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CATERPILLAR

FORM

NO. SENR7590-01
IN
I

FOR USE

SERVICE MANUALS:

VOLUME SPECIFICATIONS, REG01312


D4 TRACTOR, REG00632 D4E TRACTOR, SENR7624 D4 SA TRACTOR, REG00784 D4E SA TRACTOR, SENR7636 NO. 112F MOTOR GRADER, REG00885 120G MOTOR GRADER, REG01654 130G & 140G MOTOR GRADERS, REG01652 225 EXCAVATOR, REG01578 518SKIDDER, REG00971 920 & 930 WHEEL LOADERS, REG00514 941 TRACK-TYPE LOADER, REG00527 950 WHEEL LOADER, REG00548 951 TRACK-TYPE LOADER, REG00783 955 TRACK-TYPE LOADER, REG00634 955L TRACK-TYPE LOADER, SENR7364 955L TRACK-TYPE LOADER, SENR7672

p(iDiiifeira
3304 Vehicular Engine

7Z1-UP

3304

VEHICULAR ENGINES

SPECIFICATIONS

INTRODUCTION
book are on the basis it was written. The specifications torques, pressures of operation, measurements, adjustments and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information which is available. For a list of the most current modules and forni numbers available for each Service Manual, see the SERVICE
specifications given in this
at the

'^
If the part is

The

can be used again.

equal to or within the

of infoniiation available

time

specification given, use the part again.

When

the

word "permissible"
is

"

is in

the description,

the specification given

the

"maximum or minimum"

tolerance permitted before adjustment, repair and/or

new

parts are needed.

MANUAL CONTENTS MICROFICHE REG


When
the

139F.

words "use again" are

in the

description,
if

A comparison can be made between the measurements of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the remainder of its service life is good. If a short service life is expected,
replace the part.

the specification given can be used to determine

apart

77200X2

NOTE: For Systems


3304

VEHICULAR ENGINES, Form

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

ENGINE DESIGN
Bore
Stroke
4.75
6.0
of Cylinders
in.

(120.7

in.

(152.4

mm) mm)
4

Number
Firing

Cylinder Arrangement

'in-line
1, 3, 4,

Order (Injection Sequence)

Direction of Rotation

(when seen from flywheel end) *No. 1 Cylinder Is Opposite Flywheel End.
EXHAUST VALVES

Counterclockwise

2
INTAKE VALVES

CYLINDER AND VALVE IDENTIFICATION

NOTE: This book has been completely changed from

the former issue.

3304

VEHICULAR ENGINES

SPECIFICATIONS

INDEX
Air Inlet

and Exhaust System


43 37 42
41

Engme Design
Engine Mounting Bolts
Fuel

Air Cleaner

2 76

Camshaft Cylinder Head

Glow Plug Positioning


Exhaust Manifold Exhaust Pipe and Muffler Turbocharger Turbocharger Impeller Installation
Valves (Dl)
Valves (PC)
Valve Cover Valve Rocker Ar'ms and Lifters

43 43
46-51
44, 45

System System Timing Fuel System Usage Chart Service Meter Tachometer Drive Fuel System Scroll (Dl)
Fuel

6
6
7

7
31

Fuel Injection
Fuel Injection

32

40 38, 39 42 37

Fuel Transfer

Pump Housing Pump

31

Governor Governor Housing


Injection Nozzle

35 34

Basic Engine

Components
69 68 66 67 70
60
61

Fuel System

Scroll (PC)

Bearing Surface (Journal)

Fuel Bypass Valve Fuel Injection Equipment Fuel Transfer

Connecting Rods Main Bearings Connecting Rod


Crankshaft Crankshaft Hub Cylinder Block

Pump

33 33 27 30 27 30
28

Counterbored Block Spacer Plate Block


Cylinder Liner Cylinder Liner Projection

Governor (Earlier) Governor (Later) Fuel System Scroll {PC & Dl) Timing Gears Fuel System Sleeve Metering Fuel Injection Equipment

29

36 36
(Dl)

18 18-20
21
21

62
62 63
71 76, of the

Fuel Ratio Control Fuel Transfer

Pump

Counterbored Block Spacer Plate Block Fan Drive Flexible Drive Coupling Checking and Adjusting Alignment Flexible Drive Coupling
Flywheel Flywheel Housing Flywheel Housing Bore Flywheel Housing Tightening

77 78 73 74 75 72 72 70 64 65

Governor Governor Governor Governor


Fuel System

Control {D4E) Control (120G & 130G) Control (225) Control (518)

23 22 24
24
21

Injection Nozzle

Sleeve Metering (PC)

Fuel Injection Equipment Fuel Ratio Control Fuel Transfer

8-12
13
13 14

Pump

Flywheel Ring Gear Main Bearing and Connecting Rod Bearings Pistons and Rings

Keystone
Straight Side

Cooling System Coolant Flow Switch Fan Drive


Radiator
V-Belt Tension Chart

Governor Control (920 & 930) Governor Control (950) Governor Control (951) Governor Control (955L) Fuel System Sleeve Metering (PC & Timing Gears Water Separator

16 17 15
Dl)

25

26 25

59
71

Gauges
Converter Oil Temperature Indicator Fuel Pressure Indicator Oil Pressure Indicator
97

58
57

Water Pump Water Temperature Regulator


Electrical

96 97

57 59

Water Temperature Indicator


General Tightening Torques
Lubrication System

96
4

System
79-82

Alternators

Engine
Oil

Oil Pressure

Alternator Regulator

83
85-87
84, 85

Breather

Cap
55,

55 56

Generator Regulators Generators


Starter Magnetic Switches Starter Motors Starter Solenoids

Oil Filter Oil Oil

56
97

Pump
Pressure Switch
for Flared

52-54

92 88-92 93-95

Torque

and O-Ring

Fittings

3304

VEHICULAR ENGINES

SPECIFICATIONS

GENERAL TIGHTENING TORQUE FOR

3304

VEHICULAR ENGINES

SPECIFICATIONS

TORQUE FOR FLARED AND 0-RING


The torques shown
in the chart that

FITTINGS

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

Inverted Flared fittings (when used with steel tubing), O-ring plugs and O-ring fittings.

E^fe^&a E^^gp
45

^^^p^^^r^^^^vsss)

oaa
FLARED
12.70
.500
3/4

PB
O-RING FITTING - PLUG

INVERTED FLARED

37

FLARED

45

SWIVEL NUTS

TUBE
SIZE
(O.D.)

3.18
.125

4.78
.188

6.35
.250

7.92 .312
1/2

9.52
.375

TUBE
SIZE
(O.D.)

15.88
.625
7/8
1

19.05
.750
1

22.22
.875

25.40
1.000
1

31.75
1.250
1

38.10
1.500
1

50.80 2.000
2 1/2

THREAD
SIZE
(in.)

5/16
5
1

3/8
11

7/16

9/16
5/8

THREAD
SIZE
(in.)

1/16

3/16
1

1/4

5/16

5/8

7/8

TORQUE
N-m

16

+1

2
145 20

20 2
175

30 2

TORQUE

Nm
TORQUE
lb
.ft.

50 5
35 3

55 7

75 7
55 5

90
7

110 +7

135 15

160 15

310 30
230 20

TORQUE
Ib.in.

45 10

100

10

20

265 25

40 5

65 5

80 5

100 10

120 10

ASSEMBLY OF FITTINGS WITH STRAIGHT THREADS AND O-RING SEALS


1.

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


seal (5) as far back on fitting body (2) as possible. Hold these components in this position. Turn the fitting into the part it is used on, until backup washer (4) just makes contact with the face of the

part

it

is

used on.

NOTE:
To

If the fitting is a

connector (straight

fitting)

or

plug, the hex on the body takes the place of the locknut.
install this

type fitting tighten the hex against the


it

face of the part


2.

goes

into.
its

To

put the fitting assembly in

correct position

turn the fitting

maximum
torque

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


in the chart.
1.

body

ELBOW BODY ASSEMBLY


End
3.

shown

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

Fitting

body.

Locknut.

A71009X2

End

of fitting that

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


4.

seal. 6.

3304

VEHICULAR ENGINES

SPECIFICATIONS

FUEL SYSTEM USAGE CHART

3304

VEHICULAR ENGINES

SPECIFICATIONS

SERVICE METER
(EARLIER MODELS)

(II

Torque

for bolts

for service

which hold service meter or adapter meter drive 96 24 lb. in. (10.9
for cable nut

2.8

Nm)
N-m)
AI756axl

NOTE: Torque

50

lb. in.

(5.7

ELECTRIC SERVICE METER (LATER MODELS)

6N5906
Polarity
is

negative ground.

Operating voltage

24V DC only

TACHOMETER DRIVE

(1)

Torque

for cable nut

100

20

lb. in.

(11.3 + 2.3 N-m)

(2)

Tighten bolts which hold adapter for tachometer drive to 96

24

lb. in

10.9 2.8

Nm)

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

PC)

FUEL INJECTION EQUIPMENT

VIEW A-A

Firing order (injection

sequence)

1,3,4,2

Injection timing before

TC

(top center):
to 044,

Fuel
Fuel

pump pump

serial

numbers

899

12 30' + 13 30'

serial

numbers, 044, 900 and up

Torque

for bolt in tiole for

timing pin

108 36

lb. in.

(12.2

4.1

Nm)
(3)

Torque for bolts that hold governor tocamshaft


(1)

vi/eight carrier

End play for camshaft with sleeve installed (new) 023 .018
installing sleeve

in.

(0.58

0.46

mm)

90 101b.

in.

(10.2

1.1

Nm)
mm)

NOTE: When

Diameter of rear bearing surface


(new)

(journal) of the

camshaft

shaft to prevent

damage

to

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

2.3720

.0005

in.

(60.249

0.013

governor housing.
(4)

Bore in the rear bearing for the camshaft (new) 2.3750 .0005

Governor spring:

in.

(60.325

0.013

mm)
(5)

Make

reference to the chart


valve:

"GOVERNOR SPRINGS."
"BYPASS VALVE SPRINGS."

permissible clearance between the bearing and the camshaft bearing surface (journal)
(worn)
(2)

Maximum

Bypass

006
fuel control shaft

in.

(0.15

mm)
(6)

Make

reference to the chart

Diameter of
(new)

3530 .0003
In

in.

(8.966

0.008

mm)

Diameter of front bearing surface (journal) of the camshaft (new) 9990 .0005 in. (25.375 0.013

mm)
mm)

Bore
(new)

the housing for fuel control shaft 3543 .0005

Bore
in.

in

(8.999

0.013 mm)

(new)

the front bearing for the camshaft 1 .0005 .0005 in. (25.413 0.013

Maximum
in

permissible clearance between the bore the housing and the fuel control shaft

(worn)

003

in.

(0.08

mm)

permissible clearance between the bearing and the camshaft bearing surface (journal) (worn) 003 in. (0.08

Maximum

mm)

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

PC)

Fuel Injection

Equipment (Cont.)

GOVERNOR SPRINGS

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

PC)

Fuel Injection Equipment (Cont.)

((.OF

LIFTER

A98051X1

Install

guide pin

(A) to deptti (B) [.642

.003

in.

(16.31

0.08 mm)].
lifter.

Slot in guide pin (A)


(7) (8)

must be

in

area shown from center of

Torque

for

bushing
for injection

70 5

lb. ft.

(95

Nm)
mm)

4N4318 Spring

pump:
1

Length under test force


Test force
12.5

.35

in.

(34.3

1.3

lb.

(55.5
in.

5.8 N)

Free length after test

1.566

(39.78 (18.49

mm) mm)

Outside diameter
(9)

728

in.

Torque

for bolt holding sleeve

on
24 2
fuel lines
lb. in. (2.8

control shaft
(10)

0.2

Nm)
Nm)
7 N)

Torque for the nuts that hold the (Use 5P144 Fuel Line Socket) Torque
for the

30 5

lb. ft.

(40

(11)

nuts that hold 105

the nozzles
(12) (13)

lb. ft.

(142

Body.
Put 5P3931 Anti-Seize

Compound on
120

threads of glow plug

and tighten
(14)
(15)

to

24

lb. in.

(13.6

2.8 N-m)

Tighten nozzle finger tight on body.

Torque for precombustion chamber (put 5P3931 Anti-Seize Compound on threads) 150 10
Positioning.

lb. ft.

(205

14

Nm)

NOTE: See Glow Plug

10

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

PC)

Fuel Injection Equipment (Cont.)

TYPICAL ILLUSTRATION
(16)

Torque

tor bolts holding

clamps on

tuel Injection lines;

With rubber damper Without damper


(17) (18)

84 24 lb. in. (9.6 2.8 Nm) 108 36 lb. in. (12.2 4.1 N-m)

Lever assembly.

Clearance between lever assembly (17) and governor housing when shatt assembly (19) is pulled against 437 in. (1 the governor housing

.10

mm)

(20)

Spring for the terminal shaft. Install the spring (20) for the terminal shaft so that the end of the spring is in the 30 range as

fet^^-^ZZZZ^

shown.

9S8597 Spring

for terminal shaft:


1

Color code (stripes)

white

Length under
Test force

test force

584

in.

(14.83
lb.

mm) mm) mm) mm)


AI0Z90X1
1

56.3
1.21
in. in.

(251 N)

Free length after test

(30.7

Outside diameter

1.635

(41.53
(3.43

Diameter of wire

135

in.

2P726 Spring

for terminal shaft:

Color code (stripes)

red

Length under
Test force

test force

584

in.

(14.83
lb.

mm)

109
1

(485 N)

Free length after test

.04

in.

(26.4

mm) mm)
mm)
mm)

Outside diameter

1.635

in,

(41,53
(3.96

Diameter of wire

156

in.

4N4366 Spring
Length under
Test force

for terminal shaft:

test force

584

in.

(14.83
lb.

156
1,016
1-638
in.
in,

(692 N)

Free length after test

(25,81 (41,61

mm) mm) mm)

Outside diameter

Diameter

of wire
for terminal shaft:

168

in.

(4,27

9L6508 Spring

Color code (stripes)


Put a load on spring of
5.00
lb.

yellow

(22,2 N)

Then make spring shorter by


Total test force

700

in,

(17,78

mm) mm) mm)

1970
1

,52

lb.
in,

(87.63 2.31 N)
(44,2 0,5
in.

Free length after test

.74 ,02

Outside diameter

1,518

(38,56

11

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

PC)

Fuel Injection Equipment (Cont.)

-^r-n

(21)

9S8632 Low

Idle Spring: test force


1

Length under
Test force

.20

In.

(30.5

mm)
mm) mm)

40 4

lb. ft.

(180 18 N)
in.

Free lengttn after test

2.00

(50.8

Outside diameter

880

in.

(22.35

12

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

PC)

FUEL TRANSFER PUMP

(1)

Diameter of shaft
(new)

for idler

gear 4914 .0003

in.

(12.482

0.008 mm) 0.008 mm) 0.008 mm) 0.013 mm)

Bore
(new)
(2)

in idler

gear

4926 .0003

in.

(12.512

Thickness of gears
(new)

3736 .0003

in.

(9.489

Depth of counterbore
(new)

3750 .0005

in.

(9.525

Clearance between end of gears and surface of pump body 0006 to .0022 in. (0.01 5 to 0.056 mm) (new)

FUEL RATIO CONTROL

SPRINGS FOR FUEL RATIO CONTROL

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

PC)

GOVERNOR CONTROL
(920 & 930 Wheel Loaders)

OFF

L>nCIZI3-e,

B41 448X1

LINKAGE ADJUSTMENT PROCEDURE:


1

With the governor in the OFF position, install lever (1) at angle (B). Adjust the length of rod (6) by turning rod ends (2) and (3) so lever (4) is at angle (C).

3.

Tighten nuts on rods

(6)

and

(8). 19'"

Angle A Angle B Angle C

is
is is

Move

lever (1) to

HIGH IDLE
(7)

position and adjust rod


(5) is at

(8)

by

20 + 5"

turning rod ends

and

(9)

so pedal

angle

(A).

30

5''

14

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

PC)

GOVERNOR CONTROL
(955L Track-Type Loader)

LINKAGE ADJUSTMENT PROCEDURE:


3.
1

With lever

(5)

in

Put the governor control (2) in the OFF position (approximately .47 in. (12 mm) from the end of slot in the guide. Adjust length of rod (3) so lever engine. Tighten nuts (4) on rod
(5) is in
(3).

force needed to (65 4 N).

move governor

the center between discs, tighten nut (6) so control lever (2) is 14.6 .9 lb.

2.

the

OFF

position at the

Angle A
control

for lever (1)


(2) is

and governor
102 5

15

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

PC)

GOVERNOR CONTROL
(950 Wheel Loader)

B41 450X1

4.

Adjust length of rod


rods.

LINKAGE ADJUSTMENT PROCEDURE:


1.

(3)

and

install pin (6).

Tighten locknuts on
37
6
11"

With lever
Adjust rod

(1) in
(2)

OFF
OFF

position.
(5) is at

Angle A
angle (C).

is

2.

so lever

Angle B Angle

is

3.

Put pedal

(4) in

position.

is

16

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

PC)

GOVERNOR CONTROL
(951

Track-Type Loader)

B41451X1

LINKAGE ADJUSTMENT PROCEDURE:


1.

3.
is

Make an adjustment
(71 6.3

3.

mm)

28.20 .12 in. at center of pins. Tighten nuts on rod and install
to rod (4) so length of rod
4.

Adjust length of rod (5) so lever position. Tighten nuts on rods.

(6) at

the engine

is in

the

OFF

rod on machine.
2.

Tighten nut
Distance

(3)
is

so force on knob

(1) is

13

lb.

(58

4 N).

Put governor control lever (2) in the LOW IDLE position, approximately .25 in. (6.4 mm) from end of slot in guide.

A
is

28.20

.12 in. (716.3

3.0

mm)
15"

Angle B

17

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

Dl)

FUEL INJECTION EQUIPMENT

VIEW

A-

Firing order (injection

sequence)

1, 3, 4,

(3)

Injection timing before

TC

(top center):

End play for camshaft with sleeve installed (new) 023 .018
installing sleeve

in.

(0.58

0.46

mm)
cam-

Direct Injection Engines with turbocharger


Direct Injection Engines

NOTE: When
23
1

on end

of camshaft, support the

shaft to prevent

damage

to parts inside of injection

pump and

gover-

nor housing.

without turbocharger

29

Torque for bolts that hold governor weight carrier to camshaft

(4)

Governor spring:

10

lb. ft.

(14

Nm)
(5)

Make

reference to the chart


valve:

"GOVERNOR SPRINGS."

Make a mark

(stake) the governor weight cover apart directly over the groove in the camshaft.
(1)

in

four places 90

Bypass

4N605 Bypass Valve

Spring:

Diameter of rear bearing surface (journal) of the camshaft


(new)

Length under test force


in.

880
3.53

in.

(22.35

mm)

2.3720 .0005
in

(60.249

0.013

mm) mm)

Test force

.18

lb.

(15.7
in.

0.8 N)

Bore
(new)

the rear bearing for the camshaft 2.3750 .0005 in. (60.325

Free length after test


0.013

1.73

(43.9

mm) mm)

Outside diameter
Pressure of fuel
fuel injection
in

527

in.

(13.39

permissible clearance between the bearing and the camshaft bearing surface
(journal) (worn)
(2)

Maximum

housing

for

pumps,
30 5 psi (205 35 kPa)

006

in.

(0.15

mm)
(6)

(Full

Load)

Diameter of sleeve control shaft (new) 3530 .0003 Bore


(new)
in

in.

(8.966

0.008 mm)

the housing for the

Diameter of front bearing surface Oournal) of the camshaft (new) 9990 .0005

in.

(25.375

0.013

mm)
mm)

fuel control shaft

Bore 3543
.0005
in.

in

(8.999

0.013

mm)

(new)

the front bearing for the camshaft 1.0005 .0005 in. (25.413

0.013

permissible clearance between the bore in the housing and the sleeve
control shaft (worn)

Maximum

permissible clearance between the bearing and the camshaft bearing surface

Maximum

003

in.

(0.08

mm)

(journal) (worn)

002

in.

(0.05

mm)

18

NOTE: FOR TOROUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

Dl)

Fuel Injection Equipment (Cont.)

GOVERNOR SPRINGS

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

Dl)

Fuel Injection Equipment (Cont.)

^lOF lifter

Install

guide pin

(A) to

depth

(B) [.642
in

.003

in.

(16.31

0.08 mm)].
lifter.

Slot in guide pin (A)


(7)

must be

area shown from center of

Torque

for

bushing
for injection

70 5

lb. ft.

(95

+ 7

Nm)
mm) mm) mm)

(8)

9N5862 Spring

pump:
1.38 12.5
in.

Length under test force


Test force

(35.1

1.4 lb. (56.7

6.6 N)

Free length after test

1.61

in.

(40.9

Outside diameter
(9)

728

in.

(18.49

Torque
shaft

for bolts that

hold sleeves on control

24 2
for

lb. in. (2.8

0.2

Nm)

(10)

Torque

the nuts that hold the fuel lines (use 5P144 Fuel Line Socket)

30 5

lb. ft.

(40

7 N-m)

(11)

Spring for the terminal shaft. Install the spring (1 1) for the terminal shaft so that the end of the spring is in the 30 range as

shown.

SPRINGS FOR TERMINAL SHAFT

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

Dl)

FUEL RATIO CONTROL

SPRINGS FOR FUEL RATIO CONTROL

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

Dl)

GOVERNOR CONTROL
(120G and 130G Motor Graders)

LINKAGE ADJUSTMENT PROCEDURE:


NOTE: DO NOT use
To shut engine OFF,
1.

control lever
pull

(2) to

shut

OFF

the engine.
(11).
8.

up on accelerator treadle

Tighten nut (A) just enough so position of control lever (2) is not affected by the operation of the accelerator treadle (11) and decelerator treadle (9).
With the parking brake

Loosen locknut (14) and adjust length of rod so top of decelerator treadle (9) is .19 in. (4.8 mm) above floor plate (10)
as shown. If machine is equipped with a thick floor insulation pad, (used with enclosed cab), adjust decelerator treadle (9) so top of treadle is .38 in. (9.7 mm) above top of floor plate and tighten locknut (14).

2.

ON

and engine stopped, BE

SURE

dis9.

connect
3. 4.

sw/itch

is

OFF.

Move

control lever

(2) to

HIGH IDLE
it

position.
(12)

Remove

pin (4).
10.

Loosen LOW IDLE stop do not touch lever (12).


tvlove control lever (2) to

Turn HIGH IDLE stop


locknut
(6).

(5) until

touches lever

and lighten

(7)

and HIGH IDLE stop

(5)

so they
11.

5. 6.

LOW

IDLE
it

position.
(12)

Turn

LOW
(8).

IDLE stop

(7) until

touches lever

and tighten
12.

Loosen locknut (16) and adjust accelerator treadle (11) so that distance from bottom of plate on treadle to top of floor plate (10) is 2.38 .12 in. (60.5 + 3.0 mm) as shown.

locknut
7.

Move
rod
(1)

Adjust length of rod (13) so distance from top of lever (15) to bottom of floor plate (10) is 1.50 m. (38.1 mm) as shown

lever (3) to HIGH IDLE position so pin (4) can be installed.

and adjust length

of

13.

Install pin (4).

22

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

Dl)

GOVERNOR CONTROL
(D4E Tractor)

A48074X2

LINKAGE ADJUSTMENT PROCEDURE:

NOTE: With
shaft
in full
is

on

control lever in high idle position and governor control position, put lever (4) on shaft at angle (D).
40'

1.

With pin removed from lever


(rearward),

(4)

move

lever

(4)

to high idle position

Angle (D)

2.

Move
in. (5

lever (Y) rearward until interference

occurs

in

linkage.
.2

Dimension
Tighten nut

(A) (approximately)
(1) to

14.2

in.

(361

mm)
N-m)

3.

18

lb.

ft.

(24
in.

Adjust rod end (Z) to position holes short of alignment [approx. mm)] with hole in lever (4).

f^

Dimension

(B) (approximately)
(2) to

19.2

(488

mm)
N>m)

4.

Tighten nuts

18 5

lb. ft.

(24
in.

Dimension (C) (approximately)


Tighten nut
(3) to

18.7

(475

mm)
5.

lever (4) to shutoff position and lever (Y) forward until interference occurs. Holes In rod end (Z) must be forward of hole in lever (4). If additional adjustment is required repeat Step 3, [.2 in. (5 mm) dim. may be decreased],
t\/love

18 + 5

lb, ft.

(24

7 N-m)

Install pin

and

cotter.

23

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

Dl)

GOVERNOR CONTROL
(518 Skldder)

B42382X1

LINKAGE ADJUSTMENT PROCEDURE:


1

Move governor
(2)

shaft (3) to

SHUT OFF
(4)

position

and

install lever

on shaft

(3) at

angle

(A).

2.

Adjust length of rod (5) so stop (B) from the floor plate.

on pedal

(1

is at

dimension
28 + 5

Angle (A)

is

Dimension

(B)

is

2.25

.03

in.

(57.2

0.8

mm)

GOVERNOR CONTROL
(225 Excavator)

B41452X1

LINKAGE ADJUSTMENT PROCEDURE:


Adjust distance (A) to 2.50
to
in.

(63.5

mm)

back edge of governor control handle 1400 t 50 rpm.

from inlay mounting holes with engine running at (1


)

24

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM - PC &
Dl)

SPECIFICATIONS

AS7414X1

WATER SEPARATOR

(1)

Torque
(3),

for bolt

9 3

lb. ft.

(12

4 N-m)

(2),

(5)

and

(6)

tighten to 12
(4)

Put 8M8058 Sealant on plug and fittings and lb. ft. (17 + 5 N-m)
17

Torque

for bolts

lb. ft.

(23

Nm)

3304

VEHICULAR ENGINES
(SLEEVE METERING FUEL SYSTEM

SPECIFICATIONS

PC &

Dl)

TIMING GEARS

Tighten bolts which fasten into


front plate to

17 3

lb. ft,

(23

4 N-m)

Tighten nuts holding cover for fuel pump drive gear to


(1)

20 + 5

lb. ft.

(25

7 N-m)

With the timing pin and timing bolt correctly installed, put a clockwise force of 50 lb. ft. (70 N-m) on the drive gear
for the fuel

pump and

tighten

bolt (1) to
(2)

110 5

lb. ft.

(149 + 7 N-m)

End play

for the idler

gear (new)

004

to .016
. .

in.

(0.10 to 0.41

mm) mm)
mm)

A4SIS8X2

Maximum

permissible end play (worn)


for the idler

.034

in.

(0.86

Bore in bearing gear (new)

1.3781
idler

.0019

in.

(35.004 0.048

Diameter of shaft for gear (new)

1.3741

.0005

in.

(34.902

0.013 mm)

Clearance between shaft and bearing (new) 0016

to .0064

in.

(0.041 to 0.163

mm)
mm)

permissible clearance between shaft and bearing (worn) 009


(3) (4) (5)

Maximum

in.

(0.23

Camshaft gear.
Crankshaft gear.

End play for the balancer shafts (new) 0035 to .0075

in.

(0.089 to 0.191
.

mm) mm)

Maximum

permissible end play (worn)

.017

in.

(0.43

Diameter of balancer shaft


bearing surface (journal) (new) 2.0825 .0005
in.

(52.896 0.013

mm) mm)

bearing for balancer shaft (new) 2.0886 .0024


in

Bore

in.

(53.050 0.061

Maximum

permissible clearance

between balancer shaft and


bearing (worn)
(6) (7)

010

in,

(0.25

mm)

Idler

gear for

oil oil

pump.
pump.

Drive gear for

26

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES

3304

VEHICULAR ENGINES
(SCROLL FUEL SYSTEM

SPECIFICATIONS

PC)

FUEL INJECTION EQUIPMENT


Firing order (injection

sequence)

3, 4,
1

Injection timing before


(1)

TO

(top center)
lb. ft.

13 30'

Torque

for

bushing 130 +10 or -5

(177 +14 or -7 N-m)

(2)

Thickness of spacers:

9N6496 Spacer
9N6495 Spacer

161

in.

(4.12 (4.22 (4.32


(4.42 (4.52 (4.62 (4.72

mm) mm) mm)


mm) mm) mm) mm)

166 170 174 178 182 186 190


194

in.

5M2697 Spacer

in.

2M4208 Spacer
2fv14209

in.

Spacer

in.

2M4210 Spacer
2M421
1

in,

Spacer

in.

2M4212 Spacer
5tV12691

in.

(4.83 (4.93 (5.03 (5.16


(5.26

mm) mm) mm) mm)


mm)

Spacer

in.

5S7189 Spacer

198

in.

4N9839 Spacer 4N9840 Spacer


(3)

203
207

in.

in.

1S206 Spring;
Length under test force
Test force
15.4 1.39
in.

(35.3

mm)

.8 lb.

(68.5
in.

3.6 N)

Free length after test

1.59

(40.4

mm) mm)

Outside diameter

979
for the fuel injection

in.

(24.87

(4)

Timing dimension

pumps;
(108.395
0.051

OFF Engine Gauge

with 5P4158 or 8S7167 4.2675 .0020

in.

mm) mm)
mm) mm)
A-5P4158 GAUGE ILLUSTRATED

ON
(5)

Engine with 5P4158 or 8S7167


4.2216 .0020
in.

Gauge
Length of pump plunger (new)

(107.229

0.051

2,5934 .0015

in.

(65.872
in.

0.038

Minimum
(6)

permissible length (worn)

2.5869

(65.707

Bore

in

the bearings for the rack:

Bearing at the rear Bearing at the front

5018 ,0018 5023 ,0015 4985 .0002

in,

(12,746

0,046 mm) 0.038 mm) 0.005 mm)

in,

(12,758 (12.662

Diameter of

fuel rack

in.

fvlaximum permissible clearance between rack and bearings (worn)


(7)

005

in.

(0.13

mm)

Bore

in

bearings for the


1.8755 .0005
in,

camshaft

(47,638

0.013 mm)
0.013

Diameter of bearing surfaces (journals) of the 1.8730 .0005 in. (47.574 camshaft (new)

mm)

f^aximum permissible clearance between the bearings and the camshaft bearing surfaces
(journals) (worn)
(8)

010
fuel lines (use

in.

(0.25

mm)

Torque for the nuts that hold the 5P144 Fuel Line Socket) Torque
for

30 5

lb. ft.

(40

Nm)

(9)

the nuts that hold

the nozzles
(10) (11)

105 5

lb. ft.

(142 7

Nm)
Put 5P3931 Anti-Seize Compound on threads of precombustion chamber and 150 10 tighten to
Positioning.

Body.
Put 5P3931 Anti-Seize threads of glow plug and 120 24 tighten to
(13

Compound on
(12)

lb. in.

(13.6

2.8

Nm)

lb. ft.

(205

14

Nm)

Tighten nozzle finger tight on body.

NOTE: See Glow Plug

27

3304

VEHICULAR ENGINES
(SCROLL FUEL SYSTEM

SPECIFICATIONS

PC)

GOVERNOR
(EARLIER)

(1)
(2)

Torque for nut

9
for speed limiter:

lb. ft.

(12 4

Nm)
mm)

1S9312 Spring
Length under
Test force

test force

86
2.38

in.

(21 .8

.19

lb.

(10.52
in.

0.76 N)

Free length after test

2.62

(66.5

mm) mm)

Outside diameter
(3)

67

in.

(17.0

9M3160

Spring for governor:


(stripes)
1

Color code

blue

Put force on spring of

5.0

lb.

(22 N)

Then add more


shorter by

force to

make

spring

900
19.4

in.

(22.86

mm)

Total test force

.5 lb.

(86.6 2 N)

Free length after test

2.34

.03

in.

(59,4 0.8
in,

mm) mm)

Outside diameter
(3)

1.39

(35.3

9L3617 Spring For Governor;


Color code (stripes)
Put force on spring of
1

blue,

white
(27 N)

6,0

lb,

Then add more force


shorter by

to

make

spring

900
22.2

in.

(22.86
+

mm)
2 N)

Total test force

.5 lb.
in.

(100.8

Free length after test

2.34

.03

(59.4 0.8
.39
in.

mm)
mm)

Outside diameter
(3)

(35.3

8IV19140 Spring for governor:

Color code

(stripes)

green
(18 N)

Put force on spring of

4.0
to

lb.

Then add more force


shorter by

make

spring

900
16.6

in.

(22.86

mm)

Total test force

.3 lb.
in.

(74.0 1.3 N)

Free length after test

2.34 .03

(59.4 + 0.8
.38 in. (35.1

mm)

Outside diameter

mm)

28

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES
(SCROLL FUEL SYSTEM

SPECIFICATIONS

PC)

GOVERNOR
(LATER)

(1)
(2)

Torque

for nut

lb. ft.

(12 4

Nm)

8M9140

Spring for governor:


(stripes)
1

Color code

green (18 N)

Put force on spring of

4.0
to

lb.

Then add more force


shorter by

make

spring

900
16.6 +
.3 lb.
in.

in.

(22.86
1

mm)
.3

Total test force

(74.0

N)

Free length after test

2.34

.03

(59.4 0.8
in.

mm) mm)

Outside diameter
(3) (4)

1.38

(35.1

Collar for spring.

2S7235

Spring:
test force

Length under
Test force

375
39

in.

(9.53
+

mm)
IM)

.03

lb.

(1.75
in.

0.13

Free length after test

68
425

(17.3

mm)

Outside diameter
(5)

in.

(10.80

mm) mm)
mm) mm)

9M6303

Spring for over-fueling;


test

Length under
Test force

force

180
10.0 + .5

in.

(4.57
+

lb.

(45

2.2 N)

Free length after test (approximate)

344

in.

(8.74

Outside diameter

480

in.

(12.19

29

3304

VEHICULAR ENGINES
(SCROLL FUEL SYSTEM

SPECIFICATIONS

PC)

FUEL TRANSFER

PUIVIP

Pressure of fuel to injection

pump
(1)

25 to 32
. ,

psi

(170 to 220 kPa)

Bore of bearing (new)

.4953

.0003

in.

(12.581

0.008

mm) mm)

(2)

Depth of bore
(new)

in

body 3750
. .

.0003

in.

(9.525

0.008 0.008

Thicl<ness of gear (new)


(3)
(4)

.3730

.0003

in.

(9.474
5
lb. ft.

mm)

Torque

for nut

22

(28

Nm)
mm)
mm)

Clearance between gear and cover (new)

0014

to .0026

in.

(0.036 to 0.066

permissible clearance between gear and cover (worn)


(5)

Maximum

0035

in.

(0.089

Shaft diameter (new)

.4937

.0001

in.

(12.540

0.003

mm) mm)

Bore in shaft bearing (new)

4953

.0003

in.

(12.581

0.008

permissible clearance betv\en shaft and bearing (worn)


(6)

Maximum
8M3210

003

in.

(0.08

mm)

Spring:

Length under test force


Test force Free length after test

1.212
5.36

in.

(30.78
+

mm)

.13

lb.

(23.8
in.

0.58 N)

.82

(46.2

mm)
mm)

Outside diameter
(7)

41
gasket:

in.

(10.4

Torque

for plug

when used with


(copper)
(plastic)

2A1913 Gasket
4IM7465 Gasket

110

15
+

1b. ft.

(149

20

Nm)

27

lb. ft.

(38 4

Nm)

Put a thin layer of 8S6747 Sealer on face of pump body before installing pump cover. Do not let any of 8S6747 Sealer get into the

NOTE:

pump.

FUEL BYPASS VALVE

C^TO
psi

Pressure of fuel to injection

pump
(1)

25 to 32
for bypass valve:

(170 to 220 kPa)

4S6526 Spring
Length under
Test force

test force

1.04

in.

(26.4

mm)

3.16

.16

lb.

(14.1 0.71 N)
in. in.

Free length after test

.88

(47.8
(17.8
(1.3

mm) mm)
mm)

Outside diameter

70

Diameter of wire

05

in.

30

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES
(SCROLL FUEL SYSTEM

SPECIFICATIONS

Dl)

3304

VEHICULAR ENGINES
(SCROLL FUEL SYSTEM

SPECIFICATIONS

Dl)

FUEL INJECTION

A-5P4158

GAUGE

TYPICAL EXAMPLE

Firing order (injection

sequence)

3, 4,

Injection timing before

TC

(top center):

Direct Injection Engines

without turbocharger
(1)

27
154
11
lb. ft.

Torque

for

bushing

(205

15 N-m)

PUMP ASSEMBLY SPRINGS

3304

VEHICULAR ENGINES
(SCROLL FUEL SYSTEM

SPECIFICATIONS

Dl)

INJECTION PUMP & TIMING DIMENSION

Fuel Injection (Cont.)


(7)

Bore
(new)

in

the bearings for the camshaft


1.8765

.0010

in.

(47.663

0.025 mm)

Diameter
(new)

of bearing surfaces of the

camshaft
in.

1.8730

.0005

(47.574

in.

0.013

mm) mm)

Maximum

permissible clearance between the bearings

and the camshaft

010

(0.25

3304

VEHICULAR ENGINES
(SCROLL FUEL SYSTEM

SPECIFICATIONS

Dl)

GOVERNOR

A81478X1

INSTALL SPRING

WASHERS AS SHOWN

B14464X1

(1)
(2)

Torque

for nut

9 3

lb. ft.

(12

4 Nm)

(4)

4N6681 Spring

tor governor-

3P131 Spring:
Length under test force
Test force
21

Color code (stripes)

2 purple
4.0
to
lb.

430

in.

(10.92

mm)
N)

Put force on spring of

(18 N)

.02

lb.

(0.95

0.09
(21.6 (9.40

Then add more force


shorter by
Total test force

make

spring

Free length
after test

90
14.8

in.

(22.9

mm)

85

in.
in.

mm) mm)

.48

lb.

(67

2 N)

Outside diameter
(3)

370

Free length
after test

Seat. Install a spring washer, flat washer and spring washer between seat (3) and spring (4) as shown.

2.24

.03

in.

(56.9
in.

0.8 mm)
(34.87

Outside diameter
(5)

1.373

mm)

(4)

9L6446 Spring

for governor:
1

4N5549 Spring

for over-fueling:

Color code (stripes)


Put force on spring of

blue,

green
(18 N)

Length under test force


Test force

209
65 .03
lb.

in.

(5.31

mm)

4.0
to

lb.

(2.9
in.
in.

0.1 N)

Then add more force


shorter by
Total test force

make

spring

Free length after test

80
12.4

in.

(20.3

mm)
Outside diameter
1

859
429

(21.82

mm)
mm) mm)

.24

lb.

(55

0.8

(10.90

N)
(6)

Free length
after test

Diameter
(new)

of the outer

2.24

.03

in.

(56.9
In.

mm)
Bore
in

surface of the cylinder 1.2172 .0005 in. (30.917 0.013

the gear

Outside diameter

1.371

(34.82

mm)

(new)

1.2192 .0005

in.

(30.968

0.013 mm)

NOTE: Governor weights must

pivot freely.

34

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES
(SCROLL FUEL SYSTEM

SPECIFICATIONS

Dl)

FUEL TRANSFER PUMP


(4N4864)

Pressure of fuel to injection

pump
(1) (2)

25to32psi(170to220kPa)
.
. .

Bore of bearing (new)


Deptti of bore
In

.4953

.0003

In.

(12.581

0.008 mm) 0.008 mm) 0.008 mm)


(28

body
3750 .0003
.
.

(new)

in.

(9.525 (9.474
lb. ft.

Tfilcknessof gear(new)
(3) (4)

.3730

.0003

in.

Torque

for nut

22 5

7 N-m)

Clearance between gear and cover (new) 0014 to .0026


permissible clearance between gear and cover (worn)

in.

(0.036 to 0.066

mm)

Maximum

0035
(12.540

In.

(0.089

mm)

(5)

Shaft diameter (new)

4937 .0001

In.

0.003 mm) 0.008 mm)


In.

Bore
(new)

In

shaft bearing

4953 .0003

In.

(12.581

fvlaxlmum permissible clearance between shaft and bearing (worn)


(6)

003

(0.08

mm)

8M3210

Spring:
1.212
5.36
In.

Length under test force


Test force

(30.79

mm) mm) mm)

.13

lb.

(23.8
in.

0.58 N)

Free length after test

.82

(46.23
(10.4

Outside diameter
(7)

41

In.

Torque

for plug

when used

with gasket:
. . .

4N7465 Gasket

27 3

lb.

ft.(38

Nm)

NOTE: Put a
Installing

8S6747 Sealer on face of pump body before pump cover. Do not let any of 8S6747 Sealer get Into the
thin layer of

pump.

35

3304

VEHICULAR ENGINES
(SCROLL FUEL SYSTEM

SPECIFICATIONS

PC &

Dl)

TIMING GEARS

Torque

for

two bolts that hold front


17

cover to plate

+ 3

lb. ft.

(23

4 N-m)
7

Torque

for nuts holding

cover for

accessory drive gear


(1)

20 5

lb. ft.

(27

N-m)
N'Oi)

Torque

for nut holding

accessory drive gear


(2)

100 10

lb. ft,

(135

14

End play
(new/)

for the cannshaft

007 .003
permissible end play (worn)
of

in.

(0.18

0.08 mm)
(0.64

Maximum
Diameter

025

in.

mm)
mm) mm)

camshaft bearing surface


2.3110 .0005
in.

(journal) (new)

(58.699 0.013

Bore
(new)

in

bearing for camshaft 2.3150 .0024

in.

(58.801

0.061

and bearing surface


(3)

IVIaximum permissible clearance between bearing (journal) (worn) 008 in. (0.20

mm) mm)
mm)

End play
(new)

for the idler

gear

004

to .016
.

in.

(0.10 to 0.41

Maximum

permissible end play (worn)


idler
1

034

in.

(0.86

Bore in bearing for the gear (new)


Diameter of shaft gear (new)

.3781

.0019

in.

(35.004 0.048

mm) mm) mm)

for idler

1.3741

.0005

in.

(34.902 0.013

permissible clearance between shaft 009 and bearing (worn)


(4)

Maximum

in.

(0.23

Balancer shafts:

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

mm)
mm)

Bore

in

in.

(53.050 0.061

Maximum
shaft

permissible clearance between balancer

and bearing (worn)


for the

010

in.

(0.25

mm)

End play
(new)

balancer shaft

0035

to .0075 in. (0.089 to 0.191

mm) mm)

Maximum
(5)

permissible end play (worn)

017

in.

(0.43

Distance from front face of bushing to rear


face of cover
2.56
in.

(65.02

36

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

CAMSHAFT

NOTE: Put a
installing.
(1)

layer of graphite

grease on lobes of camsfiaft wfien

Width of groove
(new)

in

cannshaft for thrust washer 190 .002 in. (4.83

0.05

mm)

Thickness of thrust washer


(new)

183 .001
of the

in.

(4.65

0.03

mm)
mm) mm)

End play
(new)

camshaft
007 .003
in.

(0.18

in.

0.08
(0.64

Maximum
(2)

permissible end play (worn)


(journal)
in.

025

Diameter of camshaft bearing surface


(new)

2.3110
in

.0005

(58.699

0.013 mm)

(3)

Bore
(new)

bearing for camshaft 2.3150 .0024

in.

(58.801

0.061

mm) mm)

Clearance between bearing and bearing surface (journal) (new) 002 to .006 in. (0.05 to

0.1

permissible clearance between bearing and bearing surface (journal) (worn) 008 in. (0.20 mm)

Maximum

NOTE; Make reference


sions.
(5)

to

CYLINDER BLOCK

for installation

dimen-

Height of camshaft lobes.

To
A.
B.

find lobe

lift,

use the procedure that follows;


(5).

Measure camshaft lobe height


Measure base
base
is

circle
circle

(6).

C. Subtract

(STEP

B)

from lobe height (STEP

A).

The

difference
D.

actual lobe

lift (4).

Specified camshaft lobe

lift

(4) is

3300

in.

(8.382

mm) mm)
74239- 1X1

Maximum

permissible difference between actual lobe and specified lobe lift (STEP D) is 010

lift

(STEP C)
(0.25

in.

VALVE ROCKER ARMS AND LIFTERS


(1)

Bore
(new)

in

bearing for shaft

7263 .0005

in.

(18.448

0.013 mm) 0.013 mm)


in.

Diameter of shaft
(new)

7245 .0005

in.

(18.402

Maximum
(worn)
(2)

permissible clearance between bearing and shaft

008
for locknut

(0.20

mm)

Torque screw

on valve adjustment
21

lb. ft.

(26

Nm)
mm) mm)
A156S6XI

(3)

Clearance

for valves;

Intake valves

015
025
lifter

in. in.

(0.38
(0.64

Exhaust valves
(4)

Diameter of valve
(new)

1.3105
in

.0005

in.

(33.287

0.013

mm)

Bore
(new)

block for valve

lifter

1.3145

.0010

in.

(33.388

0.025 mm)

permissible clearance between for valve lifter (worn)

Maximum

lifter

and bore 012 in. (0.30

mm)

37

3304

VEHICULAR ENGINES

SPECIFICATIONS

VALVES
(PC)

NOTE: GUIDELINE FOR REUSABLE PARTS: VALVES AND VALVE SPRINGS, Forms SEBF8002 and SEBF8034 have the procedure and
specifications necessary for checking used valves and valve springs.
(1)

7S7144 Spring

for valves (new):

Length under test force


Test force
57.7

1.766

in,

(44.86

mm)
N)

4.5

lb.

(256

20

Use again minimum


test force

load at length under


46.5
1.271
.

lb.

(207 N)

Length of spring at valve open position

in.

(32.28
lb.

mm)

Use again minimum load


Free length after test

at valve

open position.

144
in.

(640 N)

2.05

(52.1

mm) mm)

Outside diameter
Spring must not be bent more than
(2)

1.386

in.

(35.20
.83

072 875

in. (1

mm) mm)
mm) mm)

Height to top of valve guide

in.

(22.23

(3)

Diameter of valve stem


(new)

3717 .0003

in.

(9.441

in.

0.008
(9.408

Use again minimum diameter


valve guide with guide installed in the head

3704

Bore

in

(new)

3733 .0010

in,

(9.482

in.

0.025
(9.578

mm)

r^aximum permissible bore (worn)


(4)

3771

mm)

Valve

lip

thicl<ness:

8N875 & 5S7232 Exhaust Valve Use again minimum


5S6449 Exhaust Valve Use again minimum 5S6452 Intake Valve Use again minimum
(5)

106

in.

(2.69

mm)

096

in.

(2.44

mm)
mm) mm) mm)

096

in.

(2.44

Diameter of valve head:

Exhaust valve
Intake valve
(6)

1.896 .005

in.

(48.16 0.13
(51.31

2.020 .005

in.

0.13

Angle

of valve face

29 1/4"

38

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

Valves (Cont.)
(PC)

(7)

Depth

of

bore

in

head

for valve seat insert:

Exhaust (5S7221 & 1P6837)


Intake:
Earlier (5S7218)

449 .005

in.

(11.40 0.13

mm)

449 .005

in.

(11.40 0.13
(8.86

mm)
mm)

Later (7N4448)
(8)

349 .005

in.

0.13

Diameter

of valve seat insert:

Exhaust (5S7221 & 1P6837)


Intake:
Earlier (5S7218)
. . .

2.0035

.0005

in.

(50.889

+ 0.013 mm)

2.1285 .0005

in. in.

(54.064 (52.032

0.013 mm) 0.013 mm)

Later (7N4448) .... 2.0485

.0005

Bore

in

head

for valve seat insert:

Exhaust (5S7221 & 1P6837)


Intake: Earlier (5S7218)
.
.
.

2.0005 .0005

in.

(50.813

0.013 mm)

2.1255 .0005

in. in.

(53.988
(51.961

0.013 mm)
0.013

Later (7N4448) .... 2.0457


(9)

.0005

mm)
30

Angle of face of valve seat

insert

(10)

Maximum
(intake

permissible width of valve seat

and exhaust) and exhaust)

076

in.

(1.93

mm)
mm)

I\^inimunn permissible width of valve seat

(intake
(11)

045

in,

(1.14

Dimension from top

of closed valve to face of head:

Iviaximum permissible dimension for 5S6449 or

5S7232 Exhaust Valves

140
for

in.

(3.56

mm) mm)

Minimum permissible dimension


5S7232 Exhaust Valves

5S6449 or
056
in.

(1.42

Maximum
Minimum

permissible dimension for Exhaust Valve


permissible dimension for

8N875
163
in.

(4.14

mm) mm) mm) mm)

8N875
079
in.

Exhaust Valve

(2.01

Maximum
Minimum

permissible dimension for 5S6452 Intake Valve 140

in.

(3.56

permissible diameter for 5S6452 Intake Valve

066

in.

(1.68

(12)

Outside diameter of the face of the valve seat or valve seat


insert:

Exhaust seat

1.810
1.860 1.934

in.

(45.97
(47.24

mm)

Maximum Maximum
(13)

permissible, exhaust seat

in.

mm) mm) mm)


15

Intake seat
permissible, intake seat

in. In.

(49.12 (50.39

1.984

Angle to grind seat face of the insert to get a reduction of maximum seat diameter

39

3304

VEHICULAR ENGINES

SPECIFICATIONS

VALVES
(Dl)

NOTE: GUIDELINE FOR REUSABLE PARTS: VALVES AND VALVE SPRINGS, Forms SEBF8002 and SEBF8034 have the procedure and specifications necessary for checking used valves and valve springs.
(1)

7S7144 Spring

for valves {new):

Length under test force


Test force
57.7
at length

1.766

in.

(44.86

mm)
N)

4.5

lb.

(256.7

20

Use again minimum load


test force

under
46.5
lb.

(207 N)

Length of spring at valve open


position
1.271
at valve
in.

(32.28

mm)

Use again minimum load open position


Free length after test

144.4

lb.

(642 N)

2.05

in.

(52.1

mm)

Outside diameter
Spring must not be bent more than
(2)

1.386

in.

(35.20 mm)
.83

072

in. (1

mm)
mm)
B9217X1

Height to top of
valve guide

875

in.

(22.23

(3)

Diameter of valve stem


(new)

3717 .0003

in.

(9.441

in.

0.008
(9.408

mm) mm)

Use again minimum diameter


Bore
in

3704
in

valve guide with guide installed

the head.

Minimum permissible (new)

3723 3772

in.

(9.456
(9.581

mm)

Maximum
(4)

permissible (worn)

in.

mm)

Valve

lip

thickness:
Valve.

6N9916 Exhaust

Use again minimum

106
Valve.

in.

(2.69

mm)

B9216X1

6N9915 Intake Valve and 7N573 Exhaust


Use again minimum
(5)

096

in.

(2.44

mm)

Diameter of valve head:

Exhaust
valves
Intake
valve
(6)
(7)

1.896

.005

in.

(48.16

0.13

mm)

2.020

.005

in.

(51.31

0.13

mm)

Angle of valve face

29 1/4
for valve seat

Depth of bore
insert

in

head

488 .005
for

in.

(12.41

0.13

mm)

(8)

Diameter of valve seat insert


valve

exhaust

2.0035
in

.0005

in.

(50.889

0.013

mm)
(11)

Dimension from top

of closed valve to face of head:

Bore
valve

head

for valve seat insert for

exhaust
in.

2.0005

.0005

(50.813

0.013

mm)

Minimum Minimum

permissible dimension for 7N573 and

6N9916 Exhaust Valve


Diameter of valve seat
insert for intake

026

in.

(0.66

mm)
mm)

permissible dimension for


.

valve

2.0485
in

.0005

in.

(5.032

0.013

mm)
(12)

6N9915 Intake Valve

006

in.

(0.15

Bore
valve
(9)

head

for valve seat

Outside diameter of the face of the valve seat

insert:
in.

insert for intake

2.0455

.0005

in.

(51.956

0.013 mm)
30

Exhaust seat

1.812
1.862 1.940

(46.02

mm)
mm) mm) mm)
15

Maximum

permissible, exhaust seat

in.

(47.29 (49.28 (50.55

Angle of face of valve seat insert


permissible width of valve seat (intake and exhaust)

(10)

Maximum

Intake seat

in.

076

in.

(1.93 mm)
(13)

Maximum

permissible, intake seat

1.990

in.

Minimum permissible width


(intake

of valve seat

and exhaust)

045

in.

(1.14

mm)

Angle to grind seat face of the insert to get a reduction of maximum seat diameter

40

FOR TOROUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS- FOR GENERAL TIGHTENING TOROUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

GLOW PLUG POSITIONING

Cyl. Nos. Cyl. Nos.

1, 2, 1

and 33304*

Cyl. No.

43304*

thru

43304"

'Engines with counterbored **Engines with spacer plate.

blocl(.

(A) Correct

range for glow plug opening.

Put 5P3931 Anti-Seize bustion chamber.


Put

Compound on
it,

the threads of the precom-

5M2667 Gasket, with "2C" on on the precombustion champrecombustion chamber in the cylinder head and tighten to 150 10 lb. ft. (205 14 N-m)
ber. Install the

NOTE:

If the hole for the glow plug is not in range precombustion chamber. Remove the gasket.

(A),

remove the

If the hole was in range (B) install 2S8959 Gasket, with "2S" on it, on the precombustion chamber. Install the precombustion chamber in the cylinder head and tighten to 150 10 lb. ft. (205 14 N-m)

If

the hole

was

in

range (C)

install

on the precombustion chamber. in the cylinder head and


tighten to

Install

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


150 10
lb. ft.

(205 i 14 N-m)

41

3304

VEHICULAR ENGINES

SPECIFICATIONS

CYLINDER HEAD

Thickness of cylinder head


(new)

Step
3.938

2.

Again tighten

all

bolts

in

number
185

.030

in.

(100.03

0.76

mm)
Step
3.

sequence sequence
Step
4.

to
all

13

lb. ft.

(250

17 N-m)

NOTE: Dimension from top of closed valve to face of cylinder head must be according to the specifications in VALVES.
Put 5P3931 Anti-Seize

Again tighten
to

bolts in

number
185 13
lb. ft.

(250

17

Nm) Nm)

Compound on
bolts
in

threads and tighten bolts

in

the

Step sequence that

follov/s:
all

Tighten all bolts in letter sequence (hand torque only) to 32 5

lb. ft.

(43

Step

1.

Tighten

number
1

sequence

to

15

lb. ft.

(155

Nm)

0^

03

02

06
11

10

.0
VALVE COVER
77077X
I

VIEW FROM RIGHT SIDE OF ENGINE

Put 5H2471

Cement on

the face of valve cover and top side of gasket.

Tighten bolts by number sequence show/n to

96

24

1b. in.

(10.9

2.8

Nm)

42

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES

SPECIFICATIONS

EXHAUST MANIFOLD

Put 5P3931 Anti-Seize


(1) (2)

Compound on

all

threads.

Torque

for for

studs
nuts holding exhaust

20 3

lb. ft.

(25

Nm)
Nm)

Torque

manifold

32 5

lb. ft.

(43

EXHAUST PIPE AND MUFFLER


Put 5P3931 Anti-SeIze
of bolts for

Compound on

threads 20 5
lb. ft.

clamps and
(25

tighten to

7 N-m)

AIR
(1)

CLEANER
20

Tighten nuts that hold


to

air filter

elbow

lb. ft.

(25

Nm) Nm)

(2)

Tighten wing nuts to

35 5

lb. in. (4.0

0.6

43

3304

VEHICULAR ENGINES

SPECIFICATIONS

TURBOCHARGER IMPELLER INSTALLATION


Schwitzer
Installation
A. Put

ONLY

Procedure Chart
if

6V1541 Quick Pure Primer on the nut and the shaft threads to clean them,

necessary.
B.

Put a small amount of 9S3265 Retaining

Compound on

the nut and shaft threads.

CAUTION
Do
not
let
it

the retaining

compoun

because

can make removal

of the

get into the compressor wheel bore on the shaft, compressor wheel difficult during future turbo-

charger disassembly.
C. Put a small

amount of lubricant, such as Lubriplate, on the nut seat area on the compressor. Do not put lubricant on the threads.
wheel
44 2
lb. ft.

D. Tighten the compressor retainer nut to

(60

3 N-m)

NOTE: Do

not bend or add stress to the shaft

when

the nut

is

tightened.

44

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

TURBOCHARGER IMPELLER INSTALLATION


(AIResearch

ONLY)

TEST FOR TYPE OF IMPELLER INSTALLATION


1.

Install the proper thrust collar and seal carrier spacer on the shaft-wheel assembly to be used. Install

2.

impeller on shaft by hand.


at the

3.

point
4.
If

Measure the distance between impeller and seal carrier where impeller no longer moves freely on shaft.
the distance
is:

(a)

more than
.31 in. (7.9

.31

in.

(7.9

mm), use heat

for installation.*

(b)

mm)

or less, use

room temperature

installation."

3304

VEHICULAR ENGINES

SPECIFICATIONS

TURBOCHARGER
(AiResearch T04B91)

46923-1X3

Make reference
No. FEG45138.

to

ANALYZING TURBOCHARGER FAILURE, Form

to GUIDELINES FOR REUSEABLE PARTS TURBOCHARGERS, Form Nos. SEBF8018 & SEBF8019.

Make reference
(1)

Torque

for

impellernut

20

lb. in.

(2.3

N-m)
100

Tighten nut an added

NOTE: Do
(2)

not bend or add stress to the shaft


for bolts holding

when
in.

nut

is

tightened.
(7)

Radial play for shaft:

Torque

back plate
(3)

75 to 90

lb,

(8.5 to 10.2

N-m)

Minimum

permissible radial play

003

in.

(0.08 (0.15

mm)
mm)

Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding compressor housing to center 115 15 lb. in. (13 1.7 N-m) section to Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding turbine housing to center section to 115 15 lb. in. (13 1.7 N-m)

Maximum
(8)

permissible radial play

006

in.

Bore

in

the

bearing

4010

to .4014

in.

(10.185 to 10.196

mm)
mm)

(4)

for the bearing


(9)

Diameter of surface on shaft (journal) 3997 to .4000 in. (10.152

to

10.160

Bore

in

housing...

.6220 to .6223

in.

(15.799 to 15.806

mm)
mm)

(5)

Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding turbocharger to 40 4 lb. ft. (55 manifold to

N-m)
(10)

Outside diameter of the 6182 to .6187 bearing

in.

(15.702 to 15.715

(6)

End play

for shaft:

Clearance between ends of


seal ring

oil

008
of

to .015

in.

(0.20 to 0.38

mm)
mm)

Minimum

permissible end play permissible end play

001

in.

(0.03 (0.10

mm)

Diameter
seal ring

bore for

oil

Maximum

004

in.

mm)

709

to .71

in.

(18.01 to 18.06

46

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

TURBOCHARGER
(AIResearch T0490)

Make

reference to No. FEG45138.

ANALYZING TURBOCHARGER FAILURE, Form


GUIDELINES FOR REUSABLE PARTS TURBONos. SEBF8018 & SEBF8019.
20
lb.

Make reference
Torque

to

CHARGERS, Form
(1)

for impeller nut

in.

(2.3

N-m)
(6)

End play

for shaft

001 to .004

in,

(0.03 to 0.10 (0.08 to 0.18

mm) mm) mm) mm) mm)

Tighten nut an added

100
(7)

Radial play for shaft

003

to .007

in.

NOTE: Do
(2)

not bend or add stress to the shaft


for bolts holding

when
lb. in.

nut

is

tightened.

Bore

in

the

Torque
plate

back
50 10
(5.7

bearing

4010

to .4014

in.

(10.185 to 10.196

1.1

N>m)

(3)

Put 5P3931 Anti-Seize Compound on threads and tighten bolt holding band clamp to 60 10 lb.

Diameter of surface on shaft (journal) for the bearing 3997 to .4000 in. (10.152
(8)

to 10.160

in.

(6.8

1.1 N-m)

Bore

in

housing

.6220 to .6223

in.

(15.799 to 15.806

(4)

Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding turbine housing to 115 15 lb.

Outside diameter of the bearing 6182 to .6187


in.

in.

(15.702 to 15.715

mm)
mm)
mm)

(13 1.7 N-m)

(9)

Clearance between ends of


seal ring

oil

(5)

Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding turbocharger to manifold to 40 4 lb. ft. (55 5 N-m)

008
oil

to .015

in.

(0.20 to 0.38

(10)

Diameter of bore for


seal ring

709

to ,71

in.

(18.01 to 18.06

47

3304

VEHICULAR ENGINES

SPECIFICATIONS

TURBOCHARGER
(AIResearch T1210 and T1224)

T98428X4

Make

reference to No. FEG45138.

ANALYZING TURBOCHARGER FAILURE, Form


GUIDELINES FOR REUSABLE PARTS TURBONos. SEBF8018 & SEBF8019.

Make reference

to

CHARGERS, Form

(5)

Put 5P3931 Anti-Seize

Compound on

threads
lb. in.

Put 5P3931 Anti-Seize elbow.

Compound on

tfireads of plug for exfiaust

of bolts holding turbocharger to

manifold and tighten to


(6)

40 4

(55 5

N-m)

Put 5P3931 Anti-Seize Compound on bolts holding support for exhaust and
tighten to
(1) (2)

End play
(new)

for shaft

006
in

to .011

in.

(0.15 to 0.27

mm) mm)
mm) mm) mm)

45 5

lb. ft.

(60

N-m)

(7)

Bore

the

See

TURBOCHARGER IMPELLER INSTALLATION.


for bolts

bearing

6268
of surface

to .6272

in.

(15.921 to 15.931

Torque
plate

holding thrust

Diameter
35 4
lb. in.

(4.0

0,5 N-m)
(8)

the bearing

on shaft (journal) for 6250 to .6254 in. (15.875


.9827 to .9832
in.

to

15.885

(3)

Tighten bolt holding band

Bore

in

housing

(24.961 to 24.973

clamp
(4)

to

120 10

lb. in.

(13.6 1.1

N-m)

Put 5P3931 Anti-Seize Compound on threads of bolts holding turbine housing and tighten to 175 15 lb. in. (19.8 1.7 N-m)

Outside diameter of the bearing 9780


(9)

to .9785
oil

in.

(24.841 to 24.854

Clearance between ends of


seal ring

008

to .015

in.

(0.20 to 0.38

mm)

48

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

TURBOCHARGER
(Schwitzer 3LK)

73113X2

Make

reference to No. FEG45138.

ANALYZING TURBOCHARGER FAILURE, Form


GUIDELINES FOR REUSABLE PARTS TURBONos. SEBF8018 & SEBF8019.
0045 .0015
In.

Make
(1)

reference to

(5)

Maximum
measured

permissible gap of
in

oil

seal ring,

CHARGERS, Form
End play
(new)

bore of housing

007

in,

(0,18

mm)

for stiaft

(6)

See

TURBOCHARGER INSTALLATION,
75025 ,00025
in,

(0.114
.008

0.038 mm)
(7)
in,

Maximum
(2)

permissible end play (worn)

(0.20

mm)
mm) mm)
(8)

Bore in housing

(19,0564 0,0064

mm)
mm)

Thickness of thrust
bearing
21
of surface
1

.001

in.

(5.36

0.03

Outside diameter of the bearing 74625 ,00025

in,

(18,9548 0,0064

(3)

Diameter

the bearing

on shaft (journal) for 44015 .00015 in. (11.1798 0.0038


44165 .00015
(11.2179 0.0038

Maximum

permissible clearance between


in

bearing and bore

housing
1005 ,0005

0045

in,

(0,114

mm)
mm)
N-m)

Bore

in

the
in.

Thickness of each thrust


ring
in,

bearing

mm)
(9)

(2,553 + 0,013

Maximum
(4)

permissible clearance between

Torque

for bolts holding

bearing and shaft

0018

in.

(0.046

mm)
(10)

impeller housing

60

lb, in,

(6,8

Put 5P3931 Anti-Seize Compound on threads and tighten bolt holding band

Put 5P3931 Anti-Seize Compound on threads of bolts holding turbocharger to manifold

clamp

to

120

lb. in.

(13,6

N-m)

and tighten

to

40 4

lb, ft,

(55

5 N-m)

49

3304

VEHICULAR ENGINES

SPECIFICATIONS

TURBOCHARGER
(Schwitzer 3LM)

A22019X2

Make Make

reference to No. FEG45138, reference to

ANALYZING TURBOCHARGER FAILURE, Form


(6)

Thickness of thrust
bearing
107 to .108
in.

GUIDELINES FOR REUSABLE PARTS TURBOCHARGERS, Form Nos. SEBF8018 & SEBF8019.
(1)

(2.72 to 2.74

mm)

(7)

Bearing:

End play

for shaft (new)

002 to ,005

in.

(0.05 to 0.13

mm)

Bore

in

housing
7500 to .7505
in.

(2)

Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding impeller housing to 60 lb. in. (6.8

for bearing

(19.050 to 19.063

mm)
mm)

Nm)

(3)

Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding turbine housing to 11 to 12 lb.
permissible gap of measured in bore of housing

for

Diameter of surface of bearing housing 7460 to .7465 Diameter of surface of

in.

(18.948 to 18.961

ft.

(15 to 17

Nm)
mm)

bearing for shaft

4415 to .4418

in.

(11.214 to

11.222mm)

(4)

Maximum

oil

seal ring,

007

in.

(0.18

Diameter of surface of shaft for bearing (journal) 4400 to .4403

in.

(11.176 to 11.184
in.

mm)

(5)

See

TURBOCHARGER

IIVIPELLER INSTALLATION.

Length

of bearing

2.425 to2.426

(61.60 to61.62

mm)

50

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

TURBOCHARGER
(Schwitzer F444, 4LF504 and E Models)

T97594X1

Make

reference to No. FEG45138.

ANALYZING TURBOCHARGER FAILURE, Form

(4)

Put 5P3931 AntiSelze


tighten bolt holding

Compound on
to
oil

band clamp

threads and 120 lb.

in.

(13.6

N-m)

Make

reference to

CHARGERS, Form

GUIDELINES FOR REUSABLE PARTS TURBONos. SEBF8018 & SEBF8019.

(5)

permissible gap of measured In bore of housing

Maximum

seal ring,

009

in.

(0.23

mm)

(6)

See

TURBOCHARGER IMPELLER
In

INSTALLATION.
(22.255 to 22.268

(1)

End play for stiaft (new)

(7)

Bore
(new)

housing

0045 .0015

in.

(0.114

0.038 mm)
In.

8762 to .8767

In.

mm)
mm)
mm)

Maximum
(2)
(3)

permissible end play (worn)


...

008

(0.20

mm)
mm) mm)
(8)

Outside diameter of the bearing (new) 8718 to .8722

in.

(22.144 to 22.154

Thickness of thrust bearing

.211

.001

in.

(5.36

0.03

Maximum
bore
In

permissible clearance between bearing and

Diameter of surface on shaft (journal) for the bearing (new) 5612 to .5615 in. (14.254 to 14.262

housing (worn)

006
1005 .0005

in.

(0.15

Thickness of each thrust


ring
in.

Bore
(new)

in

the bearing

(2.553

0.013

mm)

5627 to .5630

in.

(14.293 to 14.300

mm)
(9)

Maximum permissible clearance between bearing and shaft (worn) 003 in. (0.08

mm)

Put 5P3931 Antl-Seize Compound on threads and tighten bolts holding turbocharger to manifold to 40 4 lb. ft. (55

5 Nm)

51

3304

VEHICULAR ENGINES

SPECIFICATIONS

OIL

PUMP

(2P7830, 5S3876 & 7S9840)

(1)

Diameter of the drive


shaft (new)

7407 .0003

in.

(18.814

0.008 mm) 0.013 mm)


0.020

the bearings for the 7425 .0005 drive shaft

Bore

in

in.

(18.860

Clearance between drive shaft and bearing (new) 0018 .0008

in.

(0.046

mm) mm)

Maximum
shaft
(2)

permissible clearance between

and bearing (worn)


2.9955 .0005
in.

005
(76.086

in.

(0.13

Length of gear

0.013 mm) 0.020 mm)


0.033

Depth of counterbore
for

gear

3.0008 .0008
of gear

in.

(76.220

Clearance between end cover (new)


(3)

and 0053 .0013

in.

(0.135

mm)

Length of gear

.9975 .0005

in.

(50.737

0.013 mm)

Depth
for

of

counterbore
2,0008 .0008
of
in.

gear

(50.820 0.020

mm)

Clearance between end cover (new)


(4)

gear and 0033 .0013

in.

(0.084

0.033 mm)

Diameter of the shaft for the drive idler gear (new) 1.1225 1 .0005 in. (28.512 0.013

mm) mm) mm)

Bore
(new)

in

bearing of gear
1.1260 .0019
in.

(28,600 0.048

Clearance between shaft and bearing (new) 0035 .0024

in.

(0.089

0.061

permissible clearance between shaft and bearing (worn) 008


(5)

Maximum

in.

(0.20

mm) mm) mm) mm)


mm) mm) mm)

1S3921 Spring for pressure Length under


Test force
test force

relief

valve (engine

oil):
in.

3.25 39.8

(82.6

3.2

lb.

(177.5
in.

+ 14.0 N)
(90.7

Free length after test

3.57

Outside diameter
(6)

77

in.

(19.6

Diameter of the shaft for the idler gear (clutch pump) (new) 7407 .0003 in. (18.814 0,008

Bore

in

the bearing

7425 .0005

in,

(18,860 0,013

Clearance between shaft and bearing (new) 0.0018 .0008

in.

(0.046 0.020

permissible clearance between shaft and bearing (worn) 008


(7)

Maximum

in.

(0.20

mm)
mm)

Diameter of the shaft

for the idler

pump) (new)
Bore
idler
in

gear (scavenge 7407 .0003 in. (18.814 0.008

the bearing of the

gear

7425 .0005

in.

(18.860 0.013

mm)

(8)

4J4790 Spring
Length under

for pressure relief valve (clutch oil):


test force

Clearance between shaft and 0018 .0008 bearing (new)

1.548

in.

(39.32
lb.

mm)
mm) mm)
N-m)

in.

(0.046

0.020 mm)

Test force Free length after test

12.27

(54.6 N)

Maximum

permissible clearance between shaft and bearing (worn) 008

in.

(0.20

mm)
(9)

2.163

in.

(54.94
(18.3

Length of gear

9975 .0005
1.0008 .0008

in.

(25.337

0.013 mm)

Outside diameter

72 60
pin.

in.

Depth
for

of

counterbore
in.

Torque

for nut holding drive gear

lb. ft.

(80

gear

(25.420 0.020

mm)

Tighten farther to get alignment for cotter

52

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES

SPECIFICATIONS

OIL

PUMP

(781849 & 7S9461)

(1)

Diameter of the drive shaft 8747 .0002 (new)


the bearings for the 8763 drive shaft

in.

(22.217

0.005 mnn) 0.008 mm)


0.013
(0.13

Bore

in

.0003

in.

(22.258

Clearance between drive shaft and 0016 .0005 bearings (new)

in.

(0.041

mm) mm) mm)

Maximum
(2)

permissible clearance between shaft

and bearing (worn)


Diameter gear (new)
of the shaft for the drive idler

005

in.

1.1225

.0005

in.

(28.512 + 0.013

Bore

in

the

bearing

1.1260 .0019

in.

(28.600

0.048 mm)
in.

Clearance between shaft and 0035 .0024 bearing (new)

in.

(0.089

0.061

mm) mm)

Maximum
(3)

permissible clearance between shaft

and bearing (worn)


Diameter of the shaft for the 8747 .0002 idler gear (new)

008

(0.20

in. in.

(22.217

0.005 mm)

Bore

in

the bearing.

.8763

.0003

(22.258 0.008

mm)

Clearance between shaft and 0016 .0005 bearing (new)

in.

(0.041

0.013 mm)
in.

permissible clearance between shaft and bearing (worn)


(4)

Maximum

008

(0.20

mm) mm) mm) mm)

1S3921 Spring for pressure


Length under
Test force
Free length after test
test force

relief valve:

3.25

in.

(82.6

39.8

3.2

lb.

(177.5
in.
in.

14.0 N)

3.57

(90.7

Outside diameter
(5)

77
1

(19.6

Length

of

gear

.4988

.0010

in.

(38.070

0.025 mm) 0.020 mm) 0.046 mm) 0.025 mm) 0.020 mm) 0.046 mm)
(80

for

Depth of counterbore gear

1.5038 .0008

in.

(38.197

Clearance between end of gear 0050 .0018 and cover (new)


(6)

in.

(0.127

Length of gear

2.0003

.0010

in.

(50.808

Depth

of

counterbore
2.0053 .0008
in.

for gear

(50.935

Clearance between end of gear 0050 .0018 and cover (new)


(7)

in.

(0.127

Torque

for nut holding drive gear

60
pin.

lb. ft.

N-m)

Tighten farther to get alignment for cotter

53

3304

VEHICULAR ENGINES

SPECIFICATIONS

OIL

PUMP

(2P1785 and 6N2642)

a-.^j.^

(1)

Bore
gear

in

bearing of idler
1

.1260 .0024

in.

(28.600 0.061

mm)

Diameter of shaft for idler gear

thie

1.1255 .0005

in.

(28.588

0.013 mm)
0.074

I80o)

stiaft
(2)

Clearance between bearing and 0035 + .0029

in.

(0.089

mm) mm) mm) mm) mm)


mm)

Clearance between gears and body of pump 002 to .026


Diameter of shafts
for

in.

(0.05 to 0.66

(3)

pump
Bore
in

8747 .0002
bearings for

in.

(22.217 0.005

shafts

8763 .0003

in.

(22.258 0.008

Clearance between shafts and bearings 0016 .0005


(4)

in.

(0.041

0.013

Length

of of

gears

2.0003 .0010

in.

(50.808 0.025

Depth
gears

bore

in

pump body
of

for
in.

2.0053 .0008

(50.935 0.020

mm)
mm) mm) mm)

Clearance between end

pump body
(5)

gears and 0050 .0018

in,

(0.127 0.046

Length of gears

.4988 .0010
for

in.

(38.070 0.025

Depth of bore
gears

in

pump body
of

1.5038 .0008

in.

(38.197 0.020

Clearance between end

pump body
(6)

gears and 0050 .0018

in.

(0.127 0.046

mm)
N-m)

Torque

for bolt holding drive

gear to 32 5
lb. ft.

drive shaft

(43 7

54

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES

SPECIFICATIONS

ENGINE OIL PRESSURE

All

steps of this procedure must be followed for the pressure findings

Step

3.

Run

the engine to get the

oil

temperature

at

210 F (99 C).

to

be usable.
1.

NOTE: A
that the

Step

Besure

SAE

10 or SAE information in not apply.

engine is filled to thecorrect level with either 30 oil. If any other viscosity of oil is used, the the ENGINE OIL PRESSURE CHART does

psi (7
4.

5 F (3 C) increase in oil temperature gives approximately kPa) decrease in oil pressure.

Step

the

Keep the engine oil temperature constant. With the engine at rpm from the chart, read the pressure gauge.

Step

2.

Find a location on the engine oil manifold to install a tee. The easiest method is to remove the sending unit for the present gauge and install a tee at this location. Install a probe from the 9S9102 Thermistor Thermometer Group in one side of the tee. Connect a 8M2744 Gauge from the 5P6225 Hydraulic

Test Box to the other side of the

tee.

Make a comparison between the pressure reading on the test gauge and the minimum permissible pressure from the ENGINE OIL PRESSURE CHART. If the pressure reading on the test gauge is below the minimum permissible pressure, find the cause and correct it. Operation of the engine with low oil pressure can be the cause of engine failure or of a reduction in engine life.

ENGINE OIL PRESSURE CHART

3304

VEHICULAR ENGINES

SPECIFICATIONS

OIL FILTER
(7S6638, 7S6639

&

9S1806)

(1

Torque

for the bolt

20

+ 5 lb.

ft.

(25 7

Nm)
mm)

(2)

6F8007 Spring
Length under
Test force

for oil filter bypass valve:

test force

2.43
5.2 to 6.1

in.

(61 .7

lb.

(23 to 27 N)
(91.7

Free length after test

3.61

in.

mm)

Outside diameter

81

in.

(20.6

mm)

7S6638
(3)

Filter only:

6F8007 Spring
Length under
Test force

for oil cooler bypass valve:

test force

2.43
5.2 to 6.1

in.

(61 .7

mm)

lb.

(23 to 27 N)
(91.7

Free length after test

3.61

In. in.

mm)

Outside diameter

81

(20.6

mm)

OIL

BREATHER CAP

(1)

Torque

for bolt holding

breather cap

120+ 24

1b. in.

(13.6

2.8 N-m)

56

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES

SPECIFICATIONS

WATER PUMP

(1)

Oil seal. Put engine toward the bearings.

oil

on the seal

lip.

Assemble with the

lip

(2)

Water seal and


a.

ring.

Put water on the seal. the seal and ring together shiny face of the ring outside.
Install
in

b.

the housing bore, with the

(3)

Seal assembly.
a.
b.
c.

Remove

the spring from the seal.

Put water inside the seal assembly.


Install the seal

assembly around the


is

Installation Tool, (the tool

bon face makes


d.
(4)

shaft, with the 7N7843 with the seal group) until the carcontact with the shiny face of the ring (2).

Install

the spring.

Torque

for the bolt that

holds the

impeller
(5)

28
holds the 32

lb. ft.

(39

Nm)

Torque gear

for bolt that

51b.

ft.

(43

7Nm)

V-BELT TENSION CHART

3304

VEHICULAR ENGINES

SPECIFICATIONS

RADIATOR

T93973

TOP TANK WITH

5S1218 PRESSURE RELIEF VALVE

A59222XI

TIGHTENING PROCEDURE FOR TYPICAL TWO-ROVI/ TANK

Clean the threads


stalling
(1)

of the studs with 8M8060 Quick Cure Primer. Then put 9S3265 Retaining Compound on the threads before in-

them.
for the

filler

Torque for stud cap

40 l 5
Relief Cap:

lb. ft.

(55 7

N-m)

(2)

2S3080 Pressure

Pressure valve must not leak at Pressure valve must be open


at at a

11 .9 psi (82

kPa)

15 psi (105 kPa)

Vacuum

valve must be
of

open

pressure below
0.6 psi (4 kPa)

atmospheric

or 1.22 or 16.6
(2)

in. in.

Hg

(31.0

Hs (422

mm Hg) mm HjO)

321464 Pressure Relief Cap:

Cap must

not leak at
at

6.5 psi (45 kPa)

Cap must be open


(2)

8 psi (55 kPa)

5S1218 Pressure

Relief Valve:
o o o

Vacuum relief at a maximum


Pressure Pressure
(3)

valve to
of

open
1

psi (7

kPa)

relief relief

valve must not leak at

14 psi (95 kPa)

valve must be

open

i^
at

5O

18 psi (125 kPa)

-I Oo

Torque for bolts and shields

that hold baffles

15 5

lb. ft.

(20 7

N-m)

(4)

Bolt torque sequence for radiator tanks. not required on the bottom tank.

Sequence 5 and 6 are

TIGHTENING PROCEDURE FOR TYPICAL THREE-ROW TANK

58

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

WATER TEMPERATURE REGULATOR

7N208 Regulator:
Temperature when completely open
195= F (90
"

C)

77719X1

Minimum open

distance

375

in.

(9.53

mm)

9S3808 and 4H1991 Regulator:


Temperature when completely open
185 F (85 C)

Minimum open distance

310

in.

(7.87

mm)

85312X1

COOLANT FLOW SWITCH

4N9072 SWITCH (John W. Hobbs Number 22258)


(1)

Terminal connected to insulated contact. The other contact is connected to the body of the switch. Switch contacts are normally closed.
With paddle
in vertical

(2)

position,
(2)

the force (F) on rivet head

necessary
switch
(3)

to

open contacts

of
1

.2

.1

oz. (34

3 grams)
(65.5

Length

of

paddle
the switch
is

2.58

in.

mm)

installed in engine cooling system, the flow of coolant at cranking speed of the engine does not have enough force to activate the switch. When the engine is running at low idle the flow of coolant has enough force to activate the switch.

NOTE: When

59

3304

VEHICULAR ENGINES

SPECIFICATIONS

CYLINDER BLOCK
(Counterbored Block)
(1)

Depth

of bore in block

for liner

401 .001 top of block

in.

'10.19

0.03

mm)
CYL-

NOTE: For fieighit of liner over INDER LINER PROJECTION.


(2)

make

reference to

Camshaft bearing bore


installed

2.3150 .0020

in.

(58.801

0.051 mm)

Bore

in block for

camshaft
2.5630:
.0010
in.

bearings

(65.100

0.025 mm)

Depth to

install

bearings at block

camshaft both ends of


...

.06

.02

in.

(1.5

0.5

mm)
in-

NOTE: The camshaft bearing


within
(3)

at the front of the

block must be
joint at the

stalled with oil holes in a horizontal position

and

top

15 from

vertical.

Bore in block for main bearings


(standard size)

3.8160:

.0005

in.

(96.926

0.013 mm)

block for main bearings .020 in. (0.51

Bore

in

mm
3.8360 .0005
of
in.

oversize)
(4)

(97.434

0.013 mm)

Dimension from center

main
in.

bearing bore to top of cylinder 15.5000 .0065 block (new)


(5)

(393.700

0.165

mm)

Dimension from center of main bearing bore to bottom of cylinder 6.0625 .0040 block (new)
Clearance between
bearing cap
slot in

in.

(153.988

0.102 mm)

(6)

block and

0017

in.

.0013

(0.043 mm) loose to in. (0.033 mm) tight

Main bearing cap


width

6.4998 .0008

in.

'165.095

0.020 mm)
0.018

Width of cylinder block for main bearing 6.5000 .0007 in. (165.100 cap
(7)

mm)

block for balancer bearing

Bore

in

2.2776 .0010

in.

(57.851

0.025 mm)

(8)

Torque
a.

for bolts holding bearing


oil

caps

for

main bearings:

Put engine

on threads and washer

face.
lb. ft.

b.
c.

Tighten

all

bolts to
bolt

30 3

(40

N-m)

Put a mark on each

and cap.
90

d.

Tighten
Install

all

bolts from

mark

of the engine.

bearing caps with the part Be sure that the mark (number) on the bearing cap next to the bolt hole is in agreement with the mark in the cylinder
block.

NOTE:

number toward

the front

CAUTION
the bores for the main bearings, between cylinders 1 and 2, and 3 and 4 for piston cooler orifices. These holes must have either orifices (10) or plugs (9) installed.

There are holes

in

NOTE: NOTE:
(11)

If

a turbocharger

is

installed
oil

on the engine, be sure

to install

orifices (10)
If

and an engine

cooler.
oil

the engine has an engine


install orifices (10).

cooler and no turbocharger,

be sure to

Distance to install dowels from top of block

38

.02

in.

(9.7

0.5

mm)

(12) Distance to install stud from face of block


(13)

62

.02 in. (15.7

0.5 mm)
0.5

Llfir/A261 07-1X3

Distance to

install

dowels from
88
.02 in. (22.4

front face of block

mm)

60

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

CYLINDER BLOCK
(1)

Thickness of spacer plate


Thickness of spacer plate gasket

(With Spacer Plate) r /


\

3925 .0010
.0082

in.

(9.970 0.025

mm)

.0010

in.

(0.208

0.025 mm)
reference to

NOTE: For
(2)

height of liner over top of spacer plate

make

CYLINDER LINER PROJECTION.


Camshaft bearing bore
(installed)

2.3150 .0020

in.

(58.801

0.051

mm)

Bore

in block for camshaft bearings 2.5630 .0010

in.

(65.100

0.025 mm)

Depth

to install

bearings at block

camshaft both ends of


06 .02
at
in.

(1.5

0.5

mm)

NOTE: The camshaft bearing


stalled with
oil

holes

in

the front of the block must be ina horizontal position and joint at top within

15 from vertical.
(3)

Bore in block for main bearings (standard


size)

3.8160
in

.0005

in.

(96.926 0.013

mm)

Bore

block for main bearings .020 in. (0.51


oversize)
(4)

mm
3.8360 .0005
of
in.

(97.434 0.013

mm)

Dimension from center

main

bearing bore to top of cylinder block (new) 15.099


(5)

.006

in.

(383.51

0.15 mm)

Dimension from center bearing bore to bottom


block (new)

of

main
6.063

of cylinder

.004

in.

(154.00

0.10 mm)

(6)

Clearance between bearing cap

slot in block

and 0017

in.

.0013

(0.043 mm) loose to in. (0.033 mm) tight

Main bearing cap


width

6.4998 .0008

in.

(165.095 0.020

mm)
mm) mm)
B4 2697 XI

Width of cylinder block for main bearing cap 6.5000 .0007 in. (165.100 0.018
(7)

Bore

in

bearing
(8)

block for balancer 2.2776 .0010


for bolts holding bearing
oil

in.

(57.851

0.025

Torque
a.

caps

for

main bearings:

Put engine

on threads and washer

face.
lb. ft.

b.
c.

Tighten

all

bolts to

30 3

(40

N-m)

Put a mark on each bolt and cap.

d.

Tighten

all

bolts from

mark

90

NOTE: Install bearing caps with the part number toward the front of the engine. Be sure that the mark (number) on the bearing cap next to the bolt hole is in agreement with the mark in the cylinder block,

CAUTION
Ttiere are holes in the bores for the main bearings, between cylinders 1 and 2, and 3 and 4 for piston cooler orifices. These holes must have either orifices (10) or plugs (9) installed.

NOTE:

If

orifices (10)

turbocharger is installed on the engine, be sure to and an engine oil cooler.

install

NOTE:
(11)

If

the engine has

an engine

oil

cooler and no turbocharger

be sure to

install orifices (10).

Distance to install dowels from top of block 780 .020

in.

(19.8

0.5

mm)
mm) mm)

(12)

Distance to install stud from face of block Distance to


install

62 .02

in.

(15.7

0.5

Lltrr/J
A261 07-1X3

(13)

dowels from

front face of block

.02 in. (22.4

0.5

61

3304

VEHICULAR ENGINES

SPECIFICATIONS

CYLINDER LINER
NOTE: Make reference
to

GUIDELINE FOR REUSABLE PARTS:

PISI

TONS AND CYLINDER


(1)

LINERS, Form No. SEBF8001.


I

Bore
(new)

in liner

4.751

.001

in.

(120,68

0.03

mm)

Use again maximum bore when measured near upper end of tfie 4.755 in. (120.78 mm) wear surface of tfie cylinder liner
(2)

Ttiickness of flange

on
(3)

liner

.4048

.0008

in,

(10.282

0,020

mm)

Filler

band.

Cylinder Liner Installation


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

liner,

engine
in

liner.
filler

Immediately
band).

install liner
T8832I
-

1X1

CYLINDER LINER PROJECTION


(Counterbored Block)
IVIake reference to CYLINDER LINER Adjusting for tfie complete procedure.
1.

PROJECTION
(1)

in

Testing and
A34793Xt

Install tooling

as sfiown. Tighten bolts

evenly

in

four steps:
lb. ft. (7

1st step

N-m)

2nd step
3rd step 4th step
2,

15

lb. ft.

(20 (35 (70

Nm) Nm) Nm)

25 50

lb. ft.

lb. ft,

fvleasure cylinder liner projection with dial indicator


in

(7)

clamped

1P2402 Gauge Body (6) as shown, IVIeasure at four places around each cylinder liner near the clamped area.
Cylinder liner projection
liner

measurement

for

any cylinder
in.

must be

0020 to .0056

(0.051 to 0,142

mm)
mm)

IVIaximum permissible difference between

all

four

measurements

002

in,

(0,05

permissible difference between average projection of any two cylinders next to 002 each other

Maximum

in,

(0.05

mm)

Maximum

permissible difference between average projection of all cylinder liners under one
cylinder head

003

in,

(0,08

mm)

NOTE: If liner projection is not correct, turn the liner to a new position within the bore. If projection can not be corrected this way, move the liner to a different bore. If the projection can not be corrected this way, make reference to Special Instruction, Form No, FM055228 for complete instructions on the use of 8S3140 Counterboring Tool
Arrangement,
(1) (2) (3) (4) (5) (6) (7)

Bolts [5/8" NC, 5.5 in, (140 mm) long). Crossbar (from 8B7548 Push-Puller)

SHIM THICKNESS, COLOR CODE, AND PART NUMBER

4B4281 Washers 1 P2394 Adapter Plate

3H465 Plates
P2402 Gauge Body 1P2403 Dial Indicator
1

3304

VEHICULAR ENGINES

SPECIFICATIONS

CYLINDER LINER PROJECTION


(With Spacer Plate)

Make reference to CYLINDER LINER Adjusting for the complete procedure.


1.

PROJECTION

in

Testing and

Install

Wasfiers. Tighiten bolts


1st step

gasket and spacer plate (2) witti bolts (3) and two 1S379 (3) evenly in four steps:
10
lb. ft.

(14 (35

Nm)
Nm) Nm) Nm) Nm)
N-m)

2nd step
3rd step

25

lb. ft.

50 70 as shown. Tighten bolts


(4)

lb. ft.

(70 (95

4th step
2.

lb. ft.

Install tools

evenly

In

four steps:

1st step

5
15

lb. ft. (7

2nd step
3rd step

lb. ft.

(20

25 50

lb. ft.
lb. ft.

(35
(70

Nm) Nm)

4th step
3.

Measure cylinder liner projection with dial indicator (6) in 1P2402 Gauge Body (8) as shown. Measure at four places around each cylinder liner near the clamped area.
Cylinder liner projection
liner

measurement

for

any cylinder
in.

must be

00 13 to .0069

(0.033 to 0.1 75

mm) mm)

Maximum
four

permissible difference between

all

measurements

002

In.

(0.05

Maximum
of

any two cylinder each other

permissible difference between average projection liners next to

002

in.

(0.05

mm)

Maximum permissible difference between average projection of all cylinder liners under one cylinder head 003 in. (0.08

mm)

NOTE; If liner projection is not correct, turn the liner to a new position within the bore. If projection can not be corrected this way, move the liner to a different bore. If the projection can not be corrected this way, make reference to Special Instruction, Form No. FM055228 for complete instructions on the use of 8S3140 Counterboring Tool
Arrangement.

SHIM THICKNESS, COLOR CODE, AND PART NUMBER

3304

VEHICULAR ENGINES

SPECIFICATIONS

PISTONS AND RINGS

Make

reference to

GUIDELINE FOR REUSABLE PARTS; PISTONS

AND CYLINDER

LINERS, Form No. SEBF8001.

PISTONS AND PISTON RINGS

3304

VEHICULAR ENGINES

SPECIFICATIONS

PISTONS AND RINGS


Make reference
to

GUIDELINE FOR REUSABLE PARTS: PISTONS AND CYLINDER LINERS. Form

No. SEBF8001.

3304

VEHICULAR ENGINES

SPECIFICATIONS

CONNECTING ROD

(1)

Bore

in

bearing for piston pin (new):


1

5S6360 Rod 5S2793 Rod

5017 .0003

in.

(38.143 + 0.008 (43.210 + 0.008

mm) mm)

1.7012 .0003

in.

8N1984 Rod
(tapered)

1.5017

.0003

in.

(38.143

0.008 mm)

8N1721 Rod
(tapered)

1.7012 .0003

in.

(43.210 + 0.008

mm)
mm)
mm)

Maximum
(2)

permissible clearance between bearing

and piston pin (worn)


Bore
in

003
for

in.

(0.08

connecting rod

bearing
(3)

3.2500

.0005

in.

(82.550

0.013

Distance between center of piston pin and center of crankshaft bearing


(new)
9.595

.001

in.

(243.71

0.03

mm)

(4)

Diameter of piston pin (new):

9H4016
7N9804

Pin Pin

1.5003

.0002
.0002

in.

(38.108
(38.108 (43.175

0.005 mm) 0.005 mm)

1.5003
1.6998 1.6998

in.

8r^6487 Pin

.0002

in.

0.005
0.005

mm)
mm)

7N9805
(5)

Pin

.0002

in.

(43.175

Clearance between connecting rod bearing

and crankshaft bearing surface


(journal)

0030 to .0066

in.

(0.076 to 0.168

mm) mm)

Maximum
(worn)
(6)

permissible clearance between bearing and crankshaft

010
for
oil

in.

(0.25

Torque on nut
a.

connecting

rod:

Put engine

on threads and nut

seat.

b. c.

Tighten both nuts to

30
of bolt.

lb. ft.

(40

4 Nm)
B09139X2

Mark each nut and end

d.

Again tighten both nuts (from mark)


slot for the

90
bearing tab

Install the connecting rod in the piston with the on the same side as the V mark on the piston.

Make reference to Special Instructions, Form No. GMG02394 and SMHS7366 for information about checking and reconditioning connecting rods.

66

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

CRANKSHAFT
)

(1)

Thickness of thrust plates (new):


Without tabs

6N8940
9S3037
with tabs:

1850 .0015

in.

(4.699
(5.894

0.038 0.038

mm) mm)

2320 .0015

in.

7N9342

2150 .0015
2620 .0015
to

in.

(5.461

0.038 0.038

mm)
mm)

7N9343

in.

(6.655

NOTE: Make reference

THRUST PLATE USAGE CHART

for the

correct thrust plate to use.


(2)

THRUST PLATE USAGE CHART

Make reference to MAIN BEARINGS and BEARING SURFACE (JOURNAL) FOR MAIN BEARINGS. Make reference to CONNECTING ROD BEARINGS and BEARING SURFACE (JOURNAL) FOR CONNECTING RODS.
Tighten plugs to
17

(3)

(4)

lb. ft.

(23

Nm)

Then "stake" the crankshaft to hold plugs in place. "STAKE" use a center punch and a hammer to change the shape of the hole as shown.
(5)

Crankshaft gear:

Do
(6)

not heat gear to


for

more than 600F

(316C).

End play
(new)

crankshaft

0025 to .0145

in.

(0.064 to 0.368

mm)

Maximum
(worn)
(7)

permissible end play for crankshaft

025
seal installation:

in.

(0.64

mm)

Wear sleeve and

seal into position with correct tooling. reference to Special Instruction, Form No. SMHS7100 for instructions and the correct tooling for installing wear sleeves

Push wear sleeve and

Make

and

seals.

3304

VEHICULAR ENGINES

SPECIFICATIONS

BEARING SURFACE (JOURNAL)

FOR MAIN BEARINGS

A06090X1

BEARING SURFACE (JOURNAL) FOR MAIN BEARINGS

3304

VEHICULAR ENGINES

SPECIFICATIONS

BEARING SURFACE (JOURNAL)

FOR CONNECTING RODS

A06090X1

BEARING SURFACE (JOURNAL) FOR CONNECTING RODS

3304

VEHICULAR ENGINES

SPECIFICATIONS

MAIN BEARINGS AND CONNECTING ROD BEARINGS

Make

reference to

GUIDELINE FOR REUSABLE PARTS; MAIN BEARINGS AND CONNECTING ROD BEARINGS, Form No. SEBF8009.

CONNECTING ROD BEARINGS

3304

VEHICULAR ENGINES

SPECIFICATIONS

FAN DRIVE

(1)

Fill

chamber between bearings

half

full

of

1P808 Grease before

V///

bolts are tightened.

71

3304

VEHICULAR ENGINES

SPECIFICATIONS

FLYWHEEL RING GEAR

(1)
(2)

Ring gear.
Flywheel.
Pilot

(3)

bearing bore.
of ring gear
(1).

(4)

Chamfer side

Install ring

gear

(1) is

gear (1) on flywheel as shown.


ring

(2)

so that the chamfer side

(4)

of ring

CAUTION: Do not heat


installing

gear to more than 600F (316C) before

on the flywheel.

FLYWHEEL HOUSING
TIGHTENING

Tighten bolts
to

in

number sequence
75 10
lb.
ft.

(100 14 N-m)

(A)

Timing

bolt hole.

NOTE: On some engines

the timing bolt hole

is

below the

starter.

TYPICAL ILLUSTRATION

72

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES

3304

VEHICULAR ENGINES

SPECIFICATIONS

FLYWHEEL
Face Runout
1.

(axial eccentricity) of the Flywheel:

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

2. 3.

Set the dial indicator to read .000

in.

(0.0

mnn)

Turn the flywheel and read the indicator every 90. Put a force on
the flywheel to the rear before each reading.

4.

The difference between the lower and higher measurements taken at all four points must not be more than .006 in. (0.15 mm), which is the maximum permissible face runout (axial eccentricity)

of the flywheel.

CHECKING FACE RUNOUT OF THE FLYWHEEL

CHECKING FLYWHEEL BORE

Bore Runout
1.

(radial eccentricity) of the Flywheel:


(3)
it

Install

the dial indicator

versal
2. 3. 4.

attachment

(4)

so

and make an adjustment makes contact as shown.


in.

of the uni-

Set the

dial indicator to

read .000

(0.0

mm)

Turn the flywheel and read the indicator every 90.

The difference between the lower and higher measurements taken at all four points must not be more than .006 in. (0.15 mm),
which
ity)

is

the

maximum

permissible bore runout (radial eccentric-

of the flywheel.
for the fly-

5.

Runout (eccentricity) for the bore for the pilot bearing wheel clutch, must not exceed .005 in. (0.13 mm)

CHECKING FLYWHEEL CLUTCH PILOT BEARING BORE

73

3304

VEHICULAR ENGINES

SPECIFICATIONS

FLYWHEEL HOUSING
8S2328 DIAL INDICATOR

GROUP INSTALLED

Face Runout
1.

(axial eccentricity) of the

Flywheel Housing:

Fasten a dial indicator to ttie cranl<shaft flange so the anvil of the indicator will touch the face of the flywheel housing.
Put a force on the crankshaft toward the rear before reading the
indicator at

2.

each

point.
in.

3.

With

dial indicator set at .000

(0.0

mm)

at location (A), turn the


(B), (C)

crankshaft and read the indicator at locations


4.

and

(D).

The difference between lower and higher measurements taken all four points must not be more than .012 in. (0.30 mm), which is
the maximum permissible face runout (axial eccentricity) of the flywheel housing.

C (TOP)

A (BOTTOM)

74

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES

SPECIFICATIONS

C (TOP)

FLYWHEEL HOUSING BORE


NOTE: Write the dial indicator measurements with and negative (-) notation (signs). This notation making the calculations in the chart correctly.
1.

their positive
is

+
for

necessary

With the

dial indicator in position at (C),

adjust the dial indicator

to "0" (zero).
(C).

Push the cranl<shaft up against the top bearing. Write the measurement tor bearing clearance on line 1 in column
2.

Divide the
line
1

in

measurement from Step columns (B) & (D).

by

2.

Write this number on

3.

Turn the crankshaft to put the


indicator to "0" (zero).

dial indicator at (A).

Adjust the dial

4.

Turn the cranl<shatt counterclocl<wise to put the (B). Write the measurement in the chart. Turn the cranl<shaft counterclockwise to put the (C). Write the measurement in the chart. Turn the crankshaft counterclockwise to put the (D). Write the measurement in the chart.

dial indicator at

5.

dial indicator at

6.

dial indicator at

7.

Add

lines

&

II

by columns.

8.

Subtract the smaller number from the larger number in line III in columns (B) (D). The result is the horizontal "eccentricity" (out of round). Line III, column (C) is the vertical eccentricity.

CHART FOR DIAL INDICATOR MEASUREMENTS

3304

VEHICULAR ENGINES

SPECIFICATIONS

ENGINE MOUNTING BOLTS

NOTE: Use a torque wrench to get the correct torque mounting bolts.
The chart
for

for

all

the engine

GENERAL TIGHTENING TORQUES


all

has the correct


list

tightening torque for

the bolts except those

in

the

that follows.

D4

Tractor

941-951 Track Type Loaders


Tighten the bolts which hold the front support to the frame to 460 50

Tighten the bolts which hold the front support to the frame to 400 40
Solid rear brackets only:

lb. ft.

(540

55 N

lb. ft.

(624

70

Nm)

Tighten the bolts which hold the rear brackets together to Tighten the bolts which hold the rear brackets to the frame to

Tighten the bolts which hold thB block on the flywheel housing to the frame to 460 50 lb. ft. (624

70 N-m)

400
225

40

lb. ft.

(540

55 N
35 N m)

955 Track Type Loader


Tighten the bolts which hold the front support to the frame to 460 50

25

lb. ft.

(300

lb. ft.

(624

70

Nm)

225 Excavator
Tighten the bolts which hold the support for the hydraulic pump drive housing to the frame to 350

35

lb. ft.

(470

45 N

FLEXIBLE COUPLING DRIVE


(6P3983, 6P3984, 6P5020)

(1)

Torque

for bolts
for bolts

80 95

5 lb.

ft. (1

10 7 N-m)

(2) (3)

Torque

lb. ft.

(130

Nm)

Maximum

permissible out of square of the face of

flange in relation to the input shaft of the

torque converter
(4)

026

in.

(0.66

mm)

Maximum

permissible out of round of output flange

in

relation to the input shaft of the

torque converter

080

in.

(2.03

mm)

NOTE:

Fill

the grease lines and the area between the seals with

grease before installing in the vehicle.

76

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

FLEXIBLE DRIVE COUPLING (Earlier; Two Piece Front Flange)

TO413

(1)

Torque

tor bolts

80
160

lb. ft. (1

10 7

Nm)
Nm)
mm)

(2)

Torque for bolt holding flange


to drive

10

lb. ft.

(219

14

(3)

Maximum
Maximum

permissible "runout" axial alignment of face

(total indicator readingi


(4)

026

in.

(0.66

permissible "eccentricity" radial off

center of flywheel output flange rim to torque converter shaft (total indicator reading)

080

in.

(2.03

mm)

FLEXIBLE DRIVE COUPLING


(Earlier;

One

Piece Front Flange)

(1

Torque

for bolts

80

lb. ft. (1

10 7

Nm)
mm)

(2)

Maximum

permissible "runout" axial alignment of face

(total indicator reading)


(3)

026

in.

(0.66

Maximum

permissible "eccentricity" radial off

center of flywheel output flange rim to torque converter shaft (total indicator reading)

080

in.

(2.03

mm)

77

3304

VEHICULAR ENGINES

SPECIFICATIONS

CHECKING AND ADJUSTING ALIGNMENT OF THE FLEXIBLE COUPLING DRIVE

A09406- 1X1

Remove

the bolts, joints and torque converter flange.

2.

Fasten a 3/8 in. (9.5 mm) diameter rod 3 in. (76.2 mm) long to the torque converter input shaft with a 1J9778 Hose Clamp. Install a

7H1948 Snug onto

the rod. Assemble a

7H1942

Indicator (with a
into the

7m940
3.

Universal Attachment),

and 7H1945 Holding Rod

7H1948Snug.
Put the universal attachment on the outside diameter of the engine output flange. Rotate the indicator until it stops on "0". Turn the torque converter input shaft 360. Record the indicator measurement at each 90of rotation.

4.

The total indicator reading through 360 of rotation must not be more than .080 in. (2.03 mm). The alignment can be made correct by loosening the engine rear bolts and moving the engine from side to side. If the alignment up and down is not correct, install or remove shims under the engine rear supports.
If the holes for the support bolts have become larger because of wear, dowels should be installed after the engine has been fastened down. [See Step (8)1
.

5.

6.

Remove

the universal attachment. Put the face of the

7H1942

Indicator rod against the engine flange between the bolt

holes and

outside diameter of the flange. Turn the indicator to "0".


7.

Turn the torque converter input shaft 360. Record the indicator measurement at each 90 of rotation. The total indicator reading through 360 of rotation must not be more than .026 in. (0.66 mm). The alignment can be made correct by loosening the engine front support bolts and moving the front of the engine side to side. Check the vertical and horizontal alignment again. When the ment is correct, tighten the engine mount bolts:
align-

8.

A09407- X
1

Make

reference to

ENGINE MOUNTING BOLTS

for the correct

torque for the bolts that hold the engine to the frame.

NOTE:
If
is

is off by a large amount, inspect for the cause. can be straightened. If the engine front support badly worn, a replacement is needed.

If

the alignment
is

the frame

bent,

it

78

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES

SPECIFICATIONS

ALTERNATORS

7S5897 24V 19A

(Prestolite (Prestolite

Number ANB6001)

9S4070 24V 19A


Polarity
is

Number ANB7001

)*

negative ground.
at

Rated output

28V

19
1

Output

at

500 rpm and 28V


18 to 20

Resistance of the rotor at 77 F (25 C)

ohm
.3

Current consumption (draw)

at

77 F (25 C)
1

and 24V
(1
)

.2

to

Torque

for nut holding pulley for bolts


for screws

85 to 90

lb. ft. (1 lb. in.

15 to 120

Nm)
Nm)
N-m)

(2)
(3)
(4)

Torque
Torque

25 to 30
10 to 15

(2.8 to 3.4
.1

lb. in. (1

to

.7

Torque Torque

for terminal nuts for bolts holding the

30 to 35

lb. in.

(3.4 to 4.0

Nm)
Nm)

(5)

regulator

45

to

50

lb. in. (5.1

to 5.7

Including the

9S2329 Regulator (Prestolite

Number VSH6401)

2P1698 24V 19A

(Prestolite (Prestolite

Number ANB6002 Number ANB7002

or

ANB6004)
ANB7004)*

2P1204 24V 19A


Polarity
is

or

negative ground.
at

Rated output

28V
(21 C)

19

Output

at

6000 rpm, 28V and 70 F

25

to

30

Resistance of the rotor at 77 F (25 C)

18 to 20 ohms

Current consumption (draw) at 77 F (25 C) and 24V


(1) (2)

.20 to

.33

Torque

for nut holding pulley


field

75

lb. ft.

(100

Nm)
N-m)

Torque for nuts for ground terminals Torque

and

25 to 30

lb. in.

(2.8 to 3.4

(3)

for screws holding

terminal plate
(4)

10 to 15

lb. in. (1
lb. in.

.1

to 1.7

Nm)
Nm) Nm)

Torque

for bolts for bolts holding

25 to 30

(2.8 to 3.4

(5)

Torque

regulator
(6)

45 to 50
45
to

lb. in. (5.1

to 5.7 to 5.7

Torque Torque

for nut for terminal

50

lb. in. (5.1

Nm)
Nm)

(7)

for nut for positive

terminal

225

to

250

lb. in.

(25.4 to 28.3
(Prestolite

Including 2P1699,

4N5938 or 6N3821 Regulator VSH-6401A, VSH-6401B or VSH-6401C).

Number

79

3304

VEHICULAR ENGINES

SPECIFICATIONS

Alternators (Cont.)

6N9294 24V 35A (Delco-Remy Number 1117640)


Rotation can be either direction.
Polarity
is

negative ground-

Output

at at

28V and 2600 rpm 28V and 6500 rpm

15

Output

35 A 35 A
(27

Rated output, hot


Field current at
(1) (2)

24V and 80 F

C) 75 5 20 5
...
lb.
ft.

2.5 to 3.2

Torque

for nut

holding pulley

(100 7 N-m)
(2.3

Torque Torque

for
for

cover screws
output (POS) terminal

lb. in.

0.6 N-m)
(7

lb. ft.

N-m)

80

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
NOTE:

3304 VEHICULAR

ENGINES

SPECIFICATIONS

Alternators (Cont.)

5S9088 24V 50A (Delco-Remy Number 1117226)


Rotation can be either direction.
Polarity
is

negative ground

Circuit

B
testing

Speed for

5000 rpm

Output when cold:


Fasten carbon pile to battery to get

maximum

output

54

Rated output, hot


Field current at

50 A
F (27 C)

24V and 80

2.5 to 2.9

Voltage regulator: Voltage setting range


Adjust voltage setting to

26 to 30 28

V
V

then Increase speed to get maximum output


(1)
(2)

50
75

Torque

for nut holding pulley

lb. ft.

(100 7
(14
+
1

Nm)

Torque for output terminal

10

lb. ft.

Nm)

3P77 24V (Delco-Remy Number 1102398)


Polarity
is

negative ground.

Rotation can be either direction.

Output

at
at

26V and 2600 rpm


26V and 7000 rpm

(cold) (cold)

25 A
41

Output

Rated output (hot)


(1)

40 A
25 to 40

Torque

for stud nut for battery


lb. in.

connection
(2)

(2.8 to 4.5
ft.

Torque for pulley nut

60

+ 5 lb.

(80 7

Nm) Nm)

81

3304

VEHICULAR ENGINES

SPECIFICATIONS

Alternators (Cont.)

5A8908 24V 20A


Rotation
Polarity
is

(Mitsubishi

Number AR4020A)

clocl<wise

when

seen from drive end.

is

negative ground.
at

Rated output

24V
1150 rpm

20 28

A
V

No

load output at speed below


at

Loaded output

speed below 2500

rpm and 28 V
29.5
1 1

20 A

Resistance of field coil at 68 F (20 CI

ohms

Tension of brush spring

to 14 oz. (3.1 to 3.9 N)

Minimum

permissible tension of spring

7.4 oz. (2.1 N)

Brush length

75

in.

(19.0
(6.4

mm)

Minimum

permissible brush length

25 75
to

in.

mm)

Torque for nut holding pulley Torque for nut holding


slip rings

90

lb. ft.

(100 to 120

Nm)

35

lb. ft.

(45 IMm)

3A1997 24V 19A (Paris-Rhone Number A13RH3T)


Polarity
is

negative ground.

Rotation

is

clockwise

when

seen from drive end.

Output Output
(1)
(2) (3) (4)

at
at

4,000 rpm (hot)


1,180 rpm (hot)

19

A
V

28

Torque for pulley nut


Tension of brush spring

75 to 90

lb. ft.

(100 to 120
lb.

Nm)
mm) mm) mm)

2.25 to 2.75

(10 to 12 N)
(11.2

Minimum brush
Diameter of

length

44
1.65 1.57
lb. ft.

in.

slip ring

(new)

in.
in.

(42,0
(40.0

Minimum
(5)

permissible slip ring diameter

Torque

for slip ring nut

18 to 22

(24 to 28

Nm)

82

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

ALTERNATOR REGULATOR

6N3821 24V

(Prestolite
(Prestolite

Number VSH-6401C)

4N5938 24V
2P169g 24V

Number VSH-6401B)
Number VSH-6401A) Number VSH-6401)

(Prestolite (Prestolite

9S2329 24V
Polarity
is

negative ground.
at

Voltage setting range


(1)

70 F (21C)

27.3 to 28.7

Adjustment screw and washer.


With voltage adjustment screw (Din position "N" (center). When screw (II is in position "L", voltage will be 0.5V less. When screw (1 is in position "H", voltage will be 0.5V higher.

5A9131 24V
Voltage range

(Mitsubishi
at

Number RM4140G)
28 to 31

3000 rpm

83

3304

VEHICULAR ENGINES

SPECIFICATIONS

GENERATORS
4M9102 24V 20A (DelcoRemy Number 1106971)
Rotation
Circuit
is

clocl<wlse

when

seen from

tlie

drive end.

A
for testing
1

Speed

720 rpm

Field current at

24V and 80

F (27 C)

83 to .89 A 20 A
26 V

Output

at

720 rpm and 26V wfien cold

Output wtien cold


(1

Tension of brusfi spring

20 83

oz. (5.6 N)

(2)

Torque
pulley

for nut holding

lb. ft.

(114

11

Nm)

1^

1S151 24V 15A (DelcoRemy Number 1105241)


Rotation
Circuit
is

clockwise

when seen from

the drive end.

A
1800 rpm
F (27 C)

Speed for testing


Field current at

24V and 80

94

to

.02

A A
V

Output

at

1800 rpm and 28.5V when cold

15
28.5

e a _

Output when cold


(1

Tension of brush spring

16 oz. (4.4 N)

(2)

Torque
pulley

for nut holding

83

lb. ft. (1

14

1 1

IMm)

1S5134 24V and 25A (Oelco-Remy Number 1106887)


Rotation
Circuit
is

clockwise

when

seen from the drive end.

A
for testing

Speed

1700 rpm
F (27 C)

Field current at

24V 80

83 to.89

Output

at

700 rpm and 26V when cold

20 A
26 V

Output when cold


(1)

Tension of brush spring

20 60
10

oz. (5.6

N)

(2)

Torque for nut holding


pulley

lb. ft.

(80 14

Nm)

3304

VEHICULAR ENGINES

SPECIFICATIONS

Generators (Cont.)

5A3033 & 5A6539


Rotation
is

(Mitsubishi

Number DR 350/24MR)

clockwise

when

seen from the drive end.

Speed for testing with

a load (less than)

2000 rpm
28.5
1

Output with Output


at

a load

V A

below 2000 rpm and 28.5V


(less

Speed for testing with no load

than)

1550 rpm
28.5

Output with no load (zero Amps)


Tension of brush spring

77

lb. (3.4

N)

5A7375
Rotation

(Mitsubishi
is

Number DT 600/24 ZR)


when
seen from the drive end.

clockwise

Speed

for testing with a load (less than)


a load

1600 rpm
28

Output with Output


Speed
at

V A

below 1600 rpm and 28\/

25

for testing with

no load

(less

than)

1450 rpm
28 V

Output with no load (zero Amps)


Tension of brush spring

93

lb.

(4.2

N)

GENERATOR REGULATORS

2M6497 24V 15A (Delco-Remy Number 1119626)


Polarity
is

negative ground or insulated.

Circuit
(1)

A
relay:

Cutout

Air gap between armature and core

01 7

in.
in.

(0.43
(0.81

mm)

Point gap

032

mm)
V

Voltage closing range


(2)

22.8 to 25.2

Current regulator:
Air gap between armature and core

068

to .082

in.

(1.73 to 2.08

mm)
A

Current setting range


(3)

14 to 16

Voltage regulator:
Air gap between armature and core

067

in. (1 in.

.70

mm)
mm) V

Point gap

016
at

(0.41

Voltage setting range

85 F (29 C):
27.4 to 29.4

Upper contacts
'

Lower contacts
(4)

2 to .6V less than upper contacts

Torque

for bolt

36

lb. in. (4.1

0.7

N-m)

85

3304

VEHICULAR ENGINES

SPECIFICATIONS

Generator Regulators (Cont.)

4M9349 24V 20A (Delco-Remy Number 1119653)


Polarity
Circuit
(1)
is

negative ground or insulated.

A
relay:

Cutout
Air gap

between armature and

core

015

to .019

in.

(0.38 to 0.48

mm)

Point gap

032

in.

(0.81

mm)
V

Voltage closing range


(2)

22.8 to 25.2

Current regulator:
Air gap between armature and

core

068

to .082

in. (1

.73 to 2.08

mm)
A

Current setting range


(3)

19 to 21

Voltage regulator:
Air gap between armature and core

067

in. (1

.70

mm)

Point gap

016
at

in.

(0.41

mm) V

Voltage setting range

85 F (29 C):
27.4 to 29.4

Upper contacts Lower contacts


(4)

2 to .6V

less

than upper contacts


0.7

Torque

for bolt

36

lb. in. (4.1

Mm)

3S5028 24V 25A (DelcoRemy Number


Polarity
Circuit
(1)
is

11

19306 and 1119306-E)

negative ground.

A
relay:

Cutout

Air gap between armature and

core
Point gap

015

to .019

in.

(0.38 to 0.48

mm)

032

in.

(0.81

mm)
V

Voltage closing range


(2)

24

to 27

Current regulator:
Air gap between armature and

core

068 to .082

in. (1

.73 to 2.08

mm)
27

Current setting range


(3)

23

to

Voltage regulator:
Air gap between armature and core

060

in. (1

.52

mm)
V

Voltage setting range at 85 F (29 C)


(4)

27.5 to 29.5

Torque

for bolts

36

lb. in. (4.1

0.7

Nm)

86

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES

SPECIFICATIONS

Generator Regulators (Cont.)

3A1874 24 V
(1)

(Paris-Rhone

Number 2T216)

Cutout relay:
Air gap between armature and core

027
031

in. in.

(0.69
(0.79

mm) mml
V

Point gap
Closing range
(2)

when

cold

24.0 to 26.0

Current regulator:
Air gap between armature and core

039

In.

(0.99

mm) A

Current setting range


(3)

14 to 15

Voltage regulator:
Air gap between armature and core

043

in. (1

.09

mm) V

Voltage setting range at 85 F (29 C)


(4)

26.8 to 28.2

Torque for bolts

36

lb. in.

(4.1 + 0.7

N-m)

5A3061

(Mitsubishi

Number RW-3B)

Cutout relay:
Air gap between armature and

core

043 030 020

to .055 in. (1.09 to 1.40

mm)

Back gap
Point gap

to .047

in. in.

(0.76 to

.19

mm)
mm)
1

to .032

(0.51 to 0.81

Switch

in

24.5
(less

V A

Reverse current

than)

Voltage regulator:
Air gap between armature and

core

039 to .047

in.
in.

(0.99 to 1.19

mm)

Back gap
Regulator setting (no load)
Current regulator:
Air gap
at

029 to .043 3000 rpm

(0.74 to 1.09
.

mm)

27.5 to 29.5

between armature and

core

047

to .055 to .043

in. in.

(1.19 to 1.40

mm)

Back gap
Current limiter setting range
at

029

(0.74 to

.09

mm)
A

3000 rpm

14 to 16

5A7385

(Mitsubishi

Number RT4342E)

Cutout relay:
Air gap between armature and core

051
in.

in.

(1.30

mm) mm)
V

Point gap

016 to .024

(0.41 to 0.61

Switch

in

26
(less

to 27

Reverse current Voltage regulator:

than)

10

Air gap between armature and core

079 to .087

in.

(2.01 to 2.21

mm)
V

Regulator setting (no load)

at

3000 rpm

28 to 29

Current regulator:
Air gap

between armature and


051 to .069
at
in. (1

core

.30 to

.75

mm) A

Current limiter setting range

4000 rpm

24

to 26

87

3304

VEHICULAR ENGINES

SPECIFICATIONS

STARTER MOTORS
1P7838 24V (Delco-Remy Number 1113992)

9M1662 24V (Delco-Remy Number 1113967)


4N3182 24V (Delco-Remy Number 1114711)
Rotation
is

clockwise when seen from drive end.


with no load with no load
at

Minimum speed

5500 rpm

Maximum speed

7500 rpm

Current consumption (draw)

no

load:

Minimum

with solenoid at with solenoid at

20V 20V
36

75

Maximum

95 A

Clearance between pinion and housing


(pinion clearance)
(1) (2)
in. (9.1

mm)

Tension of brush spring

56 oz. (15.6 N)

Torque
to lever

for

screws holding nose housing housing 13 to 17


20
to

lb. ft.

(18 to 23 (25 to 35

N-m) N-m)

(3)

Torque

for terminal nuts

25

lb.

ft.

4N7902 24V (Delco-Remy Number 1113415)


Rotation
is

clockwise when seen from drive end.


with no load with no load
at

Minimum speed

5500 rpm
7500 rpm
load:

Maximum speed

Current consumption (draw)

no

Minimum

with solenoid at 20V


with solenoid at

85

Maximum

20V
36

112 A

Clearance between pinion and housing


(pinion clearance)
(1)
(2)
in. (9.1

mm)

Tension of brush spring'

36

to

40 oz. (10.0
to

to 11.1 N)

Torque for screws holding nose housing lever housing

8
lb.
ft.

lb.

ft.

(11

N-m)
N-m)

(3)

Torque

for terminal nuts

20

to

25

(25 to 35

"Minimum

for leaf springs

80 oz. (22 N)

2P2502 24V (Delco-Remy Number 1113393)

7N1285 24V (Delco-Remy Number 1113472)


Rotation
is

3T2772 24V (Delco-Remy Number 1113540)


Rotation
is

clockwise

when seen from

drive end.

clockwise when seen from drive end.


with no load with no load
at

Minimum speed

with no load
with

5500 rpm

Minimum speed

5500 rpm
7500 rpm
load:

Maximum speed

no load
at

7500 rpm
load:

Maximum speed

Current consumption (draw)

no

Current consumption (draw)

no

Minimum

with solenoid at 20V


with solenoid at 20V
1

85 A
12

Minimum

with solenoid at 20V


with solenoid at

60 A 120 A

Maximum

Maximum

20V
to .39 to

Clearance between pinion and housing 010 to .140 (pinion clearance)


(1)

in.

(0.25 to 3.56

mm)

Clearance between pinion and housing (pinion clearance) 33


(1)

in.

(8.3 to 9.9

mm)

Tension of brush spring

36

to

40 oz. (10.0 to 11.1 N)

Tension of brush spring

36

40 oz. (10.0

to 11.1 N)

(2)

Torque

screws holding nose housing to lever housing 13


for
for terminal nuts

(2)

Torque
housing

for
to

to 17

lb. ft.

(18 to 23 (25 to 35

N-m) N-m)
(3)

screws holding nose lever housing 13

to 17

lb. ft.

(18 to 23
(25 to 35

N-m)

(3)

Torque

20

to

25

lb. ft.

Torque

for terminal nuts

20 to 25

lb.

ft.

N-m)

88

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES

SPECIFICATIONS

Starter

Motors (Cont.)
drive end.

3T2647 24V (Delco-Remy Number 114845)


Rotation
is

clockwise

when seen from


no load

iVIInimum speed

witii

5500 rpm

Maximum speed

with no load

9000 rpm

Current consumption (draw) at no load:

Minimum

with solenoid at 28V


with solenoid at

70

Maximum

28V

110 A

Clearance between pinion and housing (pinion clearance) 33


(1)

to .39

in.

(8.3 to 9.9

mm)
N-m) N-m)

Torque

for terminal nuts for

20 to 25

lb. ft.

(25 to 35

(2)

Torque
to

screws holding nose housing lever housing 13 to 17

lb. ft.

(18 to 23

3T2878 24V (Delco-Remy Number 1113545)


Rotation
is

clockwise

when seen from

drive end.

Minimum speed

with no load with no load

5500 rpm 7500 rpm

Maximum speed

Current consumption (draw) at no load:

Minimum

with solenoid at 20V


with solenoid at

60
80

A
A

Maximum

20V

Clearance between pinion and housing (pinion clearance) 33 to .39


(1) (2)

in.

(8.3 to 9.9

mm)
N-m)

Torque
Torque

for terminal nuts

20 to 25

lb. ft.

(25 to 35

for screws holding nose housing to lever housing 13

to 17 lb.

ft.

(18 to 23

N-m)

7S5900 and 2P2501 24V


3P6 24V
(Prestolite

(Prestolite

Number MFY

6201 K)

Number MFY 6401 K)

4N7901 24V
Rotation
is

(Prestolite

Number MFY 6401 L)

clockwise when seen from the drive end.


load speed

Minimum no

5000 rpm

Current consumption (draw) at no load:

Maximum
(1) (2)

at

20V

65

Tension of brush spring

52 to 65 oz. (14.5 to 18.1 N)


8
lb. ft.

Torque

for bolts for terminal nuts


for the pinion
. .
.

(11

N-m) N-m)

(3)
(4)

Torque

20

to

25

lb. ft. in.

(25 to 35
1

Clearance

.020 to .050

(0.51 to

.27

mm)

7S2234 and 1P7839 24V

(Prestolite

Number MES6101K)

4N7752 24V
2P6162 24V

(Prestolite

Number MES6404K)
Number MES6301K) Number MES6601K)

(Prestolite (Prestolite

9G4338 24V
Rotation
is

clockwise when seen from drive end.


with no load

Minimum speed

5000 rpm

Current consumption (draw) with no load:

Maximum
(1) (2)
(3)

at

20V
80
to

77

Tension of brush spring

90 oz. (22.2 to 25.0 N)


8
lb.
ft.

Torque Torque

for housing bolts


for terminal nuts

(1

N-m) N-m)

20

to

25

lb. ft.

(25 to 35

(4)

Clearance between pinion and housing (pinion clearance) 020 to .050

in.

(0.51 to

.27

mm)

89

3304

VEHICULAR ENGINES

SPECIFICATIONS

Starter Motors (Cont.)

9G4337 24V
Rotation
Is

(Presfolite

Number MFY6601K)
ttie

clockwise when seen from


load speed
at

drive end-

Minimum no

5000 rpm

Current consumption (draw)

no

load:

Maximum
(1) (2)

at

207
8 20 to 25
. .

65 A
lb.
ft.

Torque Torque

for bolts tor terminal nuts


ttie

(11

N-m)

lb, ft.

(25 to

35 N-m)

(3)

Clearance for

pinion

.020 to .050

in.

(0.51 to 1.27

mm)

3T6305 24V (Robert Bosch Number 0-001-430-03)


Rotation
is

clockwise wtien seen from


load speed
at

ttie

drive end.

Minimum no

5500 rpm no load:


140 A

Current consumption (draw)

Minimum
Permissible clearance between pinion and ring gear
(1

06 to .22 20 to 24

in.

(1.5 to 5.6

mm)
N-m)

Torque

for terminal nuts

lb. ft.

(27 to 33

(2)

Minimum
thie

permissible lengtti of brusties permissible diameter of

69

in.

(17.5

mm)

(3)

Minimum

commutator

1.9 in. (48

mm)

90

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES

SPECIFICATIONS

Starter

Motors (Cont.)

3A2035 24V

(Paris-Rhone

Number D13 E76) Number D13 E77)


seen from drive end.
at

3A 1872 24V
Rotation
is

(Paris-Rhone

clocl<wise

when

iVIaximum speed with no load

20 V

6000 rpm

Current consumption (draw) at no load:

Maximum
Minimum
commutator

with solenoid

at

20 V and 6000 rpm

75

permissible diameter of the

2.05

in.

(52.1

mm)
mm)

Clearance between pinion and support


(pinion clearance)
(1) (2)

039

.020 in. (1.00 + 0.51

Tension of brush spring

53.3 5.3 oz. (14.8

1.5 N)

Torque

for screws holding

support to

lever housing
(3)

15

lb. ft.

(20 3

Nm)

Torque

for terminal nuts

20

to

25

lb. ft.

(25 to 35 IMm)

3A1529 24V (Paris-Rhone Number D13 E68)


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

clockwise

when

seen from drive end.


at

Maximum

speed with no load

20 V

6000 rpm

Current consumption (draw) with no load:

Maximum

with solenoid at 20

and 6000 rpm

75

r^

Minimum

permissible diameter of the

commutator
Clearance between pinion and thrust washer
(pinion clearance)
(1)
(2)

2.05

in.

(52.1

mm)

039

.020

in.

(1.00 + 0.51

mm)

Tension of brush spring

53.3 5.3 oz. (14.8


to

1.5 N)

Torque for screws holding support


lever housing

15

lb. ft.

(20

3 N-m)

(3)

Torque

for terminal nuts

20 to 25

lb. ft.

(25 to 35

Nm)

5A6492 and 5A3031

(IMitsubishi

Number Number

MX MT

10/24 ZR)

5A6494 and 5A3196


Rotation
is

(Mitsubishi

10/24 YR)

clockwise

when

seen from drive end.

Minimum

speed with no load

6000 rpm

Current consumption (draw) at no load:

Maximum
Stall

at

23V

110

torque

test:

Maximum
Stall
(1

current consumption (draw) at

9V
1500 A
79.6
lb. ft.

(maximum)
torque at

9V (minimum)

(108.1

Nm)
mm)

Minimum

permissible diameter of the

commutator
(2)

2.01

in.

(51.1

Tension of brush spring

2.29

.34

lb.

(10.2 1.50 N)
in,

(3)
(4)

Minimum

permissible length of brushes

55

(14.0

mm) mm)

Clearance between pinion and housing (pinion clearance) 1 18 to .138

in.

(2.99 to 3.51

91

3304

VEHICULAR ENGINES

SPECIFICATIONS

Starter Motors (Cont.)

5A6522 5A6495

(Mitsubishi
(IVIitsubishi
(IVIitsubishi
is

Number
Number Number
when

MRA 7
MTR

5/24 ER or IV1OO7T03774)

IVIRE 7 5/24

ER)

5A5744
Rotation

7 5/24

YR)

clockwise

seen from drive end.

Minimum speed with no

load

6000 rpm

Current consumption (draw) at no load:

Maximum
Stall

at

23V

10

torque

test:

Maximum
Stall
(1)

current consumption (draw) at

9V
1500

(maximum)
torque at

9V (minimum)

80

lb. ft. (1

10 N-m)

Minimum

permissible diameter of the


2.01
in.

commutator
(2)
(3)

(51.1

mm)

Tension of brush spring

4.6

.7 lb.

(20.5 3.1 N)
in.

Minimum

permissible length of brushes

55

(14.0

mm) mm)

(4) Clearance between pinion and housing 1 18 to .138 (pinion clearance)

in.

(2.99 to 3.51

STARTER MAGNETIC SWITCHES


7N3621 24V

7M4291 24V (Delco-Remy Number 1119866)


Current consumption (draw) at 20
(1)

3.5 to 3.9

7M7553

Spring:
test force

Length under
Test force

278
7.6 to 8.4

in.

(7.06

mm)

lb.
in.

(33 to 38 N)

Free length after test

657

(16.69 (13.06

mm) mm)

Outside diameter
(2)

514

in.

7M7622

Spring:
test force

Length under
Test force

56
2.65 to 3.25
lb. (1
1

in.

(14.2

mm)

.60 to 14.00 N)
in.

Free length after test

874

(22.20

mm) mm)

Outside diameter

434

in.

(11.02

9F3099 24V (Delco-Remy Number 0001481)


Current consumption (draw) both windings at 24 V
(1)

83
.

to .89

Torque

for large terminal nuts ..

30

to

40

lb. in.

(3.4 to 4.5

Mm)

5L5886 12V (Delco-Remy Number 0001486)


302266 or 9N964 12V (Delco-Remy Number 1119828)
Rating

12

V
A

Current consumption (draw) hold-in windings at 8 V


(1)

2.1 to 2.4

Torque
nuts

for large terminal

30 to 40

lb. in.

(3.4 to 4.5

Nm)

92

NOTE: FOR TOROUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES

3304

VEHICULAR ENGINES

SPECIFICATIONS

STARTER SOLENOIDS

4M1812 24V (Delco-Remy Number 1119832


Current consumption (draw):
Current
pull in
pull in
in

or 1119848)

windings windings
winding

at

5V
20 20
to

10 to 11.5

Current

at at

24V 24V

40

to 55.2 of 8.2

A A

Current hold
(1)

to

Maximum

4M1815 Spring
Length under
Test force

for contact release:

test force

42
8.5 to 9.5
lb.

in.

(10.7

mm)

(37.8 to 42.3 N)

Free length after test

83 .015
375 .010

in. in.

(21.1

0.38 mm) 0.25 mm)

Outside diameter
(2)

(9.53

9M7609

or

8M1856 Spring
test force

to return the clutch lever:

Length under
Test force

1.56

in.

(39.6

mm) mm)

14

.5 lb.

(62 2.2 N)
(70.9

Free length after test

2.79

in.

Outside diameter
(3)

1.393

.015

in.

(35.38

0.38 mm)
N-m)

Torque

for terminal

screws

16 to 30

lb. in.

(1.8 to 3.4

6NS123 24V (Delco-Remy Number 1115544)


Current consumption (draw):

Current at 20V Current at 20 to 24V


(1)

40 to 45.5 A 40 to 54.6

4M1815 Spring
Length under
Test force

for contact release:


.

test force

42
lb.

in.

(10.7

mm)

8.5 to 9.5

(38.0 to 42.5 N)

Free length after test

83 .015

in.
in.

(21.1

0.38 mm)
0.25

Outside diameter
(2)

375 .010

(9.53

mm)

9M7609 Spring
Length under
Test force

to return the clutch lever:

test force

1.56

in.

(39.6

mm) mm)
mm)
N-m)

14

.5 lb.

(62

2.2 N)

Free length after test

2.79

in.

(70.9

Outside diameter
(3)

1.393 .015

in.

(35.38 0.38
to 3.4

Torque

for terminal

screws

16 to 30

lb. in. (1 .8

93

3304

VEHICULAR ENGINES

SPECIFICATIONS

Starter Solenoids (Cont.)

1P9181 24V (Delco-Remy Number 1115526)


Current consumption (draw):

Current Current
(1)

at

20V

40 to 45.5 A
to

at

20V

24V

40 to 54.6 A

4M1815 Spring

for contact release;

Length under test force


Test force
8.5 to 9.5
lb.

42

in.

(10.7

mm) mm)
mm)

(37.8 to 42.3 N)

Free length after test

83 .015

in.
in.

(21.1

0.38

Outside diameter
(2)

375 .010

(9.53 0.25

9M7609 Spring
Length under
Test force

to return the clutch lever:

test force

1.56

in.

(39.6

mm)

14 +

.5 lb.

(62 2.2 N)
(70.9

Free length after test

2.79

in.

mm)

Outside diameter
(3)

1.393 .015

in.

(35.38

0.38 mm)
N-m)

Torque

for terminal

screws

16 to 30

lb. in.

(1.8 to 3.4

3T4704 24V (Delco-Remy Number 1115557)


Current consumption (draw):
Pull in

winding winding
for nuts

at at

5V

9 to 11.5
6.8

B38473X1

Hold
(1)

in

20V
20 to 25
lb. ft.

A IVIaximum
N-m)

Torque

(27 to 33

94

FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES
NOTE:

3304

VEHICULAR ENGINES

SPECIFICATIONS

Starter Solenoids (Cont.)

3T868 24V (Robert Bosch Number 0331 410 002)


Resistance:
Pull in

winding

513 to .567

ohm
B38474X1

Resistance:

Hold

in

winding

3.28 to 3.62

ohm

r^
3T3369 24V
9S7976 24V
(Presfolite
(Preslolite

Number SAT-4105) Number SAT-4103) Number SAT-4101)

8S1529 24V

(Prestolite

Current consumption (draw): Current pull


Current pull
in in in in

if=
23.2 to 26.6

windings windings

at at

12

V
to

20

24 V

38.6 to 52.4
4.1 to 4.8

A A A

Current hold Current hold

windings at 12

V V

windings at 20 to 24

6.8 to 9.6

3A1555 24V (Paris-Rhone Number CED65I


Current Consumption (draw):

Current both windings at Current hold


(1)
in

20V
at

70

A
A

windings

20V

11.2

1.2

Spring for contact release:

Length under
Test force

test force

295
18.7

in.

(7.49

mm)
N)

1.9 lb. (83.0 8.5


in.

Free length after test

433

.010

(11.00

0.25
(9.4

mm) mm) mm)

Outside diameter
(2)

37

in.

Spring to return the clutch lever:

Length under
Test force

test force

2.4

in. (61 .0

13.2

1.3

lb.

(58.5
in. (1

5.8 N)

Outside diameter

45

1.4

mm)

95

3304

VEHICULAR ENGINES

SPECIFICATIONS

FUEL PRESSURE INDICATOR

6N3272

Indicator (Frank

W. Murphy Mfr.

Inc.)

Gauge with color code.

CALIBRATIOIM CHART

3304

VEHICULAR ENGINES

SPECIFICATIONS

OIL

PRESSURE INDICATOR

5M1065

Indicator (Stewart Warner Corp.

Number 342-FR)

Gauge with color code.

CALIBRATION CHART

o
CITERPILLAR

o.
SENR7590-01
Printed
In

U.S.A. (10/81)