Ia Caterpillar Specifications 3304 VehicularEngine Text PDF

® FORM NO.
SENR7590-01
CATERPILLAR FOR USE IN SERVICE MANUALS:
n VOLUME SPECIFICATIONS, REG01312

I
D4 TRACTOR, REG00632
D4E TRACTOR, SENR7624
D4 SA TRACTOR, REG00784
D4E SA TRACTOR, SENR7636
NO. 112F MOTOR GRADER, REG00885
120G MOTOR GRADER, REG01654
130G & 140G MOTOR GRADERS,
REG01652
225 EXCAVATOR, REG01578
518SKIDDER, REG00971
920 & 930 WHEEL LOADERS, REG00514
941 TRACK-TYPE LOADER, REG00527
950 WHEEL LOADER, REG00548
955L TRACK-TYPE LOADER, SENR7364
955L TRACK-TYPE LOADER, SENR7672
p(i©Di©iifeira
3304 Vehicular Engine
7Z1-UP
3304 VEHICULAR ENGINES SPECIFICATIONS
INTRODUCTION •'^
The specifications given in thisbook are on the basis can be used again. If the part is equal to or within the
of infoniiation available at the it was written. The
time specification given, use the part again.
specifications torques, pressures of operation, mea-
surements, adjustments and other items can change at When the word "permissible" " is in the description,
any time. These changes can effect the service given to the specification given is the "maximum or minimum"
the product. Get the complete and most current infor- tolerance permitted before adjustment, repair and/or
mation before you start any job. Caterpillar Dealers new parts are needed.
have the most current information which is available.

A comparison can be made between the measure-
For a list of the most current modules and forni numbers
ments of a worn part, and the specifications of a new
available for each Service Manual, see the SERVICE
part to find the amount of wear. A part that is worn can
MANUAL CONTENTS MICROFICHE REG I 139F.
be safe to use if an estimate of the remainder of its
When words "use again" are service life is good. If a short service life is expected,
the in the description,
the specification given can be used to determine replace the part.
if apart
77200X2
NOTE: For Systems Operation and Testing and Adjusting, make reference to
3304 VEHICULAR ENGINES, Form No. SENR7591.
Bore
ENGINE DESIGN
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.
EXHAUST VALVES
2 3
INTAKE VALVES
CYLINDER AND VALVE IDENTIFICATION
NOTE: This book has been completely changed from the former issue.
^
INDEX
Air Inlet and Exhaust System Engme Design 2
Air Cleaner 43 Engine Mounting Bolts 76
Camshaft 37 Fuel System
Cylinder Head 42 Fuel System Timing 6
Glow Plug Positioning 41 Fuel System Usage Chart 6
Exhaust Manifold 43 Service Meter 7
Exhaust Pipe and Muffler 43 Tachometer Drive 7
Turbocharger 46-51 Fuel System — Scroll (Dl) 31
Turbocharger Impeller Installation 44, 45 Fuel Injection 32
Valves (Dl) 40 Fuel Injection Pump Housing 31
Valves (PC) 38, 39 Fuel Transfer Pump 35
Valve Cover 42 Governor 34
Valve Rocker Ar'ms and Lifters 37 Governor Housing 33
Injection Nozzle 33
Basic Engine Components Fuel System — Scroll (PC) 27
Bearing Surface (Journal)
Fuel Bypass Valve 30
Connecting Rods 69
Fuel Injection Equipment 27
Main Bearings 68
Fuel Transfer Pump 30
Connecting Rod 66
Governor (Earlier) 28
Crankshaft 67
Governor (Later) 29
Crankshaft Hub
Fuel System — Scroll {PC & Dl)
70
36
Cylinder Block
Timing Gears 36
Counterbored Block 60
Fuel System —
Sleeve Metering (Dl) 18
Spacer Plate Block 61
Fuel Injection Equipment 18-20
Cylinder Liner 62
Fuel Ratio Control 21
Cylinder Liner Projection
Fuel Transfer Pump 21
Counterbored Block 62
Governor Control {D4E) 23
Spacer Plate Block 63
Governor Control (120G & 130G) 22
Fan Drive 71
Governor Control (225) 24
Flexible Drive Coupling 76, 77
Checking and Adjusting Alignment of the
Injection Nozzle 21
Flexible Drive Coupling 78 Fuel System — Sleeve Metering (PC) 8
Flywheel 73 Fuel Injection Equipment 8-12
Flywheel Housing 74
Fuel Ratio Control 13
Flywheel Housing Bore 75 Fuel Transfer Pump 13
Flywheel Housing Tightening 72
Governor Control (920 & 930) 14
Flywheel Ring Gear 72
Main Bearing and Connecting Rod Bearings 70 Governor Control (951) 17
Pistons and Rings
Governor Control (955L) 15
Fuel System — Sleeve Metering (PC &
Keystone 64
Dl) 25
Straight Side 65 Timing Gears 26
Water Separator 25
Cooling System
Coolant Flow Switch 59 Gauges
Fan Drive 71
Converter Oil Temperature Indicator 97
Radiator 58 Fuel Pressure Indicator 96
V-Belt Tension Chart 57
Oil Pressure Indicator 97
Water Pump 57
Water Temperature Indicator 96
Water Temperature Regulator 59 General Tightening Torques 4
Electrical System Lubrication System

Alternators 79-82
Engine Oil Pressure 55
Alternator Regulator 83
Oil Breather Cap 56
Generator Regulators 85-87
Oil Filter 55, 56
Generators 84, 85
Oil Pump 52-54
Starter Magnetic Switches 92 Pressure Switch
Oil 97
Starter Motors 88-92
Starter Solenoids 93-95 Torque for Flared and O-Ring Fittings 5
GENERAL TIGHTENING TORQUE FOR

TORQUE FOR FLARED AND 0-RING FITTINGS

The torques shown in the chart that follows are to be used on the part of 37° Flared, 45° Flared and
Inverted Flared fittings (when used with steel tubing), O-ring plugs and O-ring fittings.
E^fe^&a
E^^gp
^^^p^^^r^^^^vsss)
oaa PB
INVERTED O-RING
45°FLARED 37 FLARED 45 FLARED FITTING - PLUG SWIVEL NUTS
TUBE 3.18 4.78 6.35 7.92 9.52 TUBE 12.70 15.88 19.05 22.22 25.40 31.75 38.10 50.80
SIZE SIZE
(O.D.) .125 .188 .250 .312 .375 (O.D.) .500 .625 .750 .875 1.000 1.250 1.500 2.000
THREAD 9/16 THREAD 1 3/16

5/16 3/8 7/16 1/2 3/4 7/8 1 1/16 1 5/16 1 5/8 1 7/8 2 1/2
SIZE (in.) 5/8 SIZE (in.) 1 1/4
TORQUE 5 11 16 20 30 TORQUE 50 55 75 90 110 135 160 310

N-m ±1 +1 ±2 ±2 ±2 Nm ±5 ±7 ±7 ±7 +7 ±15 ±15 ±30
TORQUE 45 100 145 175 265 TORQUE
35 ±3 40 ±5 55 ±5 65 ±5 80 ±5 100 ±10 120 ±10 230 ±20
Ib.in. ±10 ±10 ±20 ±20 ±25 lb .ft.
ASSEMBLY OF FITTINGS WITH

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

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

plug, the hex on the body takes the place of the locknut.
To install this type fitting tighten the hex against the
face of the part it goes into.
2. To put the fitting assembly in its correct position

turn the fitting body
(2) out (counterclockwise) a
maximum of 359°. Tighten locknut (3) to the ELBOW BODY ASSEMBLY
torque shown in the chart. 1. End of fitting t>ody (connects to tube). 2. Fitting
body. 3. Locknut. 4.Backup washer. 5. 0-rlng seal. 6.
A71009X2 End of fitting that goes Into other part.
FUEL SYSTEM USAGE CHART

SERVICE METER
(EARLIER MODELS)
(II Torque for bolts which hold service meter or adapter

for service meter drive 96 ± 24 lb. in. (10.9 ± 2.8 Nm)
NOTE: Torque for cable nut 50 lb. in. (5.7 N-m)
AI756axl
ELECTRIC SERVICE METER

(LATER MODELS)
6N5906
Polarity is negative ground.
Operating voltage 24V DC only
TACHOMETER DRIVE
(1) Torque for cable nut 100 ± 20 lb. in. (11.3 + 2.3 N-m)
n (2) Tighten bolts which hold adapter for

tachometer drive to 96 t 24 lb. in 10.9 ± 2.8 Nm)
(SLEEVE METERING FUEL SYSTEM — PC)
FUEL INJECTION EQUIPMENT
4 5 VIEW A-A
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 tiole for

timing pin 108 ± 36 lb. in. (12.2 ± 4.1 Nm) (3) End play for camshaft with sleeve installed
Torque for bolts that hold governor vi/eight carrier (new) 023 ± .018 in. (0.58 ± 0.46 mm)
tocamshaft 90 ± 101b. in. (10.2 ± 1.1 Nm) NOTE: When installing sleeve on end of camshaft, support the cam-
(1) Diameter of rear bearing surface (journal) of the camshaft shaft to prevent damage to parts inside of injection pump and
(new) 2.3720 ± .0005 in. (60.249 ± 0.013 mm) governor housing.
Bore in the rear bearing for the (4) Governor spring:

camshaft (new) 2.3750 ± .0005 in. (60.325 ± 0.013 mm)
Make reference to the chart "GOVERNOR SPRINGS."
Maximum permissible clearance between the bearing
and the camshaft bearing surface (journal) (5) Bypass valve:
(worn) 006 in. (0.15 mm) Make reference to the chart "BYPASS VALVE SPRINGS."
(2) Diameter of fuel control shaft (6) Diameter of front bearing surface (journal) of the
(new) 3530 ± .0003 in. (8.966 ± 0.008 mm) camshaft (new) 9990 ± .0005 in. (25.375 ± 0.013 mm)
Bore In the housing for fuel control shaft Bore in the front bearing for the camshaft
(new) 3543 ± .0005 in. (8.999 ± 0.013 mm) (new) 1 .0005 ± .0005 in. (25.413 ± 0.013 mm)
Maximum permissible clearance between the bore Maximum permissible clearance between the bearing
in the housing and the fuel control shaft and the camshaft bearing surface (journal)
(worn) 003 in. (0.08 mm) (worn) 003 in. (0.08 mm)
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
Fuel Injection Equipment (Cont.)
GOVERNOR SPRINGS
((.OF LIFTER
A98051X1
Install guide pin (A) to deptti (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 Nm)

(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 Nm)
(10) Torque for the nuts that hold the fuel lines
(Use 5P144 Fuel Line Socket) 30 ± 5 lb. ft. (40 ± 7 Nm)
(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 Nm)
NOTE: See Glow Plug Positioning.

10 PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES
TYPICAL ILLUSTRATION
(16) Torque tor bolts holding clamps on tuel Injection lines;
With rubber damper 84 ± 24 lb. in. (9.6 ± 2.8 Nm)

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 shatt assembly (19) is pulled against
the governor housing 437 in. (1 1 .10 mm)
(20) Spring for the terminal shaft. Install the spring (20) for the termi- fet^^-^ZZZZ^
nal 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)
AI0Z90X1
2P726 Spring for terminal shaft:
Color code (stripes) 1 red

Test force 109 lb. (485 N)
Free length after test 1 .04 in. (26.4 mm)

Outside diameter 1.635 in, (41,53 mm)
4N4366 Spring for terminal shaft:

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:
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 1970 ± ,52 lb. (87.63 ± 2.31 N)
Free length after test 1 .74 ± ,02 in, (44,2 ± 0,5 mm)
Outside diameter 1,518 in. (38,56 mm)
11
)
-^r-n
(21) 9S8632 Low Idle Spring:
Length under test force 1 .20 In. (30.5 mm)

Test force 40 ± 4 lb. ft. (180 ± 18 N)
Free lengttn after test 2.00 in. (50.8 mm)


FUEL TRANSFER PUMP
(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. (0.01 5 to 0.056 mm)
FUEL RATIO CONTROL
SPRINGS FOR FUEL RATIO CONTROL

GOVERNOR CONTROL
(920 & 930 Wheel Loaders)
OFF
L>nCIZI3-e,
B41 448X1
LINKAGE ADJUSTMENT PROCEDURE:

1 With the governor in the OFF position, install lever (1) at angle 3. Tighten nuts on rods (6) and (8).
(B). Adjust the length of rod (6) by turning rod ends (2) and (3)
Angle A is 19'"
so lever (4) is at angle (C).
Move lever (1) to HIGH IDLE position and adjust rod

Angle B is 20 + 5"
(8) by
turning rod ends (7) and (9) so pedal (5) is at angle (A). Angle C is 30 ± 5''

.
(SLEEVE METERING FUEL SYSTEM - PC)
GOVERNOR CONTROL
(955L Track-Type Loader)

3. With lever (5) in the center between discs, tighten nut (6) so
1 Put the governor control (2) in the OFF position (approximately force needed to move governor control lever (2) is 14.6 ± .9 lb.
.47 in. (12 mm) from the end of slot in the guide. (65 ± 4 N).
2. Adjust length of rod (3) so lever (5) is in the OFF position at the Angle A for lever (1) and governor
engine. Tighten nuts (4) on rod (3). control (2) is 102 ± 5°
15
GOVERNOR CONTROL
(950 Wheel Loader)
B41 450X1
4. Adjust length of rod (3) and install pin (6). Tighten locknuts on
LINKAGE ADJUSTMENT PROCEDURE: rods.
1. With lever (1) in OFF position. Angle A is 37°

2. Adjust rod (2) so lever (5) is at angle (C). Angle B is 6°
3. Put pedal (4) in OFF position. Angle is 11"

GOVERNOR CONTROL
(951 Track-Type Loader)
B41451X1
LINKAGE ADJUSTMENT PROCEDURE: Adjust length of rod (5) so lever the engine the OFF
3. (6) at is in
1. Make an adjustment to rod (4) so length of rod 28.20 ± .12 in.

is position. Tighten nuts on rods.
(71 6.3 ± 3. mm) at center of pins. Tighten nuts on rod and install
4. Tighten nut so force on knob 13 ± (58 ± 4 N).
(3) (1) is 1 lb.
rod on machine.
Distance A is 28.20 ± .12 in. (716.3 ± 3.0 mm)
2. Put governor control lever (2) in the LOW IDLE position, approx-
imately .25 in. (6.4 mm) from end of slot in guide. Angle B is 15"
17
(SLEEVE METERING FUEL SYSTEM — Dl)
4 5 VIEW A-
Firing order (injection sequence) 1, 3, 4, 2 (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 cam-
Direct Injection Engines
with turbocharger 23 ± 1
° shaft to prevent damage to parts inside of injection pump and gover-
nor housing.
°
without turbocharger 29 ± 1
Torque for bolts that hold (4) Governor spring:

governor weight carrier to
Make reference to the chart "GOVERNOR SPRINGS."
camshaft 10 ± 2 lb. ft. (14 ± 3 Nm)
(5) Bypass valve:
Make a mark (stake) the governor weight cover in four places 90°
apart directly over the groove in the camshaft. 4N605 Bypass Valve Spring:
(1) Diameter of rear bearing surface Length under test force 880 in. (22.35 mm)
(journal) of the camshaft
Test force 3.53 ± .18 lb. (15.7 ± 0.8 N)
(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) Outside diameter 527 in. (13.39 mm)
Maximum permissible clearance between the Pressure of fuel in housing for
bearing and the camshaft bearing surface fuel injection pumps,
(journal) (worn) 006 in. (0.15 mm) (Full Load) 30 ± 5 psi (205 ± 35 kPa)
(2) Diameter of sleeve control shaft (6) Diameter of front bearing surface
(new) 3530 ± .0003 in. (8.966 ± 0.008 mm) Oournal) of the camshaft
Bore in the housing for the

(new) 9990 ± .0005 in. (25.375 ± 0.013 mm)
fuel control shaft Bore in the front bearing for the camshaft
(new) 3543 .0005 in. (8.999 ± 0.013 mm) (new) 1.0005 ± .0005 in. (25.413 ± 0.013 mm)
Maximum permissible clearance between Maximum permissible clearance between the
the bore in the housing and the sleeve bearing and the camshaft bearing surface
control shaft (worn) 003 in. (0.08 mm) (journal) (worn) 002 in. (0.05 mm)
NOTE: FOR TOROUE VALUES NOT GIVEN, SEE THE FIRST

GOVERNOR SPRINGS
^lOF lifter
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 Nm)

(8) 9N5862 Spring for injection pump:
Length under test force 1.38 in. (35.1 mm)
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 Nm)
(10) Torque forthe nuts that hold
the fuel lines (use 5P144 Fuel
Line Socket) 30 ± 5 lb. ft. (40 ± 7 N-m)
(11) Spring for the terminal shaft. Install the spring (1 1) for the termi-
nal shaft so that the end of the spring is in the 30° range as
shown.
SPRINGS FOR TERMINAL SHAFT

FUEL RATIO CONTROL
SPRINGS FOR FUEL RATIO CONTROL

GOVERNOR CONTROL
(120G and 130G Motor Graders)

NOTE: DO NOT use control lever (2) to shut OFF the engine.
To shut engine OFF, pull up on accelerator treadle (11). 8. Loosen locknut (14) and adjust length of rod so top of de-
1. Tighten nut (A) just enough so position of control lever (2) is celerator treadle (9) is .19 in. (4.8 mm) above floor plate (10)
not affected by the operation of the accelerator treadle (11) as shown. If machine is equipped with a thick floor insulation
and decelerator treadle (9). 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
2. With the parking brake ON and engine stopped, BE SURE dis- tighten locknut (14).
connect sw/itch is OFF.
9. Move control lever (2) to HIGH IDLE position.
3. Remove pin (4).
10. Turn HIGH IDLE stop (5) until it touches lever (12) and lighten
4. Loosen LOW IDLE stop (7) and HIGH IDLE stop (5) so they locknut (6).
do not touch lever (12).
11. Loosen locknut (16) and adjust accelerator treadle (11) so that
5. tvlove control lever (2) to LOW IDLE position. 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.
6. Turn LOW IDLE stop (7) until it touches lever (12) and tighten
locknut (8). 12. Move lever (3) to HIGH IDLE position and adjust length of
7. Adjust length of rod (13) so distance from top of lever (15) to

rod (1) so pin (4) can be installed.
bottom of floor plate (10) is 1.50 m. (38.1 mm) as shown 13. Install pin (4).

GOVERNOR CONTROL
(D4E Tractor)
A48074X2
NOTE: With control lever in high idle position and governor control
1. With pin removed from lever (4) move lever (4) to high idle position
shaft in full on position, put lever (4) on shaft at angle (D).
(rearward),
Angle (D) is 40'
2. Move lever (Y) rearward until interference occurs in linkage.
Dimension (A) (approximately) 14.2 in. (361 mm) 3. Adjust rod end (Z) to position holes short of alignment [approx. .2
Tighten nut (1) to 18 ± 5 lb. ft. (24 ± 7 N-m) mm)] with hole in lever (4).
in. (5
Dimension (B) (approximately) 19.2 in. (488 mm) 4. t\/lovelever (4) to shutoff position and lever (Y) forward until inter-
f^ Tighten nuts (2) to 18 ± 5 lb. ft. (24 ± 7 N>m)
ference occurs. Holes In rod end (Z) must be forward of hole in
lever (4). If additional adjustment is required repeat Step 3, [.2 in.
Dimension (C) (approximately) 18.7 in. (475 mm) (5 mm) dim. may be decreased],
Tighten nut (3) to 18 + 5 lb, ft. (24 ± 7 N-m) 5. Install pin and cotter.
23
.
(SLEEVE METERING FUEL SYSTEM - Dl)
GOVERNOR CONTROL
(518 Skldder)
B42382X1

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)
GOVERNOR CONTROL
(225 Excavator)
B41452X1

Adjust distance (A) to 2.50 in. (63.5 mm) from inlay mounting holes
toback edge of governor control handle (1)with engine running at
1400 t 50 rpm.

(SLEEVE METERING FUEL SYSTEM - PC & Dl)
AS7414X1
WATER SEPARATOR
(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 Nm)

(SLEEVE METERING FUEL SYSTEM — PC & Dl)
TIMING GEARS
Tighten bolts which fasten into

front plate to 17 ± 3 lb. ft, (23 ± 4 N-m)
Tighten nuts holding cover for
fuel pump drive gear to 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

A4SIS8X2
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)
Maximum permissible end play (worn) . . . .017 in. (0.43 mm)
Diameter of balancer shaft
bearing surface (journal)
(new) 2.0825 ± .0005 in. (52.896 ± 0.013 mm)
Bore bearing for balancer
in
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.

26 PAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TOROUES
(SCROLL FUEL SYSTEM — PC)

Firing order (injection sequence) 1 , 3, 4, 2
°
Injection timing before TO (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)
2fv14209 Spacer 178 in. (4.52 mm)
2M4210 Spacer 182 in, (4.62 mm)
2M421 1 Spacer 186 in. (4.72 mm)
2M4212 Spacer 190 in. (4.83 mm)
5tV12691 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)

I (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) A-5P4158 GAUGE ILLUSTRATED
(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)
fvlaximum 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)
fâximum 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 Nm)
(9) Torque for the nuts that hold
the nozzles 105 ± 5 lb. ft. (142 ± 7 Nm)
(10) Body.
(11) Put 5P3931 Anti-Seize (13 Put 5P3931 Anti-Seize Compound

Compound on threads of glow plug and on threads of precombustion chamber and
tighten to 120 ± 24 lb. in. (13.6 ± 2.8 Nm) tighten to 150 ± 10 lb. ft. (205 14 Nm)
(12) Tighten nozzle finger tight on body. NOTE: See Glow Plug Positioning.
27
GOVERNOR
(EARLIER)
(1) Torque for nut 9 ± 3 lb. ft. (12 ± 4 Nm)

(2) 1S9312 Spring for speed limiter:
Length under test force 86 in. (21 .8 mm)

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)
Free length after test 2.34 ± .03 in. (59,4 ± 0.8 mm)
Outside diameter 1.39 in, (35.3 mm)
(3) 9L3617 Spring For Governor;
Color code (stripes) 1 blue, 1 white
Put force on spring of 6,0 lb, (27 N)

Total test force 22.2 ± .5 lb. (100.8 + 2 N)
Free length after test 2.34 ± .03 in. (59.4 ± 0.8 mm)
Outside diameter 1 .39 in. (35.3 mm)
(3) 8IV19140 Spring for governor:
Color code (stripes) 1 green

Total test force 16.6 ± .3 lb. (74.0 ± 1.3 N)
Free length after test 2.34 ± .03 in. (59.4 + 0.8 mm)
Outside diameter 1 .38 in. (35.1 mm)

GOVERNOR
(LATER)

(2) 8M9140 Spring for governor:
Color code (stripes) 1 green

Total test force 16.6 + .3 lb. (74.0 ± 1 .3 N)
Free length after test 2.34 ± .03 in. (59.4 ± 0.8 mm)
(3) Collar for spring.
(4) 2S7235 Spring:

Test force 39 ± .03 lb. (1.75 + 0.13 IM)
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)

29
FUEL TRANSFER PUIVIP
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)
Thicl<ness 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)
Maximum permissible clearance betv\«en shaft
(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 1b. ft. (149 ± 20 Nm)

4IM7465 Gasket (plastic) 27 + 3 lb. ft. (38 ± 4 Nm)
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

C^TO
pump 25 to 32 psi (170 to 220 kPa)
(1) 4S6526 Spring for bypass valve:

Test force 3.16 ± .16 lb. (14.1 ± 0.71 N)


(SCROLL FUEL SYSTEM — Dl)
1
FUEL INJECTION
A-5P4158 GAUGE
TYPICAL EXAMPLE
Firing order (injection sequence) 1 , 3, 4, 2

°
without turbocharger 27 ± 1
(1) Torque for bushing 154 ± 11 lb. ft. (205 ± 15 N-m)
PUMP ASSEMBLY SPRINGS

INJECTION PUMP & TIMING DIMENSION
Fuel Injection (Cont.)

(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
A81478X1
INSTALL SPRING WASHERS AS SHOWN
B14464X1 5
(1) Torque for nut 9 ± 3 lb. ft. (12 ± 4 Nm) (4) 4N6681 Spring tor governor-
(2) 3P131 Spring: Color code (stripes) 2 purple
Length under test force 430 in. (10.92 mm) Put force on spring of 4.0 lb. (18 N)
Test force 21 ± .02 lb. (0.95 ± 0.09 N) Then add more force to make spring
Free length shorter by 90 in. (22.9 mm)
after test 85 in. (21.6 mm) Total test force 14.8 ± .48 lb. (67 ± 2 N)
Outside diameter 370 in. (9.40 mm) Free length
(3) Seat. Install a spring washer, flat washer and spring washer after test 2.24 ± .03 in. (56.9 ± 0.8 mm)
between seat (3) and spring (4) as shown. Outside diameter 1.373 in. (34.87 mm)
(4) 9L6446 Spring for governor:
(5) 4N5549 Spring for over-fueling:
Color code (stripes) 1 blue, 1 green Length under test force 209 in. (5.31 mm)
Put force on spring of 4.0 lb. (18 N) Test force 65 ± .03 lb. (2.9 ± 0.1 N)
Then add more force to make spring Free length after test 859 in. (21.82 mm)
Total test force 12.4 + .24 lb. (55 ± 1 N)
(6) Diameter of the outersurface of the cylinder
Free length (new) 1.2172 ± .0005 in. (30.917 ± 0.013 mm)
after test 2.24 ± .03 in. (56.9 ± 0.8 mm)
Bore in the gear
Outside diameter 1.371 In. (34.82 mm) (new) 1.2192 ± .0005 in. (30.968 ± 0.013 mm)
NOTE: Governor weights must pivot freely.

FUEL TRANSFER PUMP

(4N4864)

pump 25to32psi(170to220kPa)
(1) Bore of bearing (new) . . . .4953 ± .0003 In. (12.581 ± 0.008 mm)
(2) Deptti of bore In body
(new) 3750 ± .0003 in. (9.525 ± 0.008 mm)
Tfilcknessof gear(new) . . .3730 ± .0003 in. (9.474 ± 0.008 mm)
(3) Torque for nut 22 ± 5 lb. ft. (28 ± 7 N-m)
(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)
fvlaxlmum permissible clearance between
shaft and bearing (worn) 003 In. (0.08 mm)
(6) 8M3210 Spring:
Length under test force 1.212 In. (30.79 mm)

Test force 5.36 + .13 lb. (23.8 ± 0.58 N)
Outside diameter 41 In. (10.4 mm)
(7) Torque for plug when used with gasket:
4N7465 Gasket . . . 27 ± 3 lb. ft.(38 ± 4 Nm)

NOTE: Put a 8S6747 Sealer on face of pump body before
thin layer of
Installing pump cover. Do not let any of 8S6747 Sealer get Into the
pump.
35
(SCROLL FUEL SYSTEM — PC & Dl)
TIMING GEARS
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'Oi)
(2) End play for the cannshaft

(new/) 007 ± .003 in. (0.18 ± 0.08 mm)
Maximum permissible end play (worn) 025 in. (0.64 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)
IVIaximum 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)
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)
(4) Balancer shafts:
Diameter of balancer shaft bearing surface

(journal) (new) 2.0825 + .0005 in. (52.896 ± 0.013 mm)
Bore bearing for balancer
in
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

CAMSHAFT
NOTE: Put a layer of graphite grease on lobes of camsfiaft wfien

installing.
(1) Width of groove in cannshaft 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 0.1 5 mm)
Maximum permissible clearance between bearing and bearing
surface (journal) (worn) 008 in. (0.20 mm)
NOTE; Make reference to CYLINDER BLOCK for installation dimen-
sions.
(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) 74239- 1X1
VALVE ROCKER ARMS AND LIFTERS

(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 Nm)
(3) Clearance for valves;
Intake valves 015 in. (0.38 mm)

Exhaust valves 025 in. (0.64 mm) A156S6XI
(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)
37
VALVES
(PC)
NOTE: GUIDELINE FOR REUSABLE PARTS: VALVES AND VALVE

SPRINGS, Forms SEBF8002 and SEBF8034 have the procedure and
specifications necessary for checking used valves and valve springs.
(1) 7S7144 Spring for valves (new):
Length under test force 1.766 in, (44.86 mm)

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 lb. (640 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 invalve guide with guide
installed in the head
(new) 3733 ± .0010 in, (9.482 ± 0.025 mm)
râximum permissible bore (worn) 3771 in. (9.578 mm)
(4) Valve lip thicl<ness:
8N875 & 5S7232 Exhaust Valve

Use again minimum 106 in. (2.69 mm)
5S6449 Exhaust Valve
5S6452 Intake Valve
(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"

Valves (Cont.)
(PC)
(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)
I\înimunn permissible width of valve seat
(intake and exhaust) 045 in, (1.14 mm)
(11) Dimension from top of closed valve to face of head:
Iviaximum 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°
39
VALVES
(Dl)
NOTE: GUIDELINE FOR REUSABLE PARTS: VALVES AND VALVE

SPRINGS, Forms SEBF8002 and SEBF8034 have the procedure and
specifications necessary for checking used valves and valve springs.
(1) 7S7144 Spring for valves {new):

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) B9217X1
(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.

B9216X1
6N9915 Intake Valve and 7N573 Exhaust Valve.

(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)
(11) Dimension from top of closed valve to face of head:
Bore in head for valve seat insert for exhaust
valve 2.0005 ± .0005 in. (50.813 ± 0.013 mm) Minimum permissible dimension for 7N573 and
6N9916 Exhaust Valve 026 in. (0.66 mm)
Diameter of valve seat
insert for intake Minimum permissible dimension for
valve 2.0485 ± .0005 in. (5.032 ± 0.013 mm) 6N9915 Intake Valve . 006 in. (0.15 mm)
Bore in head for valve seat (12) Outside diameter of the face of the valve seat insert:
insert for intake

Exhaust seat 1.812 in. (46.02 mm)
valve 2.0455 ± .0005 in. (51.956 ± 0.013 mm)
Maximum permissible, exhaust seat 1.862 in. (47.29 mm)
(9) Angle of face of valve seat insert 30°
Intake seat 1.940 in. (49.28 mm)
(10) Maximum permissible width of valve seat
(intake and exhaust) 076 in. (1.93 mm) Maximum permissible, intake seat 1.990 in. (50.55 mm)
Minimum permissible width of valve seat (13) Angle to grind seat face of the insert to get
(intake and exhaust) 045 in. (1.14 mm) a reduction of maximum seat diameter 15°

40 PAGE OF SPECIFICATIONS- FOR GENERAL TIGHTENING TOROUES
GLOW PLUG POSITIONING
Cyl. Nos. 1, 2, and 3—3304* Cyl. No. 4—3304*

Cyl. Nos. 1 thru 4—3304"
'Engines with counterbored blocl(.

**Engines with spacer plate.
(A) Correct range for glow plug opening.

Put 5P3931 Anti-Seize Compound on the threads of the precom-
bustion chamber.
Put 5M2667 Gasket, with "2C" on on the precombustion cham-

it,
precombustion chamber in the cylinder head and

ber. Install the
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
tighten to 150 ± 10 lb. ft. (205 i 14 N-m)
41
CYLINDER HEAD
Thickness of cylinder head Step 2. Again tighten all bolts in number

(new) 3.938 ± .030 in. (100.03 ± 0.76 mm) sequence to 185 ± 13 lb. ft. (250 ± 17 N-m)
NOTE: Dimension from top of closed valve to face of cylinder head Step 3. Again tighten all bolts in number
must be according to the specifications in VALVES. sequence to 185 ± 13 lb. ft. (250 ± 17 Nm)
Put 5P3931 Anti-Seize Compound on threads and tighten bolts in the Step 4. Tighten all bolts in letter sequence
Step sequence that follov»/s: (hand torque only) to 32 ± 5 lb. ft. (43 ± 7 Nm)
Step 1. Tighten all bolts in number
sequence to 1 15 lb. ft. (155 Nm)
0^ 03 02 06
11
b o
4 5 10
.0 o o o o
VALVE COVER
77077X I
VIEW FROM RIGHT SIDE

OF ENGINE
Put 5H2471 Cement on the face of valve cover and top side of gasket.
Tighten bolts by number sequence

show/n to 96 24 1b. in. (10.9 ± 2.8 Nm)

EXHAUST MANIFOLD
Put 5P3931 Anti-Seize Compound on all threads.
(1) Torque for studs 20 ± 3 lb. ft. (25 ± 4 Nm)

(2) Torque for nuts holding exhaust
manifold 32 ± 5 lb. ft. (43 ± 7 Nm)
EXHAUST PIPE AND MUFFLER

Put 5P3931 Anti-SeIze Compound on threads
of bolts for clamps and
AIR CLEANER
(1) Tighten nuts that hold air filter
to elbow 20 ± 5 lb. ft. (25 ± 7 Nm)
(2) Tighten wing nuts to 35 ± 5 lb. in. (4.0 ± 0.6 Nm)
43
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.
CAUTION
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 turbo-
charger disassembly.
C. Put a small amount of lubricant, such as Lubriplate, on the nut seat area on the
compressor. Do not put lubricant on the threads.
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.

3304 VEHICULAR ENGINES
SPECIFICATIONS
TURBOCHARGER IMPELLER INSTALLATION

(AIResearch ONLY)
TEST FOR TYPE OF IMPELLER INSTALLATION

1. Install the proper thrust collar and seal carrier spacer on the
shaft-wheel assembly to be used.
2. Install impeller on shaft by hand.
3. Measure the distance between impeller and seal carrier at the

pointwhere 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."
TURBOCHARGER
(AiResearch T04B91)
46923-1X3
Make reference to ANALYZING TURBOCHARGER FAILURE, Form

No. FEG45138.
to GUIDELINES FOR REUSEABLE PARTS TURBO-

Make reference
CHARGERS, Form Nos. SEBF8018 & SEBF8019.
(1) Torque for impellernut 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.
Radial play for shaft:
(7)
(2) Torque for bolts holding

Minimum permissible radial play 003 in. (0.08 mm)
back plate 75 to 90 lb, in. (8.5 to 10.2 N-m)
Maximum permissible radial play 006 in. (0.15 mm)
(3) Put 5P3931 Anti-Seize Compound on threads
and tighten bolts holding compressor housing to center (8) Bore in the
section to 115 ± 15 lb. in. (13 ± 1.7 N-m) bearing 4010 to .4014 in. (10.185 to 10.196 mm)
(4) Put 5P3931 Anti-Seize Compound on Diameter of surface on shaft (journal)
threads and tighten bolts holding turbine housing to for the bearing 3997 to .4000 in. (10.152 to 10.160 mm)
center section to 115 ± 15 lb. in. (13 ± 1.7 N-m)
(9) Bore in housing... .6220 to .6223 in. (15.799 to 15.806 mm)
(5) Put 5P3931 Anti-Seize Compound on
Outside diameter of the
threads and tighten bolts holding turbocharger to
bearing 6182 to .6187 in. (15.702 to 15.715 mm)
manifold to 40 ± 4 lb. ft. (55 ± 5 N-m)
(10) Clearance between ends of oil
(6) End play for shaft:
mm)
seal ring 008 to .015 in. (0.20 to 0.38
Minimum permissible end play 001 in. (0.03 mm)
Diameter of bore for oil
Maximum permissible end play 004 in. (0.10 mm) seal ring 709 to .71 1 in. (18.01 to 18.06 mm)

TURBOCHARGER
(AIResearch T0490)

No. FEG45138.
Make reference to GUIDELINES FOR REUSABLE PARTS TURBO-

(1) Torque for impeller nut 20 lb. in. (2.3 N-m)

(6) End play for shaft 001 to .004 in, (0.03 to 0.10 mm)
Tighten nut an added 100°
(7) Radial play for shaft 003 to .007 in. (0.08 to 0.18 mm)
NOTE: Do not bend or add stress to the shaft when nut is tightened.
Bore in the
(2) Torque for bolts holding back bearing 4010 to .4014 in. (10.185 to 10.196 mm)
plate 50 ± 10 lb. in. (5.7 ± 1.1 N>m)
Diameter of surface on shaft (journal)
(3) Put 5P3931 Anti-Seize Compound for the bearing 3997 to .4000 in. (10.152 to 10.160 mm)
on threads and tighten bolt holding band
(8) Bore in housing . . .6220 to .6223 in. (15.799 to 15.806 mm)
clamp to 60 ± 10 lb. in. (6.8 ±1.1 N-m)
.
Outside diameter of the

threads and tighten bolts holding turbine
housing to 115 ± 15 lb. in. (13 ± 1.7 N-m) (9) Clearance between ends of oil

seal ring 008 to .015 in. (0.20 to 0.38 mm)
threads and tighten bolts holding turbocharger (10) Diameter of bore for oil
to manifold to 40 ± 4 lb. ft. (55 ± 5 N-m) seal ring 709 to ,71 1 in. (18.01 to 18.06 mm)
47
TURBOCHARGER
(AIResearch T1210 and T1224)
T98428X4

No. FEG45138.
Make reference to GUIDELINES FOR REUSABLE PARTS TURBO-

CHARGERS, Form Nos. SEBF8018 & SEBF8019. (5) Put 5P3931 Anti-Seize Compound on threads
of bolts holding turbocharger to
Put 5P3931 Anti-Seize Compound on tfireads of plug for exfiaust
manifold and tighten to 40 ± 4 lb. in. (55 ± 5 N-m)
elbow.
(6) End play for shaft
Put 5P3931 Anti-Seize Compound on bolts
(new) 006 to .011 in. (0.15 to 0.27 mm)
holding support for exhaust and
tighten to 45 ± 5 lb. ft. (60 ± 7 N-m) (7) Bore in the
(1) See TURBOCHARGER IMPELLER INSTALLATION.
Diameter of surface on shaft (journal) for
(2) Torque for bolts holding thrust
the bearing 6250 to .6254 in. (15.875 to 15.885 mm)
plate 35 ± 4 lb. in. (4.0 ± 0,5 N-m)
(8) Bore in housing . . . .9827 to .9832 in. (24.961 to 24.973 mm)
(3) Tighten bolt holding band
clamp to 120 ± 10 lb. in. (13.6 ± 1.1 N-m) Outside diameter of the
of bolts holding turbine housing and (9) Clearance between ends of oil
tighten to 175 ± 15 lb. in. (19.8 ± 1.7 N-m) seal ring 008 to .015 in. (0.20 to 0.38 mm)

TURBOCHARGER
I (Schwitzer 3LK)
73113X2

No. FEG45138.
Make reference to GUIDELINES FOR REUSABLE PARTS TURBO- (5) Maximum permissible gap of oil seal ring,
CHARGERS, Form Nos. SEBF8018 & SEBF8019. measured in bore of housing 007 in, (0,18 mm)
(1) End play for stiaft (6) See TURBOCHARGER INSTALLATION,
(new) 0045 ± .0015 In. (0.114 ± 0.038 mm)
(7) Bore in
Maximum permissible end play (worn) . . .008 in, (0.20 mm) housing 75025 ± ,00025 in, (19,0564 ± 0,0064 mm)
(2) Thickness of thrust Outside diameter of the
bearing 21 1 ± .001 in. (5.36 ± 0.03 mm) bearing 74625 ± ,00025 in, (18,9548 ± 0,0064 mm)
(3) Diameter of surface on shaft (journal) for Maximum permissible clearance between
the bearing 44015 ± .00015 in. (11.1798 ± 0.0038 mm) bearing and bore in housing 0045 in, (0,114 mm)
Bore in the (8) Thickness of each thrust
bearing 44165 ± .00015 in. (11.2179 ± 0.0038 mm) ring 1005 ± ,0005 in, (2,553 + 0,013 mm)
Maximum permissible clearance between (9) Torque for bolts holding
bearing and shaft 0018 in. (0.046 mm) impeller housing 60 lb, in, (6,8 N-m)
(4) Put 5P3931 Anti-Seize Compound on (10) Put 5P3931 Anti-Seize Compound on
threads and tighten bolt holding band threads of bolts holding turbocharger to manifold
clamp to 120 lb. in. (13,6 N-m) and tighten to 40 ± 4 lb, ft, (55 ± 5 N-m)
49
TURBOCHARGER
(Schwitzer 3LM)
A22019X2

No. FEG45138, (6) Thickness of thrust
Make GUIDELINES FOR REUSABLE PARTS TURBO-
reference to
CHARGERS, Form Nos. SEBF8018 & SEBF8019. (7) Bearing:
(1) End play for shaft (new) 002 to ,005 in. (0.05 to 0.13 mm) Bore in housing
for bearing 7500 to .7505 in. (19.050 to 19.063 mm)
(2) Put 5P3931 Anti-Seize Compound on threads and tighten
bolts holding impeller housing to 60 lb. in. (6.8 Nm) Diameter of surface of bearing
forhousing 7460 to .7465 in. (18.948 to 18.961 mm)
and tighten bolts holding turbine Diameter of surface of
housing to 11 to 12 lb. ft. (15 to 17 Nm) bearing for shaft 4415 to .4418 in. (11.214 to 11.222mm)
(4) Maximum permissible gap of oil seal ring, Diameter of surface of shaft for
measured in bore of housing 007 in. (0.18 mm) bearing (journal) 4400 to .4403 in. (11.176 to 11.184 mm)
(5) See TURBOCHARGER IIVIPELLER INSTALLATION. Length of bearing 2.425 to2.426 in. (61.60 to61.62 mm)

TURBOCHARGER
(Schwitzer F444, 4LF504 and E Models)
T97594X1
Make reference to ANALYZING TURBOCHARGER FAILURE, Form (4) Put 5P3931 AntiSelze Compound on threads and
No. FEG45138. tighten bolt holding band clamp to 120 lb. in. (13.6 N-m)
Make (5) Maximum permissible gap of oil seal ring,

reference to GUIDELINES FOR REUSABLE PARTS TURBO- measured In bore of housing
009 in. (0.23 mm)
(6) See TURBOCHARGER IMPELLER INSTALLATION.
(1) End play for stiaft (7) Bore In housing

(new) 0045 ± .0015 in. (0.114 ± 0.038 mm)
(new) 8762 to .8767 In. (22.255 to 22.268 mm)
Maximum permissible end play (worn) Outside diameter of the bearing
008 In. (0.20 mm)
(new) 8718 to .8722 in. (22.144 to 22.154 mm)
(2) Thickness of thrust bearing ... .211 ± .001 in. (5.36 ± 0.03 mm)
Maximum permissible clearance between bearing and
(3) Diameter of surface on shaft (journal) for the bore housing (worn)
In 006 in. (0.15 mm)
bearing (new) 5612 to .5615 in. (14.254 to 14.262 mm)
(8) Thickness of each thrust
Bore in the bearing 1005 ± .0005
ring in. (2.553 ± 0.013 mm)
(new) 5627 to .5630 in. (14.293 to 14.300 mm)
(9) Put 5P3931 Antl-Seize Compound on threads and
Maximum permissible clearance between bearing and tighten bolts holding turbocharger to
shaft (worn) 003 in. (0.08 mm) manifold to 40 ± 4 lb. ft. (55 ± 5 Nm)
51
OIL PUMP
(2P7830, 5S3876 & 7S9840)
(1) Diameter of the drive

shaft (new) 7407 ± .0003 in. (18.814 ± 0.008 mm)
Bore the bearings for the
in
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)
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)
(3) Length of gear 1 .9975 ± .0005 in. (50.737 ± 0.013 mm)
for gear 2,0008 ± .0008 in. (50.820 ± 0.020 mm)
Clearance between end of gear and
cover (new) 0033 ± .0013 in. (0.084 ± 0.033 mm)
(4) Diameter of the shaft for the drive idler
gear (new) 1.1225 1 .0005 in. (28.512 ± 0.013 mm)
Bore in bearing of gear
(new) 1.1260 ± .0019 in. (28,600 ± 0.048 mm)
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)
Bore in the bearing 7425 ± .0005 in, (18,860 ± 0,013 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) (8) 4J4790 Spring for pressure relief valve (clutch oil):
Clearance between shaft and Length under test force 1.548 in. (39.32 mm)
bearing (new) 0018 ± .0008 in. (0.046 ± 0.020 mm)
Test force 12.27 lb. (54.6 N)
Length of gear 9975 ± .0005 in. (25.337 ± 0.013 mm)
(9) Torque for nut holding drive gear 60 lb. ft. (80 N-m)
for gear 1.0008 ± .0008 in. (25.420 ± 0.020 mm) Tighten farther to get alignment for cotter pin.

OIL PUMP
(781849 & 7S9461)
(1) Diameter of the drive shaft

(new) 8747 ± .0002 in. (22.217 ± 0.005 mnn)
Bore inthe 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)
bearing (new) 0035 ± .0024 in. (0.089 ± 0.061 mm)
(3) Diameter of the shaft for the
idler gear (new) 8747 ± .0002 in. (22.217 ± 0.005 mm)
Bore in the bearing. .8763 ± .0003 in. (22.258 ± 0.008 mm)
bearing (new) 0016 ± .0005 in. (0.041 ± 0.013 mm)
(4) 1S3921 Spring for pressure relief valve:

Test force 39.8 ± 3.2 lb. (177.5 ± 14.0 N)

(5) Length of gear 1 .4988 ± .0010 in. (38.070 ± 0.025 mm)
forgear 1.5038 ± .0008 in. (38.197 ± 0.020 mm)
Clearance between end of gear
and cover (new) 0050 ± .0018 in. (0.127 ±0.046 mm)
(6) Length of gear 2.0003 ± .0010 in. (50.808 ± 0.025 mm)
for gear 2.0053 ± .0008 in. (50.935 ± 0.020 mm)
Clearance between end of gear
and cover (new) 0050 ± .0018 in. (0.127 ± 0.046 mm)
(7) Torque for nut holding drive gear 60 lb. ft. (80 N-m)
Tighten farther to get alignment for cotter pin.
53
OIL PUMP
(2P1785 and 6N2642)
ta-.^j„.^
(1) Bore in bearing of idler

gear 1 .1260 ± .0024 in. (28.600 ± 0.061 mm)
Diameter of shaft for
idler gear
thie
1.1255 ± .0005 in. (28.588 ±0.013 mm)
I80o)
Clearance between bearing and
stiaft 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 Step 3. Run the engine to get the oil temperature at 210° F (99° C).
to be usable.
NOTE: A 5° F (3° C) increase in oil temperature gives approximately
Step 1. Besure that the engine is filled to thecorrect level with either 1 psi (7 kPa) decrease in oil pressure.
SAE 10 or SAE 30 oil. If any other viscosity of oil is used, the
information in the ENGINE OIL PRESSURE CHART does
Step 4. Keep the engine oil temperature constant. With the engine at
not apply.
therpm from the chart, read the pressure gauge.
Step 2. Find a location on the engine oil manifold to install a tee. The
Make a comparison between the pressure reading on the test gauge
and the minimum permissible pressure from the ENGINE OIL PRES-
easiest method is to remove the sending unit for the present
gauge and install a tee at this location. Install a probe from
SURE CHART. If the pressure reading on the test gauge is below
the minimum permissible pressure, find the cause and correct it.
the 9S9102 Thermistor Thermometer Group in one side of
Operation of the engine with low oil pressure can be the cause of
the tee. Connect a 8M2744 Gauge from the 5P6225 Hydraulic
engine failure or of a reduction in engine life.
Test Box to the other side of the tee.
ENGINE OIL PRESSURE CHART

)
OIL FILTER
(7S6638, 7S6639 & 9S1806)
(1 Torque for the bolt 20 + 5 lb. ft. (25 ± 7 Nm)

(2) 6F8007 Spring for oil filter bypass valve:
Length under test force 2.43 in. (61 .7 mm)

Test force 5.2 to 6.1 lb. (23 to 27 N)

7S6638 Filter only:
(3) 6F8007 Spring for oil cooler bypass valve:

Free length after test 3.61 In. (91.7 mm)

OIL BREATHER CAP
(1) Torque for bolt holding

breather cap 120+ 24 1b. in. (13.6 ± 2.8 N-m)

WATER PUMP
(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. the seal and ring together

Install 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 with the seal group) until the car-
is
bon face makes contact with the shiny face of the ring (2).
d. Install the spring.
(4) Torque for the bolt that holds the

impeller 28 1 lb. ft. (39 ± 1 Nm)
(5) Torque for bolt that holds the
gear 32 51b. ft. (43 ± 7Nm)
V-BELT TENSION CHART

RADIATOR
T93973
TOP TANK WITH 5S1218 PRESSURE A59222XI

RELIEF VALVE
TIGHTENING PROCEDURE FOR TYPICAL TWO-ROVI/ TANK
Clean the threadsof the studs with 8M8060 Quick Cure Primer.
Then put 9S3265 Retaining Compound on the threads before in-
stalling them.
(1) Torque for stud for the

cap
filler 40 l 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. Hs (422 mm HjO)
(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:

o o o o o o
Vacuum relief valve to open
at a maximum of 1 psi (7 kPa)
Pressure relief valve must not leak at 14 psi (95 kPa)
5-
i^ -I
Pressure relief valve must be open at 18 psi (125 kPa) O o O O O O O O O O Oo
(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 TIGHTENING PROCEDURE FOR
not required on the bottom tank. TYPICAL THREE-ROW TANK

WATER TEMPERATURE REGULATOR
7N208 Regulator:
Temperature when completely open 195= F (90 "
C)
77719X1
Minimum open distance 375 in. (9.53 mm)
9S3808 and 4H1991 Regulator:

Temperature when completely open 185° F (85° C)
Minimum open distance 310 in. (7.87 mm) 85312X1
COOLANT FLOW SWITCH
4N9072 SWITCH (John W. Hobbs Number 22258)

(1) Terminal connected to insulated contact. The other contact is
connected to the body of the switch. Switch contacts are nor-
mally 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
installed in engine cooling system, the
is
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.
59
CYLINDER BLOCK
(Counterbored Block)
(1) Depth of bore in block
for liner 401 ± .001 in. '10.19 ± 0.03 mm)
NOTE: For fieighit of liner over top of block make reference to CYL-
INDER 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 installcamshaft
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 in-
stalled 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 block for main
in
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)
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 block for
in
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: bearing caps with the part

Install number toward the front
of the engine. Be sure that the mark (number) on the bearing cap
next to the bolt hole is in agreement with the mark in the cylinder
block.
CAUTION
There are holes the bores for the main bearings, between
in ( 1
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).
(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)
Llfir/-
A261 07-1X3
front face of block 88 ± .02 in. (22.4 ± 0.5 mm)

CYLINDER BLOCK
(With Spacer
\ r Plate)/
(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 the front of the block must be in-
at
stalled 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 block for main
in
bearings .020 in. (0.51 mm
oversize) 3.8360 ± .0005 in. (97.434 ± 0.013 mm)
bearing bore to top of cylinder
block (new) 15.099 ± .006 in. (383.51 ± 0.15 mm)
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 B4 2697 XI
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,
CAUTION
Ttiere are holes in the bores for the main bearings, between
cylinders 1 and 2, and 3 and 4 for piston cooler orifices. These
holes must have either orifices (10) or plugs (9) installed.
NOTE: If 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).

top of block 780 ± .020 in. (19.8 ± 0.5 mm)
Distance to install stud from
(12)
face of block 62 ± .02 in. (15.7 ± 0.5 mm) Lltrr/J
A261 07-1X3
front face of block + .02 in. (22.4 ± 0.5 mm)
61
CYLINDER LINER
NOTE: Make reference to GUIDELINE FOR REUSABLE PARTS: PIS-

TONS AND CYLINDER LINERS, Form No. SEBF8001.
I
I
(1) Bore in liner

(new) 4.751 ± .001 in. (120,68 ± 0.03 mm)
Use again maximum bore when measured near upper end of tfie
wear surface of tfie cylinder liner 4.755 in. (120.78 mm)
(2) Ttiickness 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 0-rings. Install 0-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). T8832I - 1X1
CYLINDER LINER PROJECTION

(Counterbored Block)
IVIake reference to CYLINDER LINER PROJECTION in Testing and

Adjusting for tfie complete procedure.
A34793Xt
1. Install tooling as sfiown. Tighten bolts (1) evenly in four steps:
1st step 5 lb. ft. (7 N-m)
2nd step 15 lb. ft. (20 Nm)

3rd step 25 lb. ft. (35 Nm)
4th step 50 lb. ft, (70 Nm)
2, fvleasure cylinder liner projection with dial indicator (7) clamped
in 1P2402 Gauge Body (6) as shown, IVIeasure 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)
IVIaximum 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)
projection of all cylinder liners under one
cylinder head 003 in, (0,08 mm)
NOTE: If liner projection is not correct, turn the liner to a new position
within the bore. If projection can not be corrected this way, move the
liner to a different bore. If the projection can not be corrected this
way, make reference to Special Instruction, Form No, FM055228 for
complete instructions on the use of 8S3140 Counterboring Tool
Arrangement,
SHIM THICKNESS, COLOR CODE, AND PART NUMBER
(1) Bolts [5/8" NC, 5.5 in, (140 mm) long).
(2) Crossbar (from 8B7548 Push-Puller)
(3) 4B4281 Washers
(4) 1 P2394 Adapter Plate
(5) 3H465 Plates

(6) 1P2402 Gauge Body
(7) 1P2403 Dial Indicator
CYLINDER LINER PROJECTION

(With Spacer Plate)
Make reference to CYLINDER LINER PROJECTION in Testing and

Adjusting for the complete procedure.
1. Install gasket and spacer plate (2) witti bolts (3) and two 1S379
Wasfiers. Tighiten bolts (3) evenly in four steps:
1st step 10 lb. ft. (14 Nm)

2nd step 25 lb. ft. (35 Nm)
4th step 70 lb. ft. (95 Nm)
2. Install tools as shown. Tighten bolts (4) evenly In four steps:
1st step 5 lb. ft. (7 Nm)

2nd step 15 lb. ft. (20 N-m)
4th step 50 lb. ft. (70 Nm)
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 00 13 to .0069 in. (0.033 to 0.1 75 mm)
Maximum permissible difference between all
four measurements 002 In. (0.05 mm)

Maximum permissible difference between average projection
ofany two cylinder liners next to
each other 002 in. (0.05 mm)
projection of all cylinder liners under one
cylinder head 003 in. (0.08 mm)
NOTE; If liner projection is not correct, turn the liner to a new position
within the bore. If projection can not be corrected this way, move the
liner to a different bore. If the projection can not be corrected this
way, make reference to Special Instruction, Form No. FM055228 for
complete instructions on the use of 8S3140 Counterboring Tool
Arrangement.
SHIM THICKNESS, COLOR CODE, AND PART NUMBER

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

PISTONS AND RINGS

Make reference to GUIDELINE FOR REUSABLE PARTS: PISTONS AND CYLINDER LINERS. Form No. SEBF8001.
CONNECTING ROD
(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)
(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)
8r^6487 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 Nm)

B09139X2
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 connect-
ing rods.

CRANKSHAFT
) 2
(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.
THRUST PLATE USAGE CHART
(2) Make reference to MAIN BEARINGS and BEARING SURFACE
(JOURNAL) FOR MAIN BEARINGS.
(3) Make reference to CONNECTING ROD BEARINGS and BEAR-
ING SURFACE (JOURNAL) FOR CONNECTING RODS.
(4) Tighten plugs to 17 ± 3 lb. ft. (23 ± 4 Nm)
Then "stake" the crankshaft to hold plugs in place. "STAKE" use
a center punch and a hammer to change the shape of the hole
as shown.
(5) Crankshaft gear:
Do 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 tooling for installing wear sleeves
and seals.
BEARING SURFACE (JOURNAL)

FOR MAIN BEARINGS
A06090X1
BEARING SURFACE (JOURNAL) FOR MAIN BEARINGS

BEARING SURFACE (JOURNAL)

FOR CONNECTING RODS
A06090X1
BEARING SURFACE (JOURNAL) FOR CONNECTING RODS

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

FAN DRIVE
V///
(1) Fill chamber between bearings half full of 1P808 Grease before
bolts are tightened.
71
FLYWHEEL RING GEAR
(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.
CAUTION: Do not heat ring gear to more than 600°F (316°C) before
installing on the flywheel.
FLYWHEEL HOUSING
TIGHTENING
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.
TYPICAL ILLUSTRATION

FLYWHEEL
Face Runout (axial eccentricity) of the Flywheel:
1. the dial indicator as shown. Put a force on the flywheel

Install
toward the rear.
2. Set the dial indicator to read .000 in. (0.0 mnn)
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 eccentric-
ity) of the flywheel.
CHECKING FACE RUNOUT OF THE FLYWHEEL
CHECKING FLYWHEEL BORE
Bore Runout (radial eccentricity) of the Flywheel:
1. Install the dial indicator (3) and make an adjustment of the uni-
versal 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 eccentric-
ity) of the flywheel.
5. Runout (eccentricity) for the bore for the pilot bearing for the fly-
wheel clutch, must not exceed .005 in. (0.13 mm)
CHECKING FLYWHEEL CLUTCH
PILOT BEARING BORE
73
FLYWHEEL HOUSING
8S2328 DIAL INDICATOR GROUP INSTALLED

Face Runout (axial eccentricity) of the Flywheel Housing:
1. Fasten a dial indicator to ttie cranl<shaft 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. C (TOP)
A (BOTTOM)

)
3304 VEHICULAR ENGINES

SPECIFICATIONS
C (TOP)
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 cranl<shaft up against the top bearing.
Write the measurement tor 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 cranl<shatt counterclocl<wise to put the dial indicator at

(B). Write the measurement in the chart.
5. Turn the cranl<shaft counterclockwise to put the dial indicator at

(C). Write the measurement in the chart.
6. Turn the crankshaft counterclockwise to put the dial indicator at

(D). Write the measurement in the chart.
7. Add lines I & II by columns.

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

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 941-951 Track Type Loaders

Tighten the bolts which hold the front Tighten the bolts which hold the front support
support to the frame to 400 ± 40 lb. ft. (540 + 55 N to the frame to 460 ± 50 lb. ft. (624 t 70 Nm)
Solid rear brackets only: Tighten the bolts which hold thB block on the flywheel
housing to the frame to 460 ± 50 lb. ft. (624 ± 70 N-m)
Tighten the bolts which hold the rear
brackets together to 400 ± 40 lb. ft. (540 ± 55 N 955 Track Type Loader
Tighten the bolts which hold the rear Tighten the bolts which hold the front support
brackets to the frame to 225 + 25 lb. ft. (300 ± 35 N m) to the frame to 460 ± 50 lb. ft. (624 ± 70 Nm)
225 Excavator
Tighten the bolts which hold the support
for the hydraulic pump drive housing to the
frame to 350 + 35 lb. ft. (470 ± 45 N
FLEXIBLE COUPLING DRIVE

(6P3983, 6P3984, 6P5020)
(1) Torque for bolts 80 ± 5 lb. ft. (1 10 ± 7 N-m)
(2) Torque for bolts 95 ± 5 lb. ft. (130 ± 7 Nm)

(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.

FLEXIBLE DRIVE COUPLING

(Earlier; Two Piece Front Flange)
TO413
(1) Torque tor bolts 80 ± 5 lb. ft. (1 10 ± 7 Nm)
(2) Torque for bolt holding flange
to drive 160 ± 10 lb. ft. (219 ± 14 Nm)
(3) Maximum permissible "runout" axial alignment of face
(total indicator readingi 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)
FLEXIBLE DRIVE COUPLING

(Earlier; One Piece Front Flange)
(1 ) Torque for bolts 80 ± 5 lb. ft. (1 10 ± 7 Nm)

(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)
77
.
CHECKING AND ADJUSTING ALIGNMENT OF THE

FLEXIBLE COUPLING DRIVE
A09406- 1X1
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
7m940 Universal Attachment), and 7H1945 Holding Rod into the
7H1948Snug.
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 measure-
ment 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.
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)1 .
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 align- A09407- X
1 1
ment 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 is off by a large amount, inspect for the cause.

the alignment
If the frame is can be straightened. If the engine front support
bent, it
is badly worn, a replacement is needed.

ALTERNATORS
7S5897 24V 19A (Prestolite Number ANB6001)

9S4070 24V 19A (Prestolite Number ANB7001 )*
Rated output at 28V 19 A

Output at 1 500 rpm and 28V 1 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. (1 15 to 120 Nm)
(2) Torque for bolts 25 to 30 lb. in. (2.8 to 3.4 Nm)
(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 Nm)
(5) Torque for bolts holding the
regulator 45 to 50 lb. in. (5.1 to 5.7 Nm)
•Including the 9S2329 Regulator (Prestolite Number VSH6401)
2P1698 24V 19A (Prestolite Number ANB6002 or ANB6004)

2P1204 24V 19A (Prestolite Number ANB7002 or ANB7004)*

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 Nm)
(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 Nm)
(4) Torque for bolts 25 to 30 lb. in. (2.8 to 3.4 Nm)
(5) Torque for bolts holding
regulator 45 to 50 lb. in. (5.1 to 5.7 Nm)
(6) Torque for nut for terminal 45 to 50 lb. in. (5.1 to 5.7 Nm)
(7) Torque for nut for positive
terminal 225 to 250 lb. in. (25.4 to 28.3 Nm)
4N5938 or 6N3821 Regulator
•Including 2P1699, (Prestolite Number
VSH-6401A, VSH-6401B or VSH-6401C).
79
Alternators (Cont.)
6N9294 24V 35A (Delco-Remy Number 1117640)

Rotation can be either direction.
Polarity is negative ground-
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

(1) Torque for nut holding pulley 75 ± 5 lb. ft. (100 ± 7 N-m)
(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)

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

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
n (1)
(2)
Torque for nut holding pulley
Torque for output terminal

75
10
±
±
5 lb. ft.
1
(100 ± 7
lb. ft. (14 + 1

Nm)
Nm)
3P77 24V (Delco-Remy Number 1102398)
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 Nm)
(2) Torque for pulley nut 60 + 5 lb. ft. (80 ± 7 Nm)
81
Alternators (Cont.)
5A8908 24V 20A (Mitsubishi Number AR4020A)

Rotation is clocl<wise 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° CI 29.5 ohms
Tension of brush spring 1 1 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 Nm)
Torque for nut holding slip rings 35 lb. ft. (45 IMm)
3A1997 24V 19A (Paris-Rhone Number A13RH3T)

Rotation is clockwise when seen from drive end.
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 Nm)
(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 Nm)

)
ALTERNATOR REGULATOR
6N3821 24V (Prestolite Number VSH-6401C)

4N5938 24V (Prestolite Number VSH-6401B)
2P169g 24V (Prestolite Number VSH-6401A)
9S2329 24V (Prestolite Number VSH-6401)
Voltage setting range at 70° F (21°C) 27.3 to 28.7 V

(1) Adjustment screw and washer.
•With voltage adjustment screw (Din position

"N" (center). When screw (II is in position
"L", voltage will be 0.5V less. When screw (1
is in position "H", voltage will be 0.5V higher.
5A9131 24V (Mitsubishi Number RM4140G)

Voltage range at 3000 rpm 28 to 31 V
83
L
)
GENERATORS
4M9102 24V 20A (DelcoRemy Number 1106971)

Rotation is clocl<wlse when seen from tlie drive end.
Circuit A
Speed for testing 1 720 rpm
Field current at 24V and 80° F (27° C) 83 to .89 A
Output at 1 720 rpm and 26V wfien cold 20 A

Output wtien cold 26 V
(1 Tension of brusfi spring 20 oz. (5.6 N)

1^
pulley 83 ± 8 lb. ft. (114 ± 11 Nm)
1S151 24V 15A (DelcoRemy Number 1105241)
Rotation is clockwise when seen from the drive end.
Circuit A
Field current at 24V and 80° F (27° C) 94 to 1 .02 A
e a _
Output at 1800 rpm and 28.5V when cold 15 A
Output when cold 28.5 V
(1 Tension of brush spring 16 oz. (4.4 N)

pulley 83 ± 8 lb. ft. (1 14 ± 1 1 IMm)
1S5134 24V and 25A (Oelco-Remy Number 1106887)
Circuit A
Field current at 24V 80° F (27° C) 83 to.89 A
Output at 1 700 rpm and 26V when cold 20 A
Output when cold 26 V
(1) Tension of brush spring 20 oz. (5.6 N)

pulley 60 ± 10 lb. ft. (80 ± 14 Nm)
Generators (Cont.)
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 1 5 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)

Speed for testing with a load (less than) 1600 rpm

Output with a load 28 V
Output at below 1600 rpm and 28\/ 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
2M6497 24V 15A (Delco-Remy Number 1119626)

Polarity is negative ground or insulated.
Circuit A
(1) Cutout relay:
Air gap between armature and core 01 7 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:
Air gap between armature and core 067 in. (1 .70 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)
85
Generator Regulators (Cont.)
4M9349 24V 20A (Delco-Remy Number 1119653)

Polarity is negative ground or insulated.
Circuit A
(1) Cutout relay:

core 015 to .019 in. (0.38 to 0.48 mm)
Voltage closing range 22.8 to 25.2 V

core 068 to .082 in. (1 .73 to 2.08 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 Mm)
3S5028 24V 25A (DelcoRemy Number 11 19306 and 1119306-E)
Circuit A
(1) Cutout relay:

core 015 to .019 in. (0.38 to 0.48 mm)
Voltage closing range 24 to 27 V

core 068 to .082 in. (1 .73 to 2.08 mm)
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 Nm)

Generator Regulators (Cont.)
3A1874 24 V (Paris-Rhone Number 2T216)

(1) Cutout relay:
Air gap between armature and core 027 in. (0.69 mm)
Point gap 031 in. (0.79 mml
Closing range when cold 24.0 to 26.0 V
Air gap between armature and core 039 In. (0.99 mm)
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:

core 043 to .055 in. (1.09 to 1.40 mm)
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:

core 039 to .047 in. (0.99 to 1.19 mm)
Back gap 029 to .043 in. (0.74 to 1.09 mm)
Regulator setting (no load) at 3000 rpm . . 27.5 to 29.5 V
Current regulator:

core 047 to .055 in. (1.19 to 1.40 mm)
Back gap 029 to .043 in. (0.74 to 1 .09 mm)
Current limiter setting range at 3000 rpm 14 to 16 A
5A7385 (Mitsubishi Number RT4342E)

Cutout relay:
Air gap between armature and core 051 in. (1.30 mm)
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:

core 079 to .087 in. (2.01 to 2.21 mm)
Regulator setting (no load) at 3000 rpm 28 to 29 V
Current regulator:

core 051 to .069 in. (1 .30 to 1 .75 mm)
Current limiter setting range at 4000 rpm 24 to 26 A
87
STARTER MOTORS

9M1662 24V (Delco-Remy Number 1113967)
4N3182 24V (Delco-Remy Number 1114711)
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)
(1) Tension of brush spring 56 oz. (15.6 N)
(2) Torque forscrews 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)



(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)

"Minimum for leaf springs 80 oz. (22 N)
7N1285 24V (Delco-Remy Number 1113472) 3T2772 24V (Delco-Remy Number 1113540)
Rotation is clockwise when seen from drive end. Rotation is clockwise when seen from drive end.
Minimum speed with no load 5500 rpm Minimum speed with no load 5500 rpm
Maximum speed with no load 7500 rpm Maximum speed with no load 7500 rpm
Current consumption (draw) at no load: Current consumption (draw) at no load:
Minimum with solenoid at 20V 85 A Minimum with solenoid at 20V 60 A

Maximum with solenoid at 20V 1 12 A Maximum with solenoid at 20V 120 A
Clearance between pinion and housing Clearance between pinion and housing
(pinion clearance) 010 to .140 in. (0.25 to 3.56 mm) (pinion clearance) 33 to .39 in. (8.3 to 9.9 mm)
(1) Tension of brush spring 36 to 40 oz. (10.0 to 11.1 N) (1) Tension of brush spring 36 to 40 oz. (10.0 to 11.1 N)
(2) Torque screws holding nose

for (2) Torque for screws holding nose
housing to lever housing 13 to 17 lb. ft. (18 to 23 N-m) 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) (3) Torque for terminal nuts 20 to 25 lb. ft. (25 to 35 N-m)

Starter Motors (Cont.)

3T2647 24V (Delco-Remy Number 114845)
iVIInimum speed witii no load 5500 rpm


(pinion clearance) 33 to .39 in. (8.3 to 9.9 mm)
(2) Torque screws holding nose housing
for
to lever housing 13 to 17 lb. ft. (18 to 23 N-m)


(pinion clearance) 33 to .39 in. (8.3 to 9.9 mm)
(2) Torque for screws holding nose
housing to lever housing 13 to 17 lb. ft. (18 to 23 N-m)
7S5900 and 2P2501 24V (Prestolite Number MFY 6201 K)

3P6 24V (Prestolite Number MFY 6401 K)
4N7901 24V (Prestolite Number MFY 6401 L)
Minimum no load speed 5000 rpm

Maximum at 20V 65 A
(1) Tension of brush spring 52 to 65 oz. (14.5 to 18.1 N)
(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:
Maximum at 20V 77 A
(1) Tension of brush spring 80 to 90 oz. (22.2 to 25.0 N)
(2) Torque for housing bolts 8 lb. ft. (1 1 N-m)

(4) Clearance between pinion and housing
(pinion clearance) 020 to .050 in. (0.51 to 1 .27 mm)
89
)
9G4337 24V (Presfolite Number MFY6601K)

Rotation Is clockwise when seen from ttie drive end-

Maximum at 207 65 A
(1) Torque for bolts 8 lb. ft. (11 N-m)

(2) Torque tor terminal nuts 20 to 25 lb, ft. (25 to 35 N-m)
(3) Clearance for ttie pinion . . . .020 to .050 in. (0.51 to 1.27 mm)
3T6305 24V (Robert Bosch Number 0-001-430-03)

Rotation is clockwise wtien seen from ttie drive end.
Minimum 140 A
Permissible clearance between

pinion and ring gear 06 to .22 in. (1.5 to 5.6 mm)
(1 Torque for terminal nuts 20 to 24 lb. ft. (27 to 33 N-m)
(2) Minimum permissible lengtti of

thie brusties 69 in. (17.5 mm)
(3) Minimum permissible diameter of
commutator 1.9 in. (48 mm)

3A2035 24V (Paris-Rhone Number D13 E76)

3A 1872 24V (Paris-Rhone Number D13 E77)
Rotation is clocl<wise when seen from drive end.
iVIaximum 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)
(1) Tension of brush spring 53.3 ± 5.3 oz. (14.8 i 1.5 N)
(2) Torque for screws holding support to

lever housing 15 ± 2 lb. ft. (20 ± 3 Nm)
(3) Torque for terminal nuts 20 to 25 lb. ft. (25 to 35 IMm)

flotation is clockwise when seen from drive end.
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
r^ 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)
(3) Torque for terminal nuts 20 to 25 lb. ft. (25 to 35 Nm)
5A6492 and 5A3031 (IMitsubishi Number MX 10/24 ZR)
5A6494 and 5A3196 (Mitsubishi Number MT 10/24 YR)


Maximum at 23V 110 A

Stall torque test:
Maximum current consumption (draw) at 9V

(maximum) 1500 A
Stall torque at 9V (minimum) 79.6 lb. ft. (108.1 Nm)
(1 ) Minimum permissible diameter of the
(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)

(pinion clearance) 1 18 to .138 in. (2.99 to 3.51 mm)
91
5A6522 (Mitsubishi Number MRA 7 5/24 ER or IV1OO7T03774)
5A6495 (IVIitsubishi Number IVIRE 7 5/24 ER)
5A5744 (IVIitsubishi Number MTR 7 5/24 YR)

Maximum at 23V 1 10 A
Stall torque test:
Maximum current consumption (draw) at 9V

(maximum) 1500 A
Stall torque at 9V (minimum) 80 lb. ft. (1 10 N-m)
(1) Minimum permissible diameter of the

(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)

(pinion clearance) 1 18 to .138 in. (2.99 to 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
(1) 7M7553 Spring:


(2) 7M7622 Spring:

Test force 2.65 to 3.25 lb. (1 1 .60 to 14.00 N)

9F3099 24V (Delco-Remy Number 0001481)

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 Mm)
5L5886 12V (Delco-Remy Number 0001486)
302266 or 9N964 12V (Delco-Remy Number 1119828)
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 Nm)

STARTER SOLENOIDS
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:

Test force 8.5 to 9.5 lb. (37.8 to 42.3 N)
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)
6NS123 24V (Delco-Remy Number 1115544)
Current at 20V 40 to 45.5 A

Current at 20 to 24V 40 to 54.6 A
(1) 4M1815 Spring for contact release:
Length under test force .•

42 in. (10.7 mm)

(2) 9M7609 Spring to return the clutch lever:

Test force 14 ± .5 lb. (62 ± 2.2 N)

(3) Torque for terminal screws . . 16 to 30 lb. in. (1 .8 to 3.4 N-m)
93
Starter Solenoids (Cont.)
Current at 20V 40 to 45.5 A
Current at 20V to 24V 40 to 54.6 A
(1) 4M1815 Spring for contact release;


(2) 9M7609 Spring to return the clutch lever:

Test force 14 + .5 lb. (62 ± 2.2 N)

(3) Torque for terminal screws . . 16 to 30 lb. in. (1.8 to 3.4 N-m)

B38473X1
Pull in winding at 5V 9 to 11.5 A
Hold in winding at 20V 6.8 A IVIaximum
(1) Torque for nuts 20 to 25 lb. ft. (27 to 33 N-m)

Starter Solenoids (Cont.)
3T868 24V (Robert Bosch Number 0331 410 002)

Resistance:
Pull in winding 513 to .567 ohm

Resistance:
B38474X1
Hold in winding 3.28 to 3.62 ohm
r^
3T3369 24V (Presfolite Number SAT-4105)
9S7976 24V (Preslolite Number SAT-4103)
8S1529 24V (Prestolite Number SAT-4101)
Current pull windings V

if=
in at 12 23.2 to 26.6 A
Current pull in windings at 20 to 24 V 38.6 to 52.4 A o
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 CED65I

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)
Free length after test 433 i .010 in. (11.00 ± 0.25 mm)
(2) Spring to return the clutch lever:

Test force 13.2 ± 1.3 lb. (58.5 ± 5.8 N)
Outside diameter 45 in. (1 1.4 mm)
95
FUEL PRESSURE INDICATOR
6N3272 Indicator (Frank W. Murphy Mfr. Inc.)
Gauge with color code.
CALIBRATIOIM CHART
OIL PRESSURE INDICATOR
5M1065 Indicator (Stewart Warner Corp. Number 342-FR)

Gauge with color code.
CALIBRATION CHART
o
n
o
®
CITERPILLAR
o.
SENR7590-01
Printed In U.S.A. (10/81)

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® FORM NO.

CATERPILLAR FOR USE IN SERVICE MANUALS:

n VOLUME SPECIFICATIONS, REG01312

have the most current information which is available.

CYLINDER AND VALVE IDENTIFICATION

Electrical System Lubrication System

GENERAL TIGHTENING TORQUE FOR

TORQUE FOR FLARED AND 0-RING FITTINGS

THREAD 9/16 THREAD 1 3/16

TORQUE 5 11 16 20 30 TORQUE 50 55 75 90 110 135 160 310

ASSEMBLY OF FITTINGS WITH

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

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

2. To put the fitting assembly in its correct position

FUEL SYSTEM USAGE CHART

(II Torque for bolts which hold service meter or adapter

ELECTRIC SERVICE METER

Operating voltage 24V DC only

n (2) Tighten bolts which hold adapter for

FUEL INJECTION EQUIPMENT

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

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 tiole for

Bore in the rear bearing for the (4) Governor spring:

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

(SLEEVE METERING FUEL SYSTEM — PC)

Fuel Injection Equipment (Cont.)

Fuel Injection Equipment (Cont.)

(7) Torque for bushing 70 ± 5 lb. ft. (95 ± 7 Nm)

Free length after test 1.566 in. (39.78 mm)

(13) Put 5P3931 Anti-Seize Compound on threads of glow plug

(14) Tighten nozzle finger tight on body.

(15) Torque for precombustion chamber

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

(SLEEVE METERING FUEL SYSTEM — PC)

Fuel Injection Equipment (Cont.)

(16) Torque tor bolts holding clamps on tuel Injection lines;

With rubber damper 84 ± 24 lb. in. (9.6 ± 2.8 Nm)

(17) Lever assembly.

(18) Clearance between lever assembly (17) and governor

Color code (stripes) 1 white

Length under test force 584 in. (14.83 mm)

Free length after test 1.21 in. (30.7 mm)

Color code (stripes) 1 red

Length under test force 584 in. (14.83 mm)

Free length after test 1 .04 in. (26.4 mm)

Length under test force 584 in. (14.83 mm)

Free length after test 1,016 in. (25,81 mm)

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)

(SLEEVE METERING FUEL SYSTEM — PC)

Fuel Injection Equipment (Cont.)

(21) 9S8632 Low Idle Spring:

Length under test force 1 .20 In. (30.5 mm)

Free lengttn after test 2.00 in. (50.8 mm)

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST

(SLEEVE METERING FUEL SYSTEM — PC)

FUEL TRANSFER PUMP

(1) Diameter of shaft for idler gear

(2) Thickness of gears

FUEL RATIO CONTROL