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SPECIFICATIONS 3208 DIESEL TRUCK ENGINE Index Specifications (Section 1) bi Compressr 19 fteraters An gulatrs 135 Auras Trg Advance Unt fe Bearings For Connecting Rods And Mains 128 Canshat +10 Gonoctng od tot Ganchat 128 Granta Seas 1 Grarkease Verleion ave My Gyinder Block 123 Shinde Head. ne Drive Gear For The ection Pap 19 Engine Design 1 Ene 01 Coo And itr vie Extoue Manis i Fan Mounting Ply Asseries 123 Fito 10 Fywnoa ous Bare rs Fon Hwsing cad 132 Fiyuheel Rout mers Fe ler Bese 1 Foolinacton Pump wossovocncoscnoe i Fao Transl Puro a Go 15 Ijction Nozzles wv Mounting Group For ATS4D, MT643, and MTESQ Aeon Taner 131 Ol Level Gauge. 121 OiPen 121 SiPume 1 Fstons And Rings (wo rng piston 135 Peters ang rings een pst) te Paley And Damper te Starter Moor Sloois M1 Sater Neto 13 Sot sarod va Tuocharaer 8 Tvocargetriirtlation i Vale Covers ne Valve Rocker Arms And Lifters Valve Seals And Inseris 442 mad Valves Z 1413 Water PUMP sss 424 ‘Water Temporature Regulators 122 NOTE: Refer to the complete Service Manual for information ‘at found hare. AC" in the lel marga is an indication of change from the former isu. Introduction The specications given in this book are on the basis of information avaiable at tho tine the book was written, These specifications give the torques, operating pressures, ‘moasuremonis of new parts, adusiments and ather lems that wil atfect the service of the product When the words “use again” are in the description, the specification given can be used to determine fa part can be Used again the partis equal to or within the specification ‘gven, use the part again \When the word ‘permissible is in the description, the specification glen is tha 'maximum or mininur” tolerance parmitied betore adjustment, repa anc/or new parts are needed ‘A comparison can be made between the measurements of a ‘worn part and the specification of @ new part to find the. ‘amount of wear. A pat that is worn can be safe to use if an ‘estimate of the remainder of its service ie i$ good. Ita short ‘sensi Iie s expected, replace the part NOTE: The specication gven for ‘use again’ and “permissible” are intended for guidance only anc Caterpillar Inc. hereby expressly denies and excludes any representation, warranly or implied warranty ofthe reuse of ‘any component. 3208 Diesel Truck Engine 13 Index Specifications Engine Design PeSESES a DODO] OS miter | (Cylinder, Valve And Injeton Pump Location Bore 143mm (45) Stroke i sw 127.0 (8.0) Number Of Oylndts nase 3 8 (Cylinder Arrangement ov Fring Order (injection Sequence) 12734568 Direction Of Rotation (As Seen From Fywhes! Ene) Counterclockwise Fuel Injection Pump ing order (rjecion sequence) Injection timing BTC (before top center. 12734568 Engines with 118742 Fuel Pump Group Bat Engines with 708866 and 7W5479 Fuel Pump Groups 10st Engines with 7E9890 Fuel PUmp GOUPS srs TST Engines with 708988, 7CBE62, 708970, TOAST! and 4P4260 Fuel Pump Groups i251 Al other engines rag “Torque forthe nuts thal nod the fuel ines (Use 6014 Fue Line Socket). 40+7Nem @O+5 bf) 735281 (1) Bote in the rear bearing fer the camshalt (new) 60.905 + 0.013 mm (2.8780: 0005 in) Diameter cf rear bearing surface (journal) of the ccamratt (n0W) 60249=001amm (23720: 0008 ny ‘Maximum permissible clearance between the bearing ‘and the camshait bearing surface (ournal) (ween) vewenee O15 em ( 006 n) (2) Torque for screws that hold sloave control levers 28402Nem (24-2 bin) (9) Bote in the housing for the fuel contr! shaft (en) 8.990 = 0.013 mm (3543 0005 in) Diamater of sleeve control shaft (re) 18,966 = 0,008 mm (3690 .0003n) Maximum permissive clearance between the bare nine housing ard the sieeve contol shat (worn). .03,mm {003i} (4) End pay for camshat with seove instaed (oem s 0.58: 046mm (008 + 018 r) NOTE: Wan instaling ¢eeve on end of camshalt, supa the camshaft to prevent damage fo paris inte o injestion pump and governor housing (8) Bow in the front bezrng forthe carnshat (raw 25.418=0.018 mm (1.0005: 0005 in) Diameter cf ron bearing surface (oumal ot te camshaft (no)... 25.375: 013mm (9990+ 0005 in) Maximum permissible clearance belween he bearirg and the camshatt bearing surface (ournal) (worn) ©.10mm (0049) 3208 Diesel Truck Engine 4 Specifications 2 MW crzr091 (8) Torque for bushing 82 7Nem (605101) () Crossover levers. NOTE: For adjustment of crossover levers, see the Testing ‘And Adjusting Section © Torque for sorews that hold ercasover levers 28=02Nem (24+21bin) (@ ane 19) Fuel contro! shatts (11) Dowel pin (linkage between crossover levers). (12) Distance guide pin extends into bore... 1204010 mm (047004 in) NOTE: Install guide pin with sot toward the top of the iter (13) 9NSBE2 Spring for injection pur: Length undo 108 F108 nme $5.49 mm (1.983) Test force 567 EGON (124 1.410) Z Free length ater teat 40.0 mn (1.608 in) Cutsce diameter 18.49mm (728 in) 3 AA. Reverse Flow Check Valve (AFC). os B. Orificed Dalvery Valve (COW) . Orlioad Delivay Valve - Lo Volume (ODM). Amari D. Ottices Reverse Flow Check Valve (ORFC). 9208 Diesel Truck Engine 15 Specifications ——-srern Spring Chart (= Fentto. (twas [ay exan29 (9) ana ane mane] [ Color eoce swine) Ore Pure | ‘Two Pink Two Green Tree Gres Two White Pura foe: W77ON @90N W779N 13368 13340 on spring ot ow) (20%) ow) fet) (08) Then add more free to | 46.00 mm 78mm 1778 men 7778 mn 1778 men make sorng shor by | __'(390'n) (700'n) ‘Goan, (700'") (700) He2eisan | sea2e0en | sreieisin | so7ie1i6N | sooetsin Total test force (isaoe 308) | (30% 20m | (is20z30m) | Gimoz ze) | (laeor 240) [7 = 051mm | 420% 051mm | 44202 051mm | 42142089 mm | 44202051 min Frosiengmnatertest | (1ss0% 020m) | (740e.020m | (irdox can | cecuzonm | (1702 020m 36 56mm 37.84 men 38.56 mm 38.25 mm 36.25 mm Outsae damerer (sien) (190 (sein) (1508) (508m) ‘Governor Spring Chart Par Ne yaLss08 (i Tus807 () 16008 ansess—_[__(ay6naei7 “Cake sede Stine] One Yalow Tee Yelow “Three Fink ‘One Pik Nore Puta foe Z226N ‘890 3.90N 445 330" on spreg ot ou eon @or ion @0% Then aad more free to | ¥7-78 mm 7528 mn 15.24 mm 778mm amen make sotng shorn ty | (700k (90) 600") (roam (zum Grese2ain | wsees0N | a7so= son | oo0eesGN | 2ast= GON Total tet foros (e7os-sm | @asi2m | 22i20 | @oosizm | Geor 1m) 44202051 mm | @i42059mm | 524=10mm | @29020Simm | O1.244051 mm Freelenatatertest | (17402 020m) | cases corm | eoess eee | (esos-aavim | \1:1se% Geol 38.501 37.84 mn a784 mm 38.8 mm 1482 Oude same | (hate (acm, (480m) ised (satin) a er vertvting Serings =i Parte. “=NOSaT ence Tangin under Br wen 7900 nes teat toroe (3am rar) Gaszo05N | oe 006N est trea (192 oem) | cies cen) Free engi 8.8 mm 28 50 en or tas (720m ities 2.4 mm 2:14 nm (301m (360m None ne White (8) Torque for bolts that hold governor weight cartier to ccarsshatt (sally) 1423Nem (10 2Ib tt) Torque for bolls that hold governor weight cari to ccarnshaft (later with thin bolt heed)... 10.23 1.1 Nem (8010 in) 3208 Diesel Truck Engine 16 Specifications Fuel Transfer Pump (1) Bypass valve Fuel pressure at FULL LOAD ... 20595 kPa (3015 psi) 44N605 Spring for bypass valve: LLengtn under test force Test force Free length after test (Ourside ciameter @ 22.36 mm (880 in) 80N (53.18 b) 43.82 mn (1.723) 13.39mm (527 in) is7 (3) Thickness of gears (new) 2.489 0,008 mn (3798 = 000310) Depth of counterbore (nen) 9525 0013mm (3750 + 0005 in) (4) Dlametar of shaft for idler gee nn 12482 20.008 mm (4914 = 0008 in) Bote in iar goar 12.5124 0.008mm (2826 + 0008 in) (© Puta thin ayer of SS1454 Sealing Compound on the utside diarmater of the seals belore inslalaton. Remove the extra sealing compound after assembly, (6) install nner seal from outside edge of body assembly to distance of 1151 £0.25 mm [483+ O10in) (7) Install eutside seal from outside edge of body assembly loa distance of 10.760 25mm (030: 010) Injection Nozzles 9N3979 and 1W5829 re 5 zone Bench test noz7es using clean SAE J987 Calération Ci (Kent-Moore Corp 1:26400 or Viscor Calibration Flu 14870. SAE J:9670) ata temperature of... 1810 20°C (65 to 70°) Nozzie setting pressures (valve it adustment screw turned 3/4 3 1/6 turn from closed position): Used nozzle 10.8000 17 690 KPa (1500 to 2600 paid Used, adjusted nozzle 16 645to 17 600 kPa (240 to 2600 psi Return oll leakage test pressure 96300 11 045 KPa {1400 to 1600 psi) Leakage in 18 seconds NO minimum or maximum Maximum tip leakage &s 20 drops in 1 seconds wth a preseure of 1900 KPa (200 psi less than opening pressure (1) Torque for valve it locknut 40105.1Nem (35104510 in) (2) Torque for pressure serow locknut 801091 Nem (70108010) (8) Torque tor cap 12410 18.6Nem (110 to 12010 in} 17 3208 Diesel Truck Engine Specifications c 7000 Series Nozzle Fuel Filter Base a 1 ASOBSTPY (1) Bleed sce, u ~ (9) Put 952269 Tinead Lock Compound onthe treads of the taperes endl the sd toa Glance fn 7 rn @o © on o\ @ (2) Seating surtace of stu NOTE: Dr not camage ris surtce wens {8} Torque for stud * 707 Nem (505 Ib it) (2) Osta rm sing sustace of base fo er ct Shih ensvoscnsresene BAGELS (OT #5 iN) Tertn teed screws to ne flowing toeues eee £00 Ronn 80 Nom 1M Bleed sxen B sone} 8£02Nem (1629 Bleed scone Cand 5 2B 08Nem (2027 1p NOTE: Al uelinecton ine us re tgtened oa torque a ABET Nem (IES 1D ay 3208 Diesel Truck Engine 18 Specifications tr Automatic Timing Advance Unit 3.5° and 5° unit (0.08 0 054 ms (003 0.037 in) (Teaver screw 79£06Nem (10516) “Stake” (ake @ mark wih a punch) core (3 in two paces. End play between washer (2) and tiring advance unit a Drive Gear For The Injection Pump rrae2301 (1) Torque forthe bolt that holds the ceive gear to the camshaft ef the njacton pump 149 14Nem (110 101th) 3208 Diesel Truck Engine 19 ‘Specifications c Camshaft (1) Diameter of the surfaces (ournals) for the camshatt bearings (new) .. 63.500 0.013 mm (2.5000 + 0006 in) Bore in the five bearings for the camshaft (new) (68.569 + 0.038 mm (2.5035 + 0015 in) Maximum permissibe clearance between bearing and Dearing surface (ournal) (worn)... 0.18mm (007 in) (2) Tight ft between the gear and camshatt (0.030 to 0.071 mm (.0012 t0.0028in) ‘Maximum permissibe temperature of the gear for instalation on the camshaft (do not use @ torch) «. 3158S (Corr) (3) End play forthe camshatt 0:18+0.08 mm (007 +003 in) “Maximum permissibi ond piay (worn) 051mm (020 in) (4) Wiato of thrust groove in camshaft (90m) 9.14: 0105 mm ( 360 00in) Diameter of trust pin (164) weve: 897 £0.03 mm (353.001 in) 48 7Nem (8525101) Torque for thrust pin (©) Height of camshat lobes, To find lobe it, use the procedure that follows: A. Measure camstatt lobe height (5) B. Measure base circle (7). . Subtract base circle (Step B) from lobe height (Step A). The difference is actual lobe it (6) D. Specitied camshat abe it (6): ‘9N5290 Camshatt used with role ites 2. Exhaust lobe 9.40mm (970in) B. Intake lobe .. 9.33 mm (367 in) 24238 Camshalt used with fat face liters: ‘c. Exhaust lobe 9.40mm (370in) 4. Intake lobe. 8.06 mm (387 in) Maximum permissibie difference between actual lobe lit (Step ©) and spectied lobe it (Step D) is 0.25 men (010 in). agia19R8 3208 Diesel Truck Engine Specifications S View AA (@) Distance ftom the end of 9NS771 Dowel tothe fave of eat 111.81 £0.13 mm (465 +008 in} View 6-8 (@) Distance trom the end of SP4283 Dowel tothe face of AMEE sn 2.00 +£0.25mm (079: O10 in) ‘Camshatt Installation NOTE: For installation of camshall, the tening mark on the ‘eamshatt gear taath must bein alignment with the timing, mark on the tooth space ofthe crarkshall gear Intake Valve Timing 41. Check the No.1 intake valve clearance with the engine ‘Sopped. The vale clearance rust be 0.30 to 0.48 rm (012 to O18 in). the valve clearance ss not inthis range, acjust the clearance to 0.38 rm (016 in} . Mark Top Center Position of the crankshaft onthe oration camper or pully, 18. Use a ala indicate to measure the intake valve rovernent 4. Rotate the erankshalt inthe direction of nermal engine relation. Slop when the intake valve is 1.81 mm (O75 in) Off its seat in ha opening sequence. At ths point the Crankshaft must be 10 = 2" After Tap Center ‘9208 Diesel Truck Engine Specifications Valve Rocker Arms And Lifters For Engines That Have Flat Face Lifters (1) Torque fer bots that hold rocker arms ue 247 Nem (BESO) (2) Torque for locknut for valve acjustment serew 507 Nem (24:6 bof) @ Dameter ofthe shafl forthe rocker errs 21.793 1021 814 mm (8560 to 8585 in) ‘Minimum permissible diametor (warn 21.788mm (8570in) Bore in bearings forthe rocker arms For Engines That Have Roller Lifters asian 1 5 1. Tum camshaft so cam lobe opposite litter bore 2. Install quide sexing on tfter. 2. Putliter assemby in engine oll and instal nto iter bore 0 thatthe lap on the guide spring is located within area rr 4, Push iter into bace until contacts mace with camshatt (nee) 221,952 + 0.020 mmm (.8803 + 0008 in) 1) Torque for bolts that hold rocker arms 24k 7Nem Maximum permissibie Doce (Won) 21 920mm a ferent (2630 7} Maximum permissible cleerance between bore in beating (2) Torque for locknut for valve edustment and shalt (wotn) 0.13 (008 0) screw 30=7 Nem 242611) (4) Clearance for valves (intake valve)... 0.98 mm (015 in) {8) Diameter of the shat forthe rocker ‘Clearance for valves (exhaust valve). 0.64 mm ,02Sin) ans 21.785 t021.814 mm (.8580 10.8528 in) (8) Diameter of cam follower 29.495 +0.010mm_ beri srt (wom * pat (1.1889 0004 in, Bore in bearings fr the rocker arms Minimum permissible diameter (WOrR) 0. 28-401 mm (new) ‘21.852 4 0.020 mm (603+ 0008 in) (1457510) Maximum parriesble bare (worn) 21 g20mm ore in ook for Gam fOlOWEr nnn. 28.825 + 0.025 mm (8630'n} (11624: 00105) Maximum permissible clearance beiween bore in bearing Maximum permissible bore (worm) Baim and shat (wer) 0.13 mm (008 in) oreo (2) Cleararce fr valves (intake vaio)... 038mm (015in) (2) Tone forthe trurpinfor the carota. 46:4 7Nem Clearance ‘or valves (raul valve). 0.64 mm (025in) ~ (6) Diameter of iter. 29,484 0.018 mm (1-1600.0008 in) Bove in block foriter 225250025 mm (11624+.001016) 3208 Diesel Truck Engine 112 Specifications Valves () Diamotor of valve siom: a beteett ret eae ey Note. uDELNE fom aeuseL= Pas. yALvES NS sencianigamacsae VALVE SPRINGS, Forms SEBF8002 and SEBFB034, have the areas sd ios Estausl Vales ei conn in) en eee aes. ard i Exh Vi apo Songs a Sree ie teenie interim tenes eae Uae rina and tba dT Baht epee paste ons ome ares omen Nears ied biel feecinotie Le eee an sree sey w-nonctate mone arab mane oe {6) Diameter of valve head (intake vale .. 63.19: 0.13mm | ears narsewiantesltase (8) Thickness of valve lip: Intake valve 2.31 mm (094 in) | 6 (Use again minimum valve ip thickness 178m oe" ae Exhaust valve 1.60 mm (063 in) Use again minimum vaive ip thickness 127mm (1) 9N5496 Soring for valves (outer (050i) Length under test 10168 nserver, ABA men (1.790) Test force 1850+ 180N 416+ 4b) Use again minimum load at length under test force : 166 (37.310) ‘Longth of spring at valve open postion”... 30.23 mm (1-190in) Use again minimum load at valve open postion... 600 (13515) Free length after test 51.77 mm (2.038 in) Outside diameter 39.62 mm (1.560in) ‘Spring must not be bent more than... 1.8mm (071 in) \ (1) 95495 Spring for valves (ne: Length uncer test force 42.47 mm (1.672in) Teast force 91.2+80N (205+ 216) Use again minimum load at length under test force BION (18.41) Length of spring at valve open positon wu. 27. 23mm (1972in) Use again minimum load at valve open position... 2951N (66.310) Free length attr test 48.77 mm (1.320in) (Quiside diameter 26.67 mm (1.050 in) Spring must not be bent more than... 1.70 mm (067 in) @ - Distance from the end ofthe valve to the valve spring spacer seat 52.40-+0.38 mm (2 063+.015in) 3208 Diesel Truck Engine 1418 ‘Specifications c Valve Seats And Inserts Intake Valve (with valve seat insert) Tos0ee01 7 (1) Diameter ofthe valve seat insert... 54.610 0.013 mm (2.1500 .0005in) 54.534 20.013 mm (@:1470-+.0008in) (2) Depth of bore in head for valve seat insert 11 280.05 mm (442 + 002in) ‘Maximum permissibie width ofthe face ofthe valve seat insert 805mm (120in) (4) Distance from head of valve to cylinder head face: ‘Maximum permissibie (valve closed)... 173 mm (068 in) Minimum permissole (valve closed) ... 081 rm (058 in) (5) Angle ofthe face ofthe valve seat insert... 80 Yack W? (6) Outside diameter of the fece of the valve seat insert '52.28 0.13 mm (2.045.005 in) Maximum permissible $52.45 mm (2.085 in) ‘Angle to grins face of seat insert (to get a reduction of ‘meximum seat clameter) of {Bore in head for valve seat insert a a Intake Valve (without valve seat insert) se on (1) Distance trom head of valve to cyincer head face: Maximum permissible (valve closed) .. 1.73 mm (068 in) Minimum permissible (valve closed)... 0.91 mn (O86: (2) Maximum permissible width of the face of the valve 8 nr : 305mm (120in) (9) Outside dlameter ofthe valve seat... 6223 0.13 mm (2.045 + 005in) Maximum perissibie 52.45 mm (2.065 in) (4) Angle of the face of the valve seat 20¥ (5) Diameter ofthe bore 54.61 mm (2.150in) (© Maximum permissible dopth of the bore to make the face of the valve seat emalir 432mm (170in) 3208 Diesel Truck Engine Specifications Exhaust Valve (A —? T90007.163 (1) Depth of bore in head for valve seat insert sn 1123 0-19 rm (442+ 085 in) @ Diameter of vaive saat insert 48.565 40.013 mm (1.9120 0008 in) Boxe in head for valve seat insert... 48.489 0.013 mm (1.9080 2 6008 in) (@)_Maxierum permissible width of the face of the valve seat insert 2.67 mm (105 in) (4), Distance from head of valve to cylinder head tace: Maximum permissible (valve closed) .. 2.18 mm (085in) inimum permissible (valve closed) ... 1.27 mm (050m) (5) Angie a the faoe ofthe valve soat insert... 45% "| (6) Outside diamator of the face of tha valve seat insert ‘44.07 $0.13 mi (1.785: 005 in) Maximum permissible 44.20. (1.760 9) (7) Angie to grina face of seat insert (to gota reduction of ‘maximum seat ciametes) 15 Cylinder Head (1) Put 64876 Motykote Lubricant on boll threads and tighten bolts according to the Head Bot Torque Chart that fallow: Tend Bok Torque Chart Earler Bots | — Later Bote “Tohtening iwth Sar | Ctn Seven Procecure | Dasmarks)' | Gash Merk) Sip 1. Tighten Boks * rough 180 te07 Nm | 15027 N-m rum tomuanca to: | GOZSbI | (10=56 Sap 2 Loosen bots rough 18 unt tho wiasnrscan be | tuned ret, Si 8. Thien bots Teough Bin 80:4 14tm | 80: 14Nem umber sequence to | (GO= 10M | (60 10H Sip 4. Teron bats frougniain t0t7nm | s5027Km rumoorsewanets | fas=smm) | (05° Step 5, Agen tort oe Timah te | 1907Nem | 3657 Nm nurtersegancets. | @sesmn) | (20260 Sisp6, Thon bots {9 Brough 2210 asetnm | a=tiem _imorsecverceter | Gessioi) | G2x5bm See liusraton 1 for ientiicatin of EARLIER and LATER bots 3208 Diesel Truck Engine Specifications corzesers ASH MARKS EARLIER LATER (six gaeh marks) (exvan dash marks) \Mustration 1, Bolt head identification, Valve Covers: (2) Holes for fuel injection nozzles. NOTICE “The higher cylinder head bolt torque may be used on earlier engines ONLY ifthe bolts are replaced with the later higher Strength bolts (seven dash marks on the bolt head), Ifthe ‘earlier bolts are tightened to the later torque specification, they may yield (stretch) and lose the'r clamping force. ‘Head Bolt ~ ee a a iadasaquonnay | uae as — [asset | eater sane | —Taanas — [seater | teas [wie —[ wemmeoon] — preinjeanee See | ornare om aan faomeon] 2 - 1B 2 swam fl ‘Time pt ted rena TT Hidehahtstinrd iperett nt New 96.14 + 0.15 mm (3.785 + 006 in} Hanes dust ase ang se menor (,006 in) total, and a maximum of 0.08 mm (.003 in) for «( 3208 Diesel Truck Engine 116 ‘Specifications i ; Crankcase Ventilation Valve Turbocharger Impeller Installation (Schwitzer Only) Installation Procedure ‘A, Put GV1541 Quick Cure Primer on the nut and the shaft threads to clean them, necessary. B, Puta emall amount of 958265 Re'aining Compound on ‘he rut and shat treads NOTICE ‘Do not et the retaining compound get into the compressor ‘wheel bore or on the shaft, because it can make removal of ‘the compressor wheel difficult during future turbocharger disassembly. (1), Texque ‘or hase olamps 2) Torque tor bots 23-4 02Nem (20 2b in) 342 05Nem 0 4lbin) Exhaust Manifold nosater2 Put 8P931 Anli-Seize Compound on threads of bolts. Torque for bolts. +t 7 Nem (32-5 ib ft) Locks must be bent on a flat side ofthe bolt head. Belts ‘must be lurned no more than 30° in the araction of increased torque only fer the alignment of locks with a tat ‘side ofthe belt head. C. Puta smal amount of lubricant, such as Lubrplate, on the nut seat area on the compressor.Do not put lubrication on the threads D. Tighten ihe compressor whee! retainer nut to vo 285 3Nem (22+ 2 io!) NOTICE De not bend or add stress tothe shaft when nut is loosened or tightened. 3208 Diesel Truck Engine Turbocharger © 4TF555 & 4TF606 6 asisr4r2 (1) End pay for shat (rem) 0.1140.038 mm (0048 0015 in) Maximum permissible end play (worn) 020mm (006in) (2) Thickness of trust bearing 5:56+003mm (211 001m) (8) Diameter of surace on shalt joura) forthe bearing (020) wenn 14.2580 14262 mem (561205815 in) Bore in the bearing (new) 142930 14300 mm (S627 t0.5630in) Maximum permissibie closrance between bearing anc shaft (worn) 9.08 mm {008in) (4) Put P3931 AntiSeize Compound on threads and tighten | bolt holding band clamp 10 ns onom 136Nem (120 Din) (6) Maximum permissible gap of of seal ring, measured in bore of housing ‘0.23 mm (.008in) (6) Nut for impeller (See Turbocharger impeler Installation). NOTICE Do not bend or add stress to the shaft when nut is loosened or tightened, Bore in Housing (98H) sn vnnnsn nn 22-256 to 22-268 em (876210 8767 in) (Outside clameter of the bearing (00M) rn 22.148 10 22-154 men (8718 19.8722 in) ‘Maximum permissible Clearance between bearing and Dore in housing (worn) (0.15:mm (006i) ® Thickness of each thrust ring 2.563+0.013mm (1005 0005 in) Turbocharger TMS1 & TM54 (1) End play for shalt (new) 10.051 100.081 mm ((0020 to.0032 in) (2) Tighten bolts that hold back plate to bearing housing 10 vn sevnsoe 952 Nem (649 in) (@) Tighten screns that hold thrust bearing 10 vn 25202 Nem (22 + 2ibin) (4) Diameter of surtace on shaft Journal forthe bearing (new) 1299210 13.000mm (5115t0 5118in) Bore in the Bearing (NEW) ensnnne 12.0280 13.088 mm (5129 to 5133in) 20.175 t0 20.188 mm (7943 to 7948 in) (8) Bora in housing (naw) ‘Outside diameter of the bearing (new) 20.069 to 20.081 men (7901 to.7906 in) (@) Turbine end ai seal rng, end gap when installed in a bore of 20.90 mm (823 in) (0.100038 mm (004 to 015 in) (@) Put 2°2506 Thread Lubricant on the shaft threads and ‘on the nut face and tighten nut fo ....... 4 Nem (36 fin) Tighien nut more 12" NOTICE Do not bend or add stress tothe shat when nut is loosened or tightened. {@) Impeler end oil seal ring, end gap when installed in @ ‘bore of 17.489 mm (6875 in) (0.08 100.38 mm (003 015in) (9) Thickness of thrust bearing 4959 104.969mm (i7iet0-1720'n) (10) Put 58981 Ant Seize Compound on treads and tighten bolt heaing Bans clap fo" iat Nem (ize bin) Engine Oil Cooler And Filter il pressure ciference that makes the oi fiter bypass valve open 140+ 25 KPa (20+ 4 ps) it presaure citference that makes the oil cooler bypass valve open 1254 25KPa (18+ 4 ps) (1) 918188 Spring (ol cooler and ot iter bypass valve) Length under test force 432mm (1.70'n) Test force 156N (56) Froe tangth alter test 57:9mm (228 in} Outside diameter 11.48 mm (440 in) (2) Oil fiter bypass valve, (@) Torque tor nuts that hold oll cocler core toll cooler base {hand torque only) 22£3Nem (162 BH) NOTE: I applicable, assemble gasket to oll cooler base with indexing point toward the front of the engine and in the up positon. (4) Oil cooler bypass valve. 3208 Diesel Truck Engine a Oil Pump NOTE: Tighten relia! valve guide to (1) Front housing assembiy, (2) Ol pump cover assembiy. (3) 1/1788 Spring (oump pressure tee valve) Lenat under test foe 5,94 mm (2.360 in) Test force 14k ANT +36) Froe length itor test 78.23. (3.080 in) Outside ciametor 22.23 mm (B75 in) (@) 12208 Spring (pump pressure reli valve) Length under test force 59.94 mim (2.360 in) Test fore 200+ 14 N (65+ 3 b) Free length atter test £85.85 mm (3.380 in) Outside ciameter £22.23 mm (875 in) (4) Width of oi pump rotors (new)... 96.474 + 0.008 mm (1.4960 +0003 in) Dept af counterbore in frant housing (ren) 36 576% 0.025 mm (1.4400 + 0010 in) (6) Maximum permissible end clearance of ol pump rotors when measured with oll pump installed to front cover ct (0.15 mm (.006 in) 3208 Diesel Truck Engine 1-20 csseres View A-A Of Rotor O1| Pump (©) Clearance of ot pume rotor tip when measured with ol [Pump inetalle to front cover 10.05 t00.20 mm (002 to 008 in) Maximum permissible clearance of oll pump roter tip (028mm (011 in) View A-A Of Front Housing| ” ® Bearing junction Diameter of bearing fo rotor (new) .. 71.224: 0.056 mm (26041 + 0022 in) Positon of main bearing juetion from vertical centerline ° 75+ 90° ‘Specifications Oil Pan Water Pump 2 a aaa (1) Torque for bolts that nals oi pan Bata Nem (TE3I0%) (2) Torque for oll pan ceain plug 70+ 14 Nem (= 1%) Oil Level Gauge astiazet — i é (1), Guide assembly ‘Assemble lower part of guide assembly (1) so that Point Ais even vith bottom surface of block wittan + (08 mm (+ 03 in) asiaz0e1 NOTE: The outer beering 0.0. and nousing bore must be tee at al before assembing bearing into housing, ‘Alter assembly, apply 409608 Sealant Wicking tothe chamfer area chy. Remove excess sealant Allerrate sealant: Pul 858263 Thvead Lack on outer bearing © D. anki housing bore before asvombly (1) Clearance between the water pump impeller face ‘and Wort cover (0.28100 84 mn (011 10.093.) (2) Terque tor pulley 7547 Nem (55 +Sib4t} 3208 Diesel Truck Engine Specifications ‘BELT TENSION CHART | worn | WioTH Top | BELTTENSION | BELT TENSION | eeursze| of?Te | Seeley | “aman “useD™ BORROUGHS GAUGE NUMBERS ‘GAUGE READING | GAUGE READING mm [me [am] | NW ® N |__| OLD GAUGE NO, | NEW GAUGE NO, 3/8 o72| 422] 965) 380 | 445222| 10025 | 400222) O05 | BT-3305 BT-33-87_ ve [1968 | sa7 | 1270) s00 |su=z| 12025 |«00=m| 9=10) OTS95 Brs07 sv__|1sae| ees | 1524 | coo |su=za| ozs |«ooeea| s=10) eTavreais | era072 1/1748 | 600 | 1500) 25 [scax22| 0x5 | ao0ese| s0210 | aTaaT4is | eToo72C aye | 19.05 | 780 | 1753 | 690 | 53422 12025 | 40044] 90210) 679972415 BT-33.72C ise 2aes| sea | 2200| era |soezoe| 10025 | a Alternators And Regulators Delco Remy Alternators 1 2 SS t Ls wom 77889 Alternator Voltage rating rv Polarity son Neg Gerd Rotation ‘ Either Dsction ‘Speed for testing (1pm) 2600 10 6500 Output (co's) 2BA@IAV Ouiput (co's) i BZA @ 14v Rated output (hot) at max speed A Fld curont at rated voltage and 27° C (80°F) ou. THOBA Positive output terminal troue 52t080Nem (681671 bin) (1), Ground terinal torque (2) Shatt nut torque 1.7t02.9Nem (15 02610 n) 95 0 108 Nem (70080 bt) Regulator (9G5235-Inside Alternator) Voltage setting No Aduustment Pormissibie voltage range .. 1310 16 376352 Alternator Votage rating vw BAY Polarity Nag Gna Rotation Eitne Direction ‘Speed for testing (To) 2600 0 8500 Output (cold). 15a @28v Output (cola) 5A. @ 28 Rated output (hol) at max speed 5A, Fels current at rated vokage and 27°C (80°F)... 2510328 Positive outpud terminal torque 6.2%08.0Nem (651071 bin) (1), Ground termina torque (2) Shart nut torque 1.710 29Nem (151026b in) 95to 109Nem (70 to 801 (1) Regulator (376354 - Inside alternator) Voltage setting Poxmissbie voltage range No Aajustrment 26t030¥ 3208 Diesel Truck Engine 1-35 ‘Specifications 966079 & 611194 Alternators Bosch Alternators Voltage rating 1 Polriy Neg Gind : Fotation enn Ether Becton ‘Output at 2000 rom (eo) 308 (Output at 5000 rpm (eo) 57h 1 Fated output hot) = BIA (1) Torque fer stud rut for battery connection 281045 Nem (25 0.401 9) (2) Torque tor pulley nut 100: 7 Nem 75.4516 19) Voltage Reousior (988826) is ntrnally mourted rd i not adustabi. 9G6081 & 611196 Alternators Polarity. .. Neg Grnd ovation 2 Ether Orection (Cuput at 2600 rp (eld) 254 = Output et 7000 pm fect) aq Baer > Rated output (ot) 408 (1) Torque for stud nut for batery cannection 281045 Nem (510 401bin} 7no720 ‘anerastoF (2) Torque for pul rut 100 7Nem (755i) Voltage Reguitor (276354) is itenaly mounted and not Vote rating any acjstaole Polrty Neg Gira Roiaten EtherDieston Spaed fr testing (pm) - 4000 Cutout coi) as Cutout (rot) aA Feld Curent at 28¥ ane 25° © (77°F) 184 (1) Torque for puley nut... 9510 119'Nem (710 BOI (2) Torque fox output erin > 75810 10Nem 6510706 Toraue for ground terminal... 21 to28N«m (19025 in fb) Fegultor Number oarser 3208 Diesel Truck Engine 1-36 ‘Specifications a Bosch Regulators Go VY to exzrsP1 967567 Regulator Voltage rating 2av Peolarty Neg Gerd ‘93043 Alternator Voltage setting range 267:0283 vata Tag 2av Max cut at 28 408 Polarity ‘Neg Genes acera: D> ator oe Clockwise pe eunehee Speed for testing (rom) vn $000 Vottage rating 28 Outpt (coe) as 408 Palarty Neg Gene Output (ne) 528 Voltage setting range 275102850 Feld current at 28Y and 25°C (TPF) 200 Max output at 284 Bea (8) Torque for pulley nut 50-4 5Nem (37 41D) (2) Torque for output texinal B+ 7808Nen (0710) . (9) Torque for id D+ terminal nut 170:0.25Nem (is22bH) (4). Toraue for groune (6) termina ut... 9:60:08 Nem @2z7bK) rq for W torial not shown) 2.282025 Nem (#2010) Regulator Number 96145 o 3208 Diesel Truck Engine 137 Specifications EEE Nippondenso Alternator ‘Altornator Specifications 964574 Alternator Grane. | seus | aT Tetags 5 ou a Fal Tog Grd | hag Fen oT Tt apedae) | 600 000 Rated ova pe | 28a A Oantvoinge | ABE TH | Taos = 37 Turner aped FA]_[— ato 20 Withe | Warn Cynnernareae | Toesny | WSesne ong, Desh marnita | Beem tien (3) B+ nut torque (952910 in) ores (3 atery era alee Biome (86 0in) Nippondenso Regulator ‘tan omar 435 10% fates ‘aceon esr pecatona T= 10 hem aT ‘or aa a ero Tas 088m e) {986 bin) Polarity: Neg Grn ‘Neg Grnd Volage ae [are v | uae SV ©) OF carers T2786 Regulator 3208 Diesel Truck Engine 1-38 Specifications Starter Motors 5 Delco Remy 1 cxerores eossoer2 £79685 Reguor Air Compressor (1) Torque for nut that holds the crive pulley... 7Nem (sown NOTE: Tignan nut more to get algrment of hole fr otter pn (2). Terque tor studs that nol th ai compressor 707 Nem (70=5Ibt) > 3208 Diesel Truck Engine 1-39 Specitications | Delco-Remy Starter Motors Vorage 7 Tv 2aV 2Wv av Caterilar Ne aNE2ES Be36s ‘280800 acsea7 ‘03651 Rotation 8 seen 7 from the drive end cw ow | ow ow ow ‘No Load Speed MineMax rom 000-7000 8800-Ta00 5500-9000, 6300-8400 500-8400 Current T al Consumption 140t0 100%0 70t0 1108 6010 75a, 6010 758 (Draw) with 2168 700, solenois at V* { "TBV Startor Moters Selena at 10 24V Starter Motors Solenoid at 20 (1) Terminal nut torque ...... 27.010 338 Nem (20 0.25 lf) Bosch (2) Screw torque Clearance between pinion nd housing 17.6t0230Nem (18017 Wf) gt089mm (33ie 39in) Prestolite ewer eaearoe1 Bosch Starling Motors (24) (Caer roar [asia | —ove005 [770768 otaion as sen trom iu cro ond ow Prestolite Staring Motor (24V) No Load Sed [Gael Norte 30687 arian pm 5600 Rotaion 23 seen ow | [Minion Goren “a0 from the ce en brow No Load Speed Ey wna or [caret Coneunior con (1) Terminal au toe... 27t053Nem (1.119191) [@orew) at 20¥. (2) Service limit of brushes 17.5 mm (.69 in} (2) Servos imit of commutator dametat... 48mm (1.9 in) (1) Housing ot tore 11Nem lot) Prion toring goar clarence. 151085 (06 to .22 in) 2) Terminal rut torque .... 27.019 $3.8Nem (20 10 25 Io th (8) Clearance batiwoen pinion and housing (057 t0 1.27 mm (020 to 050in) Solenoid terminal torque AtoSerm (1610 20 n) ‘3208 Diesel Truck Engine 4-40 Specifications Starter Motor Solenoids Delco-Remy Votage pay Caterpiler Part Number 78854 Current Consumption (Draw Pullin windings 910 15A@SV Holdin windings 68 Amex. @ 20 Yotage tev Caterpila Part Number T0258 Caterplar Part Number ere8ee ‘Current Consumption (Draw): Pulkn windings 2Blo3S7A@SV Holase windings 4N11816 Spring (contact release) Length uncer test force Test force Fras largth after ‘est Outsiae diameter 1310 154A @ 10¥ cn 10.7 rm (42 in) 40+2N (0+ 51b} 21 105mm (83+ 02in} 9534 .0.25 mm (375+ .010in) Prestolite pero © 2 Voltage 2av Caterpillar Part Number 378635 (Current Consumption (Draw): Pulkin windings Holdin windings Torque for srall terminals 232102668 @ 12V 4.110488 @ 12 1.702.2N (15102010 in) Bosch (2) 97608 Spring to return the clutch lever LLongth under test force 39.6. (1.56in) Tost force 242N (140+ 5b) Froe length afte test 7090.5 mm (2.79.02 in) eats Outside diameter...” 35.38 0.35 mm (1 393.015 in) (@) Torque for small terminal nuts 1.B1034Nem (16t0 010 in) Torque for large terminal ruts 21.4 10387 Nem Voltage a 2a (2ot025 m1) Caterpillar Part Numboc T0868 Current Consumption (Draw: ulin windings 310 125aa5v Holeie winoings 54t065Aal 200 Resistance of pullin nindings 410 Sahm Resistance of halen wincings 8.1103.7 ohm 3208 Diesel Truck Engine 141 Specifications 820 Shutoff Solenoids a ale 4 ote = Ss SB S 1 2 3 4 5 6 rere Caterpillar | Figure | Voltage | Coil Resistance yy Number | Number | Rating | et 25scqrr°r) anras 7 4200 517 hms_| or750 3 4230 5.17 ens er6121 2 42310 517 che THES 3 wv [42010 547 nme 205523 5 5.2510 140 ohm eosea7__[ 5 7126 101.40 ohms eioes | 6 43%0_ 300m [erates 4 777 024.7 os er610 2 177 t021.7 ons 7H 7 ze [18310187 ome 7N665 3 177 0217 ome acseze 5 48510 598 onms ([Teenzae a 49510538 obs > ‘9208 Diesel Truck Engine 1-42 Specifications (a

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