Thermo King TK 2.44 User manual

Overhaul Manual
TK 2.44, 2.49, 3.66,
3.74, 3.88 and 3.95
TK 8312-2 (Rev. 1/97)
Copyright©1988 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

This manual is published for informational purposes only and the information so provided should not be considered
as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation should be
consulted.
Sale of product shown in the Manual is subject to Thermo King’s terms and conditions including, but not limited to,
the Thermo King Limited Express Warranty. Such terms and conditions are available upon request.
Thermo King’s warranty will not apply to any equipment which has been “so repaired or altered outside the manu-
facturer’s plants as, in the manufacturer’s judgment, to effect its stability.”
No warranties, express or implied, including warranties of fitness for a particular purpose or merchantabil-
ity, or warranties arising from course of dealing or usage of trade, are made regarding the information, rec-
ommendations, and descriptions contained herein. Manufacturer is not responsible and will not be held
liable in contract or in tort (including negligence for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the installation of any
Thermo King product or its mechanical failure.

Specifications 1
Engine Disassembly 2
Inspection and Reconditioning 3
Engine Assembly 4
Lubrication System 5
Fuel System 6
Electrical 7
Run In 8

Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TK 2.44 & TK 3.66 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
TK 2.49 & TK 3.74 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
TK 3.88 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
TK 3.95 Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Torque Values for TK 2.44 & TK 3.66 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Torque Values for TK 2.49 & TK 3.74 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Torque Values for TK 3.88 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Torque Values for TK 3.95 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Inspection and Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Inspection and Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Connecting Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Valve Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Valve Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Valve Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Push Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Rocker Arm Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Wrist Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Assembly Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Table of Contents (Continued)
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Bleeding Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Major Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Delivery Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Fuel Control Rack And Pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Plunger Barrel Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Plunger and Plunger Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Plunger Guide Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Fuel Limit Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Individual Cylinder Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Timing Injection Pump To Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Maximum Speed Stop Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Fuel Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Fuel Solenoid Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Gears and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Major Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
No Load Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Run In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Dynamometer Run In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Run In Procedure Without Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Three Cylinder Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Two Cylinder Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

1
Specifications 1
Table of Contents . . . . . . . . . . . . . . . . . . . . . 1
TK 2.44 & TK 3.66 Diesel Engine Specifications . . . . . 3
TK 2.49 & TK 3.74 Diesel Engine Specifications . . . . . 8
TK 3.88 Diesel Engine Specifications . . . . . . . . . . 13
TK 3.95 Diesel Engine Specifications . . . . . . . . . . 18
Torque Values for TK 2.44 & TK 3.66 Engines . . . . . 23
Torque Values for TK 2.49 & TK 3.74 Engines . . . . . 24
Torque Values for TK 3.88 Engine . . . . . . . . . . . . 25
Torque Values for TK 3.95 Engine . . . . . . . . . . . . 26

3
TK 2.44 & TK 3.66 Diesel Engine
Specifications
The TK 2.44 is a two cylinder engine. The TK 3.66 is a three cylinder engine. Unless it is otherwise noted, the specifications
for both of these engines are the same.
General TK 2.44 TK 3.66
Model 2TN66 3TN66
Type Four Stroke Cycle
Water Cooled
Four Stroke Cycle
Water Cooled
Number of Cylinders 2 3
Bore 2.60 in. (66.0 mm) 2.60 in. (66.0 mm)
Stroke 2.53 in. (64.2 mm) 2.53 in. (64.2 mm)
Displacement 26.8 cu. in. (439 cc) 40.2 cu. in. (658 cc)
Power Rating 8.2 hp (6.0 kW) 11.2 hp (8.2 kW)
Compression Ratio 23 to 1 23 to 1
Direction of Rotation Counterclockwise
(Viewed from Flywheel)
Counterclockwise
(Viewed from Flywheel)
Firing Order 1, 2 1, 3, 2
Fuel Injection Timing 14 Degrees BTDC 14 Degrees BTDC
Nozzle Injection Pressure 1707 psi (11768 kPa) 1707 psi (11768 kPa)
Oil Pressure 18.5 psi (127 kPa) Minimum
@ 230 F (110 C) & 1600 rpm
18.5 psi (127 kPa) Minimum
@ 230 F (110 C) & 1600 rpm
Valve Train Standard Dimensions Wear Limit
Valve Spring
Free Length 1.10 in. (28.0 mm) 0.99 in. (25.2 mm)
Inclination .03 in. (0.8 mm)
Valve Guide Inside Diameter
Intake .2165-.2171 in. (5.500-5.515 mm) .2197 in. (5.580 mm)
Exhaust .2165-.2171 in. (5.500-5.515 mm) .2197 in. (5.580 mm)
Valve Stem Outside Diameter
Intake .2150-.2156 in. (5.460-5.475 mm) .2126 in. (5.400 mm)
Exhaust .2144-.2150 in. (5.445-5.460 mm) .2126 in. (5.400 mm)
Valve Depth
Intake .016 in. (0.40 mm) .039 in. (1.00 mm)
Exhaust .033 in. (0.85 mm) .039 in. (1.00 mm)
Valve Guide Projection
Intake .276 in. (7.00 mm)
Exhaust .276 in. (7.00 mm)
Valve Stem to Rocker Arm Clearance
Intake .008 in. (0.20 mm)
Exhaust .008 in. (0.20 mm)
Valve Seat Angle
Intake 30 Degrees
Exhaust 45 Degrees

TK 2.44 & TK 3.66 Diesel Engine Specifications (Rev 1/97)
4
Valve Train (continued) Standard Dimensions Wear Limit
Valve Seat Width
Intake .045 in. (1.15 mm) .065 in. (1.65 mm)
Exhaust .056 in. (1.41 mm) .075 in. (1.91 mm)
Push Rod Length 4.488-4.528 in. (114.00-115.00 mm)
Rocker Arm Bushing Inside Diameter .3937-.3945 in. (10.000-10.020 mm) .3972 in. (10.090 mm)
Rocker Arm Shaft Outside Diameter .3925-.3933 in. (9.970-9.990 mm) .3919 in. (9.955 mm)
Rocker Arm Bushing to Rocker Arm
Shaft Clearance .0004-.0020 in. (0.010-0.050 mm) .0053 in. (0.135 mm)
Tappet Outside Diameter .7067-.7074 in. (17.950-17.968 mm) .7059 in. (17.930 mm)
Tappet Bore Inside Diameter .7087-.7094 in. (18.000-18.018 mm) .7106 in. (18.050 mm)
Tappet To Tappet Bore Clearance .0013-.0027 in. (0.032-0.068 mm)
Camshaft
Cam Lobe 1.1799-1.1823 in. (29.970-30.030 mm) 1.1713 in. (29.750 mm)
Camshaft Journal
Timing Gear End 1.4150-1.4157 in. (35.940-35.960 mm) 1.4114 in. (35.850 mm)
Middle 1.4138-1.4148 in. (35.910-35.935 mm) 1.4114 in. (35.850 mm)
Flywheel End 1.4150-1.4157 in. (35.940-35.960 mm) 1.4114 in. (35.850 mm)
Camshaft Bearing Inside Diameter
Timing Gear End Bearing Insert 1.4173-1.4199 in .(36.000-36.065 mm) 1.4213 in. (36.100 mm)
Middle Bearing 1.4173-1.4183 in. (36.000-36.025 mm) 1.4213 in. (36.100 mm)
Flywheel End Bearing 1.4173-1.4183 in. (36.000-36.025 mm) 1.4213 in. (36.100 mm)
Camshaft Journal to
Camshaft Bearing Clearance
Timing Gear End .0016-.0049 in. (0.040-0.125 mm)
Middle .0026-.0045 in. (0.065-0.115 mm)
Flywheel End .0016-.0033 in. (0.040-0.085 mm)
Camshaft Deflection .001 in. (0.02 mm)
Camshaft End Play .002-.006 in. (0.05-0.15 mm) .016 in. (0.40 mm)
Piston, Piston Rings, and Wrist Pin
Piston Outside Diameter Measuring
Point (From Bottom of Piston) .20 in. (5.0 mm)
Piston Outside Diameter
Standard 2.5956-2.5967 in .(65.927-65.957 mm) 2.5925 in .(65.850 mm)
1st Oversize 2.6054-2.6066 in .(66.177-66.207 mm) 2.6024 in. (66.100 mm)
2nd Oversize 2.6152-2.6164 in .(66.427-66.457 mm) 2.6122 in. (66.350 mm)
Piston to Cylinder Wall Clearance .0017-.0041 in .(0.043-0.103 mm)

TK 2.44 & TK 3.66 Diesel Engine Specifications (Rev 1/97)
5
Piston, Piston Rings, and Wrist Pin (continued)
Piston Ring Groove Width
Top Ring Groove .0612-.0618 in .(1.555-1.570 mm)
Middle Ring Groove .0598-.0604 in. (1.520-1.535 mm)
Bottom Ring Groove .1382-.1388 in. (3.510-3.525 mm)
Piston Ring Width
Top Ring .0579-.0587 in. (1.470-1.490 mm)
Middle Ring .0579-.0587 in. (1.470-1.490 mm)
Bottom Ring .1366-.1374 in. (3.470-3.490 mm)
Piston Ring to Ring Groove Clearance
Top .0026-.0039 in. (0.065-0.100 mm) .0079 in. (0.200 mm)
Middle .0012-.0026 in. (0.030-0.065 mm) .0079 in. (0.200 mm)
Bottom .0008-.0022 in. (0.020-0.055 mm) .0079 in. (0.200 mm)
Piston Ring End Gap
Top Ring .006-.014 in. (0.15-0.35 mm) .059 in. (1.50 mm)
Middle Ring .010-.016 in. (.025-.040 mm) .059 in. (1.50 mm)
Bottom Ring .006-.014 in. (0.15-0.35 mm) .059 in. (1.50 mm)
Wrist Pin Bore Inside Diameter .7874-.7877 in .(20.000-20.008 mm) .7882 in. (20.020 mm)
Wrist Pin Outside Diameter .7870-.7874 in .(19.991-20.000 mm) .7864 in. (19.975 mm)
Wrist Pin to Wrist Pin Bore Clearance 0-.0007 in. (0-.017 mm) .0018 in. (0.045 mm)
Connecting Rod
Wrist Pin Bushing Inside Diameter .7884-.7889 in .(20.025-20.038 mm) .7913 in. (20.100 mm)
Wrist Pin to Wrist Pin Bushing
Clearance .0010-.0019 in .(0.025-0.047 mm) .0043 in (0.110 mm)
Side Clearance (Crank to Rod) .008-.016 in .(0.20-0.40 mm) .022 in. (0.55 mm)
Twist per 4 in. (100 mm) .002 in. (0.05 mm) .003 in. (0.08 mm)
Parallelism per 4 in. (100 mm) .002 in. (0.05 mm) .003 in. (0.08 mm)
Crankshaft and Crankshaft Bearings
Main Journal Outside Diameter
Standard 1.5736-1.5740 in. (39.970-39.980 mm) 1.5717 in. (39.920 mm)
Undersize 1.5638-1.5642 in. (39.720-39.730 mm) 1.5618 in. (39.670 mm)
Main Bearing Inside Diameter
Standard 1.5748-1.5765 in. (40.000-40.042 mm) 1.5776 in. (40.070 mm)
Undersize 1.5650-1.5666 in. (39.750-39.792 mm) 1.5677 in. (39.820 mm)
Main Bearing Clearance .0008-.0028 in .(0.020-0.072 mm) .0059 in. (0.150 mm)
Rod Journal Outside Diameter
Standard 1.4161-1.4165 in. (35.970-35.980 mm) 1.4142 in. (35.920 mm)
Undersize 1.4063-1.4067 in. (35.720-35.730 mm) 1.4043 in. (35.670 mm)

TK 2.44 & TK 3.66 Diesel Engine Specifications (Rev 1/97)
6
Crankshaft and Crankshaft Bearings (continued)
Rod Bearing Inside Diameter
Standard 1.4173-1.4190 in. (36.000-36.042 mm) 1.4201 in. (36.070 mm)
Undersize 1.4075-1.4091 in. (35.750-35.792 mm) 1.4102 in. (35.820 mm)
Rod Bearing Clearance .0008-.0028 in. (0.020-0.072 mm) .0059 in .(0.150 mm)
End Play .0037-.0105 in. (0.095-0.266 mm) .0130 in .(0.330 mm)
Deflection .0008 in. (0.020 mm)
Cylinder Block
Cylinder Inside Diameter
Standard 2.5984-2.5996 in. (66.000-66.030 mm) 2.6063 in. (66.200 mm)
1st Oversize 2.6083-2.6094 in. (66.250-66.280 mm) 2.6161 in. (66.450 mm)
2nd Oversize 2.6181-2.6193 in. (66.500-66.530 mm) 2.6260 in. (66,700 mm)
Cylinder Roundness 0-.0004 in. (0-0.010 mm) .0008 in. (0.020 mm)
Deck Distortion .002 in. (0.05 mm)
Cylinder Head
Distortion 0-.002 in. (0-0.05 mm) .006 in. (0.15 mm)
Timing Gears
Timing Gear Lash
Crankshaft Gear to Idler Gear .0016-.0047 in. (0.040-0.120 mm) .0079 in. (0.200 mm)
Crankshaft Gear to Oil Pump Gear .0043-.0075 in. (0.110-0.190 mm) .0079 in. (0.200 mm)
Idler Gear to Camshaft Gear .0016-.0047 in. (0.040-0.120 mm) .0079 in. (0.200 mm)
Idler Gear to Fuel Injection Pump
Gear .0016-.0047 in. (0.040-0.120 mm) .0079 in. (0.200 mm)
Idler Gear Bushing Inside Diameter .7874-.7882 in. (20.000-20.021 mm) .7906 in .(20.080 mm)
Idler Gear Shaft Outside Diameter .7858-.7866 in. (19.959-19.980 mm) .7846 in. (19.930 mm)
Idler Gear Shaft to Idler Gear Bushing
Clearance .0008-.0024 in. (0.020-0.062 mm) .0059 in. (0.150 mm)
Oil Pump
Type Trocoid
Outer Rotor to Pump Body Clearance .0039-.0063 in. (0.100-0.160 mm) .0098 in. (0.250 mm)
Inner Rotor Tip to Outer Rotor Lobe
Clearance .0059 in. (0.150 mm)
Rotor Plate to Rotor Clearance .0012-.0035 in. (0.030-0.090 mm) .0051 in. (0.130 mm)
Rotor Shaft to Rotor Shaft Bore
Clearance .0006-.0019 in. (0.015-0.048 mm) .0079 in. (0.200 mm)
Pressure Control Valve Setting 42.7-56.9 psi (294-392 kPa)

TK 2.44 & TK 3.66 Diesel Engine Specifications (Rev 1/97)
7
Starter
No Load Test
Voltage 11 volts
Current 180 amps @ 11 volts
Speed More than 3500 rpm @ 11 volts
Commutator Outside Diameter 1.18 in. (30.0 mm) 1.14 in. (29.0 mm)

8
TK 2.49 & TK 3.74 Diesel Engine
Specifications
The TK 2.49 is a two cylinder engine. The TK 3.74 is a three cylinder engine. Unless it is otherwise noted, the specifications
for both of these engines are the same.
General TK 2.49 TK 3.74
Model 2TNE66KC 3TNE66KC
Type Four Stroke Cycle
Water Cooled
Four Stroke Cycle
Water Cooled
Number of Cylinders 2 3
Bore 2.60 in. (66.0 mm) 2.60 in. (66.0 mm)
Stroke 2.83 in. (72.0 mm) 2.83 in. (72.0 mm)
Displacement 30.1 cu. in. (493 cc) 45.1 cu. in. (739 cc)
Power Rating 9.1 hp (6.8 kW) 12.5 hp (9.3 kW)
Compression Ratio 23.1 to 1 23.1 to 1
Direction of Rotation Counterclockwise
(Viewed from Flywheel)
Counterclockwise
(Viewed from Flywheel)
Firing Order 1, 2 1, 3, 2
Fuel Injection Timing 14 Degrees BTDC 14 Degrees BTDC
Nozzle Injection Pressure 1707 psi (11768 kPa) 1707 psi (11768 kPa)
Oil Pressure 18.5 psi (127 kPa) Minimum
@ 230 F (110 C) & 1600 rpm
18.5 psi (127 kPa) Minimum
@ 230 F (110 C) & 1600 rpm
Valve Train Standard Dimensions Wear Limit
Valve Spring
Free Length 1.10 in. (28.0 mm) 0.99 in. (25.2 mm)
Inclination
Valve Guide Inside Diameter
Intake .2165-.2171 in. (5.500-5.515 mm) .2197 in. (5.580 mm)
Exhaust .2165-.2171 in. (5.500-5.515 mm) .2197 in. (5.580 mm)
Valve Stem Outside Diameter
Intake .2150-.2156 in. (5.460-5.475 mm) .2126 in. (5.400 mm)
Exhaust .2144-.2150 in. (5.445-5.460 mm) .2126 in. (5.400 mm)
Valve Depth
Intake .012-.020 in. (0.30-0.50 mm) .039 in. (1.00 mm)
Exhaust .030-.037 in. (0.75-0.95 mm) .039 in. (1.00 mm)
Valve Guide Projection
Intake .276 in. (7.00 mm)
Exhaust .276 in. (7.00 mm)
Valve Stem to Rocker Arm Clearance
Intake .006-.010 in. (0.15-0.25 mm)
Exhaust .006-.010 in. (0.15-0.25 mm)
Valve Seat Angle
Intake 30 Degrees
Exhaust 45 Degrees

TK 2.49 & TK 3.74 Diesel Engine Specifications (Rev 1/97)
9
Valve Train (continued) Standard Dimensions Wear Limit
Valve Seat Width
Intake .045 in. (1.15 mm) .065 in. (1.65 mm)
Exhaust .056 in. (1.41 mm) .075 in. (1.91 mm)
Push Rod Length 4.488-4.528 in. (114.00-115.00 mm)
Rocker Arm Bushing Inside Diameter .3937-.3945 in. (10.000-10.020 mm) .3972 in. (10.090 mm)
Rocker Arm Shaft Outside Diameter .3926-.3932 in. (9.972-9.987 mm) .3917 in. (9.950 mm)
Rocker Arm Bushing to Rocker Arm
Shaft Clearance .0005-.0019 in. (0.013-0.048 mm) .0055 in. (0.140 mm)
Tappet Outside Diameter .7067-.7074 in. (17.950-17.968 mm) .7059 in. (17.930 mm)
Tappet Bore Inside Diameter .7087-.7094 in. (18.000-18.018 mm) .7106 in. (18.050 mm)
Tappet To Tappet Bore Clearance .0013-.0027 in. (0.032-0.068 mm) .0047 in. (0.120 mm)
Camshaft
Cam Lobe 1.1799-1.1823 in. (29.970-30.030 mm) 1.1713 in. (29.750 mm)
Camshaft Journal
Timing Gear End 1.4150-1.4157 in. (35.940-35.960 mm) 1.4114 in. (35.850 mm)
Middle 1.4138-1.4148 in. (35.910-35.935 mm) 1.4114 in. (35.850 mm)
Flywheel End 1.4150-1.4157 in. (35.940-35.960 mm) 1.4114 in. (35.850 mm)
Camshaft Bearing Inside Diameter
Timing Gear End Bearing Insert 1.4173-1.4199 in .(36.000-36.065 mm) 1.4213 in. (36.100 mm)
Middle Bearing 1.4173-1.4183 in. (36.000-36.025 mm) 1.4213 in. (36.100 mm)
Flywheel End Bearing 1.4173-1.4183 in. (36.000-36.025 mm) 1.4213 in. (36.100 mm)
Camshaft Journal to
Camshaft Bearing Clearance
Timing Gear End .0016-.0033 in. (0.040-0.085 mm)
Middle .0026-.0045 in. (0.065-0.115 mm)
Flywheel End .0016-.0049 in. (0.040-0.125 mm)
Camshaft Deflection .001 in. (0.02 mm) .002 in. (0.05 mm)
Camshaft End Play .002-.010 in. (0.05-0.25 mm) .016 in. (0.40 mm)
Piston, Piston Rings, and Wrist Pin
Piston Outside Diameter Measuring
Point (From Bottom of Piston) .39 in. (10.0 mm)
Piston Outside Diameter
Standard 2.5969-2.5980 in .(65.960-65.990 mm) 2.5945 in .(65.900 mm)
1st Oversize 2.6067-2.6079 in .(66.210-66.240 mm) 2.6043 in. (66.150 mm)
2nd Oversize 2.6165-2.6177 in .(66.460-66.490 mm) 2.6142 in. (66.400 mm)
Piston to Cylinder Wall Clearance .0010-.0022 in .(0.025-0.055 mm)

TK 2.49 & TK 3.74 Diesel Engine Specifications (Rev 1/97)
10
Piston, Piston Rings, and Wrist Pin (continued)
Piston Ring Groove Width
Top Ring Groove .0610-.0618 in .(1.550-1.570 mm)
Middle Ring Groove .0622-.0628 in. (1.580-1.595 mm)
Bottom Ring Groove .1185-.1191 in. (3.010-3.025 mm)
Piston Ring Width
Top Ring .0579-.0587 in. (1.470-1.490 mm)
Middle Ring .0579-.0587 in. (1.470-1.490 mm)
Bottom Ring .1169-.1177 in. (2.970-2.990 mm)
Piston Ring to Ring Groove Clearance
Middle .0035-.0049 in. (0.090-0.125 mm)
Bottom .0008-.0022 in. (0.020-0.055 mm)
Piston Ring End Gap
Top Ring .006-.014 in. (0.15-0.35 mm) .059 in. (1.50 mm)
Middle Ring .006-.014 in. (.015-.035 mm) .059 in. (1.50 mm)
Bottom Ring .006-.014 in. (0.15-0.35 mm) .059 in. (1.50 mm)
Wrist Pin Bore Inside Diameter .7874-.7877 in .(20.000-20.008 mm) .7882 in. (20.020 mm)
Wrist Pin Outside Diameter .7870-.7874 in .(19.991-20.000 mm) .7835 in. (19.900 mm)
Wrist Pin to Wrist Pin Bore Clearance 0-.0007 in. (0-.017 mm) .0047 in. (0.120 mm)
Connecting Rod
Wrist Pin Bushing Inside Diameter .7884-.7889 in .(20.025-20.038 mm) .7913 in. (20.100 mm)
Wrist Pin to Wrist Pin Bushing
Clearance .0010-.0019 in .(0.025-0.047 mm) .0079 in (0.200 mm)
Side Clearance (Crank to Rod) .008-.016 in .(0.20-0.40 mm) .022 in. (0.55 mm)
Twist per 4 in. (100 mm) .001 in. (0.03 mm) .003 in. (0.08 mm)
Parallelism per 4 in. (100 mm) .001 in. (0.03 mm) .003 in. (0.08 mm)
Crankshaft and Crankshaft Bearings
Main Journal Outside Diameter
Standard 1.5736-1.5740 in. (39.970-39.980 mm) 1.5709 in. (39.900 mm)
Undersize 1.5638-1.5642 in. (39.720-39.730 mm) 1.5610 in. (39.650 mm)
Main Bearing Inside Diameter
Standard 1.5753-1.5759 in. (40.013-40.029 mm) 1.5768 in. (40.050 mm)
Undersize 1.5655-1.5661 in. (39.763-39.779 mm) 1.5669 in. (39.800 mm)
Main Bearing Clearance .0013-.0023 in .(0.033-0.059 mm) .0059 in. (0.150 mm)
Rod Journal Outside Diameter
Standard 1.4161-1.4165 in. (35.970-35.980 mm) 1.4138 in. (35.910 mm)
Undersize 1.4063-1.4067 in. (35.720-35.730 mm) 1.4039 in. (35.660 mm)

TK 2.49 & TK 3.74 Diesel Engine Specifications (Rev 1/97)
11
Crankshaft and Crankshaft Bearings (continued)
Rod Bearing Inside Diameter
Standard 1.4178-1.4185 in. (36.013-36.029 mm) 1.4197 in. (36.060 mm)
Undersize 1.4080-1.4086 in. (35.763-35.779 mm) 1.4098 in. (35.810 mm)
Rod Bearing Clearance .0013-.0023 in. (0.033-0.059 mm) .0059 in .(0.150 mm)
End Play .0035-.0107 in. (0.090-0.271 mm) .0130 in .(0.330 mm)
Deflection .0008 in. (0.020 mm)
Cylinder Block
Cylinder Inside Diameter
Standard 2.5984-2.5996 in. (66.000-66.030 mm) 2.6063 in. (66.200 mm)
1st Oversize 2.6083-2.6094 in. (66.250-66.280 mm) 2.6161 in. (66.450 mm)
2nd Oversize 2.6181-2.6193 in. (66.500-66.530 mm) 2.6260 in. (66,700 mm)
Cylinder Roundness 0-.0004 in. (0-0.010 mm) .0012 in. (0.030 mm)
Deck Distortion .002 in. (0.05 mm)
Cylinder Head
Distortion 0-.002 in. (0-0.05 mm) .006 in. (0.15 mm)
Timing Gears
Timing Gear Lash
Crankshaft Gear to Idler Gear .0016-.0047 in. (0.040-0.120 mm) .0079 in. (0.200 mm)
Crankshaft Gear to Oil Pump Gear .0043-.0075 in. (0.110-0.190 mm) .0079 in. (0.200 mm)
Idler Gear to Camshaft Gear .0016-.0047 in. (0.040-0.120 mm) .0079 in. (0.200 mm)
Idler Gear to Fuel Injection Pump
Gear .0016-.0047 in. (0.040-0.120 mm) .0079 in. (0.200 mm)
Idler Gear Bushing Inside Diameter .7874-.7882 in. (20.000-20.021 mm) .7906 in .(20.080 mm)
Idler Gear Shaft Outside Diameter .7858-.7866 in. (19.959-19.980 mm) .7846 in. (19.930 mm)
Idler Gear Shaft to Idler Gear Bushing
Clearance .0008-.0024 in. (0.020-0.062 mm) .0059 in. (0.150 mm)
Oil Pump
Type Trocoid
Outer Rotor to Pump Body Clearance .0039-.0063 in. (0.100-0.160 mm) .0098 in. (0.250 mm)
Inner Rotor Tip to Outer Rotor Lobe
Clearance .0059 in. (0.150 mm)
Rotor Plate to Rotor Clearance .0012-.0035 in. (0.030-0.090 mm) .0051 in. (0.130 mm)
Rotor Shaft to Rotor Shaft Bore
Clearance .0005-.0017 in. (0.013-0.043 mm) .0079 in. (0.200 mm)
Pressure Control Valve Setting 42.7-56.9 psi (294-392 kPa)

TK 2.49 & TK 3.74 Diesel Engine Specifications (Rev 1/97)
12
Starter
No Load Test
Voltage 11 volts
Current 180 amps @ 11 volts
Speed More than 3500 rpm @ 11 volts
Commutator Outside Diameter 1.18 in. (30.0 mm) 1.14 in. (29.0 mm)

13
TK 3.88 Diesel Engine Specifications
General TK 3.88
Model 3TNA72
Type Four Stroke Cycle
Water Cooled
Number of Cylinders 3
Bore 2.83 in. (72.0 mm)
Stroke 2.83 in. (70.2 mm)
Displacement 53.6 cu. in. (879 cc)
Power Rating 15.2 hp (11.2 kW)
Compression Ratio 22.3 to 1
Direction of Rotation Counterclockwise
(Viewed from Flywheel)
Firing Order 1, 3, 2
Fuel Injection Timing 16 Degrees BTDC
Nozzle Injection Pressure 1707 psi (11768 kPa)
Oil Pressure 18.5 psi (127 kPa) Minimum
@ 230 F (110 C) and 1600 rpm
Valve Train Standard Dimensions Wear Limit
Valve Spring
Free Length 1.47 in. (37.4 mm) 1.33 in. (33.7 mm)
Inclination .04 in. (1.0 mm)
Valve Guide Inside Diameter
Intake .2758-.2764 in. (7.005-7.020 mm) .2787 in. (7.080 mm)
Exhaust .2758-.2764 in. (7.005-7.020 mm) .2787 in. (7.080 mm)
Valve Stem Outside Diameter
Intake .2734-.2740 in. (6.945-6.960 mm) .2717 in. (6.900 mm)
Exhaust .2734-.2740 in. (6.945-6.960 mm) .2717 in. (6.900 mm)
Valve Depth
Intake .020 in. (0.50 mm) .039 in. (1.00 mm)
Exhaust .033 in. (0.85 mm) .039 in. (1.00 mm)
Valve Guide Projection
Intake .354 in. (9.00 mm)
Exhaust .354 in. (9.00 mm)
Valve Stem to Rocker Arm Clearance
Intake .008 in. (0.20 mm)
Exhaust .008 in. (0.20 mm)
Valve Seat Angle
Intake 30 Degrees
Exhaust 45 Degrees

TK 3.88 Diesel Engine Specifications (Rev 1/97)
14
Valve Train (continued) Standard Dimensions Wear Limit
Valve Seat Width
Intake 0.57 in. (1.44 mm) .078 in. (1.98 mm)
Exhaust .070 in. (1.77 mm) .089 in. (2.27 mm)
Push Rod Length 5.551-5.591 in. (141.00-142.00 mm)
Rocker Arm Bushing Inside Diameter .4724-.4732 in. (12.000-12.020 mm) .4760 in. (12.090 mm)
Rocker Arm Shaft Outside Diameter .4711-.4718 in. (11.966-11.984 mm) .4707 in. (11.955 mm)
Rocker Arm Bushing to Rocker Arm
Shaft Clearance .0006-.0021 in. (0.016-0.054 mm) .0053 in. (0.135 mm)
Tappet Outside Diameter .8239-.8252 in. (20.927-20.960 mm) .8240 in. (20.930 mm)
Tappet Bore Inside Diameter .8268-.8276 in. (21.000-21.021 mm) .8287 in. (21.050 mm)
Tappet To Tappet Bore Clearance .0016-.0037 in. (0.040-0.094 mm)
Camshaft
Cam Lobe 1.3366-1.3406 in. (33.950-34.050 mm) 1.3287 in. (33.750 mm)
Camshaft Journal
Timing Gear End 1.5724-1.5732 in. (39.940-39.960 mm) 1.5689 in. (39.850 mm)
Middle 1.5713-1.5722 in. (39.910-39.935 mm) 1.5689 in. (39.850 mm)
Flywheel End 1.5724-1.5732 in. (39.940-39.960 mm) 1.5689 in. (39.850 mm)
Camshaft Bearing Inside Diameter
Timing Gear End Bearing Insert 1.5748-1.5774 in. (40.000-40.065 mm) 1.5787 in. (40.100 mm)
Middle Bearing 1.5748-1.5758 in. (40.000-40.025 mm) 1.5787 in. (40.100 mm)
Flywheel End Bearing 1.5748-1.5758 in. (40.000-40.025 mm) 1.5787 in .(40.100 mm)
Camshaft Journal to
Camshaft Bearing Clearance
Timing Gear End .0016-.0049 in. (0.040-0.125 mm)
Middle .0026-.0045 in. (0.065-0.115 mm)
Flywheel End .0016-.0033 in. (0.040-0.085 mm)
Camshaft Deflection .001 in. (0.02 mm)
Camshaft End Play .002-.006 in. (0.05-0.15 mm) .016 in. (0.40 mm)
Piston, Piston Rings, and Wrist Pin
Piston Outside Diameter Measuring
Point (From Bottom of Piston) .31 in .(8.0 mm)
Piston Outside Diameter
Standard 2.8316-2.8328 in. (71.922-71.952 mm) 2.8272 in. (71.810 mm)
1st Oversize 2.8414-2.8426 in. (72.172-72.202 mm) 2.8370 in. (72.060 mm)
2nd Oversize 2.8513-2.8524 in. (72.422-72.452 mm) 2.6469 in. (72.310 mm)
Piston to Cylinder Wall Clearance .0019-.0043 in. (0.048-0.108 mm)

TK 3.88 Diesel Engine Specifications (Rev 1/97)
15
Piston, Piston Rings, and Wrist Pin (continued)
Piston Ring Groove Width
Top Ring Groove .0616-.0622 in .(1.565-1.580 mm)
Middle Ring Groove .0598-.0604 in. (1.520-1.535 mm)
Bottom Ring Groove .1382-.1388 in. (3.510-3.525 mm)
Piston Ring Width
Top Ring .0579-.0587 in. (1.470-1.490 mm)
Middle Ring .0579-.0587 in. (1.470-1.490 mm)
Bottom Ring .1366-.1374 in. (3.470-3.490 mm)
Piston Ring to Ring Groove Clearance
Top .0030-.0043 in. (0.075-0.110 mm) .0079 in. (0.200 mm)
Middle .0012-.0026 in. (0.030-0.065 mm) .0079 in. (0.200 mm)
Bottom .0008-.0022 in. (0.020-0.055 mm) .0079 in. (0.200 mm)
Piston Ring End Gap
Top Ring .004-.010 in. (0.10-0.25 mm) .059 in. (1.50 mm)
Middle Ring .010-.016 in. (.025-.040 mm) .059 in. (1.50 mm)
Bottom Ring .006-.014 in. (0.15-0.35 mm) .059 in. (1.50 mm)
Wrist Pin Bore Inside Diameter .8268-.8271 in .(21.000-21.009 mm) .8276 in. (21.020 mm)
Wrist Pin Outside Diameter .8264-.8268 in .(20.991-21.000 mm) .8258 in. (20.975 mm)
Wrist Pin to Wrist Pin Bore Clearance 0-.0007 in. (0-.018 mm) .0018 in. (0.045 mm)
Connecting Rod
Wrist Pin Bushing Inside Diameter .8278-.8283 in .(21.025-21.038 mm) .8307 in. (21.100 mm)
Wrist Pin to Wrist Pin Bushing
Clearance .0010-.0019 in .(0.025-0.047 mm) .0043 in (0.110 mm)
Side Clearance (Crank to Rod) .008-.016 in .(0.20-0.40 mm) .022 in. (0.55 mm)
Twist per 4 in. (100 mm) .002 in. (0.05 mm) .003 in. (0.08 mm)
Parallelism per 4 in. (100 mm) .002 in. (0.05 mm) .003 in. (0.08 mm)
Crankshaft and Crankshaft Bearings
Main Journal Outside Diameter
Standard 1.7311-1.7315 in. (43.970-43.980 mm) 1.7291 in. (43.920 mm)
Undersize 1.7213-1.7217 in. (43.720-43.730 mm) 1.7193 in. (43.670 mm)
Main Bearing Inside Diameter
Standard 1.7323-1.7339 in. (44.000-44.042 mm) 1.7350 in. (44.070 mm)
Undersize 1.7224-1.7241 in. (43.750-43.792 mm) 1.7252 in. (43.820 mm)
Main Bearing Clearance .0008-.0028 in .(0.020-0.072 mm) .0059 in. (0.150 mm)
Rod Journal Outside Diameter
Standard 1.5736-1.5740 in. (39.970-39.980 mm) 1.5717 in. (39.920 mm)
Undersize 1.5638-1.5642 in. (39.720-39.730 mm) 1.5618 in. (39.670 mm)

TK 3.88 Diesel Engine Specifications (Rev 1/97)
16
Crankshaft and Crankshaft Bearings (continued)
Rod Bearing Inside Diameter
Standard 1.5748-1.5765 in. (40.000-40.042 mm) 1.5776 in. (40.070 mm)
Undersize 1.5650-1.5666 in. (39.750-39.792 mm) 1.5677 in. (39.820 mm)
Rod Bearing Clearance .0008-.0028 in. (0.020-0.072 mm) .0059 in .(0.150 mm)
End Play .0035-.0107 in. (0.090-0.271 mm) .0130 in .(0.330 mm)
Deflection .0008 in. (0.020 mm)
Cylinder Block
Cylinder Inside Diameter
Standard 2.8346-2.8358 in. (72.000-72.030 mm) 2.8425 in. (72.200 mm)
1st Oversize 2.8445-2.8457 in. (72.250-72.280 mm) 2.8524 in. (72.450 mm)
2nd Oversize 2.8543-2.8555 in. (72.500-72.530 mm) 2.8622 in. (72,700 mm)
Cylinder Roundness 0-.0004 in. (0-0.010 mm) .0008 in. (0.020 mm)
Deck Distortion .002 in. (0.05 mm)
Cylinder Head
Distortion 0-.002 in. (0-0.05 mm) .006 in. (0.15 mm)
Timing Gears
Timing Gear Lash
Crankshaft Gear to Idler Gear .0016-.0047 in. (0.040-0.120 mm) .0079 in. (0.200 mm)
Crankshaft Gear to Oil Pump Gear .0043-.0075 in. (0.110-0.190 mm) .0079 in. (0.200 mm)
Idler Gear to Camshaft Gear .0016-.0047 in. (0.040-0.120 mm) .0079 in. (0.200 mm)
Idler Gear to Fuel Injection Pump
Gear .0016-.0047 in. (0.040-0.120 mm) .0079 in. (0.200 mm)
Idler Gear Bushing Inside Diameter .7874-.7882 in. (20.000-20.021 mm) .7906 in .(20.080 mm)
Idler Gear Shaft Outside Diameter .7858-.7866 in. (19.959-19.980 mm) .7846 in. (19.930 mm)
Idler Gear Shaft to Idler Gear Bushing
Clearance .0008-.0024 in. (0.020-0.062 mm) .0059 in. (0.150 mm)
Oil Pump
Type Trocoid
Outer Rotor to Pump Body Clearance .0039-.0063 in. (0.100-0.160 mm) .0098 in. (0.250 mm)
Inner Rotor Tip to Outer Rotor Lobe
Clearance .0059 in. (0.150 mm)
Rotor Plate to Rotor Clearance .0012-.0035 in. (0.030-0.090 mm) .0051 in. (0.130 mm)
Rotor Shaft to Rotor Shaft Bore
Clearance .0006-.0019 in. (0.015-0.048 mm) .0079 in. (0.200 mm)
Pressure Control Valve Setting 42.7-56.9 psi (294-392 kPa)