ENGINE REBUILD SHEET

Customer : PT MBSS
Eng. Model : 3412C/60M11209
Start Date : 8/4/2016
Finish Date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
1. CYLINDER BLOCK
C - Clean Cylinder Block, all Oil and Coolant Passages.
1 Apply 6V-6640 Sealant to the outside diameter of the cup
plugs before installation into the cylinder block.
2 Apply 5P-3413 Pipe Sealant to the threads of the plugs
before installation into the front and rear of the cylinder block.
3 The dowels extend from the top deck of the cylinder
block.18.5 ± 0.5 mm (0.73 ± 0.02 inch)
4 Tighten the studs into the front of the cylinder block
the following torque. ... 35 ± 5 N·m (26.0 ± 4.0 lb ft)
5 The dowels project from the front of the cylinder block and
from the rear of the cylinder block. Distance ... 19.0 ± 0.5 mm (0.75 ± 0.02 inch)
6 Width of the main bearing caps ... 215.900 ± 0.025 mm (8.5000 ± 0.0010 inch)
The width of the slot that is machined into the cylinder block
for the main bearing caps ... 215.900 ± 0.013 mm (8.5000 ± 0.0005 inch)
7 Tighten the plugs to the following torque. ... 80 ± 15 N·m (60 ± 10 lb ft)
CONDITION
CHECK REPORTED BY CHECKED BY
OK REWORKED REPLACED REPAIR
BLOCK CASTING V V
TOP DECK V V
CAM BORE V V
MAIN BORE V V
CAM IDLER BORE V V MECHANIC
W/P IDLER BORE V V date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
2. CAMSHAFT
BUSHING C - Make sure Bushing P/N is correct.

C - Make sure all oil holes and passages are clean.

Reused bearing

Spect Bearing
Inner bearings ... 69.982 ± 0.061 mm (2.7552 ± 0.0024 inch) 69.995 mm

INFORMATION REPORTED BY CHECKED BY

BUSHING CONDITION
PART NO. QTY OK REWORKED REPLACED

4N-6658 2 V V
4N-0685 5 V V MECHANIC
date : date : date :
 ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
6. THRUST BEARING
REPLACE M - Measure the thickness of each thrust bearing.

MEASUREMENT RESULT
SPECIFICATION
POSITION 1 2
MM IN T1

- MIN 0.1900 T2

- MAX 0.1945 T3
REPORTED BY CHECKED BY

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
7. CRANKSHAFT
C - Install Crankshaft.

C - Coat all round main journal with lubriplate P/N 1242.

I - Install Thrust Bearing with lubriplate P/N 1242.

C - Ensure the Grooves in the Thrust Bearing must point toward

the Crankshaft

C - Do not rotate Crankshaft before main bearing Cap Screw

final Torque is done.
INFORMATION
REPORTED BY CHECKED BY
CONDITION
CRANKSHAFT
OK REWORKED REPLACED REPAIR
MAIN JOURNAL V V
CON ROD JOURNAL V V
FRONT GEAR V V
REAR GEAR V V
MAIN BEARING V V
CON ROD BEARING V V MECHANIC
CRANKSHAFT V V date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
8. MAIN BEARING CAP
C - Install Lower Main Bearing on the Cap.

C - Make sure Cap Number has the same number that is stamped
on the block.

C - Use engine oil, lubricate the Cap Screw Heads, Threads, and
the Washer. Do not use Impact Wrench, the Main Bearing
Shells can fall out.
 T - Tighten main bearing cap screw by following the step bellow.

SPECIFICATION REPORTED BY CHECKED BY

RESULT
N.m STEP lb-ft
1 190
2 190
3 120 deg

MECHANIC
date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
9. SIDE BOLT
C - Use Engine Oil to Lubricate the cap screw head threads.

I - Install the cap screw for side of the main bearing cap.

C - Use the following steps to tighten the Capscrews in the

sequence shown.

C - All except inline engine for Cap Side Bolt.

SPECIFICATION REPORTED BY CHECKED BY

RESULT
N.m STEP ft-lbs
260 1 190
260 2 190
120 deg 3 120 deg MECHANIC
4 X date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
10. CRANKSHAFT END
CLEARANCE C - Use a Dial Indicator group with magnetic base

M - Measure Crankshaft End Clearance.

CRANKSHAFT INFORMATION SPECIFICATION MM IN RESULT

PART NO. OK REWORKED REPLACED REPAIR MIN 0.15 mm 0.006
0.17 mm
V V MAX 0,51 mm 0.020

REPORTED BY CHECKED BY

MECHANIC
date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
11. CYLINDER LINER
C - Calculate Liner Protrution prior to the installation.
 I - Install Cylinder Liner.

RECORDED REPORTED BY CHECKED BY

CYLINDER LINER CONDITION
PART NO. QTY OK REWORKED REPLACED

197-9322 12 V V
MECHANIC
date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
12. CYLINDER LINER
PROTRUSION - Use a gauge block, P/N 8T0455 , or equivalent.

- The clamps must touch the highest part of the liner.

* Install the clamps and the cap screw torque Tighten the bolts evenly
- in four steps: 14 N·m (5 lb ft), 35 N·m (25 lb ft), 70 N·m (50 lb ft)

* and then to 95 N·m (70 lb ft).

SPECIFICATION
MM IN
0.025 MIN 0.001
0.152 MAX 0.006

CYLINDER LINER NUMBER

POSITION
2R 4R 6R 8R 10R 12R
12 O'CLOCK 0.030 mm 0.031 mm 0.030 mm 0.029 mm 0.031 mm 0.029 mm
3 O'CLOCK 0.030 mm 0.031 mm 0.030 mm 0.029 mm 0.031 mm 0.029 mm
6 O'CLOCK 0.030 mm 0.031 mm 0.030 mm 0.029 mm 0.031 mm 0.029 mm
9 O'CLOCK 0.030 mm 0.031 mm 0.030 mm 0.029 mm 0.031 mm 0.029 mm

CYLINDER LINER NUMBER

POSITION
1L 3L 5L 7L 9L 11L
12 O'CLOCK 0.027 mm 0.028 mm 0.028 mm 0.027 mm 0.026 mm 0.028 mm
3 O'CLOCK 0.027 mm 0.028 mm 0.028 mm 0.027 mm 0.026 mm 0.028 mm
6 O'CLOCK 0.027 mm 0.028 mm 0.028 mm 0.027 mm 0.026 mm 0.028 mm
9 O'CLOCK 0.027 mm 0.028 mm 0.028 mm 0.027 mm 0.026 mm 0.028 mm

REPORTED BY CHECKED BY

MECHANIC
date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
13. PISTON RING
 END GAP C - Use a feeler gauge to measure the end gap.

C SPEC Ring Gap For Mechanical Injector

MIN MAX
POSITION
MM IN MM IN
C TOP 0.55 0.022 0.65 0.028
SECOND 1.08 0.0425 1.27 0.05
C OIL 0.57 0.022 0.76 0.03

CYLINDER NUMBER
PISTON RING
1 2 3 4 5 6 7 8 9 10 11 12

TOP 0.57 mm 0.56 mm 0.58 mm 0.56 mm 0.56 mm 0.57 mm 0.57 mm 0.58 mm 0.60 mm 0.58 mm 0.60 mm 0.57 mm

2ND 1.10 mm 1.09 mm 1.11 mm 1.09 mm 1.09 mm 1.10 mm 1.10 mm 1.11 mm 1.12 mm 1.11 mm 1.12 mm 1.10 mm

OIL 0.59 mm 0.58 mm 1.00 mm 0.58 mm 0.58 mm 0.59 mm 0.59 mm 1.00 mm 1.00 mm 1.00 mm 1.00 mm 0.59 mm

REPORTED BY CHECKED BY

MECHANIC
date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
16. PISTON
C - Install Piston Rings with stamped mark facing upwards and
with tools P/N 7M-3978.

C - The Gap in the Oil Ring Expanding (10) must be turned 180
degrees opposite the Gap on the Oil Ring (11) or the Rings and
Piston will be damaged.

C - Rotate the Rings so the Gap are not aligned with the adjacent
Ring or the Piston Pin Bore.

C - Make sure for correct Piston P/N.

ENGINE PISTON SET CONDITION

REMARK
PART PART NO. QTY OK REWORKED REPLACED
TOP RING 134-3761 12 V V
2ND RING 2P-2817 12 V V
OIL RING 7N-7078 12 V V
PISTON 9Y-7212 12 V V
 REPORTED BY CHECKED BY

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
17. CONNECTING ROD
CAP SCREW T - Tighten the Capscrew alternately and evenly using the
folowing Torque Increments.

C -

C - Be sure the anvilis centered in the hole of the Rod Capscrew

and the tools contacts the head correctly.

SPECIFICATION CONDITION
RESULT CHECK
N.m STEP lb ft PART NO. QTY OK REWORKED REPLACED REPAIR

80 1 60 160-8178 12 V V
120 deg 2 120 deg CON-ROD

- 3

- 4 8L-3441 24 V V
- 5 BOLT & NUT 6N-8942 24 V V
- 6
REPORTED BY CHECKED BY

MECHANIC
date : date : date :

ASSEMBLING
CHECK POINT REMARKS
WORK PROCESS
19. PISTON COOLING
NOOZLE I - Install Piston Cooling Noozle.

C - Ensure the tip of each nozzle is directed at the centre of each

Piston Shacker Hole.
Do not use washers on the mounting Cap Screw of the Piston
Cooling Noozle. Contact between Connecting Rod and
Cap Screw Head will result engine damage.

T - Torque Cap Screw refer to specification.

PISTON COOLING NOOZLE INFORMATION

PART NO. QTY OK REWORKED REPLACED

7W-4990 12 V V
 SPECIFICATION TORQUED COOLING NOOZLE CAP SCREW RECORD
RESULT
BOLT N.m lb ft 2R 4R 6R 8R 10R 12R
18 18 18 18 18 18
24 18

1L 3L 5L 7L 9L 11R
18 18 18 18 18 18
24 18

REPORTED BY CHECKED BY

MECHANIC FOREMAN/ SPV Q.A. OFFICER

date : date : date :