3204 Long Blocks

T E C H N I C A L S U P P L E M E N T
3204 Long Blocks

Long Block Selection: General Information
The purpose of this technical supplement is to help you decide if there is a Caterpillar Remanufactured long
block available for a particular engine application. When making your decision, please keep the following points
in mind.
� Long blocks are not available for every engine application. The long blocks we do offer can, however,
be used to service many applications even though the long block does not exactly match the original
engine configuration. When the consist of the Reman product offering differs from the consist of a
customer’s engine, only the dealer and customer can decide whether or not it makes economic
sense to change the parts that differ.
� It’s Caterpillar’s policy to incorporate the latest critical engineering changes into Cat Reman products.
Therefore, long blocks may be offered with some parts from a later design era as service repairs for
engines from an earlier design era. An example is the 3406C crankshaft, connecting rods, and
pistons which are in certain 3406B long blocks. The result is that the parts in the long blocks match
each other but do not match the parts consist of new production engines, nor do they match any
single Parts Book. When long block parts consists differ from the official parts list, Reman provides
an engine plate alerting the customer to Special Instruction or Service Magazine articles for
information on non-standard parts.
� Make sure any future engine/long block repairs which do not use parts called for by the original Parts
Book, or official replacements called for by parts and service sources, are carefully documented. If
you choose to make any configuration or consist changes, good documentation can prevent
problems the next time parts are ordered.
3204 Long Block Selection
First, use normal parts information sources (parts books, microfiche, SIS, NPR, the Reman Products Guide,
etc.) to look up the Reman short block intended to service the customer’s engine arrangement. Next, find that
short block in the following “consists” chart and read the long block part number from the top of the same
column.
Next, follow the long block candidate column down into the consist section of the chart. Check the camshaft,
then cylinder head part numbers shown against the part numbers called for by normal parts information sources
to service the customer’s engine. Don’t forget to check the NPR to determine that you are using the most
current part number. Now check the other part numbers listed in the same column of the consist chart. For a
long block candidate to become a “selection”, all the part numbers listed under the long block part number
should match the correct service part numbers for the customer’s engine. If, at any point in the above process
the Reman consist fails to match the part numbers called for to service the customer’s engine, Reman does not
have an offering that matches the customer’s engine. You may select a long block which isn’t a perfect match if
you believe changing the parts which don’t match is worth the time and money to do the work.
SELD0188-03 (5/02)
Technical Supplement 3204 Long Block
Use The Correct Oil Pump

In some cases, changing the oil pump may be required. When a 3204 long block without piston cooling jets is
used as a service repair for an engine with cooling jets, a different oil pump is called for. Be sure to read the
Service Magazine articles referenced at the bottom of the following “Consist and Selection” chart.
Some Disassembly May Be Required
3204 long blocks are shipped with the valve train fully installed and adjusted at the factory to ensure all valve
train parts will function properly. The engine front plate is not included. When the camshaft gear is pressed on,
the camshaft must be removed from the long block before the customer’s original front plate can be installed.
This will require resetting the valves upon reassembly.
Lifting eyes and a valve cover (with gasket) are installed for shipping purposes. If these parts do not match the
parts from the customer’s engine, the customer’s parts must be transferred to the long block. Any parts
removed from the long block must be returned with the engine core. Add charges will be assessed for any
missing parts.
3204 Long Block Consist and Selection Chart

REMAN LONG BLOCK 0R4351 0R4352 0R4353 0R4354
APPLICATION PC NA EARLY* DI NA EARLY* DI NA CURRENT DI T CURRENT
BLOCK W/O JETS** BLOCK W/O JETS** BLOCK W/O JETS** BLOCK WITH
JETS**
Ref. production block group 4N0172 4N0172 1W4326 6N9049 or 6N2390
8N5536 or
Ref. production piston & rod group 4N0191 8N4079 2W1040 or 4P0533
7C1146
LONG BLOCK CONSIST INFORMATION
Assembled Complete
Short Block 0R0724 0R0725 0R0727 0R3592
Cylinder Head Gp 4N0486 6N2467 6N2467 6N2397
Valve Mech Gp In head gp 1W5720 1W5720 1W5720
Valve Cover Gp In head gp 1W1352 1W1352 1W1352
Camshaft Gp 4N0174 6N2393 6N2393 2W1337#
Lifting Eye Gp 4N0180 4N0180 4N0180 4N0180
(Fuel Pump Idler) Gear As 4N0087 7N6311 7N6311 7N6311
SHIP LOOSE ITEMS
(Breather) Element 4N0490 NONE NONE NONE
Breather As NONE 8S0248 8S0248 8S0248
@
Oil Cooler Core 2W7590 2W7590 2W7590 and 9N5659 9N5659
Water Pump Gp 0R1242 0R1242 0R1242 0R1242
* Current blocks are not interchangeable with early parts. See: “Changes to 3204 Engine Accessory Drive and Engine Block;
New Engine Arrangements Used” Service Magazine (October 4, 1982).
** Piston Cooling Jets. See: “New Pistons Used” and “Cooling Jets Removed and Different Oil Pump Used” Service Magazine
(February 9, 1987).
# With wide valve train gears. Requires current front cover, implement pump gear & spacer, and Tach. drive Gp. See:
“Improved Engine Timing Gear Train” (for 943 & 953 Loaders). Service Magazine (October 4, 1982).
@ Use the one that fits. One of these new oil cooler cores (in addition to the customer’s old oil cooler core) must be returned
with the engine core.
SELD0188-03 (5/02)
© 2002 Caterpillar Inc.

3204 Long Blocks

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T E C H N I C A L S U P P L E M E N T

3204 Long Blocks

Use The Correct Oil Pump

3204 Long Block Consist and Selection Chart

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