G342 specREV1

FORM NO.
REG01526-01
C.ATERPILLAR® FOR USE IN SERVICE MANUAl:

G342 ENGINE, REG01523
VOLUME I SPECIFICATIONS,
REG01312
G342 Engine
718750-UP
G342 ENGINE SPECIFICATIONS
GENERAL TIGHTENING TORQUE FOR

BOlTS, NUTS AND TAPERlOCK STUDS
The following charts give the standard torque values for bolts, nuts
and mperlock studs of SAE Grade 5 or better quality. Exceptions are
~~ Y
given in other sections of the Service Manual where needed.
THREAD DIAMETER STANDARD TORQUE
inches millimeters lb. ft. N'm*
............... Use these torques for bolts and nuts with stan-
iii) dard threads (conversions are approximate).
1/4
• 6.35 9±3 12±4
5/16 7.94 18±5 25±7
3/8 9.53 32±5 45±7
7/16 11.11 5O±10 70± 15
1/2 12.70 75 ±10 100 ± 15
9/16 14.29 110 ± 15 150± 20
5/8 15.88 150 ±2O 2OO±25
3/4 19.05 265±35 360±50
7/8 22.23 42O±60 570±80
1 25.40 640±80 875 ± 100
1 1/8 28.58 8OO±100 1100 ± 150
1 1/4 31.75 1000 ± 120 1350 ± 175
13/8 34.93 1200 ± 150 1600 ± 200
11/2 38.10 1500 ± 200 2000 ± 275
Use these torques for bolts and nuts on

hydraulic valve bodies.
5/16 7.94 13 ±2 20±3

3/8 9.53 24±2 35±3
7/16 11.11 39±2 50±3
1/2 12.70 60±3 80±4
5/8 15.88 118 ±4 160 ±6
TljllrIocII slIId
C8ID Use these torques for studs with Taperlock threads.
1/4 6.35 5±2 7±3

5/16 7.94 10±3 15 ± 5
3/8 9.53 2O±3 3O±5
7/16 11.11 3O±5 4O± 10
1/2 12.70 4O±5 55 ± 10
9/16 14.29 60 ± 10 80± 15
5/8 15.88 75 ±10 100 ± 15
3/4 19.05 110 ± 15 150 ± 20
7/8 22.23 170 ± 20 230 ± 30
1 25.40 260±3O 35O±4O
1 1/8 28.58 32O±3O 400±4O
11/4 31.75 400±4O 55O±50
13/8 34.93 480±4O 650±50
11/2 38.10 550±50 750±70
*1 newton meter (N·m) is approximately the same as 0.1 mkg. T95416-7
2
TORQUE FOR FLARED AND O-RING FITTINGS

The torques shown in the chart that follows are to be used on the part of 37° Flared, 45° Flared and
Inverted Flared fittings (when used with steel tubing), O-ring plugs and O-ring fittings .
w INVERTED
45° FLARED
~
37° FLARED
.r77>t.
~-
45° FLARED
)u-LJ
I
~~
O-RING
FITTING ~ PLUG
m
SWIVEL NUTS
TUBE mm 3.18 4.78 6_35 7.92 9.52 TUBE mm 12.70 15.88 19.05 22.22 25.40 31.75 38.10 50_80
SIZE SIZE
(0.0.) m. .125 .188 _250 .312 .375 10.0.1 m. .500 .625 .750 .875 1.000 1.250 1.500 2.000
THREAD 9/16 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 , 7/8 2 1/2
SIZE Im.l 5/8 SIZE Im.l 1 1/4
TORQUE 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
Ib-in. ±10 ±1O ±20 35 ±4 55 ± 4 75 ±4 90 ±4 100± 7 135 ± 7 165 ± 7 235 ± 10
±20 ±25 Ib.lt.
ASSEMBLY OF FITTINGS WITH

STRAIGHT THREADS AND O-RING SEALS
I. Put locknut (3), backup washer (4) and O-ring

seal (5) as far back on fitting body (2) as possible. 2
Hold these components in this position. Tum the
fitting into the part it is used on, until backup
washer (4) just makes contact with the face of the
part it is used on. 3
4
NOTE: If the fitting is a connector (straight fitting) or

plug, the hex on the body takes the place of the locknut.
To install this type fitting tighten, the hex against the
face of the part it goes into.
2. To put the fitting assembly in its correct position
5--------11li~ii:~- __ 6
tum the fitting body (2) out (counterclockwise) a
maximum of 359°. Tighten locknut (3) to the ELBOW BODY ASSEMBLY
torque shown in the chart. 1. End ot tlttlng body (connects to tube). 2. Filling
body. 3. Locknut. 4. Backup washer. 5. O-ring seal. 6.
A71009X3 End ot tilling that goes Into other part.
3
INTRODUCTION
The 'IKclfications given in this hook are on the hasis can be used again. If the part is equal to or within the
oj lill'mmation 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 "pemlissible" is in the description.
any time. These changes can effect the service given to the specification given is the "maximum or minimum"
thc 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.
l.dve the most current information which is available. A comparison can be made between the measure-
I:m a list of the most current modules and form numbers ments of a worn part. and the specifications of a new
available for e;tch 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 todetemline if a part replace the part.
77200X2
NOTE; For Systems Operation, Testing and Adjusting, make reference to

G342 ENGINE, Form No. REG01525.
INDEX
Air Starting Motor. . .. . . 40 Oil Filter. . . . . . . . . . . . . .. .. 21

Alternators . 37 Oil Filter Base 21
Alternator Regulator . 38 Oil Pump.... 19
AUXiliary Water Pump . . 22 Oil Pump Drive , 20
Oil Pump Valves " . . . . . . .. . . . . . . . . .. . .. 19
Camshaft. .. ........... ..... ............ 16
Connecting Rod " . . . . .. .. . 30 Pistons and Rings.. . . . . . . .. .. . . . . .. 29
Cooling System Pressure Cap. . . . . . .. . . . . . . . . . . 24 Pressure Regulating Valve for Air Starting Motor . . .. 40
Crankshaft 31
Cylinder Block " .. . .. .. .. . . 25 RegUlator for Gas Pressure . 9
Cylinder Head....................... 17
Service Meter " . . . . . . .. . . . . . . .. . . . . . . .. . 13
Cylinder Liner. . . . .. . . . .. . . . . .. .. . .. . . . . . . . . . . .. 27
Spark Plug and Adapter " 7
Cylinder Liner Projection. . . ." .......... 27
Starter Motors ... ........ ...... .. .. 35
Differential Pressure Regulator . 9 Starter Solenoids . . . . . . . . . . . . . . . .. 36
Fan Drive ... , . . . . . . .. . ... .. . . .. . . . . .. . 23 Timing Gears . . 13

Flywheel .. . . . . .. . .. . . . . . . . . . . . . . . . . . .. . .. 33 Transformers . 7
Flywheel Housing Bore. . . .. . . .. . . . . . . . .. 32 Turbocharger . 11
Flywheel Housing Runout .. . . . . . . . . . . . . . . . . . . . . . .. 33
V-Belt TenSion Chart. ........... 23
Flywheel Runout . . 34
Vacuum Regulator. 8
Gauge for Oil Pressure . 8
Valve Rocker Arms and Lifter. 12
Gauge for Water Temperature. 8
Valves . 14
Generator . 39
Vibration Damper. . 30
Generator Regulator . 39
Governor and Magneto Drive . 10 22
Water Pump
Governor Linkage . 10 . 24
Water Pump Idler Gear .....
Water Temperature RegUlators 24
Magneto Drive . 5
Magneto Timing. " . 5
4
MAGNETO DRIVE
Rotation is clockwise as seen from rear of engine.

(1) Bore for
bearing 1.4205 ± .0015 in. (36.081 ± 0.038 mm)
Diameter of magneto
drive shaft 1.4155 ± .0005 in. (35.954 ± 0.013 mm)
(2) Bore for bearing 629 to .630 in. (15.98 to 16.00 mm)
Diameter of magneto
drive shaft 6235 ± .0003 in. (15.837 ± 0.008 mm)
(3) Bore for bearing 629 to .630 in. (15.98 to 16.00 mm)
Diameter of
drive shaft 6235 ± .0003 in. (15.837 ± 0.008 mm)
90429X I
(4) Bore for
bearing.......... 1.4365 ± .0005 in. (36.487 ± 0.013 mm)
Diameter of
drive shaft......... 1.4337 ± .0003 in. (36.416 ± 0.008 mm)
MAGNETO TIMING
(7L3031 SPARK GAP MAGNETO)
Ignition Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-5-3-6-2-4

Magneto point gap . .017 in. (0.43 mm)
(1) Drive tang viewed from rear of engine.
(2) Angle of drive tang from vertical. . . . . . . . . . . . . . . . . . . . . . .. 0°
No.1 CYLINDER TIMING ANGLES

Compression Degrees BTC on
Rallo Conditions Compression Stroke
10.5:1 NA 20 0
10.5:1 TA (90 Water)
0
12.5°
10.5:1 NA (Propane) 10° 90430Xl 2
7.5:1 NA 25°
7.5:1 TA (130° Water) 20°
NA (Wet Natural)
7.5:1 15°
Gas and Butane)
5
2
MAGNETO TIMING
3N527 Solid State Magneto (Fairbanks Morse)

Ignition Sequence. . . . . .. . . . . . . ... . . . . . . . . . . . . . . . . .. 1-5-3-6-2-4
(1) Drive tang rotation CW as seen from rear of engine (end cap of
magneto).
(2) Angle of drive tang from vertical.. . . . . . . . . . .. . . . . . . . . .. 30 0

Compression Engine Engine at
Ratio Conditions t Slopped Rated Speed
10.5:1 NA 100 ATC 20 0 BTC
10.5:1 TA (900 Water) 17.50 ATC 12.50 BTC
10.5:1 NA (Propane) 20 0 ATC 100 BTC
7.5:1 NA 50 ATC 25 0 BTC
7.5:1 TA (130 0 Water) 100 ATC 20 0 BTC
NA (Wet Natural
7.5:1 150 ATC 150 BTC
Gas and Butane)
BTC = Before top center. ATC = After top center.
tNatural Gas at 1000 BTU high heat value gas (900 BTU low
heat value) and Vaporous Propane at 2500 BTU high heat 90431XI
value gas (approx. 2250 BTU low heat value).
B50098Xl
2W3749 Solid State Magneto (Altronlc)

Ignition Sequence 1,5,3,6,2,4
(1) Timing marks.
(2) Drive tang viewed from rear of engine.
(3) Angle of drive tang from vertical ... , ..... , . . . . . . . . . . . . .. 00

/,L,
Compression
Ratio
Other
Conditions
Flywheel Mark
Engine Stopped
or Running
,\ "I"
I'
,,'
I
I
10.5:1 N.A. (Natural Gas) 35 0 BTC

10.5:1 T.A. (Natural Gas) 25 0 BTC
10.5:1 N.A. (Propane) 17.50 BTC
10.5:1 T.A. (Propane) 150 BTC
8:1 N.A. (Natural Gas) 40 0 BTC
8:1 T.A. (Natural Gas) 35 0 BTC
8:1 N.A. (Propane) 30 0 BTC
8:1 TA (Propane) 20 0 BTC
BTC = Before top center.
2 3
NOTE: FOR TORQUE VALUES NOT GIVEN. SEE THE FIRST

6 PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
TRANSFORMERS
6L2832 Transformer for Spark Gap Magneto

Resistance:
Primary coil measured between positive post (1) and
negative post (2) of transformer , 6 ohms ± 5%
73813Xl
Secondary coil measured between negative post (2)
of transformer and outlet (3) for the 6L2832 AND 7L6791 TRANSFORMERS
high current (tension) .' ..... ,. ... . . . . . . . . ... 10.500 ohms ± 5%
7L6791 Transformer for Fairbanks Morse Solid State Magneto

Resistance:
negative post (2) of transformer. . .. .3 to .6 ohms
of transformer and outiet (3) for the
high current (tension) 11,000 to 13,000 ohms
2W3747 Transformer for Altronic Solid State Magneto

Resistance:
negative post (3) of transformer. . . . . . . . . . . . . . . .. 0.1 to 0.2 ohms
of transformer and outlet (1) for the 2W3747 TRANSFORMER
high current (tension) ,. . . . 5,000 to 8,000 ohms
SPARK PLUG AND ADAPTER
(1) Torque for spark plug adapter: (Apply

5P3931 Anti-Seize Compound to
adapter threads) 150 lb. ft. (205 Nom)
(2) Torque for spark plug. . . . .. . . .. .. 25 ± 4 lb. ft. (35 ± 5 Nom)
(3) Gap of the spark plug...... .014 ± .001 in. (0.36 ± 0.03 mm)
7
GAUGE FOR OIL PRESSURE

(3N2780 and 6L2310)
Switch adjustment range 0 to 75 psi (0.0 to 520 kPa)

Pressure selling of the contact point. . . . . . . . . . . .. 8 psi (55 kPa)
Pressure setting of the lockout. 15 psi (105 kPa)
GAUGE FOR WATER TEMPERATURE

(3N2781 and 6L2311)
Switch adjustment range. . ..... . ... 100 to 2200 F (37 to 104 0 C)

Temperature setting of the contact point.. 210 0 F (99 0 C)
2
VACUUM REGULATOR
(3N4630)
(1) Adjustment nul.

(2) Pressure differential between carburetor gas inlet and air inlet
for propane at 2500 BTU (low heat value 2250 BTU)
at idle speed " -1 in. H 2 0 (-25.4 mm H 2 0)
at full load " . .. -2 in. H 2 0 (-50.8 mm H 2 0)
NOTE: These values are for first adjustments only. Make reference to
the subject Adjustment to the Fuel to Air Ratio in the G342 Engine
book, Form No. REG01525 for the correct last adjustments accord- 93100- 1X 1
ing to application of the engine.
(3) Pressure in supply line for propane:
Turbocharged engines......... 12 to 20 psi (85 to 140 kPa)
Naturally aspirated engines...... 3 to 20 psi (20 to 140 kPa)
NOTE: FOR TOROUE VALUES NOT GIVEN, SEE THE FIRST

8 PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES
REGULATOR FOR GAS PRESSURE

(6L4104)
(1) Adjustment screw.

(2) Regulator outlet.
(3) Regulator spring:
Part Outlet (2) Color

Number Preaaure Range Code
8.5 to 18 in. H 2 O
6L5792 Gray
(215.9 to 457.2 mm H 2 O)
3.5 to 6.5 in. H 2 O
6L7140 Red
(88.9 to 165.1 mm H2 O)
2.0 to 4.5 in. H2 O
7N2388 Brown
(50.8 to 114.3 mm H 2 O)
(4) Regulator inlet.
DIFFERENTIAL PRESSURE REGULATOR

(7S7810)
(1) Dimension for valve testing with two 1S9030 Spacers (5) in
place:
Put pressure in chamber
at (A)... . .. .. .. .. .. .. .... . . .. 6.66 to 7.21 psi (46 to 50 kPa)
Maximum dimension
under test pressure. . . . . . . . . . . . . . . . . . .. 2.893 in. (73.48 mm)
(2) 2S4655 Spring:
Length under test force.................. 3.05 in. (77.5 mm)
Test force... .. .. . .. . . 81.5 ± 4 lb. (363 ± 18 N)
Free length after test 4.28 in. (108.7 mm)
Outside diameter. . . . . . . . . . . . . . . . . . . . . . .. 2.63 in. (66.8 mm)
(3) Torque for nut............... 55 ± 15 lb. in. (6.3 ± 1.7 N'm)
(4) Torque for bolts 55 ± 151b. in. (6.3 ± 1.7 N·m)
(5) 1S9039 Spacers for altitude adjustment:
Use two between 0 to 1500 ft. (0 to 457 m)
Use one between 1500 to 4000 ft. (457 to 1219 m)
Use none between 4000 to 6500 ft. (1219 to 1981 m)
9
GOVERNOR AND MAGNETO DRIVE
(1) 8M2250 Governor Spring Assembly

(2) Distance from top of bearing to top of machined face of
housing, with the governor weights tight against the
governor shaft. . ... 2115 ± 010 In. (5372 ± 0 25 mm)
To make an adjustment to get distance (2) add or remove shims
(4) as necessary
(3) D,amefer of
governor shaft 627 to 628 in (1593 to 1595 mm)
Bore in bearing
for shaft . 6295 ± 0005 in (15989:,: 0 013 mm)
Maximum permissible clearance
between bearing and shaft ... 005 in (0.13mm)
(4) 1M7534 Shim
(5) End play tor accessory
drive shaft . 003 to 010 In (008 to 0 25 mm)
(6) Diameter
of shaft. 1 4335 to 1 4345 in (36.411 to 36.436 mm)
Bore in bearings
for shaft. 1 436 to 1 437 in (3647 to 36 50 mm)
(7) Free movement between governor drive
gear and governor pmion gear
(backlash) . 002 to 006 In (0 05 to 0 15 mm)
To make an adjustment between governor drive gear and gov-
ernor pinion gear add or remove shims (8) as necessary
(8) 687342 Shim
(9) Torque for nut that holds
the gear. 150 Ib ft. (205 N'm)
GOVERNOR LINKAGE
(1) With throttle in closed position make angle for lever (2)
with mechanical governor .... . . 42°
Connect rod assembly to lever (2) In hole 1 In (254 mm) from
center of throttle shaft.
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

\0 PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
TURBOCHARGER
(Schwitzer 4MD354)
3 5
A84488X1
(1) End play of shaft 004 to .006 in. (0.10 to 0.15 mm) (7) Diameter of bore in
housing.. . . . . .. 1.0628 to 1.0633 in. (26.995 to 27.008 mm)
Maximum permissible end play of shaft. .008 in. (0.20 mm)
Outside diameter of the
(2) Torque for bolts for thrust bearing.. . . . .. 60 lb. in. (7 N'm) bearing. . . . . . . .. 1.0585 to 1.0590 in. (26.886 to 26.899 mm)
(3) Thickness of each thrust (8) Width of groove in sleeve for
ring 099 to .100 in. (2.51 to 2.54 mm) ring seals 128 to .130 in. (3.25 to 3.30 mm)
(4) Diameter of bearing surface (journal) for Side clearance between two of the ring seals
shaft bearing..... .6862 to .6865 in. (17.429 to 17.437 mm) and sleeve groove. . . . . . .. .002 to .006 in. (0.05 to 0.15 mm)
Bore in bearing... .6880 to .6883 in. (17.475 to 17.483 mm) (9) Clearance between housing and
(5) Maximum permissible gap of ring impeller. ... . ... .. . . . .. .. .018 to .022 in. (0.46 to 0.55 mm)
seal (worn) , .009 in. (0.23 mm) (10) Torque for nut for band clamp
Maximum permissible groove in ring (see note) 120 ± 24 lb. in. (13.6 ± 2.8 N'm)
seal (worn) . , .068 in. (1.73 mm) (11) Thickness of thrust
Minimum permissible width of ring bearing 225 to .226 in. (5.72 to 5.74 mm)
seal (worn) .062 in. (1.57 mm) (12) Torque for nut for band clamp
(6) Torque for nut that holds the (see note) 120 ± 24 lb. in. (13.6 ± 2.8 N'm)
Impeller .. " . " . . . . . .. .. . . . . . . .. 32 ± 2 lb. ft. (43 ± 3 N'm) NOTE: After tightening. tap clamp lightly
NOTE: Do not bend or add stress to the shaft when nut is tightened. all around. then retighten to a torque
of " , 120 ± 24 lb. in. (13.6 ± 2.8 N·m)
II
VALVE ROCKER ARMS AND LIFTERS
!
I
I
I
(1) Turn nut until contact is made with washer,
then turn an additional '" 2'1. Turns l
(2) Torque for nuts that hold bracket for
rocker arm shaft 30 ± 5 lb. ft. (40 ± 7 Nom)
\
(3) Clearance for valves:
\
Exhaust valves.......................... .028 in. (0.71 mm)
8
\
T70354-1X3
Intake valves , " , .016 in. (0.41 mm)
(4) Torque for locknut on valve
adjustment screw 40 ± 5 lb. ft. (55 ± 7 Nom) TYPICAL ILLUSTRATION
(5) Diameter of
shaft 1.223 to 1.224 in. (31.06 to 31.09 mm)
Bore in bearing
for shaft 1.2260 ± .0005 in. (31.140 ± 0.013 mm)
Maximum permissible clearance between
bearing and shaft " .010 in. (0.25 mm)
(6) Torque for bolts that hold guide for
valve lifter (follower) 32 ±5 lb. ft. (43 ± 7 Nom)
(7) Diameter of guide for valve lifter
(follower) 1.6875 ± .001 in. (42.862 ± 0.03 mm)
Bore in block for guide for valve lifter
(follower) 1.691 ± .002 in. (42.95 ± 0.05 mm)
(8) Diameter of valve lifter
(follower) 9965 ± .0005 in. (25.311 ± 0.013 mm)
Bore in guide for valve lifter
(follower) 9995 ± .0005 in. (25.387 ± 0.013 mm)
Maximum permissible clearance between lifter
(follower) and bore in guide " .008 in. (0.20 mm)

4
TIMING GEARS
(1) 4H7114 Gear; governor and magneto drive.

(2) 4H7384 Gear; large outer gear on camshaft.
(3) 2M6548 Gear; water pump drive idler.
1-------6
(4) 2M6569 Gear; water pump drive.
7
(5) 2M4091 Gear; inner gear on camshaft.
(6) 457863 Gear; on crankshaft.
(7) 2F7651 Gear; oil pump drive idler.
(8) 2F7652 Gear; oil pump drive. 8
NOTE: Timing mark "A" on gear (6) is not for the G342 Engine.
SERVICE METER
Rotation of the tachometer drive is one half of engine rpm.

(1) Torque for retainer nut .... , . ..... 35 ± 5 lb. ft. (45 ± 7 Nom)
(2) Diameter of
shaft 5523 ± .0003 in. (14.028 ± 0.008 mm)
Bore in bearing
for shaft 5560 ± .0005 in. (14.122 ± 0.013 mm)
13
VALVES
NOTE: GUIDELINE FOR REUSABLE PARTS; VALVES AND VALVE

SPRINGS, Forms SEBF8002 and SEBF8034, have the procedure
and specifications necessary for checking used valves and valve
springs.
(1) 9M5350 Spring for valve (outer): 2----~~
Length under test force " 2.219 in. (56.36 mm)
Test force , 65 ± 6.5 lb. (290 ± 29 N)
Use again minimum load at length 3-----F=:;~
under test force '" 57.0 lb. (255 N)
Length of spring at valve
open position.. . . .. 1.614 in. (41.00 mm)
Use again minimum load at valve
open position. ...... ..... . .. 165.5 lb. (736.5 N)
Free length after test...... .. .. 2.57 in. (65.3 mm)
Outside diameter , 1.713 in. (43.51 mm)
Spring must not be bent
more than. .. .. .090 in. (2.29 mm)
(2) 9M5349 Spring for valve (inner):
Length under test force 1.791 in. (45.49 mm)
4
Test force 20 ± 2 lb. (90 ± 9 N)
Use again minimum load at length
under test force.... .. ..... ..... .. . ....... 17.4 lb. (77.5 N)
Length of spring at valve
open position........................ 1.187 in. (30.15 mm) Bore in valve guides (later intake
Use again minimum load at valve and eXhaust). . . . . . . . .. .3734 ± .0005 in. (9.484 ± 0.013 mm)
open position , 47.9 lb. (213.0 N) Maximum permissible bore in the later valve guides (worn):
Free length after test....... . . 2.18 in. (55.4 mm) Measure .75 in. (19.0 mm) deep in valve guide bore from
Outside diameter 1.215 in. (30.86 mm) both ends of the valve guide. . . .. .3760 in. (9.550 mm)
Spring must not be bent (4) Thickness of valve lip (earlier and later):
more than............................. .076 in. (1.93 mm) Exhaust valve, minimum
permissible " .094 in. (2.39 mm)
(3) Diameter of valve stem (earlier intake and
exhaust) .4955 ± .0005 in. (12.586 ± 0.013 mm) Intake valve, minimum
permissible... .. .141 in. (3.58 mm)
Minimum permissible diameter
of valve stem .4935 in. (12.535 mm) (5) Diameter of valve head (earlier and later):
Minimum bore in earlier valve Exhaust valve 2.282 ± .005 in. (57.96 ± 0.13 mm)
guides with guides installed in
the head '" .. .. .5000 in. (12.700 mm) Intake valve 2.343 ± .005 in. (59.51 ± 0.13 mm)
Maximum permissible diameter of bore (6) Angle of valve face (earlier and later) 44V. o
in (earlier) valve guide 5030 in. (12.776 mm)
Diameter of valve stem (later):
1W1818 Intake
Valve 3717 ± .0005 in. (9.441 ± 0.013 mm)
Use again minimum diameter of
the valve stem " .3704 in. (9.408 mm)
1W1819 Exhaust Valve (tapered stem):
Head end of valve
stem 3707 ± .0005 in. (9.416 ± 0.013 mm)
Use again minimum diameter of
the head end of valve stem. . . . . . . . . . . .. .369 in. (9.37 mm)
Lock end of valve
stem 3717 ± ,0005 in. (9.441 ± 0.013 mm)
Use again minimum diameter of the lock end
of valve stem........ .. ..... . . .. . .... ,3704 in. (9.408 mm)
NOTE: FOR TOROUE VALUES NOT GIVEN. SEE THE FIRST

Valves (Cont.)
7 I I
T94267X I
(7) Depth of bore in head for

valve seat insert. . . . ... . .. .509 ± .001 in. (12.93 ± 0.03 mm)
(8) Diameter of valve
seat insert 2.5030 ± .0005 in. (83.576 ± 0.013 mm)
Bore in head for valve
seat insert 2.5000 ± .0005 in. (83.500 ± 0.013 mm)
(9) Angle of face of valve seat insert. . . . . . . . . . . . . . . . . . . . .. 45°
(10) Maximum permissible width of valve seat:
Exhaust valve 185 in. (4.70 mm)
Intake valve 145 in. (3.68 mm)
(11) Dimension from top of closed valve to face of head:
Maximum permissible dimension for 93961 Xl.
Exhaust Valve.......................... .130 in. (3.30 mm)

Minimum permissible dimension for
Exhaust Valve. . .. . . . .. .. .076 in. (1.93 mm)
Maximum permissible dimension for
Intake Valve 185 in. (4.70 mm)
Minimum permissible dimension for
Intake Valve , , .. . .. . .134 in. (3.40 mm)
(12) Outside diameter of the face of the vaive seat insert:
Exhaust seat 2.2665 in. (57.569 mm)
Maximum permissible.
exhaust seat ' .. . . . . . . .. 2.291 in. (58.19 mm)
Intake seal. 2.3195 in. (58.915 mm)
Maximum permissible,
intake seat , 2.343 in. (59.51 mm)
(13) Angle to grind seat face of the insert to get
a reduction of maximum seat diameter................ 15°
(14) Distance guide is above surface
of head , 1.690 ± .020 in. (42.93 ± 0.51 mm)
15
CAMSHAFT
(1) Diameter of bearing surface (journal) of

the camshaft 2.6195 ± .0005 in. (66.535 ± 0.013 mm)
(2) Get temperature of the gear to a maximum of 750 0 F (398 0 C)
before installation on the camshaft.
Diameter of shaft for
gear 2.6833 ± .0005 in. (68.156 ± 0.013 mm) -11-----8
~~;p1
Bore in gear 2.6795 ± .0003 in. (68.059 ± 0.008 mm)
(3) Torque for nuts 75 ± 10 lb. ft. (100 ± 14 N'm) 9-H---',--
(4) Diameter of seat
for gear " 4.748 ± .001 in. (120.60 ± 0.03 mm)
Bore in gear 4.750 to 4.751 in. (120.65 to 120.68 mm) ez603Xl
(5) End play for

the camshaft " .010 to .020 in. (0.25 to 0.51 mm)
Maximum permissible end play
(6)
for the camshaft
Bore in bearings for
camshaft
,. .. .035 in. (0.89 mm)
2.6235 ± .0015 in. (66.637 ± 0.038 mm)

•
10
+
(7) Bore in housing for
bearings 2.874 to 2.875 in. (73.00 to 73.03 mm)
(8) Distance from bearing
to face of housing 03 in. (0.8 mm) 11
(9) Distance from end of dowel
to face of housing 19 in. (4.8 mm)
(10) Height of camshaft lobes.
To find lobe lift, use the following procedure:
A. Measure camshaft lobe height (11).
B. Measure base circle (12).
C. Subtract base circle (STEP B) from lobe height (STEP A).
The difference is actual lobe lift (10).
D. Specified camshaft lobe lift
(10) is .. '" , .4030 in. (10.236 mm) 74239X5
f+---12 ---1
Maximum permissible difference between actual lobe lift (STEP C)
and specified lobe lift (STEP D) is .010 in. (0.25 mm).

CYLINDER HEAD
(Engines With Spacer Plates)
o
o o o 08 0 o
o
o o 00 o
o
o o
o o o oo
00 o
o o
o
A61597XI
Put 5P3931 Anti-Seize Compound on bolt threads and tighten bolts (1) Torque lor studs lor
in the Step sequence that lollows: water manilold , . . . . .. 20 ± 5 lb. It. (25 ± 7 Nom)
Step 1. Tighten bolts 1 thru 13 in number (2) Torque lor studs for
sequence to . . .. .. . . 100 lb. It. (135 Nom) valve covers 75 ± 10 lb. It. (100 ± 14 N'm)
Step 2. Tighten bolts A thru H in leller (3) Distance from lace 01 cylinder
sequence to . . . . . . .... .. . .. . ... 210 lb. It. (284 Nom) head to the end 01
valve guides. . . . . . . . . . . .. 1.690 ± .020 in. (42.93 ± 0.51 mm)
Step 3. Again tighten bolts A thru H in
letter sequence to.............. 420 lb. It. (565 Nom) (4) Torque lor precombustion chamber
(put 5P3931 Anti-Seize Compound
Step 4. Again tighten bolts 1 thru 13 in on threads) 200 lb. It. (270 N'm)
number sequence to . . 200 lb. It. (270 N·m)
(5) Torque lor studs lor
Step 5. Tighten bolts 14 thru 19 in exhaust manilold . . . . . . . . . . . . . . . .. 40 ± 5 lb. It. (55 ± 7 Nom I
number sequence (hand torque
only) to 75 lb. ft. (100 N·m) (6) Thickness 01 cylinder
head (new) 5.3775 ± .0025 in. (136.589 ± 0.064 mm)
Step 6. Again tighten bolts A thru H in
letter sequence (hand torque NOTE: Spacer plate gasket must be replaced il cylinder head has
only) to 420 lb. It. (565 N·m) been removed.
Step 7. Again tighten bolts 1 thru 13
in number sequence (hand torque
only) to 200 lb. It. (270 N·m)
17
CYLINDER HEAD
(Engines Without Spacer Plates)
0
0
@3 0
@2 0 1@ 4@
00 0 0 00 0 0 00 0 0 0
0
@ 0 @B 0 C@ 0 @
9@~
H @ F
@'
oR! ~1~ 13 °0
A61598X1
Put 5P3931 Anti-Seize Compound on stud threads and tighten nuts (1) Torque for studs for
in the Step sequence that follows: water manifold. . . . . . . . . . . . . . . . . .. 20 ± 5 lb. It. (25 ± 7 Nom)
Step 1. Tighten all nuts in number (2) Torque lor studs for
sequence to 60 lb. ft. (80 N'm) valve covers 50 ± 5 lb. ft. (70 ± 7 Nom)
Step 2. Tighten all nuts in letter (3) Distance Irom face of cyli nder
sequence to 150 lb. ft. (205 N'm) head to the end of valve
guides. . . .. . . ... . . . . . .. .. 1.690 ± .020 in. (42.93 ± 0.51 mm)
Step 3. Again tighten all nuts in letter
sequence to '" 300 lb. ft. (410 Nom) (4) Torque for precombustion chamber
(put 5P3931 Anti-Seize Compound
Step 4. Again tighten all nuts in number on threads) 200 lb. ft. (270 N'm)
sequence to................... 120 lb. ft. (160 Nom)
(5) Torque for studs lor
Step 5. Again tighten all nuts in letter sequence exhaust manifold. . . .. .. . . . ... .... 40 ± 5 lb. ft. (55 ± 7 N'm)
(hand torque only) to 300 lb. ft. (410 Nom)
(6) Thickness of cylinder head
Step 6. Again tighten all nuts in number sequence (new).............. 5.3775 ± .0025 in. (136.589 ± 0.064 mm)
(hand torque only) to . . . 120 lb. ft. (160 Nom)
Step 7. Check all nuts in number sequence after dynamometer
engine test.
Minimum torque....... ... .. . .. 105 lb. ft. (142 Nom)
Step 8. Check all nuts in letter sequence after dynamometer
engine test.
Minimum torque. '" .. . . 260 lb. It. (354 Nom)

G342 ENGINE SPECIFICAnONS
OIL PUMP
Pressure of SAE lOW oi I at 195 ± 10° F (90 ± 6° C) when measured at

the clean side of the oil filter at the oil filter base:
Full load rpm 39 ± 7 psi (270 ± 50 kPa)
Low idle rpm. . . . . . . . . . . . . . . . . . . .. 25 ± 7 psi (170 ± 50 kPa)
(1) Diameter of the
drive shaft 7407 ± .0003 in. (IB.BI4 ± O.OOB mm)
Bore in the bearing for the
drive shaft 743 to .744 in. (1B.B7 to lB.90 mm)
shaft and bearings.. .. .... . . . . .. . ... .... .006 in. (0.15 mm)
(2) Clearance between gears
and cover. . . . . . . . . . . .. .0020 to .0046 in. (0.051 to 0.117 mm)
and body 0020 to .0045 in. (0.051 to 0.114 mm)
and body. . . . . . . . . . . .. .0020 to .0046 in. (0.051 to 0.117 mm)
(5) Diameter of the
idler shaft.......... .7405 to .7410 in. (IB.B09 to lB.B21 mm)
Bore in the bearings in the gears for the
idler shaft 743 to .744 in. (IB.B7 to lB.90 mm)
OIL PUMP VALVES
(1) 7F2237 Spring for oil pump relief valve:

Length under test force I.4B4 in. (37.69 mm)
Test force....... . .. . . .. 52.3 to 57.B lb. (233 to 257 N)
Free length after test.... . . . . . . .. 2.13 in. (54.1 mm)
Outside diameter 1.05 in. (26.7 mm)
(2) 5H7B07 Spring for oil pump control valve:
Length under test force.................. 2.7B in. (70.6 mm)
Test force....... .... . .. .... ... 18.0 to 21.1 lb. (BO to 94 N)
Free length after test. . . . . . . . . . . . . . . . . . .. 3.30 in. (B3.8 mm)
Outside diameter......................... .69 in. (17.5 mm)
19
OIL PUMP DRIVE
(1) End play for

shaft..... .. ... ..... .•.... .003 to .019 in. (0.08 to 0.48 mm)
(2) Length of shaft from
bracket 1.625 ± .010 in. (41.28 ± 0.25 mm)
(3) Diameter of the shaft for the drive
idler gear.. ... . .. 1.2475 to 1.2485 in. (31.687 to 31.712 mm)
Bore in bearing
for the shaft 1.2510 ± .0015 in. (31.775 ± 0.038 mm)
(4) Diameter of the drive shaft for the
oil pump 7410 ± .0005 in. (18.821 ± 0.013 mm)
Bore in bearing for the drive shaft for
the oil pump..... ..... .. .. .744 ± .001 in. (18.90 ± 0.03 mm)
(5) The "V" mark on idler shaft (5) must be in alignment with "V"
mark on bracket.
(6) The "V" mark on bearing (6) must be in alignment with "V" mark
on bracket.
OIL FILTER
(1) Torque for screw that holds the cap assembly to

oil filter case , 50 ± 10 lb. ft. (70 ± 14 Nom)
(2) 6B806 Spring:
Umgth under test force 75 in. (19.1 mm)
Test force 27.8 to 32.6 lb. (123.5 to 145.5 N)
Free length after test. . . . . . . . . . . . • . . . . . .. 1.75 in. (44.5 mm)
Outside diameter........................ 1.62 in. (41.1 mm)
(3) Torque lor stud 110 ± 15 lb. ft. (149 ± 20 Nom)

OIL FILTER BASE

(258877 Oil Filler Assembly)
Oil pressure that makes the oil filter

bypass valve open.. . . . .. . . . . . . .. .. .. 26 ± 3 psi (180 ± 20 kPa)
Oil pressure that makes the oil cooler
bypass valve open 26 ± 3 psi (180 ± 20 kPa)
(1) 8M3182 Spring for bypass valve for the oil filter:
Test force. .. . . .. . . . .. . . .. .. .. .. . . . .. 8.92 lb. (39.7 N)
Free length after test 3.61 in. (91.7 mm)
Outside diameter , .81 in. (20.6 mm)
(2) 8M3182 Spring for bypass valve for the oil cooler:
Test force ,. 8.92 lb. (39.7 N)
Free length after test.................... 3.61 in. (91.7 mm)
Outside diameter , .. . . . . . . .. .. .81 in. (20.6 mm)
(3) 8M9929 Retainer.
NOTE: Retainer (3) must be even with the face of the filter base
after installation.
(4) Distance from face of filter base
to inside face of plugs , 31 in. (7.9 mm)
(5) 9M4685 Spring for turbocharger lubrication valve:
Length under test force 1.78 in. (45.2 mm)
Test force 29.80 ± 2.38 lb. (132.6 ± 10.6 N)
Free length after test. . . . . . . . . . . .. . . .. . .. 3.06 in. (77.7 mm)
Outside diameter........................ 1.42 in. (36.1 mm)
OIL FILTER BASE

(6L3714 Oil Filler Assembly)
Oil pressure that makes the oil filter

bypass valve open 26 ±3 psi (180 ± 20 kPa)
Oil pressure that makes the oil cooler
bypass valve open................... 26 ± 3 psi (180 ± 20 kPa)
(1) 8M3182 Spring for bypass valve for the oil filter:
Length under test force ,. . . 2.50 in. (63.5 mm)
Test force. . . . . .. ... . . . .. . . .. .. . .. 8.92 lb. (39.7 N)
Free length after test. . .. . .. . . . .. ... .. 3.61 in. (91.7 mm)
Outside diameter... .. .. . . .. . . .. . . .. .. .81 in. (20.6 mm)
(2) 8M3182 Spring for bypass valve for the oil cooler:
Test force.. . .. .. . .. . . . . . .. 8.92 lb. (39.7 N)
Free length after test. . . . . . . . .. . .. . .. 3.61 in. (91.7 mm)
Outside diameter. . . . . . . . . . . . .. . . . . . . .. .81 in. (20.6 mm)
(3) Distance from face of filter base
to inside face of plugs " .31 in. (7.9 mm)
21
WATER PUMP
Tighten nut (1) that holds the impeller to a torque of 55 lb. ft. (75
Nom). Continue to tighten until the cotter pin can be installed.
Use the procedure that follows to install the seal assembly:
a. Put water on seal (4).
b. Use 7N8268 Installation Tool and hand pressure only to install
seal (4) and the ring together in the housing bore with the shiny
face of the ring outside.
c. Remove spring (2) from seal (3).
d. Put water inside the seal assembly.
e. Install the seal assembly around the shaft, with the 7N8268 5
Installation Tool, (the tool is with the seal group) until the
carbon face makes contact with the shiny face of the ring.
f. Install spring (2).
NOTE: Put engine oil on the lip of seal (5).
AUXILIARY WATER PUMP
(1) 6F7043 Nut.

(2) Clearance between housing
and impeller. . . . . . . . . .. . .. .005 to .020 in. (0.13 to 0.51 mm)
NOTE: Hit nut (1) before checking clearance. Turn impeller while
checking.
(3) Torque for nut 55 lb. ft. (75 N'm)
NOTE: FOR TORQUE VALUES NOT GIVEN o SEE THE FIRST

650072Xl
FAN DRIVE
Tighten bolts (1) to a

torque 01 85 ± 5 lb. It. (115 ± 7 Nom)
Tighten bolts (2) to a
torque 01 590 ± 50 lb. It. (800 ± 70 Nom)
Tap with a hammer and retighten to a
torque 01 590 ± 50 lb. It. (800 ± 70 Nom)
V-BELT TENSION CHART

BELT TENSION BELT TENSION
WIDTH TOP
"INmAL"· "USED"-
BELT SIZE WIDTH OF PULLEY BORROUGHS GAUGE NUMBERS
BELT TOP GROOVE GAUGE READING GAUGE READING
In. mm In. mm lb. N lb. N OLD GAUGE NO. NEW GAUGE 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 .686 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
MEASURE TENSION OF BELT FARTHEST FROM THE ENGINE
·"INITIAL" BELT TENSION is lor a new belt.
·"USED" BELT TENSION is lor a ben which has more than 30 minutes of operation at rated speed 01 engine. Al0232X5
23
WATER PUMP IDLER GEAR I

)
II
'~i
(1) Diameter of
shaft... . .. .. .... 1.4320 to 1.4325 in. (36.373 to 36.386 mm)
II
Bore in bearing
for shaft 1.4350 ± .0005 in. (36.450 ± 0.013 mm)
(2) Diameter of
shaft 1.4940 to 1.4945 in. (37.948 to 37.960 mm)
Bore in bearing
for shaft 1.4970 ± .0005 in. (38.024 ± 0.013 mm)
(3) Dimension from end of shaft to
outer face of front cover....... . . .. . . .... .188 in. (4.78 mm)
8039SX I II 3
COOLING SYSTEM PRESSURE CAP

(6L8617)
Pressure that makes relief

valve open. .... .. 6.5 to 8.0 psi (45 to 55 kPa)
X2646
~~
0:-
r-
WATER TEMPERATURE REGULATORS
'- ./
li\~ml-
r-
4L7615 Regulator:
'--- ~
~
Temperature when completely open 180 0 F (82 0 C)

1"94800 ~
Minimum completely open distance. . . .. . .375 in. (9.53 mm)
9N2894 Regulator:
I \
I I
Minimum completely open distance. .. . . . .375 in. (9.53 mm)
959160 Regulator:
~::::;;
........,. .......,
Minimum completely open distance. . .. .375 in. (9.53 mm) I""""::::: ::=---
1"--=
51865Xl
- ----

CYLINDER BLOCK
(Engines With Spacer Plate)
(1) Make expansion of tube assembly to make a tight fit, then flare
end of tube.
(2) Thickness of top
plate .486 ± .001 in. (12.34 ± 0.03 mm)
Thickness of gasket between top plate and
cylinder block .008 ± .001 in. (0.20 ± 0.03 mm)
Height of liner over plate under
installation pressure 005 ± .003 in. (0.13 ± 0.08 mm)
Maximum permissible difference in height of
liners next to each other in the
same spacer plate... .. . . . . . . . . .. . .. . . .. .002 in. (0.05 mm)
Maximum permissible difference between high
and low measurements made at four places
around each cylinder liner ,. .002 in. (0.05 mm)
(3) Length of dowels (four) out of the
block face , . . . .. . . .. .88 in. (22.4 mm)
(4) Bore in bearings
for camshaft 2.6243 ± .0012 in. (66.657 ± 0.030 mm)
(5) Bore in block for
main bearing ..... 4.6245 ± .0005 in. (117.462 ± 0.013 mm)
Alignment for the bore in the block for
the main bearings. . . .. ... .000 to .003 in. (0.00 to 0.08 mm)
(6) Clearance between main bearing caps and
cylinder block 0000 to .0005 in. (0.000 to 0.013 mm)
11
Maximum permissible clearance between cap for
main bearings and cylinder block 0012 in. (0.030 mm)
Install caps with part number toward front.
(7) Make expansion of tube assembly to make a tight fit, then flare
end of tube.
(8) Bore in block for bearings
for camshaft ..... , ... 2.874 to 2.875 in. (72.99 to 73.03 mm)
(9) Torque for studs for
main bearing caps 170 ± 20 lb. ft. (230 ± 25 N'm)
(10) Torque for nuts that hold the caps for main bearings:
a. Put 2P2506 Thread Lubricant on threads and washer face.
12
b. Tighten both nuts to 100 ± 5 lb. ft. (135 ± 7 N·m) !
c. Put a mark on each nut and cap. A61793Xl
d. Tighten each nut from mark

(11) Dimension from center of main
bearing bore to top of cylinder
block (new). . .. .. 23.6945 ± .0035 in. (601.840 ± 0.089 mm)
(12) Dimension from center of main
bearing bore to bottom of cylinder
block (new) 3.750 ± .001 in. (95.28 ± 0.03 mm)
25
CYLINDER BLOCK
(Engines Without Spacer Plate)
(1) Torque lor 7/8 in. studs

lor head . . . . . . . . . . . . . . . . . . .. 170 ± 20 lb. It. (230 ± 25 Nom)
(2) Torque lor 5/8 in. studs
lor head 75 ± 10 lb. It. (100 ± 14 Nom)
,F=~~~L&
(3) Depth 01 bore in block
lor liner " .492 to .494 in. (12.50 to 12.55 mm)
Maximum permissible depth 01 bore ~~~~~I='F~~~t
after reconditioning.... .... .... .... . .. .538 in. (13.67 mm)
Height 01 liner over block, under 11 A617l14XI
installation pressure 004 to .008 in. (0.10 to 0.20 mm)
Maximum permissible difference in height
01 liners next to each other under
the same cylinder head. . . . . . . . . . . . . . . .. .002 in. (0.05 mm)
Maximum permissible difference between
high and low measurements made at lour
places around each cylinder liner... .... .002 in. (0.05 mm)
(4) Make expansion 01 tube assembly to make a tight lit, then flare
end 01 tube.
(5) Bore in bearings
lor camshaft , 2.6243 ± .0012 in. (66.657 ± 0.030 mm)
(6) Bore in block lor
main bearing ..... 4.6245 ± .0005 in. (117.462 ± 0.013 mm)
Alignment lor the bore in block lor
the main bearings. . . . . . .. .000 to .003 in. (0.00 to 0.08 mm)
(7) Clearance between main bearing caps and
cylinder block 0000 to .0005 in. (0.000 to 0.013 mm)
Maximum permissible clearance between cap lor
main bearings and cylinder block. . . .. .0012 in. (0.030 mm)
Install caps with part number toward Iront.
(8) Make expansion 01 tube assembly to make a tight lit, then flare
end 01 tube.
(9) Bore in block for bearings
lor camshaft 2.874 to 2.875 in. (72.99 to 73.03 mm)
(1 0) Torque lor studs lor
main bearing 170 ± 20 lb. It. (230 ± 25 Nom)
(11) Torque lor nuts that hold the caps lor main bearings:
a. Put 2P2506 Thread LUbricant on threads and washer lace.
b. Tighten both nuts to 100 ±5 lb. It. (135 ± 7 Nom)
A61602Xl
c. Put a mark on each nut and cap.
d. Tighten each nut from mark.. ... .. . . . . . . ... . . .. .. 1200
(12) Dimension Irom center 01 main
bearing bore to top of cylinder block
(new).. .... . . .. .. 24.1875 ± .0035 in. (614.363 ± 0.089 mm)
(13) Dimension Irom center 01 main
bearing bore to bottom 01 cylinder
block (new) 3.750 ± .001 in. (95.28 ± 0.03 mm)

CYLINDER LINER
(1) Bore in liner 5.751 ± .001 in. (146.08 ± 0.03 mm)
Use again maximum bore when measured
near upper end of the wear surtace of the
cylinder liner 5.755 in. (146.18 mm)
(2) Thickness of flange on
liner .4990 ± .0008 in. (12.675 ± 0.020 mm) I II
(3) Filler band. I II
Cylinder Liner Installation I I'
Put liquid soap on bottom liner bore in block, on grooves in lower
liner, and on O-rings. Install O-rings on liner. Put filler band (3) in
engine oil for a moment and install on liner. Immediately install liner
in cylinder block (before expansion of filler band).
I I ,
T88321X I
NOTE: Make reference to GUIDELINE FOR REUSABLE PARTS;

PISTONS AND CYLINDER LINERS, FORM NO. SEBF8001.
CYLINDER LINER PROJECTION

(WITH SPACER PLATE)
Make reference to CYLINDER LINER PROJECTION in Testing and

Adjusting for the complete procedure.
1. Install gasket (10) and spacer plate (9) with bolts (1). Tighten
bolts (1) evenly in four steps:
1st step 10 lb. ft. (14 Nom)
2nd step 25 lb. ft. (35 Nom)
3rd step 50 lb. ft. (70 N'm)
4th step 70 lb. ft. (95 Nom)
2. Install tooling as shown. Tighten bolts (4) evenly in four steps:
1st step. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5 lb. ft. (7 Nom)
3rd step 25 lb. ft. (35 Nom)
3. Measure cylinder liner projection with dial indicator (3) in
1P2402 Gauge Body (2) as shown. Measure at four places
around each cylinder liner near the clamped area.
Average of four projection measurements from any
cylinder liner must be .005 ± .003 in. (0.13 ± 0.08 mm)
Measure permissible difference between all
four measurements. . . .002 in. (0.05 mm)
Maximum permissible difference between average
projection of any two cylinder liners next to ADJUSTMENT SHIMS FOR LINER PROJECTION
each other in the same spacer plate.. . ... .002 in. (0.05 mm) SHIM THICKNESS, COLOR CODE, AND PART NUMBER
4. Minimum permissible depth to machine counterbore .007 In. .008 In. .009 In. .015 In. .030 In.
to adjust cylinder liner projection. . . . . . .. .030 in. (0.76 mm) (0.18 mm) (0.20 mm) (0.23 mm) (0.38 mm) (0.76 mm)
Maximum permissible depth to machine counterbore to BLACK RED GREEN BROWN BLUE
adjust cylinder liner projection 045 in. (1.14 mm) 5S8143 5S8144 5S8145 5S8146 5S8147
Install a .030 in. (0.76 mm) shim plus any added shims necessary
to get the correct cylinder liner projection.
NOTE: Be sure that the .030 in. (0.76 mm) shim is directly under
the cylinder liner flange.
(5) 3H465 Plate.
(6) 8B7548 Push-puller Crossbar.
(7) 1P2397 Adapter plate.
(8) 3H465 Plate (installed upside down).
27
CYLINDER LINER PROJECTION

(WITHOUT SPACER PLATE)
Make reference to CYLINDER LINER PROJECTION in Testing and

Adjusting for the complete procedure.
1. Install tooling as shown. Tighten nuts for crossbar evenly in four
steps:
1st step. . . . . . . . . . . . . .. .. .. . . . .. . . .. . .. . 5 lb. ft. (7 Nom)
3rd step 25 lb. ft. (35 Nom)
2. Measure cylinder liner projection with dial indicator (2) in
1P2402 Gauge Body (3) as shown. Measure at four places
around each cylinder liner near the clamped area.
Average of four projection measurements from any
cylinder liner must be 004 to .008 in. (0.10 to 0.20 mm)
Maximum permissible difference between all
four measurements. . . . . . . . . . . . . . . . . . . . .. .002 in. (0.05 mm)
Maximum permissible difference between
average projection of any two cylinder liners
next to each other under anyone head. .. .002 in. (0.05 mm)
3. Depth of bore in block
for liner. . . . . . . . . . . . . . . .. .492 to .494 in. (12.50 to 12.55 mm)
Maximum permissible depth to machine counterbore to
adjust cylinder liner projection ... " . .. .. .538 in. (13.67 mm)
Install a .030 in. (0.76 mm) shim plus any added shims necessary
to get the correct cylinder liner projection. ADJUSTMENT SHIMS FOR LINER PROJECTION
NOTE: Be sure that the .030 in. (0.76 mm) shim is directly under SHIM THICKNESS, COLOR CODE, AND PART NUMBER
the cylinder liner flange.
.007 In. .008 In• •009 In• .015 In. .030 In.
(1) 3H465 Plate. (0.18 mm) (0.20 mm) (0.23 mm) (0.38 mm) (0.76 mm)
(4) 8B7548 Push-puller Crossbar. BLACK RED GREEN BROWN BLUE
(5) 1P2397 Adapter plate. 588143 588144 588145 588146 588147

PISTONS AND RINGS

Make reference to GUIDELINE FOR REUSABLE PARTS; PISTONS AND CYLINDER
LINERS. Form No. SEBF8001.
PISTONS AND PISTON RINGS

(1) TOP RING (2) INTERMEDIATE RINGS (3) OIL CONTROL RING
'4N387S '2S8884 "SMS697
.~
Width of groove in piston 1918 ± .0003 in. .0970 ± .0005 in. .2510 ± .0005 in .
for piston ring (new). (4.872 ± 0008 mm) (2.464 ± 0.013 mm) (6.375 ± 0.013 mm)
Thickness of piston .186S +.0000 to -.0008 m. .0935 +.0000 to -.0008 in . .2485 ± .0005 in .
ring (new). (4.737 +0.000 to -0.020 mm) (2.375 +0.000 to 0.020 mm) (6.312 ± 0.013 mm)
Clearance between .0050 to .0064 in. .0030 to .0048 in . .0025 ± .0010 in .
groove and piston (0.127 to 0.163 mm) (0.076 to 0.122 mm) (0.064 ± 0025 mm)
ring (new).
Clearance between
ends of piston ring when
installed in a cylinder .0305 ± .0075 in. .0285 ± .0075 in. .0275 ± .0075 in .
liner with a bore size (0.775 ± 0.191 mm) (0.724 ± 0.191 mm) (0.699 ± 0.191 mm)
of 5.750 in. (146.05 mm)
Increase in clearance
between ends of piston
ring for each .001 in. .003 in.
(0.03 mm) increase in (0.08 mm)
cylinder liner bore size.
'Install piston ring with "UP" side toward top of piston.

NOTE: 4N3875 Top Ring (1) has the mark "UP-l."
2S8884 Intermediate Rings (2) have the mark "UP-2."
"'nstall 5M5697 Oil Control Ring (3) with the gap in the spring 180 0 away from the gap in the ring.
NOTE: Use 5P3519 PISTON RING GROOVE GAUGE to check top and center ring grooves with straight sides. For instructions
on the use of the gauge. see the GUIDELINE FOR REUSABLE PARTS; PISTONS AND CYLINDER LINERS, Form No. SEBF8001 .
(4) Bore in piston

. _{~
for pin............ 2.3906 ± .00015 in. (60.721 ± 0.0038 mm)
Clearance between pin and bore in 19746Xl
piston (new) 0004 to .0011 in. (0.010 to 0.028 mm)

Maximum permissible clearance between piston
pin and bore in piston (worn) . . .. . .... . .. .002 In. (0.05 mm)
NOTE: When installed in the engine. the "V" mark on top of the piston
must be in alignment with the "V" mark on the cylinder block.
29
CONNECTING ROD
(1) Bore in bearing for

piston pin 2.3913 ± .0003 in. (60.739 ± 0.008 mm)
bearing and piston pin .003 in. (0.08 mm)
(2) Bore in connecting rod
for bearing......... 3.9670 ± .0005 in. (100.762 ± 0.013 mm)
4
(3) Distance between center of bearing
for piston pin and center of bearing
for crankshaft 15.000 ± .001 in. (381.00 ± 0.03 mm)
4874BX 1
(4) Diameter of piston
pin 2.3898 ± .0002 in. (60.701 ± 0.005 mm)
(5) Bore in bearing for crankshaft bearing surface
(journal) . . . . . . . .. 3.6279 to 3.6300 in. (92.149 to 92.202 mm)
(6) Torque on nuts for connecting rod.
a. Put 2P2506 Thread Lubricant on threads and nut seat.
b. Tighten both nuts to 75 ± 5 lb. ft. (100 ± 7 N'm)
c. Put a mark on each nut and end of bolt.
d. Tighten each nut from mark 60 0
VIBRATION DAMPER
(1) Torque for bolts that hold

damper to hub 85 ± 5 lb. ft. (115 ± 7 Nom)
(2) Torque for bolt that holds hub and damper
on crankshaft. " 590 ± 50 lb. ft. (805 ± 70 N'm)
Hit bolt with hammer and again
tighten bolt to 590 ± 50 lb. ft. (805 ± 70 N'm)
NOTE: FOR TOROUE VALUES NOT GIVEN. SEE THE FIRST

CRANKSHAFT
'5 '6
(fo on
'-- I--
0
1;2
~ Q
8261OX3
Get the temperature of the thrower to a maximum of 500 0 F (260° C)
before installation on the crankshaft.
Get the temperature of the gear to a maximum of 400 0 F (204° C)
before installation on the crankshaft.
(1) Width of groove
in thrower 2515 ± .0005 in. (6.388 ± 0.013 mm)
Clearance between seal ring
and groove 0025 to .0045 in. (0.064 to 0.114 mm)
Clearance between ends of
seal ring... . .... . . . . . . . .010 to .050 in. (0.25 to 1.27 mm)
(2) Maximum "runout" (axial eccentricity) of groove
in thrower for seal ring 006 in. (0.15 mm)
(3) Distance between thrust faces of crankshaft for center (5) End play for
main bearing ,. 3.873 ± .003 in. (98.37 ± 0.08 mm) the crankshaft 013 to .022 in. (0.33 to 0.56 mm)
Distance between thrust faces of center Maximum permissible end play
main bearing ,. 3.857 ± .001 in. (97.97 ± 0.03 mm) for the crankshaft. . . . . . . . . . . . . . . . . . . . . .. .035 in. (0.89 mm)
(4) Diameter of bearing surfaces (journals) (6) Diameter of bearing surface (journals)
for the connecting rods [standard, for the main bearings [standard,
original size] ., '" 3.624 ± .001 in. (92.05 ± 0.03 mm) original size] 4.260 ± .001 in. (108.20 ± 0.03 mm)
Minimum permissible diameter 3.6175 in. (91.885 mm) Minimum permissible diameter 4.2555 in. (108.090 mm)
Diameter of bearing surfaces (journals) for the Diameter of bearing surfaces (journals) for the main
connecting rods [.025 in. (0.64 mm) smaller than bearings [.025 in. (0.64 mm) smaller than the
the original size I 3.599 ± .001 in. (91.41 ± 0.03 mm) original size] 4.235 ± .001 in. (107.57 ± 0.03 mm)
Diameter of bearing surfaces (journals) for the Diameter of bearing surfaces (journals) for the main
connecting rods [.050 in. (1.27 mm) smaller than bearings [.050 in. (1.27 mm) smaller than the
the original size) 3.574 ± .001 in. (90.78 ± 0.03 mm) original size) 4.210 ± .001 in. (106.93 ± 0.03 mm)
Maximum permissible difference from round Maximum permissible difference from
bearing surface (journal) .005 in. (0.13 mm) round bearing surface (journal) . . . . .. .. .. .005 in. (0.13 mm)
Clearance between connecting rod bearing and Clearance between main bearing and
connecting rod bearing surface (journal) main bearing surface (journal)
of crankshaft. 0021 to .0063 in. (0.053 to 0.160 mm) of crankshaft. 0024 to .0066 in. (0.061 to 0.168 mm)
Maximum permissible clearance between Maximum permissible clearance between
connecting rod and connecting rod bearing main bearing and main bearing surface
surface (journal) of crankshaft...... .012 in. (0.30 mm) (journal) of crankshaft.. .. . .. . . .010 in. (0.25 mm)
31
C (TOP)
FLYWHEEL HOUSING BORE
D 8
NOTE: Write the dial Indicator measurements with their positive (+)
and negative (-) notation (signs). This notation is necessary lor
making the calculations in the chart correctly.
1. With the dial indicator in position at (C), adjust the dial indicator
to "a" (zero). Push the crankshaft up against the top bearing.
Write the measurement for bearing clearance On line 1 in column
(C)
2. Divide the measurement from Step 1 by 2. Write this number on
line 1 in columns (8) & (D). Al02.33Xl A (BOTTOM)
3. Turn the crankshaft to put the dial indicator at (A). Adjust the dial
indicator to "a" (zero).
4. Turn the crankshaft counterclockwise to putlhe dial indicator at
(8). Write the measurement in the chart.
5. Turn the crankshaft counterclockwise to put the dialindicator at
(C). Write the measurement in the chart.
6. Turn the crankshaft counterclockwise to put the dial indicator at
(D). Write the measurement in the chart.
7. Add lines I & II by columns.
8. Subtract the smaller number from the larger number in line III in
columns (8) & (D). The result is the horizontal "eccentricity"
(out of round). Line III, column (C) is the vertical eccentricity.
CHART FOR OIAL INOICATOR MEASUREMENTS

Position of
dial indicator
in ± .012
Line mm (O.30)
No. A B C 0
Correction for bearing clearance I 0 010

(0 ZSI
Dial Indicator Reading
Total of Line 1 & 2
II
III
0
0 .. . .. 008
(O.ZO)
*Total Vertical eccentricity (out of round), .006

""Subtract the smaller No. from the larger No. The difference is (0. lSI
the total horizontal eccentricity.
At0234xl
.004
(0.10l
9. On the graph for total eccentricity find the point of intersection .002
(0.05)
of the lines for vertical eccentricity and horizontal eccentricity.
10. If the point of intersection is in the range marked "Acceptable"
the bore is in alignment. If the point of intersection is in the range ± .002 ± 004 t. 006 t.OO8 ± .010 t .012 In
marked "Not Acceptable," the flywheel housing must be (0.05) (0.10) (O.tSI 10.20) (0.251 fO.301 mm
changed.

FLYWHEEL HOUSING RUNOUT
852328 DIAL INDICATOR GROUP INSTALLED
C (TOP)
Face Runout (axial eccentricity) 01 the Flywheel Housing:

1. Fasten a dial indicator to the crankshaft flange so the anvil of the
indicator will touch the face of the flywheel housing.
2. Put a force on the crankshaft toward the rear before reading the
indicator at each point.
3. With dial indicator set at .000 in. (0.0 mm) at location (A), turn
the crankshaft and read the indicator at locations (B), (e, and B
D
(0).
4. The difference between lower and higher measurements taken
all four points must not be more than .012 in. (0.30 mm), which is
the maximum permissible face run out (axial eccentricity) of the
flywheel housing.
AlOZJ3Xl A (BOTTOM)
FLYWHEEL
(1) Torque for bolts that hold the flyWheel

to crankshaft 280 ± 20 lb. ft. (377 ± 25 Nom)
A77626Xl
33
FLYWHEEL RUNOUT
Face Runout (axial eccentricity) 01 Ihe Flywheel:

1. Install the dial indicator as shown. Put a lorce on the IIywheel
toward the rear.
2. Set the dial indicator to read .000 in. (0.0 mm).
3. Turn the flywheel and read the indicator every 90°. Put a force on
the IIywheel to the rear before each reading.
4. The difference between the lower and higher measurements
taken at all four points must not be more than .006 in. (0.15 mm),
which is the maximum permissible face run out (axial eccen-
CHECKING FACE RUNOUT OF THE FLYWEEEL
tricity) of the flywheel.
CHECKING FLYWHEEL BORE
Bore Runout (radial eccentricity) 01 the Flywheel:

1. Install the dial indicator (3) and make an adjustment of the
universal attachment (4) so it makes contact as shown.
2. Set the dial indicator to read .000 in. (0.0 mm).
3. Turn the flywheel and read the indicator every 90 0 .
4. The difference between the lower and higher measurements
taken at all four points must not be more than .006 in. (0.15 mm),
which is the maximum permissible bore runout (radial eccen-
tricity) of the flywheel.
5. Runout (eccentricity) of the bore for the pilot bearing for the CHECKING FLYWHEEL CLUTCH
flywheel clutch, must not exceed .005 in. (0.13 mm). PILOT BEARING BORE

STARTER MOTORS
24 Volt Starter Molars (Delco-Remy - Enclosed Lever - Heavy Duty)

(1 ) (2)
Torque lor
No Load screws Clearance
holding between
Current nose pinion &
Rotation Consumption Torque 01 housing housing
as seen Speed (Draw) terminal to lever (pinion
Irom (rpm) with solenoid nuts housing clearance)
Caterpillar Delco-Remy drive at 20V lb. It. lb. It. in.
Number Number end Min. Max. Min. Max. (Nom) (Nom) (mm)
4N3349 1109642 127.5 A 160.1 A
3T8949 1990231 CW 5500 7500 95 A 120 A 20 to 25 13 to 17 .33 to .39
(25 to 35) (18 to 23) (8.3 to 9.9)
3T8953 1990235 95 A 120 A
24 Volt Starter Molars (Prestollte)

(1) (2) (3)
Clearanca
between
No Load Torque Torque pinion &
Rotation lor lor housing
as seen Current housing tennlnal (pinion
from Min. Consumption bolts nuts clearance)
Caterpillar Prestollte drive Speed (Draw) lb. It. lb. It. In.
Number Number end (rpm) at 12V (Nom) (Nom) (mm)
7G7906 MMV6001A 8.3 20 to 25 .020 to .050
6T640 MMV6001D
CW 3500 95 A
(11.3) (25 to 35) (0.51 to 1.27)
35
STARTER SOLENOIDS
Starter Solenoids (Delco-Remy)

(1) (2)
Torque Torque
Terminal Terminal
Nuts Screws
Caterpillar Delco-Remy Voltage Current Consumption (Draw) lb. II. lb. In.
Number Number Rating Pull-In Windings Hold-In Windings (N·m) (N'm)
7N9236 1115548 9 to 12 A 6 to 7 A
24 V at 5 V at 20 V 20 to 25 16 to 30
9to11.5A 6.8 A max. (25 to 35) (1.8 to 3.4)
3T3421 1115559 at 5 V at 20 V
Slarter Solenoids (Prestollte)
Current Consumption (Draw)

at 70 0 F (21 0 C)
Caterpillar Prestollte Voltage
Number Number Rating Pull·ln Winding Hold-In Winding
23.2 to 26.6A 4.1 to 4.8A
3T8635 SAT4107 24V at 12V
at 12V

ALTERNATORS
4N3986 24V (Delco-Remy Number 1117734)

Rotation can be either direction.
Polarity: negative, positive or insulated.
Circuit.. . . .. . . .. .... .. . .... B
o
Output at 26V and 2600 rpm (cold). . . . . . . . . . . . . . . . . . . . . . .. 46 A
Output at 26V and 6500 rpm (cold). . . . . . . . . . . . . . . . . . . . . . .. 60 A
2
Rated output, hot 60 A
3
Field current at 24V and 80 0 F (27 0 C) 2.2 to 2.7 A
Voltage regulator:
Voltage selli ng range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 26 to 30 V
Adjust voltage selting to. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28 V
then increase speed to get
maximum output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 60 A
(1) Torque lor nut holding
pulley , 75 ± 5 lb. fl. (100 ± 7 Nom)
(2) Torque lor output
terminal. . . .. . . . .. 55 to 75 lb. in. (6.3 to 8.5 Nom)
NOTE: Adjust voltage with 4-position cap (3): high; med. high-3;
med. low-2; and low.
B12735X1
2N6398 24V (Motorole Number 8MH3005F)

Rotation can be either direction.
Poiarity is negative ground.
Output at 28V and 1800 rpm. .... ..... .. 21.5A
Output at 28V and 2500 rpm. . . . . . . . . . . . . . . . . . . . . . . . . .. 31 A
Rated output, hot 31.2 A
Field current at 24V and 80 F (27 C) 0 0
MAX. 3.0A
(1) Torque lor nut that holds
the pulley. . . . . . . . . . . . . . . . . . . .. 40 to 50 lb. It. (53 to 67 Nom)
(2) Tension lor brush spring.. . . . 6 to e oz. (1.7 to 2.2 N)
37
ALTERNATOR REGULATOR
6N3160 24V (Motorola Number 8RD3019)

Polarity is negative ground Or insulated.
Voltage setting range 26.8 to 29.2 V
(1) Remove cap to adjust voltage.
Turn the adjustment screw clockwise to increase voltage. There
are five adjustment positions.
Position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29.25 ± .35V
A18833Xl
Position 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28.6 ± .3V
Position 3' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28.0 ± .3V
Position 4 '" " 27.4 ± .3V
Position 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 26.8 ± .3V
'New regulators are adjusted at the factory to Position 3.

GENERATOR
6L5049 24V 15A (Delco-Remy Number 1105236)

Circuit. A
Speed for testing '" . 1800 rpm
Rotation is clockwise when seen from drive end.
Output at 1800 rpm and 28.5V (cold) 15 A
Output when cold. . . . . . . . . . . . . . • . . . • . . . . . . . . . . . . . . . . . . .. 28.5 V
90434XI
Field current at 24V and 80° F (27° C) 0.94 to 1.02 A
(1) Torque for nut
holding gear " 35 lb. ft. (45 Nom)
(2) Tension of brush spring.. .... .•. ... ... 16 oz. (4.4 N)
GENERATOR REGULATOR
8H587524V 15A (Delco-Remy Number 1119233)

Polarity is negative ground.
Circuit. ....................................•.....•.......... A
(1) Cutout relay:
Air gap between armature
and core.................. .015 to .019 in. (0.38 to 0.48 mm)
Point gap. . .. . ... . . .. . . . •. . . . . . .032 in. (0.81 mm)
Voltage closing range 24 to 27 V
(2) Current regulator: """"
and core 068 to .082 in. (1.72 to 2.08 mm)
Current setting range........................ 13.5 to 16.5 A
(3) Voltage regulator:
and core. . .. . . .. . . . .. .. . .. .068 to .082 in. (1.72 to 2.08 mm)
Point gap ,. . . ... .••. ••. .016 in. (0.41 mm)
Voltage setting range at 85° F (29° C) ......•.. 27.5 to 29.5 V
(4) Torque for bolt................ 36 ± 61b. in. (4.1 ± 0.7 Nom)
39
92617X4
AIR STARTING MOTOR
(BN3789 Inget'1loll-Rand Number 150 BMP-E78RH-54)

Output torque 50 lb. ft. (70 Nom)
with motor at 2240 rpm
at a pressure of .. .....•. 120 psi (830 kPa)
Horsepower............................................... 15
(1) Clearance between rotor
and end plate.. .. ... . .. .. .. . .. .. .. .. . ... .032 in. (0.81 mm)
(2) Torque for bolts of rear cover (tighten
bolts evenly) . .. .. . .. . .. .. ..... 20 to 25 lb. ft. (25 to 35 Nom)
(3) Torque for bolts of pinion housing (tighten
bolls evenly) 100 lb. in. (11.3 Nom)
PRESSURE REGULATING VALVE

FOR AIR STARTING MOTOR
(1) Adjustment screw.

(2) Maximum permissible inlet pressure. . . . .. 250 psi (1720 kPa)
(3) Ma,ximum permissible outlet pressure .... 150 psi (1030 kPa)
Minimum outlet pressure ....•..•.•..... . .. 90 psi (620 kPa)
C.ATERPILLAR®
REG01526-01 Printed in U.S.A (7/83)

G342 specREV1

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FORM NO.

C.ATERPILLAR® FOR USE IN SERVICE MANUAl:

GENERAL TIGHTENING TORQUE FOR

THREAD DIAMETER STANDARD TORQUE

inches millimeters lb. ft. N'm*

Use these torques for bolts and nuts on

5/16 7.94 13 ±2 20±3

C8ID Use these torques for studs with Taperlock threads.

1/4 6.35 5±2 7±3

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

TORQUE FOR FLARED AND O-RING FITTINGS

ASSEMBLY OF FITTINGS WITH

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

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

NOTE; For Systems Operation, Testing and Adjusting, make reference to

Air Starting Motor. . .. . . 40 Oil Filter. . . . . . . . . . . . . .. .. 21

Fan Drive ... , . . . . . . .. . ... .. . . .. . . . . .. . 23 Timing Gears . . 13

Rotation is clockwise as seen from rear of engine.

Ignition Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-5-3-6-2-4

No.1 CYLINDER TIMING ANGLES

3N527 Solid State Magneto (Fairbanks Morse)

No.1 CYLINDER TIMING ANGLES

value gas (approx. 2250 BTU low heat value).

2W3749 Solid State Magneto (Altronlc)

No.1 CYLINDER TIMING ANGLES

10.5:1 N.A. (Natural Gas) 35 0 BTC

NOTE: FOR TORQUE VALUES NOT GIVEN. SEE THE FIRST

6L2832 Transformer for Spark Gap Magneto

7L6791 Transformer for Fairbanks Morse Solid State Magneto

2W3747 Transformer for Altronic Solid State Magneto

SPARK PLUG AND ADAPTER

(1) Torque for spark plug adapter: (Apply

GAUGE FOR OIL PRESSURE

Switch adjustment range 0 to 75 psi (0.0 to 520 kPa)

GAUGE FOR WATER TEMPERATURE

Switch adjustment range. . ..... . ... 100 to 2200 F (37 to 104 0 C)

(1) Adjustment nul.

NOTE: FOR TOROUE VALUES NOT GIVEN, SEE THE FIRST

REGULATOR FOR GAS PRESSURE

(1) Adjustment screw.

Part Outlet (2) Color

(4) Regulator inlet.

DIFFERENTIAL PRESSURE REGULATOR

GOVERNOR AND MAGNETO DRIVE

(1) 8M2250 Governor Spring Assembly

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

VALVE ROCKER ARMS AND LIFTERS

NOTE: FOR TOROUE VALUES NOT GIVEN, SEE THE FIRST

(1) 4H7114 Gear; governor and magneto drive.

Rotation of the tachometer drive is one half of engine rpm.

NOTE: GUIDELINE FOR REUSABLE PARTS; VALVES AND VALVE

NOTE: FOR TOROUE VALUES NOT GIVEN. SEE THE FIRST

(7) Depth of bore in head for

Exhaust Valve.......................... .130 in. (3.30 mm)

(1) Diameter of bearing surface (journal) of

(5) End play for

2.6235 ± .0015 in. (66.637 ± 0.038 mm)

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

NOTE: FOR TORQUE VALUES NOT GIVEN. SEE THE FIRST

Pressure of SAE lOW oi I at 195 ± 10° F (90 ± 6° C) when measured at

OIL PUMP VALVES

(1) 7F2237 Spring for oil pump relief valve:

OIL PUMP DRIVE

(1) End play for