Cat 3204 di engine

Perth, Australia

#1 Dec 25, 2008
I got a rebuilt 3204 di engine it will not start the only thing that I think that wrong is the diesel timing. The pulley fits on a tappered shaft with no timing marks. The rebuilder said its close. But when I try to start only white smoke comes out and not sign of starting. How can I fix the diesel timing?

Since: Jul 08

Location hidden

#2 Dec 26, 2008
checking the timing is fairly simple.

- first you need a 3/8"-16 NC bolt long enough to reach the flywheel timing thread through the flywheel housing plug (facing towards the front of the engine).

- turn the crankshaft counterclockwise untill you can install the bolt to the flywheel. if you turn the crackshaft past the timing hole alingment, turn it 30 degrees in the reverse direction (clockwise) and then counterclockwise untill the holes are alinged and the bolt can be turned on the thread by hand.

- remove the valvecover and check the valvelash on cylinder one. if both valves have lash and the flywheel timing bolt can be installed you have the TDC position for cylinder one and you can proceed to checking the injection pump timing. if the valves on cylinder one have no lash and the exhaust valve is compressed you need to remove the flywheel timing bolt. then turn the crankshaft 360 degrees counterclocwise untill the timing bolt can be installed. now you should have cylinder one on TDC.

- remove the fuel filter to gain full access to the injection pump side cover.

- remove the four bolts and the cover.

- now you see a hole (a bore of 3/8" in diameter) and at the end of the hole you see the injection pump main shaft surface.
when cyl one is at TDC and the flywheel timing bold installed you should see a machined slot on the shaft. you should use a specified timing pin for checking this but its fairly accurate this way too. it you see the slot and the slot seems to be alinged with the bore which you are looking trough the timing is correct. if not the timing pump has been timed incorrectly for the cylinder four TDC. this happens fairly often.

- if you cannot see the machined slot when cylinder one is at TDC, the injection pump gear needs to be loosened and re-timed. loosening the gear reguires a specific tool. you need to contact the performer of the rebuild for rework on the timing.

ask for additional info, hope this helps!

Valcea, Romania

#3 Jul 10, 2010
could you post some pictures from inside the injrction pump ?

Valcea, Romania

#4 Jul 10, 2010
i want to buy injection valves for 3204 engine .
do yuo know some supplyers?
pls, send me an offer to "[email protected] "

Since: Jul 08

Location hidden

#5 Jul 11, 2010
you will need the original cat part number for the nozzles so that you can start searching for aftermarket ones. give me the engine serial number and i'll give you the part number.

Since: May 12

Bucharest, Romania

#8 May 4, 2012
how to block injection pump to resolv a leaking down to injection pump? There are 2 plugs in front of the pump . Witch of them i have to take it out to blok the injection pump shaft?
tazmanian dante

Mobile, AL

#9 Jul 11, 2014
I'm trying to pull a cat 3204 cracnkshaft pulley so I can take the front plate off. The pulley wont budge at all using a crowbar brute force. Can anyone give me an idea to try, please?

Tell me when this thread is updated:

Subscribe Now Add to my Tracker

Add your comments below

Characters left: 4000

Please note by submitting this form you acknowledge that you have read the Terms of Service and the comment you are posting is in compliance with such terms. Be polite. Inappropriate posts may be removed by the moderator. Send us your feedback.

Caterpillar Discussions

Title Updated Last By Comments
Cat engine 3126 (Oct '06) 10 hr Mack Shaw 723
Caterpillar C15 Engine TPS error code (May '09) Feb 23 James grest 69
CAT C15 help!! (Jun '08) Feb 23 Rickey 161
cat 3406e diesel specs (Feb '07) Feb 21 jpinskey 136
D5m transmission control cable Feb 21 Rogerf 1
cat 3406e burning oil after rebuild (Nov '11) Feb 19 Cory 7
cat 320 hyd problems (Sep '09) Feb 15 ali 70
More from around the web