IA L” * “ USED” **
B E LT SIZE W IDTH OF PULLEY R n R R n ilfiH S ftA IIG F NUM BERS
BE LT TOP GROOVE G AUG E READING G AUG E READING

in. mm in. mm lb. N lb. N O LD G AUGE NO. NEW G AUG E NO.

3 /8 .422 10.72 .380 9.65 100 ± 5 445 ± 22 90 ± 5 400 ± 22 BT-33-73F BT-33-95

1/2 .547 13.89 .500 12.70 120 ± 5 534 ± 22 90 ± 10 400 ± 44 BT-33-96-4-16 BT-33-95

5V .625 15.88 .600 15.24 120 ± 5 534 ± 22 90 ± 10 400 ± 44 BT-33-72-4-15 BT-33-72C

11/16 .688 17.48 .625 15.88 120 ± 5 534 ± 22 90 ± 10 400 ± 44 BT-33-72-4-15 BT-33-72C
3 /4 .750 19.05 .690 17.53 120 ± 5 534 ± 22 90 ± 10 400 ± 44 BT-33-72-4-15 BT-33-72C
15/16 .938 23.83 .878 22.30 120 ± 5 534 ± 22 90 ± 10 400 ± 44 BT-33-72-4-15 BT-33-72C

M EASURE TENSIO N OF BELT FARTHEST FROM THE ENGINE

'"IN IT IA L " BELT TENSION is for a new belt.

‘' “ USED ” BELT TENSIO N is for a belt which has more than 30 minutes of operation at rated speed of engine. A 1 0232X 5

NOTE: FOR TORQUE V A L U E S N O T G IV E N , SEE THE FIRST

42 PAGE OF SPECIFICATIO NS FOR G E N E R A L T IG H T E N IN G TORQUES
 C aterpillar. Cat and (B are Tradem arks o f C aterpillar T ra cto r Co

From the library of Barrington Diesel Club

A P R IL 1982
DRM N O . R E G 01254-04
P R IN T E D IN U.S.A.
A T E R P IL LA R F U N D A M E N T A L E N G LIS H