Especificaciones 3304

Especificaciones
3304 VEHICULAR ENGINE
Número de medio ‐ Fecha de publicación ‐ Fecha de actualización ‐

SENR7590‐01 01/10/1981 12/10/2001
Engine Design
Bore ... 4.75 in.(120.7 mm)
Stroke ... 6.0 in.(152.4 mm)
Number of Cylinders ... 4
Cylinder Arrangement ... *in‐line
Firing Order (Injection Sequence) ... 1, 3, 4, 2
Direction of Rotation (when seen from flywheel end) ... Counterclockwise
*
No. 1 Cylinder Is Opposite Flywheel End.
Cylinder and Valve Identification
Fuel System Usage Chart

Fuel System Timing
Typical Example
The timing bolt must go in the flywheel housing when the timing pin is installed in the
notch in the fuel injection pump camshaft.
Service Meter
(Earlier Models)
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(1) Torque for bolts which hold service meter or adapter for service meter drive ... 96 ±
24 lb. in.(10.9 ± 2.8 N·m)
NOTE: Torque for cable nut ... 50 lb. in.(5.7 N·m)
Electric Service Meter

(Later Models)
6N5906
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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
N·m)
Fuel Injection Equipment

(Sleeve Metering Fuel System - PC)
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Firing order (injection sequence) ... 1, 3, 4, 2
Injection timing before TC (top center):
Fuel pump serial numbers to 044, 899 ... 12° 30' ± 1°

Fuel pump serial numbers, 044, 900 and up ... 13° 30' ± 1°
Torque for bolt in hole for timing pin ... 108 ± 36 lb. in.(12.2 ± 4.1 N·m)
Torque for bolts that hold governor weight carrier to camshaft ... 90 ± 10 lb. in.(10.2 ±
1.1 N·m)
(1) Diameter of rear bearing surface (journal) of the camshaft (new) ... 2.3720 ± .0005
in.(60.249 ± 0.013 mm)
Bore in the rear bearing for the camshaft (new) ... 2.3750 ± .0005 in.(60.325 ± 0.013
mm)
Maximum permissible clearance between the bearing and the camshaft bearing surface
(journal) (worn) ... .006 in.(0.15 mm)
(2) Diameter of fuel control shaft (new) ... .3530 ± .0003 in.(8.966 ± 0.008 mm)
Bore in the housing for fuel control shaft (new) ... .3543 ± .0005 in.(8.999 ± 0.013 mm)
Maximum permissible clearance between the bore in the housing and the fuel control
shaft (worn) ... .003 in.(0.08 mm)
(3) End play for camshaft with sleeve installed (new) ... .023 ± .018 in.(0.58 ± 0.46 mm)
NOTE: When installing sleeve on end of camshaft, support the camshaft to prevent
damage to parts inside of injection pump and governor housing.
(4) Governor spring:
Make reference to the chart "GOVERNOR SPRINGS."
(5) Bypass valve:
Make reference to the chart "BYPASS VALVE SPRINGS."
(6) Diameter of front bearing surface (journal) of the camshaft (new) ... .9990 ± .0005
in.(25.375 ± 0.013 mm)
Bore in the front bearing for the camshaft (new) ... 1.0005 ± .0005 in.(25.413 ± 0.013
mm)
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Install Spring As Shown
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NOTE: If the spring keeps the pressure in the fuel injection pump housing above 25 psi
(170 kPa) with the engine operating under full load, the spring is good.
Pressure of fuel in housing for fuel injection pumps, (Full Load) ... 30 ± 5 psi(205 ± 35
kPa).
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Install guide pin (A) to depth (B) [.642 ± .003 in. (16.31 ± 0.08 mm)]. Slot in guide pin
(A) must be in area shown from center of lifter.
(7) Torque for bushing ... 70 ± 5 lb. ft.(95 ± 7 N·m)
(8) 4N4318 Spring for injection pump:
Length under test force ... 1.35 in.(34.3 mm)
Test force ... 12.5 ± 1.3 lb.(55.5 ± 5.8 N)
Free length after test ... 1.566 in.(39.78 mm)
Outside diameter ... .728 in.(18.49 mm)
(9) Torque for bolt holding sleeve on control shaft ... 24 ± 2 lb. in.(2.8 ± 0.2 N·m)
(10) Torque for the nuts that hold the fuel lines (Use 5P144 Fuel Line Socket) ... 30 ± 5
lb. ft.(40 ± 7 N·m)
(11) Torque for the nuts that hold the nozzles ... 105 ± 5 lb. ft.(142 ± 7 N)
(12) Body.
(13) Put 5P3931 Anti-Seize Compound on threads of glow plug and tighten to ... 120 ±
24 lb. in.(13.6 ± 2.8 N·m)
(14) Tighten nozzle finger tight on body.
(15) Torque for precombustion chamber (put 5P3931 Anti-Seize Compound on threads)
... 150 ± 10 lb. ft.(205 ± 14 N·m)
NOTE: See Glow Plug Positioning.
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Typical Illustration
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(16) Torque for bolts holding clamps on fuel injection lines:
With rubber damper ... 84 ± 24 lb. in.(9.6 ± 2.8 N·m)
Without damper ... 108 ± 36 lb. in.(12.2 ± 4.1 N·m)

(17) Lever assembly.
(18) Clearance between lever assembly (17) and governor housing when shaft assembly
(19) is pulled against the governor housing ... .437 in.(11.10 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 shown.
9S8597 Spring for terminal shaft:
Color code (stripes) ... 1 white
Length under test force ... .584 in.(14.83 mm)
Test force ... 56.3 lb.(251 N)
Outside diameter ... 1.635 in.(41.53 mm)
Diameter of wire ... .135 in.(3.43 mm)
2P726 Spring for terminal shaft:
Color code (stripes) ... 1 red
Test force ... 109 lb.(485 N)
4N4366 Spring for terminal shaft:
Test force ... 156 lb.(692 N)
9L6508 Spring for terminal shaft:

Color code (stripes) ... 1 yellow
Put a load on spring of ... 5.00 lb.(22.2 N)
Then make spring shorter by ... .700 in.(17.78 mm)
Total test force ... 19.70 ± .52 lb.(87.63 ± 2.31 N)
Free length after test ... 1.74 ± .02 in.(44.2 ± 0.5 mm)
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(21) 9S8632 Low Idle Spring:
Test force ... 40 ± 4 lb. ft.(180 ± 18 N)

Fuel Transfer Pump

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(1) Diameter of shaft for idler gear (new) ... .4914 ± .0003 in.(12.482 ± 0.008 mm)
Bore in idler gear (new) ... .4926 ± .0003 in.(12.512 ± 0.008 mm)
(2) Thickness of gears (new) ... .3736 ± .0003 in.(9.489 ± 0.008 mm)
Depth of counterbore (new) ... .3750 ± .0005 in.(9.525 ± 0.013 mm)
Clearance between end of gears and surface of pump body (new) ... .0006 to .0022
in.(0.015 to 0.056 mm)
Fuel Ratio Control

(Sleeve Metering System - PC)
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Governor Control
(920 & 930 Wheel Loaders)

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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).
2. Move lever (1) to HIGH IDLE position and adjust rod (8) by turning rod ends (7) and
(9) so pedal (5) is at angle (A).
3. Tighten nuts on rods (6) and (8).
Angle A is ... 19°
Angle B is ... 20 ± 5°
Angle C is ... 30 ± 5°
(955LTrack-Type Loader)
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1. Put the governor control (2) in the OFF position (approximately .47 in. (12 mm) from
the end of slot in the guide.
2. Adjust length of rod (3) so lever (5) is in the OFF position at the engine. Tighten nuts
(4) on rod (3).
3. With lever (5) in the center between discs, tighten nut (6) so force needed to move
governor control lever (2) is 14.6 ± .9 lb. (65 ± 4 N).
Angle A for lever (1) and governor control (2) is ... 102 ± 5°
(950 Wheel Loader)

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1. With lever (1) in OFF position.
2. Adjust rod (2) so lever (5) is at angle (C).
3. Put pedal (4) in OFF position.
4. Adjust length of rod (3) and install pin (6). Tighten locknuts on rods.
Angle A is ... 37°
Angle B is ... 6°
Angle C is ... 11°
(951 Track-Type Loader)

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1. Make an adjustment to rod (4) so length of rod is 28.20 ± .12 in. (716.3 ± 3.0 mm) at
center of pins. Tighten nuts on rod and install rod on machine.
2. Put governor control lever (2) in the LOW IDLE position, approximately .25 in. (6.4
mm) from end of slot in guide.
3. Adjust length of rod (5) so lever (6) at the engine is in the OFF position. Tighten nuts
on rods.
4. Tighten nut (3) so force on knob (1) is 13 ± 1 lb. (58 ± 4 N).

Distance A is ... 28.20 ± .12 in.(716.3 ± 3.0 mm)
Angle B is ... 15°
Fuel Injection Equipment (Sleeve Metering Fuel

System - DI)
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Direct Injection Engines with turbocharger ... 23 ± 1°
Direct Injection Engines without turbocharger ... 29 ± 1°

Torque for bolts that hold governor weight carrier to camshaft ... 10 ± 2 lb. ft.(14 ± 3
N·m)
Make a mark (stake) the governor weight cover in four places 90° apart directly over the
groove in the camshaft.
(1) Diameter of rear bearing surface (journal) of the camshaft (new) ... 2.3720 ± .0005
in.(60.249 ± 0.013 mm)
Bore in the rear bearing for the camshaft (new) ... 2.3750 ± .0005 in.(60.325 ± 0.013
mm)
(2) Diameter of sleeve control shaft (new) ... .3530 ± .0003 in.(8.966 ± 0.008 mm)
Bore in the housing for the fuel control shaft (new) ... .3543 ± .0005 in.(8.999 ± 0.013
mm)
Maximum permissible clearance between the bore in the housing and the sleeve control
shaft (worn) ... .003 in.(0.08 mm)
(3) End play for camshaft with sleeve installed (new) ... .023 ± .018 in.(0.58 ± 0.46 mm)
NOTE: When installing sleeve on end of camshaft, support the camshaft to prevent
damage to parts inside of injection pump and governor housing.
(4) Governor spring:
Make reference to the chart 'GOVERNOR SPRINGS.'
(5) Bypass valve:
4N605 Bypass Valve Spring:
Test force ... 3.53 ± .18 lb.(15.7 ± 0.8 N)
Pressure of fuel in housing for fuel injection pumps, (Full Load) ... 30 ± 5 psi(205 ± 35
kPa)
(6) Diameter of front bearing surface (journal) of the camshaft (new) ... .9990 ± .0005
in.25.375 ± 0.013 mm)
Bore in the front bearing for the camshaft (new) ... 1.0005 ± .0005 in.(25.413 ± 0.013
mm)
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Install Spring As Shown
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Install guide pin (A) to depth (B) [.642 ± .003 in. (16.31 ± 0.08 mm)]. Slot in guide pin
(A) must be in area shown from center of lifter.
(8) 9N5862 Spring for injection pump:
Test force ... 12.5 ± 1.4 lb.(56.7 ± 6.6 N)

(9) Torque for bolts that hold sleeves on control shaft ... 24 ± 2 lb. in.(2.8 ± 0.2 N·m)
(10) Torque for 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 (11) for the terminal shaft so that the
end of the spring is in the 30 ° range as shown.
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Fuel Ratio Control

(Sleeve Metering Fuel System - DI)
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Fuel Transfer Pump

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(1) Diameter of shaft for idler gear (new) ... .4914 ± .0003 in.(12.482 ± 0.008 mm)
Bore in idler gear (new) ... .4926 ± .0003 in.(12.512 ± 0.008 mm)
(2) Thickness of gears (new) ... .3736 ± .0003 in.(9.489 ± 0.008 mm)
Depth of counterbore (new) ... .3750 ± .0005 in.(9.525 ± 0.013mm)
Clearance between end of gears and surface of pump body (new) ... .0006 to .0022 in.(0.015 to 0.056
mm)
Injection Nozzle (7N449)

Bench test nozzles using clean SAEJ967 Calibration Oil (Kent-Moore Corp. J-26400 or
Viscor Calibration Fluid 1487C-SAEJ967L) at a temperature of ... 65 to 75°F(18 to
24°C)
Nozzle setting pressures (valve lift adjustment screw turned 3/4± 1/8turn from closed
position):
Used Nozzle ... 1500 to 2600 psi(10 300 to 17 690 kPa)
Used, adjusted nozzle ... 2400 to 2600 psi(16 545 to 17 690 kPa)
Return oil leakage test pressure ... 1400 to 1600 psi(9630 to 11 045 kPa)
Leakage in 15 seconds ... No minimum or maximum
Maximum tip leakage is 20 drops in 15 seconds with a pressure of 200 psi (1380 kPa)
less than opening pressure.
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(1) Torque for valve lift locknut ... 35 to 45 lb. in.(4.0 to 5.1 N·m)
(2) Torque for pressure screw locknut ... 70 to 80 lb. in.(8.0 to 9.1 N·m)
(3) Torque for cap ... 110 to 120 lb. in.(12.4 to 13.6 N·m)
Governor Control
(120G and 130G Motor Graders)

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NOTE: DO NOT use control lever (2) to shut OFF the engine.
To shut engine OFF, pull up on accelerator treadle (11).
1. 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).
2. With the parking brake ON and engine stopped, BE SURE disconnect switch is OFF.
3. Remove pin (4).
4. Loosen LOW IDLE stop (7) and HIGH IDLE stop (5) so they do not touch lever (12).
5. Move control lever (2) to LOW IDLE position.
6. Turn LOW IDLE stop (7) until it touches lever (12) and tighten locknut (8).
7. Adjust length of rod (13) so distance from top of lever (15) to bottom of floor plate
(10) is 1.50 in. (38.1 mm) as shown.
8. 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).
9. Move control lever (2) to HIGH IDLE position.
10. Turn HIGH IDLE stop (5) until it touches lever (12) and tighten locknut (6).
11. 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.
12. Move lever (3) to HIGH IDLE position and adjust length of rod (1) so pin (4) can be
installed.
13. Install pin (4).
(D4E Tractor)
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NOTE: With control lever in high idle position and governor control shaft in full on
position, put lever (4) on shaft at angle (D).
Angle (D) is ... 40 °
Dimension (A) (approximately) ... 14.2 in.(361 mm)
Tighten nut (1) to ... 18 ± 5 lb. ft.(24 ± 7 N·m)
Dimension (B) (approximately) ... 19.2 in.(488 mm)
Tighten nuts (2) to ... 18 ± lb. ft.(24 ± 7 N·m)
Dimension (C) (approximately) ... 18.7 in.(475 mm)
Tighten nut (3) to ... 18 ± 5 lb. ft.(24 ± 7 N·m)
1. With pin removed from lever (4) move lever (4) to high idle position (rearward).
2. Move lever (Y) rearward until interference occurs in linkage.
3. Adjust rod end (Z) to position holes short of alignment [approx. .2 in. (5 mm)] with
hole in lever (4).
4. Move 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].
5. Install pin and cotter.
(518 Skidder)
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1. Move governor shaft (3) to SHUT OFF position and install lever (2) on shaft (3) at
angle (A).
2. Adjust length of rod (5) so stop (4) on pedal (1) is at dimension (B) from the floor
plate.
Angle (A) is ... 28 ± 5 °
Dimension (B) is ... 2.25 ± .03 in.(57.2 ± 0.8 mm)
225 Excavator)
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Adjust distance (A) to 2.50 in. (63.5 mm) from inlay mounting holes to back edge of
governor control handle (1) with engine running at 1400 ± 50 rpm.
Water Separator
(Sleeve Metering Fuel System - PC & DI)
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(1) Torque for bolt ... 9 ± 3 lb. ft.(12 ± 4 N·m)
(2), (3), (5) and (6) Put 8M8058 Sealant on plug and fittings and tighten to 12 ± 4 lb. ft.
(17 ± 5 N·m)
(4) Torque for bolts ... 17 ± 3 lb. ft.(23 ± 4 N·m)
Timing Gears
(Sleeve Metering Fuel System - PC & DI)
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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 ... 20 ± 5 lb. ft.(25 ± 7 N·m)
(1) 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 ... 110 ± 5 lb.
ft.(149 ± 7 N·m)
(2) End play for the idler gear (new) ... .004 to .016 in.(0.10 to 0.41 mm)
Maximum permissible end play (worn) ... .034 in.(0.86 mm)

Bore in bearing for the idler gear (new) ... 1.3781 ± .0019 in.(35.004 ± 0.048 mm)
Diameter of shaft for idler 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)
Maximum permissible clearance between shaft and bearing (worn) ... .009 in.(0.23 mm)
(3) Camshaft gear.
(4) Crankshaft gear.
(5) End play for the balancer shafts (new) ... .0035 to .0075 in.(0.089 to 0.191 mm)
Diameter of balancer shaft bearing surface (journal) (new) ... 2.0825 ± .0005 in.(52.896
± 0.013 mm)
Bore in bearing for balancer shaft (new) ... 2.0886 ± .0024 in.(53.050 ± 0.061 mm)
Maximum permissible clearance between balancer shaft and bearing (worn) ... .010
in.(0.25 mm)
(6) Idler gear for oil pump.
(7) Drive gear for oil pump.
Fuel Injection Equipment

(Scroll Fuel System - PC)
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A ‐ 5P4158 Gauge Illustrated
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Injection timing before TC (top center) ... 13° 30' ± 1°
(1) Torque for bushing 130 +10 or -5 lb. ft. (177 +14 or -7 N·m)
(2) Thickness of spacers:
9N6496 Spacer ... .161 in.(4.12 mm)
9N6495 Spacer ... .166 in.(4.22 mm)
5M2697 Spacer ... .170 in.(4.32 mm)
2M4208 Spacer ... .174 in.(4.42 mm)
2M4209 Spacer ... .178 in.(4.52 mm)
2M4210 Spacer ... .182 in.(4.62 mm)
2M4211 Spacer ... .186 in.(4.72 mm)
2M4212 Spacer ... .190 in.(4.83 mm)
5M2691 Spacer ... .194 in.(4.93 mm)
5S7189 Spacer ... .198 in.(5.03 mm)

4N9839 Spacer ... .203 in.(5.16 mm)
4N9840 Spacer ... .207 in.(5.26 mm)
(3) 1S206 Spring:
Test force ... 15.4 ± .8 lb.(68.5 ± 3.6 N)
Outside diameter ... 979 in.(24.87 mm)
(4) Timing dimension for the fuel injection pumps:
OFF Engine with 5P4158 or 8S7167 Gauge ... 4.2675 ± .0020 in.(108.395 ± 0.051 mm)
ON Engine with 5P4158 or 8S7167 Gauge ... 4.2216 ± .0020 in.(107.229 ± 0.051 mm)
(5) Length of pump plunger (new) ... 2.5934 ± .0015 in.(65.872 ± 0.038 mm)
Minimum permissible length (worn) ... 2.5869 in.(65.707 mm)
(6) Bore in the bearings for the rack:
Bearing at the rear ... .5018 ± .0018 in.(12.746 ± 0.046 mm)
Bearing at the front ... .5023 ± .0015 in.(12.758 ± 0.038 mm)
Diameter of fuel rack ... .4985 ± .0002 in.(12.662 ± 0.005 mm)
Diameter of fuel rack ... .4985 ± .0002 in.(12.662 ± 0.005 mm)
Maximum permissible clearance between rack and bearings (worn) ... .005 in.(0.13 mm)
(7) Bore in bearings for the camshaft ... 1.8755 ± .0005 in.(47.638 ± 0.013 mm)
Diameter of bearing surfaces (journals) of the camshaft (new) ... 1.8730 ± .0005
in.(47.574 ± 0.013 mm)
Maximum permissible clearance between the bearings and the camshaft bearing
surfaces (journals)(worn) ... .010 in.(0.25 mm)
(8) Torque for the nuts that hold the fuel lines (use 5P144 Fuel Line Socket) ... 30 ± 5
lb. ft.(40 ± 7 N·m)
(9) Torque for the nuts that hold the nozzles ... 105 ± 5 lb. ft.(142 ± 7 N·m)
(10) Body.
(11) Put 5P3931 Anti-Seize Compound on threads of glow plug and tighten to ... 120 ±
24 lb. in.(13.6 ± 2.8 N·m)
(12) Tighten nozzle finger tight on body.
(13) Put 5P3931 Anti-Seize Compound on threads of precombustion chamber and

tighten to ... 150 ± 10 lb. ft.(205 ± 14 N·m)
NOTE: See Glow Plug Positioning.
Governor
(Earlier)
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(1) Torque for nut ... 9 ± 3 lb. ft.(12 ± 4 N·m)
(2) 1S9312 Spring for speed limiter:

Test force ... 2.38 ± .19 lb.(10.52 ± 0.76 N)
(3) 9M3160 Spring for governor:
Color code (stripes) ... 1 blue
Put force on spring of ... 5.0 lb.(22 N)
Then add more force to make spring shorter by ... .900 in.(22.86 mm)
Total test force ... 19.4 ± .5 lb.(86.6 ± 2 N)
(3) 9L3617 Spring For Governor:
Color code (stripes) ... 1 blue, 1 white
Total test force ... 22.2 ± .5 lb.(100.8 ± 2 N)
Color code (stripes) ... 1 green

(Later)
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Color code (stripes) ... 1 green
(3) Collar for spring.

(4) 2S7235 Spring:
Test force ... .39 ± .03 lb.(1.75 ± 0.13 N)
Free length after test ... .68 in.(17.3 mm)
(5) 9M6303 Spring for over-fueling:
Test force ... 10.0 ± .5 lb.(45 ± 2.2 N)
Free length after test (approximate) ... .344 in.(8.74 mm)
Fuel Transfer Pump

Pressure of fuel to injection pump ... 25 to 32 psi(170 to 220 kPa)
(1) Bore of bearing (new) ... .4953 ± .0003 in.(12.581 ± 0.008 mm)
(2) Depth of bore in body (new) ... .3750 ± .0003 in.(9.525 ± 0.008 mm)
Thickness of gear (new) ... .3730 ± .0003 in.(9.474 ± 0.008 mm)
(4) Clearance between gear and cover (new) ... .0014 to .0026 in.(0.036 to 0.066 mm)
Maximum permissible clearance between gear and cover (worn) ... .0035 in.(0.089 mm)
(5) Shaft diameter (new) ... .4937 ± .0001 in.(12.540 ± 0.003 mm)
Bore in shaft bearing (new) ... .4953 ± .0003 in.(12.581 ± 0.008 mm)
(6) 8M3210 Spring:
Test force ... 5.36 ± .13 lb.(23.8 ± 0.58 N)

(7) Torque for plug when used with gasket:
2A1913 Gasket (copper) ... 110 ± 15 lb. ft.(149 ± 20 N·m)
4N7465 Gasket (plastic) ... 27 ± 3 lb. ft.(38 ± 4 N·m)
NOTE: 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 pump.
Fuel Bypass Valve

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(1) 4S6526 Spring for bypass valve:
Test force ... 3.16 ± .16 lb.(14.1 ± 0.71 N)

Fuel Injection Pump Housing

(Scroll Fuel System - DI)
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(1) Install dowel to get a dimension from the centerline of the fuel injection pump bore
to dowel of ... .5840 ± .0020 in.(14.834 ± 0.051 mm)
Use an aluminum ball to seal each dowel hole.
(2) Bearing joint and oil hole must be within area A.
(3) Install rear rack bearing to a depth of ... .195 ± .005 in.(4.95 ± 0.13 mm)
The centerline through the small holes in the bearing must be located parallel to the
vertical centerline through the injection pump bores.
(4) Front rack bearing alignment - the center of the rack bearing tab must be within .002
in. (0.05 mm) of a vertical line that:
(a) goes through the center of the rack bearing.

(b) is parallel to the vertical centerline through the injection pump bores.
NOTE: 5P1665 Alignment Plate, 9S6329 Driver, 1B9575 Bolt and 1D4716 Nut are
available to help install the bearing in the correct position.
(5) Ends of both pins must make contact with the shoulder inside the housing.
(6) Bore in bearings for the camshaft (new) ... 1.8765 ± .0010 in.(47.663 ± 0.025 mm)
Diameter of bearing surfaces of the camshaft (new) ... 1.8730 ± .0005 in.(47.574 ±
0.013 mm)
Maximum permissible clearance between the bearings and the camshaft ... .010 in.(0.25
mm)
Install the camshaft bearings to a depth of ... .010 ± .005 in.(0.25 ± 0.13 mm)
Fuel Injection
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Direct Injection Engines without turbocharger ... 27 ± 1°
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A‐5P4158 Gauge Typical Example
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(6) Bore for the rack and diameter of the rack:
Bearing at the rear (new) ... .5018 ± .0018 in.(12.746 ± 0.046 mm)
Bearing at the front (new) ... .5023 ± .0018 in.(12.758 ± 0.046 mm)
Diameter of fuel rack (new) ... .4985 ± .0002 in.(12.662 ± 0.0005 mm)
Maximum permissible clearance between rack and bearings (worn) ... .005 in.(0.13 mm)
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(7) Bore in the bearings for the camshaft (new) ... 1.8765 ± .0010 in.(47.663 ± 0.025
mm)
Diameter of bearing surfaces of the camshaft (new) ... 1.8730 ± .0005 in.(47.574 ±
0.013 mm)
Maximum permissible clearance between the bearings and the camshaft ... .010 in.(0.25
mm)
Governor Housing
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(1) Bore in the bearings (new) ... .6230 ± .0005 in.(15.824 ± 0.013 mm)
Diameter of the shaft (new) ... .6188 ± .0005 in.(14.718 ± 0.013 mm)
(2) Distance between the bearings for the governor control shaft ... 2.385 ± .005
in.(60.58 ± 0.13 mm)
(3) Distance from the center line of the control group bolt holes to the end of the bearing
for the governor control shaft ... 1.075 ± .010 in.(27.30 ± 0.25 mm)
(4) Install seal with lip to the inside.
(5) Distance from face of housing to plug ... .09 ± .02 in.(2.3 ± 0.5 mm)
Injection Nozzle (7N449)

Ver imagen
Bench test nozzles using clean SAEJ967 Calibration Oil (Kent-Moore Corp. J-26400 or
Viscor Calibration Fluid 1487C-SAEJ967L) at a temperature of ... 65 to 75°F(18 to
24°C)
Nozzle setting pressures (valve lift adjustment screw turned 3/4± 1/8turn from closed
position):
Used Nozzle ... 1500 to 2600 psi(10 300 to 17 690 kPa)
Used, adjusted nozzle ... 2400 to 2600 psi(16 545 to 17 690 kPa)
Return oil leakage test pressure ... 1400 to 1600 psi(9630 to 11 045 kPa)
Leakage in 15 seconds ... No minimum or maximum
Maximum tip leakage is 20 drops in 15 seconds with a pressure of 200 psi (1380 kPa)
less than opening pressure.
(1) Torque for valve lift locknut ... 35 to 45 lb. in.(4.0 to 5.1 N·m)
(2) Torque for pressure screw locknut ... 70 to 80 lb. in.(8.0 to 9.1 N·m)
(3) Torque for cap ... 110 to 120 lb. in.(12.4 to 13.6 N·m)
Governor
Ver imagen
Ver imagen
Install Spring Washers As Shown
(1) Torque for nut ... 9 ± 3 lb.ft.(12 ± 4 N·m)
(2) 3P131 Spring:
Test force ... 21 ± .02 lb.(0.95 ± 0.09 N)
(3) Seat. Install a spring washer, flat washer and spring washer between seat (3) and
spring (4) as shown.
(4) 9L6446 Spring for governor:
Color code (stripes) ... 1 blue, 1 green

Total test force ... 12.4 ± .24 lb.(55 ± 1 N)
(4) 4N6681 Spring for governor:
Color code (stripes) ... 2 purple
Total test force ... 14.8 ± .48 lb.(67 ± 2 N)
(5) 4N5549 Spring for over-fueling:
Test force ... .65 ± .03 lb.(2.9 ± 0.1 N)
(6) Diameter of the outer surface of the cylinder (new) ... 1.2172 ± .0005 in.(30.917 ±
0.013 mm)
Bore in the gear (new) ... 1.2192 ± .0005 in.(30.968 ± 0.013 mm)
NOTE: Governor weights must pivot freely.
Fuel Transfer Pump (4N4864)

Ver imagen
(1) Bore of bearing (new) ... .4953 ± .0003 in.(12.581 ± 0.008 mm)
(2) Depth of bore in body (new) ... .3750 ± .0003 in.(9.525 ± 0.008 mm)
Thickness of gear (new) ... .3730 ± .0003 in.(9.474 ± 0.008 mm)
(4) Clearance between gear and cover (new) ... .0014 to .0026 in.(0.036 to 0.066 mm)
Maximum permissible clearance between gear and cover (worn) ... .0035 in.(0.089 mm)
(5) Shaft diameter (new) ... .4937 ± .0001 in.(12.540 ± 0.003 mm)
Bore in shaft bearing (new) ... .4953 ± .0003 in.(12.581 ± 0.008 mm)
(6) 8M3210 Spring:
Test force ... 5.36 ± .13 lb.(23.8 ± 0.58 N)

(7) Torque for plug when used with gasket:
4N7465 Gasket ... 27 ± 3 lb. ft.(38 ± 4 N·m)
NOTE: 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 pump.
Timing Gears
(Scroll Fuel System - PC & DI)
Ver imagen
Torque for two bolts that hold front cover to plate ... 17 ± 3 lb. ft.(23 ± 4 N·m)
Torque for nuts holding cover for accessory drive gear ... 20 ± 5 lb. ft.(27 ± 7 N·m)
(1) Torque for nut holding accessory drive gear ... 100 ± 10 lb. ft.(135 ± 14 N·m)
(2) End play for the camshaft (new) ... .007 ± .003 in.(0.18 ± 0.08 mm)
Diameter of camshaft bearing surface (journal) (new) ... 2.3110 ± .0005 in.(58.699 ±
0.013 mm)
Bore in bearing for camshaft (new) ... 2.3150 ± .0024 in.(58.801 ± 0.061 mm)
Maximum permissible clearance between bearing and bearing surface (journal) (worn)
... .008 in.(0.20 mm)
(3) End play for the idler gear (new) ... .004 to .016 in.(0.10 to 0.41 mm)
Bore in bearing for the idler gear (new) ... 1.3781 ± .0019 in.(35.00 ± 0.048 mm)
Diameter of shaft for idler gear (new) ... 1.3741 ± .0005 in.(34.902 ± 0.013 mm)
Ver imagen
(4) Balancer shafts:
Diameter of balancer shaft bearing surface (journal) (new) ... 2.0825 ± .0005 in.(52.896
± 0.013 mm)
Bore in bearing for balancer shaft (new) ... 2.0886 ± .0024 in.(53.050 ± 0.061 mm)
Maximum permissible clearance between balancer shaft and bearing (worn) ... .010
in.(0.25 mm)
End play for the balancer shaft (new) ... .0035 to .0075 in.(0.089 to 0.191 mm)
(5) Distance from front face of bushing to rear face of cover ... 2.56 in.(65.02 mm)
Camshaft
Ver imagen
NOTE: Put a layer of graphite grease on lobes of camshaft when installing.
(1) Width of groove in camshaft for thrust washer (new) ... .190 ± .002 in.(4.83 ± 0.05
mm)
Thickness of thrust washer (new) ... .183 ± .001 in.(4.65 ± 0.03 mm)
End play of the camshaft (new) ... .007 ± .003 in.(0.18 ± 0.08 mm)
(2) Diameter of camshaft bearing surface (journal) (new) ... 2.3110 ± .0005 in.(58.699 ±
0.013 mm)
(3) Bore in bearing for camshaft (new) ... 2.3150 ± .0024 in.(58.801 ± 0.061 mm)
Clearance between bearing and bearing surface (journal) (new) ... .002 to .006 in.(0.05
to 0.15 mm)
Maximum permissible clearance between bearing and bearing surface (journal) (worn)
... .008 in.(0.20 mm)
NOTE: Make reference to CYLINDER BLOCK for installation dimensions.
Ver imagen
(5) Height of camshaft lobes.
To find lobe lift, use the procedure that follows:
A. Measure camshaft lobe height (5).
B. Measure base circle (6).
C. Subtract base circle (STEP B) from lobe height (STEP A). The difference is actual
lobe lift (4).
D. Specified camshaft lobe lift (4) is ... .3300 in.(8.382 mm)
Maximum permissible difference between actual lobe lift (STEP C) and specified lobe
lift (STEP D) is ... .010 in(0.25 mm)
Valve Rocker Arms and Lifters

Ver imagen
(1) Bore in bearing for shaft (new) ... .7263 ± .0005 in.(18.448 ± 0.013 mm)
Diameter of shaft (new) ... .7245 ± .0005 in.(18.402 ± 0.013 mm)
Maximum permissible clearance between bearing and shaft (worn) ... .008 in(0.20 mm)
(2) Torque for locknut on valve adjustment screw ... 21 ± 5 lb. ft.(26 ± 7 N·m)
(3) Clearance for valves:
Intake valves ... .015 in.(0.38 mm)
Exhaust valves ... .025 in.(0.64 mm)
(4) Diameter of valve lifter (new) ... 1.3105 ± .0005 in.(33.287 ± 0.013 mm)
Bore in block for valve lifter (new) ... 1.3145 ± .0010 in.(33.388 ± 0.025 mm)
Maximum permissible clearance between lifter and bore for valve lifter (worn) ... .012
in.(0.30 mm)
Valves (PC)
Ver imagen
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):
Test force ... 57.7 ± 4.5 lb.(256 ± 20 N)
Use again minimum load at length under test force ... 46.5 lb.(207 N)
Length of spring at valve open position ... 1.271 in.(32.28 mm)
Use again minimum load at valve open position ... 144.4 lb.(642 N)

Spring must not be bent more than ... .072 in.(1.83 mm)
(2) Height to top of valve guide ... .875 in.(22.23 mm)
(3) Diameter of valve stem (new) ... .3717 ± .0003 in.(9.441 ± 0.008 mm)
Use again minimum diameter ... .3704 in. (9.408 mm)
Bore in valve guide with guide installed in the head (new) ... .3733 in. ±.0010 in.(9.482
±0.025 mm)
Maximum permissible bore (worn) ... .3771 in.(9.578 mm)
(4) Valve lip thickness:
8N875 & 5S7232 Exhaust Valve Use again minimum ... .106 in.(2.69 mm)
5S6449 Exhaust Valve Use again minimum ... .096 in.(2.44 mm)
5S6452 Intake Valve Use again minimum ... .096 in.(2.44 mm)
(5) Diameter of valve head:
Exhaust valve ... 1.896 ± .005 in.(48.16 ± 0.13 mm)
Intake valve ... 2.020 ± .005 in.(51.31 ± 0.13 mm)
(6) Angle of valve face ... 29 1/4°
Ver imagen
(7) Depth of bore in head for valve seat insert:
Exhaust (5S7221 & 1P6837) ... .449 ± .005 in.(11.40 ± 0.13 mm)
Intake:
Earlier (5S7218) ... .449 ± .005 in.(11.40 ± 0.13 mm)
Later (7N4448) ... .349 ± .005 in.(8.86 ± 0.13 mm)
(8) Diameter of valve seat insert:
Exhaust (5S7221 & 1P6837) ... 2.0035 ± .0005 in.(50.889 ± 0.013 mm)
Intake:
Earlier (5S7218) ... 2.1285 ± .0005 in.(54.064 ± 0.013 mm)
Later (7N4448) ... 2.0485 ± .0005 in.(52.032 ± 0.013 mm)
Bore in head for valve seat insert:
Exhaust (5S7221 & 1P6837) ... 2.0005 ± .0005 in.(50.813 ± 0.013 mm)
Intake:
Earlier (5S7218) ... 2.1255 ± .0005 in.(53.988 ± 0.013 mm)
Later (7N4448) ... 2.0457 ± .0005 in.(51.961 ± 0.013 mm)
(9) Angle of face of valve seat insert ... 30°
(10) Maximum permissible width of valve seat (intake and exhaust) ... .076 in.(1.93
mm)
Minimum permissible width of valve seat (intake and exhaust) ... .045 in.(1.14 mm)
(11) Dimension from top of closed valve to face of head:
Maximum permissible dimension for 5S6449 or 5S7232 Exhaust Valves ... .140 in.(3.56
mm)
Minimum permissible dimension for 5S6449 or 5S7232 Exhaust Valves ... .056 in.(1.42
mm)
Maximum permissible dimension for 8N875 Exhaust Valve ... .163 in.(4.14 mm)
Minimum permissible dimension for 8N875 Exhaust Valve ... .079 in.(2.01 mm)
Maximum permissible dimension for 5S6452 Intake Valve ... .140 in.(3.56 mm)
Minimum permissible diameter for 5S6452 Intake Valve ... .066 in.(1.68 mm)
(12) Outside diameter of the face of the valve seat or valve seat insert:
Exhaust seat ... 1.810 in.(45.97 mm)
Maximum permissible, exhaust seat ... 1.860 in.(47.24 mm)
Intake seat ... 1.934 in.(49.12 mm)
Maximum permissible, intake seat ... 1.984 in.(50.39 mm)
(13) Angle to grind seat face of the insert to get a reduction of maximum seat diameter
... 15°.
Test force ... 57.7 ± 4.5 lb.(256.7 ± 20 N)
Use again minimum load at length under test force ... 46.5 lb.(207 N)
Length of spring at valve open position ... 1.271 in.(32.28 mm)
Use again minimum load at valve open position ... 144.4 lb.(642 N)
Spring must not be bent more than ... .072 in.(1.83 mm)
(2) Height to top of valve guide ... .875 in.(22.23 mm)
(3) Diameter of valve stem (new) ... .3717 ± .0003 in.(9.441 ± 0.008 mm)
Use again minimum diameter ... .3704 in.(9.408 mm)
Bore in valve guide with guide installed in the head.
Minimum permissible (new) ... .3723 in.(9.456 mm)
Maximum permissible (worn) ... .3772 in.(9.581 mm)
(4) Valve lip thickness:
6N9916 Exhaust Valve.
Use again minimum ... .106 in.(2.69 mm)
6N9915 Intake Valve and 7N573 Exhaust Valve.
Use again minimum ... .096 in.(2.44 mm)
(5) Diameter of valve head:
Exhaust valves ... 1.896 ± .005 in.(48.16 ± 0.13 mm)
Intake valve ... 2.020 ± .005 in.(51.31 ± 0.13 mm)

(6) Angle of valve face ... 29 1/4°
(7) Depth of bore in head for valve seat insert ... .488 ± .005 in.(12.41 ± 0.13 mm)
(8) Diameter of valve seat insert for exhaust valve ... 2.0035 ± .0005 in.(50.889 ± 0.013
mm)
Bore in head for valve seat insert for exhaust valve ... 2.0005 ± .0005 in.(50.813 ± 0.013
mm)
Diameter of valve seat insert for intake valve ... 2.0485 ± .0005 in.(5.032 ± 0.013 mm)
Bore in head for valve seat insert for intake valve ... 2.0455 ± .0005 in.(51.956 ± 0.013
mm)
(9) Angle of face of valve seat insert ... 30°
(10) Maximum permissible width of valve seat (intake and exhaust) ... .076 in.(1.93
mm)
Minimum permissible width of valve seat (intake and exhaust) ... .045 in.(1.14 mm)
(11) Dimension from top of closed valve to face of head:
Minimum permissible dimension for 7N573 and 6N9916 Exhaust Valve ... .026 in.(0.66
mm)
Minimum permissible dimension for 6N9915 Intake Valve ... .006 in.(0.15 mm)
(12) Outside diameter of the face of the valve seat insert:
Exhaust seat ... 1.812 in.(46.02 mm)
Maximum permissible, exhaust seat ... 1.862 in.(47.29 mm)
Intake seat ... 1.940 in.(49.28 mm)
Maximum permissible, intake seat ... 1.990 in.(50.55 mm)

(13) Angle to grind seat face of the insert to get a reduction of maximum seat diameter
... 15°
Glow Plug Positioning
Cyl. Nos. 1, 2, and 3--3304*Cyl. Nos. 1 thru 4--3304**
*
Engines with counterbored block.
**
Engines with spacer plate.
Ver imagen
Cyl. No. 4--3304*
*
Engines with counterbored block.
(A) Correct range for glow plug opening.
Put 5P3931 Anti-Seize Compound on the threads of the precombustion chamber.
Put 5M2667 Gasket, with "2C" 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)
NOTE: If the hole for the glow plug is not in range (A), remove the precombustion
chamber. Remove the gasket.
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
If the hole was in range (C) install 2S8960 Gasket, with "2X" on it, on the
precombustion chamber. Install the precombustion chamber in the cylinder head and
Cylinder Head
Ver imagen
Thickness of cylinder head (new) ... 3.938 ± .030 in.(100.03 ± 0.76 mm)
NOTE: Dimension from top of closed valve to face of cylinder head must be according
to the specifications in VALVES.
Put 5P3931 Anti-Seize Compound on threads and tighten bolts in the Step sequence that
follows:
Step 1. Tighten all bolts in number sequence to ... 115 lb. ft.(155 N·m)
Step 2. Again tighten all bolts in number sequence to ... 185 ± 13 lb. ft.(250 ± 17 N·m)
Step 3. Again tighten all bolts in number sequence to ... 185 ± 13 lb. ft.(250 ± 17 N·m)
Step 4. Tighten all bolts in letter sequence (hand torque only) to ... 32 ± 5 lb. ft.(43 ±7
N·m)
Valve Cover
Ver imagen
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 shown to ... 96 ± 24 lb. in.(10.9 ± 2.8 N·m)
Exhaust Manifold
Ver imagen
Put 5P3931 Anti-Seize Compound on all threads.
(1) Torque for studs ... 20 ± 3 lb. ft.(25 ± 4 N·m)
(2) Torque for nuts holding exhaust manifold ... 32 ± 5 lb. ft.(43 ± 7 N·m)
Exhaust Pipe And Muffler
Put 5P3931 Anti-Seize Compound on threads of bolts for clamps and tighten to ... 20 ±
5 lb. ft.(25 ± 7 N·m)
Air Cleaner
(1) Tighten nuts that hold air filter to elbow ... 20 ± 5 lb. ft.(25 ± 7 N·m)
(2) Tighten wing nuts to ... 35 ± 5 lb. in.(4.0 ± 0.6 N·m)
Turbocharger Impeller Installation
Schwitzer Only
Installation Procedure Chart
A. Put 6V1541 Quick Pure Primer on the nut and the shaft threads to clean them, if
necessary.
B. Put a small amount of 9S3265 Retaining Compound on the nut and shaft threads.
NOTICE
Do not let the retaining compoun get into the compressor wheel bore
on the shaft, because it can make removal of the compressor wheel
difficult during future turbocharger 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.
D. Tighten the compressor wheel retainer nut to ... 44 ± 2 lb. ft.(60 ± 3 N·m)
NOTE: Do not bend or add stress to the shaft when the nut is tightened.
(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.
2. Install impeller on shaft by hand.
3. Measure the distance between impeller and seal carrier at the point where impeller no
longer moves freely on shaft.
4. If the distance is:
(a) more than .31 in. (7.9 mm), use heat for installation.*
(b) .31 in. (7.9 mm) or less, use room temperature installation.**
Ver imagen
Turbocharger
(AiResearch T04B91)
Ver imagen
Make reference to ANALYZING TURBOCHARGER FAILURE, Form No.
FEG45138.
Make reference to GUIDELINES FOR REUSEABLE PARTS TURBOCHARGERS,

Form Nos. SEBF8018 & SEBF8019.
(1) Torque for impeller nut ... 20 lb. in.(2.3 N·m)
Tighten nut an added ... 100°
NOTE: Do not bend or add stress to the shaft when nut is tightened.
(2) Torque for bolts holding back plate ... 75 to 90 lb. in.(8.5 to 10.2 N·m)
(3) Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding compressor
housing to center section to ... 115 ± 15 lb. in.(13 ± 1.7 N·m)
(4) 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)
(5) Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding turbocharger
to manifold to ... 40 ± 4 lb. ft.(55 ± 5 N·m)
(6) End play for shaft:
Minimum permissible end play ... .001 in.(0.03 mm)
Maximum permissible end play ... .004 in.(0.10 mm)
(7) Radial play for shaft:
Minimum permissible radial play ... .003 in.(0.08 mm)
Maximum permissible radial play ... .006 in.(0.15 mm)
(8) Bore in the bearing ... .4010 to .4014 in.(10.185 to 10.196 mm)
Diameter of surface on shaft (journal) for the bearing ... .3997 to .4000 in.(10.152 to
10.160 mm)
(9) Bore in housing ... .6220 to .6223 in.(15.799 to 15.806 mm)
Outside diameter of the bearing ... .6182 to .6187 in.(15.702 to 15.715 mm)
(10) Clearance between ends of oil seal ring ... .008 to .015 in.(0.20 to 0.38 mm)
Diameter of bore for oil seal ring ... .709 to .711 in.(18.01 to 18.06 mm)
(AiResearch T0490)
Ver imagen
FEG45138.
Make reference to GUIDELINES FOR REUSABLE PARTS TURBOCHARGERS,

(1) Torque for impeller nut ... 20 lb. in.(2.3 N·m)
Tighten nut an added ... 100°
NOTE: Do not bend or add stress to the shaft when nut is tightened.
(2) Torque for bolts holding back plate ... 50 ± 10 lb. in.(5.7 ± 1.1 N·m)
(3) Put 5P3931 Anti-Seize Compound on threads and tighten bolt holding band clamp to
... 60 ± 10 lb. in.(6.8 ± 1.1 N·m)
housing to ... 115 ± 15 lb. in.(13 ± 1.7 N·m)
(6) End play for shaft ... .001 to .004 in.(0.03 to 0.10 mm)
(7) Radial play for shaft ... .003 to .007 in.(0.08 to 0.18 mm)
Bore in the bearing ... .4010 to .4014 in.(10.185 to 10.196 mm)
10.160 mm)
(10) Diameter of bore for oil seal ring ... .709 to .711 in.(18.01 to 18.06 mm)
(AiResearch T1210 and T1224)

Ver imagen
FEG45138.

Put 5P3931 Anti-Seize Compound on threads of plug for exhaust elbow.
Put 5P3931 Anti-Seize Compound on bolts holding support for exhaust and tighten to ...
45 ± 5 lb. ft.(60 ± 7 N·m)
(1) See TURBOCHARGER IMPELLER INSTALLATION.
(2) Torque for bolts holding thrust plate ... 35 ± 4 lb. in.(4.0 ± 0.5 N·m)
(3) Tighten bolt holding band clamp to ... 120 ± 10 lb. in.(13.6 ± 1.1 N·m)
(4) 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)
(5) Put 5P3931 Anti-Seize Compound on threads of bolts holding turbocharger to
manifold and tighten to ... 40 ± 4 lb. in.(55 ± 5 N·m)
(6) End play for shaft (new) ... .006 to .011 in.(0.15 to 0.27 mm)
(7) Bore in the bearing ... .6268 to .6272 in.(15.921 to 15.931 mm)
15.885 mm)
(Schwitzer 3LK)
Ver imagen
FEG45138.

(1) End play for shaft (new) ... .0045 ± .0015 in.(0.114 ± 0.038 mm)
(2) Thickness of thrust bearing ... .211 ± .001 in.(5.36 ± 0.03 mm)
(3) Diameter of surface on shaft (journal) for the bearing ... .44015 ± .00015 in.(11.1798
± 0.0038 mm)
Bore in the bearing ... .44165 ± .00015 in.(11.2179 ± 0.0038 mm)
Maximum permissible clearance between bearing and shaft ... .0018 in.(0.046 mm)
... 120 lb. in.(13.6 N·m)
(5) Maximum permissible gap of oil seal ring, measured in bore of housing ... .007
in.(0.18 mm)
(6) See TURBOCHARGER INSTALLATION.
(7) Bore in housing ... .75025 ± .00025 in.(19.0564 ± 0.0064 mm)
Outside diameter of the bearing ... .74625 ± .00025 in.(18.9548 ± 0.0064 mm)
Maximum permissible clearance between bearing and bore in housing ... .0045 in.(0.114
mm)
(8) Thickness of each thrust ring ... .1005 ± .0005 in.(2.553 ± 0.013 mm)
(9) Torque for bolts holding impeller housing ... 60 lb. in.(6.8 N·m)
(10) Put 5P3931 Anti-Seize Compound on threads of bolts holding turbocharger to

manifold and tighten to ... 40 ± 4 lb. ft.(55 ± 5 N·m)
(Schwitzer 3LM)
Ver imagen
FEG45138.

(1) End play for shaft (new) ... .002 to .005 in.(0.05 to 0.13 mm)
(2) Put 5P3931 Anti-Seize Compound on threads and tighten bolts holding impeller
housing to ... 60 lb. in.(6.8 N·m)
housing to ... 11 to 12 lb. ft.(15 to 17 N·m)
in.(0.18 mm)
(6) Thickness of thrust bearing ... .107 to .108 in.(2.72 to 2.74 mm)
(7) Bearing:
Bore in housing for bearing ... .7500 to .7505 in.(19.050 to 19.063 mm)
Diameter of surface of bearing for housing ... .7460 to .7465 in.(18.948 to 18.961 mm)
Diameter of surface of bearing for shaft ... .4415 to .4418 in.(11.214 to 11.222 mm)
Diameter of surface of shaft for bearing (journal) ... .4400 to .4403 in.(11.176 to 11.184
mm)
Length of bearing ... 2.425 to 2.426 in.(61.60 to 61.62 mm)
(Schwitzer F444, 4LF504 and E Models)

Ver imagen
FEG45138.

(1) End play for shaft (new) ... .0045 ± .0015 in.(0.114 ± 0.038 mm)
(2) Thickness of thrust bearing ... .211 ± .001 in.(5.36 ± 0.03 mm)
(3) Diameter of surface on shaft (journal) for the bearing (new) ... .5612 to .5615
in.(14.254 to 14.262 mm)
Bore in the bearing (new) ... .5627 to .5630 in.(14.293 to 14.300 mm)
Maximum permissible clearance between bearing and shaft (worn) ... .003 in.(0.08 mm)
... 120 lb. in.(13.6 N·m)
in.(0.23 mm)
(7) Bore in housing (new) ... .8762 to .8767 in.(22.255 to 22.268 mm)
Outside diameter of the bearing (new) ... .8718 to .8722 in.(22.144 to 22.154 mm)
Maximum permissible clearance between bearing and bore in housing (worn) ... .006
in.(0.15 mm)
(8) Thickness of each thrust ring ... .1005 ± .0005 in.(2.553 ± 0.013 mm)
Oil Pump
(2P7830, 5S3876 & 7S9840)

Ver imagen
(1) Diameter of the drive shaft (new) ... .7407 ± .0003 in.(18.814 ± 0.008 mm)
Bore in the bearings for the drive shaft ... .7425 ± .0005 in.(18.860 ± 0.013 mm)
Clearance between drive shaft and bearing (new) ... .0018 ± .0008 in.(0.046 ± 0.020
mm)
(2) Length of gear ... 2.9955 ± .0005 in.(76.086 ± 0.013 mm)
Depth of counterbore for gear ... 3.0008 ± .0008 in.(76.220 ± 0.020 mm)
Clearance between end of gear and cover (new) ... .0053 ± .0013 in.(0.135 ± 0.033 mm)
(4) Diameter of the shaft for the drive idler gear (new) ... 1.1225 ± .0005 in.(28.512 ±
0.013 mm)
Bore in bearing of gear (new) ... 1.1260 ± .0019 in.(28.600 ± 0.048 mm)
Clearance between shaft and bearing (new) ... .0035 ± .0024 in.(0.089 ± 0.061 mm)
(5) 1S3921 Spring for pressure relief valve (engine oil):
Test force ... 39.8 ± 3.2 lb.(177.5 ± 14.0 N)
(6) Diameter of the shaft for the idler gear (clutch pump) (new) ... .7407 ± .0003
in.(18.814 ± 0.008 mm)
Clearance between shaft and bearing (new) ... 0.0018 ± .0008 in.(0.046 ± 0.020 mm)
(7) Diameter of the shaft for the idler gear (scavenge pump) (new) ... .7407 ± .0003
in.(18.814 ± 0.008 mm)
Bore in the bearing of the idler gear ... .7425 ± .0005 in.(18.860 ± 0.013 mm)
Length of gear ... .9975 ± .0005 in.(25.337 ± 0.013 mm)
(8) 4J4790 Spring for pressure relief valve (clutch oil):
Test force ... 12.27 lb.(54.6 N)
(9) Torque for nut holding drive gear ... 60 lb. ft.(80 N·m)
Tighten farther to get alignment for cotter pin.
(7S1849 & 7S9461)

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(1) Diameter of the drive shaft (new) ... .8747 ± .0002 in.(22.217 ± 0.005 mm)
Bore in the bearings for the drive shaft ... .8763 ± .0003 in.(22.258 ± 0.008 mm)
Clearance between drive shaft and bearings (new) ... .0016 ± .0005 in.(0.041 ± 0.013
mm)
(2) Diameter of the shaft for the drive idler gear (new) ... 1.1225 ± .0005 in.(28.512 ±
0.013 mm)
Bore in the bearing ... 1.1260 ± .0019 in.(28.600 ± 0.048 mm)
(3) Diameter of the shaft for the idler gear (new) ... .8747 ± .0002 in.(22.217 ± 0.005
mm)
(4) 1S3921 Spring for pressure relief valve:
Test force ... 39.8 ± 3.2 lb.(177.5 ± 14.0 N)
(7) Torque for nut holding drive gear ... 60 lb. ft.(80 N·m)
Tighten farther to get alignment for cotter pin.
(2P1785 and 6N2642)

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(1) Bore in bearing of idler gear ... 1.1260 ± .0024 in.(28.600 ± 0.061 mm)
Diameter of shaft for the idler gear ... 1.1255 ± .0005 in.(28.588 ± 0.013 mm)
Clearance between bearing and shaft ... .0035 ± .0029 in.(0.089 ± 0.074 mm)
(2) Clearance between gears and body of pump ... .002 to .026 in.(0.05 to 0.66 mm)
(3) Diameter of shafts for pump ... .8747 ± .0002 in.(22.217 ± 0.005 mm)
Bore in bearings for shafts ... .8763 ± .0003 in.(22.258 ± 0.008 mm)
Clearance between shafts and bearings ... .0016 ± .0005 in.(0.041 ± 0.013 mm)
(4) Length of gears ... 2.0003 ± .0010 in.(50.808 ± 0.025 mm)
Depth of bore in pump body for gears ... 2.0053 ± .0008 in.(50.935 ± 0.020 mm)
Clearance between end of gears and pump body ... .0050 ± .0018 in.(0.127 ± 0.046 mm)
(5) Length of gears ... 1.4988 ± .0010 in.(38.070 ± 0.025 mm)
Depth of bore in pump body for gears ... 1.5038 ± .0008 in.(38.197 ± 0.020 mm)
Clearance between end of gears and pump body ... .0050 ± .0018 in.(0.127 ± 0.046 mm)
(6) Torque for bolt holding drive gear to drive shaft ... 32 ± 5 lb. ft.(43 ± 7 N·m)
Engine Oil Pressure
All steps of this procedure must be followed for the pressure findings to be usable.
Step 1. Be sure that the engine is filled to the correct level with either SAE 10 or SAE
30 oil. If any other viscosity of oil is used, the information in the ENGINE OIL
PRESSURE CHART does not apply.
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.
Step 3. Run the engine to get the oil temperature at 210°F (99°C).
NOTE: A 5°F (3°C) increase in oil temperature gives approximately 1 psi (7 kPa)
decrease in oil pressure.
Step 4. Keep the engine oil temperature constant. With the engine at the rpm from the
chart, read the pressure gauge.
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.
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Oil Filter
(2P686, 2P916, 2P6475, 2P6525 & 4N6034)

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Oil cooler bypass valve and oil filter bypass valve must open at a pressure difference of
... 25 ± 3 psi(170 ± 20 kPa)
(1) 8M3182 Spring for oil cooler bypass valve:
Test force ... 8.92 lb.(39.7 N)
(2) 8M3182 Spring for oil filter bypass valve:

Test force ... 8.92 lb.(39.7 N)
(3) Torque for stud:
Put 9S3263 Thread Lock Compound on threads of the stud and tighten the stud to ... 50
± 10 lb. ft.(70 ± 14 N·m)
(4) Put engine oil on seal (4). Put filter (5) in position and tighten until the seal makes
contact with the base. Turn the filter an additional 270°.
(7S6638, 7S6639 & 9S1806)

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(1) Torque for the bolt ... 20 ± 5 lb. ft.(25 ± 7 N·m)
(2) 6F8007 Spring for oil filter bypass valve:
Test force ... 5.2 to 6.1 lb.(23 to 27 N)
7S6638 Filter only:
(3) 6F8007 Spring for oil cooler bypass valve:
Oil Breather Cap
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(1) Torque for bolt holding breather cap ... 120 ± 24 lb. in.(13.6 ± 2.8 N·m)
Water Pump
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(1) Oil seal. Put engine oil on the seal lip. Assemble with the lip toward the bearings.
(2) Water seal and ring.
a. Put water on the seal.
b. Install the seal and ring together in the housing bore, with the shiny face of the ring
outside.
(3) Seal assembly.
a. Remove the spring from the seal.
b. Put water inside the seal assembly.
c. Install the seal assembly around the shaft, with the 7N7843 Installation Tool, (the tool
is with the seal group) until the carbon face makes contact with the shiny face of the
ring (2).
d. Install the spring.
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(4) Torque for the bolt that holds the impeller ... 28 ± 1 lb. ft.(39 ± 1 N·m)
(5) Torque for bolt that holds the gear ... 32 ± 5 lb. ft.(43 ± 7 N·m)
V-Belt Tension Chart
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Radiator
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Top Tank With 5S1218 Pressure Relief Valve
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Tightening Procedure For Typical Two-Row Tank
Clean the threads of the studs with 8M8060 Quick Cure Primer. Then put 9S3265
Retaining Compound on the threads before installing them.
(1) Torque for stud for the filler cap ... 40 ± 5 lb. ft.(55 ± 7 N·m)
(2) 2S3080 Pressure Relief Cap:
Pressure valve must not leak at ... 11.9 psi(82 kPa)
Pressure valve must be open at ... 15 psi(105 kPa)
Vacuum valve must be open at a pressure below atmospheric of ... 0.6 psi(4 kPa)or 1.22
in. Hg (31.0 mm Hg) or 16.6 in. H2 (422 mm H2O)
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Tightening Procedure For Typical Three-Row Tank
(2) 321464 Pressure Relief Cap:
Cap must not leak at ... 6.5 psi(45 kPa)
Cap must be open at ... 8 psi(55 kPa)
(2) 5S1218 Pressure Relief Valve:
Vacuum relief valve to open at a maximum of ... 1 psi(7 kPa)
Pressure relief valve must not leak at ... 14 psi(95 kPa)
Pressure relief valve must be open at ... 18 psi(125 kPa)
(3) Torque for bolts that hold baffles and shields ... 15 ± 5 lb. ft.(20 ± 7 N·m)
(4) Bolt torque sequence for radiator tanks. Sequence 5 and 6 are not required on the
bottom tank.
Water Temperature Regulator
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7N208 Regulator:
Temperature when completely open ... 195°F(90°C)
Minimum open distance ... .375 in.(9.53 mm)
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9S3808 and 4H1991 Regulator:
Temperature when completely open ... 185°F(85°C)
Minimum open distance ... .310 in.(7.87 mm)
Coolant Flow Switch
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4N9072 SWITCH (Jon 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.
(2) With paddle in vertical position, the force (F) on rivet head (2) necessary to open
contacts of switch ... 1.2 ± .1 oz.(34 ± 3 grams)
(3) Length of paddle ... 2.58 in.(65.5 mm)
NOTE: When the switch is 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.
Cylinder Block
(Counterbored Block)
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(1) Depth of bore in block for liner ... 401 ± .001 in.(10.19 ± 0.03 mm)
NOTE: For height of liner over top of block make reference to CYLINDER LINER
PROJECTION.
(2) 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 camshaft bearings at both ends of block ... .06 ± .02 in.(1.5 ± 0.5 mm)
NOTE: The camshaft bearing at the front of the block must be installed with oil holes
in a horizontal position and joint at the top within ± 15° from vertical.
(3) Bore in block for main bearings (standard size) ... 3.8160 ± .0005 in.(96.926 ± 0.013
mm)
Bore in block for main bearings .020 in. (0.51 mm oversize) ... 3.8360 ± .0005
in.(97.434 ± 0.013 mm)
(4) Dimension from center of main bearing bore to top of cylinder block (new) ...
15.5000 ± .0065 in.(393.700 ± 0.165 mm)
(5) Dimension from center of main bearing bore to bottom of cylinder block (new) ...
6.0625 ± .0040 in.(153.988 ± 0.102 mm)
(6) Clearance between slot in block and bearing cap ... .0017 in.(0.043 mm) loose to
.0013 in. (0.033 mm) tight
Main bearing cap width ... 6.4998 ± .0008 in.(165.095 ± 0.020 mm)
Width of cylinder block for main bearing cap ... 6.5000 ± .0007 in.(165.100 ± 0.018
mm)
(7) Bore in block for balancer bearing ... 2.2776 ± .0010 in.(57.851 ± 0.025 mm)
(8) Torque for bolts holding bearing caps for main bearings:
a. Put engine oil on threads and washer face.
b. Tighten all bolts to ... 30 ± 3 lb. ft.(40 ± 4 N·m)
c. 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.
NOTICE
There 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 a turbocharger is installed on the engine, be sure to install orifices (10) and
an engine oil cooler.
NOTE: If the engine has an engine oil cooler and no turbocharger, be sure to install
orifices (10).
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(11) 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 ... .62 ± .02 in.(15.7 ± 0.5 mm)
(13) Distance to install dowels from front face of block ... .88 ± .02 in.(22.4 ± 0.5 mm)
(With Spacer Plate)

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(1) Thickness of spacer plate ... .3925 ± .0010 in.(9.970 ± 0.025 mm)
Thickness of spacer plate gasket ... .0082 ± .0010 in.(0.208 ± 0.025 mm)
NOTE: For height of liner over top of spacer plate make reference to CYLINDER
LINER PROJECTION.
(2) 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 camshaft bearings at both ends of block ... .06 ± .02 in.(1.5 ± 0.5 mm)
NOTE: The camshaft bearing at the front of the block must be installed with oil holes
in a horizontal position and joint at top within ± 15° from vertical.
(3) Bore in block for main bearings (standard size) ... 3.8160 ± .0005 in.(96.926 ± 0.013
mm)
Bore in block for main bearings .020 in. (0.51 mm oversize) ... 3.8360 ± .0005
in.(97.434 ± 0.013 mm)
(4) Dimension from center of main bearing bore to top of cylinder block (new) ...
15.099 ± .006 in.(383.51 ± 0.15 mm)
(5) Dimension from center of main bearing bore to bottom of cylinder block (new) ...
6.063 ± .004 in.(154.00 ± 0.10 mm)
(6) Clearance between slot in block and bearing cap ... .0017 in.(0.043 mm) loose to
.0013 in. (0.033 mm) tight
Main bearing cap width ... 6.4998 ± .0008 in.(165.095 ± 0.020 mm)
Width of cylinder block for main bearing cap ... 6.5000 ± .0007 in.(165.100 ± 0.018
mm)
(7) Bore in block for balancer bearing ... 2.2776 ± .0010 in.(57.851 ± 0.025 mm)
(8) Torque for bolts holding bearing caps for main bearings:
a. Put engine oil on threads and washer face.
b. Tighten all bolts to ... 30 ± 3 lb. ft.(40 ± 4 N·m)
c. 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.
NOTICE
There 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 a turbocharger is installed on the engine, be sure to install orifices (10) and
an engine oil cooler.
NOTE: If the engine has an engine oil cooler and no turbocharger be sure to install
orifices (10).
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(11) Distance to install dowels from top of block ... .780 ± .020 in.(19.8 ± 0.5 mm)
(12) Distance to install stud from face of block ... .62 ± .02 in.(15.7 ± 0.5 mm)
(13) Distance to install dowels from front face of block ... .88 ± .02 in.(22.4 ± 0.5 mm)
Cylinder Liner
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NOTE: Make reference to GUIDELINE FOR REUSABLE PARTS: PISTONS AND
CYLINDER LINERS, Form No. SEBF8001.
(1) Bore in liner (new) ... 4.751 ± .001 in.(120.68 ± 0.03 mm)
Use again maximum bore when measured near upper end of the wear surface of the
cylinder liner ... 4.755 in.(120.78 mm)
(2) Thickness of flange on liner ... .4048 ± .0008 in.(10.282 ± 0.020 mm)
(3) Filler band.
Cylinder Liner Installation

Put liquid soap on bottom liner bore in block, on grooves in lower liner, and on O-rings.
Install O-rings on liner. Put filler band (3) in engine oil for a moment and install on
liner. Immediately install liner in cylinder block (before expansion of filler band).
Cylinder Liner Projection
(Counterbored Block)
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Make reference to CYLINDER LINER PROJECTION in Testing and Adjusting for the
complete procedure.
1. Install tooling as shown. Tighten bolts (1) evenly in four steps:
1st step ... 5 lb. ft.(7 N·m)
2nd step ... 15 lb. ft.(20 N·m)
3rd step ... 25 lb. ft.(35 N·m)
4th step ... 50 lb. ft.(70 N·m)
2. Measure cylinder liner projection with dial indicator (7) clamped in 1P2402 Gauge
Body (6) as shown. Measure at four places around each cylinder liner near the clamped
area.
Cylinder liner projection measurement for any cylinder liner must be ... .0020 to .0056
in.(0.051 to 0.142 mm)
Maximum permissible difference between all four measurements ... .002 in.(0.05 mm)
Maximum permissible difference between average projection of any two cylinders next
to each other ... .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.
(1) Bolts [5/8" NC, 5.5 in. (140 mm) long].
(2) Crossbar (from 8B7548 Push-Puller)
(3) 4B4281 Washers
(4) 1P2394 Adapter Plate
(5) 3H465 Plates
(6) 1P2402 Gauge Body
(7) 1P2403 Dial Indicator
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(With Spacer Plate)

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Make reference to CYLINDER LINER PROJECTION in Testing and Adjusting for the
complete procedure.
1. Install gasket and spacer plate (2) with bolts (3) and two 1S379 Washers. Tighten
bolts (3) evenly in four steps:
1st step ... 10 lb. ft.(14 N·m)
2nd step ... 25 lb. ft.(35 N·m)
3rd step ... 50 lb. ft.(70 N·m)
4th step ... 70 lb. ft.(95 N·m)
2. Install tools as shown. Tighten bolts (4) evenly in four steps:
1st step ... 5 lb. ft.(7 N·m)
2nd step ... 15 lb. ft.(20 N·m)
3rd step ... 25 lb. ft.(35 N·m)
4th step ... 50 lb. ft.(70 N·m)

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 measurement for any cylinder liner must be ... .0013 to .0069
in.(0.033 to 0.175 mm)
Maximum permissible difference between all four measurements ... .002 in.(0.05 mm)
Maximum permissible difference between average projection of any two cylinder liners
next to each other ... .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.
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4. Minimum permissible depth to machine counterbore to
adjust cylinder liner projection ... 030 in.(0.76 mm)
Maximum permissible depth to machine counterbore to adjust cylinder liner projection

... .045 in.(1.14 mm)
Install a .030 in. (0.76 mm) shim plus any added shims necessary to get the correct
cylinder liner projection.
NOTE: Be sure that the .030 in. (0.76 mm) shim is directly under the cylinder liner
flange.
Put 7M7260 Liquid Gasket on the top of the top shim and on the bottom of the bottom
shim before installing.
(1) Crossbar (from 8B7548 Puller).

(2) Spacer plate.
(3) S1589 Bolt with two 1S379 Washers.
(4) 1D4595 Bolt.
(5) 3H465 Plate.
(6) 1P2403 Dial Indicator.
(7) 1P2394 Adapter Plate.
(8) 1P2402 Gauge Body.
Pistons And Rings
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(4) Bore in piston for pin:
9N5404 Piston ... 1.7006 ± .0003 in.(43.195 ± 0.008 mm)
8N2533 Piston ... 1.7006 ± .0003 in.(43.195 ± 0.008 mm)
Clearance between pin and bore in piston ... .0003 to .0013 in.(0.008 to 0.033 mm)
Maximum permissible clearance (worn) ... .002 in.(0.05 mm)
NOTE: When installed in the engine, the "V" mark on top of the must be in alignment
with the "V" mark on the cylinder block.
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(4) Bore in piston for pin:
8N3183 Piston ... 1.7006 ± .0003 in.(43.195 ± 0.008 mm)
1W6759 Piston ... 1.7006 ± .0003 in.(43.195 ± 0.008 mm)
9S8913 Piston ... 1.5011 ± .0002 in.(38.128 ± 0.005 mm)
4N4029 Piston ... 1.5011 ± .0002 in.(38.128 ± 0.005 mm)
4N9258 Piston ... 1.7006 ± .0003 in(43.195 ± 0.008 mm)
Clearance between pin and bore in piston ... .0003 to .0013 in.(0.008 to 0.033 mm)
Maximum permissible clearance (worn) ... .002 in.(0.05 mm)
NOTE: When installed in the engine, the "V" mark on top of the piston must be in
alignment with the "V" mark on the cylinder block.
Connecting Rod
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(1) Bore in bearing for piston pin (new):
5S6360 Rod ... 1.5017 ± .0003 in.(38.143 ± 0.008 mm)
5S2793 Rod ... 1.7012 ± .0003 in.(43.210 ± 0.008 mm)
8N1984 Rod (tapered) ... 1.5017 ± .0003 in.(38.143 ± 0.008 mm)
8N1721 Rod (tapered) ... 1.7012 ± .0003 in.(43.210 ± 0.008 mm)
Maximum permissible clearance between bearing and piston pin (worn) ... .003 in.(0.08
mm)
(2) Bore in connecting rod for bearing ... 3.2500 ± .0005 in.(82.550 ± 0.013 mm)
(3) Distance between center of piston pin and center of crankshaft bearing (new) ...
9.595 ± .001 in.(243.71 ± 0.03 mm)
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(4) Diameter of piston pin (new):
9H4016 Pin ... 1.5003 ± .0002 in.(38.108 ± 0.005 mm)
7N9804 Pin ... 1.5003 ± .0002 in.(38.108 ± 0.005 mm)
8M6487 Pin ... 1.6998 ± .0002 in.(43.175 ± 0.005 mm)
7N9805 Pin ... 1.6998 ± .0002 in.(43.175 ± 0.005 mm)
(5) Clearance between connecting rod bearing and crankshaft bearing surface (journal)
... .0030 to .0066 in.(0.076 to 0.168 mm)
Maximum permissible clearance between bearing and crankshaft (worn) ... .010 in.(0.25
mm)
(6) Torque on nut for connecting rod:
a. Put engine oil on threads and nut seat.
b. Tighten both nuts to ... 30 ± 3 lb. ft.(40 ± 4 N·m)
c. Mark each nut and end of bolt.
d. Again tighten both nuts (from mark) ... 90°
Install the connecting rod in the piston with the slot for the bearing tab 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.
Crankshaft
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(1) Thickness of thrust plates (new):
Without tabs
6N8940 ... .1850 ± .0015 in.(4.699 ± 0.038 mm)
9S3037 ... .2320 ± .0015 in.(5.894 ± 0.038 mm)
with tabs:
7N9342 ... .2150 ± .0015 in.(5.461 ± 0.038 mm)
7N9343 ... .2620 ± .0015 in.(6.655 ± 0.038 mm)
NOTE: Make reference to THRUST PLATE USAGE CHART for the correct thrust
plate to use.
(2) Make reference to MAIN BEARINGS and BEARING SURFACE (JOURNAL)

FOR MAIN BEARINGS.
(3) Make reference to CONNECTING ROD BEARINGS and BEARING SURFACE

(JOURNAL) FOR CONNECTING RODS.
(4) Tighten plugs to ... 17 ± 3 lb. ft.(23 ± 4 N·m)
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 not heat gear to more than 600°F (316°C).
(6) End play for crankshaft
(new) ... .0025 to .0145 in.(0.064 to 0.368 mm)
Maximum permissible end play for crankshaft (worn) ... .025 in.(0.64 mm)
(7) Wear sleeve and seal installation:
Push wear sleeve and seal into position with correct tooling. Make reference to Special
Instruction, Form No. SMHS7100 for instructions and the correct for installing wear
sleeves and seals.
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Bearing Surface (Journal) For Main Bearings
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Bearing Surface (Journal) For Connecting Rods
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Main Bearings And Connecting Rod Bearings
Make reference to GUIDELINE FOR REUSABLE PARTS: MAIN BEARINGS AND

CONNECTING ROD BEARINGS, Form No. SEBF8009.
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Crankshaft Hub
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(1) Torque for bolt that holds hub to crankshaft ... 230 ± 20 lb. ft.(307 ± 25 N·m)
Hit bolt with hammer and again tighten bolt to ... 230 ± 20 lb. ft.(307 ± 25 N·m)
NOTE: Install washer with the maximum flat area next to the hub.
Fan Drive
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(1) Fill chamber between bearings half full of 1P808 Grease before bolts are tightened.
Flywheel Ring Gear
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(1) Ring gear.
(2) Flywheel.
(3) Pilot bearing bore.
(4) Chamfer side of ring gear (1).
Install ring gear (1) on flywheel (2) so that the chamfer side (4) of ring gear (1) is as
shown.
NOTICE
Do not heat ring gear to more than 600°F (316°C) before installing on
the flywheel.
Flywheel Housing Tightening
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Typical Illustration
Tighten bolts in number sequence to ... 75 ± 10 lb. ft.(100 ± 14 N·m)
(A) Timing bolt hole.
NOTE: On some engines the timing bolt hole is below the starter.
Flywheel
Face Runout (axiel eccentricity) of the Flywheel:

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Checking Face Runout Of The Flywheel
1. Install the dial indicator as shown. Put a force on the flywheel toward the rear.
2. Set the dial indicator to read .000 in. (0.0 mm)
3. Turn the flywheel and read the indicator every 90°. Put a force on the 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.
Bore Runout (radial eccentricity) of the Flywheel:

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Checking Flywheel Bore
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Checking Flywheel Clutch Pilot Bearing Bore
1. Install the dial indicator (3) and make an adjustment of the universal attachment (4)
so it makes contact as shown.
2. Set the dial indicator to read .000 in. (0.0 mm)
3. Turn the flywheel and read the indicator every 90°.
4. The difference between the lower and higher measurements taken at all four points
must not be more than .006 in. (0.15 mm), which is the maximum permissible bore
runout (radial eccentricity) of the flywheel.
5. Runout (eccentricity) for the bore for the pilot bearing for the flywheel clutch, must
not exceed .005 in. (0.13 mm)
Flywheel Housing
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8S2328 Dial Indicator Group Installed
Face Runout (axial eccentricity) of the Flywheel

Housing:
1. Fasten a dial indicator to the crankshaft flange so the anvil of the indicator will touch
the face of the flywheel housing.
2. Put a force on the crankshaft toward the rear before reading the indicator at each
point.
3. With dial indicator set at .000 in. (0.0 mm) at location (A), turn the crankshaft and
read the indicator at locations (B), (C) and (D).
4. The difference between lower and higher measurements taken all four points must not
be more than .012 in. (0.30 mm), which is the maximum permissible face runout (axial
eccentricity) of the flywheel housing.
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Flywheel Housing Bore
NOTE: Write the dial indicator measurements with their positive (+) and negative (-)
notation (signs). This notation is necessary for making the calculations in the chart
correctly.
1. With the dial indicator in position at (C), adjust the dial indicator to "0" (zero). Push
the crankshaft up against the top bearing. Write the measurement for bearing clearance
on line 1 in column (C).
2. Divide the measurement from Step 1 by 2. Write this number on line 1 in columns
(B) & (D).
3. Turn the crankshaft to put the dial indicator at (A). Adjust the dial indicator to "0"
(zero).
4. Turn the crankshaft counterclockwise to put the dial indicator at (B). Write the
measurement in the chart.
5. Turn the crankshaft counterclockwise to put the dial indicator at (C). Write the
6. Turn the crankshaft counterclockwise to put the dial indicator at (D). Write the
7. Add lines I & 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.
9. On the graph for total eccentricity find the point of intersection of the lines for
vertical eccentricity and horizontal eccentricity.
10. If the ponit of intersection is in the range marked "Acceptable" the bore is in
alignment. If the point of intersection is in the range marked "Not Acceptable" the
flywheel housing must be changed.
Engine Mounting Bolts
NOTE: Use a torque wrench to get the correct torque for all the engine mounting bolts.
The chart for GENERAL TIGHTENING TORQUES has the correct tightening torque
for all the bolts except those in the list that follows.
D4 Tractor
Tighten the bolts which hold the front support to the frame to ... 400 ± 40 lb. ft.(540 ±
55 N·m)
Solid rear brackets only:

Tighten the bolts which hold the rear brackets together to ... 400 ± 40 lb. ft.(540 ± 55
N·m)
Tighten the bolts which hold the rear brackets to the frame to ... 225 ± 25 lb. ft.(300 ±
35 N·m)
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·m)
941-951 Track Type Loaders

70 N·m)
Tighten the bolts which hold the block on the flywheel housing to the frame to ... 460 ±
50 lb. ft.(624 ± 70 N·m)
955 Track Type Loader

70 N·m)
Flexible Coupling Drive
(6P3983, 6P3984, 6P5020)

Ver imagen
(3) Maximum permissible out of square of the face of flange in relation to the input
shaft of the torque converter ... .026 in.(0.66 mm)
(4) 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.
(Earlier; Two Piece Front Flange)

Ver imagen
(2) Torque for bolt holding flange to drive ... 160 ± 10 lb. ft.(219 ± 14 N·m)
(3) Maximum permissible "runout" axial alignment of face (total indicator reading) ...
.026 in.(0.66 mm)
(4) Maximum permissible "eccentricity" radial off center of flywheel output flange rim
to torque converter shaft (total indicator reading) ... .080 in.(2.03 mm)
(Earlier; One Piece Front Flange)

Ver imagen
(2) Maximum permissible "runout" axial alignment of face (total indicator reading) ...
.026 in.(0.66 mm)
(3) Maximum permissible "eccentricity" radial off center of flywheel output flange rim
to torque converter shaft (total indicator reading) ... .080 in.(2.03 mm)
Checking And Adjusting Alignment Of The Flexible

Coupling Drive
Ver imagen
1. 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 7H1940 Universal Attachment), and 7H1945 Holding Rod
into the 7H1948 Snug.
3. 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 90° of 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.
Ver imagen
5. 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)].
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.
8. Check the vertical and horizontal alignment again. When the alignment is correct,
tighten the engine mount bolts:
Make reference to ENGINE MOUNTING BOLTS for the correct torque for the bolts
that hold the engine to the frame.
NOTE: If the alignment is off by a large amount, inspect for the cause. If the frame is
bent, it can be straightened. If the engine front support is badly worn, a replacement is
needed.
Alternators
7S5897 24V 19A (Prestolite Number ANB6001);

9S4070 24V 19A (Prestolite Number ANB7001)
Ver imagen
Rated output at 28V ... 19 A
Output at 1500 rpm and 28V ... 10 A

Resistance of the rotor at 77° F (25° C) ... 18 to 20 ohm
Current consumption (draw) at 77° F (25° C) and 24V ... 1.2 to 1.3 A
(1) Torque for nut holding pulley ... 85 to 90 lb. ft.(115 to 120 N·m)
(2) Torque for bolts ... 25 to 30 lb. in.(2.8 to 3.4 N·m)
(3) Torque for screws ... 10 to 15 lb. in.(1.1 to 1.7 N·m)
(4) Torque for terminal nuts ... 30 to 35 lb. in.(3.4 to 4.0 N·m)
(5) Torque for bolts holding the regulator ... 45 to 50 lb. in.(5.1 to 5.7 N·m)
*
Including the 9S2329 Regulator (Prestolite Number VSH6401)
2P1698 24V 19A (Prestolite Number ANB6002 or

ANB6004); 2P1204 24V 19A (Prestolite Number
ANB7002 or ANB7004)
Ver imagen
Output at 6000 rpm, 28V and 70° F (21° C) ... 25 to 30 A
Resistance of the rotor at 77° F (25° C) ... 18 to 20 ohms
Current consumption (draw) at 77° F (25° C) and 24V ... 1.20 to 1.33 A
(1) Torque for nut holding pulley ... 75 ± 5 lb. ft.(100 ± 7 N·m)
(2) Torque for nuts for field and ground terminals ... 25 to 30 lb. in.(2.8 to 3.4 N·m)
(3) Torque for screws holding terminal plate ... 10 to 15 lb. in.(1.1 to 1.7 N·m)
(4) Torque for bolts ... 25 to 30 lb. in.(2.8 to 3.4 N·m)
(5) Torque for bolts holding regulator ... 45 to 50 lb. in.(5.1 to 5.7 N·m)
(6) Torque for nut for terminal ... 45 to 50 lb. in.(5.1 to 5.7 N·m)
(7) Torque for nut for positive terminal ... 225 to 250 lb. in.(25.4 to 28.3 N·m)
*
Including 2P1699, 4N5938 or 6N3821 Regulator (Prestolite Number VSH-6401A,
VSH-6401B or VSH-6401C).
6N9294 24V 35A (Delco-Remy Number 1117640)

Ver imagen
Rotation can be either direction.
Output at 28V and 2600 rpm ... 15 A
Output at 28V and 6500 rpm ... 35 A
Rated output, hot ... 35 A
Field current at 24V and 80° F (27° C) ... 2.5 to 3.2 A
(2) Torque for cover screws ... 20 ± 5 lb. in.(2.3 ± 0.6 N·m)
Torque for output (POS) terminal ... 5 ± 1 lb. ft.(7 ± 1 N·m)
5S9088 24V 50A (Delco-Remy Number 1117226)

Ver imagen
Polarity is negative ground
Circuit ... B
Speed for testing ... 5000 rpm
Output when cold:
Fasten carbon pile to battery to get maximum output ... 54 A
Rated output, hot ... 50 A
Field current at 24V and 80° F (27° C) ... 2.5 to 2.9 A
Voltage regulator:
Voltage setting range ... 26 to 30 V
Adjust voltage setting to ... 28 V
then increase speed to get maximum output ... 50 A
(2) Torque for output terminal ... 10 ± 1 lb. ft.(14 ± 1 N·m)
3P77 24V (Delco-Remy Number 1102398)

Ver imagen
Output at 26V and 2600 rpm (cold) ... 25 A
Output at 26V and 7000 rpm (cold) ... 41 A
Rated output (hot) ... 40 A
(1) Torque for stud nut for battery connection ... 25 to 40 lb. in.(2.8 to 4.5 N·m)
(2) Torque for pulley nut ... 60 ± 5 lb. ft.(80 ± 7 N·m)
5A8908 24V 20A (Mitsubishi Number AR4020A)

Ver imagen
Rotation is clockwise when seen from drive end.
No load output at speed below 1150 rpm ... 28 V
Loaded output at speed below 2500 rpm and 28 V ... 20 A
Resistance of field coil at 68° F (20° C) ... 29.5 ohms
Tension of brush spring ... 11 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 mm)
Minimum permissible brush length ... .25 in.(6.4 mm)
Torque for nut holding pulley ... 75 to 90 lb. ft.(100 to 120 N·m)
Torque for nut holding slip rings ... 35 lb. ft.(45 N·m)
3A1997 24V 19A (Paris-Rhone Number A13R-113T)

Ver imagen
Output at 4,000 rpm (hot) ... 19 A
Output at 1,180 rpm (hot) ... 28 V
(1) Torque for pulley nut ... 75 to 90 lb. ft.(100 to 120 N·m)
(2) Tension of brush spring ... 2.25 to 2.75 lb.(10 to 12 N)
(3) Minimum brush length ... .44 in.(11.2 mm)
(4) Diameter of slip ring (new) ... 1.65 in.(42.0 mm)
Minimum permissible slip ring diameter ... 1.57 in.(40.0 mm)
(5) Torque for slip ring nut ... 18 to 22 lb. ft.(24 to 28 N·m)
Alternator Regulator
6N3821 24V (Prestolite Number VSH-6401C); 4N5938
24V (Prestolite Number VSH-6401B); 2P1699 24V
(Prestolite Number VSH-6401A); 9S2329 24V
(Prestolite Number VSH-6401)
Ver imagen
Voltage setting range at 70° F (21° C) ... 27.3 to 28.7 V*
(1) Adjustment screw and washer.
*
With voltage adjustment screw (1) in position "N" (center). When screw (1) 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 (Mitsubishi Number RM4140G)

Ver imagen
Voltage range at 3000 rpm ... 28 to 31 V
Generators
4M9102 24V 20A (Delco-Remy Number 1106971)

Ver imagen
Rotation is clockwise when seen from the drive end.
Circuit ... A
Field current at 24V and 80° F (27° C) ... .83 to .89 A
Output at 1720 rpm and 26V when cold ... 20 A
Output when cold ... 26 V
(1) Tension of brush spring ... 20 oz.(5.6 N)
1S151 24V 15A (Delco-Remy Number 1105241)

Circuit ... A
Field current at 24V and 80° F (27° C) ... .94 to 1.02 A
Output at 1800 rpm and 28.5V when cold ... 15 A
Output when cold ... 28.5 V
1S5134 24V and 25A (Delco-Remy Number 1106867)

Circuit ... A
Field current at 24V 80° F (27° C) ... .83 to .89 A
Output at 1700 rpm and 26V when cold ... 20 A
Output when cold ... 26 V

3A 1873 2V (Paris-Rhone Number G 13 R81)

Ver imagen
Circuit ... B
Output at 2400 rpm and 28.5V ... 15 A
Output when cold ... 28.5 V
Field current at 24V 80° F (27° C) ... 0.7 to 0.8 A
(1) Tension of brush spring ... 2.75 lb.(12 N)
Minimum permissible length of the brush (worn) ... .31 in.(7.9 mm)
(2) Minimum permissible diameter of the commutator (worn) ... 2.05 in.(52.1 mm)
5A3033 & 5A6539 (Mitsubishi Number DR 350/24MR)

Speed for testing with a load (less than) ... 2000 rpm
Output with a load ... 28.5 V
Output at below 2000 rpm and 28.5V ... 15 A
Speed for testing with no load (less than) ... 1550 rpm
Output with no load (zero Amps) ... 28.5 V
Tension of brush spring ... .77 lb.(3.4 N)
5A7375 (Mitsubishi Number DT 600/24 ZR)

Ver imagen
Speed for testing with a load (less than) ... 1600 rpm
Output with a load ... 28 V
Output at below 1600 rpm and 28V ... 25 A
Speed for testing with no load (less than) ... 1450 rpm
Output with no load (zero Amps) ... 28 V
Tension of brush spring ... .93 lb.(4.2 N)

Generator Regulators

Ver imagen
Polarity is negative ground or insulated.
Circuit ... A
(1) Cutout relay:
Air gap between armature and core ... .017 in.(0.43 mm)
Point gap ... .032 in.(0.81 mm)
Voltage closing range ... 22.8 to 25.2 V
(2) Current regulator:
Air gap between armature and core ... .068 to .082 in.(1.73 to 2.08 mm)
Current setting range ... 14 to 16 A
(3) Voltage regulator:

Point gap ... .016 in.(0.41 mm)
Voltage setting range at 85° F (29° C):
Upper contacts ... 27.4 to 29.4 V
Lower contacts ... .2 to .6V less than upper contacts
(4) Torque for bolt ... 36 ± 6 lb. in.(4.1 ± 0.7 N·m)

Ver imagen
Polarity is negative ground or insulated.
Circuit ... A
(1) Cutout relay:
Point gap ... .032 in.(0.81 mm)
Voltage closing range ... 22.8 to 25.2 V

Point gap ... .016 in.(0.41 mm)
Voltage setting range at 85° F (29° C):
Upper contacts ... 27.4 to 29.4 V
Lower contacts ... .2 to .6V less than upper contacts
(4) Torque for bolt ... 36 ± 6 lb. in.(4.1 ± 0.7 N·m)
3S5028 24V 25A (Delco-Remy Number 1119306 and

1119306-E)
Circuit ... A
(1) Cutout relay:
Point gap ... .032 in.(0.81 mm)
Voltage closing range ... 24 to 27 V
Voltage setting range at 85° F (29° C) ... 27.5 to 29.5 V
(4) Torque for bolts ... 36 ± 6 lb. in.(4.1 ± 0.7 N·m)
3A1874 24 V (Paris-Rhone Number 2T216)

Ver imagen
(1) Cutout relay:
Point gap ... .031 in.(0.79 mm)
Closing range when cold ... 24.0 to 26.0 V
Voltage setting range at 85° F (29° C) ... 26.8 to 28.2 V
(4) Torque for bolts ... 36 ± 6 lb. in.(4.1 ± 0.7 N·m)
5A3061 (Mitsubishi Number RW-3B)

Cutout relay:
Back gap ... .030 to .047 in.(0.76 to 1.19 mm)
Point gap ... .020 to .032 in.(0.51 to 0.81 mm)
Switch in ... 24.5 ± 1 V
Reverse current (less than) ... 7 A
Voltage regulator:
Regulator setting (no load) at 3000 rpm ... 27.5 to 29.5 V
Current regulator:
Current limiter setting range at 3000 rpm ... 14 to 16 A
5A7385 (Mitsubishi Number RT4342E)

Ver imagen
Cutout relay:
Point gap ... .016 to .024 in.(0.41 to 0.61 mm)
Switch in ... 26 to 27 V
Reverse current (less than) ... 10 A
Voltage regulator:
Regulator setting (no load) at 3000 rpm ... 28 to 29 V
Current regulator:
Current limiter setting range at 4000 rpm ... 24 to 26 A
Starter Motors
1P7838 24V (Delco-Remy Number 1113992); 9M1662
24V (Delco-Remy Number 1113967); 4N3182 24V
(Delco-Remy Number 1114711)
Ver imagen
Minimum speed with no load ... 5500 rpm
Maximum speed with no load ... 7500 rpm
Current consumption (draw) at no load:
Minimum with solenoid at 20V ... 75 A
Maximum with solenoid at 20V ... 95 A
Clearance between pinion and housing (pinion clearance) ... .36 in.(9.1 mm)
(2) Torque for screws holding nose housing to lever housing ... 13 to 17 lb. ft.(18 to 23
N·m)
(3) Torque for terminal nuts ... 20 to 25 lb. ft.(25 to 35 N·m)
4N7902 24V (Delco-Remy Number 1113415)


Clearance between pinion and housing (pinion clearance) ... .36 in.(9.1 mm)
(1) Tension of brush spring* ... 36 to 40 oz.(10.0 to 11.1 N)
(2) Torque for screws holding nose housing to lever housing ... 8 lb. ft.(11 N·m)
(3) Torque for terminal nuts ... 20 to 25 lb. ft.(25 to 35 N·m) ... 80 oz.(22 N)
*
Minimum for leaf springs
2P2502 24V (Delco-Remy Number 1113393); 7N1285

24V (Delco-Remy Number 1113472)
Clearance between pinion and housing (pinion clearance) ... .010 to .140 in.(0.25 to 3.56
mm)
(1) Tension of brush spring ... 36 to 40 oz.(10.0 to 11.1 N)
N·m)
3T2772 24V (Delco-Remy Number 1113540)

Clearance between pinion and housing (pinion clearance) ... .33 to .39 in.(8.3 to 9.9
mm)
N·m)

Clearance between pinion and housing (pinion clearance) ... 33 to .39 in.(8.3 to 9.9 mm)
Ver imagen
N·m)

Clearance between pinion and housing (pinion clearance) ... 33 to .39 in.(8.3 to 9.9 mm)
N·m)
7S5900 and 2P2501 24V (Prestolite Number MFY

6201K); 3P6 24V (Prestolite Number MFY 6401K);
4N7901 24V (Prestolite Number MFY 6401L)
Minimum no load speed ... 5000 rpm
Maximum at 20V ... 65 A
Ver imagen
(2) Torque for bolts ... 8 lb. ft.(11 N·m)
(4) Clearance for the pinion ... .020 to .050 in.(0.51 to 1.27 mm)
7S2234 and 1P7839 24V (Prestolite Number

MES6101K); 4N7752 24V (Prestolite Number
MES6404K); 2P6162 24V (Prestolite Number
MES6301K); 9G4338 24V (Prestolite Number
MES6601K)
Current consumption (draw) with no load:

(2) Torque for housing bolts ... 8 lb. ft.(11 N·m)
(4) Clearance between pinion and housing (pinion clearance) ... .020 to .050 in.(0.51 to
1.27 mm)
9G4337 24V (Prestolite Number MFY6601K)

Ver imagen
(1) Torque for bolts ... 8 lb. ft.(11 N·m)
(3) Clearance for the pinion ... .020 to .050 in.(0.51 to 1.27 mm)
3T6305 24V (Robert Bosch Number 0-001-430-03)

Minimum ... 140 A
Permissible clearance between pinion and ring gear ... .06 to .22 in.(1.5 to 5.6 mm)
Ver imagen
(2) Minimum permissible length of the brushes ... .69 in.(17.5 mm)
(3) Minimum permissible diameter of commutator ... 1.9 in.(48 mm)
3A2035 24V (Paris-Rhome Number D13 E76); 3A 1872

24V (Paris-Rhone Number D13 E77)
Maximum speed with no load at 20 V ... 6000 rpm
Maximum with solenoid at 20 V and 6000 rpm ... 75 A
Minimum permissible diameter of the commutator ... 2.05 in.(52.1 mm)
Clearance between pinion and support (pinion clearance) ... .039 ± .020 in.(1.00 ± 0.51
mm)
Ver imagen
(1) Tension of brush spring ... 53.3 ± 5.3 oz.(14.8 ± 1.5 N)
(2) Torque for screws holding support to lever housing ... 15 ± 2 lb. ft.(20 ± 3 N·m)
3A1529 24V (Paris-Rhone Number D13 E68); 3A1531

24V (Paris-Rhone Number D13 E75)
Maximum speed with no load at 20 V ... 6000 rpm
Current consumption (draw) with no load:
Maximum with solenoid at 20 V and 6000 rpm ... 75 A
Minimum permissible diameter of the commutator ... 2.05 in.(52.1 mm)
Clearance between pinion and thrust washer (pinion clearance) ... .039 ± .020 in.(1.00 ±
0.51 mm)
(1) Tension of brush spring ... 53.3 ± 5.3 oz.(14.8 ± 1.5 N)
(2) Torque for screws holding support to lever housing ... 15 ± 2 lb. ft.(20 ± 3 N·m)

5A6492 and 5A3031 (Mitsubishi Number MT 10/24
ZR); 5A6494 and 5A3196 (Mitsubishi Number MT
10/24 YR)
Stall torque test:
Maximum current consumption (draw) at 9V (maximum) ... 1500 A
Stall torque at 9V (minimum) ... 79.6 lb. ft.(108.1 N·m)
Ver imagen
(1) Minimum permissible diameter of the commutator ... 2.01 in.(51.1 mm)
(2) Tension of brush spring ... 2.29 ± .34 lb.(10.2 ± 1.50 N)
(3) Minimum permissible length of brushes ... .55 in.(14.0 mm)
3.51 mm)
5A6522 (Mitsubishi Number MRA 7 5/24 ER or
MOO7T03774); 5A6495 (Mitsubishi Number MRE 7
5/24 ER); 5A5744 (Mitsubishi Number MTR 7 5/24
YR)
Stall torque test:
Maximum current consumption (draw) at 9V (maximum) ... 1500 A
Stall torque at 9V (minimum) ... 80 lb. ft.(110 N·m)
Ver imagen
(1) Minimum permissible diameter of the commutator ... 2.01 in.(51.1 mm)
(2) Tension of brush spring ... 4.6 ± .7 lb.(20.5 ± 3.1 N)
(3) Minimum permissible length of brushes ... .55 in.(14.0 mm)
3.51 mm)
Starter Magnetic Switches
7N3621 24V; 7M4291 24V (Delco-Remy Number

1119866)
Current consumption (draw) at 20 V ... 3.5 to 3.9 A
Ver imagen
(1) 7M7553 Spring:
(2) 7M7622 Spring:
Test force ... 2.65 to 3.25 lb.(11.60 to 14.00 N)

9F3099 24V (Delco-Remy Number 0001481)
Ver imagen
Current consumption (draw) both windings at 24 V ... .83 to .89 A
(1) Torque for large terminal nuts ... 30 to 40 lb. in.(3.4 to 4.5 N·m)
5L5886 12V (Delco-Remy Number 0001486); 302266 or

Rating ... 12 V
Current consumption (draw) hold-in windings at 8 V ... 2.1 to 2.4 A
(1) Torque for large terminal nuts ... 30 to 40 lb. in.(3.4 to 4.5 N·m)
Starter Solenoids
Ver imagen
4M1812 24V (Delco-Remy Number 1119832 or
1119848)
Current consumption (draw):
Current pull in windings at 5V ... 10 to 11.5 A
Current pull in windings at 20 to 24V ... 40 to 55.2 A
Current hold in winding at 20 to 24V ... Maximum of 8.2 A
(1) 4M1815 Spring for contact release:
Free length after test ... .83 ± .015 in.(21.1 ± 0.38 mm)
Outside diameter ... .375 ± .010 in.(9.53 ± 0.25 mm)
(2) 9M7609 or 8M1856 Spring to return the clutch lever:
Test force ... 14 ± .5 lb.(62 ± 2.2 N)

Outside diameter ... 1.393 ± .015 in.(35.38 ± 0.38 mm)
(3) Torque for terminal screws ... 16 to 30 lb. in.(1.8 to 3.4 N·m)

Current at 20V ... 40 to 45.5 A
Current at 20 to 24V ... 40 to 54.6 A
(2) 9M7609 Spring to return the clutch lever:
Test force ... 14 ± .5 lb.(62 ± 2.2 N)
1P9181 24V (Delco-Remy Number 1115526)

Ver imagen
Current at 20V ... 40 to 45.5 A
Current at 20V to 24V ... 40 to 54.6 A
(2) 9M7609 Spring to return the clutch lever:
Test force ... 14 ± .5 lb.(62 ± 2.2 N)

Ver imagen
Pull in winding at 5V ... 9 to 11.5 A
Hold in winding at 20V ... 6.8 A Maximum
(1) Torque for nuts ... 20 to 25 lb. ft.(27 to 33 N·m)
3T868 24V (Robert Bosch Number 0331 410 002)

Ver imagen
Resistance:
Pull in winding ... .513 to .567 ohm
Resistance:
Hold in winding ... 3.28 to 3.62 ohm
3T3369 24V (Prestolite Number SAT-4105); 9S7976

24V (Prestolite Number SAT-4103); 8S1549 24V
(Prestolite Number SAT-4101)
Ver imagen
Current pull in windings at 12 V ... 23.2 to 26.6 A
Current pull in windings at 20 to 24 V ... 38.6 to 52.4 A
Current hold in windings at 12 V ... 4.1 to 4.8 A
Current hold in windings at 20 to 24 V ... 6.8 to 9.6 A
3A1555 24V (Paris-Rhone Number CED65)

Ver imagen
Current Consumption (draw):
Current both windings at 20V ... 70 ± 7 A
Current hold in windings at 20V ... 11.2 ± 1.2 A

(1) Spring for contact release:
Test force ... 18.7 ± 1.9 lb.(83.0 ± 8.5 N)
(2) Spring to return the clutch lever:
Test force ... 13.2 ± 1.3 lb.(58.5 ± 5.8 N)
Fuel Pressure Indicator
Ver imagen
6N3272 Indicator (Frank W. Murphy Mfr. Inc.)

Gauge with color code.
Ver imagen
Water Temperature Indicator
Ver imagen
3S4824 Indicator (Stewart Warner Corp. Number 346-
EX-101)
Ver imagen
Oil Pressure Indicator
Ver imagen
5M1065 Indicator (Stewart Warner Corp. Number
342-FR)
Ver imagen
Oil Pressure Switch

Ver imagen
2N7744 Switch (Metals and Controls Number 20PS66-

1)
With an increase in pressure, switch closes at a maximum of ... 12 psi (85 kPa)
With a decrease in pressure, switch opens at a minimum of ... 5 psi (35 kPa)
Converter Oil Temperature Indicator
Ver imagen
1P5486 Indicator (Frank W. Murphy Mfr. Inc.
Number 10-35-01-175)
Ver imagen

Especificaciones 3304

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3304 VEHICULAR ENGINE

Número de medio ‐ Fecha de publicación ‐ Fecha de actualización ‐

Bore ... 4.75 in.(120.7 mm)

Stroke ... 6.0 in.(152.4 mm)

Number of Cylinders ... 4

Cylinder Arrangement ... *in‐line

Firing Order (Injection Sequence) ... 1, 3, 4, 2

Direction of Rotation (when seen from flywheel end) ... Counterclockwise

Cylinder and Valve Identification

Fuel System Usage Chart

NOTE: Torque for cable nut ... 50 lb. in.(5.7 N·m)

Electric Service Meter

Polarity is negative ground.

Operating voltage ... 24V DC only

Fuel Injection Equipment

Firing order (injection sequence) ... 1, 3, 4, 2

Injection timing before TC (top center):

Fuel pump serial numbers to 044, 899 ... 12° 30' ± 1°

(4) Governor spring:

Make reference to the chart "GOVERNOR SPRINGS."

(5) Bypass valve:

Make reference to the chart "BYPASS VALVE SPRINGS."

Install Spring As Shown

(7) Torque for bushing ... 70 ± 5 lb. ft.(95 ± 7 N·m)

(8) 4N4318 Spring for injection pump:

Length under test force ... 1.35 in.(34.3 mm)

Test force ... 12.5 ± 1.3 lb.(55.5 ± 5.8 N)

Free length after test ... 1.566 in.(39.78 mm)

Outside diameter ... .728 in.(18.49 mm)

NOTE: See Glow Plug Positioning.

(16) Torque for bolts holding clamps on fuel injection lines:

With rubber damper ... 84 ± 24 lb. in.(9.6 ± 2.8 N·m)

Without damper ... 108 ± 36 lb. in.(12.2 ± 4.1 N·m)

9S8597 Spring for terminal shaft:

Color code (stripes) ... 1 white

Length under test force ... .584 in.(14.83 mm)

Test force ... 56.3 lb.(251 N)

Free length after test ... 1.21 in.(30.7 mm)

Outside diameter ... 1.635 in.(41.53 mm)

Diameter of wire ... .135 in.(3.43 mm)

2P726 Spring for terminal shaft:

Color code (stripes) ... 1 red

Length under test force ... .584 in.(14.83 mm)

Test force ... 109 lb.(485 N)

Free length after test ... 1.04 in.(26.4 mm)

Outside diameter ... 1.635 in.(41.53 mm)

Diameter of wire ... .156 in.(3.96 mm)

4N4366 Spring for terminal shaft:

Length under test force ... .584 in.(14.83 mm)

Test force ... 156 lb.(692 N)

Free length after test ... 1.016 in.(25.81 mm)

Outside diameter ... 1.638 in.(41.61 mm)

Diameter of wire ... .168 in.(4.27 mm)

9L6508 Spring for terminal shaft:

Put a load on spring of ... 5.00 lb.(22.2 N)

Then make spring shorter by ... .700 in.(17.78 mm)

Total test force ... 19.70 ± .52 lb.(87.63 ± 2.31 N)