SPECIFICATIONS 3208 DIESEL TRUCK ENGINEIndex Specifications (Section 1) ie Comprar 199 ‘Mlrnaore Arc Roget ena aed utc Tang Nara Unit sonvosocnccnese 38 Geariag For Conn Rod Are Mains 128 aims 110 Gorrecing Fd tee Gureora : 128 Great Seas lar Grancaoe Ventlaion Valea scsonnss v Gini Block encsssccoceconnnn nae 428 Ghinder ead 0022 IIMs Dive Gear For The ction AMP aes OO Engne DION ee cones Engine Ol Cook fd Fer” 19 Sshst Wand one SON Fan Yeuning Puy Asserts 129 Firatins 190 lywhod Housing Bore un 0nannninmensarnonmaimanieae 18S ‘Flywhea Housing Runout 132 Fated Punt sn ucsouuntucsmnasac 34 Foal eter Beso cout Ful nccton Pan 4 Fual Teter Pong menenmeenst | @ 210 rene 15 Infection O22 cnn esas HP oan ap Fr ATS, MTEC, ars MTES Aton Teramisson = Sai OF Ler Gauge osee sain conn 2 Stans it St Pump 12 Fistor Ard ings tno ing piston) 125 Prone Ard ge tre 4 pon) te Paley An Dame! 2 Starter Motor Sencids ut Sorter tre ros enemy Shot San : 1 — 18 Teanga ror tation 7 Valve Cover - Valve locker Arms And Litors Valve Seais And Inaets VEN wren water Pure Water Temperature Regulars NOTE: Rete o tie complete Servce Mamua! for infomation et founs hers. AO" inthe el marge i an wnleaton of a change trom the former 'ssu, Introduction “The specications glen in this back are = the basis of ‘informaton avatabe atthe me the book was wetten Those specications give the foraes, operating pressures, ‘measurements of new paris. adusiments and other tems tha val afect the Sarvee ofthe product \Whon the wards ‘use again’ are in the description, the epectication given can bo used to determine fa art can be Used again Hf the part S equal to © wltin the specification ‘given, se the part again. Wren the word ‘permissible’ isin the description, the speclication gen the ‘maximum er mei trance Permittan betsre acustinen’ epar ardor new parts are ede ‘Acompareon can be made between the meatwsmacts of 8 \Wern part and the speaficaion ct a new part to find the ‘amouni cf wear, A par tras wom can bo safe tc use it an tslimate of he ramander 0) ls serace Iles Good. a short servca He s expected, repiace tne part NOTE: The spasiication quon tor use seain’ ard “permssitle’ are nterded for guience ory and Caterpilar Inc, hereby excressiy denes and exudes any rapresentaton, wartanly cr mped wararty Gl the use of any component ‘3208 Diesel Truck Engine a IndexIndex Specifications (Section 1) ie Comprar 199 ‘Mlrnaore Arc Roget ena aed utc Tang Nara Unit sonvosocnccnese 38 Geariag For Conn Rod Are Mains 128 aims 110 Gorrecing Fd tee Gureora : 128 Great Seas lar Grancaoe Ventlaion Valea scsonnss v Gini Block encsssccoceconnnn nae 428 Ghinder ead 0022 IIMs Dive Gear For The ction AMP aes OO Engne DION ee cones Engine Ol Cook fd Fer” 19 Sshst Wand one SON Fan Yeuning Puy Asserts 129 Firatins 190 lywhod Housing Bore un 0nannninmensarnonmaimanieae 18S ‘Flywhea Housing Runout 132 Fated Punt sn ucsouuntucsmnasac 34 Foal eter Beso cout Ful nccton Pan 4 Fual Teter Pong menenmeenst | @ 210 rene 15 Infection O22 cnn esas HP oan ap Fr ATS, MTEC, ars MTES Aton Teramisson = Sai OF Ler Gauge osee sain conn 2 Stans it St Pump 12 Fistor Ard ings tno ing piston) 125 Prone Ard ge tre 4 pon) te Paley An Dame! 2 Starter Motor Sencids ut Sorter tre ros enemy Shot San : 1 — 18 Teanga ror tation 7 Valve Cover - Valve locker Arms And Litors Valve Seais And Inaets VEN wren water Pure Water Temperature Regulars NOTE: Rete o tie complete Servce Mamua! for infomation et founs hers. AO" inthe el marge i an wnleaton of a change trom the former 'ssu, Introduction “The specications glen in this back are = the basis of ‘informaton avatabe atthe me the book was wetten Those specications give the foraes, operating pressures, ‘measurements of new paris. adusiments and other tems tha val afect the Sarvee ofthe product \Whon the wards ‘use again’ are in the description, the epectication given can bo used to determine fa art can be Used again Hf the part S equal to © wltin the specification ‘given, se the part again. Wren the word ‘permissible’ isin the description, the speclication gen the ‘maximum er mei trance Permittan betsre acustinen’ epar ardor new parts are ede ‘Acompareon can be made between the meatwsmacts of 8 \Wern part and the speaficaion ct a new part to find the ‘amouni cf wear, A par tras wom can bo safe tc use it an tslimate of he ramander 0) ls serace Iles Good. a short servca He s expected, repiace tne part NOTE: The spasiication quon tor use seain’ ard “permssitle’ are nterded for guience ory and Caterpilar Inc, hereby excressiy denes and exudes any rapresentaton, wartanly cr mped wararty Gl the use of any component ‘3208 Diesel Truck Engine a IndexSpecifications Engine Design seam eXeSS—Gs) (Cinder, Valve Ana Injection Pump Location EEE owmeomncsuson 11430 4S) SHH nn sennesnve 12701mEn (GOin) Nurioer OF Gyinders eee 8 yincor Arrangomor, so" Fling Crier drjactin Saquonce) 12134583 Drecton Of Rtation (as Soon From Fyre) Ena ‘Courtercbclense Fuel Injection Pump Fig order (niection secuenca) 1a784508 injection tining BTC teetore too center: Engines with 1WW6742 Fuel Puree Grou aur hgines wth 7CEEG6 and 7}6479 Fuel Pune Sous wort Engines nih TE98S0 Fus ump Graps nese Engmes nih 708968, 708868, TC#S7O, TORSTI and 44260 Fuel PUMP Gr0U08 12551" All ther ergines oye EM Torque forthe ruts that hod the fuel bos (Use SPO144 Fuel Line Sacks). 402 / Nem U5 Of) res280°) 11) Bere inthe rear bearing forthe carshest 60.305 £0.019rr (2750+, 0035 in} Diametes ef rear bearrg surface (aura) ol the in 20240001 (23720 0005 im) Masirum permieibie eloarance betwee the Searing arc the carshalt bearng surfaes puma) (ween) (045 mm (008 my Terque for serous that hold elaeve contra! vers . 2840.2 Nem (24 4 21b in} (@)Fere in tha housing foe the tl earn! chat ines) 290-49. 1Aimm [35484 0005) Diameter ef sieave contol shat: (ne) 8.565 +0.008-rm (2580+ C008") lWaeanian permésibia clearance ostvrean the bore n the housing ard the sleeve conic! shait (mere)... QOSr¥” (00317) (4) © py for camehatt nit sisaue Inetaon en) 58-+ 048 mm (023.0189) NOTE: When instaling seve on end of carta, support the camehatt prevent camago ‘o pars inside oF nection burp ar govarno: housing (8) Bere n te trot beating fr the camsnalt (ren) 25-418 4 0.018 mm (1.0008:+ 0005 in) Dameer f front baring sure (uri ol the ‘camenatt (new)... 25.875 + COTS ren (9020+ C005 in) Maximum parmsibio clearance betwee" the Searing anche earshe bong sroce Goal (worn) a see O10 mm £004) 3208 Diesel Truck Engine Specificationsom @ 2 " 0 crzronet (6) Torqps forbusting 2+ 7 Hem O51) Th, Crossover avers NOTE: For adjastmant of crossever levers sew the Testing And Adjusting Section {) Torque fr screws that hold crossover lovers. 2a D2Nem @E+2Ibin) (ane 10) Fuel cory shatts (11) Dow pin lineage beter crossover lve (12)Distence guide pin extends ino bore 010mm = 0041r) NOTE: Install quda on wih slot toward tho top ot he mar bore (199 95852 Spry for inaction pup Langin unas tet force Text bree ot Free eral altar test ) Cuisise ameter 18.49 mm (728i) Reverse Flow Check Valve (R>O}. Orifoed Daivery Valve (O0V) Oiiliced Detvery Valve -Lo Volume (O04), COiliced Reverse Flow Check Vaie (ORF), poe> 8208 Diesel Truck Engine 15 Specifications‘Governor Spring Char Parte. (yiwasss | tena cn aaa cen camer | ale end (2ri=8) Ore Pere Two Pk “wo Greet Thee Green Tec Whe Pita ce TaN Bs raw "34h v34n onprect (ob) ow ow ‘sai 800) Tren acdmostesee | 1800.00 177808 778 0e0 T7780 17am irate sprig shorty | _s30F) (700m Ge (rear (707) Haein | wesosy | waieisin | soretseN | seesisin Total os frc0 isa tom | Wace nm | (isms) | (aos zen | (raebs 340) $eg7 #05imm | 44202051 mm | 46 20205tmm | a2742089mn | a4g0 2051 mm Frontnatvatieriest | (S04 0001) | G.740:t.000m) | race dace) | (hasez oar) | tirade ooo) 3356 mn 3784 rer sapere 3825 mm Cutede demeter (isiaim (180i iistein (ieoin Goveno: Spi Chat Panne yatesee [i sso7 (i) wee (ay nessa ewer Caer ce Sires), ‘One Yolon | Thee elow | Thee Prk One Pk Nene Pita fre 7226H 350N E50) 1450 a4 on apirg ot ow | _(208) 2.01) (01) ow) Tren aadnoelacee | W7zana | 1624 ma E24 en 778 mew 08 rn make sorig wort oy | _\roem (anor) (o'r) (70a (ar) weseesn | wse=80N | a7s0=69N | mce=sow | cAo12 Gon Total test force (emeam | eorty | Gxsiem | @sosiem | (ses ten ‘eave ostmn | %2142050m | 224z100m | deassasimm | SLz408t wm Frostretraterest | ince oan | Ceca crm | ease owe) | Goes won | Wia+ om 3356 STBarm sas mm 2806 im Vase en urge damstoy neem Rect nec (tae) Gain =~ (i Overuelng Spree Pert anosz7 eee Tengin uncer | 8.71 men 8.007 testtose (Sin rae) Tass008N dees o08W Test oc (H8e02m (ees 2b) Fras eath 18.28 260mm stor tae 720 rari Outi0 ttmn 8.4mm |_alanerer edi am cots cate (0) None Ove vite (6) Tope forbots that rad govrner wright car to arena (are) THEdNm ADEeI A) Tora for bolita “ld govern weg cae to camnsaf ater wih thin ot Fead) wes, 1021.1 Nem (Oe 1019 > 3208 Diesel Truck Engine 16 ‘Specifications oeFuel Transfer Pump spear ) Bypass vave Fuel prasours at FULLLOAD ,, 205: 8640 3015 psi) (2) 48605 Spring for bypass valve engin unde tet force 22:35 mm (80 9) Test force 167 20B0N @53— 18D) Froo lenath altor tect see mw (1.729 1) use olarnator 18 881m (327 1) @) Thicaness of gears (new 9489 D008 @m (8135+ .0159 n) Deprh of cointerbore ine) 9525:0012em ($750 £ 0005 n) 4) Diameter of eral or wer gear... 12-482 4: 0.008 mm (4914 4.0003 n) Bove in flor gaa 42512-40008 mm (4906 + .0003n) '8) Puta thn jayer of 591454 Sealing Compound on the fuelds clamarer ofthe seals be'ore listatation, errove the aura sealing compoune afer essembhy (6) Inaal inver aca rom outside cage of bocy atsombly to auisance ot TE £025 ern (459 » O10 7) Insalloutsk seal liom ausde edge of body assemly toa dotence of ssnun 9.784026 (G90 010in) Injection Nozzles ra Ni (Kent Mere Corp 4}26400 or Viscor Caityation Fad 14876. SAE 9570) at @ lemperatute of... 1812 20°C (6510 70°) Nozalo cottrigprbseures (valve it adustnent sorew turned S)e 1/9 trom clesed postions 10:300-» 17.690 KPa (15000 2600p) 18545 10 17 €90kPa (2400%02609ps) turn ol akaga test prassure 96301011 04S kPa {149350 1603 ps} Leakage jn 15 scons AO mirimumer maximun Meat tin leakagn is 20 deep in 15 seconds wth a rosaure of 1980 ka (200 pa leas than coone'g pressure, (1) Torave for vane Itt lockat 4.0105.1Nem ‘G5t45b n) 12) Torque lor pressure Stren toxert 8010941 New (7ta £2) Torque ter a0 124610 19 Nem (11010 129 1m) 8208 Diesel Truck Engine vr Specifications¢ 7000 Series Nozzle Fuel Filter Base © ® » © ee A 8 2 a “4 4 1) FUSS Thread Look Sompoure onthe treadsot eo @ a Q\ @ 12) Seta ates nee (8) Terous for stud a. 7O=TNem (G05 ib fi) eee o ee = 7Automatic Timing Advance Unit 3.5° and 5° unit BI 2 Le ly te | opr = f= soauere SI End play betwoan washer (2) and ining advance unit Ww 0.08 to 0.98 an 005 to 087 in) (8) Tota for 92700) nanan, 28 DENeM (70-45 (bin) “Stake (mako a mark wth a punch) cozow (3) n two paca, 3208 Diesel Truck Engine Drive Gear For The Injection Pump si u (1) Torque for the bolt thal holds the drive guar tothe carroratt of tha irjecton pump. aa ann (010m Specificationsc Camshaft = (1) Diametor of tho eurtaces (journals) tor tre camehatt earings (new) . 68.600+ 0.013 mm @.5£00 + C605 In) Bore in the tho Learns for he cams (ne) (63.582 0.068 mm (2.5005 + 015 in) Mariam permissiie eesrance between beating and Deering scrtace (uma (Warn... DAB me (COT ir) @) Tot fit betwen the gear anc camenatt. 10.090 100.071 mm (0572 to 6028 in) Maxum permssibie temperate of the gear for Insaiation ov ina casa (20 not Use ah). SIC (00°F) ©) End play forthe camshatt 0:18 0.081rem (007 # 003) Maxum permissible 0nd Bay (WORN) vac nvenn OST mT (020i) (8) Wath of thaust groove in camshatt (8) ‘9.14 0.05 mm (960-4 0029) Diarneter ust pn (Pew) 897 +063mm (353 001 in) “Torque for theust pin 4847 Nem (3525101 (©) Height of camshaft lobes To fin lobe it, use the procedure that flows: A. Moaaize camshait lave height (8) B. Measise base erie (7). , Sublrect bese cre (Step E) from lobe hesghk (Sep A ‘The alee now actual I6be i 6) . Specie’ camehatt lobo if (6) x on6230 Camehat ueod with rer ies 2, Exhaust be 9.40 (370 in) Be. intake tobe 8.33 mn (367 in) ‘2W4238 Camera use wit at Face Hers ‘840mm ( 370m) 8.06 mn (357 in) Maxum permiestsiedtterence between actual abe it (SiepC) hd spectied bei. [Stey Djs 0.28 107 (970 in) Al 21001 13208 Diesel Truck Engine ‘Specificationslow AA {8} Distance tom tha end of 9NS771 lowe! the face of gee 11.81 £0.13mm (405 + 005:n) ven Be (@) Disia-ce Foi te end ol caarshall. Camstait Instaliation NOTE: For instelaion ol camishal, he Lring mark 0” the ‘sameratt gear teoth must be in ignmant wath tie eng mark on te teat space of he crash all ge Intake Valve Timing 11 Check the No, | intake valve lawaree wah she engine Storped The vave clerarce must be 0 lo B48 mm £0'%0 01d in} the vave closrarce re not n this rane, Boast Ne claeraioe fo 038/170 015 i), 2. Marc Tap Canta’ Poston oF the tarkshal vibration Carper ot pulley, 8. Use a del indicator to meacure the intske sae rowarrent 4. Pluie the crankshall i the dhoction ef normal engine Folalion, Slop when the inlaxe vave is 1.81 mm {O75 n} ff ie cealin tc permng coruonce. Al ths part the rankshat must be 10-4 Alte Too Gene! toe 3208 Diesel Truck Engine SpecificationsValve Rocker Arms And Lifters For Engines That Have Flat Face Lifters Torque Tor bolts thal hold rocker ans ee 247 Nem (geben Toraus fo jochnut for vave agstmant eorew SDE TNem (24451) (@) Diemeier ofthe shat forth rocker airs wn 21.7038 21.814 nm (8580 10 888 ir) Minimum permissible ameiot (WT) aw 21088 rr9 (35700) ‘Bore in bow ngs forthe rocker ams For Engines That Have Roller Lifters paisi7=2 5 4. Tun carnstatt so cam labe 'seppnste Ite horn 2. insta gues ring on Stier 8. Putte’ asemby in engine ol anc! inal Into Iter bore 0 that the tao on the guido eprra ie located whi aroa a 4, Push ter into bore until contact male wih cemsha't EI) saan 1,852 = 0.0207 (.8603 & 0005 =) (1) Torque for belts that hold mcker arms. 2447 Nem Maxima permsetbis bore wor) 2192000. ae eee Huacrurpormectie cearince bites com is tmenng (2) Tora fr edrut eva aduemant Soar fer hon (amb on SE Nemeat5wt) ( Clerarea raves tks vave) 38mm (O15.m) Sarat of ihe shal oe rack ‘Glaerance for valvos (ahatst vale). €.8¢ mn (025i) am 21, 783:021 A nm (z600 10 be (2) area of a tone 28.448 0010 nn es penis ara (1.1889 008 1p Bore n bearings fo the rocker arms “ Aun prise die (tN nn 29401 Fea rade Logo (860.000 cus Aci gars eee (cm) ise Sere in B00 ca ono... 255-2 D085 er eon oO) Mocqurssemssble carne baleen bs Barn Modrum pormzebe sere (em) aS ca eer Samm {eet (4) Clearance for velves (intake valve) 0.38 mm {.015in) (© Terqua or sn recs. 45-47 Nemn Clearance arabes (ous va)» Or (025i) om \ (8) Deer ft on eae + 0015 te 000) foro rer pases +075 (ie coro) 3208 Diesel Truck Engine 2 SpecificationsValves NOTE: GUIDELINE FOR REUSABLE PARTS: VALVES AND VALVE SPRINGS, Forms SEBFSCC2 and SEBFECS4, have the procedure arc epectealans necessary for chocking used valves ane vahe springs. (8) Diameter of valve sem: 7E302 ane 9.7682 Intake Valve... 94000013 min (3725: 0005in) (Use again minirum clameter ofthe valve slam 3.42 mm (971 in) 91 TSG and S525 Eanaust Valve fapared ser) Head end of valve stem 9415 40.019 me (3708 =.00081), Use again minimum diameter cf the head ers of vale ‘tern ‘3.37 me (3899) Lock end of vane stern 9.4962 0.013 m0 (3715 0005) Use again minimum ciaeter cf the lock ard of valve ster 8 40m (37049) Bore inthe value guides (take and exrausi) 9512+0.013mm (3745+ .0005in) Maximum permissice bore the vale quices (worn) Messure 190 rm (731m) da2p m vave guce owe tom both ends othe valve gude =... 8580"e" 37601") (A) Ande of vaiveoce Ike VON oon ene ene OPENS Exraust vane ss 45515 (8) Diameter of valve had (ciake vai) 58 19-40.13 m7 (2084+ casin) Daareter of valve head (owen —— \ahe) 4582 013mm (1804 = CO5in) f (8) Tmckress of vaio ip teaka vane 281mm (0911 anak Use again miriam val ip ices {7am a (G01) Exhaust valve ‘80 un (083) Use agun misma vaie ip NESS mnnee 12TM (1). 96498 Sarin for valves (outen (65019) Leng urder tes trea $8.47 nm (17900) TESLA soerensracene 18502 TOON (LEESB) Use aga minimum load at rgth under tas force 1e6N G73) Lge erg eae spss a S2zare Use aga minim. ad at vane open poston “600 38) Free rai afte tes 5177 mm (20980) Oitees derratr senzmm (1.801) Sorng must rat be bert wore than... 180mm (O71) (1) 985485 Sexing er valves fre: Lengbs under test orca $247 nm (1.8720) Tae foro a1 2=90N Ose 26) Use again mii oe al gt ander last teve : BION (184m) Lenge’ of spy eave open postion 2 23urn (1072) Use agan minimum load at va open positon. 29610 ‘eae, Free lngt ator ost 487 mm (1 9201) Gulsde darter 26.67 mm (1 050") Song must net ba bert ethan 170m (087 0) (@Dctance om thon ft valve tha vate ering spacer seat 52.0 ECE nm (2088 O1SiN) ‘3208 Diesel Truck Engine ‘Specificationsc Valve Seats And Inserts Intake Valve (with valve seat insert) (1) Diamneser ofthe valve Sea in .. 546400053 mn (2 15004 O00 in) Bore head lor valve Seal insert... 54.564 10.073 mm (214704 0006 in) (2 Depth of bore in head tor vai seat insert 11.23 0.0% mm (442 + 0Oin) (@ Mexin permissiie wid ofthe face of the valve seal reser 8.06 yn (120 in) (4) Distance ‘tom head of vale to ovine reed feces Masimum permissibe (vake cles). 7.73-rm (068 in) Minimum permissible (ava ciogod) .. 0 mm (06 in) (8) Angle ofthe face ofthe vawve seat inert... gO vest He" (6) Qumda dame ofthe kee ol Lie valvo seat inser 52 23:4 0.13mm (2045 2 005 np Meximam permeuite 2.05 nm (2.086 (Argo ting face ot rmesirnurn seat dameter) 15 Intake Valve (without valve seat insert) ~~ ¥ co (1) Dietaree trom neas \aNe to he bow cf the vahe seat smaler to maka the face 432mm (770m) ‘3208 Diesel Truck EngineExhaust Valve w @ rp °° a 6 © ” Tee) Deoth of bore in head ior valve seat MRE sssoiennenne 128 013 mm (442.005) Diameter of vave coat crt 98.565 +0013 men (.9120 1 0005 in) Bora in heast for valve sie Pert. 8 489 + 0.018 ire. 17.9090 OO0E in) Mextrum permisscte with othe lace ofthe valva sest insert 2a? mm (105%) ‘Ditanez ‘tom head of valve to evince head face Maximum permite (uae ) Turbocharger ‘TMS1 & TMS4 (1) Era play for att (ren) (0051100081 mrs {0020 to,0332 in) Tighten botte that hols Beck plate te Dearing heusing © ‘O52 7 Nem (649 bin) ‘Tiahlen screws that hed thnust beating a 2B = 02 Nem (2220 in) ‘Dametar of suriace on shat oural) fr te bearing @ ® (en) 1298910 13 000mm (511510 S118 in) NOTICE Bore in the Dearing (907) ene mnns 13.028 0 13.088 en Do rot bend or add stress to the shaft when nut is loosenec (51290 5133in) oF tightened, © Bore n housing (new) 20.175 10 20,128 mmm (.70430.7348 in) Ouseide ciametor ofthe beara (nen) 120006912 29.081 mm (7901 to 7806 n) > (©) Turbine enc ol sal ing, end gan when istaied in a bore of 20.90 mm (828 in. -010100.38 mm (02410 945 in 3208 Diese! Truck Engine 148) Specifications(7%) Put 22506 Throad Lubricant on tho shat threads and fon the nul face and ighten rut to... Nem @Slo “Thien rut more rer NOTICE Do not bond or add stress tothe shaft when nut is hosened (or tightened. (lope end ol sea ing. end gap when installed in 2 bore of 17.463 mm (6875 1). 10.03 00.38 mm (oea6 D5 n) (9) Thickness of trust bearing 495910469 mm (716 9.1720 7) (10)Put $P3967 An Seize Compound on thas and tigen ‘ot hadina bans San 2 ren jintbn Engine Oil Cooler And Filter use ‘ asez20re Laer Oi preseure cilerence that makes the cl iter yas valve OPIN ne 1025 MPa 20+ 4 pa) i pressure aierence tnat make Ihe i cooler bypass valve open 425.4 25KPa (16-4 4 ps) (1) 9.9188 Soria (ol cosier ane of iter types valve) Length under test force 482mm (170 0) Test force ISEN G50) Fee length aller et 57. 9rm 2.26 n (uisde aemcter Hem (420 n) ©) Ot iter bypass valve (@) Torqua fr ruts that hotel colar core ol calor hase (rand terque ony) 2243Nem (16-2216) NOTE: 1 appicatie, assemble gasket tool cooler base with indexing ein toveard the front of the engine and the uo poston, (4) Ot coder bypass vave. 3208 Diesel Truck EngineOil Pump > cours ew WFR OF Pare (6) Clearance of oll purnp rotor tip when measured with oll pene ion oe Soswezomm en una ria cone i Siem (oni NOTE: Taro level. to 24700 wa (1) Front hag ansony on 2) 0 pnp cover ase (181788 Sina (uno cana rel! vate) Length detest fee 5.54 nm 2960" Vere Oe RUN aE) free rg ie azar ao} Oascosanctr Geesmnlare 2) (8) W228 Song (ure eraser ll vase} 00 Lavette al fo nae S04 (28507) ; Test force 0 14N (65 +3) es Fas rgb aka Ses G30} a, Outous dametr wzimmcarsn) ==) Resa wns (©) Damote of barn earn). 71.2240. en (4) i of pup rs pe). 9647430008 oasis bern {1.4960 0003 ir) nae eee Depo courte fet heg €) Posi ota bwatngjncten rar verbow (EW) oan 36.576 0.025 mm (1.44004 0010 n) RL weet Teo (6) Manu parcial ft pure ee then sured ne lary ncaiod grt = ae ae gr (0264) > 3208 Diesel Truck Engine +20 Specifications eeOil Pan Water Pump i” 9) a ee (1) Teme for bots that hokt oil pan Pat ANern (2) Teme for of pan cra pis boo must Delo assembing Lea a ma housing Iv, ooply 409608 Seolant Wicang fo the Oil Level Gauge (rly, Remove oxceas cealon note susan: Pur 983263 Thread Low 19 OD, anu fmising bore be‘ assembly aN 1 Q ase (1) Guide cosartly, Ascerrle lower part of quide aeserrby (1) =o tt Point 41s evan vith totom surface of bisck wihin OB mm OBini 3208 Diesel Truck Engine 421 Specifications | oSL BELT TENSION CHART wer | woTH7GP | SELTTENSON | BELTTENSION | persue ofr Tor | OF PULLEY INITIAL *useD™ BORROUGHS GAUGE NUMBERS GAUGE READING | GAUGE READING mR fem) im | N r N | tb | OLD GAUGE NO. | NEW GAUGE NO. 3a wr | aaa | 96s 300 [ase 22] oss | mosm| ors | BTsI95 Br357 [11588 | 5e7 [7270 500 [suaz22| ozs | Oosa| 90210) BTSs Bra3e7 sv 1588 | s28 [1524 600 | su=22| 1205 | aooeae| Sz 10) eTaaTeais | BraTz | Tin 1748) 286 [ 1868625 [eoe22| w0xs | dose | eosi0| eTaz724is | eTao72 ye | 1905) 700 [1759 680 [so 22] 12024 | aoosae| QOF10) OTAIIEW | _ATATIC Wee | 2909 | oes [2250 | ove | sae =z2| 7025 | eoosm| oE10) TaRTZETS | eTasTEC ek | 272 | 1000 soos 20 | 10=6 | weg eas | 110270 Bro 108 I ‘MEASURE TENSION OF BELT FARTHEST FROM THE ENGNE TRITAL BELT TENSION orarew bat, USED" BELT TENSON s for bel! witch hes more then 20 minus of operation a ated speed of eine avoese4rt c Water Temperature Regulators eee eer, ‘9N5121 And 763472 Temperature Regulators ecer7e1 reas “Temperature when completly oxen ‘ONS121 Watar Temperature Reguator .... 92°C (197%F) CRATE Water Tergaraturs Raguiator 98°C (208°F) (1) Disance comply 2penmpeteiens nl be mare tran = 37.85 mm (1.490in) 3208 Diesel Truck Engine 182 ‘Specificationssore [standart anal 114300 0 114338 rn 5000 16 07S tocommencalon mase 29 aka he Cyn eF De tre rest ze ger when the sie as bore i. 114.382 mn (4.506010 Gyre tore must be made ne nox sto larger when Be azeol te Soe & "44520 mon (450809 Gyre bore 1.57 om (029) srger than te cr gral SUC] eerie 17MBRT E0013 mm (4 SE + ONS “The tevarrmerdation is made to maka the cine tore theres size larger wher tha a2 of the.nore s 114.860 mm (45260 n) Gyinde bore musi be mace Une next age largor when ire sea ol re nore is 118.087 mm 45290 in) Gide brs 02m (019 ame tar te ofa reas SLU] sens ony 178-329-0013 tam (1 5405 = £005 in) Mant patio waar of oye bores fecplocorent of he eyinds Book is novetsay) Naso (482900) Temperature when completly (@ Borein lock tor camshaft baacheg 67 374+0014 mm NIT Wate Temperature Regus. 92% (187%) C225 = 00058) Minimum completly open dfatenes NOTE: rst carnchaft bearings withthe cil noe toware the lop of he eyarar bho (3) Wan oth Bean cap iss. TERBZEEOOIB MM 6500-4 COO? F) i iim perrésible wid of min brs Cylinder Block eH we 579 ren 16 8680 in) vio ci man aearrg exp aude tn cytesor a3 105599 1 2ot3mn WEED OOSIep (2) oven block tor nan bentIAD i.e. S47! £0013 rey (2707S + 0005 7) Permasie amourt o! darrian in bore 194:191094-2! mm (870610 3.709 +) Measure veer ofthe ofincer core at the top and bottam of siston rine travel (8), Torque fo: Sots holding caps for main bearings ‘2, Pul 2P2306 Thvead Lurican! on bolt hvaais end washer aca b. Tehlen af nots in ruroor sequence Dy 40h OE SIOK ¢. Pula mark on each bol and coo. 18. Tighion al wots i rurber sequaree ‘rom atk 105 3208 Diesel Truck Engine 1:23 ‘Specifications,co Connecting Rod ! i <— “Cy (8) Dimension (nen) from canterine of crankshaft bearing ‘bow 19 botom of Mock (pth ais) -- 95.250 40.088 mm (7300 £0015 in (7) Dimensic (nea) Irom ganterine of crankshaft boars Dore 1219p of BECK top J) nn $22.86 0.13 mm (12.708: 008i) NOTICE, “There are holes in the bores forthe main bearings, between the eyinders for pston cooling orifices. These hows must have ois opus stale low l pressure wile te she baz fort ol caser fe 957.2 em (14.06 i) tong the fengie bas piston cocling ofics installed if the base for he oil cocker is 268.2 mm (10.56 in) long he engine hes slugs inetaios Pion coalig onions wore eliminated from 3208 nck engines effect with tuck engine 2730692 wth a rating of 180 Kv (200 np) @ 200 rpm er 169 ) (9) Face tuvoul ol spacer TLR. [Total indicate reacina) anwserea ATSAD 51mm (020) NITES, Ura (020mm £008) (4) Torque for bolts that hole ywrieel ars adactar to carkshalt TEAT Nom GSES BI) (©) Bore neout of acapier TLR 28mm (O10) 33 oe NMTBA3, M59 sosssn reece» O-¥8etam (028 n) 3208 Diesel Truck Engine 131 ‘Specifications |Bore Runout (Radial Eccentricity) Of The Flywheel: : > reste 5. Puno (escent) ofthe sore tre tywhel cutch, mus: no: exceed betring tor Flywheel Housing Runout Ccheceang Fywnost Bore Face Runout (Axial Eccentric Of The Set te dla Inccstor to ree! 0.00 en (200) Turn the yee! ane ced the nd calor very SO" The difference between tha lower arc hicher meseurerents taken at al four cores must nat ce mere thar 0.15 mm (C08 i}, which s the meximurn permesibi ‘ote runout (ral eocenmicty) ofthe aro {875096 Dal Inciostor Group Ietalod ia ndicato 0 tho crenkahaft tange go the anvi owl Louch the fe of te Mhwrnee! housing. 2. Auta force on the crankset lowasd the rear batora racing tho indicctar at each pan. 308 Diesel Truck Engine 1-32 Specifications — $lCc ec70P) zaarn A (pOTTOM 3, Wan ial nesoatr seta! £00 mr (000 in) a wocaion <4), turn te crac hstat and real he Incicatr at jocaors (B). (Cans iO) 4A. The itterence batwaen lower and higher measurements Oo taken aa four pois must aot be move than 0:25 mr (O*0 i), wich i the raarrum dermissible ce ru cut laxal eoventrety) of tho 1yrhaal housing, Flywheel Housing Bore cToP) oes ‘A (BOTTOM) NOTE: Write the dia indicator measuremenis with the poeta (4) and negative (-) lation (gre) The rotation is aneary for making Ine oakeuatiors inthe charl cae aioerier 11. wits the dal ncicatr in postion a (C), aust the cal indie lo 0" Geto), sh the cranksha up agus! the top beering, Wits tro “eaeureent for beering clearance cine tin 2ohien (C)- 2, Divide tne rreasurament fom Sleo | by 2 Wrie ts umber on ne tineaumne (8) & (D), 8. Tum the crankshaft to put the di Incteator at (A) Ads ‘al nica 10" (200). ‘3208 Diesel Truck Engine 1-33 Specifications4 Turn the eranianett oourtesiocivise to put the dial inscar al (8), Wri the meas-rern=nt H tho crort 5, Tuin the crankshett courtarcicckafs fo pt the cal inciwator et (0) Wie the reasuramert in the chart 6. Tum the crankshett countereicckaise fo pat the elt Incteator at (0). Whe the measurement n tha ert 7. hale ines | and by eating, 8. Subtraci the smaller number tor sho lerger furiber in ine Min columns () 8 (C) The resut isthe Fexzareal “ecoentaty" (oul of round), Line. eatumn (C)i2 he varlica! sxcerticty, | pie i sderar ne cpet—--t—J Fem! eres ean out ctr REN Shr A em creriaet Nor acceeraste_| are |_| | AScePTABLE (64) ae (ox) 1 T L ‘TOTAL VERTICAL ECCENTRICITY 065 3 Ow oo (02) (os) (005) (208) TOTAL HORIZONTAL ECCENTRICITY ws Hi ie Total Horizcntal Eecanlety 8, 01 the graph tor total eccentioty rd the pont of iersecio: ol the Ines fr varied eccerrety ana ronzanta eosertieity. 410. | tno paint a ttersetion is in the rane masked! "Accentaole" ihe bors isin algrrert Fhe port of Inte-geckin fs nthe renge marke= "Not Acceptable’, ne fywheal nousiig must be onanate, 8208 Diesel Truck Engine 134 ‘Specifications >Alternators And Regulators Aegulsor (905295 Inside Alternator) oO Vo Si ani No Ashmont Delco Remy Alternators Ferman vole erge : rate 16v ‘376352 Alternator Votace rating Day Forty Neg Gene Rotation ther Draeson Speed for testing rem) 2600 10 6800 Output (00d) 1A@ 284 Output (cole) - sn@20v Fated outout (het) at max seed 35a Fila current at ated voltage and 27°C (80%)... 25103.2A, Postive output toma 1162 6.2%080Nm 51071 Ibi) (1) Gieund terminal torque -... 1 7to23Nem (15 10261 In) @ Srett nat toove 85 lo 1OONem (7D t0 8016 th Regulotor (376354 - Inside alternator) ed siereaet Votage setting ho Adustrnent Pernisibe voltage range eve 2Gt00¥ TGT8B9 Alternator Voltage tating wi tay Pouity Neg Gms Rotation Ether Creation ‘Speed ‘or testing (iprm) 28009 6500 Oulput (cctl nnn BA @ IAN ‘Quip (ale pen@ ay Fated eutput (hot) et max sp0sd ws nco 08 Feld current at ated votaga and 27°C OF) wun. Tinga AaBeAEPR Foste output torinal toroue 821080Nem (Sto 71 6) §) Ground terminal toque .... 17%02.SNem (150 26 bin) £2) Shalt rut torque sce 95t0 109 Nem (7010.80 0) 3208 Diesel Truck Engine 1:35 Specifications:9805078 & 6T1194 Alternators Voltage rating tv Play eis Nag Gen Fioteton Either Direction Output et 2000 mpm (cold) 204 Output et 5000 rom (cold) Fated output (het) [N} Toxque fer et nut for battery connection 28104 Nem (25104001) (2) Torque fer pulley ms 027 Nem 755101 Voltage Regulator (58828) Is interally mounted an is no asjustable B14 908081 8 671196 Alternators Bosch Alternators Pelarty Negima = Rrtston tho: Dracton tpt 3 2500 rem fea 2A ‘Quiput at 7000 rm feold) ata arse Rata cut (2 404 (0) Toreus sorts mt or lier =ennection Z8i045Nem (251040) ——_a90 arenetor (2) Toraus ‘or uy soo Nem (iosbiot, ‘Voliaga Reguiater (376354) ie itary mourios and nit Noes tite — asian. Polarty Neg iva ott EtrorDrecton Speed lor ssing (pm) sa att ca wa Cutout het. ara Feld Curent a 28V and 25° (77°F aa (9) Torque tr puley nto $510 1}ONen (7010 Inf) (2) Toreus fer opt trina = 75%0 10 Nor Geterobm Toqe to gous taming... 2/10 28Ner (191925 rb) Fegultr umber 97567 3208 Diese! Truck Engine 136 Specifications =Bosch Regulators 9867567 Regulator Volege rating Pay Poly Neg Gera 83043 Alternator Veiage setting range 26710289 Voltage rating ae aay 408 Polerty Nea ine 808145 Regulator D> Reiaion Cocrniss ee nems Speed fr testing (roto. z ‘5000 Vvatage rating Output (eal) 7 402 Pasay Output hot 50h Vottage seting ange Fete ourran et 28V and 25° (7°) 298 Max Outpt at 28V sore (1) Torque for pley nut SOtSNeM ET EAM (2) Terque tor output wanna) Bs 78+05Ne (+7 %m) , (Torque for eld De terminal nat 1.70-2025N-m (1522 In) (@) Torus for ground (6) ermal ut Torque for W terminal foot shown e209) Regulator Nunber 05148 3208 Diesel Truck Engine 137 ‘Specifications eee ———Nippondenso Alternator ‘Arse Spcaiiatine Tamiarne | _s04sra oa ‘Wokage rating av | uv Polarity [Nes ond ‘Neg Grid } Feito tie Coke Tes e05 FE) 009 3000 Fated ett et 25 a Out cage sa 1a) ames Turn on speed (rpm) | 2000 2000, {0027Nem | 107m (adteynatverae | Vessbm | CeLeae wits aseanone | geenm 4th eT0709 Nerretar ers-mtuce | deni ) Bary trina 4ELOR Nw Bion (ete) Nippondenso Regulator ert tran 41D wm 8) toraue (9829 bn) Regulator Specifications 413 0X Gaiaaiarno 71a oo ern aisbeid eas retin av 1, Genre wens sea Tit Fog ed —| g : weuspomnge | 275e1v | 14058 350 rears ones 7727S equator 2G4574 Alternalor 3208 Diesel Truck Engine 1-38 SpecificationsStarter Motors Delco Remy [57069 Rogulator Air Compressor ngs I | ‘ (1) Torque for nut that holds the eve oulay 7onen obi) NOTE: Tighten nul more to get alignment of hole for oxen pin, (@) Toes tor enue rat hola a i compress TO+7Nem(7045b') 3208 Diesel Truck Engine 138 Specifications a neeeeeeeeeeeeeeeeeeeeeeeeeeeeeeentlDelco Remy Saver Motors 7 vorage [wv wv |v a pay ae Ccateplar No er) sects | _—_a5000 308547 aca0s Rovaion a= sea fro to ae ore ow ow ow ow ow No Load Seed nates Fm 0.7000 ssoo00 500.900 33008400 e000. 8400 uren: Cormureton 1010 1000 FoWw 108 so1074A 5010784 (Craw wits ise 1704 Selena" "TRV Starter Votre Scendia at OV 28V Starter Motors Solenoid at OY (1) Tetrrnal torque... 27.040 28 Nem (201928 9") Bosch 2) Screw ‘orque 47.610230Nem (191017 by Clearance betawen pinier and housing ASto8amm (38to 891) Prestolite Brust ie ‘Bosch Starting Weters (28) Catwolerwunter —_[anaiax| —areans | Troe later es eer fom thet snd cw Prestolite Staring Mato @4V) pias po [Saterita Nontber 6557 Waar 5500 oteton as seen ow Wisma Corot 10h ro the dvs end Cran Ro Load Spee 7000 Nirirom ary Fount Gersorpon tA (6) Toma! mut oQh0 oon 7OIINEM (1ST) ee eae (2 Service limit of brushes: woes 125. (691) {3} Serve limit of commutator dame... 48 mn (1.9in) (1) Housing bat oreue won TYNE BIO Prion ng oearcloarance 1g0s80m (2) Termina rut torcue vai... 27,0 10308 Ker (202025 ‘Soienoid terminal torque dioB mm (108 OOK (3) Clearance between pinion and NOUS sss 05118122 mm (020 t0.060in > 3208 Diesel Truck Engine 1-40 SpecificationsStarter Motor Solenoids Prestolite Delco-Remy Voltage Caterer Prt Rurnber a Gument Consusrotan (Craw) Putin winds coo BBZWD BBA @ IV Haid in WiNciNGS vcersanenene M1 DEBA @ 12 Torque for sal NETHMAIS ooo ns 1 1OZEN (151020 bin) Vig issiainstcunastisinaieias pay Oslerpir Part Number — Trees Bosch ‘Curren Gonsumption (Dray Puli ing se De T1SA@sY Hedin woargs BE Aman @ 20 voltage raw | I > Ssteroter Part naan rags civ eae ve (I ent Conaurpton (Dean) Putin mings . 22026 7A@5V Holdin nincings » 136 (544 @ 10 1), 4¥M818 Spring (eantact release: Longtn ureer ost free 107 em (22in) Toa tx @+2N@D4 Sip) Frome legit aioe eat "33.105 ( 832 021m) Outs demeter ...... 863-£025rm | S75=.010in) (2) O7608 Spring te return the citoh eve Lenat under es fe seme en BRGiren (1680) TOE ITED ene nvemninnrngr ee SEEN (140 51) Free length tio eat |. FOB L Smmm (379+ 02 im) Poi Outside emer... 36.36 + 0.36 rm 1.983.4.015in (8) Torqua tor small termina ute. 181034Nem (181030 919) “Torque tor arge ternal rut wan es 27-110387 Nem Vatiage 2av iesbe Caterilar Par] Number 70866 Curert Consumption Draw) Palin win 8310 125AaiSY Holdin sincinge LAN Slo BBA at2v Resstarce of pulin windings Resstarce of holon windings 9208 Diesel Truck Engine 141 Specifications ss