CAT 3512 Service Manual 66Z SENR2382

SENR2373-07
SENR2374-04
SENR2382-00
3512 MARINE
S/N – 66Z1-Up
3500 Marine Engines
Total
Page
SENR2373-07
Specifications
INDEX 1
Engine Design 5
Engine Design 6
Fuel Filter (Primary) 7
Fuel Pressure Regulator 8
Fuel Transfer Pump 9
Fuel Injector Mechanism 10
Governor Drive 12
Fuel Injection Control Linkage 14
Governor Linkage 16
Manual Shutoff 18
Aftercooler 19
Camshaft 20
Camshaft Bearing Position 22
Valve Mechanism 23
Valve Mechanism 25
Type 1
Type 2
Cylinder Head 27
Cylinder Head 29
Cylinder Head 31
Cylinder Head Valves 33
Cylinder Head Valves 35
Turbocharger 37
Turbocharger 38
Turbocharger 39
Turbocharger 40
Exhaust Manifold 41
Exhaust Manifold 42
Air Inlet and Exhaust Lines 43
Air Shutoff 44
Engine Oil Pump 45
Engine Oil Pump 47
Engine Oil Pump 51
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves 55
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves 57
Crankcase Breather 59
Engine Oil Pan 62
Engine Oil Pan 63
Engine Oil Pan 64
Water Temperature Regulator 66
Water Pump 67
Type 1
Type 2
Assembly Procedure
Water Pump 70
Cylinder Block 71
Cylinder Liner 73
Piston and Rings - One-Piece Piston 74
Piston and Rings 76
Piston and Rings - Two-Piece Piston 78
Top Piston Ring (1)
Intermediate Piston Ring (2)
Oil Control Piston Ring (3)
Piston Pin Bore (4)
Piston Pin (5)
Pin Retainer (6)
Connecting Rod 80
Connecting Rod and Main Bearing Journals 83
Crankshaft 84
Crankshaft 85
Crankshaft 86
Crankshaft Wear Sleeves and Seals 87
Gear Group (Front) 89
Gear Group (Rear) 90
Gear Group (Rear) 92
Accessory Drive (Lower Left Hand) 94
Accessory Drive (Lower Left Hand) 95
Accessory Drive (Upper Right Hand) 97
Accessory Drive (Upper Left Hand) 98
Flywheel 100
Flywheel Housing 101
Vibration Damper 105
Vibration Damper Guard 106
Belt Tension Chart 107
Alternator and Regulator 109
Alternator Mounting 110
197-9087 Belt Tension Chart
Electric Starting Motor 112
Electric Starting Motor 114
Air Starting Motor 115
Air Starting Motor Pressure Regulating Valve 116
Coolant Temperature Switch 117
Engine Oil Pressure Sensor 118
Engine Coolant Temperature Sensor 119
Engine Speed Sensor 120
SENR2374-04
Systems Operation
INDEX 122
Fuel System Operation 126
Fuel Injector 131
Fuel Injection Cycle 132
Governor - 3161 134
Operation of the 3161 Governor
Increase In Speed Setting
Decrease In Speed Settings
Shutdown
Electronic Governors 138
Air Inlet and Exhaust System Operation 140
Aftercooler 141
Valve System Components 142
Turbocharger 144
Lubrication System Operation 145
Cooling System Operation - Jacket Water Aftercooled 147
Cylinder Block, Liners and Heads 149
Pistons, Rings and Connecting Rods 150
Pistons, Rings and Connecting Rods - Two-Piece Piston 151
Pistons, Rings and Connecting Rods 152
Crankshaft 153
Camshaft 154
Air Starting System 155
Electrical System Operation 157
Alternator 158
Starting Solenoid 159
Starting Motor 160
Starting Motor Protection
Coolant Temperature Switch 162
Magnetic Switch 163
Circuit Breaker 164
SENR2374-04
Testing and Adjusting
General Information (Fuel System) - Diesel 165

Fuel System Inspection 166
Checking Engine Cylinders 167
Fuel Pressure - Diesel System 168
Specifications
Introduction
Required Tools
Test Preparation - Fuel Manifold Pressure
Test Preparation - Fuel Transfer Pump Pressure
Test Procedure - Transfer Pump and Fuel Manifold Pressure
Engine Rotation 172
Finding the Top Center Position for the No. 1 Piston 173
Introduction
Required Tools
Check Preparation
Camshaft Timing 175
Timing Check
Timing Adjustment
Engine Speed Measurement 178
Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting 179
Fuel Injector Timing 181
Fuel Injector Synchronization 184
Fuel Setting 186
Fuel Setting Adjustment
Restriction of Air Inlet and Exhaust 189
Measuring Inlet Manifold Pressure 190
Measuring Exhaust Temperature 192
Crankcase Pressure 193
Compression 194
Cylinder Heads 195
Valves
Valve Seat Inserts
Valve Guides
Checking Valve Guide Bores
Bridge Dowels
Valve Lash Check 196
Valve Lash and Valve Bridge Adjustment 197
Valve Bridge Adjustment
Installation
Valve Lash Adjustment
General Information (Lubrication System) 202
Engine Oil Pressure - Test 203
Excessive Bearing Wear - Inspect 206
Excessive Engine Oil Consumption - Inspect 207
Engine Oil Leaks on the Outside of the Engine
Engine Oil Leaks into the Combustion Area of the Cylinders
Increased Engine Oil Temperature - Inspect 208
Engine Oil Pressure is Low 209
Low Engine Oil Level
Engine Oil Pressure Gauge
Contaminated Engine Oil
Improper Circulation of the Engine Oil
Worn Components
Engine Oil Pressure is High 211
Indicators for Engine Oil Pressure 212
General Information (Cooling System) 213
Visual Inspection 215
Test Tools for the Cooling System 217
Cooling System Pressure Cap - Test 219
Radiator and Cooling System - Test 221
Water Temperature Regulator - Test 223
Introduction
Test Procedure
Connecting Rod Bearings 224
Main Bearings 225
Cylinder Block 226
Cylinder Liner Projection 227
Specifications
Introduction
Required Tools
Preparation
Cylinder Liner out of the Cylinder Block - Check
Cylinder Liner Installed in the Cylinder Block - Check
Flywheel - Inspect 230
Face Runout (Axial Eccentricity) of the Flywheel
Bore Runout (Radial Eccentricity) of the Flywheel
Flywheel Housing - Inspect 232
Face Runout (Axial Eccentricity) of the Flywheel Housing
Bore Runout (Radial Eccentricity) of the Flywheel Housing
Vibration Damper 235
General Information (Air/Electric Starting System) 236
Electrical Side Of The Air System
Air Side Of The Air System
Pressure Regulating Valve 238
Lubrication 239
Test Tools for the Electrical System 240
177-2330 Battery Analyzer
271-8590 Starting/Charging Analyzer Gp
225-8266 Ammeter Tool Gp
146-4080 Digital Multimeter Gp
Battery 243
Charging System 244
Alternator Regulator 245
Tightening the Alternator Pulley Nut
Electric Starting System 246
Pinion Clearance Adjustment 247
SENR2382-00
Disassembly and Assembly
INDEX 248
Alternator (An Attachment) 250
Manual Shutoff 252
Air Cleaner Housings 254
Exhaust Elbow 255
Gauge Panel 256
Junction Box 261
Air Intake Shutoff (3508) 264
Service Meter 271
Tachometer Drive 272
Water Temperature Regulators 276
Water Pump 278
Auxiliary Pump (Fresh Water) (An Attachment) 283
Fuel Filter Housing 295
Water Temperature Contactor 298
Fuel Priming Pump 299
Expansion Tank 304
Oil Pump 305
Oil Filter Housing 310
Oil Pan 315
Oil Sequence Valves 318
Oil Cooler 319
Oil Sump Pump And Check Valve (An Attachment) 325
Oil Sump Pump (An Attachment) 327
Governor 329
Governor Drive 330
Turbochargers 334
Turbochargers (3512) 336
Turbochargers (3508) 342
Exhaust Manifolds 347
Aftercooler 349
Hydramechanical Shutoff Control (An Attachment) 353
Hydramechanical Shutoff Drive (An Attachment) 364
Accessory Drive (Front) 367
Oil And Water Pump Drive 370
Crankshaft Vibration Damper 373
Crankshaft Front Seal And Wear Sleeve 374
Crankshaft Rear Seal And Wear Sleeve 377
Front Drive Housing 380
Air Starter 384
Air Starter (An Attachment) 385
Flywheel 396
Valve Covers 401
Rocker Shafts And Push Rods 402
Rocker Shaft Assemblies 404
Fuel Injectors 406
Fuel Injectors 408
Cylinder Heads 414
Piston Cooling Sets 419
Valves 420
Valve Lifters 422
Bridge Dowels 423
Valve Seat Inserts 424
Valve Guides 425
Connecting Rod Bearings 426
Front Balancer Group (3508) 428
Rear Gear Group 431
Spacer Plates 435
Crankshaft Main Bearings 437
Pistons 441
Cylinder Liners 444
Camshafts 447
Camshaft Bearings 452
Crankshaft 454
1
SENR2373-07
INDEX
3500 Marine Engines, SENR2373-07
Specifications
Engine Design INDEX 000

001 1
5
Engine Design 002 6
Fuel Filter (Primary) 003 7
Fuel Pressure Regulator 004 8
Fuel Transfer Pump 005 9
Fuel Injector Mechanism 006 10
Governor Drive 007 12
Fuel Injection Control Linkage 008 14
Governor Linkage 009 16
Manual Shutoff 010 18
Aftercooler 011 19
Camshaft 012 20
Camshaft Bearing Position 013 22
Valve Mechanism 014 23
Valve Mechanism 015 25
Type 1
Type 2
Cylinder Head 016 27
Cylinder Head Valves 019 33
Cylinder Head Valves 020 35
Turbocharger 021 37
Turbocharger 022 38
Turbocharger 023 39
Turbocharger 024 40
Exhaust Manifold 025 41
Exhaust Manifold 026 42
Air Inlet and Exhaust Lines 027 43
Air Shutoff 028 44
Engine Oil Pump 029 45
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves 032 55
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves 033 57
Crankcase Breather 034 59
Engine Oil Pan 037 62
SENR2373-07
2

Water Temperature Regulator 040 66
Water Pump 041 67
Type 1
Type 2
Assembly Procedure
Water Pump 042 70
Cylinder Block 043 71
Cylinder Liner 044 73
Piston and Rings - One-Piece Piston 045 74
Piston and Rings 046 76
Piston and Rings - Two-Piece Piston 047 78
Top Piston Ring (1)
Piston Pin Bore (4)
Piston Pin (5)
Pin Retainer (6)
Connecting Rod 048 80
Connecting Rod and Main Bearing Journals 049 83
Crankshaft 050 84
Crankshaft 051 85
Crankshaft 052 86
Crankshaft Wear Sleeves and Seals 053 87
Gear Group (Front) 054 89
Gear Group (Rear) 055 90
Gear Group (Rear) 056 92
Accessory Drive (Lower Left Hand) 057 94
Accessory Drive (Lower Left Hand) 058 95
Accessory Drive (Upper Right Hand) 059 97
Accessory Drive (Upper Left Hand) 060 98
Flywheel 061 100
Flywheel Housing 062 101
Vibration Damper 064 105
Vibration Damper Guard 065 106
Belt Tension Chart 066 107
Alternator and Regulator 067 109
Alternator Mounting 068 110
Electric Starting Motor 069 112
Electric Starting Motor 070 114
Air Starting Motor 071 115
Air Starting Motor Pressure Regulating Valve 072 116
Coolant Temperature Switch 073 117
Engine Oil Pressure Sensor 074 118
SENR2373-07
3
Engine Coolant Temperature Sensor 075 119

Engine Speed Sensor 076 120
SENR2373-07
4
SENR2373-07
5
001 Specifications
Engine Design
Illustration 1 g00293348
Cylinder And Valve Location, (A) Inlet valves (B) Exhaust valves
Number and arrangement of cylinders ... 60 degree V-8

Valves per cylinder ... 4
Displacement ... 34.5 L (2105 cu in)
Bore ... 170 mm (6.7 inch)
Stroke ... 190 mm (7.5 inch)
Compression ratio
One piece piston ... 13:1
Two-piece piston ... 13.5:1
Combustion ... Direct injection
On engines with standard rotation, when the crankshaft is viewed from the flywheel end, the crankshaft
rotates in the following direction. ... Counterclockwise
Firing order (injection sequence)
Standard rotation CCW ... 1, 2, 7, 3, 4, 5, 6, 8
Reverse rotation CW ... 1, 8, 7, 2, 6, 5, 4, 3
Valve lash
Inlet ... 0.50 mm (.020 inch)
Exhaust ... 1.00 mm (.040 inch)
Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right side of the
engine are determined from the flywheel end. The number 1 cylinder is the front cylinder on the right side.
The number 2 cylinder is the front cylinder on the left side.
6
002 Specifications
Engine Design
Cylinder And Valve Location, (A) Inlet valves (B) Exhaust valves
Number and arrangement of cylinders ... 60 degree V-12

Valves per cylinder ... 4
Displacement ... 51.8 L (3158 cu in)
Bore ... 170 mm (6.7 inch)
Stroke ... 190 mm (7.5 inch)
Compression ratio
One piece piston ... 13:1
Two-piece piston ... 13.5:1
Combustion ... Direct injection
On engines with standard rotation, when the crankshaft is viewed from the flywheel end, the crankshaft
rotates in the following direction. ... Counterclockwise
Firing order (injection sequence)
Standard rotation CCW ... 1, 12, 9, 4, 5, 8, 11, 2, 3, 10, 7, 6
Reverse rotation CW ... 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7, 12
Valve lash
Inlet ... 0.50 mm (.020 inch)
Exhaust ... 1.00 mm (.040 inch)
Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right side of the
engine are determined from the flywheel end. The number 1 cylinder is the front cylinder on the right side.
The number 2 cylinder is the front cylinder on the left side.
7
003 Specifications
Fuel Filter (Primary)

S/N - 29Z1-UP , S/N - 50Y1-UP , S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 72Z1-UP , S/N - 96Y1-UP
Table 1
Specification for 8N-6435 Primary Fuel Filter Gp, 7E-6719 Primary Fuel Filter Gp, and 2W-6071
Primary Fuel Filter Gp
Item Qty
Part Specification Description
Torque to
1 1 7N-1628 Nut
25 ± 5 N·m (221 ± 44 lb in).
2J-0157 O-Ring Seal Lubricate the bore of the O-ring seal and the shaft lightly with clean
2 1
engine oil.
Length under test force is
27.94 mm (1.100 inch).
Test force
3 1 7S-9323 Spring
27.7 to 32.3 N (6.2 to 7.3 lb).
Free length after test is
42.67 mm (1.680 inch).
8
004 Specifications
Fuel Pressure Regulator

, S/N - -
, (2) Valve plunger
Table 1
Specification for 114-5477 Valve Plunger
Item Qty Part Specification Description
Length under test force is 28.4 mm (1.12 inch).
Test force is
1 1 9N-4053 Spring
40.79 ± 2.05 N (9.17 ± 0.46 lb).
Free length after test force is
57.15 mm (2.250 inch).
9
005 Specifications
Fuel Transfer Pump

, S/N - -
Table 1
Specification for 8N-6151 Fuel Transfer Pump Gp, 332-7928 Fuel Transfer Pump Gp, 313-7770 Fuel
Transfer Pump Gp and 377-5900 Fuel Transfer Pump Gp
Before installation, inside diameter of the terminal bushing for
gear shaft is
7C-2870 Terminal
1 4 12.783 mm (0.5033 inch).
Bushing
Installation depth of terminal bushing is
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
Diameter of the gear is
268-1903 Drive Shaft As 29.801 ± 0.006 mm (1.1733 ± 0.0002 inch).
2 1
Length of the gear is
25.347 ± 0.008 mm (0.9979 ± 0.0003 inch).
Diameter of the idler gear assembly is
29.801 ± 0.006 mm (1.1733 ± 0.0002 inch).
3 1 1W-4003 Idler Gear As
Length of the gear is
25.347 ± 0.008 mm (0.9979 ± 0.0003 inch).
10
006 Specifications
Fuel Injector Mechanism

, S/N - 29Z1-UP , S/N - 50Y1-UP , S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 72Z1-UP , S/N - 96Y1-UP
Table 1
Specification for 195-1926 Valve Mechanism Gp and 379-4834 Valve Mechanism Gp
Item Qty
1 1 3J-9196 Jam Nut Torque to 70 ± 15 N·m (52 ± 11 lb ft).
Diameter is
7C-2377 Arm Shaft 37.084 ± 0.013 mm (1.4600 ± 0.0005 inch).
2 1
Assembly Bore of the bearing is
37.140 ± 0.015 mm (1.4622 ± 0.0006 inch).
Use the following procedure in order to install the fuel injector:
1. Put multipurpose grease in the bore of the cylinder head in order to
lubricate the O-ring seals.
2.Put the fuel injector in the bore. Use the bolt and the clamp in order to
push the fuel injector into the correct position.
- - -
Note: Do not tap or hit surface "Y" in order to install the injector.
3.Tighten bolt (3) that holds the fuel injector clamp. Torque to
65 ± 7 N·m (48 ± 5 lb ft).
3.After the clamp has been tightened, the fuel injector rack "X" must
move freely.
Fuel timing dimension:
A - - Refer to TMI (Technical Marketing Information) for the correct timing
specifications for the adjustment of the fuel injection pump.
5 3 7N-4782 Lifter Guide springs must not be used again. Always install new guide springs.
11
Guide Spring
Diameter of new lifter assembly is
346-7515 Lifter As 29.900 ± 0.010 mm (1.1772 ± 0.0004 inch).
6 3
Bore in head for lifter assembly is
30.000 ± 0.025 mm (1.1811 ± 0.0010 inch).
12
007 Specifications
Governor Drive
, S/N - -
Table 1
Specification for 1W-2135 Governor Drive Gp
Item Qty
Diameter (C) is 34.000 ± 0.013 mm (1.3386 ± 0.0005 inch).
7N-5701 Governor Drive Use the 7N-5694 Shim (1) to achieve the assembled backlash of
2 1
Pinion the governor drive pinion is
0.075 to 0.150 mm (0.0030 to 0.0059 inch).
3 2 0S-1621 Bolt Do not tighten the bolt until governor is aligned vertically.
4 1 8C-5197 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.
5 2 1D-4588 Bolt Lubricate the bore lightly with the lubricant that is being sealed.
Diameter (E) is
34.000 ± 0.013 mm (1.3386 ± 0.0005 inch).
Dimensions for the sleeve bearing (F) :
6 1 1N-3409 Bevel Gear Outside diameter of the sleeve bearing is
40.545 ± 0.013 mm (1.5963 ± 0.0005 inch).
Bore in the sleeve bearing after installation is
34.072 mm (1.3414 inch).
13
Bore diameter of drive housing (D) is

40.432 ± 0.025 mm (1.5918 ± 0.0010 inch).
Bore diameter (A) is
7 1 7N-5700 Adapter
34.072 ± 0.025 mm (1.3414 ± 0.0010 inch).
8 1 6V-8260 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.
9 1 6J-2244 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.
10 1 061-9457 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.
11 2 1A-7669 Bolt Do not tighten the bolt until governor is aligned vertically.
14
008 Specifications
Fuel Injection Control Linkage

, S/N - 29Z1-UP , S/N - 4MJ1-UP , S/N - 50Y1-UP , S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 72Z1-UP , S/N
- 96Y1-UP
Typical example
(1) Bore of the bearings in the bracket assemblies after installation ... 21.925 ± 0.015 mm (0.8632 ± 0.0006
inch) (2) Diameter of the surfaces for the bearings and the rod assemblies on the shafts ... 21.850 ± 0.015 mm
(0.8602 ± 0.0006 inch) (3) Bore of the bearings in the two support assemblies after assembly ... 21.925 ±
0.015 mm (0.8632 ± 0.0006 inch) (4) Torque for the pin ... 10 ± 2 N·m (90 ± 18 lb in)
15
Front view
(5) Torque for the locknuts at each end of the bellcrank ... 8 ± 2 N·m (70 ± 18 lb in) (6) Torque for the
plugs ... 25 ± 5 N·m (18 ± 4 lb ft) (D) Clearance between the lever assemblies on the front cross shaft and the
side shafts ... 0.20 ± 0.10 mm (0.008 ± 0.004 inch)
16
009 Specifications
Governor Linkage
, S/N - -
, (A) Shutoff position is 8.5 degrees (B) Fuel-on position is 32 degrees (C) Shutoff position is 30 ± 5 degrees
Table 1
Specification for 150-4146 Fuel Injection Pump Fastener
Item Qty
4W-5029 Lever
1 1 Diameter of the shaft is 19.050 ± 0.013 mm (0.7500 ± 0.0005 inch).
As
8L-6376 Bore in bearing after assembly in the bracket is
2 2
Bushing 19.126 ± 0.038 mm (0.7529 ± 0.0015 inch).
6V-8186 Full Torque to
6 1
Nut 12 ± 4 N·m (106 ± 35 lb in).
5L-3708
Torque to
8 4 Taperlock Stud
17 ± 5 N·m (151 ± 44 lb in).
Use the following procedure in order to adjust the linkage:
Install lever (3) with the control linkage in the shutoff position against the
stop.
Lever (8) must be installed at the angle that is shown with the actuator lever in
- - - the shutoff position against the stop.
With lever (3) and lever (8) in the shutoff position, adjust rod end (4) and rod
assembly (6) to the needed length. Tighten nuts (5) in order to hold the rod
ends in position.
17
The threads of rod end (4) must be visible through the holes in the rods in
order to make sure that there is minimum thread engagement.
Connect lever (3) and lever (8) together with rod assembly (6) .
18
010 Specifications
Manual Shutoff
, S/N - -
Table 1
Specification for 7N-4869 Manual Shutoff
Item Qty
The shutoff group must be installed on the same side of the engine as the
- - -
governor.
When the shutoff group is right hand mounted, (1) "RH FRONT" should be
- - - visible from the front of the engine. When the shutoff group is left hand mounted,
(2) "LH FRONT" should be visible from the front of the engine.
2H-3932 O-
3 1 Lubricate the bore lightly with the lubricant that is being sealed.
Ring Seal
3K-2593 Lip
4 1 Lubricate the sealing lip lightly with the lubricant that is being sealed.
Type Seal
Pull the shutoff lever until the governor linkage stops against the internal stop.
4B-3643
5 1 Turn the adjustment setscrew until the adjustment setscrew contacts the lever.
Setscrew
Turn the adjustment setscrew by one additional turn. Tighten the locknut.
19
011 Specifications
Aftercooler
Table 1
Specification for 1W-9466 Water Aftercooler Gp
Item Qty
7M-9909 O-Ring Seal
1 2 Before assembly, lubricate the bore lightly with glycerin.
6V-1454 O-Ring Seal
Torque to
3 44 0L-1143 Bolt
55 ± 7 N·m (41 ± 5 lb ft).
Apply Loctite RTV Silicone Clear to the mating surfaces of the
4 - -
housing.
031-4630 Locking Bolt Torque to
5 22
32 ± 7 N·m (283 ± 62 lb in).
Torque to
6 4 1T-0720 Bolt
55 ± 7 N·m (41 ± 5 lb ft).
8C-5209 O-Ring Seal
20
012 Specifications
Camshaft
, S/N - 4MJ1-UP , S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 72Z1-UP
Typical example, (A) Direction toward the front of the engine.
(1) Washer
Thickness of a new washer ... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)
Thickness of the groove in a new camshaft ... 8.75 ± 0.05 mm (0.344 ± 0.002 inch)
End play for new camshafts ... 0.15 to 0.35 mm (0.006 to 0.014 inch)
(2) Journal surface
Diameter of surface (journals) for new camshaft bearings ... 85.88 ± 0.02 mm (3.381 ± 0.001 inch)
Bore in bearings for camshafts after assembly ... 86.00 ± 0.06 mm (3.386 ± 0.002 inch)
(3) Dowel
The dowel extends from the end of the rear right hand camshaft and the front left hand camshaft by the
following value. ... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)
(4) Bolt
21
Clean the threads of the bolts and the contact surfaces of the parts thoroughly.
Hand tighten the bolts to the following torque. ... 55 ± 7 N·m (40 ± 5 lb ft)
(6) Camshaft lobe height
In order to determine the height, use the procedure that follows:
1. Measure camshaft lobe height (5) .
2. Measure base circle (7) .
3. Subtract the base circle (Step 2) from the lobe height (Step 1). The difference is the actual lobe lift.
4. Specified camshaft lobe lift (6)
Inlet lobe (8) ... 9.314 mm (0.3667 inch)
Injector lobe (9) ... 13.574 mm (0.5344 inch)
Exhaust lobe (10) ... 9.078 mm (0.3574 inch)
22
013 Specifications
Camshaft Bearing Position

, S/N - 66Z1-UP
Right side view
Table 1
Specification for 240-6650 Cylinder Block Gp and 373-2260 Cylinder Block Gp
The camshaft bearings from the rear surface of the cylinder block are the following dimensions:
The oil holes must be aligned at the correct angle when the bearings are installed. Refer to Specifications,
"Cylinder Block" for the correct angle.
Distance from rear face of cylinder block is
A - -
1660.0 ± 1.5 mm (65.35 ± 0.06 inch).
B - -
1390.0 ± 1.5 mm (54.72 ± 0.06 inch).
C - -
1120.0 ± 1.5 mm (44.09 ± 0.06 inch).
D - -
850.0 ± 1.5 mm (33.46 ± 0.06 inch).
E - -
580.0 ± 1.5 mm (22.83 ± 0.06 inch).
F - - 310.0 ± 1.5 mm (12.20 ± 0.06 inch).
G - -
40.0 ± 1.5 mm (1.58 ± 0.06 inch).
23
014 Specifications
Valve Mechanism
Table 1
Item Qty
7C-2376 Rocker Arm Diameter of the rocker arm shaft is 37.084 ± 0.013 mm (1.4600 ±
1 1
Shaft 0.0005 inch).
If the bolt is removed for service, apply black Loctite Gasket Maker
2 2 334-1626 Bolt
#2 to the threads.
Torque to
3 3 3J-9196 Jam Nut
70 ± 15 N·m (52 ± 11 lb ft).
Torque to
4 2 8T-7581 Bolt
120 ± 20 N·m (89 ± 15 lb ft).
Inlet valve lash is
- - -
0.50 mm (0.020 inch).
Exhaust valve lash is
- - -
1.00 mm (0.040 inch).
24
Table 2
Item Qty
After installation, bore of the bushing in the injector rocker arm
196-4795 Rocker Arm
E 1 assembly (5) is
As
37.140 ± 0.015 mm (1.4622 ± 0.0006 inch).
After installation, bore of the bushing in the injector rocker arm
9Y-1741 Rocker Arm
F 2 assembly (6) is
As
37.140 ± 0.015 mm (1.4622 ± 0.0006 inch).
25
015 Specifications
Valve Mechanism
, S/N - -
Type 1
Typical example
(1) Locknut
Torque ... 70 ± 15 N·m (50 ± 11 lb ft)
(2) Rocker arm shaft
Bore in the bearings for the rocker arm shaft
After the bearing is installed in the rocker arm the bearing must be machined to size. ... 37.140 ± 0.015
mm (1.4622 ± 0.0006 inch)
Maximum roughness average (Ra) ... 0.8 micrometer (32 microinch)
Diameter of the rocker arm shaft ... 37.084 ± 0.013 mm (1.4600 ± 0.0005 inch)
(3) Valve lash
Inlet ... 0.50 mm (0.020 inch)
Exhaust ... 1.00 mm (0.040 inch)
(4) Height of dowel
Height to the top of the dowel ... 66.5 ± 0.5 mm (2.62 ± 0.02 inch)
(5) Locknut
Torque ... 30 ± 4 N·m (22 ± 3 lb ft)
(6) Lifter
Diameter of the new valve lifter ... 29.900 ± 0.010 mm (1.1772 ± 0.0004 inch)
Bore in the head for the valve lifter ... 30.000 ± 0.025 mm (1.1811 ± 0.0010 inch)
(7) Dowel
Diameter of the new dowel ... 11.008 ± 0.003 mm (0.4334 ± 0.0001 inch)
Bore in the bridge for the dowel ... 11.07 ± 0.03 mm (0.436 ± 0.001 inch)
26
Bore in the head for the dowel ... 10.968 ± 0.020 mm (0.4318 ± 0.0008 inch)
(8) Mounting bolt
Torque ... 120 ± 20 N·m (90 ± 15 lb ft)
(9) Guide springs
Refer to Guidelines For Reusable Parts, SEBF8172, "Visual Inspection of 7N-4782 Lifter Guide Spring -
3500 Family of Engines".
Type 2
Typical example
(1) Locknut
Torque ... 70 ± 15 N·m (50 ± 11 lb ft)
(2) Rocker arm shaft
Bore in the bearings for the rocker arm shaft
After the bearing is installed in the rocker arm the bearing must be machined to size. ... 37.140 ± 0.015
mm (1.4622 ± 0.0006 inch)
Maximum roughness average (Ra) ... 0.8 micrometer (32 microinch)
Diameter of the rocker arm shaft ... 37.084 ± 0.013 mm (1.4600 ± 0.0005 inch)
(3) Valve lash
Inlet ... 0.50 mm (0.020 inch)
Exhaust ... 1.00 mm (0.040 inch)
(4) Lifter
Diameter of the new valve lifter ... 29.900 ± 0.010 mm (1.1772 ± 0.0004 inch)
Bore in the head for the valve lifter ... 30.000 ± 0.025 mm (1.1811 ± 0.0010 inch)
(5) Mounting bolt
Torque ... 120 ± 20 N·m (90 ± 15 lb ft)
(6) Guide springs
Refer to Guidelines For Reusable Parts, SEBF8172, "Visual Inspection of 7N-4782 Lifter Guide Spring -
3500 Family of Engines".
27
016 Specifications
Cylinder Head
, S/N - 29Z1-UP , S/N - 50Y1-UP , S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 72Z1-UP
Table 1
Specification for 285-3086 Cylinder Head Gp, and 101-0830 Cylinder Head Gp
Item Qty
During installation, shrunk the valve seat insert with reduced
130-2607 Valve Seat temperature (Reference temperature :
1 2
Insert −60° C (−76° F)) and ress the insert into the cylinder heads
counterbore.
During installation, shrunk the valve seat insert with reduced
130-2608 Valve Seat temperature (Reference temperature :
2 2
Insert −60° C (−76° F)) and ress the insert into the cylinder heads
counterbore.
Apply Loctite 11358 to the bores for the cup plugs prior to the
3 5 3B-0623 Cup Plug
installation.
Apply Loctite 11358 to the bores for the cup plugs prior to the
installation.
Installation depth for cup plug is
D - -
9.0 ± 0.5 mm (0.35 ± 0.02 inch).
Installation depth for cup plug is

E - -
1.0 ± 0.5 mm (0.04 ± 0.02 inch).
28
Table 2
Item Qty
Before assembly, lubricate the threads with Loctite C5A Copper
5 1 5B-7890 Pipe Plug
Anti-Seize.
Use the following procedure to tighten the bolts for the cylinder
head:
1. Before assembly, apply clean engine oil to the threads of the
131-0420 Cylinder Head bolts.
6 6
Fastener Gp 2. Tighten bolt 1 through bolt 8 in the numerical sequence as shown
in Illustration 2 to a torque of
30 ± 5 N·m (22 ± 4 lb ft).
3. Again, tighten bolt 1 through bolt 8 in the numerical sequence as
shown in Illustration 2 to a torque of
200 ± 15 N·m (148 ± 11 lb ft).
131-0421 Cylinder Head 4. Again, retighten bolt 1 through bolt 8 in the numerical sequence
7 2 as shown in Illustration 2 to a torque of
Fastener Gp
200 ± 15 N·m (148 ± 11 lb ft).
5. Turn bolt 1 through bolt 8 in the numerical sequence to an angle
of 180 ± 5 degrees as shown in Illustration 2.
6. Tighten two bolts (8) only after bolt 1 through bolt 8 have been
given the final torque.
8 2 5B-0213 Bolt
7. Tighten two bolts (8) to
55 ± 10 N·m (41 ± 7 lb ft).
29
017 Specifications
Cylinder Head
Typical example, (1) Locating pad
NOTICE
The pipe plug at location (2) is installed in the cylinder head for
engines with dry exhaust manifolds. If the pipe plug is not installed into
the water passage, the coolant will leak and engine damage will result.
For engines with dry exhaust manifolds, make sure that the pipe plug
is installed.
(3) Before assembly, lubricate the thread of the pipe plug with Loctite C5A Copper Anti-Seize.
Use the following procedure to tighten the bolts of the cylinder head that is shown in Illustration 2:
Note: Before assembly, coat the threads of the bolt with clean engine oil.
1. Tighten the bolt 1 through bolt 8 in the numerical sequence to 30 ± 5 N·m (22 ± 4 lb ft).
2. Tighten the bolt 1 through bolt 8 in the numerical sequence to 270 ± 35 N·m (200 ± 26 lb ft).
3. Again tighten the bolt 1 through bolt 8 in the numerical sequence to 450 ± 20 N·m (330 ± 15 lb ft).
30
Note: Tighten the bolts (4) only after the cylinder head bolts have been given final torque., (4) Torque for
two bolts ... 55 ± 10 N·m (41 ± 7 lb ft)
Typical example
(A) Height of the new cylinder head ... 142.00 ± 0.15 mm (5.591 ± 0.006 inch)
Note: Before assembly, apply 6V-6640 Sealant to the bore of the cup plugs., (B) Installation depth of the cup
plugs from the top surface of the cylinder head ... 9.0 ± 0.5 mm (0.35 ± 0.02 inch) (D) Installation depth of
the cup plugs from the top surface of the cylinder head ... 1.0 ± 0.5 mm (0.04 ± 0.02 inch)
31
018 Specifications
Cylinder Head
, S/N - 29Z1-UP , S/N - 50Y1-UP , S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 96Y1-UP
Table 1
Specification for 4W-0095 Cylinder Head Gp
Item Qty
Before assembly, apply Loctite C5A Copper Anti-Seize to the
1 1 5B-7890 Pipe Plug
threads.
Before assembly, apply engine oil to cylinder head bolt threads.
Use the following procedure in order to tighten the cylinder head
131-0420 Cylinder Head bolts. Refer to Illustration 1 for the tightening sequence:
2 6
Fastener Gp 1. Tighten bolt (1) through bolt (8) in the numerical sequence to
30 ± 5 N·m (22 ± 4 lb ft).
2. Again tighten bolt (1) through bolt (8) in the numerical sequence to
131-0421 Cylinder Head 270 ± 35 N·m (200 ± 26 lb ft).

3 2 3. Again tighten bolt (1) through bolt (8) in the numerical sequence to
Fastener Gp
450 ± 20 N·m (332 ± 15 lb ft).
4. Tighten two bolts (4) only after bolt 1 through bolt 8 have been
4 2 5B-0213 Bolt given the final torque. Tighten two bolts (4) to
55 ± 10 N·m (41 ± 7 lb ft).
32
Table 2
Item Qty
Before assembly, apply high strength or high temperature anaerobic
flange sealant to the bore.
130-2607 Valve Seat During installation, shrunk the valve seat insert and ress the insert into
6 2
Insert the cylinder heads counterbore.
130-2608 Valve Seat During installation, shrunk the valve seat insert and ress the insert into
7 2
Insert the cylinder heads counterbore.
8 2 3B-0623 Cup Plug Installation depth (B) of the cup plugs from the top surface of the
cylinder head is
9.0 ± 0.5 mm (0.35 ± 0.02 inch).
Installation depth (D) is
1.0 ± 0.5 mm (0.04 ± 0.02 inch).
33
019 Specifications
Cylinder Head Valves

- 96Y1-UP
Typical example
(1) Height to the top of the valve guides ... 26.00 ± 0.50 mm (1.024 ± 0.020 inch) (2) 7N-1904 Spring
Length under test force ... 56.4 mm (2.22 inch)
Test force ... 254 ± 25 N (57.1 ± 5.6 lb)
Free length after test ... 62.5 mm (2.46 inch)
Outside diameter ... 43.96 mm (1.731 inch)
(3) 7N-1903 Spring
Test force ... 125 ± 12 N (28 ± 2.7 lb)
(4) Valve stem diameter and valve guide bore
Diameter of the new valve stems in the area of the valve guide ... 9.441 ± 0.008 mm (0.3717 ± 0.0003
inch)
When the valve guides are installed in the cylinder head the bore in the valve guides is the following
value: ... 9.487 ± 0.025 mm (0.3735 ± 0.0010 inch)
When the valve guides are installed in the cylinder head the maximum bore that can be used again in
the valve guides is the following value: ... 9.540 mm (0.3756 inch)
(5) Diameter of the valve heads ... 56.00 ± 0.15 mm (2.205 ± 0.006 inch) (6) Angle of the valve faces:
Inlet ... 19.40 ± 0.25 degrees
Exhaust ... 44.40 ± 0.25 degrees
34
Typical example
(7) Depth of bore in head for valve seat inserts ... 14.00 ± 0.15 mm (0.551 ± 0.006 inch) (8) Diameter of
valve seat inserts:
Inlet ... 60.627 ± 0.015 mm (2.3869 ± 0.0006 inch)
Exhaust ... 60.119 ± 0.015 mm (2.3669 ± 0.0006 inch)
Bore in head for valve seat inserts

Inlet ... 60.508 ± 0.025 mm (2.3822 ± 0.0010 inch)
Exhaust ... 60.000 ± 0.025 mm (2.3622 ± 0.0010 inch)
(9) Angle of face of valve seat inserts
Inlet ... 20 ± 0.25 degrees
Exhaust ... 45 ± 0.25 degrees
(10) Outside diameter of the face of the valve seat inserts ... 53.60 mm (2.110 inch)
35
020 Specifications
Cylinder Head Valves

Table 1
Specification for 338-8671 Cylinder Head Gp , 338-8672 Cylinder Head Gp , and 317-2440 Cylinder
Head Gp
Item Qty
Test force is
1 4 316-5976 Spring 460 ± 23 N (103 ± 5 lb).
74.8 mm (2.94 inch).
57.5 mm (2.26 inch).
Test force is
2 4 316-5977 Spring
248.0 ± 12.4 N (55.8 ± 2.8 lb).
71.4 mm (2.81 inch).
316-5980 Valve Stem Seal Install the valve stem seal to the inlet valves.
3 2
Before assembly, coat with engine oil.
4 2 316-5981 Washer Install the washer to the exhaust valves.
Height from the top of the cylinder head to the top of the valve
A - - guides is
26.0 ± 1.0 mm (1.02 ± 0.04 inch).
5 2 197-6995 Valve Guide Bore of the exhaust valve guide after installation is
36
12.619 ± 0.025 mm (0.4968 ± 0.0010 inch).

Bore of the inlet valve guide after installation is
6 2 133-9306 Valve Guide
9.487 ± 0.025 mm (0.3735 ± 0.0010 inch).
Before assembly, coat the exhaust valve stems with clean engine
oil.
Stem diameter (B) is
7 2 443-2712 Exhaust Valve 12.573 ± 0.01mm (0.4950 0.0004 inch).
Valve diameter (D) is
56.00 ± 0.15 mm (2.205 ± 0.006 inch).
Face angle is 44.40 ± 0.25 degrees.
Before assembly, coat the inlet valve stems with clean engine oil.
Stem diameter (C) is

8 2 210-2542 Inlet Valve 9.441 ± 0.010 mm (0.3717 ± 0.0004 inch).
Valve diameter (E) is
56.00 ± 0.15 mm (2.205 ± 0.006 inch).
Diameter of exhaust valve seat insert is
60.119 ± 0.015 mm (2.3669 ± 0.0006 inch).
130-2608 Valve Seat Insert
9 2 Bore in the cylinder head is
60.000 ± 0.025 mm (2.3622 ± 0.0010 inch).
Diameter of inlet valve seat insert is
60.627 ± 0.015 mm (2.3869 ± 0.0006 inch).
130-2607 Valve Seat Insert
10 2 Bore in the cylinder head is
60.508 ± 0.025 mm (2.3822 ± 0.0010 inch).
37
021 Specifications
Turbocharger
, S/N - 4MJ1-UP , S/N - 66Z1-UP , S/N - 96Y1-UP
(1) Bolt (2) Washers (3) Nut
Lubricate the bearing surfaces of bolt (1), washers (2), and nut (3) and lubricate the threads of the bolt and
the nut with 4C-5597 Anti-Seize Compound ., (4) Bolt
Torque ... 55 ± 10 N·m (41 ± 7 lb ft)
(5) Lock
After assembly, bend the short end of the lock against the bolt head. Bend the long end of the lock around the
turbine clamp. Do not reuse an opened lock., (6) Washer
Lubricate the bearing surfaces of washer (6) with 4C-5597 Anti-Seize Compound ., (7) Bolt
Lubricate the bolt's bearing surfaces and threads with 4C-5597 Anti-Seize Compound .
Torque ... 45 ± 10 N·m (33 ± 7 lb ft)
(8) Bolt
Torque ... 55 ± 10 N·m (41 ± 7 lb ft)
38
022 Specifications
Turbocharger
, S/N - 50Y1-UP , S/N - 66Z1-UP , S/N - 72Z1-UP , S/N - 96Y1-UP
Typical example
(1) Bolts that hold the turbocharger to the exhaust manifold
Put 5P-3931 Anti-Seize Compound on the bolt threads and the bearing surface before assembly.
Torque ... 54 ± 5 N·m (40 ± 4 lb ft)
(1) Bolts that hold the turbocharger to the exhaust manifold (2) Turbocharger clamps
1. Tighten the turbocharger clamps.
Torque ... 14.0 ± 1.5 N·m (10 ± 1 lb ft)
2. Gently hit around the turbocharger clamps with a soft faced hammer.
3. Again tighten the turbocharger clamps.
Torque ... 14.0 ± 1.5 N·m (10 ± 1 lb ft)
(3) Bolts
After tightening the bolts, close the ends of the lock plates. Replace the lock plates if the lock plates have
been opened.
Torque ... 20.0 ± 1.5 N·m (15 ± 1 lb ft)
(4) Seal
Install the rings so that the gaps in the rings are not aligned.
Angle of rotation between the gaps ... 90°
39
023 Specifications
Turbocharger
, S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 72Z1-UP , S/N - 96Y1-UP
Typical example
(1) Bolts that hold the turbocharger to the exhaust manifold
Put 5P-3931 Anti-Seize Compound on the bolt threads and the bearing surface before assembly.
Torque ... 54 ± 5 N·m (40 ± 4 lb ft)
(2) Turbocharger clamps
1. Tighten the turbocharger clamps.
Torque ... 14.0 ± 1.5 N·m (10 ± 1 lb ft)
2. Gently hit around the turbocharger clamps with a soft faced hammer.
3. Again tighten the turbocharger clamps.
Torque ... 14.0 ± 1.5 N·m (10 ± 1 lb ft)
40
024 Specifications
Turbocharger
, S/N - 66Z1-UP
Table 1
Specification for 327-7739 Turbocharger Gp
Item Qty
Before assembly, lubricate the threads, bearing surfaces with Loctite C5A
copper anti seize.
Use the following procedure to tighten the clamp assembly :
1. Tighten to
20 N·m (177 lb in).
283-4294 Clamp
1 1 2. Gently hit around the clamp assembly with a soft hammer.
As
3. Again, tighten
30 ± 2 N·m (266 ± 18 lb in).
4. Gently hit around the clamp assembly with a soft hammer.
5. Again, tighten the nut to
30 ± 2 N·m (266 ± 18 lb in).
Before assembly, lubricate the threads, bearing surfaces with Loctite C5A
copper anti seize.
2 8 287-7200 Bolt
Torque to the clamp plate bolts to
40 ± 3 N·m (30 ± 2 lb ft).
41
025 Specifications
Exhaust Manifold
(1) Left manifold (2) Right manifold (3) Bolt
1. Put 5P-3931 Anti-Seize Compound on the threads of the bolts.
2. Tighten the bolts to the following torque:
Torque ... 55 ± 10 N·m (41 ± 7 lb ft)
(4) Stud
1. Put 5P-3931 Anti-Seize Compound on the threads of the studs.
2. Tighten the studs to the following torque:
Torque ... 30 ± 5 N·m (22 ± 4 lb ft)
42
026 Specifications
Exhaust Manifold
Table 1
Specification for 8N-7721 Exhaust Manifold Gp , 8N-0367 Exhaust Manifold Gp , and 7N-8641
Exhaust Manifold Gp
Item Qty
Before assembly, apply Loctite C5A Copper Anti-Seize to threads
5P-2755 High Temperature and bearing surfaces.
1 40
Bolt Torque to
55 ± 5 N·m (41 ± 4 lb ft).
and bearing surfaces.
2 48 3B-1915 Bolt
Torque to
50 ± 5 N·m (37 ± 4 lb ft).
3 4 3B-1915 Bolt
and bearing surfaces.
43
027 Specifications
Air Inlet and Exhaust Lines

- 96Y1-UP
Typical example
(1) Plug
Apply 4C-5597 Anti-Seize Compound to the plugs.
Torque ... 20 ± 5 N·m (15 ± 4 lb ft)
44
028 Specifications
Air Shutoff
Table 1
Specification for 144-8275 Air Shutoff Gp
Item Qty
129-3021
1 1 Before assembly, apply Loctite 411 to the housing.
Ring
A
2W-4880
2 1 0.8 mm (0.03 inch) feeler gauge must not pass between the plate and the housing
Plate As
at any point when the plate is in the closed position.
45
029 Specifications
Engine Oil Pump

, S/N - -
Table 1
Specification for the 106-9872 Engine Oil Pump Gp
Item Qty
Length of the new gear is 110.000 ± 0.015 mm (4.3307 ± 0.0006
inch).
1 2 106-9866 Gear
Depth of the bore in the oil pump body for the new gear is
110.15 ± 0.02 mm (4.337 ± 0.001 inch).
Diameter of the 106-9865 Idler Shaft is
31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
106-9867 Idler Shaft Distance (B) from the end of the shaft to the gear face is
2 2
Assembly 34.0 ± 0.5 mm (1.34 ± 0.02 inch).
Bore in the bushing for idler shaft assembly is

46
31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).

107.16 mm (4.219 inch).
Test force is
3 1 107-7175 Spring
555.6 ± 20.0 N (124.9 ± 4.5 lb).
144.5 mm (5.69 inch).
Diameter of the new 106-9868 Shaft is
31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
106-9869 Oil Pump Drive Bore in the bushing for oil pump drive shaft assembly is
4 1
Shaft As 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).
Distance (C) from the end of the shaft to the gear face is
47.0 ± 0.5 mm (1.85 ± 0.02 inch).
Installation depth is
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
5 6 7W-0060 Bushing
Position of bushing joints from the centerline through the bearing
bores is 45 ± 15 degrees.
Extension of the hollow dowel from the oil pump cover is
F 2 4M-3248 Hollow Dowel
6.0 ± 0.5 mm (0.24 ± 0.02 inch).
Extension of the dowel from the oil pump cover is
G 2 7N-2043 Dowel
6.0 ± 1.0 mm (0.24 ± 0.04 inch).
The rotation of the drive gear is clockwise when you view the engine oil pump from the drive end.
Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in
order to ensure that the pump rotates freely.
Bench test specifications:
Unrestricted flow rate at 1000 rpm is
- - - 410 L (108 US gal).
Pump pressure at 300 rpm with fully blocked outlet is
570 to 630 kPa (83 to 91 psi ).
47
030 Specifications
Engine Oil Pump

Table 1
Specification for 7N-8715 Engine Oil Pump Gp
298-6387 O-Ring Before assembly, lubricate the bore lightly with 5P-3975 Rubber
1 1
Seal Lubricant .
48
Table 2
Test force is
2 1 2S-2760 Spring 499 ± 24 N (112 ± 5 lb).
152.91 mm (6.020 inch).
Section A-A
Table 3
Item Qty
Length of new gear is
54.000 ± 0.015 mm (2.1260 ± 0.0006 inch).
C 2 7N-6733 Gear
54.15 ± 0.02 mm (2.132 ± 0.001 inch).
Diameter is
31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
D 2 7W-1017 Shaft After assembly, bore in the 7W-0060 Bushing for the new shaft
assembly is
31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).
Extension from the oil pump cover is
E 2 4M-3248 Hollow Dowel
6.0 ± 0.5 mm (0.24 ± 0.02 inch).
Distance from the end of the idler shaft to the gear face is
F - -
34.0 ± 0.5 mm (1.34 ± 0.02 inch).
Diameter is
31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
49
After assembly, bore in the 7W-0060 Bushing for the new shaft
7N-5058 Pump Drive Shaft
G 1 assembly is
31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).
Distance from the end of the shaft to the gear face is
H - -
47.0 ± 0.5 mm (1.85 ± 0.02 inch).
Installation depth of 7W-0060 Bushing in the pump cover is
J 1 7W-0050 Pump Cover
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
Installation depth of 7W-0060 Bushing in the oil pump body
7W-0051 Oil Pump Body
K 1 assembly is
As
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
Table 4
Extension from the oil pump cover is
L 2 7N-2043 Dowel
6.0 ± 1.0 mm (0.24 ± 0.04 inch).
50
Table 5
Item Qty Part
Specification Description
Position of 7W-0060 Bushing joints from the centerline through the bearing bores is
M - -
45 ± 15 degrees.
51
031 Specifications
Engine Oil Pump

, S/N - -
Table 1
298-6387 O-Ring Before assembly, lubricate the O-ring seal lightly with 5P-3975
1 1
Seal Rubber Lubricant .
52
Table 2
Test force is
2 1 2S-2760 Spring 499 ± 24 N (112 ± 5 lb).
152.91 mm (6.020 inch).
Section A-A
Table 3
Item Qty
Length of the new gear is
84.000 ± 0.015 mm (3.3071 ± 0.0006 inch).
C 2 7N-5052 Gear
84.15 ± 0.02 mm (3.313 ± 0.001 inch).
Diameter of the new shaft is
31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
D 2 7W-1017 Shaft
Bore in the sleeve bearing for the new shaft assembly is
31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).
Extension of the hollow dowel from the oil pump cover is
E 2 4M-3248 Hollow Dowel
6.0 ± 0.5 mm (0.24 ± 0.02 inch).
Distance from the end of the idler shaft to the gear face is
F - -
34.0 ± 0.5 mm (1.34 ± 0.02 inch).
Diameter of the new shaft is
G 1 7W-1017 Shaft 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
53
Bore in the sleeve bearing for the new shaft after assembly is
31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).
Distance from the end of the shaft to the gear face is
H - -
47.0 ± 0.5 mm (1.85 ± 0.02 inch).
Installation depth of the sleeve bearing in the pump cover is
J 1 7W-0050 Pump Cover
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
Installation depth of the sleeve bearing in the oil pump body
4P-5637 Oil Pump Body
K 1 assembly is
As
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
Table 4
Specification for the 8N-6152 Engine Oil Pump Gp
Extension of hollow dowel from the oil pump cover is
L 2 7N-2043 Dowel
6.0 ± 1.0 mm (0.24 ± 0.04 inch).
54
Table 5
Specification for the 8N-6152 Engine Oil Pump Gp
Item Qty Part
Position of bearing joints from the centerline through the bearing bores is 45 ± 15
M - -
degrees.
55
032 Specifications
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves

, S/N - 29Z1-UP , S/N - 4MJ1-UP , S/N - 50Y1-UP , S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 72Z1-UP
Right side view
Typical example
Front view
Typical example
Use the following tightening sequence for the clamp bolts:

1. Snugly tighten the clamp assembly (3) to the tube (4) .
2. Tighten two bolts (2) of the clamp assembly to the elbow (10) to 47 ± 9 N·m (35 ± 7 lb ft).
3. Tighten two bolts (1) of the clamp assembly to the tube (4) to 47 ± 9 N·m (35 ± 7 lb ft).
Note: The cooling jet sequence valves must start to open at a pressure difference of 130 ± 30 kPa (19.0 ± 4.5
psi).
Note: The cooling jet sequence valves must be fully open at a pressure difference of 200 ± 30 kPa (29.0 ± 4.5
56
psi)., (5) 6B-9202 Spring for the cooling jet sequence valve
Quantity ... 2
Test force ... 85 to 102 N (19 to 23 lb)
Note: The oil cooler bypass valve must open with a pressure difference of 180 ± 20 kPa (26 ± 3 psi)., (6)
2W-1635 Spring for oil cooler bypass valve
Test force ... 518 ± 26 N (115.0 ± 5.8 lb)
(7) Lubricate the bore of the O-ring seals lightly with the clean engine oil. (8) Lubricate the bore of two O-
ring plugs lightly with the clean engine oil. (9) Torque for the plug ... 100 ± 15 N·m (75 ± 11 lb ft)
57
033 Specifications
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves

- 96Y1-UP
Typical example
(1) Clamp bolts
Torque ... 47 ± 9 N·m (35 ± 7 lb ft)
Tightening sequence for the clamp bolts

1. Snugly tighten the clamp assembly to the tube.
2. Tighten the clamp assembly to the elbow.
3. Tighten the clamp assembly to the tube.
(2) Plug
Lubricate the bore lightly with clean engine oil.
Torque ... 100 ± 15 N·m (75 ± 11 lb ft)
(3) 6B-9202 Spring for the cooling jet sequence valve
There is a spring at each end of the block.
58
Test force ... 85 to 100 N (19.0 to 22.4 lb)

Both of the cooling jet sequence valves must start to open at the following pressure difference: ... 130 ± 30
kPa (19 ± 4 psi)
Both of the cooling jet sequence valves must be fully open at the following pressure difference: ... 200 ± 30
kPa (29 ± 4 psi), (4) 2W-1635 Spring for oil cooler bypass valve
Test force ... 518 ± 26 N (115 ± 5.8 lb)
The oil cooler bypass valve must open with the following pressure difference: ... 180 ± 20 kPa (26 ± 3 psi)
59
034 Specifications
Crankcase Breather
Table 1
Specification for 124-5512 Breather Gp
1 3 033-6031 O-Ring Seal Before assembly, lightly lubricate the bore with clean engine oil.
2 3 5P-0597 Hose Clamp Torque to 3.0 ± 0.5 N·m (26.6 ± 4.4 lb in).
Torque to
3 2 180-3007 Hose Clamp
3.0 ± 0.5 N·m (26.6 ± 4.4 lb in).
60
035 Specifications
Crankcase Breather
Typical example
Front view
Table 1
Specification for the 124-5513 Breather Gp and 247-4696 Breather Gp
1 4 033-6031 O-Ring Seal Lubricate the bore of O-ring seals lightly with clean engine oil.
2 4 5P-0597 Hose Clamp Torque to 3.0 ± 0.5 N·m (27.0 ± 4.4 lb in).
Apply green Loctite 620 to the joint surfaces.
3 4 101-4199 Cover As Seat the shoulder of 4W-1287 Adapter against the cover.
Apply green Loctite 290 to 4W-1287 Adapter after assembly.
61
036 Specifications
Crankcase Breather
- 96Y1-UP
Typical example, (1) Breather assembly (2) Cover assembly
(3) Torque for the hose clamps ... 3.0 ± 0.5 N·m (27 ± 4 lb in)
62
037 Specifications
Engine Oil Pan

, S/N - -
Table 1
Specification for 8N-7236 Oil Pan Gp
Item Qty
1 - - Before assembly, as required apply red Loctite 596 to the surface.
6V-4315 O-Ring Seal
3P-0654 O-Ring Seal
4B-2363 Oil Drain
4 1 Torque to 145 ± 15 N·m (107 ± 11 lb ft).
Plug
After assembly, as required apply red Loctite LV Core Plug Sealant to
5 50 5P-5855 Bolt
threads.
Lubricate the bore lightly with the lubricant that is being sealed.
6I-0723 Oil Drain
6 1 Torque to
Plug
55 ± 7 N·m (41 ± 5 lb ft).
63
038 Specifications
Engine Oil Pan

, S/N - -
Top view
Table 1
Specification for 7C-4711 Oil Pan Gp
Item Qty
3P-0654 O-Ring Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate
1 2
Seal the bores.
7X-1547 O-Ring Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate
2 2
Seal the bores.
In order to prevent stress on the tube assembly (5), use the following
3 2 0S-1590 Bolt tightening procedure during assembly:
1. Tighten two bolts (4) to
47 ± 9 N·m (35 ± 7 lb ft).
4 2 0S-1588 Bolt 2. Then tighten two bolts (3) to
47 ± 9 N·m (35 ± 7 lb ft).
4B-2363 Oil Torque to
6 2
Drain Plug 145 ± 15 N·m (107 ± 11 lb ft).
As required, apply Loctite RTV Silicone Clear, Permatex No # 2, or Red
7 - -
Loctite High Tack GS S to the joints of the gasket.
64
039 Specifications
Engine Oil Pan

, S/N - -
Top view
Table 1
Specification for 7C-7178 Oil Pan Gp
Item Qty
3P-0654 O-Ring Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate
1 3
Seal the bores.
7X-1547 O-Ring Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate
2 2
Seal the bores.
65
In order to prevent stress on the tube assembly (5) , use the following
3 2 0S-1590 Bolt tightening procedure during assembly:
1. Tighten two bolts (4) to 47 ± 9 N·m (35 ± 7 lb ft).
4 2 0S-1588 Bolt 2. Then tighten two bolts (3) to
47 ± 9 N·m (35 ± 7 lb ft).
4B-2363 Oil Drain Torque to
6 2
Plug 145 ± 15 N·m (107 ± 11 lb ft).
As required, apply Loctite RTV Silicone Clear to the joints of the gasket.
7 - -
66
040 Specifications
Water Temperature Regulator

, S/N - -
Table 1
Specification for 6I-4950 Water Temperature Regulator
A - - Minimum opening distance at fully open temperature is 10.4 mm (0.41 inch).
Start to open temperature is
81 to 84 °C (178 to 183 °F).
Fully open temperature is
92 °C (198 °F).
67
041 Specifications
Water Pump
, S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 96Y1-UP
Type 1
Typical example
(1) Oil seal (2) Ring assembly (3) Ceramic ring and rubber seal (4) Seal assembly (5) Spring
Follow these recommendations for installation of the seals:
Note: The seal installation tool is part of the replacement seal assembly.
1. Install ring assembly (2) and oil seal (1) into the pump housing. Install the oil seal dry. Do not lubricate the
sealing lip. Use the correct installation tool and use a slow, even motion to press the seal into the pump
housing.
2. Install shaft (6) through the oil seal.
3. Install the shaft's thrust washer (7) .
4. Lubricate the outside diameter of the ceramic ring and rubber seal (3) with clean water.
5. Orient the polished face of the ceramic ring toward seal assembly (4). Use the installation tool and hand
pressure to seat the ceramic ring and the rubber seal into the pump housing.
6. Remove spring (5) from the seal assembly. Lubricate the inside diameter of the seal assembly with clean
water.
7. Use the seal installation tool and hand pressure to install the seal assembly onto the shaft until the face of
the seal assembly makes light contact with the face of the ceramic ring and rubber seal.
8. Install the spring onto the seal assembly.
(6) Shaft
Width of shaft's groove for thrust washer ... 8.75 ± 0.05 mm (0.345 ± 0.002 inch)
(7) Thrust washer
Thickness ... 8.50 ± 0.05 mm (0.3346 ± 0.0020 inch)
(8) Nut
68
Torque ... 200 ± 25 N·m (150 ± 18 lb ft)

(9) Stud
Torque ... 35 ± 5 N·m (26 ± 4 lb ft)
(10) Nut
Torque ... 27 ± 4 N·m (20 ± 3 lb ft)
(11) O-ring seal
Lubricate the O-ring seal with clean engine oil., (12) O-ring seal
Lubricate the O-ring seal with clean engine coolant., (13) O-ring seal
Lubricate the O-ring seal with glycerin., (14) Adapter
Torque ... 100 ± 10 N·m (75 ± 7 lb ft)
Maximum leakage per minute for the water seal at 138 kPa (20 psi) of air pressure ... 20 cc (1.22 cu in)
Maximum leakage per minute for the oil seal at 138 kPa (20 psi) of air pressure ... 24 cc (1.46 cu in)
Type 2
Typical example
(1) Oil seal (2) Ring assembly (3) Ceramic ring and rubber seal (4) Seal assembly (5) Spring (6) Shaft
Shaft's outer diameter for impeller ... 25.400 ± 0.013 mm (1.0000 ± 0.0005 inch)
Width of shaft's groove for thrust washer ... 8.75 ± 0.05 mm (0.345 ± 0.002 inch)
(7) Thrust washer
Thickness ... 8.50 ± 0.05 mm (0.3346 ± 0.0020 inch)
(8) Impeller
Diameter of impeller's bore ... 25.342 ± 0.013 mm (0.9977 ± 0.0005 inch)
(9) O-ring seal (10) O-ring seal (11) Stud
Torque ... 35 ± 5 N·m (26 ± 4 lb ft)
(12) Nut
Torque ... 27 ± 4 N·m (20 ± 3 lb ft)
(13) O-ring seal (14) Adapter
Torque ... 100 ± 10 N·m (75 ± 7 lb ft)
69
Assembly Procedure
Follow this procedure for assembly:
Note: The seal installation tool is part of the replacement seal assembly.
1. Install ring assembly (2) and oil seal (1) into the pump housing. Install the oil seal dry. Do not lubricate the
sealing lip. Use the correct installation tool and use a slow, even motion to press the seal into the pump
housing.
2. Install shaft (6) through the oil seal and through the ring assembly.
3. Install thrust washer (7) .
4. Lubricate the outside diameter of the ceramic ring and rubber seal (3) with clean water or with 207-1600
Rubber Lubricant .
5. Orient the polished face of the ceramic ring toward seal assembly (4). Use the installation tool and hand
pressure to seat the ceramic ring and the rubber seal into the pump housing.
6. Remove spring (5) from the seal assembly. Lubricate the inside diameter of the seal assembly with clean
water or with 207-1600 Rubber Lubricant .
7. Use the seal installation tool and hand pressure to install the seal assembly onto the shaft until the face of
the seal assembly makes light contact with the face of the ceramic ring and rubber seal.
8. Install the spring onto the seal assembly.
9. Lubricate the shaft with clean engine oil. Place the shaft onto a fixture that will absorb the load and press
impeller (8) onto the shaft until the face of the impeller is flush with the face of the shaft.
10. Lubricate the bore for O-ring seal (9) with clean engine oil.
11. Lubricate the bore for O-ring seal (10) with clean engine coolant.
12. Tighten studs (11) according to the specified torque.
13. Tighten nuts (12) according to the specified torque.
14. Lubricate the bore for O-ring seal (13) with glycerin.
15. Tighten adapter (14) according to the specified torque.
Maximum leakage per minute for the water seal at 138 kPa (20 psi) of air pressure ... 20 cc (1.22 cu in)
Maximum leakage per minute for the oil seal at 138 kPa (20 psi) of air pressure ... 24 cc (1.46 cu in)
70
042 Specifications
Water Pump
, S/N - -
Table 1
Specification for 2W-9729 Water Pump Gp
Item Qty
8C-5236 Lip Type
1 1 Do not lubricate the sealing lip of the lip type seal.
Seal
149-5462 O-Ring Lubricate the bore of the O-ring seals with glycerin or an approved
2 1
Seal equivalent.
212-8184 Impeller Bore of the impeller for new shaft is 25.342 ± 0.013 mm (0.9977 ± 0.0005
3 1
inch).
9M-2151 Torque to
4 3
Taperlock Stud 35 ± 5 N·m (26 ± 4 lb ft).
9S-8752 Full Nut Torque to
5 3
27 ± 4 N·m (239 ± 35 lb in).
Thickness of new thrust washer is
7N-4758 Thrust 8.5 mm (0.33 inch).
6 1
Washer Width of the groove for thrust washer is
8.75 ± 0.05 mm (0.344 ± 0.002 inch).
5H-6734 O-Ring Lubricate the bore of the O-ring seals with glycerin or an approved
7 1
Seal equivalent.
Lubricate the shaft with a thin film of clean engine oil before pressing the
impeller onto the shaft. The end of the shaft must be flush with the face of
212-8180 Pump the impeller within
Drive Shaft As 0.15 mm (0.006 inch).
8 1 Diameter of the shaft for impeller seating is
25.400 to 25.413 mm (1.0000 to 1.0005 inch).
Clearance between the impeller and the cover is
B - -
0.5000 ± 0.4925 mm (0.01968 ± 0.01939 inch).
71
043 Specifications
Cylinder Block
Front view of cylinder block
(1) Spacer plate
Thickness of spacer plates ... 12.313 mm (0.4848 inch)
(2) Gasket
Thickness of gasket between the cylinder block and spacer plates ... 0.18 to 0.22 mm (0.007 to 0.009
inch)
(3) Dowel
All dowels extend above the face by the following distance: ... 21.0 ± 0.5 mm (0.83 ± 0.02 inch)
(4) Plug
Torque ... 100 ± 15 N·m (75 ± 11 lb ft)
(5) Height of Cylinder liner
For the correct method of determining height of the liner, refer to Testing And Adjusting, "Cylinder Liner
Projection"., (6) Bore
Bore in the block for the camshaft bearings ... 98.000 ± 0.020 mm (3.8583 ± 0.0008 inch)
(7) Camshaft bearing junction (8) Centerline through oil holes in camshaft bearings
Oil holes must be positioned from horizontal at angle (X) to the following angle: ... 20 ± 5 degrees
72
Note: All centerlines through oil holes in the camshaft bearings (8) and bearing junctions (7) must be in the
position that is shown for each side of the cylinder block., (9) New dimension from centerline of crankshaft
bearing bore to the top of the block ... 586.00 mm (23.071 inch) (10) Main bearing cap width
Width of main bearing cap ... 340.030 ± 0.015 mm (13.3870 ± 0.0006 inch)
Width of cylinder block for main bearing cap ... 339.985 ± 0.015 mm (13.3852 ± 0.0006 inch)
Tight press fit between the sides of the main bearing cap and the cylinder block ... 0.075 mm (0.0030
inch)
Loose press fit between the sides of the main bearing cap and the cylinder block ... 0.015 mm (0.0006
inch)
(11) Bore in the block for the main bearings
Standard, original new size ... 169.742 ± 0.020 mm (6.6827 ± 0.0008 inch)
0.63 mm (0.025 inch) larger than original size ... 170.372 ± 0.020 mm (6.7076 ± 0.0008 inch)
(12) New dimension from the centerline of the crankshaft bearing bore to the bottom of the block (pan
rails) ... 230.00 mm (9.055 inch) (13) Main bearing cap bolts
Install main bearing caps with the part number and FRONT toward the front of the block. Each cap has a
number. Each cap must be installed in the same position as the correct number on the side of the cylinder
block pan rail.
Note: The procedure to tighten the main bearing cap bolts depends on the diameter of the bolts. There is a
different procedure for 3/4 inch bolts and for 7/8 inch bolts.
Procedure for Tightening 3/4 Inch Diameter Bolts ( 5P-8288 Bolt )
1. Put clean engine oil on the bolts before assembly.
2. Tighten the bolts in the letter sequence.
Torque ... 136 ± 14 N·m (100 ± 10 lb ft)
3. Tighten the bolts in the letter sequence again.
Rotation ... 210 ± 5 degrees
Procedure for Tightening 7/8 Inch Diameter Bolts ( 7X-7925 Bolt )

1. Put clean engine oil on the bolts before assembly.
2. Tighten the bolts in the letter sequence.
Torque ... 190 ± 14 N·m (140 ± 10 lb ft)
3. Tighten the bolts in the letter sequence again.
Rotation ... 180 ± 5 degrees
(14) Dowel
The dowel extends from the rear face of the block by the following distance: ... 6.0 ± 0.5 mm (0.24 ±
0.02 inch)
(15) Plug
Torque ... 100 ± 15 N·m (75 ± 11 lb ft)
(16) Dowel
The dowels extend from the front face of the block by the following distance: ... 6.0 ± 0.5 mm (0.24 ±
0.02 inch)
(17) Dowel
The dowels extend from the rear face of the block by the following distance: ... 19.0 ± 0.5 mm (0.75 ±
0.02 inch)
(18) Dowel
The dowels extend from the front face of the block by the following distance: ... 40.0 ± 0.5 mm (1.58 ±
0.02 inch)
73
044 Specifications
Cylinder Liner
, S/N - -
Table 1
Specification for 211-7826 Cylinder Block Liner, 118-9494 Cylinder Block Liner, and 350-0074
Cylinder Liner
Item Qty Part
Bore (A) in new cylinder liner is
1 - -
170.025 ± 0.025 mm (6.6939 ± 0.0010 inch).
Thickness (B) of flange on cylinder liner is
2 - -
12.65 ± 0.02 mm (0.498 ± 0.001 inch).
Use the following procedure to install the cylinder liner:
1. Apply liquid soap on the cylinder block liner bore surfaces and the rubber seals that
are on the lower end of the cylinder liner.
- - -
2. Dip the filler band completely in clean engine oil for a moment.
3. Immediately install the filler band in the groove that is under the flange.
4. Immediately install the cylinder liner into the cylinder block before the expansion of
the filler band.
74
045 Specifications
Piston and Rings - One-Piece Piston

Table 1
Specification for 223-6362 Piston and Rod Gp and 223-6363 Piston and Rod Gp
Item Qty
Refer to Guideline for Reusable Parts for information on the pistons, the
piston pins, and the retaining rings.
- - -
This piston has a square top piston ring. Use the 246-1176 Piston Ring
Groove Gauge Gp for measuring the top piston ring groove.
This piston has a keystone type of intermediate piston ring. Use the 1U-6431
Piston Ring Groove Gauge Gp for measuring the intermediate piston ring
- - -
groove. For correct use of the piston ring groove gauge group, refer to the
instruction card that is with the piston ring groove gauge group.
Before assembly of the piston rings, lubricate the ring grooves with clean
- - - engine oil. After assembly, lubricate the mating surfaces of the rings to the
cylinder liner with clean engine oil.
Install the top piston ring with the "UP-1" side toward the top of the piston.
When the new top piston ring is installed in a cylinder liner with a bore size
214-6066 Top of 170 mm (6.7 inch), the clearance between the ends of the piston ring is
1 1
Piston Ring 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch).
Thickness of new top piston ring is
3.88 mm (0.153 inch).
Install the intermediate piston ring with the "UP-2" side toward the top of the
piston.
144-5695 When the new intermediate piston ring is installed in a cylinder liner with a
2 1 Intermediate bore size of
Piston Ring 170 mm (6.7 inch), the clearance between the ends of the piston ring is
1.00 ± 0.15 mm (0.039 ± 0.006 inch).
Thickness intermediate piston ring is
75
3.785 mm (0.1490 inch).

The ends of the oil control piston ring should be a distance of 180 degrees
from the ring end gap when the oil control piston ring is assembled.
Width of groove in new piston for the oil control piston ring is
4.04 to 4.07 mm (0.159 to 0.160 inch).
Thickness oil Control piston ring is
223-6361 Oil
3.97 to 3.99 mm (0.156 to 0.157 inch).
3 1 Control Piston
Ring When the new oil control piston ring is installed in a cylinder liner with a bore
size of
170 mm (6.7 inch), the clearance between the ends of the piston ring is
0.5 to 0.8 mm (0.02 to 0.03 inch).
After the piston rings have been installed, rotate the piston rings so that the
end gaps are 120 degrees from each other.
Bore diameter for piston pin is
4 - -
70.060 to 70.075 mm (2.7583 to 2.7589 inch).
Before assembly, lubricate the piston pin, the piston pin bore, the connecting
rod eye, and the connecting rod pin bearing with clean engine oil.
197-0560 Piston Outside diameter is
5 1
Pin 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch).
Length is
101.85 ± 0.15 mm (4.010 ± 0.006 inch).
Assemble the pin retainer with the gap towards the top of the piston.
253-1238 Pin
6 2 Thickness is
Retainer
2.36 ± 0.08 mm (0.093 ± 0.003 inch).
Refer to Table 2 for the part numbers of the tools that are used in servicing
- - -
the piston.
Table 2
Service Tools
- - 6V-4020 Piston Ring Expander Gp
- - 6V-4023 Handle As
- - 6V-4024 Guide Ring
- - 1P-1861 Retaining Ring Pliers
- - 1U-7616 Piston Ring Compressor Gp
- - 246-1176 Piston Ring Groove Gauge Gp (1)
- - 1U-6431 Piston Ring Groove Gauge Gp (2)
(1) Only for the top ring groove
(2) Only for the intermediate ring groove
76
046 Specifications
Piston and Rings

This piston has a Keystone style top and Keystone style intermediate rings. The 1U-6431 Keystone Piston
Ring Groove Gauge is necessary for measuring the ring grooves. For correct use of the gauge group, see the
instruction card that is with the gauge group., (1) Top ring
Install the top ring with the "Up-1" side toward the top of the piston.
When the piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance
between the ends of the piston ring is the following value. ... 0.80 ± 0.20 mm (0.031 ± 0.008 inch)
There is an increase in the clearance between the ends of the piston ring. For each 0.03 mm (0.001 inch)
increase in the ring clearance, the cylinder liner bore size increases by the following value. ... 0.08 mm (0.003
inch), (2) Intermediate ring
Install the intermediate ring with the "Up" side toward the top of the piston.
When the piston is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between
the ends of the piston ring is the following value. ... 0.80 ± 0.20 mm (0.031 ± 0.008 inch)
increase in the ring clearance, the cylinder liner bore increases by the following value. ... 0.08 mm (0.003
inch), (3) Oil control ring
Install the oil control ring so that the gap in the spring is 180 degrees away from the gap in the ring. The
white portion of the spring must be visible at the ring end gap.
Width of groove in piston for the new piston ring ... 5.050 ± 0.010 mm (0.1988 ± 0.0004 inch)
Thickness of new piston ring ... 4.954 ± 0.019 mm (0.1950 ± 0.0007 inch)
Clearance between groove and new piston ring ... 0.067 to 0.125 mm (0.0026 to 0.0049 inch)
When the piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance
between the ends of the piston ring is the following value. ... 0.70 ± 0.19 mm (0.028 ± 0.007 inch)
increase in ring clearance, the cylinder liner bore increases by the following value. ... 0.08 mm (0.003 inch),
77
(4) Piston pin bore

Measure the pin bore in two places.
Take one measurement within the minor diameter.
Move laterally and take another measurement within the minor diameter.
Take the measurements close to the center of the pin bore.
Do not take the measurements on the outside edges.
Minor pin bore diameter ... 70.003 ± 0.005 mm (2.7560 ± 0.0002 inch)
Pin
Measure the pin diameter on each end in a vertical and horizontal direction.
Pin diameter ... 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch), (5) Retainer
Assemble the retainer with the opening above line A-A.
78
047 Specifications
Piston and Rings - Two-Piece Piston

- 96Y1-UP
This piston has a Keystone top and Keystone intermediate rings. The 1U-6431 Piston Ring Groove Gauge is
necessary for measuring the ring grooves in Keystone pistons. For correct use of the gauge group, see the
instruction card that is with the gauge group.
Top Piston Ring (1)

Install the top ring with the "Up-1" side toward the top of the piston.Thickness of new top piston ring ... 3.91
mm (0.154 inch)When the piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch),
the clearance between the ends of the piston ring is the following value. ... 0.625 ± 0.125 mm (0.0246 ±
0.0049 inch)The increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore size is the following value. ... 0.08 mm (0.003 inch)

Install the intermediate ring with the "Up-2" side toward the top of the piston.Thickness of new intermediate
piston ring ... 3.785 mm (0.1490 inch)When the piston is installed in a cylinder liner with a bore size of 170
mm (6.7 inch), the clearance between the ends of the piston ring is the following value. ... 1.00 ± 0.15 mm
(0.039 ± 0.006 inch)The increase in the clearance between the ends of the piston ring for each 0.03 mm
(0.001 inch) increase in the cylinder liner bore size is the following value. ... 0.08 mm (0.003 inch)

Width of groove in piston for the new piston ring ... 5.050 ± 0.010 mm (0.1988 ± 0.0004 inch)Thickness of
new piston ring ... 4.954 ± 0.019 mm (0.1950 ± 0.0007 inch)Clearance between groove and new piston
ring ... 0.067 to 0.125 mm (0.0026 to 0.0049 inch)When the piston ring is installed in a cylinder liner with a
bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. ...
79
0.70 ± 0.19 mm (0.028 ± 0.007 inch)The increase in the clearance between the ends of the piston ring for
each 0.03 mm (0.001 inch) increase in the cylinder liner bore size is the following value. ... 0.08 mm (0.003
inch)Install the oil control ring so that the gap in the spring is 180 degrees away from the gap in the ring. The
white portion of the spring must be visible at the ring gap.After all of the piston rings have been installed,
rotate the rings so that the end gaps are separated by 120 degrees. The ring gap for the oil ring must be
aligned in the plane of the pin bore.
Piston Pin Bore (4)

Measure the piston pin bore in the bushings in two places for each bushing in a vertical direction.Bore
diameter in the crown assembly for piston pin ... 70.035 ± 0.005 mm (2.7573 ± 0.0002 inch)Bore diameter in
the piston skirts for piston pin ... 69.983 ± 0.005 mm (2.7552 ± 0.0002 inch)
Piston Pin (5)

Measure the piston pin diameter on each end in a vertical and horizontal direction.Inside diameter of the
piston pin ... 35.0 ± 0.5 mm (1.38 ± 0.02 inch)Outside diameter of the piston pin ... 69.962 ± 0.005 mm
(2.7544 ± 0.0002 inch)Length of the piston pin ... 133.00 ± 0.13 mm (5.236 ± 0.005 inch)
Pin Retainer (6)

Assemble the retainer with the opening toward the top of the piston.
80
048 Specifications
Connecting Rod
- 96Y1-UP
View H-H, (4) Location pin for correct installation of connecting rod caps
81
Table 1
Specification for 190-3936 Connecting Rod Gp, 6I-2861 Piston and Rod Gp, 101-0829 Piston and Rod
Gp, 118-1654 Connecting Rod, 161-2500 Rod As, 223-6362 Piston and Rod Gp and 223-6363 Piston
and Rod Gp
Item Qty
Angle (A) above the centerline on either side of the bearing joint for the sleeve bearing for the piston pin is
10 degrees.
The connecting rod may be heated from
175 to 260 °C (347 to 500 °F) for the installation of the sleeve bearing for the piston pin. Minimum length
(B) for heating the connecting rod is
105 mm (4.1 inch). Do not use a torch to heat the connecting rod.
Thoroughly lubricate the piston pin with clean engine oil prior to assembly of the
piston and the connecting rod.
118-1655 Bore in the bushing for the piston pin after installation of the bushing is
C 1
Bushing 70.000 ± 0.008 mm (2.7559 ± 0.0003 inch).
Bore in the connecting rod for the bushing is
75.760 ± 0.015 mm (2.9827 ± 0.0006 inch).
Distance between the center of the bearings is
D - -
380 mm (15.0 inch).
7N-2043 Protrusion of the dowel from the connecting rod cap is
E 1
Dowel 4.0 ± 0.5 mm (0.16 ± 0.02 inch).
Bore in the connecting rod for the bearing for the crankshaft connecting rod journal
F - - after applying final torque to the connecting rod bolts is
143.028 ± 0.015 mm (5.6310 ± 0.0006 inch).
Bore in the connecting rod bearing for crankshaft is
G - -
135.133 to 135.194 mm (5.3202 to 5.3226 inch).
Etch the cylinder number on the connecting rod and the cap in this location. Mark
the connecting rod and the cap with numbers. Mark the numbers on the same side
1 - - of the connecting rod as the bearing retainer notch.
Install the connecting rod in the engine with the part number to the rear of the
engine.
Use the following procedure for tightening the connecting rod bolts:
Bolt 1 and bolt 2 must be on the same end of the connecting rod cap that has
bearing tabs and location pin (4).
1. Before assembly, apply Molylube on the bolt threads, the bolt shank, and the
bolt seat.
7N-2405 2. Sequentially tighten the bolt 1 and bolt 2 to
2 4
Bolt 90 ± 5 N·m (66 ± 4 lb ft).
3. Sequentially tighten the bolt 3 and bolt 4 to
90 ± 5 N·m (66 ± 4 lb ft).
4. Again, sequentially tighten the bolt 3 and bolt 4 to
90 ± 5 N·m (66 ± 4 lb ft).
5. Tighten all bolts for an additional 90 ± 5 degrees.
The chamfer side must be next to the crank pin thrust surface when the connecting
3 - -
rod and piston group is assembled in the engine.
Side clearance between two connecting rods on the same new crankshaft pin is
0.850 ± 0.332 mm (0.0335 ± 0.0131 inch).
82
83
049 Specifications
Connecting Rod and Main Bearing Journals

Refer to Guidelines For Reusable Parts, SEBF8009, "Main Bearings And Connecting Rod Bearings" for
more information.
Connecting Rod Bearing Journals
Table 1
Diameter Of Crankshaft Journal (Bearing Surface) For Connecting Rod Bearings
Original Size Journal 135.000 ± 0.025 mm (5.3150 ± 0.0010 inch)
Undersize Journal
134.370 ± 0.025 mm (5.2902 ± 0.0010 inch)
0.63 mm (0.025 inch)
Undersize Journal
133.730 ± 0.025 mm (5.2650 ± 0.0010 inch)
1.27 mm (0.050 inch)
Clearance between bearing and new journal ... 0.107 to 0.218 mm (0.0042 to 0.0086 inch)
Main Bearing Journals
Table 2
Diameter Of Crankshaft Journal (Bearing Surface) For Main Bearings
Original Size Journal 160.000 ± 0.025 mm (6.2992 ± 0.0010 inch)
Undersize Journal
159.370 ± 0.025 mm (6.2744 ± 0.0010 inch)
0.63 mm (0.025 inch)
Undersize Journal
158.730 ± 0.025 mm (6.2492 ± 0.0010 inch)
1.27 mm (0.050 inch)
Clearance between bearing and new journal ... 0.122 to 0.241 mm (0.0048 to 0.0095 inch)
84
050 Specifications
Crankshaft
, S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 72Z1-UP
Typical example
Table 1
Specification for 8N-7103 Crankshaft Gp , 161-6926 Crankshaft Gp , and 379-4851 Crankshaft Gp
Item Qty
Refer to Specifications, "Connecting Rod And Main Bearing Journals" for more information.
7C-6209 Thrust
1 2 Use only on the center main bearing as shown in the Illustration
Plate
B - - End play for the new crankshaft is 0.17 to 0.63 mm (0.007 to 0.025 inch).
2W-2288 Plug Torque to
2 6
50 ± 7 N·m (37 ± 5 lb ft).
Use the following procedure to tighten the bolts:
1. Prior to assembly, lubricate the bolt threads, the bolt shank, the washer, and
the underside of the bolt head with 6V-4876 Lubricant .
128-4845 Bolt
3 36 2. Torque the bolts evenly to
As
70 ± 5 N·m (50 ± 4 lb ft).
3. Rotate each bolt for an additional 120 ± 5 degrees.
Do not reuse counterweight bolts.
85
051 Specifications
Crankshaft
, S/N - -
Table 1
Specification for 128-6786 Crankshaft, and 201-4250 Crankshaft
Item Qty
2W-2288 Torque to
1 6
Plug 50 ± 7 N·m (37 ± 5 lb ft).
1. Before assembly, lubricate the threads of the bolts, the bolt shank, the washers,
128-4845 and the contact surface under the bolt head with molylube.
2 36
Bolt As 2. Tighten the bolts evenly to
70 ± 5 N·m (52 ± 4 lb ft).
86
052 Specifications
Crankshaft
, S/N - -
Table 1
Specification for 128-6788 Crankshaft
Item Qty
2W-2288 Torque to
1 8
Plug 50 ± 7 N·m (37 ± 5 lb ft).
1. Before assembly, lubricate the threads of the bolts, the bolt shank, the washers,
128-4845 and the contact surface under the bolt head with molylube.
2 48
Bolt As 2. Tighten the bolts evenly to
70 ± 5 N·m (52 ± 4 lb ft).
87
053 Specifications
Crankshaft Wear Sleeves and Seals

, S/N - -
, (1) Flywheel housing group (2) Front housing group
Table 1
Specification for the 7W-3813 Crankshaft Seal Gp
Item Qty
The crankshaft seal group cannot be used once the seal has been separated from the wear sleeve.
Make sure that the correct crankshaft seal group is installed on each end of the crankshaft.
Install the crankshaft seal group in the flywheel housing group on
113-8433 Crankshaft standard rotation engine.
3 1
Seal Gp Install the crankshaft seal group in the front housing on reverse rotation
engine.
Install the crankshaft seal group in the front housing on standard rotation
113-8432 Crankshaft engine.
4 1
Seal Gp Install the crankshaft seal group in the flywheel housing group on
reverse rotation engine.
The crankshaft seal group is installed from both ends of the crankshaft at
A - -
the distance of 8.0 ± 0.5 mm (0.31 ± 0.02 inch).
The wear sleeve is installed from both ends of the crankshaft at the
B - - distance of
0.5 ± 0.5 mm (0.02 ± 0.02 inch).
88
Table 2
Specification for the 332-7911 Crankshaft Seal Gp
Item Qty
The crankshaft seal group cannot be used once the seal has been separated from the wear sleeve.
Make sure that the correct crankshaft seal group is installed on each end of the crankshaft.
436-1479 Crankshaft standard rotation engine.
3 1
Seal Install the crankshaft seal group in the front housing on reverse
rotation engine.
436-1478 Crankshaft reverse rotation engine.
4 1
Seal Install the crankshaft seal group in the front housing on standard
rotation engine.
The crankshaft seal group is installed from both ends of the crankshaft
A - - at the distance of
3.45 ± 0.05 mm (0.136 ± 0.002 inch).
89
054 Specifications
Gear Group (Front)

, S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 72Z1-UP
Typical example, (5) Idler gear assembly (6) Water pump drive gear (7) Crankshaft gear
Note: Install the socket setscrew to the bottom of the threaded hole., (1) Torque for the socket setscrew ... 6 ±
1 N·m (53 ± 9 lb in) (2) Pump drive shaft assembly
Bore in sleeve bearing after assembly ... 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch)
Diameter of new pump drive shaft assembly. ... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch)
(3) Lubricate the bore of the O-ring seals lightly with lubricant that is being sealed. (4) Thrust washer
Thickness of new thrust washer ... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)
Width of groove in new pump drive shaft assembly. ... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch)
End play for the pump drive shaft assembly ... 0.175 to 0.325 mm (0.0069 ± 0.0128 inch)
(8) Idler shaft
Diameter of the idler shaft ... 105.88 ± 0.02 mm (4.168 ± 0.001 inch)
Bore in the sleeve bearing for idler shaft ... 105.970 ± 0.010 mm (4.1720 ± 0.0004 inch)
90
055 Specifications
Gear Group (Rear)

, S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 96Y1-UP
91
Table 1
Specification for 116-9854 Rear Gear Gp

Item Qty
Before assembly, clean the taper of the camshaft and the tapered bore of the
7E-3897 Camshaft
1 2 camshaft drive gear with lint free cloth saturated with cleaning solvent to
Drive Gear
remove excess oil. Clean with alcohol wipe.
Bore of 125-9751 Bushing after installation is
112-1554 Idler 81.060 ± 0.010 mm (3.1913 ± 0.0004 inch).
2 2
Gear As Installation depth is
1.00 ± 0.25 mm (0.039 ± 0.010 inch).
Bore of 4P-5438 Bushing after installation is
4P-5459 Balancer 75.060 ± 0.010 mm (2.9551 ± 0.0004 inch).
3 1
Gear Assembly Installation depth is
1.50 ± 0.50 mm (0.059 ± 0.020 inch).
The mark on the cluster idler gear (3) must be in alignment with the mark on
4 - -
the crankshaft gear (5).
Use the following procedure to tighten the bolt for the camshaft drive gears:
1. Tighten the bolt for the camshaft drive gear to

360 ± 40 N·m (266 ± 30 lb ft).
2. Mark a vertical line on the head of the bolt for the camshaft drive gear.
6 2 9X-8887 Bolt Refer to Illustration 2.
3. Place a driver against the retaining plate of the camshaft drive gear. Strike
the driver solidly with a hammer 3 to 4 times.
4. Again, tighten the bolt for the camshaft drive gear to
360 ± 40 N·m (266 ± 30 lb ft).
5. Repeat Step 3 and Step 4 until the mark on the bolt turns a minimum of 90
degrees. Refer to Illustration 2.
112-1552 Idler Diameter is
7 2
Shaft 81.000 ± 0.010 mm (3.1890 ± 0.0004 inch).
Torque to
8 4 1B-4367 Bolt
240 ± 20 N·m (177 ± 15 lb ft).
4P-5437 Gear Diameter is
9 1
Shaft 74.990 ± 0.010 mm (2.9524 ± 0.0004 inch).
Torque to
10 4 8M-2530 Bolt
140 ± 10 N·m (103 ± 7 lb ft).
Torque to
11 2 8S-2331 Bolt
240 ± 20 N·m (177 ± 15 lb ft).
101-1368 Thrust Thickness is
12 2
Washer 1.90 ± 0.10 mm (0.075 ± 0.004 inch).
92
056 Specifications
Gear Group (Rear)

93
Table 1
Specification for 116-9856 Rear Gear Gp
Item Qty
7E-3897 Before assembly, clean the taper of the camshaft and the tapered bore of the
1 2 Camshaft Drive camshaft drive gear with lint free cloth saturated with cleaning solvent to
Gear remove excess oil. Clean with alcohol wipe.
Bore of 125-9751 Bushing after installation is
112-1554 Idler 81.060 ± 0.010 mm (3.1913 ± 0.0004 inch).
2 2
1.00 ± 0.25 mm (0.039 ± 0.010 inch).
Bore of 4P-5438 Bushing after installation is
107-2477 Idler 75.060 ± 0.010 mm (2.9551 ± 0.0004 inch).
3 1
1.50 ± 0.50 mm (0.059 ± 0.020 inch).
The mark on the cluster idler gear (3) must be in alignment with the mark on
4 - -
the crankshaft gear (5).
Use the following procedure to tighten the bolt for the camshaft drive gears:
1. Tighten the bolt for the camshaft drive gear to

360 ± 40 N·m (266 ± 30 lb ft).
2. Mark a vertical line on the head of the bolt for the camshaft drive gear.
6 2 9X-8887 Bolt Refer to Illustration 2.
3. Place a driver against the retaining plate of the camshaft drive gear. Strike
the driver solidly with a hammer 3 to 4 times.
4. Again, tighten the bolt for the camshaft drive gear to
360 ± 40 N·m (266 ± 30 lb ft).
5. Repeat Step 3 and Step 4 until the mark on the bolt turns a minimum of 90
degrees. Refer to Illustration 2.
112-1552 Idler Diameter is
7 2
Shaft 81.000 ± 0.010 mm (3.1890 ± 0.0004 inch).
Torque to
8 4 1B-4367 Bolt
240 ± 20 N·m (177 ± 15 lb ft).
4P-5437 Gear Diameter is
9 1
Shaft 74.990 ± 0.010 mm (2.9524 ± 0.0004 inch).
Torque to
10 4 8M-2530 Bolt
140 ± 10 N·m (103 ± 7 lb ft).
Torque to
11 2 8S-2331 Bolt
240 ± 20 N·m (177 ± 15 lb ft).
101-1368 Thrust Thickness is
12 2
Washer 1.90 ± 0.10 mm (0.075 ± 0.004 inch).
94
057 Specifications
Accessory Drive (Lower Left Hand)

, S/N - -
, (2) 7N-5279 Adapter As (5) 2W-7320 Accessory Drive Gear (7) 116-3242 Idler Gear As
Table 1
Specification for 8N-5678 Accessory Drive Gp
Item Qty
7N-7539 Thrust Washer Thickness of one new thrust washer is
1 2
8.50 ± 0.05 mm (0.335 ± 0.002 inch).
Before assembly, lightly lubricate the bore for the O-ring seals with
3 3 -
the fluid that is being sealed.
Diameter is
7N-5874 Auxiliary 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
4 1
Drive Shaft Width of groove for thrust washer is
8.75 ± 0.10 mm (0.344 ± 0.004 inch).
After assembly, bore is
6 1 127-5400 Bushing
75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).
After assembly, bore is
105.970 ± 0.010 mm (4.1720 ± 0.0004 inch).
8 1 116-1365 Bearing
2.3 ± 0.5 mm (0.09 ± 0.02 inch).
Diameter is
9 1 7C-3259 Shaft
105.880 ± 0.020 mm (4.1685 ± 0.0008 inch).
95
058 Specifications
Accessory Drive (Lower Left Hand)

- 96Y1-UP
, (4 ) Drive gear for jacket water pump and oil pump (5 ) Crankshaft gear (6 ) Idler gear
Table 1
Item Qty
Bore of 127-5400 Bushing after assembly is 75.140 ± 0.055 mm
(2.9583 ± 0.0022 inch).
1 1 441-3369 Adapter As
1.5 mm (0.06 inch)
7N-7539 Thrust Washer Thickness of new thrust washer is
2 2
8.50 ± 0.05 mm (0.335 ± 0.002 inch).
Diameter of new shaft is
7N-5874 Auxiliary Drive 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
3 1
Shaft Width of groove in new shaft is
8.750 ± 0.025 mm (0.3445 ± 0.0010 inch).
Bore in the bushing after assembly is
90.000 ± 0.010 mm (3.5433 ± 0.0004 inch).
7 1 140-9597 Bushing
After, the bearing is installed in the gear the bearing must be
machined to size.
8 1 7C-3260 Shaft
89.880 ± 0.020 mm (3.5386 ± 0.0008 inch).
96
Table 2
Specification for 152-4986 Accessory Drive Gp
Item Qty
Bore of 127-5400 Bushing after assembly is
1 1 7N-5278 Adapter
75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).
Thickness of new thrust washer is
2 2 7N-7539 Thrust Washer
8.50 ± 0.05 mm (0.335 ± 0.002 inch).
7N-5874 Auxiliary Drive 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
3 1
Shaft Width of groove in new shaft is
8.750 ± 0.025 mm (0.3445 ± 0.0010 inch).
Bore in the bushing after assembly is
90.000 ± 0.010 mm (3.5433 ± 0.0004 inch).
7 1 140-9597 Bushing
After, the bearing is installed in the gear the bearing must be
machined to size.
8 1 7C-3260 Shaft
89.880 ± 0.020 mm (3.5386 ± 0.0008 inch).
97
059 Specifications
Accessory Drive (Upper Right Hand)

Typical example
Table 1
Specification for 4P-0853 Accessory Drive Gp , 147-3175 Accessory Drive Gp , and 7C-4113 Accessory
Drive Gp
Item Qty
259-4598 O-Ring
1 1 Lubricate the bore lightly with lubricant that is being sealed.
Seal
235-3546 O-Ring
2 1 Lubricate the bore lightly with lubricant that is being sealed.
Seal
Bore in 127-5400 Bushing after assembly is 75.000 ± 0.055 mm (2.9527
7C-4165 Adapter As ± 0.0022 inch).
A 1
Diameter of 7W-1102 Accessory Drive Gear Shaft is
74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
Bore in 127-5400 Bushing after assembly is
7C-4164 Adapter As 75.000 ± 0.055 mm (2.9528 ± 0.0022 inch).
B 1
Diameter of 7W-1102 Accessory Drive Gear Shaft is
74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
98
060 Specifications
Accessory Drive (Upper Left Hand)

, S/N - -
Table 1
Item Qty
Part Specification description
Lightly lubricate the bore with the lubricant that is being sealed.
1 1 235-3546 O-Ring Seal
2 1 259-4598 O-Ring Seal
3 2 9X-7371 O-Ring Seal
Inside diameter of the bushing after assembly in the adapter
4 2 127-5400 Bushing assembly is
75.000 ± 0.055 mm (2.9528 ± 0.0022 inch).
Diameter is
74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
7N-5874 Auxiliary Drive Width of the groove in the new auxiliary drive shaft for the
5 1
Shaft thrust washer is
8.75 ± 0.10 mm (0.344 ± 0.004 inch).
99
End play for the auxiliary drive shaft is

0.175 to 0.325 mm (0.0069 to 0.0128 inch).
Thickness of the new thrust washer is
E 2 7N-7539 Thrust Washer
8.50 ± 0.05 mm (0.335 ± 0.002 inch).
6 1 5P-0840 O-Ring Seal
7 1 6V-3348 O-Ring Seal
100
061 Specifications
Flywheel
- 96Y1-UP
Typical example, (1) Flywheel gear (2) Crankshaft
Table 1
Specification for the 7N-4851 Flywheel Gp, 7N-7784 Flywheel Gp, 7W-0968 Flywheel Gp, 286-0244
Flywheel Gp, 333-3742 Flywheel Gp, 8N-6038 Flywheel Gp, 8N-6439 Flywheel Gp, 2W-8772 Flywheel
Gp, 333-3743 Flywheel Gp, 336-9989 Flywheel Gp, 336-9990 Flywheel Gp, and 317-4398 Flywheel Gp

When the flywheel assembly is installed, align the dash mark on the flywheel assembly with the dash mark
on the crankshaft.
Before assembly, lubricate the threads of the bolts with clean engine oil,
9S-8893 molybdenum disulfide, or graphite base lubricant.
3 12
Bolt Torque to
1150 ± 60 N·m (840 ± 44 lb ft).
101
062 Specifications
Flywheel Housing
- 96Y1-UP
Bolt locations
102
Left side view

Table 1
Specification for 101-0836 Flywheel Housing Gp, 297-7000 Flywheel Housing Gp, 383-6541 Flywheel
Housing Gp, 384-8033 Flywheel Housing Gp, and 7W-3722 Flywheel Housing Gp
Before installation of the flywheel housing, inspect the front face of the flywheel housing and the rear face
of the cylinder block. The components must be free of the following substances: oil, fuel, water, gasket
adhesive, assembly compounds, and any other foreign materials.
To seal the joint between the flywheel housing and the cylinder block, apply Loctite High Flex GM to the
front face of the flywheel housing.
Length of 1/2 inch diameter bolt is
57.15 mm (2.250 inch).
1 6 9X-8873 Bolt
Torque to
135 ± 20 N·m (100 ± 15 lb ft).
88.90 mm (3.500 inch).
2 4 9X-8875 Bolt
Torque to
135 ± 20 N·m (100 ± 15 lb ft).
171.5 mm (6.75 inch).
9M-7269 (1)
Torque to
135 ± 20 N·m (100 ± 15 lb ft).
3 2
228.6 mm (9.00 inch).
6M-9613 (2)
Torque to
135 ± 20 N·m (100 ± 15 lb ft).
203.20 mm (8.000 inch).
4 2 9S-1374 Bolt
Torque to
135 ± 20 N·m (100 ± 15 lb ft).
114.30 mm (4.500 inch).
5 4 8S-9089 Bolt
Torque to
135 ± 20 N·m (100 ± 15 lb ft).
120.65 mm (4.750 inch).
6 16 1D-4590 Bolt
Torque to
270 ± 40 N·m (199 ± 30 lb ft).
Apply blue Loctite High Flex GM to the surface of the gasket before
7 - -
assembly.
(1) This bolt is used if the engine is not equipped with a support bracket for the air lines.
(2) This bolt is used if the engine is equipped with a support bracket for the air lines.
103
063 Specifications
Flywheel Housing
, S/N - 50Y1-UP , S/N - 66Z1-UP
Rear view of the engine
104
Table 1
Specification for 107-7177 Flywheel Housing Gp and 102-3540 Flywheel Housing Gp
Before installation of the flywheel housing, inspect the front face of the flywheel housing and the rear face
of the cylinder block. The components must be free of the following substances: oil, fuel, water, gasket
adhesive, assembly compounds, and any other foreign materials.
To seal the joint between the flywheel housing and the cylinder block, apply Loctite High Flex GM to the
front face of the flywheel housing.
Length of 1/2 inch diameter bolt is 57.15 mm (2.250 inch).
9X-8873 Bolt
1 8 Torque to
135 ± 20 N·m (100 ± 15 lb ft).
1D-4574 Bolt 152.40 mm (6.000 inch).
2 6
Torque to
135 ± 20 N·m (100 ± 15 lb ft).
9X-8874 Bolt 76.20 mm (3.000 inch).
3 2
Torque to
135 ± 20 N·m (100 ± 15 lb ft).
1D-4597 Bolt 165.10 mm (6.500 inch).
4 2
Torque to
270 ± 40 N·m (199 ± 30 lb ft).
1D-4593 Bolt 139.70 mm (5.500 inch).
5 12
Torque to
270 ± 40 N·m (199 ± 30 lb ft).
9X-8878 Bolt 133.35 mm (5.250 inch).
6 4
Torque to
135 ± 20 N·m (100 ± 15 lb ft).
1D-4602 Bolt 241.30 mm (9.500 inch).
7 2
Torque to
270 ± 40 N·m (199 ± 30 lb ft).
Before assembly, apply Loctite High Flex GM to the sealing surfaces of
- - -
the gasket.
105
064 Specifications
Vibration Damper
, S/N - -
Table 1
Specification for 4W-0278 Damper Gp
Item Qty
The alignment mark on the crankshaft (2) must be aligned with the alignment mark on the damper adapter
(3) .
Before assembly, lubricate the threads with molybdenum disulfide base
8S-4757 Bolt lubricant.
1 6
Torque to 1150 ± 60 N·m (848 ± 44 lb ft).
3B-1915 Bolt Torque to
4 18
55 ± 7 N·m (41 ± 5 lb ft).
106
065 Specifications
Vibration Damper Guard

- 96Y1-UP
Typical example
Table 1
Specification for 102-8616 Damper Guard Gp and 4P-1602 Damper Guard Gp
Torque to
1 4 0S-1591 Bolt
15 ± 3 N·m (133 ± 27 lb in).
Torque to
2 6 030-8535 Locking Bolt
15 ± 3 N·m (133 ± 27 lb in).
107
066 Specifications
Belt Tension Chart

, S/N - 29Z1-UP , S/N - 50Y1-UP , S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 72Z1-UP
Table 1
Specification for the 7N-9693 Tension Chart
Item Qty Part
The new belt tension chart has been standardized. The belt tension chart eliminates
confusion about the correct belt tension to use. Studies were completed with different belt
suppliers and the information that was gathered from the studies was developed into a new
belt tension for each belt size.
The chart does not apply to belts that use a spring loaded tensioner.
For more accurate results, a Clavis frequency gauge should be used in order to measure the
natural frequency of the belt. By the use of a formula, the natural frequency is converted
into the belt tension force. If the Clavis frequency gauge cannot be used, then use the
- - -
appropriate Kent-Moore belt tension gauge to measure the belt tension force.
When matched sets of belts are used, check the tension of all the belts in order to verify
that the lowest belt is in the acceptable tolerance range. Variations in tension between the
belts can vary by as much as 65 lbs.
In order to determine the tension of a "banded" belt, refer to the chart above. Multiply the
tension value of the belt by the number of belts that are banded together.Two 1/2 inch belts
would require a used belt tension equal to twice the value of the used belt tension for one
1/2 inch belt (2 X 80 = 160 lb).
Table 2
Field Service Tension
Belt Tension Chart
Check
SAE or RMA Width of Belt Setting Tension of Setting Tension of Reset Belt Tension if
Belt Size ( Reference) New Belt (2)
Used Belts Tension Falls Below
MM
IN IN MM LB N LB N LB N
3/8 (0.380) 10A 145±10
0.42 10.72 645±44 115±10 510±44 70±10 311±44
7/16 11A 155±10
0.46 11.68 689±44 125±10 560±10 75±10 333±44
(0.440)
1/2 (0.500) 13A 165±10
0.55 13.89 734±44 130±10 580±10 80±10 356±44
180±10
5V/5VX 5V 0.63 15.88 801±44 145±10 645±10 85±10 378±44
11/16 15A 180±10
0.69 17.48 801±44 145±10 645±10 85±10 378±44
(0.600)
3/4 (0.660) 17A 205±10
0.75 19.05 912±44 165±10 730±44 95±10 422±44
7/8 (0.790) 20A 205±10
0.88 22.23 912±44 165±10 730±44 95±10 422±44
N/A 205±10
15/16 0.98 23.83 912±44 165±10 730±44 95±10 422±44
4K 0.54 13.72 645±44 115±10 510±44 60±10 267±44

4PK 145±10
108
6PK 215±10
6K 0.82 20.94 956±44 170±10 755±10 90±10 400±44
8PK 285±10 1179±44
8K 1.1 27.82 230±10 1025±10 115±10 511±44
10PK 355±10 1579±44
10K 1.38 35.05 285±10 1270±10 145±10 645±44
12PK 425±10 1891±44
12K 1.66 42.16 340±10 1510±10 175±10 778±44
14PK 495±10 2202±44
14K 1.94 49.28 395±10 1755±10 205±10 912±44
15PK 530±10 2358±44
15K 2.08 52.83 425±10 1890±44 215±10 956±44
(2) Belt tension with less than 10 hours of operation
109
067 Specifications
Alternator and Regulator

, S/N - -
Table 1
Specification for 4N-3986 Charging Alternator Gp
Item Qty
Load the battery with a carbon pile 4C-4911 Battery Load Tester in
- - -
order to get the maximum alternator output.
187-2034 Flange Nut
1 1 Torque to 102 ± 7 N·m (75 ± 5 lb ft).
Use a 7/16 ring terminal for (B+) terminal. , (B+) terminal. Torque to
2 - 6V-8187 Nut
6.75 ± 1.50 N·m (59.74 ± 13.28 lb in).
Torque to
3 1 4B-2047 Nut
2.25 ± 0.25 N·m (20.00 ± 2.00 lb in)
(B-) terminal. Torque to
4 - 6V-8187 Nut
6.75 ± 1.50 N·m (59.74 ± 13.28 lb in).
3T-6354 Voltage Voltage setting is not adjustable.
5 1
Regulator As Permissible voltage range is 27 to 29 V.
- - - Voltage is 24 V.
- - - Amperage is 60 amp.
- - - Polarity is negative ground.
- - - Rotation is either direction.
- - - Maximum turn on speed is 2000 rpm.
Alternator performance at
- -
25 °C (77 °F).
- - - Minimum full load current at 5000 rpm is 68 amp.
- - - Minimum full load current at 2000 rpm is 42 amp.
- - - Output voltage is 28 ± 1 V.
110
068 Specifications
Alternator Mounting
, S/N - 29Z1-UP , S/N - 4MJ1-UP , S/N - 66Z1-UP , S/N - 69Z1-UP
Table 1
Specification for 7E-4836 Alternator Mounting Gp and 335-4161 Alternator Mounting Gp
Item Qty
Tighten the pulley retaining nut to 110 ± 10 N·m (81 ± 7 lb ft).
2 - - Maximum misalignment between pulley assembly (3) and pulley (1)
is 0.4 degrees.
141-7116 Serpentine Adjust the belt tension of the serpentine belt according to the 197-
4 1
Belt 9087 Tension Chart .
235-2484 Lip Type Lubricate the sealing lip lightly with the lubricant that is being sealed.
5 1
Seal
111

Table 2
Specification for 197-9087 Belt Tension Chart
Gauge
Gauge
Gauge Reading (Frequency)
(Force)
Belt Tension Belt Tension
Size of Width of Belt Belt (Frequency) (Frequency)
Belt Belt Tension Tension Basic "Initial" (1) "Used" (2) (3) Gauge
(Force) (Force) Gauge
Number
"Initial" "Used" Number
(1) (2) (3)
8 - RIB 27.82 mm 800 ± 22 N 489 ± 44 N

BT-33-109 Clavis Type
POLY - (1.095 (180 ± 5 lb) (110 ± 10 98 ± 10 HZ 76 ± 8 HZ
14
RIB inch) lb)
Do not use the belt tension chart for belts with tensioners that are spring loaded.
Measure the tension of the belt that is farthest from the engine.
(1) Belt tension "lnitial" is for a new belt.
(2) Belt tension "Used" is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(3) If a belt falls below the "Used" belt tension, the belt should be tightened again to the high side of the "Used" belt tension.
112
069 Specifications
Electric Starting Motor

, S/N - -
Table 1
Specification for 6V-0927 Electric Starting Motor Gp
Item Qty
The clearance between the pinion and the housing is
B - -
9.1 mm (0.36 inch).
Torque to
1 2 6V-8188 Nut
30.5 ± 3.5 N·m (270.0 ± 30.0 lb in).
Current consumption at 20V and
338-3453 Starting 25 °C (77 °F):
2 1
Motor Solenoid 1. For Pull-in windings is 49.3 ± 3.3 amp
2. For Hold-in windings is 6.8 amp max
Torque to
3 1 6V-8188 Nut
30.5 ± 3.5 N·m (270.0 ± 30.0 lb in).
Torque to
4 1 4B-2049 Nut
2.25 ± 0.25 N·m (20.00 ± 2.00 lb in).
The switch terminal must be insulated with heat shrink tubing. Do not use
molded terminals.
5 1 4B-2049 Nut
Torque to
2.25 ± 0.25 N·m (20.00 ± 2.00 lb in).
A maximum of three cable terminals or wire terminals may be used with the
battery terminal nut (5). A maximum of two of the terminals may be equal
6 1 6V-8188 Nut to or greater than 0 AWG.
30.5 ± 3.5 N·m (270.0 ± 30.0 lb in)

7 1 6V-8188 Nut 30.5 ± 3.5 N·m (270.0 ± 30.0 lb in)
When the electric starting motor is viewed from the pinion end, the motor
rotates in the clockwise direction.
113
No load performance at
25 °C (77 °F)
- - - 1. Speed is 6950 ± 1650 rpm
2. Current draw is 115 ± 25 Amp
3. Voltage is 23 VDC
114
070 Specifications
Electric Starting Motor

, S/N - -
When the electric starting motor is viewed from the pinion end, the motor rotates in the following direction.
... Clockwise, (B) The clearance between the pinion and the housing ... 9.1 mm (0.36 inch) (1) Final
installation torque for the nut for ground terminal ... 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in) (2) Final installation
torque for the nut for ground terminal ... 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in) (3) Final installation torque for
the nut for switch terminal ... 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in) (4) Final installation torque for the nut for
motor terminal ... 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in)
Note: A maximum of three cable terminals or wire terminals may be used with the nut. A maximum of two
of the terminals may be equal to or greater than 0 AWG., (5) Final installation torque for the nut for battery
terminal ... 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in) (6) Final installation torque for the nut for motor frame
terminal ... 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in)
Solenoid
Current consumption (draw) at 32 V and at 25 °C (77 °F)
Pull-in windings ... 41 ± 3 Amp
Hold-in windings ... 6.3 Amp
Operating temperature ... −25 to 121 °C (−13 to 250 °F)
115
071 Specifications
Air Starting Motor

- 96Y1-UP
Typical example
(1) Cover
Tighten the bolts evenly in small increases until the following torque is reached: ... 80 N·m (60 lb ft)
(2) Bolt
Torque ... 36 N·m (27 lb ft)
(3) Bolt
(4) Bolt (pinion)
(5) Rotor clamp nut
Tighten the rotor clamp nut until the following clearance between the rear end plate and the rotor is
reached: ... 0.03 to 0.08 mm (0.001 to 0.003 inch)
Check the clearance again after the bolt for the rotor clamp nut is tightened., (6) Rotor retainer bolt
116
072 Specifications
Air Starting Motor Pressure Regulating Valve

, S/N - -
Table 1
Specification for 1L-2073 Pressure Reducing Valve
Inlet pressure is 1723 kPa (250 psi).
1 - -
Maximum inlet pressure is
3103 kPa (450 psi).
Outlet pressure at outlet port is
2 - -
621 ± 758 kPa (90 ± 110 psi).
117
073 Specifications
Coolant Temperature Switch

, S/N - -
Table 1
Specification for 3E-7298 Temperature Switch
1 1 - Torque to 40 ± 5 N·m (30 ± 4 lb ft).
Operating range is
- -
-40 to 150 °C (-40 to 302 °F).
Actuation temperature to open at
- - -
21 ± 3 °C (70 ± 5 °F).
Minimum deactuation temperature is
- - -
13 °C (55 °F).
- - - Contact position is normally closed below deactuation temperature.
118
074 Specifications
Engine Oil Pressure Sensor

, S/N - 29Z1-UP , S/N - 4MJ1-UP , S/N - 50Y1-UP , S/N - 66Z1-UP , S/N - 69Z1-UP , S/N - 96Y1-UP
(1) Sensor assembly (2) Plug with socket A, socket B, and socket C (3) Port fitting
Torque ... 10 ± 2 N·m (88 ± 18 lb in)
Operating range ... -40° to 125 °C (-40° to 257 °F)

Maximum pressure ... 839 kPa (122 psi)
Voltage Supply ... 8.0 ± 0.5 VDC
Maximum supply current ... 20 mA
Install the sensor so that the input pressure port is lower than the wire end and as close to vertical as possible.
119
075 Specifications
Engine Coolant Temperature Sensor

, S/N - -
Table 1
Specification for 102-2240 Engine Coolant Temperature Sensor Gp
Torque to
1 1 102-2240 Engine Coolant Temperature Sensor Gp 20 ± 3 N·m (177 ± 27 lb in).
Operating voltage is 4.75 to 8.50 VDC.
120
076 Specifications
Engine Speed Sensor

- 96Y1-UP
Table 1
Specification for 6V-2455 Speed Sensor Gp
Item Qty Part
- - - Use the following procedure to tighten the engine speed sensor:
1. Install the engine speed sensor into the 5/8 threaded hole and turn until the magnetic
- - -
core contact with a tooth of the flywheel ring gear.
- - - 2. Back out 180 degrees and tighten the locknut (1) .
- - - Tighten the locknut (1) to 25 ± 5 N·m (19 ± 4 lb ft).
The clearance between the engine speed sensor and the flywheel ring gear is
- - -
0.56 to 0.84 mm (0.022 to 0.033 inch).
121
077 Specifications
Engine Speed Sensor

, S/N - -
Table 1
Specification for the 189-5746 Engine Speed Sensor Gp and 116-6680 Engine Speed Sensor
Torque to
25 ± 5 N·m (18 ± 4 lb ft).
1 - -
Resistance at
25 °C (77 °F) is 142 Ω.
122
SENR2374-04
INDEX
Systems Operation
Fuel System Operation INDEX 000

001 1
5
Fuel Injector 004 10
Fuel Injection Cycle 005 11
Governor - 3161 006 13
Shutdown
Electronic Governors 007 17
Air Inlet and Exhaust System Operation 008 19
Aftercooler 009 20
Valve System Components 010 21
Turbocharger 011 23
Lubrication System Operation 012 24
Cooling System Operation - Jacket Water Aftercooled 013 26
Cylinder Block, Liners and Heads 014 28
Pistons, Rings and Connecting Rods 015 29
Pistons, Rings and Connecting Rods - Two-Piece Piston 016 30
Pistons, Rings and Connecting Rods 017 31
Crankshaft 018 32
Camshaft 019 33
Air Starting System 020 34
Electrical System Operation 021 36
Alternator 022 37
Starting Solenoid 023 38
Starting Motor 024 39
Coolant Temperature Switch 026 41
Magnetic Switch 027 42
Circuit Breaker 028 43
Testing and Adjusting
General Information (Fuel System) - Diesel 001 44

Fuel System Inspection 002 45
Checking Engine Cylinders 003 46
Fuel Pressure - Diesel System 004 47
SENR2374-04
123
Specifications
Introduction
Required Tools
Engine Rotation 005 51
Finding the Top Center Position for the No. 1 Piston 006 52
Introduction
Required Tools
Check Preparation
Camshaft Timing 007 54
Timing Check
Timing Adjustment
Engine Speed Measurement 008 57
Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting 009 58
Fuel Injector Timing 010 60
Fuel Injector Synchronization 011 63
Fuel Setting 012 65
Restriction of Air Inlet and Exhaust 013 68
Measuring Inlet Manifold Pressure 014 69
Measuring Exhaust Temperature 015 71
Crankcase Pressure 016 72
Compression 017 73
Cylinder Heads 018 74
Valves
Valve Seat Inserts
Valve Guides
Bridge Dowels
Valve Lash Check 019 75
Valve Lash and Valve Bridge Adjustment 020 76
Installation
General Information (Lubrication System) 021 81
Engine Oil Pressure - Test 022 82
Excessive Bearing Wear - Inspect 023 85
Excessive Engine Oil Consumption - Inspect 024 86
Increased Engine Oil Temperature - Inspect 025 87
Engine Oil Pressure is Low 026 88
SENR2374-04
124

Worn Components
Engine Oil Pressure is High 027 90
Indicators for Engine Oil Pressure 028 91
General Information (Cooling System) 029 92
Visual Inspection 030 94
Test Tools for the Cooling System 031 96
Cooling System Pressure Cap - Test 032 98
Radiator and Cooling System - Test 033 100
Water Temperature Regulator - Test 034 102
Introduction
Test Procedure
Connecting Rod Bearings 035 103
Main Bearings 036 104
Cylinder Block 037 105
Cylinder Liner Projection 038 106
Specifications
Introduction
Required Tools
Preparation
Flywheel - Inspect 039 109
Flywheel Housing - Inspect 040 111
Vibration Damper 041 114
General Information (Air/Electric Starting System) 042 115
Pressure Regulating Valve 043 117
Lubrication 044 118
Test Tools for the Electrical System 045 119
Battery 046 122
Charging System 047 123
Alternator Regulator 048 124
Electric Starting System 049 125
Pinion Clearance Adjustment 050 126
SENR2374-04
125
SENR2374-04
126
001 Systems Operation
Fuel System Operation
Fuel flow schematic (typical example), (1) Fuel manifolds (2) Fuel filter (3) Fuel priming pump (4) Fuel injectors (5) Pressure
regulating valve (6) Fuel return to tank (7) Primary fuel filter (8) Fuel transfer pump (9) Fuel line to filter (10) Fuel supply line
from the primary fuel filter (11) Fuel line to priming pump
Fuel is pulled through primary fuel filter (7) by fuel transfer pump (8). Fuel transfer pump (8) delivers the
fuel to fuel filter (2) .
Fuel transfer pump (8) has a check valve and a bypass valve. The check valve is located in the pump head
assembly. The pump head assembly is located behind the connection for fuel line (9). The check valve
prevents fuel flow back through the fuel transfer pump when fuel priming pump (3) is used.
The bypass valve is located behind a cap (plug) in the drive end of the pump. The bypass valve limits the
maximum pressure of the fuel. The bypass valve will open the outlet side of the pump to the pump inlet if the
fuel pressure exceeds 860 kPa (125 psi). This process helps prevent damage to the fuel system components
from too much pressure.
127
, (1) Fuel manifold (2) Fuel filter (8) Fuel transfer pump (9) Fuel line to filter (10) Fuel supply line from the primary fuel filter
(11) Fuel line to priming pump
Fuel flow through injector, (4) Fuel injector (12) Outlet fuel line (13) Inlet fuel line (14) Drilled passage (15) Cylinder head (16)
Cylinder
The fuel transfer pump delivers fuel through fuel filter (2). The fuel transfer pump then delivers fuel to fuel
manifolds (1). The fuel flows through fuel manifold (1) to inlet fuel line (13) which is connected to the right
side of each cylinder head (15).
Filter screens are located in the ports of the fuel injector. Drilled passage (14) in the cylinder head delivers
fuel to a circular chamber around fuel injector (4). The chamber is made by the O-rings on the outside
128
diameter of the fuel injector and by the injector bore in the cylinder head.
Cylinder heads, (4) Fuel injector (12) Outlet fuel line (13) Inlet fuel line
Only part of the fuel in the chamber is used for injection. Approximately three to five times the amount of
fuel that is needed for normal combustion flows through the chamber. This fuel then flows to a drilled
passage in the left side of the cylinder head. This passage is connected by outlet fuel line (12) to the bottom
section of the fuel manifold. This constant flow of fuel around the injectors helps to cool the injectors.
The fuel flows back through fuel manifolds (1). The fuel flows to pressure regulating valve (5) on the front of
the right fuel manifold. The fuel flows through this valve. Fuel then flows back to the tank.
Pressure regulating valve (5) consists of a spring and a plunger. This arrangement is between the bottom
section of the fuel manifolds and the line that returns fuel to the tank. The valve keeps the pressure of the fuel
between 415 to 450 kPa (60 to 65 psi).
129
Fuel injector control linkage, (1) Fuel injector (2) Left control shaft (3) Bellcrank (4) Control rod (5) Rack (6) Lever (7) Governor
shaft (8) Right control shaft (9) Cross shaft
Fuel injector (1) is located in each cylinder head. The position of rack (5) controls the amount of fuel that is
injected into the cylinder. The rack is pulled out of the injector for more fuel. The rack is pushed in the
injector for less fuel.
The rack position is changed by bellcrank (3). The bellcrank is moved by control rod (4). The control rods
have an adjustment screw on the top. The adjustment screw is used to synchronize the injectors. The control
rods are spring loaded. If the rack of one injector sticks, it will still be possible for the governor to control the
other racks so the engine can be shutdown.
Each control rod on the right side of the engine is connected by lever (6) to right control shaft (8). When
governor shaft (7) is viewed from the front of the engine and the governor shaft rotates in a clockwise
direction, the action of the governor linkage moves the right control shaft in a counterclockwise direction.
This counterclockwise direction is the "FUEL ON" position.
Right control shaft (8) and left control shaft (2) are connected by cross shaft (9). The linkage between the
injectors on the left side of the engine and the left control shaft is similar to the linkage on the right side.
If the linkage becomes disconnected from the governor, the weight of the control linkage will move the fuel
injector racks to the "FUEL OFF" position and the engine will stop.
130
Fuel Transfer Pump
, (1) Check valve (2) Bypass valve
The fuel transfer pump is located on the right side of the engine. The lower shaft of the engine oil pump
drives the gear type transfer pump. Fuel from the supply tank is pulled through the primary fuel filter by the
fuel transfer pump. The fuel is sent to the fuel filter housing.
The fuel transfer pump has a check valve (1) and a bypass valve (2). The check valve (1) is located in the
pump head assembly. The check valve prevents fuel flow back through the transfer pump when the fuel
priming pump is used. The bypass valve (2) is located behind a cap (plug) in the drive end of the pump. The
bypass valve limits the maximum pressure of the fuel. The bypass valve will open the outlet side of the pump
to the pump inlet if the fuel pressure exceeds 860 kPa (125 psi). This process helps prevent damage to the
fuel system components from too much pressure.
131
Fuel Injector
Fuel injector operation, (1) Screw (2) Rocker arm (3) Clamp (4) Control rod (5) Rack (6) Plunger (7) Lifter assembly (8)
Camshaft
The fuel injector is held in position by clamp (3). Fuel is injected when rocker arm (2) pushes the top of the
fuel injector downward. The movement of the rocker arm is controlled by camshaft (8) through lifter
assembly (7) and control rod (4). The amount of fuel that is injected is controlled by rack (5). Movement of
the rack causes the rotation of a gear that is fastened to plunger (6). Rotation of the plunger changes the
effective stroke of the plunger.
Injection timing is a product of two factors. The two factors include the angular location of the camshaft and
the location of the plunger. The angular location of the camshaft is controlled by the camshaft drive gears at
the rear of the engine. The location of the plunger can be adjusted with screw (1).
132
Fuel Injection Cycle
Fuel injection cycle, (1) Screw (2) Rocker arm (3) Rack (4) Upper port (5) Drilled passage (6) Plunger (7) Lower port (8) Injector
barrel (9) Fuel passage (10) Needle valve (11) Piston
When plunger (6) is at the top of a stroke, fuel flows from the chamber for the fuel supply, around the
injector, and through lower ports (7) and through upper ports (4) of injector barrel (8). As the plunger is
moved downward by rocker arm (2), fuel is pushed back into the supply chamber through the lower port.
Fuel can also go through drilled passage (5) in the center of the plunger, around the relief groove, and
through the upper port of the injector barrel. As the lower port is closed by the bottom of the plunger, fuel
can still flow through the upper port until the port is closed by the upper edge of the relief groove on the
plunger. At this point, injection starts and the effective stroke of the plunger begins.
During the effective stroke, fuel is injected into the cylinder until the downward movement of the plunger
allows the scroll (helix) to open the lower port. This downward movement of the plunger also releases the
fuel pressure. The amount of fuel that is injected during the effective stroke is determined by the position of
the scroll in relation to the lower port.
Fuel goes through the center passage of the plunger and fuel goes through the lower port during the
remainder of the downstroke. As the lower port is opened, the sudden release of very high pressure causes the
fuel to hit the deflector for spills with a high force. The deflector for spills gives protection to the injector
housing from erosion because of the force of the released fuel. On the return stroke, the injector barrel is
filled with fuel again from the fuel supply chamber.
The plunger can be turned by rack (3) while the plunger is moved upward and the plunger is moved
downward by the rocker arm. The upper part of the plunger has a flat side that fits through the gear. The gear
is engaged with the rack. The plunger slides upward and the plunger slides downward in the gear. As the rack
133
moves, the gear and the plunger rotate together. This rotation of the plunger controls the fuel output of the
injector. The rotation of the plunger changes the relation of the scroll to the lower port in the injector barrel.
The rotation of the plunger also increases or the rotation decreases the length of the effective stroke for
injection. The scroll can set the amount of fuel per injection stroke. Therefore, the fuel rate to the engine can
be controlled in relation to different engine loads.
No injection takes place during the downstroke of the plunger when the rack is moved all the way against the
fuel injector body. This is the "Fuel Off" position. Fuel injection begins when the rack is moved outward by a
small distance. As the rack continues to move outward, the amount of fuel that is injected into the cylinder is
increased until the maximum fuel position is reached.
During the fuel injection stroke, fuel passes from the injector barrel through a valve assembly. The valve
assembly has a spring-loaded needle valve (10) and fuel flows through fuel passages (9) around the needle
valve to the valve chamber. The fuel pressure lifts the needle valve off the seat. The fuel can now flow
through the orifices in the tip into the combustion chamber.
If the needle valve is held open between injection cycles by small debris, then gases from combustion could
enter the injector. The gases will cause damage. A flat check valve is used above the needle valve in order to
keep these high pressure gases from combustion out of the injector. The injector operates with the flat check
valve until the foreign particle has been washed away through the orifices by the fuel and normal operation
again takes place.
The tip of the injector extends a short distance below the cylinder head into the combustion chamber. The tip
has several small orifices that are evenly spaced around the outside diameter in order to spray fuel into the
combustion chamber. The top surface of piston (11) is designed with a shaped crater that causes the air to
swirl. The fuel is sprayed into the air that is swirling for more complete combustion.
134
Governor - 3161
3161 Governor (typical example), (1) Manual speed setting control (2) Speed adjusting motor head (3) External droop adjustment
The 3161 Governor is a hydromechanical governor. The 3161 Governor is connected to the engine fuel
system by a mechanical linkage. The governor controls the rate of fuel that is injected into each of the engine
cylinders in order to adjust for engine loads.
The speed adjusting motor is located on the governor cover and runs on 24 VDC power supply. When the
motor is actuated, the motor rotates a speed adjusting screw in order to adjust the position of the governor
speed adjusting lever.
The manual speed setting control (1) which is located on the front of the governor can be increased or
decreased by the engine speed. Turn the manual speed setting control (1) clockwise in order to increase the
speed setting. Turn the manual speed setting control (1) counterclockwise in order to decrease the speed
setting. The high speed stops and the low speed stops will limit the adjustments.
The 3161 Governor has a maximum of 11 N·m (9 lb ft) of torque output over the full 42 degrees of terminal
shaft rotation while the fuel is in the ON direction and the OFF directions. The governor terminal shafts are
moved in both directions by hydraulic pressure. No return spring is used on the outside of the governor. The
return spring is located on the inside of the governor. This spring will cause the terminal shafts to rotate to
the full shutoff position when the governor is not in operation.
The recommended travel (rotation) of the terminal shafts is approximately 30 degrees from low idle to full
load. The following results will take place:
¡ There will be extra play at each end of the terminal shafts.
¡ The governor will make a complete shutdown.
¡ The maximum amount of fuel will be provided.
The 3161 Governor is connected to the engine oil system. The pressurized engine oil supply is sent to the
governor through an orifice and through internal passages. The governor maintains the correct oil level and
the governor will drain excess oil back into the engine. This will give a constant flow of engine oil through
the governor.
The governor must be filled with approximately 1.8 L (1.9 qt) of clean engine oil before engine start-up. Fill
the governor with oil if the governor has been removed or if the governor has been overhauled. The oil fill
cap on the 3161 Governor is located on the top cover.
135
Schematic for 3161 Governor (typical example)

The 3161 Governor uses engine lubrication oil for the hydraulic system. The pressurized engine oil supply is
sent to the governor oil reservoir through an orifice which can be removed from the governor housing for
cleaning. First, the oil will travel through internal passages to the suction side of the gerotor pump. The oil
will then travel to the pressure side of the gerotor pump as the drive shaft is turned by the engine. An
accumulator spring and a piston will keep the pump pressure at approximately 690 kPa (100 psi). The
accumulator piston moves upward in the piston cylinder until the pump pressure is 690 kPa (100 psi). The
ports in the piston will open in order to control the pump pressure, after the established pump pressure is
reached.The pump pressure, which is set by the accumulator, controls the work output of the governor.
136
When the speed setting shaft is turned clockwise, the speed setting of the governor is increased. The high idle
screw limits the high speed setting of the governor. As the speed setting shaft turns, the speed setting lever
pushes down on the floating lever which is fastened to the speeder plug. The downward pressure on the
speeder plug puts the speeder spring under compression. The force of the speeder spring will then become
greater than the centrifugal force of the ballhead flyweights. The ballhead pilot valve plunger will move
down. The governor speed setting is then increased.When the pilot valve plunger is moved down the
pressurized engine oil will move under the power piston. This process will push the piston upward. This will
move the terminal lever upward. Turn the output shafts toward the increased fuel position in order to increase
engine speed.Before the engine reaches the new set speed, the compensation system will return the pilot
valve plunger back to the center position. This will put the governor under stable control.The oil above the
power piston is connected to the upper side of the buffer piston and lower side of the pilot valve
compensation land. As the power piston moves upward, the oil pressure will push the buffer piston
downward. This will increase the compression of the lower buffer piston spring. The force of the spring
works against the buffer piston movement and this results in a small increase in oil pressure on the upper side
of the buffer piston. The increased pressure is directed to the lower side of the pilot valve compensation land.
This will force the pilot valve plunger up to the center position. This stops the flow of pressurized engine oil
to the lower side of the power piston and movement of the piston is stopped.As the pilot valve plunger is
returned to the center position and the power piston movement is stopped, there is oil leakage through the
needle valve orifice. This will allow the oil pressure above the pilot valve compensation land and the oil
pressure below the pilot valve compensation land to become equal. When this process is complete, the pilot
valve plunger movement is stopped and the engine speed is returned to a stable condition. As the oil pressure
above the pilot valve compensation land and the oil pressure below the pilot valve compensation land
become equal, the buffer springs return the buffer piston to the center position.
When the speed setting shaft is turned counterclockwise, the speed setting of the governor is decreased. The
low idle screw limits the low speed setting of the governor with the exception of the D11N. As the speed
setting shaft is turned counterclockwise, the force of the speed setting lever on the floating lever is removed.
This lowers the compression of the speeder spring. Centrifugal force from the ballhead flyweights will lift the
pilot valve plunger. This will open the control port that is inside of the rotating bushing. The control oil under
the power piston will drain into the sump. This will permit the power piston to move down. Turn the output
shafts toward the decreased fuel position in order to decrease engine speed.Before the engine reaches the new
set speed, the compensation system will return the pilot valve plunger back to the center position. This will
put the governor under stable control.When the pilot valve plunger is lifted, the oil that is under the power
piston will drain back into the governor sump. The pump pressure oil on the bottom of the buffer piston will
force the buffer piston upward. The oil above the buffer piston will put a force on the top of the power piston
in order to move the power piston downward.The upward movement of the buffer piston will increase the
compression of the upper buffer piston spring. The force of the upper spring works against the movement of
the buffer piston. This will result in a small increase to the pump oil pressure on the lower side of the buffer
piston and on the top surface of the pilot valve plunger compensation land. The increase in the pump oil
pressure is greater than the oil pressure that is in the pilot valve plunger. The difference in the pressure on
both sides of the pilot valve plunger compensation land will create a force that will push the pilot valve back
to the center position.The force of the pressure difference on the pilot valve plunger compensation land will
put the pilot valve plunger in the center position. This will occur when the new fuel setting and the setting for
the output shafts are equal. The movement of the power piston and the output shaft is now stopped.The
continued decrease of engine speed to the steady state setting will result in a continued increase in downward
force of the speeder spring on the pilot valve plunger as the ballhead flyweights move in. When the ballhead
flyweights move in the pressure difference for the buffer piston and the pressure for the pilot valve plunger
compensation land is released by the flow of oil through the needle valve orifice. This controlled discharge
allows the buffer piston to return slowly to the normal position. The speeder spring will put a downward
force on the pilot valve plunger until the spring force and the force of the ballhead flyweights become equal.
The controlled reduction of the pressure difference on the two sides of the pilot valve plunger compensation
land occur at the same rate. The pilot valve plunger remains centered until the engine is again at the on-
137
engine speed condition at the new speed setting.Note: An increase or a decrease in engine load will give the
governor movement as an increase or a decrease in governor speed setting.
Shutdown
The limit/shutdown pilot valve is located in the pump oil pressure supply line to the ballhead pilot valve.
When the engine shutdown system is activated, the limit/shutdown rod pushes the limit/shutdown pilot valve
plunger below the supply passage. This drains oil from the supply to the ballhead pilot valve plunger. The
power piston will move downward as the output shafts turn in the decreased fuel direction. When engine
speed is decreased, the ballhead flyweights move in. This will lower the ballhead pilot valve. The oil from
the power piston will drain into the governor sump at a faster rate. As the power piston continues to move
down, the output shaft is turned to the shutdown position until the engine is stopped.
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Electronic Governors
The 2301 Electric Governor Control System consists of the following components:
¡ 2301 Electric Governor Control (EGC)
¡ Actuator
¡ Engine Speed Sensor
2301 Electric Governor Control (EGC)
The 2301 Electric Governor System gives precision engine speed control. The 2301 Control measures the
engine speed constantly. The 2301 Control makes the necessary corrections to the engine fuel setting through
an actuator. The actuator is connected to the fuel system.
Engine speed sensor (typical example), (1) Engine speed sensor
The engine speed is detected by an engine speed sensor. This sensor makes an AC voltage that is sent to the
2301 Control. The 2301 Control now sends a DC voltage signal to the actuator.
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Front of engine (typical example), (2) EG6P actuator
The actuator changes the electrical input from the 2301 Control to a mechanical output. The mechanical
output is connected to the fuel system by a linkage. For example, if the engine speed is more than the speed
setting, the 2301 Control will decrease the output. The actuator will now move the linkage in order to
decrease the fuel to the engine.
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Air Inlet and Exhaust System Operation
The components of the air inlet and exhaust system control the quality and the amount of air that is available
for combustion. There are separate turbochargers and exhaust manifolds on each side of the engine. A
common aftercooler is located between the cylinder heads in the center of the engine. The inlet manifold is a
series of elbows that connect the aftercooler chamber to the inlet ports (passages) of the cylinder heads. There
is one camshaft in each side of the block. The two camshafts control the movement of the valve system
components.
Air inlet and exhaust system, (1) Exhaust manifold (2) Aftercooler (3) Engine cylinder (4) Air inlet (5) Turbocharger compressor
wheel (6) Turbocharger turbine wheel (7) Exhaust outlet
Clean inlet air from the air cleaners is pulled through air inlet (4) into the turbocharger compressor by
turbocharger compressor wheel (5). The rotation of the turbocharger compressor wheel causes the air to
compress. The rotation of the turbocharger compressor wheel then forces the air through a tube to aftercooler
(2). The aftercooler lowers the temperature of the compressed air before the air gets into the inlet chambers in
each cylinder head. This cooled and compressed air fills the inlet chambers in the cylinder heads. Air flow
from the inlet chamber into the cylinder heads is controlled by the inlet valves.
There are two inlet valves and two exhaust valves for each cylinder. Refer to Systems Operation, "Valve
System Components". The inlet valves open when the piston moves down on the inlet stroke. The cooled,
compressed air is pulled into the cylinder from the inlet chamber.
The inlet valves close and the piston starts to move up on the compression stroke. When the piston is near the
top of the compression stroke, fuel is injected into the cylinder. The fuel mixes with the air and combustion
starts. The force of the combustion pushes the piston downward on the power stroke. When the piston moves
upward the piston is on the exhaust stroke. The exhaust valves open and the exhaust gases are pushed
through the exhaust port into exhaust manifold (1). After the piston makes the exhaust stroke, the exhaust
valves close and the cycle starts again.
Exhaust gases from the exhaust manifold go into the turbine side of the turbocharger. The exhaust gases
cause turbocharger turbine wheel (6) to turn. The turbine wheel is connected to the shaft that drives the
turbocharger compressor wheel. The exhaust gases exit through exhaust outlet (7).
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Aftercooler
The aftercooler is located at the center of the vee. The aftercooler has a core assembly that is charged with
coolant. Coolant from the water pump flows through a pipe into the aftercooler. Coolant then flows through
the core assembly (assemblies). Coolant flows back out the aftercooler through a different pipe.
There is a connector (tube) that connects the bottom rear of each core to the cylinder block. This connector is
used in order to drain the aftercooler when the coolant is drained from the engine.
Inlet air from the compressor side of the turbochargers flows into the aftercooler through pipes. The air then
passes through the fins of the core assembly which lowers the temperature. The cooler air flows out of the
bottom of the aftercooler and into the inlet manifold. The air flows upward through the elbows to the inlet
ports (passages) in the cylinder heads.
There are sensors for the aftercooler water temperature and for the inlet manifold air temperature.
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Valve System Components
The valve system components control the flow of the inlet air and the exhaust gases into the cylinders and out
of the cylinders during engine operation.
The crankshaft gear drives the camshaft gears through idlers. Both camshafts must be timed to the crankshaft
in order to get the correct relation between the piston and the valve movement.
Valve system components that illustrate the adjustable valve bridge, (1) Rocker arm (2) Bridge (3) Rotocoil (4) Valve spring (5)
Pushrod (6) Lifter
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Valve system components that illustrate the nonadjustable valve bridge, (1) Rocker arm (2) Bridge (3) Rotocoil (4) Valve spring
(5) Pushrod (6) Lifter
The camshafts have three lobes for each cylinder. Two lobes operate the valves and the other lobe operates
the fuel injector.
As each camshaft turns, the lobes on the camshaft cause lifters (6) to move up and down. This movement
causes pushrods (5) to move rocker arms (1). The movement of the rocker arm causes bridges (2) to move up
and down on the dowels in the cylinder head. The bridges allow one rocker arm to open two valves. When
the lifters move downward the action of valve springs (4) closes the valves. The valves can be either inlet
valves or exhaust valves. There are two inlet valves and two exhaust valves for each cylinder.
Rotocoils (3) cause the valves to turn while the engine is running. The rotation of the valves keeps the carbon
deposits on the valves to a minimum which gives the valves a longer service life.
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Turbocharger
Two turbochargers are used on the top of the engine. A turbocharger is located on each side of the vee. The
turbine side of each turbocharger is mounted to the respective exhaust manifold. The compressor side of each
turbocharger is connected by pipes to the top of the aftercooler housing.
Turbocharger (Typical Example), (1) Compressor wheel (2) Bearing (3) Oil inlet (4) Bearing (5) Turbine wheel (6) Exhaust outlet
(7) Air inlet (8) Coolant passages (9) Oil outlet () Exhaust inlet
The exhaust gases go into the exhaust inlet (10) of the turbine housing. The gases push the blades of turbine
wheel (5). The turbine wheel and the compressor wheel turn at speeds up to 90,000 rpm.
Clean air from the air cleaners is pulled through the compressor housing air inlet (7) by the rotation of the
compressor wheel (1). The action of the compressor wheel blades compress the inlet air. This compression
gives the engine more power because the compression allows the engine to burn additional fuel with greater
efficiency.
The maximum speed of the turbocharger is controlled by the engine's electronic control of fuel delivery.
When the engine is operating, the height above the sea level also controls the maximum speed of the
turbocharger.
Bearing (2) and bearing (4) in the turbocharger use engine oil under pressure for lubrication. The oil is sent
through the oil inlet line to oil inlet (3) at the top. The oil then goes through passages in the center section for
lubrication of the bearings. The oil goes out of oil outlet (9) at the bottom. The oil then goes back to the
engine block through the drain line.
The bearing housing in the turbocharger is also cooled by the jacket water coolant. Coolant from the coolant
inlet line enters the side of the center section. The coolant travels through coolant passages (8) in the bearing
housing. The coolant then leaves the turbocharger at the other side of the center section. The coolant outlet
lines return the coolant back to the jacket water radiator top tank.
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Lubrication System Operation
Main oil pump and lubrication system schematic (typical example), (1) Main oil gallery (2) Left camshaft oil gallery (3) Piston
cooling jet oil gallery (4) Piston cooling jet oil gallery (5) Right camshaft oil gallery (6) Oil supply lines (7) Sequence valve (8)
Sequence valve (9) Adapter (10) Engine oil filter bypass valve (11) Engine oil cooler (12) Engine oil cooler bypass valve (13) Oil
pump relief valve (14) Engine oil pump (15) Elbow (16) Suction bell (17) Engine oil filter housing
This system uses an engine oil pump (14) with three pump gears. The pump gears are driven by the front gear
train. Engine oil is pulled from the pan through suction bell (16) and elbow (15) by engine oil pump (14).
Suction bell (16) has a screen in order to clean the engine oil.
There is an oil pump relief valve (13) in the engine oil pump. The oil pump relief valve controls the pressure
of the engine oil from the engine oil pump. This allows the engine oil that is not needed to go back to the
inlet oil passage of the engine oil pump.
The engine oil pump pushes oil through engine oil cooler (11) and the engine oil filters to main oil gallery (1)
and left camshaft oil gallery (2) in the cylinder block. Engine oil cooler (11) lowers the temperature of the
engine oil before the engine oil is sent to the filters.
Engine oil cooler bypass valve (12) allows engine oil to flow directly to the filters if engine oil cooler (11)
becomes plugged or if the engine oil becomes thick enough to increase the oil pressure differential by 180 ±
20 kPa (26 ± 3 psi).
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Engine oil filters are located in engine oil filter housing (17) at the front of the engine. A single bypass valve
is located in the engine oil filter housing.
Clean engine oil from the filters goes through adapter (9) into the cylinder block. Part of the engine oil goes
to left camshaft oil gallery (2). The remainder of the engine oil goes to main oil gallery (1) .
Left camshaft oil gallery (2) and right camshaft oil gallery (5) are connected to each camshaft bearing by a
drilled hole. The engine oil goes around each camshaft journal. The engine oil then travels through the
cylinder head and the rocker arm housing to the rocker arm shaft. A drilled hole connects the bores for the
valve lifters to the oil hole for the rocker arm shaft. The valve lifters are lubricated at the top of each stroke.
The main oil gallery is connected to the main bearings by drilled holes. Drilled holes in the crankshaft
connect the main bearing oil supply to the rod bearings. Engine oil from the rear of the main oil gallery goes
to the rear of the right camshaft oil gallery.
Sequence valve (7) and sequence valve (8) allow engine oil from the main oil gallery to go to both piston
cooling jet galleries (3) and (4). The sequence valves begin to open at approximately 130 kPa (19 psi). The
sequence valves will not allow engine oil into the piston cooling jet galleries until there is pressure in the
main oil gallery. This decreases the amount of time that is necessary for pressure buildup when the engine is
started. This also helps hold pressure at idle speed.
Piston cooling and lubrication (typical example), (18) Piston cooling jet
There is a piston cooling jet (18) below each piston. Each cooling jet has two openings. One opening is in the
direction of a passage in the bottom of the piston. This passage takes engine oil to a manifold behind the ring
band of the piston. A slot (groove) is in the side of both piston pin bores. This slot connects with the manifold
behind the ring band. The other opening is in the direction of the center of the piston. This helps cool the
piston and this supplies lubrication to the piston pin.
Turbochargers (typical example), (6) Oil supply lines (19) Oil drain lines
Oil supply lines (6) send oil from the rear adapter to the turbochargers. Oil drain lines (19) are connected to
the flywheel housing on each side of the engine.
Engine oil is sent to the front and rear gear groups through drilled passages. The drilled passages are in the
front housing, the rear housing, and the faces of the cylinder block. These passages are connected to left
camshaft oil gallery (2) and right camshaft oil gallery (5) .
After the engine oil flows through the lubrication system, the engine oil returns back to the engine oil pan.
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Cooling System Operation - Jacket Water Aftercooled
Schematic of cooling system (typical example), (1) Water manifold (2) Aftercooler (3) Water temperature regulator housing (4)
Tube (5) Cylinder head (6) Cylinder block (7) Engine oil cooler (8) Tube (9) Water pump (10) Bypass tube
Coolant goes into water pump (9) through an elbow. The elbow connects to the radiator or to the heat
exchanger. The coolant flow is divided at the outlet of the water pump. Part of the coolant flow is sent to
aftercooler (2) through tube (8). The remainder of the coolant goes through engine oil cooler (7) .
Coolant that is sent to the aftercooler goes through the aftercooler core. The coolant is sent by an elbow into a
passage in cylinder block (6). The passage is near the center of the vee at the rear of the cylinder block.
The coolant flows through the engine oil cooler into the water jacket of the cylinder block at the right rear
cylinder. The cooler coolant and the hotter coolant are then mixed. The coolant goes to both sides of the
cylinder block through distribution manifolds. The distribution manifolds are connected to the water jacket of
all the cylinders. The main distribution manifold is located just above the main bearing oil gallery.
The coolant flows upward through the water jackets. The coolant flows around the cylinder liners from the
bottom to the top. The hottest temperature is near the top of the cylinder liners. The water jacket is smaller
near the top of the cylinder liners. This shelf causes the coolant to flow faster for better liner cooling.
Coolant from the top of the liners goes into cylinder head (5). The cylinder head sends the coolant around the
hottest parts. Coolant then goes to the top of the cylinder head. The coolant goes out through an elbow at
each cylinder head and into water manifold (1) at each bank of cylinders. Coolant goes through the water
manifold to temperature regulator housing (3) .
The water temperature regulator housing has an upper flow section and a lower flow section. The housing
uses four temperature regulators. The sensing bulbs of the four temperature regulators are in the lower
section of the housing. Before the regulators open, cold coolant is sent through bypass tube (10) back to the
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inlet of water pump (9). As the temperature of the coolant increases and the regulators start to open, the
coolant flow in the bypass tube is restricted. Some coolant is sent through the outlets to the radiator or to the
heat exchanger.
The total system capacity will depend on the amount of coolant in the following components: cylinder block,
radiator or the heat exchanger and the coolant lines.
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Cylinder Block, Liners and Heads
The cylinders in the left side of the block form a 60 degree angle with the cylinders in the right side. The
main bearing caps are fastened to the cylinder block with four bolts per cap.
The cylinder liners can be removed for replacement. The top surface of the cylinder block is the seat for the
cylinder liner flange. Engine coolant flows around the cylinder liners in order to keep the cylinder liners cool.
Three O-ring seals around the bottom of the cylinder liner make a seal between the cylinder liner and the
cylinder block. A filler band goes under the cylinder liner flange. This makes a seal between the top of the
cylinder liner and the cylinder block.
The engine has a separate cylinder head for each cylinder. Two inlet valves and two exhaust valves, which
are controlled by a pushrod valve system, are used for each cylinder. Valve guides without shoulders are
pressed into the cylinder heads. The opening for the unit injector is located between the four valves. A lobe
on the camshaft moves the pushrod that operates the unit injector. Fuel is injected directly into the cylinder.
There is an aluminum spacer plate between each cylinder head and the cylinder block. Coolant goes out of
the cylinder block through the spacer plate and into the cylinder head through eight openings in each cylinder
head face. Water seals are used in each opening to prevent coolant leakage. Gaskets seal the engine oil drain
line between the cylinder head, the spacer plate, and the cylinder block.
Left side of engine (typical example), (1) Camshaft covers (2) Crankcase covers
Camshaft covers (1) allow access to the camshaft and to the valve lifters. Crankcase covers (2) allow access
to the crankshaft connecting rods, to the main bearings, and to the piston cooling jets. When the covers are
removed, all the openings can be used for inspection and for service.
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Pistons, Rings and Connecting Rods
, (1) Piston (2) Compression rings (3) Oil ring (4) Connecting rod (5) Piston pin (6) Pin retainer (7) Bolt (8) Connecting rod cap
(9) Connecting rod bearing
Aluminum pistons (1) have three rings. The rings include two compression rings (2) and one oil ring (3). All
the rings are located above the piston pin bore. The top two compression rings are rectangular. The oil ring is
a two-piece ring. Engine oil returns to the crankcase through holes in the oil ring groove.
Note: Earlier designs of the pistons had a cast iron band for the top two rings in order to help reduce wear on
the compression ring grooves. The newer design has a band for the top ring only.
The piston is attached to connecting rod (4) with piston pin (5) and with two pin retainers (6). The connecting
rod has a taper on the pin bore end. This taper gives the connecting rod and the piston more strength in the
areas with the most load. Four bolts (7), which are set at a small angle, hold connecting rod cap (8) to the
connecting rod. This design keeps the connecting rod width to a minimum, so that a larger connecting rod
bearing (9) can be used and the connecting rod can still be removed through the cylinder liner.
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Pistons, Rings and Connecting Rods - Two-Piece Piston
, (1) Top ring (2) Intermediate ring (3) Oil control ring (4) Piston pin bore (5) Piston pin (6) Piston pin retainer
The piston is a two-piece, articulated design. The piston consists of a forged, steel crown and a cast,
aluminum skirt. The two pieces of the piston assembly are connected to the piston pin. The two pieces of the
piston assembly pivot about the piston pin. The steel crown carries all three piston rings. Oil from the piston
cooling jets flows through a chamber which is located directly behind the rings. The oil cools the piston
which improves the life of the rings. The pistons have three rings which include two compression rings and
one oil ring. All the rings are located above the piston pin bore. The oil ring is a standard ring. Oil returns to
the crankcase through holes in the oil ring groove.
The connecting rod has a taper on the pin bore end. This taper gives the rod and the piston more strength in
the areas with the most load. Four bolts, which are set at a small angle, hold the rod cap to the rod. The
design keeps the rod width to a minimum. A larger rod bearing is used and the rod can still be removed
through the liner.
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Pistons, Rings and Connecting Rods
, (1) Piston (2) Compression rings (3) Oil ring (4) Pin retainer (5) Piston pin (6) Connecting rod (7) Connecting rod bearing (8)
Connecting rod cap (9) Bolt
Aluminum pistons (1) have three rings. The rings include two compression rings (2) and one oil ring (3). All
the rings are located above the piston pin bore. The top two compression rings are rectangular. The oil ring is
a two-piece ring. Engine oil returns to the crankcase through holes in the oil ring groove.
Note: Earlier designs of the pistons had a cast iron band for the top two rings in order to help reduce wear on
the compression ring grooves. The newer design has a band for the top ring only.
The piston is attached to connecting rod (6) with piston pin (5) and with two pin retainers (4). The connecting
rod has a taper on the pin bore end. This taper gives the connecting rod and the piston more strength in the
areas with the most load. Four bolts (9), which are set at a small angle, hold connecting rod cap (8) to the
connecting rod. This design keeps the connecting rod width to a minimum, so that a larger connecting rod
bearing (7) can be used and the connecting rod can still be removed through the cylinder liner.
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Crankshaft
The crankshaft changes the combustion forces in the cylinder into usable rotating torque. A vibration damper
is used at the front of the crankshaft in order to reduce torsional vibrations (twist) that can cause damage to
the engine.
The crankshaft drives a group of gears that are on the front of the engine and on the rear of the engine. The
gear group on the front of the engine drives the oil pump, the jacket water pump, the fuel transfer pump, and
the accessory drives.
The rear gear group, which is also driven by the crankshaft, drives the camshafts and the accessory drives.
Seals and wear sleeves are used at both ends of the crankshaft. The seals and wear sleeves are replaceable.
Pressure oil is supplied to all main bearings through drilled holes in the webs of the cylinder block. The oil
then flows through drilled holes in the crankshaft in order to provide oil to the connecting rod bearings. The
3508 crankshaft is held in place by five main bearings. The 3512 crankshaft is held in place by seven main
bearings. The 3516 crankshaft is held in place by nine main bearings. A thrust plate at either side of the
center main bearing controls the end play of the crankshaft.
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Camshaft
There is one camshaft assembly per side. The 3508 camshaft is supported by five bearings. The 3512
camshaft is supported by seven bearings. The 3516 camshaft is supported by nine bearings. Each camshaft is
driven by the rear gear group.
As the camshaft turns, each lobe moves a lifter. There are three lifters for each cylinder. Each outside lifter
moves a pushrod and two valves. The valves can be inlet valves or exhaust valves. The center lifter moves a
pushrod that operates the unit injector.
The camshafts must be in time with the crankshaft. The relation of the camshaft lobes to the crankshaft
position causes the valves and unit injectors in each cylinder to operate at the correct time.
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Air Starting System
Air starting system (typical example), (1) Relay valve (2) Hose (3) Starting motor solenoid (4) Hose (5) Air starting motor
Air starting motor, (6) Air inlet (7) Vanes (8) Rotor (9) Pinion (10) Reduction gears (11) Piston (12) Piston spring
When the main supply of pressurized air is ON, pressurized air is provided to relay valve (1). The main
supply of pressurized air is blocked by the relay valve. The relay valve allows some control air pressure to
flow through hose (2) from the bottom of the relay valve to another valve that is connected to starting motor
solenoid (3) .
When the normally closed starting motor solenoid is activated for start-up, the solenoid opens the connected
valve. The valve allows the control air pressure to flow behind piston (11) inside air starting motor (5) .
The control air pressure pushes the piston. The piston compresses piston spring (12) and the piston moves the
drive shaft for pinion (9) outward in order to engage the pinion with the flywheel ring gear. The starting
motor does not crank the engine yet.
After the pinion is engaged with the flywheel ring gear, a port in the starting motor is opened in order to
allow the control air pressure to flow through hose (4) to the top of relay valve (1). The relay valve opens in
order to allow the main supply of pressurized air to flow through the starting motor's air inlet (6) .
The pressurized air causes vanes (7) and rotor (8) to rotate. The rotor uses reduction gears (10) to rotate the
drive shaft for the pinion and the pinion rotates the flywheel in order to crank the engine.
When the engine starts to run, the flywheel will begin to rotate faster than the pinion. The design of the drive
shaft for the pinion allows the pinion to move away from the flywheel. This prevents damage to the air
starting motor, to the pinion, and to the flywheel ring gear.
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When the engine control senses the crank terminate speed, starting motor solenoid (3) is de-energized. The
solenoid closes the attached valve and the control air pressure is removed from piston (11). Piston spring (12)
retracts the piston, the drive shaft, and pinion (9) .
The retraction of piston (11) closes the passage for the control air pressure to relay valve (1). The relay valve
closes in order to shut off the main supply of pressurized air to the starting motor.
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Electrical System Operation
The electrical system has three separate circuits. The circuits are the charging circuit, the starting circuit, and
the low amperage circuit. Some of the electrical system components are used in more than one circuit. The
following components are common in each of the circuits:
¡ Battery
¡ Circuit breaker
¡ Ammeter
¡ Cable
¡ Wires for the battery
The charging circuit is in operation when the engine is running. An alternator makes electricity for the
charging circuit. A voltage regulator in the circuit controls the electrical output in order to keep the battery at
full charge.
The starting circuit is in operation only when the start switch is activated.
The low amperage circuit is connected to the same side of the ammeter as the charging circuit. The starting
circuit connects to the opposite side of the ammeter.
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Alternator
NOTICE
Never operate the alternator without the battery in the circuit. Making
or breaking an alternator connection with heavy load on the circuit can
cause damage to the regulator.
Alternator components (typical example), (1) Regulator (2) Roller bearing (3) Stator winding (4) Ball bearing (5) Rectifier bridge
(6) Field winding (7) Rotor assembly (8) Fan
The alternator is driven by a belt from an auxiliary drive at the front right corner of the engine. This
alternator is a three-phase, self-rectifying charging unit, and regulator (1) is part of the alternator.
This alternator design has no need for slip rings or brushes, and the only part that has movement is rotor
assembly (7). All conductors that carry current are stationary. The conductors are field winding (6), stator
windings (3), six rectifying diodes, and the regulator circuit components.
Rotor assembly (7) has many magnetic poles. Air space is between the opposite poles.
The poles have residual magnetism that produces a small amount of magnetic lines of force between the
poles. As rotor assembly (7) begins to turn between field windings (6) and stator windings (3), a small
amount of alternating current (AC) is produced in stator windings (3). This current is from the small,
magnetic lines of force that are made by the residual magnetism of the poles. This alternating current (AC) is
changed to a direct current (DC). The change occurs when the current passes through the diodes of rectifier
bridge (5). Most of this current completes two functions. The functions are charging the battery and
supplying the low amperage circuit. The remainder of the current is sent to field windings (6). The DC
current flow through field windings (6) (wires around an iron core) now increases the strength of the
magnetic lines of force. These stronger lines of force increase the amount of AC current that is produced in
stator windings (3). The increased speed of rotor assembly (7) also increases the current and voltage output of
the alternator.
Voltage regulator (1) is a solid-state, electronic switch. The regulator feels the voltage in the system. The
regulator will start and the regulator will stop many times in one second in order to control the field current to
the alternator. The output voltage from the alternator will now supply the needs of the battery and the other
components in the electrical system. No adjustment can be made in order to change the rate of charge on
these alternator regulators.
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Starting Solenoid
A solenoid is an electromagnetic switch that does two basic operations.

¡ The solenoid closes the high current starting motor circuit with a low current start switch circuit.
¡ The solenoid engages the starter motor pinion with the ring gear.
Typical solenoid schematic
The solenoid has windings (one or two sets) around a hollow cylinder. The cylinder contains a spring loaded
plunger. The plunger can move forward and backward. When the start switch is closed and the electricity is
sent through the windings, a magnetic field is made. The magnetic field pulls the plunger forward in the
cylinder. This moves the shift lever in order to engage the pinion drive gear with the ring gear. The front end
of the plunger makes contact across the battery and the motor terminals of the solenoid. The starting motor
begins to turn the flywheel of the engine.
When the start switch is opened, current no longer flows through the windings. The spring pushes the plunger
back to the original position. The spring simultaneously moves the pinion gear away from the flywheel.
When two sets of windings in the solenoid are used, the windings are called the hold-in windings and the
pull-in windings. Both of the windings have the same number of turns around the cylinder. However, the
pull-in winding uses a wire with a larger diameter in order to produce a greater magnetic field. When the start
switch is closed, part of the current flows from the battery through the hold-in windings. The rest of the
current flows through the pull-in windings to the motor terminal. The current then goes through the motor to
the ground. When the solenoid is fully activated, current is shut off through the pull-in windings. Only the
smaller hold-in windings are in operation for the extended period of time. This period of time is the amount
of time that is needed for the engine to start. The solenoid will now take less current from the battery. The
heat that is made by the solenoid will be kept at an acceptable level.
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Starting Motor
The starting motor is used to turn the engine flywheel in order to start the engine.
Cross section of the starting motor (typical example), (1) Field winding (2) Solenoid (3) Clutch (4) Pinion (5) Commutator (6)
Brush assembly (7) Armature
The starting motor has a solenoid (2). When the start switch is activated, electricity will flow through the
windings of the solenoid. The solenoid core will move in order to push pinion (4) with a mechanical linkage.
This will engage with the ring gear on the flywheel of the engine. Pinion (4) will engage with the ring gear
before the electric contacts in solenoid (2) close the circuit between the battery and the starting motor. When
the circuit between the battery and the starting motor is complete, pinion (4) will turn the engine flywheel. A
clutch gives protection to the starting motor. The engine can not turn the starting motor too fast. When the
start switch is released, pinion (4) will move away from the flywheel ring gear.

The starting motor is protected from damage in two ways:
¡ The starting motor is protected from engagement with the engine when the engine is running. The
control feature will not allow the starting motor to engage if the speed is above 0 rpm.
¡ The starting motor is protected from continuous starting. For example, if an operator is holding the key
in the Start position after the engine starts, the starting motor solenoid will disengage after engine
speed reaches 300 rpm.
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Engine Speed Sensor
Schematic of engine speed sensor, (1) Magnetic lines of force (2) Wire coils (3) Gap (4) Pole piece (5) Flywheel ring gear
The engine speed sensor is a permanent magnet generator. This engine speed sensor has a single pole. The
engine speed sensor is made of wire coils (2). The wire coils go around a permanent magnet pole piece (4) .
As the teeth of flywheel ring gear (5) cut through magnetic lines of force (1) that are generated by the
permanent magnet, an AC voltage is generated in wire coils (2). The frequency of this voltage is directly
proportional to engine speed.
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Coolant Temperature Switch
Coolant temperature switch
The coolant temperature switch is installed in the regulator housing. An adjustment to the temperature range
of the contactor cannot be made. The element feels the temperature of the coolant. The element then operates
the microswitch in the contactor when the coolant temperature is too high. The element must be in contact
with the coolant in order to operate correctly. The coolant temperature switch will not operate if the engine is
too hot due to low coolant level or no coolant level.
The coolant temperature switch is normally connected to the electric shutoff system in order to stop the
engine. The switch can also be connected to an alarm system. As the coolant temperature lowers back to the
operating range, the water temperature contactor switch opens automatically.
163
Magnetic Switch
A magnetic switch is used in the circuit for the starting motor solenoid. The switch electrically operates in the
same manner as the solenoid. The magnetic switch is used in order to reduce the low current load on the start
switch. The magnetic switch also controls the low current to the starting solenoid.
164
Circuit Breaker
The circuit breaker is a switch that opens the battery circuit if the current in the electrical system goes higher
than the rating of the circuit breaker.
A heat-activated metal disc with a contact point completes the electric circuit through the circuit breaker. If
the current in the electrical system gets too high the metal disc will get hot. This heat causes a distortion of
metal disc. The disc opens the contacts. The disc breaks the circuit.
NOTICE
Find and correct the problem that causes the circuit breaker to open.
This will help prevent damage to the circuit components from too
much current.
165
001 Testing and Adjusting
General Information (Fuel System) - Diesel
Either too much fuel or not enough fuel for combustion can be the cause of a problem in the fuel system.
Work is often done on the fuel system when the problem is really with some other part of the engine. Finding
the cause of the problem can be difficult, especially when smoke comes from the exhaust. Smoke that comes
from the exhaust can be caused by a faulty fuel injector. Smoke can also be caused by one or more of the
reasons that follow:
¡ Not enough air for good combustion
¡ An overload at high altitudes (if applicable)
¡ Oil leakage into combustion chamber
¡ Air inlet and exhaust leaks
¡ Not enough compression
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Fuel System Inspection
A problem with the components that supply fuel to the engine can cause low fuel pressure. This can decrease
engine performance.
1. Check the fuel level in the fuel tank. Look at the cap for the fuel tank. Make sure that the vent is not filled
with debris.
2. Check the fuel lines for fuel leakage. Be sure that none of the fuel lines have a restriction or a faulty bend.
3. Install new main fuel filters. Clean the primary fuel filter.
4. Inspect the fuel pressure relief valve in the fuel transfer pump. Make sure that there is no restriction.
167
Checking Engine Cylinders
When the engine is under load, the temperature of an exhaust manifold port can indicate the condition of a
fuel injector. Low temperature at an exhaust manifold port is an indication of no fuel to the cylinder. This can
possibly indicate an injector with a defect or a problem with the control system. An extra high temperature at
an exhaust manifold port can indicate too much fuel to the cylinder. High temperatures may also be caused
by an injector with a defect.
Refer to Testing And Adjusting, "Measuring Exhaust Temperature" for the procedure to check the exhaust
manifold port temperatures.
168
Fuel Pressure - Diesel System

Specifications
Table 1
Parameter Value
Fuel Manifold Pressure 415 to 450 kPa (60 to 65 psi)
Fuel Transfer Pump Pressure 415 to 450 kPa (60 to 65 psi)
Introduction
Use this procedure to check the regulated fuel pressure.
Required Tools
Table 2
Required Tools
Qty Part Number
1 1U-5470 Engine Pressure Gp
1U-5470 Engine Pressure Group , (1) Pressure indicators (2) Zero adjustment screw (3) Pressure indicator (4) Pressure tap (5)
Pressure indicator
This tool group has an indicator that is used to read the pressure in the fuel manifolds. The Special
Instruction, SEHS8907 is with the tool group.
169
Fuel leaked or spilled onto hot surfaces or electrical components can

cause a fire. To help prevent possible injury, turn the start switch off
when changing fuel filters or water separator elements. Clean up fuel
spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a
suitable cover over disconnected fuel system component.
NOTICE
Use a suitable container to catch any fuel that might spill. Clean up any
spilled fuel immediately.
Fuel manifold and lines, (6) Fuel supply line to cylinder head (7) Fuel manifold
1. Turn off the engine
2. Install a tee fitting into fuel line (6) . Connect the 1U-5470 Engine Pressure Gp to the tee fitting. Refer to
Illustration 2
170

spills immediately.
NOTICE
NOTICE
Fuel manifold and lines, (6) Fuel supply line to cylinder head (7) Fuel manifold
1. Turn off the engine
2. Install a tee fitting into fuel line (6) . Connect the 1U-5470 Engine Pressure Gp to the tee fitting. Refer to
Illustration 2
171

spills immediately.
NOTICE
NOTICE
1. Turn off the engine.
Fuel transfer fuel lines and fuel filter fuel lines., (8) Fuel inlet line to priming pump (9) Plug (10) Line from fuel filters to fuel
manifolds (filtered fuel) (11) Fuel priming pump adapter (12) Fuel line from transfer pump (13) Fuel filters
2. Slowly loosen plug (9) . Refer to Illustration 4.
3. Connect the 1U-5470 Engine Pressure Gp into the pressure tap (9) .
1. Start the engine
2. Operate the engine at rated speed and load.
3. Note the pressure readings.
If, the pressures are not within the specifications refer to Troubleshooting, "Fuel Pressure is Low"
172
Engine Rotation
The SAE standard engine crankshaft rotation is counterclockwise from the flywheel end of the engine.
173
Finding the Top Center Position for the No. 1 Piston

Introduction
Use this procedure to find the top center position for the number 1 piston.
Required Tools
Table 1
Required Tools Quantity
9S-9082 Engine Turning Tool 1
Check Preparation
1. Turn off the engine.
Timing bolt location (typical example), (1) Cover (2) Timing bolt (3) Plug
2. Remove cover (1) and plug (3) from the right front side of the flywheel housing. Refer to Illustration 1.
Timing bolt installation (typical example), (2) Timing bolt (4) 9S-9082 Engine Turning Tool
3. Put timing bolt (2) through the timing hole in the flywheel housing. Use the 9S-9082 Engine Turning Tool
(4) and a 1/2 inch drive ratchet wrench to turn the flywheel in the direction of normal engine rotation. Turn
the flywheel until the timing bolt engages with the hole in the flywheel. Refer to Illustration 2.
Note: If the flywheel is turned beyond the point of engagement, the flywheel must be turned in the
direction that is opposite of normal engine rotation. Turn the flywheel by approximately 30 degrees. Then
turn the flywheel in the direction of normal engine rotation until the timing bolt engages with the threaded
174
hole. This procedure will remove the play from the gears when the No. 1 piston is on the top center.
4. Remove the valve cover for the No. 1 cylinder head.
5. The inlet and exhaust valves for the No. 1 cylinder are fully closed if the No. 1 piston is on the
compression stroke. The rocker arms can be moved by hand when the No. 1 piston is on the compression
stroke. If the rocker arms cannot be moved and the valves are slightly open, the No. 1 piston is on the
exhaust stroke. Find the cylinders that can be checked or adjusted for the stroke position of the crankshaft
once the timing bolt has been installed. Refer to Testing and Adjusting, "Crankshaft Position for Fuel
Injector Adjustment and Valve Lash Setting".
Note: When the actual stroke position is identified and the other stroke position is needed, remove the
timing bolt from the flywheel. Turn the flywheel by 360 degrees in the direction of normal engine rotation.
175
Camshaft Timing
Timing Check
Table 1
Tools Needed Quantity
Location of timing pins (typical example), (1) Timing hole (2) Timing pin (3) Slot in the camshaft for the timing pin
1. Remove rear camshaft covers from both sides of the engine.
2. Find the top center position for the number one piston. Refer to Testing and Adjusting, "Finding the Top
Center Position for the No. 1 Piston" for the correct procedure.
Note: When the timing bolt is installed in the flywheel, it is not necessary to remove the No. 1 valve cover
in order to find the compression stroke. Both rear camshaft covers must be removed in order to check the
timing.
3. When the timing bolt is installed in the flywheel, look at the rear end of the camshaft. If the timing ring is
visible, then the No. 1 piston is on the compression stroke. If the timing ring is not visible, feel the back of
the camshaft for the groove. If the groove is at the back of the camshaft, the flywheel must be turned by
360 degrees in order to put the No. 1 piston on the compression stroke.
4. When the timing bolt is installed in the flywheel and the No. 1 piston is on the compression stroke, remove
timing pins (2) from the storage positions.
5. Install the timing pins through timing holes (1) on each side of the engine. Install the timing pins into
groove (3) in the camshaft on each side of the engine. In order to time the engine correctly, the timing pins
must fit into the groove of each camshaft.
6. If the timing pins do not engage in the grooves of both camshafts, the engine is not in time, and one or both
camshafts must be adjusted.
7. Both camshafts are adjusted in the same manner. Refer to "Timing Adjustment" for the procedure to put
the camshafts in time with the crankshaft.
NOTICE
If a camshaft is out of time more than 18 degrees (approximately 1/2
the diameter of timing pin out of groove), the valves can make contact
with the pistons. This will cause damage that will make engine repair
necessary.
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Timing Adjustment
Table 2
6V-3010 Puller Group 1
8S-9089 Bolts 2
5P-1076 Hard Washers 2
Note: The timing must be checked before the timing adjustments are made. Refer to "Timing Check" for this
procedure.
After the Timing Check procedure is complete, the timing bolt will be engaged in the flywheel. The No. 1
piston will be at the top center (TC) position.
, (4) Bolt (5) Rocker shaft
1. Remove all of the valve covers on the side for the camshaft adjustment. Now, loosen bolts (4) that hold
rocker shafts (5) to the valve cover bases until all rocker arms are free from the injectors and the valves.
Note: The above procedure must be done before camshaft drive gear (6) is pulled off the camshaft taper.
2. Remove the covers from the flywheel housing.
3. Remove bolt (8) and plate (7) from the end of the camshaft.
4. Install the 6V-3010 Puller Group, two 8S-9089 Bolts, and two 5P-1076 Hard Washers. Loosen drive gears
(6) from the taper on the camshafts. Remove the tooling and the gears.
5. Remove timing pins (2) from the storage position on each side of the engine.
177
6. Turn the camshafts until the timing pins can be installed through the engine block and into grooves (3)
(slots) in the camshafts.
7. Put camshaft drive gears (6) in position on the camshafts.
8. Use hand pressure to turn and hold the camshaft drive gears in the opposite direction of the rotation. This
removes all gear clearance (backlash) between the camshaft drive gears and the idler gears.
9. Install plate (7) on the camshaft in order to hold the camshaft drive gears to each camshaft.
10. Tighten bolts (8) .
Refer to the engine's Specifications manual.
11. Install the gaskets and covers on the flywheel housing.
12. Remove timing pins (2) from the camshafts. Install the timing pins in the storage positions. Install covers
over the camshafts and timing pins.
13. Remove the timing bolt from the flywheel housing. Install the 8T-6765 Pipe Plug in the flywheel housing
timing hole. Remove the engine turning tool. Install the cover and the gasket.
14. Be certain that the rocker arms are correctly engaged with the pushrods. Tighten the bolts in order to hold
all of the rocker shafts in position.
15. Make valve lash adjustments to the unit injectors. Refer to Testing And Adjusting, "Valve Lash and Valve
Bridge Adjustment" for the correct procedures.
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Engine Speed Measurement

Table 1
9U-7400 Multitach 1
9U-7400 Multitach
The 9U-7400 Multitach can measure engine speed from an engine speed sensor on the flywheel housing. The
9U-7400 Multitach also has the ability to measure engine speed from visual engine parts in rotation.
The Operating Instructions, NEHS0605 are included with the 9U-7400 Multitach and these operating
instructions contain instructions for the test procedure.
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Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting
Note: Do not use the following valve lash setting sequence for serial numbers SLM1-UP, TTC1-UP, TTE1-UP, TTF1-UP, TTG1-UP, E3W1-UP,
E3X1-UP, E3Y1-UP, F2X1-UP, LLK1-UP, NJT1-UP, S2N1-UP, R1T1-UP, S2H1-UP, SCC1-UP, R1S1-UP, T3P1-UP, T3R1-UP, T3S1-UP, T3W1-
UP, T3Y1-UP, TKP1-UP and LLT1-UP.
Note: The sequence for the injectors in 3508 Engines was last changed in December 2005. The sequence for the injectors in 3516 Engines was last
changed in December 2012. Articles announcing the changes were published in Engine News and Service Magazine.
Table 1
Counterclockwise Rotation (Standard) from the Flywheel End of the Engine
Cylinders to Check/Adjust
Engine Correct Stroke For No. 1 Piston At Top Center Position (1) Inlet Valves Exhaust Valves Injectors
Compression 1-2-6-8 1-2-3-7 2-3-4-7
3508
Exhaust 3-4-5-7 4-5-6-8 1-5-6-8
Compression 1-3-6-7-10-12 1-4-5-6-9-12 2-4-5-8-9-11
3512
Exhaust 2-4-5-8-9-11 2-3-7-8-10-11 1-3-6-7-10-12
Compression 1-2-5-7-8-12-13-14 1-2-3-4-5-6-8-9 3-4-6-9-10-5-15-16
3516
Exhaust 3-4-6-9-10-11-15-16 7-10-11-12-13-14-15-16 1-2-11-7-8-12-13-14
(1) Put the No. 1 Piston at the top center (TC) position and identify the correct stroke. Refer to Testing and Adjusting, "Finding the Top Center Position for the No 1 Piston". Find the
top center position for a particular stroke and make the adjustment for the correct cylinders. Remove the timing bolt . Turn the flywheel by 360 degrees in the direction of normal
engine rotation. Turning the flywheel will put the No. 1 piston at the top center (TC) position on the other stroke. Install the timing bolt in the flywheel and complete the adjustments
for the cylinders that remain.
Table 2
Clockwise Rotation (Reverse) from the Flywheel End of the Engine
Cylinders To Check/Adjust
Engine Correct Stroke For No. 1 Piston At Top Center Position (1) Inlet Valves Exhaust Valves Injectors
Compression 1-3-4-8 1-2-7-8 2-6-7-8
3508
Exhaust 2-5-6-7 3-4-5-6 1-3-4-5
Compression 1-3-4-6-7-12 1-4-5-8-9-12 2-5-8-9-10-11
3512
Exhaust 2-5-8-9-10-11 2-3-6-7-10-11 1-3-4-6-7-12
Compression 1-2-5-6-7-8-13-14 1-2-3-4-5-6-9-10 3-4-9-10-5-12-15-16
3516
Exhaust 3-4-9-10-11-12-15-16 7-8-11-12-13-14-15-16 1-2-11-6-7-8-13-14
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(1) Put the No. 1 Piston at the top center (TC) position and identify the correct stroke. Refer to Testing and Adjusting, "Finding the Top Center Position for the No 1 Piston". Find the
top center position for a particular stroke and make the adjustment for the correct cylinders. Remove the timing bolt . Turn the flywheel by 360 degrees in the direction of normal
engine rotation. Turning the flywheel will put the No. 1 piston at the top center (TC) position on the other stroke. Install the timing bolt in the flywheel and complete the adjustments
for the cylinders that remain.
181
Fuel Injector Timing
NOTICE
The camshafts must be correctly timed with the crankshaft before an
adjustment of fuel timing is made. The timing pins must be removed
from the camshafts before the crankshaft is turned or damage to the
cylinder block will be the result.
Note: Ensure that the engine is in time. Refer to Testing And Adjusting, "Camshaft Timing".
Note: Refer to Testing and Adjusting, "Crankshaft Position for Fuel Injector Adjustment and Valve Lash
Setting". All of the injectors can be checked or adjusted with the crankshaft positions that are given in the
chart. This check will make sure that the pushrod lifters are off the lobes and on the base circles of the
camshafts.
Refer to the TMI (Technical Marketing Information) for the correct fuel timing dimension to use.
Table 1
Tools Needed
5P-4160 Indicator Contact Point 1
1U-8869 Dial Indicator 1
9U-5138 Setting Gauge 1
9U-5233 Magnetic Fixture Group 1
1U-8869 Dial Indicator
1. The digital dial indicator needs to be programmed to read actual timing dimensions. Since the 9U-5138
Setting Gauge in the timing and fuel setting tool group is 87.00 mm, set the digital dial indicator for 87.00
mm. Use the following steps in order to program the indicator to read 87.00 mm.
a. Turn the indicator to the ON position by pushing the "on/off" button.
b. Push the "in/mm" button so the display shows "mm".
c. A negative "-" sign should be in the display window under "REV". If that space is blank, push the "+/-"
button so the display shows a negative "-" sign. When this is done, the movement of the plunger into the
indicator will be displayed. The display will be shown as a negative movement. The movement of the
plunger out of the indicator will be displayed as a positive movement.
d. Push the preset button and hold the preset button down until there is a flashing "P" in the upper right
corner of the display. Then release the button.
e. Push the preset button and hold the preset button down until the flashing "P" disappears and a flashing
indicator bar is seen in the lower left corner of the display. Then release the button. Use the preset button
182
so that this position is blank.

f. Push the preset button and hold the preset button down until the flashing indicator begins flashing under
the first number position. The first number position is located in the fourth position to the left of the
decimal. Then release the button. Momentarily pushing the preset will cause the display number in that
position to change. Use the preset until this position reads zero (0).
g. Use the preset button to move the flashing indicator and change the display numbers until the display
shows 0087.00 mm. Push the preset button and hold the preset button until the flashing "P" is shown in
the upper right corner of the display. Release the preset button. Momentarily push the preset button so
the flashing "P" and the zeroes to the left of 87.00 mm disappear.
h. The indicator can now be turned off. The indicator will retain the preset number in memory. To recall
the preset number, repeat Steps 1.a through 1.d.
2. Install a 5P-4160 Indicator Contact Point in the indicator stem.
3. Install the indicator into the 9U-5233 Magnetic Fixture Group. Leave the collet loose.
Adjustment of fuel timing tools, (1) 1U-8869 Dial Indicator (2) 9U-5233 Magnetic Fixture Group (3) 9U-5138 Setting Gauge
4. Place the fixture and the indicator on the 9U-5138 Setting Gauge with the extension rod of the bracket on
the step of the gauge. Position the indicator in the bracket so that the indicator plunger can travel
adequately. Tighten the collet.
5. Repeat Steps 1.a through 1.d.
183
Fuel timing tools in position, (1) 1U-8869 Dial Indicator (2) 9U-5233 Magnetic Fixture Group (4) Injector follower (5)
Shoulder on fuel injector body
6. Momentarily push the preset button on the digital dial indicator in order to stop the "P" in the upper right
hand corner from flashing. The display should show 87.00 mm. Place the 1U-8869 Dial Indicator and the
9U-5233 Magnetic Fixture Group in the correct position on the injector. Make sure that the magnetic base
of the timing fixture is on the top surface of injector follower (4) and that the extension rod is on the top
surface of shoulder on fuel injector body (5) .
Note: In order to ensure an accurate fuel timing dimension, the top surfaces of injector follower (4) and
shoulder on fuel injector body (5) must be clean and dry.
7. The digital dial indicator should now read the actual fuel timing dimension of the injector that is being
checked.
8. No adjustment is necessary if the dial indicator reads the correct fuel timing dimension. Refer to the TMI
(Technical Marketing Information) for the engine that is being checked. Proceed to Step 12.
9. If the dial indicator does not read the correct fuel timing dimension or the desired fuel timing dimension,
proceed with Steps 10 through 13.
10. Ensure that the 1U-8869 Dial Indicator and the 9U-5233 Magnetic Fixture Group are in the correct
position on the injector. Loosen the locknut for the pushrod adjustment screw.
11. Turn the adjustment screw until the desired fuel timing dimension is read on the digital dial indicator.
Note: Turning the adjustment screw clockwise will lower the fuel timing dimension. Turning the
adjustment screw counterclockwise will increase the fuel timing dimension.
Tighten the adjustment screw locknut to a torque of 70 ± 15 N·m (50 ± 11 lb ft) and check adjustment
again. If necessary, repeat the procedure until the adjustment is correct.
12. Remove the timing bolt from the flywheel when the fuel timing check is completed.
13. Turn the flywheel by 360 degrees in the direction of normal engine rotation. Install the timing bolt for the
flywheel. Repeat the procedure for the other half of the engine.
184
Fuel Injector Synchronization

Table 1
Tools Needed
8T-2684 Rack Synchronization Gauge 1
Injector synchronization is the setting of all fuel injector racks to a reference position so each injector gives
the same amount of fuel to each cylinder. Injector synchronization is done by setting each fuel injector rack
to the same position while the control linkage is in a fixed position. Use the following procedure for the
adjustment of injector synchronization:
Location of fuel setting cover and synchronization pin (typical example), (1) Plug (2) Synchronization pin (3) Cover
1. The top bolt that holds cover (3) in position is synchronization pin (2). Remove synchronization pin (2)
and plug (1) from the front drive housing. DO NOT destroy the seal or remove cover (3) .
2. Remove the washer from the synchronization pin. Remove the plug and install the synchronization pin into
the threaded hole. Tighten the synchronization pin.
Position of the synchronization pin (typical example), (2) Synchronization pin (4) Fuel stop lever
3. Turn the governor or the actuator terminal shaft to the fuel ON position until the flat face of fuel stop lever
(4) contacts synchronization pin (2). This is the synchronizing position or zero reference point. Hold the
control linkage in this position when the injectors are adjusted.
4. Remove the valve covers.
185
Location for gauge and control rod adjustment (typical example), (5) 8T-2684 Rack Synchronization Gauge (6) Control rod
5. With the fuel stop lever against the synchronization pin, put the 8T-2684 Rack Synchronization Gauge (5)
on the round part of the fuel injector rack between the fuel injector body and the end of the rack. Use a
screwdriver and make an adjustment of control rod (6). Turn the screw that is located on the control rod
one click at a time until the 8T-2684 Rack Synchronization Gauge fits between the fuel injector body and
the shoulder at the end of the rack. Remove the screwdriver from the control rod so that no pressure
remains on the linkage. Check the setting with the rack synchronization gauge. Any pressure on the linkage
with the screwdriver will not give a correct indication when the setting is checked with the rack
synchronization gauge. Ensure that the linkage is free and that the linkage is giving an accurate setting by
moving the linkage. Check the setting again. Put the box end of a combination wrench over the nut and the
bolt. The nut and the bolt connect control rod (6) and the bellcrank. Pull upward on the control rod three
times. Check the setting again.
Gauge in place on the fuel injector rack (typical example), (5) 8T-2684 Rack Synchronization Gauge (7) Fuel injector rack
6. If the other injectors need to be adjusted, use rack synchronization gauge (5). When all adjustments have
been made, release the actuator terminal shaft.
Adjustment of fuel control rod (typical example), (5) 8T-2684 Rack Synchronization Gauge .
7. Install the valve covers.
8. Check the fuel setting and perform any necessary adjustments. Refer to Testing And Adjusting, "Fuel
Setting" for this procedure.
186
Fuel Setting
Table 1
Tools Needed
9U-5132 Engine Timing Tool Group 1
4C-8753 Extended Collet 1
6V-3075 Dial Indicator 1
5P-7263 Indicator Contact Point 1
8T-2684 Rack Synchronization Gauge 1
Refer to Special Instruction, SEHS9278 for the instructions on the use of the 4C-8753 Extended Collet .
Fuel setting is the adjustment of the fuel setting screw to a specified position. The fuel setting screw limits
the power output of the engine by setting the maximum travel of all the fuel injector racks.
Synchronization and fuel setting tools, (1) 8T-2684 Rack Synchronization Gauge (2) 6V-3075 Dial Indicator (3) 4C-8753
Extended Collet (4) 5P-7263 Indicator Contact Point
Before the fuel setting is checked, the injectors must be correctly synchronized. Refer to Testing And
Adjusting, "Fuel Injector Synchronization". After the injectors are synchronized correctly, leave the
synchronization pin in place for the procedure that follows.
1. Put 6V-3075 Dial Indicator (2) with 5P-7263 Indicator Contact Point Contact Point (4) in 4C-8753
Extended Collet (3). Remove the plug from the right side of fuel setting cover (8) .
Installed dial indicator (typical example), (2) 6V-3075 Dial Indicator with 5P-7263 Indicator Contact Point (3) 4C-8753
Extended Collet
2. Move the governor or the actuator terminal shaft toward the ON position. The flat face of fuel stop lever
(6) should make contact with synchronization pin (5). Hold the linkage in this position.
187
, (2) 6V-3075 Dial Indicator (4) 5P-7263 Indicator Contact Point (5) Synchronization pin (6) Fuel stop lever
3. Install dial indicator (2) and extended collet (3) in the threaded hole. After indicator contact point (4)
touches fuel stop lever (6), slide dial indicator (2) until the indicator reads zero. Keep the dial indicator in
this position by tightening collet (3) .
Checking fuel setting (typical example), (2) 6V-3075 Dial Indicator (5) Synchronization pin (8) Fuel setting cover
4. Unscrew synchronization pin (5) by 25 mm (1 inch) or remove synchronization pin (5). Slowly move the
governor or the actuator terminal shaft toward the fuel ON position until the flat face of the fuel stop lever
is against the end of the fuel setting screw. The dial indicator reading will be the present fuel setting when
the linkage is held in this position.
Note: Refer to the TMI (Technical Marketing Information) for the correct fuel setting.
5. If the fuel setting is correct, remove the dial indicator and the synchronization pin. Install the two plugs,
and install the synchronization pin back into cover (8) .
6. If the fuel setting needs adjustment, see "Fuel Setting Adjustment".
NOTICE
A mechanic with governor and fuel setting training is the ONLY one to
make adjustments to the engine fuel setting.

1. Cut the seal wire and remove fuel setting cover (8) and the gasket. Loosen locknut (7). Hold the fuel stop
lever against the end of the fuel setting screw. Turn the fuel setting screw clockwise or counterclockwise
until the correct reading is on the dial indicator.
188
Adjustment of the fuel setting screw (typical example)
2. Now tighten locknut (7). Be sure that the fuel setting screw does not turn when the locknut is tightened.
Release the fuel system linkage and move the linkage toward the fuel ON position. Check the dial indicator
reading again in order to be sure that the fuel setting is still correct.
3. Remove dial indicator (2) and synchronization pin (5). Install the two plugs.
Installed cover (typical example), (7) Locknut (8) Fuel setting cover
4. Put fuel setting cover (8) and the gasket in position over the fuel setting screw. Install the bolt and
synchronization pin (5) in the cover. Install a new seal wire.
189
Restriction of Air Inlet and Exhaust
There will be a reduction in the performance of the engine if there is a restriction in the air inlet system or the
exhaust system.
The flow of air through the air cleaner may have a restriction. The pressure at the restriction of the flow of air
must not exceed 6.25 kPa (25 inches of H2O).
Back pressure is the difference in the pressure between the exhaust at the outlet elbow and the atmospheric
air. Back pressure from the exhaust must not be more than 6.75 kPa (27 inches of H2O).
190
Measuring Inlet Manifold Pressure
The efficiency of an engine can be checked. Compare the pressure in the inlet manifold with the
specifications that are given in the Fuel Setting and Related Information in the TMI (Technical Marketing
Information). This test is performed when there is a decrease in the horsepower from the engine yet there is
no real sign of a problem with the engine.
The correct pressure for the inlet manifold is given in the TMI. Development of this information is done with
these conditions:
¡ 96 kPa (28.8 inches of Hg) dry barometric pressure
¡ 29 °C (84 °F) outside air temperature
¡ 35 API rated fuel
Any change from these conditions can change the pressure in the inlet manifold. The outside air may have a
higher temperature and a lower barometric pressure than the values that are given above. This will cause a
lower horsepower and a lower inlet manifold pressure measurement than the pressure that is given in the TMI
(Technical Marketing Information). Outside air that has a lower temperature and a higher barometric pressure
will cause a higher horsepower and a higher inlet manifold pressure measurement.
A difference in the fuel rating will change the horsepower in the inlet manifold and the pressure in the inlet
manifold. If the fuel is rated above 35 API, the pressure in the inlet manifold can be less than the pressure
that is given in the TMI. If the fuel is rated below 35 API, the pressure in the inlet manifold can be more than
the pressure that is given in the TMI.
When you are checking the pressure in the inlet manifold, be sure that the air inlet or the exhaust is not
restricted.
Pressure test location (typical example), (A) Pipe plug
In order to check the inlet manifold pressure, remove the 1/2-14-NPTF pipe plug (A). Connect the 1U-5470
Engine Pressure Group to this opening in the inlet manifold.
This tool group has a gauge to read pressure in the inlet manifold. Refer to Special Instruction, SEHS8524 for
further instructions.
191
1U-5470 Engine Pressure Group , (1) Pressure indicators (2) Zero adjustment screw (3) Pressure indicator (4) Pressure tap (5)
Pressure indicator
192
Measuring Exhaust Temperature
Use the 164-3310 Infrared Thermometer in order to check the exhaust temperature. Refer to the instructions
that are packaged with the tool for additional information.
Individual cylinder head exhaust temperatures can be checked with the 4C-6090 Temperature Selector
Group, the 6V-9130 Temperature Adapter, and the 237-5130 Digital Multimeter. Refer to Operating Manual,
NEHS0537 for the complete operating instructions for using the 4C-6090 Temperature Selector Group.
193
Crankcase Pressure
Several conditions can cause high crankcase pressure:

¡ High engine oil level
¡ Plugged crankcase breather and/or ventilation
¡ Loose fuel injector
¡ Damaged oil seal in the turbocharger
¡ Internal engine problem
Damaged pistons and/or piston rings cause excessive pressure in the crankcase. This condition will cause the
engine to run rough. Excessive fumes flow through the crankcase breather and the crankcase breather can be
quickly restricted. Restriction of the crankcase breather and the corresponding increase in crankcase pressure
can cause engine oil to leak from gaskets and seals.
Internal engine problems can cause a rapid increase of crankcase pressure. For this reason, the engine is shut
down if the crankcase pressure exceeds the ambient air pressure by 7 kPa (1 psi).
194
Compression
An engine that runs roughly can have a leak at the valves. An engine that runs roughly can also have valves
that need an adjustment. Removing the head and inspecting the valves and valve seats is necessary in order to
find the small defects. Repairs of these problems are normally done when you are reconditioning the engine.
195
Cylinder Heads
The cylinder heads have valve seat inserts, valve guides, and bridge dowels that can be removed when the
parts are worn or damaged. Refer to Disassembly And Assembly for the replacement of these components.
Valves
The removal and the installation of the valves is easier with use of the 1P-3527 Valve Spring Compressor .
Valve Seat Inserts

Use the 166-7441 Valve Seat Extractor Tool for the removal and the installation of the valve seat inserts.
Lower the temperature of the insert before the insert is installed in the head.
Valve Guides
The tools for the removal and for the installation of the valve guides are the 5P-1729 Valve Guide Bushing
and the 7M-3975 Valve Guide Driver. The counterbore in the driver bushing installs the guide to the correct
height.

Use the 5P-3536 Valve Guide Gauge Group in order to check the bore of the valve guides. Refer to Special
Instruction, GMG02562 for the instructions for the use of this tool.
5P-3536 Valve Guide Gauge Group
Bridge Dowels
Use a 5P-0944 Dowel Puller Group and a 5P-0942 Dowel Extractor. Remove the bridge dowels. Install a
new bridge dowel with a 6V-4009 Dowel Driver. This dowel driver installs the bridge dowel to the correct
height.
196
Valve Lash Check
The Electronic Control Module produces high voltage. To prevent

personal injury make sure the Electronic Control Module is not
powered and do not come in contact with the fuel injector solenoid
terminals while the engine is running.
Valve lash is measured between the rocker arm and the bridge for the valves. All of the clearance
measurements and the adjustments must be made with the engine stopped. The valves must be fully closed.
If the measurement of the valve lash is in the acceptable range, no adjustments are necessary. The range is
given in Table 1.
Table 1
Valve Lash Check: Engine Stopped
Valves Acceptable Valve Lash Range
Inlet 0.42 to 0.58 mm (0.017 to 0.023 inch)
Outlet 0.92 to 1.08 mm (0.036 to 0.043 inch)
If the measurement is not within this range, adjustment is necessary. Refer to Testing And Adjusting, "Valve
Lash and Valve Bridge Adjustment".
197
Valve Lash and Valve Bridge Adjustment
, (1) 147-2060 Wrench (2) 147-2059 Torque Wrench (3) 148-7211 Bridge Nut Socket (4) 145-5191 Gauge Support (5) 147-2056
Dial Indicator (6) 147-5536 Indicator Contact Point (7) 147-2057 Indicator Contact Point (8) 147-2058 Indicator Extension
Table 1
147-2060 Wrench 1
147-2059 Torque Wrench 1
148-7211 Bridge Nut Socket 1
145-5191 Gauge Support 1
147-2056 Dial Indicator 1
147-5536 Indicator Contact Point 1
147-2057 Indicator Contact Point 1
147-2058 Indicator Extension 1
147-5537 Dial Indicator (not shown) 1
Note: The 145-5191 Gauge Support (4), the 147-2057 Indicator Contact Point (7), the 147-2058 Indicator
Extension (8), and the 147-5536 Indicator Contact Point (6) are included in the 147-5482 Valve Lash Gauge
Group .
Note: The 147-2056 Dial Indicator or the 147-5537 Dial Indicator (Metric, not shown) can be used with the
147-5482 Valve Lash Gauge Group .
There are two different design of valve bridges that are used. If the engine is equipped with an adjustable
valve bridge (Illustration 2), proceed to the "Valve Bridge Adjustment". If the engine is equipped with a
nonadjustable valve bridge (Illustration 3), proceed to the "Valve Lash Adjustment".
198
Adjustable valve bridge
Nonadjustable valve bridge

Note: When the 147-5482 Valve Lash Gauge Group is used, it is not necessary for you to remove the rocker
arm shaft assemblies. The valves must be fully closed when the adjustment is made. Refer to Testing and
Adjusting, "Finding the Top Center Position for the No. 1 Piston".
199
Installation
1. Assemble the 147-2058 Indicator Extension and the 147-5536 Indicator Contact Point on the 147-2056
Dial Indicator or on the 147-5537 Dial Indicator .
Illustration 4 g00286279 Illustration 5 g00286280

145-5191 Gauge Support , (1) Knurled knob , (2) Valve cover base rear bolt hole
, (3) 147-5536 Indicator Contact Point (4) Top edge of the valve bridge
2. Install the 145-5191 Gauge Support in the rear bolt hole (2). The rear bolt hole is located in the valve cover
base. Adjust contact point (3) on the top edge of valve bridge (4) .
, (5) Adjustment screw
200
3. Loosen the locknut for the adjustment screw. Loosen the adjustment screw (5) by several turns.
4. Apply a force of 5 N (1 lb) to 45 N (10 lb). Push down on the top contact surface of the valve bridge. Zero
the indicator.
5. Turn adjustment screw (5) in the clockwise direction until the dial indicator reads 0.038 mm (0.0015 inch).
This measurement is equal to turning the adjustment screw 20 to 30 degrees clockwise after the screw
contacts the end of the valve.
, (6) 148-7211 Bridge Nut Socket
6. Hold the adjustment screw with the 148-7211 Bridge Nut Socket (6) in order to tighten the locknut to 30 ±
4 N·m (22 ± 3 lb ft). You may use a sliderule torque computer in order to determine the torque wrench dial
reading for the different extensions. Refer to Special Instruction, SEHS7150, "Snap On Torque Computer".

Note: Adjust the valve bridges before you make the valve lash adjustments.
Table 2
Valve Lash Setting: Engine Stopped
Valves Gauge Dimension
Inlet 0.50 mm (0.020 inch)
Exhaust 1.00 mm (0.040 inch)
1. Ensure that the number 1 piston is at the top center position. Refer to Testing and Adjusting, "Finding the
Top Center Position for the No. 1 Piston".
2. The number 1 piston should be at the top center position of the correct stroke. Make adjustments to the
valves according to the chart: Refer to Testing and Adjusting, "Crankshaft Positions for Fuel Injector
Adjustment and Valve Lash Setting".
Note: Tap each rocker arm on the top of the adjustment screw before you make any adjustments. Use a
soft hammer. Make sure that the lifter roller is seated against the base circle of the camshaft.
201
, (1) 145-5191 Gauge Support (2) 147-2057 Indicator Contact Point
3. Install the 145-5191 Gauge Support (1). Use the 147-2056 Dial Indicator or use the 147-5537 Dial
Indicator. Use the 147-2057 Indicator Contact Point (2). Install the tool in the rear bolt hole. The rear bolt
hole is located on the valve cover base.
, (3) 147-2060 Wrench (4) 147-2059 Torque Wrench
, (3) 147-2060 Wrench (4) 147-2059 Torque Wrench
4. Move the rocker assembly upward and move the rocker arm assembly downward. Move the rocker
assembly several times. The oil film is removed in order to get a true zero reading on the dial indicator.
Use the 147-2060 Wrench (3) and use the 147-2059 Torque Wrench (4). Install the socket wrench and
install the torque wrench on the nut of the rocker arm. Apply upward pressure to the front of the rocker
assembly. Set the dial indicator to zero. The weight of the torque wrench (4) allows the valve lash to be
read. Do not apply any pressure on the torque wrench.
5. Loosen the locknut. The locknut is located on the adjustment screw of the pushrod. Turn the adjustment
screw until the valve lash is set to specifications. Tighten the nut for the adjustment screw to 70 ± 15 N·m
(50 ± 11 lb ft ). The 147-2059 Torque Wrench is preset to the torque that is required. Check the adjustment
again.
202
General Information (Lubrication System)
The following problems generally indicate a problem in the engine's lubrication system.
¡ Excessive consumption of engine oil
¡ Low engine oil pressure
¡ High engine oil pressure
¡ Excessive bearing wear
¡ Increased engine oil temperature
203
Engine Oil Pressure - Test
Work carefully around an engine that is running. Engine parts that are
hot, or parts that are moving, can cause personal injury.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Table 1
Tools Needed
Part Number Part Name Quantity
1U-5470 Engine Pressure Group 1
1U-5470 Engine Pressure Group
The 1U-5470 Engine Pressure Group measures the engine oil pressure in the system. This engine tool group
can read the engine oil pressure inside the oil manifold.
Note: Refer to Special Instruction, SEHS8907, "Using the 1U-5470 Engine Pressure Group " for more
information on using the 1U-5470 Engine Pressure Group .
204
Location of the oil gallery plug
Typical example, (1) Plug
1. Install the 1U-5470 Engine Pressure Group into oil gallery plug (1) .
Note: Engine oil pressure to the camshaft and main bearings should be checked on each side of the
cylinder block at oil gallery plug (1) .
2. Start the engine. Run the engine with SAE 10W30 or SAE 15W40 oil. The information in the engine oil
pressure graph is invalid for other oil viscosities. Refer to Operation and Maintenance Manual, "Engine
Oil" for the recommendations of engine oil.
Note: Allow the engine to reach operating temperature before you perform the pressure test.
Note: The engine oil temperature should not exceed 115 °C (239 °F).
3. Record the value of the engine oil pressure when the engine has reached operating temperature.
4. Locate the point that intersects the lines for the engine rpm and for the engine oil pressure on the engine oil
pressure graph.
205
Engine oil pressure graph

5. The results must fall within the "ACCEPTABLE" range on the chart. A problem exists when the results
fall within the "NOT ACCEPTABLE" range on the chart. The problem needs to be corrected. Engine
failure or a reduction in engine life can be the result if engine operation is continued with oil manifold
pressure outside this range.
Note: A record of engine oil pressure can be used as an indication of possible engine problems or damage.
A possible problem could exist if the engine oil pressure suddenly increases or decreases 70 kPa (10 psi)
and the engine oil pressure is in the "ACCEPTABLE" range. The engine should be inspected and the
problem should be corrected.
6. Compare the recorded engine oil pressure with the engine oil pressure indicators on the instrument panel.
7. An engine oil pressure indicator that has a defect or an engine oil pressure sensor that has a defect can give
a false indication of a low engine oil pressure or a high engine oil pressure. If there is a notable difference
between the engine oil pressure readings make necessary repairs.
8. If the engine oil pressure is low, refer to Testing and Adjusting, "Engine Oil Pressure is Low" for the
possible causes of low engine oil pressure.
9. If the engine oil pressure is high, refer to Testing and Adjusting, "Engine Oil Pressure is High" for the
possible causes of high engine oil pressure.
206
Excessive Bearing Wear - Inspect
When some components of the engine show bearing wear in a short time, the cause can be a restriction in a
passage for engine oil.
An indicator for the engine oil pressure may show that there is enough engine oil pressure, but a component
is worn due to a lack of lubrication. In such a case, look at the passage for the engine oil supply to the
component. A restriction in an engine oil supply passage will not allow enough lubrication to reach a
component. This will result in early wear.
207
Excessive Engine Oil Consumption - Inspect

Check for leakage at the seals at each end of the crankshaft. Look for leakage at the gasket for the engine oil
pan and all lubrication system connections. Look for any engine oil that may be leaking from the crankcase
breather. This can be caused by combustion gas leakage around the pistons. A dirty crankcase breather will
cause high pressure in the crankcase. A dirty crankcase breather will cause the gaskets and the seals to leak.

Engine oil that is leaking into the combustion area of the cylinders can be the cause of blue smoke. There are
several possible ways for engine oil to leak into the combustion area of the cylinders:
¡ Leaks between worn valve guides and valve stems
¡ Worn components or damaged components (pistons, piston rings, or dirty return holes for the engine
oil)
¡ Incorrect installation of the compression ring and/or the intermediate ring
¡ Leaks past the seal rings in the turbocharger shaft
¡ Overfilling of the crankcase
¡ Wrong oil level gauge or guide tube
¡ Sustained operation at light loads
Excessive consumption of engine oil can also result if engine oil with the wrong viscosity is used. Engine oil
with a thin viscosity can be caused by increased engine temperature.
208
Increased Engine Oil Temperature - Inspect
If the engine oil temperature is higher than normal, the engine oil cooler may have a restriction. Look for a
restriction in the passages for engine oil in the engine oil cooler. The engine oil pressure will not necessarily
decrease due to a restriction in the engine oil cooler.
Determine if the engine oil cooler bypass valve is held in the open position. This condition will allow the
engine oil to flow through the valve rather than through the engine oil cooler. The engine oil temperature will
increase.
Make sure that the cooling system is operating properly. A high coolant temperature in the engine oil cooler
will cause high engine oil temperature.
209
Engine Oil Pressure is Low
The following conditions can cause an indication of low engine oil pressure:
¡ Low engine oil level
¡ Problem with the engine oil pressure gauge
¡ Contaminated engine oil
¡ Improper circulation of the engine oil
¡ Worn components

Check the engine oil level. If the engine oil level is too far below the suction tube, the engine oil pump
cannot supply enough lubrication for the engine components. If the engine oil level is low, add engine oil in
order to obtain the correct level. For the correct engine oil to use, refer to Operation and Maintenance
Manual, "Engine Oil".

Refer to Testing and Adjusting, "Engine Oil Pressure - Test". If the engine oil pressure gauge is incorrect,
install a new gauge.

Engine oil that is contaminated with another liquid will cause low engine oil pressure. High engine oil level
can be an indication of contamination. Determine the reason for contamination of the engine oil and make the
necessary repairs. Change the engine oil and the engine oil filter. For the correct engine oil to use, refer to
Operation and Maintenance Manual, "Engine Oil".

Several factors could cause improper circulation of the engine oil:
¡ The engine oil filter is clogged. Replace the engine oil filter.
¡ A line or a passage for the engine oil is disconnected or broken. Replace the line or clear the passage.
¡ The engine oil cooler is clogged. Thoroughly clean the engine oil cooler.
¡ There is a problem with a piston cooling jet or sequence valve. The piston cooling jets direct engine oil
toward the bottom of the pistons in order to cool the pistons after the sequence valve opens. This also
provides lubrication for the piston pin. Breakage, a restriction, or incorrect installation of a piston
cooling jet will cause seizure of the piston.
¡ The inlet screen of the suction tube for the engine oil pump can have a restriction. This restriction can
cause cavitation and a loss of engine oil pressure. Check the inlet screen on the suction tube and
remove any material that may be restricting engine oil flow.
¡ The suction tube is drawing in air. Check the joints of the suction tube for cracks or a damaged O-ring
seal.
¡ There is a problem with the engine oil pump. Check the gears of the engine oil pump for excessive
wear. Engine oil pressure is reduced when gears in the engine oil pump have too much wear.
210
Worn Components
Excessive clearance at the crankshaft or camshaft bearings will cause low engine oil pressure. Also, inspect
the clearance between the rocker arm shafts and the rocker arms. Check the engine components for excessive
clearance.
211
Engine Oil Pressure is High
The following conditions can cause high engine oil pressure:

¡ The engine oil level is too high. Drain the excess engine oil.
¡ The engine oil temperature is too low. Low engine oil temperature increases the viscosity of the engine
oil.
¡ The engine oil filter bypass valve is stuck in the closed position. Thoroughly clean the valve. Replace
the engine oil filters.
¡ A line or a passage for the engine oil is restricted. Clean the component.
212
Indicators for Engine Oil Pressure
An oil pressure indicator that has a defect or a sender that has a defect can give an indication of a low oil
pressure or a high oil pressure.
213
General Information (Cooling System)
This engine has a pressure type cooling system. A pressure type cooling system has two advantages.
¡ The pressure helps prevent cavitation.
¡ The risk of boiling is reduced.
Cavitation occurs when mechanical forces cause the formation of air bubbles in the coolant. The bubbles can
form on the cylinder liners. Collapsing bubbles can remove the oxide film from the cylinder liner. This
allows corrosion and pitting to occur. If the pressure of the cooling system is low, the concentration of
bubbles increases. The concentration of bubbles is reduced in a pressure type cooling system.
The boiling point is affected by three factors: pressure, altitude and concentration of glycol in the coolant.
The boiling point of a liquid is increased by pressure. The boiling point of a liquid is decreased by a higher
altitude. Illustration 1 shows the effects of pressure and altitude on the boiling point of water.
The boiling point of the coolant also depends on the type of coolant and the concentration of glycol. A
greater concentration of glycol has a higher boiling temperature. However, glycol transfers heat less
effectively than water. Because of the boiling point and the efficiency of heat transfer, the concentration of
glycol is important.
Three basic problems can be associated with the cooling system:
¡ Overheating
¡ Coolant loss
¡ Overcooling
If the cooling system is not properly maintained, solids such as scale and deposits reduce the ability of the
cooling system to transfer heat. The engine operating temperature will increase.
When the engine is overloaded, the engine will run in the lug condition. When the engine is running in the
lug condition, the engine is operating at a lower engine rpm that reduces the coolant flow. Decreased coolant
flow during high load will cause overheating.
Coolant can be lost by leaks. Overheated coolant can be lost through the cooling system's pressure relief
valve. Lower coolant levels contribute to additional overheating. Overheating can result in conditions such as
cracking of the cylinder head and piston seizure.
A cracked cylinder head or cylinder liner will force exhaust gas into the cooling system. The additional
pressure causes coolant loss, cavitation of the water pump, less circulation of coolant, and further
overheating.
Overcooling is the result of coolant that bypasses the water temperature regulators and flows directly to the
radiator or to the heat exchanger. Low load operation in low ambient temperatures can cause overcooling.
Overcooling is caused by water temperature regulators that remain open. Overcooling reduces the efficiency
of operation. Overcooling enables more rapid contamination of the engine oil. This results in the formation of
214
sludge in the crankcase and carbon deposits on the valves.

Cycles of rapid heating and cooling can result in cracked cylinder heads, gasket failure, accelerated wear, and
excessive fuel consumption.
If a problem with the cooling system is suspected, perform a visual inspection before you perform any tests
on the system.
215
Visual Inspection
Perform a visual inspection of the cooling system before a test is made with test equipment.
Personal injury can result from escaping fluid under pressure.

If a pressure indication is shown on the indicator, push the release valve
in order to relieve pressure before removing any hose from the radiator.
1. Check the coolant level in the cooling system. Add coolant, if necessary.
If the coolant level is too low, air will get into the cooling system. Air in the cooling system reduces
coolant flow. Air creates bubbles that contribute to cavitation. Bubbles in the coolant also reduce the
cooling capability.
2. Check the quality of the coolant. The coolant should have the following properties:
n Color that is similar to new coolant
n Odor that is similar to new coolant
n Free from contamination
n Properties that are recommended by the engine's Operation and Maintenance Manual
If the coolant does not have these properties, drain the system and flush the system. Refill the cooling
system according to the engine's Operation and Maintenance Manual.
3. Check for air in the cooling system. Air can enter the cooling system in different ways. The following
conditions cause air in the cooling system:
n Filling the cooling system incorrectly
n Combustion gas leakage into the cooling system
Combustion gas can get into the system through the following conditions: internal cracks, damaged
cylinder head and damaged cylinder head gasket.
4. Inspect the radiator (if equipped) and the air-to-air aftercooler (if equipped). Make sure that the air flow is
not restricted. Look for the following conditions. Make corrections, if necessary:
n Bent fins
n Debris between the folded cores
n Damaged fan blades
5. Check the heat exchanger (if equipped) for internal blockage. Make sure that the filters for the water are
not clogged.
The condition of the water that is circulated through the heat exchanger can decrease the effectiveness of
the heat exchanger. Operating with water that contains the following types of debris will adversely affect
the heat exchanger system: silt, sediment, salt and algae. In addition, intermittent use of the engine will
adversely affect the heat exchanger system.
6. Check the pressure cap.
If the pressure cap does not maintain the correct pressure on the cooling system, the engine could overheat.
A decrease in cooling system pressure reduces the temperature of the water's boiling point.
7. Inspect the cooling system hoses and clamps.
Damaged hoses with leaks can normally be seen. Hoses that have no visual leaks can soften during
operation. The soft areas of the hose can become kinked or crushed during operation. These areas of the
hose restrict the coolant flow. Hoses can crack after a period of time. The inside of a hose can deteriorate
and the loose particles of the hose can restrict the coolant flow.
8. Check the water temperature regulators.
A water temperature regulator that does not open or a water temperature regulator that only opens part of
the way can cause overheating.
216
A water temperature regulator that does not close enables overcooling.

9. Check the engine water pump and check the auxiliary pump.
Check for a fluid leak from the pump's weep hole during engine operation and check for a leak when the
engine is stopped. If either coolant or oil is leaking from the weep hole, replace the pump.
A water pump with a damaged impeller does not pump enough coolant for correct coolant flow. This
affects the engine's operating temperature. Remove the water pump and check for damage to the impeller.
Also inspect the inside of the pump's housing for scratches from the impeller.
10. Check the aftercooler.
A restriction of water flow through the aftercooler can cause overheating. Check for debris or deposits
which restrict the free flow of water through the aftercooler.
217
Test Tools for the Cooling System

Table 1
Tools Needed
348-5430 Multi-Tool Gp 1
9S-8140 Pressurizing Pump 1
245-5829 Coolant/Battery Tester Gp 1
Making contact with a running engine can cause burns from hot parts
and can cause injury from rotating parts.
When working on an engine that is running, avoid contact with hot
parts and rotating parts.
Steam or hot coolant can cause severe burns.

Do not loosen the filler cap or the pressure cap on a hot engine.
Allow the engine to cool before removing the filler cap or the pressure
cap.
348-5430 Multi-Tool Gp
The 348-5430 Multi-Tool Gp is used in the diagnosis of overheating conditions and in the diagnosis of
overcooling conditions. This group can be used to check temperatures in several different parts of the cooling
system. Refer to Tool Operating Manual, NEHS1087, " 348-5430 Multi-Tool Gp " for the testing procedure.
The 348-5430 Multi-Tool Gp is used to check the air flow through the radiator core. Refer to Tool Operating
Manual, NEHS1087 for the test procedure for checking the air flow through the radiator core.
The 348-5430 Multi-Tool Gp is used to check the fan speed. Refer to Tool Operating Manual, NEHS1087 for
the testing procedure.
218
The 348-5430 Multi-Tool Gp can measure engine rpm from a magnetic pickup. The magnetic pickup is
located in the flywheel housing. Refer to Tool Operating Manual, NEHS1087 for the testing procedure.
The 348-5430 Multi-Tool Gp is also a photo-tachometer that is held by hand for general use. The multi-tool
can measure the engine speed by placing a piece of reflective tape on the crankshaft pulley.
9S-8140 Pressurizing Pump
The 9S-8140 Pressurizing Pump is used to test the filler caps. This pressurizing pump is also used to pressure
test the cooling system for leaks.
245-5829 Coolant/Battery Tester Gp
Check the coolant frequently in cold weather for the proper glycol concentration. Use the 245-5829
Coolant/Battery Tester Gp in order to ensure adequate freeze protection. The tester gives immediate, accurate
readings. The tester can be used for antifreeze and coolants that contain ethylene or propylene glycol.
219
Cooling System Pressure Cap - Test
Pressurized System: Hot coolant can cause serious burns. To open the
cooling system filler cap, stop the engine and wait until the cooling
system components are cool. Loosen the cooling system pressure cap
slowly in order to relieve the pressure.
Table 1
Tools Needed
One cause for a pressure loss in the cooling system can be inadequate sealing of the pressure cap.
After the engine is cool, loosen the pressure cap and allow the pressure out of the cooling system. Then
remove the pressure cap.
Inspect the pressure cap carefully. Look for damage to the seal or to the sealing surface. Any foreign material
or foreign deposits that accumulate on the following parts must be removed: cap, seal and sealing surface.
Typical schematic of filler cap, (1) Sealing surface of both filler cap and radiator
The 9S-8140 Pressurizing Pump is used to pressure test the caps and the cooling system for leaks.
To check the pressure cap opening pressure, use the procedure that follows:
1. Remove the pressure cap from the radiator.
2. Put the pressure cap on the 9S-8140 Pressurizing Pump .
220
3. Look at the gauge for the exact pressure that makes the pressure cap open.
4. Compare the reading on the gauge with the correct opening pressure that is labelled on the cap.
5. The pressure cap must open within ± 1 psi. Otherwise, install a new pressure cap.
221
Radiator and Cooling System - Test

Table 1
9S-8140 Pressurizing Pump 1
Typical pressure relief valve system, (1) Pressure relief valve (2) Stud for filler cap
Steam or hot coolant can cause severe burns.

Do not loosen the filler cap or the pressure cap on a hot engine.
Allow the engine to cool before removing the filler cap or the pressure
cap.
Use the following procedure to check the pressure in the cooling system:
1. After the engine is cool, loosen the filler cap slowly and allow pressure out of the cooling system. Then
remove the filler cap from the radiator.
2. Inspect the filler cap carefully. Look for damage to the seal or to the surface that seals. Any foreign
material or deposits on the cap must be removed. Any foreign material or deposits on the seal must be
removed. Any foreign material or deposits on the surface that seals must be removed.
3. Make sure that the coolant level is above the top of the radiator core.
4. Install the filler cap. Tighten the filler cap.
9S-8140 Pressurizing Pump , (3) Release valve (4) Adapter (5) Hose
5. Remove hose (5) from adapter (4) .
6. Remove the pressure test plug for the radiator top tank.
222
7. Install the end of the hose (5) in the hole for the pressure test plug.
8. Operate the pump until the pointer on the pressure indicator does not increase. The highest pressure
indication on the pressure indicator is the point that opens the relief valve. The open pressure is
approximately 124 kPa (18 psi).
9. If the relief valve does not open within the pressure specification, replacement of the relief valve is
necessary.
10. If the relief valve is within specifications, check the radiator for outside leakage.
11. Check all connections and hoses of the cooling system for outside leakage.
12. The radiator and the cooling system do not leak if the following conditions exist. There is no outside
leakage. The pressure reading on the pressure indicator stays same after five minutes. If the reading on the
pressure indicator goes down and no outside leak is visible, the inside of the cooling system is leaking.
Make the necessary repairs.

13. Remove hose (5) from the pressure test location on the radiator.
14. Install the plug in the pressure test location.
223
Water Temperature Regulator - Test

Introduction
This procedure is intended to give information on testing the water temperature regulator.
Test Procedure

1. Remove the water temperature regulator from the engine.

2. Heat water in a pan until the temperature of the water is equal to the fully open temperature of the water
temperature regulator. Refer to Specifications, "Water Temperature Regulator" for the fully open
temperature of the water temperature regulator. Stir the water in the pan. This will distribute the
temperature throughout the pan.
3. Hang the water temperature regulator in the pan of water. The water temperature regulator must be below
the surface of the water. The water temperature regulator must be away from the sides and the bottom of
the pan.
4. Keep the water at the correct temperature for ten minutes.
5. After ten minutes, remove the water temperature regulator. Immediately measure the opening of the water
temperature regulator. Refer to Specifications, "Water Temperature Regulator" for the minimum opening
distance of the water temperature regulator at the fully open temperature.
If the distance is less than the amount listed in the manual, replace the water temperature regulator.
224
Connecting Rod Bearings
The connecting rod bearings fit tightly in the bore in the rod. If the bearing joints are fretted, check the bore
size. This can be an indication of wear because of a loose fit.
Connecting rod bearings are available with 0.63 mm (0.025 inch) and 1.27 mm (0.050 inch) smaller inside
diameter than the original size bearing. These bearings are for crankshafts that have been reground.
225
Main Bearings
Main bearings are available with a larger outside diameter than the original size bearings. These bearings are
available for the cylinder blocks with the main bearing bore that is made larger than the bores' original size.
The size that is available has a 0.63 mm (0.025 inch) outside diameter that is larger than the original size
bearings.
226
Cylinder Block
If the main bearing caps are installed without bearings, the bore in the block for the main bearings can be
checked. Tighten the nuts that hold the caps to the torque that is shown in the Specifications. Alignment error
in the bores must not be more than 0.08 mm (0.003 inch). Refer to Special Instruction, SMHS7606 for the
use of the 1P-4000 Line Boring Tool Group for the alignment of the main bearing bores. The 1P-3537 Dial
Bore Gauge Group can be used to check the size of the bores. The Special Instruction, GMG00981 is with
the group.
1P-3537 Dial Bore Gauge Group
227
Cylinder Liner Projection

Specifications
Table 1
Dimensions for Acceptable Cylinder Liner Projection with the 362-8264 Cylinder Head Gasket
Part Dimension Value
211-7826 Cylinder Block Liner flange 12.65 ± 0.02 mm (0.498 ± 0.0001 inch) Z
362-9677 Spacer Plate 12.33 ± 0.03 mm (0.4854 ± 0.0012 inch) X
110-6994 Spacer Plate 12.31 ± 0.03 mm (0.4846 ± 0.0012 inch) X
144-5692 Plate Gasket 0.21 ± 0.03 mm (0.008 ± 0.001 inch) Y
0.08 mm (0.003 inch) to
Allowable projection
0.15 mm (0.006 inch)
Table 2
Dimensions for Acceptable Cylinder Liner Projection with the 110-6991 Cylinder Head Gasket
Part Dimension Value
211-7826 Cylinder Block Liner flange Z
12.65 ± 0.02 mm (0.498 ± 0.0001 inch)
110-6994 Spacer Plate X
12.31 ± 0.03 mm (0.4846 ± 0.0012 inch)
362-9677 Spacer Plate X
12.33 ± 0.03 mm (0.4854 ± 0.0012 inch)
144-5692 Plate Gasket Y
0.21 ± 0.03 mm (0.008 ± 0.001 inch)
0.06 mm (0.002 inch) to
Allowable projection
0.20 mm (0.008 inch)
Introduction
Use this procedure to check the cylinder liner projection out of the cylinder block and installed in the cylinder
block.ReferenceRefer to Reuse And Salvage Guidelines, "Procedure to Salvage Top Decks of Cylinder
Blocks of 3500 Engines" for additional information about reuse and/or salvage of the cylinder block.
Required Tools
Table 3
1U-9895 Crossblock 1
3H-0465 Push-Puller Plate 2
8F-6123 Bolt (3/4-16 thread,
2
139.7 mm (5.5.50 inch) long
3B-1925 Washer (COPPER) 4
1A-0075 Bolt (3/4-16 thread,
4
44.45 mm (1.750 inch) long
8T-0455 Liner Projection Tool Group 1
6V-7059 Micrometer 1
228
Preparation
For checking the cylinder liner projection with the liner out of the cylinder block, ensure that the following
surfaces are clean prior to measuring:
¡ Cylinder liner flanges
¡ Spacer plate
¡ Spacer plate gasket
For checking the installed cylinder liner projection, ensure that the following surfaces are clean prior to
measuring:
¡ Top surface of the cylinder block
¡ Cylinder liner bores
¡ Cylinder liner flanges
¡ Spacer plates
¡ Spacer plate gasket
1. Use the 6V-7059 Micrometer to measure the thickness of the following items:
n (X) Spacer Plate
n (Y) Spacer Plate Gasket
n (Z) Cylinder Liner Flange
The cylinder liner projection depends on which spacer plate is used. Refer to Table 1 or to Table 2.
Note: To determine the cylinder liner projection, subtract the thickness of the spacer plate and gasket from
the thickness of the cylinder liner flange.
2. Refer to Table 1 or to Table 2 for the correct value of your cylinder liner projection based on your spacer
plate.
229
Measuring the cylinder liner projection, (1) 3H-0465 Push-Puller Plate (2) 1P-2403 Dial Indicator (3) 1P-2402 Gauge Body (4)
1A-0075 Bolt and 3B-1925 Washer (COPPER) (5) Spacer plate (6) 1U-9895 Crossblock
1. Install a new gasket and spacer plate (5) on the cylinder block.
2. Install the cylinder liner in the cylinder block without seals or bands.
3. Hold spacer plate (5) and the cylinder liner in position according to the following procedure:
a. Install four 3B-1925 Washers (COPPER) and four 1A-0075 Bolts (4) around spacer plate (5). Tighten
the bolts evenly to a torque of 95 N·m (70 lb ft).
b. Install the following components: 1U-9895 Crossblock (6), two 3H-0465 Push-Puller Plates (1) and two
8F-6123 Bolts. Ensure that 1U-9895 Crossblock (6) is in position at the center of the cylinder liner.
Ensure that the surface of the cylinder liner is clean. Tighten the bolts evenly to a torque of 70 N·m (50
lb ft).
c. Check the distance from the bottom edge of 1U-9895 Crossblock (6) to the top edge of spacer plate (5).
The vertical distance from both ends of the 1U-9895 Crossblock must be equal.
4. Use 8T-0455 Liner Projection Tool Group (6) to measure the cylinder liner projection.
5. Mount 1P-2403 Dial Indicator (2) in 1P-2402 Gauge Body (3). Use the back of the 1P-5507 Gauge Block
to zero dial indicator (2).
6. Refer to Table 1 or to Table 2 for the correct value of the cylinder liner projection based on the part
number of the spacer plate.
7. Read the measurement on the outer flange of the cylinder liner at four equally distant positions. Do not
read the measurement on the inner flange. The maximum allowable difference between the high
measurements and the low measurements at four positions around each cylinder liner is 0.05 mm (0.002
inch). The maximum allowable difference between the four measurements must not exceed 0.05 mm
(0.002 inch) on the same cylinder liner.
Note: If the cylinder liner projection is not within specifications, turn the cylinder liner to a different position
within the bore. Measure the projection again. If the cylinder liner projection is not within specifications,
move the cylinder liner to a different bore. Inspect the top face of the cylinder block.
Note: When the cylinder liner projection is correct, put a temporary mark on the cylinder liner and the spacer
plate. Be sure to identify the particular cylinder liner with the corresponding cylinder. When the seals and the
filler band are installed, install the cylinder liner in the marked position.
230
Flywheel - Inspect
Table 1
Tools Needed
8T-5096 Dial Indicator Gp 1
Checking face runout of the flywheel
1. Refer to illustration 1 and install the dial indicator. Always put a force on the crankshaft in the same
direction before the dial indicator is read. This will remove any crankshaft end clearance.
2. Set the dial indicator to read 0.0 mm (0.00 inch).
3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.
4. Take the measurements at all four points. Find the difference between the lower measurements and the
higher measurements. This value is the runout. The maximum permissible face runout (axial eccentricity)
of the flywheel must not exceed 0.15 mm (0.006 inch).
231
Checking bore runout of the flywheel, (1) 7H-1945 Holding Rod (2) 7H-1645 Holding Rod (3) 7H-1942 Dial Indicator (4) 7H-
1940 Universal Attachment
1. Install the 7H-1942 Dial Indicator (3). Make an adjustment of the 7H-1940 Universal Attachment (4) so
that the dial indicator makes contact on the flywheel.
2. Set the dial indicator to read 0.0 mm (0.00 inch).
3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.
higher measurements. This value is the runout. The maximum permissible bore runout (radial eccentricity)
of the flywheel must not exceed 0.15 mm (0.006 inch).
Flywheel clutch pilot bearing bore
higher measurements. This value is the runout. The maximum permissible pilot bore runout of the flywheel
must not exceed 0.13 mm (0.005 inch).
232
Flywheel Housing - Inspect

Table 1
8T-5096 Dial Indicator Gp 1
Checking face runout of the flywheel housing
If you use any other method except the method that is given here, always remember that the bearing
clearance must be removed in order to receive the correct measurements.
1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the face of the flywheel
housing.
2. Put a force on the crankshaft toward the rear before the dial indicator is read at each point.
Checking face runout of the flywheel housing
3. Turn the flywheel while the dial indicator is set at 0.0 mm (0.00 inch) at location (A). Read the dial
indicator at locations (B), (C) and (D) .
4. The difference between the lower measurements and the higher measurements that are performed at all
four points must not be more than 0.38 mm (0.015 inch), which is the maximum permissible face runout
(axial eccentricity) of the flywheel housing.
233
Checking bore runout of the flywheel housing
1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the bore of the flywheel
housing.
2. While the dial indicator is in the position at location (C) adjust the dial indicator to 0.0 mm (0.00 inch).
Push the crankshaft upward against the top of the bearing. Refer to the illustration 4. Write the
measurement for bearing clearance on line 1 in column (C) .
Note: Write the measurements for the dial indicator with the correct notations. This notation is necessary
for making the calculations in the chart correctly.
3. Divide the measurement from Step 2 by two. Write this number on line 1 in columns (B) and (D) .
4. Turn the flywheel in order to put the dial indicator at position (A). Adjust the dial indicator to 0.0 mm
(0.00 inch).
Checking bore runout of the flywheel housing
5. Turn the flywheel counterclockwise in order to put the dial indicator at position (B). Write the
measurements in the chart.
6. Turn the flywheel counterclockwise in order to put the dial indicator at position (C). Write the
measurement in the chart.
7. Turn the flywheel counterclockwise in order to put the dial indicator at position (D). Write the
measurement in the chart.
234
8. Add the lines together in each column.

9. Subtract the smaller number from the larger number in column B and column D. Place this number on line
III. The result is the horizontal eccentricity (out of round). Line III in column C is the vertical eccentricity.
Graph for total eccentricity, (1) Total vertical eccentricity (2) Total horizontal eccentricity (3) Acceptable value (4)
Unacceptable value
10. On the graph for total eccentricity, find the point of intersection of the lines for vertical eccentricity and
horizontal eccentricity.
11. The bore is in alignment, if the point of intersection is in the range that is marked "Acceptable". If the point
of intersection is in the range that is marked "Not acceptable", the flywheel housing must be changed.
235
Vibration Damper
Damage to the damper or failure of the damper will increase vibrations. This will result in damage to the
crankshaft.
Replace the damper if the damper is bent or damaged. Replace the damper if the bolt holes are oversize.
Replacement of the damper is also needed at the time of a crankshaft failure due to torsional forces.
236
General Information (Air/Electric Starting System)
This starting system uses an electric solenoid to position an air valve in order to activate the air starting
motor. If the starting motor does not function, do the procedure that follows:
1. Check the indicator reading for the air pressure.
2. If the reading is not acceptable then use a remote source to charge the system.
3. If the reading is acceptable then open the main tank drain valve for a moment. Verify the pressure that is
shown on the pressure indicator. Listen for the sound of the high pressure from the discharge.

1. Move the start control switch in order to activate the starting solenoids. Listen for the sound of the
engagement of the air starter motor pinion with the flywheel gear.
a. If the sound of the engagement can be heard, the problem is with the Air Side Of The Air System.
Proceed to the Air Side Of The Air System.
b. If no sound of the engagement can be heard, the problem could be with the Electrical Side Of The Air
System.
Control valve (typical example), (1) Control valve (2) Connector
2. Check the electrical system by disconnecting the leads from the control valve (1) at connector (2). Set the
multimeter in the "DCV" range. Measure voltage across the disconnected leads that connect to the starting
switch.
a. A voltage reading shows that the problem is in the control valve (2) or the air starting motor. Go to Step
2 of Air Side Of The Air System.
b. A "ZERO" reading shows that the problem is in the control switch or the problem is in the wires for the
control switch.
3. Fasten the multimeter lead to the start switch at the terminal for the wire from the battery. Fasten the other
lead to a good ground.
a. A "ZERO" reading indicates a broken circuit from the battery. With this condition, check the circuit
breaker and wiring.
b. The problem is in the control switch if either a voltage reading is found at the control switch or if a
voltage reading is found in the wires from the control switch to the control valve.
237
Air starting system (typical example), (1) Control valve (2) Connector (3) Connection (4) Air hose (5) Relay valve
1. Activate the control switch. If the engagement of the air starter motor pinion with the flywheel ring gear
can be heard then remove the small air hose (4) from the top of the relay valve (5) .
a. Full air pressure comes from the end of the air hose (4) when the control switch is activated. The relay
valve (5) is worn or the air starting motor is damaged.
b. If no air pressure comes from the end of the air hose (4), then the problem is in the pinion nose housing
for the air starting motor.
2. The sound of the air starter motor pinion is not heard when the control switch is activated. Voltage was
measured at the control valve. Remove the other small air hose from the connection (3) .
a. If no air comes from the end of the removed air hose, the control valve (1) is worn.
b. If the air comes from the end of the removed hose, then the problem is in the pinion nose housing for the
air starting motor.
238
Pressure Regulating Valve
Each engine installation must be inspected in order to determine the most advantageous starting conditions.
The setting of the pressure regulating valve is affected by the following factors:
¡ Loads from attachments that are pulled by the engine during the start-up
¡ Ambient temperature conditions
¡ Viscosity of the lubricant for the air starting motor
¡ Capacity of the air reservoir
¡ Condition of the engine
Higher pressures provide increased torque for the starting motor and faster rotation of the engine. Lower
pressures prolong the supply of pressurized air.
Use the following procedure to check and adjust the pressure regulating valve:
1. Purge the pressurized air from the system.
Pressure regulating valve, (1) Adjusting screw (2) Regulator inlet (3) Regulator outlet
2. Disconnect the air line from regulator outlet (3) .
3. Connect an 8T-0849 Pressure Gauge to regulator outlet (3) .
4. Apply air pressure to the gauge and check the pressure.
5. Use adjusting screw (1) to adjust the air pressure to 620 to 1030 kPa (90 to 150 psi).
6. After the pressure is correct, purge the pressurized air from the system.
7. Remove the 8T-0849 Pressure Gauge Group from the regulator outlet. Reconnect the air line.
239
Lubrication
Always use an air line lubricator with the air starting motors that have vanes.
For temperatures above 0 °C (32 °F), use a SAE 10W nondetergent oil of high quality.
For temperatures below 0 °C (32 °F), use air tool oil.
To maintain the efficiency of the starting motor, flush the starting motor at regular intervals. Pour
approximately 0.5 L (0.53 qt) of diesel fuel into the air inlet of the starting motor and operate the starting
motor. This procedure will remove the dirt, the water and the mixture of oil from the vanes of the air starting
motor.
240
Test Tools for the Electrical System

Table 1
177-2330 Battery Analyzer 1
271-8590 Starting/Charging Analyzer Gp 1
225-8266 Ammeter Tool Gp 1
146-4080
or Digital Multimeter Gp 1
257-9140
Most of the tests for the electrical system can be done on the engine. First, check that the insulation for the
wiring is in good condition. Ensure that the wire connections and cable connections are clean and tight.
Check that the battery is fully charged. If the on-engine test shows that a component is not functioning
properly, remove the component from the engine for more testing.
Refer to Testing And Adjusting Electrical Components, REG00636 for complete specifications and test
procedures for the components of the starting circuit and the charging circuit.
The 177-2330 Battery Analyzer will quickly test any 6 V or 12 V battery with a 50 to 4000 Cold Cranking
Amp (CCA), 65 to 5000 Cranking Amp (CA), or 6 to 500 Amp Hour (A-Hr) capacity.
The test can be completed in just 20 seconds and determines whether the battery is good.
The 177-2330 Battery Analyzer features the following:
¡ Quickly and accurately test the condition of 6 V and 12 V batteries (even discharged to as low as one
volt). Checks for full state charge, condition of battery, and battery voltage.
¡ Batteries can be tested in the machine or vehicle. The battery does not have to be fully charged at the
time of testing.
¡ Saves time and money by allowing dealers to test the condition of a battery while the customer is
present (works great for warranty claims).
241
¡ Eliminates the need to charge and discharge a battery to test its condition.
¡ Compensates for cold temperatures when testing batteries in extreme conditions.
¡ Power-down feature prolongs battery life in the analyzer.
Note: Refer to Operating Manual, NEHS0764 for more complete information for the use of the 177-2330
Battery Analyzer .

The 271-8590 Starting/Charging Analyzer Gp is a portable, hand-held tool that is used to test the condition of
all 6, 8, and 12 Volt batteries, as well as 6, 8, 12 and 24 Volt battery packs. The tester can also be used to test
the starting and the charging system. The analyzer has a multifunction input for use with multimeter probes
that are an optional purchase. The analyzer also has a print function that is used with a printer that is an
optional purchase.
Note: Refer to Operating Manual, NEHS0973 for more complete information for the use of the 271-8590
Starting/Charging Analyzer Gp .
242
The 225-8266 Ammeter Tool Gp is a completely portable, self-contained instrument that allows electrical
current measurements to be made without breaking the circuit or without disturbing the insulation of a
conductor. A digital display is located on the ammeter for displaying current measurements in a range from 1
to 1200 amperes. A 6V-6014 Cable can be connected between the ammeter and a digital multimeter in order
to measure a current of less than 1 ampere.
A lever is used to open a jaw on the meter that clamps on any conductor up to 23 mm (0.90 inch) in diameter.
The jaw of the meter closes around the conductor for the current measurement. A dial is used to set the
appropriate range for the amperage reading. A "HOLD" button on the meter allows the latest reading to be
sustained on the display. If a measurement is taken in a limited access area, the meter will retain the
measurement data that is on the display until the user clears the data. Batteries are used to power the
ammeter.
Note: Refer to the ammeter's User's Guide for complete information that is related to the use of the ammeter.
This guide is packaged with the unit.
The 146-4080 Digital Multimeter Gp is a portable instrument that has a digital display. This multimeter is
case hardened with a rubber protector cover that provides extra protection against damage in field
applications. The 146-4080 Digital Multimeter Gp can be used to perform the following measurements:
¡ Amperage
¡ Capacitance
¡ Frequency
¡ Pulse Width Modulation (PWM)
¡ Resistance
¡ Temperature
¡ Voltage
The multimeter has an instant ohms indicator that permits the checking of continuity for fast circuit
inspection. Temperature measurements can be taken by using the adapter for type K thermocouples. An RS-
232 interface adaptor can be used to interface with other electronic tools and displays.
Note: Refer to multimeter's Operator's Manual for complete information that is related to the use of the
multimeter. The operator's manual is packaged with the unit.
243
Battery
Never disconnect any charging unit circuit or battery circuit cable from
the battery when the charging unit is operated. A spark can cause an
explosion from the flammable vapor mixture of hydrogen and oxygen
that is released from the electrolyte through the battery outlets. Injury
to personnel can be the result.
The battery circuit is an electrical load on the charging unit. The load is variable because of the condition of
the charge in the battery.
NOTICE
The charging unit will be damaged if the connections between the
battery and the charging unit are broken while in operation. Damage
occurs because the load from the battery is lost and because there is an
increase in charging voltage. High voltage will damage the charging
unit, the regulator, and other electrical components.
Use the 4C-4911 Battery Load Tester in order to test a battery that does not maintain a charge when the
battery is active. Refer to Operating Manual, SEHS9249 for detailed instruction on the use of the 4C-4911
Battery Load Tester. See Special Instruction, SEHS7633 for the correct procedure and for the specifications
to use when you test the batteries.
244
Charging System
The condition of charge in the battery at each regular inspection will indicate whether the charging system
operates correctly. An adjustment is necessary when the battery is constantly in a low condition of charge or
a large amount of water is needed. A large amount of water would be more than one ounce of water per cell
per week or per every 100 service hours.
When it is possible, test the charging unit and the voltage regulator on the engine. Use wiring and
components that are a permanent part of the system. This testing will give an indication of needed repair.
After repairs are made, perform a test in order to prove that the units have been repaired to the original
condition of operation.
To check for correct output of the alternator, see the Specifications module.
For complete service information, refer to Service Manual Module, SENR7503, "Delco-Remy Bulletin 1G-
255". This module is part of Service Manual, REG00636.
Before the start of on-engine testing, the charging system and the battery must be checked according to the
following steps.
1. The battery must be at least 75 percent (1.225 Sp Gr) of the full charge. The battery must be held tightly in
place. The battery holder must not put too much stress on the battery.
2. Cables between the battery, the starter, and the engine ground must be the correct size. Wires and cables
must be free of corrosion. Wires and cables must have cable support clamps in order to prevent stress on
battery connections (terminals).
3. Leads, junctions, switches, and panel instruments that have direct relation to the charging circuit provide
correct circuit control.
4. Inspect the drive components for the charging unit in order to be sure that the components are free of
grease and oil. Be sure that the drive components have the ability to operate the charging unit.
245
Alternator Regulator
The charging rate of the alternator should be checked when an alternator is charging the battery too much.
The charging rate of the alternator should be checked when an alternator is not charging the battery enough.
Make reference to the Specifications module in order to find all testing specifications for the alternators and
regulators.
No adjustment can be made in order to change the rate of charge on the alternator regulators. If the rate of
charge is not correct, a replacement of the regulator is necessary.
Tools for tightening the alternator pulley nut, (1) 8T-9293 Torque Wrench (2) 261-0444 Adapter (1/2 inch female to 3/8 inch
male) (3) 2P-8267 Socket Assembly (4) 8H-8517 Combination Wrench (1-1/8 inch) (5) 8T-5314 Socket
Tighten the nut that holds the pulley with the tools shown. Refer to the Specifications module for the torque.
246
Electric Starting System
Use the multimeter in the DCV range to find the starting system components which do not function.
Move the start control switch in order to activate the starting solenoids. The starting solenoid operation can
be heard as the pinions of the starting motors are engaged with the ring gear on the engine flywheel.
If a solenoid for a starting motor will not operate, the current from the battery may not have reached the
solenoid. Fasten one lead of the multimeter to the connection (terminal) for the battery cable on the solenoid.
Put the other lead to a good ground. A zero reading indicates that there is a broken circuit from the battery.
More testing is necessary when there is a voltage reading on the multimeter.
The solenoid operation also closes the electric circuit to the motor. Connect one lead of the multimeter to the
solenoid connection (terminal) that is fastened to the motor. Fasten the other lead to a good ground. Activate
the starting solenoid and look at the multimeter. A reading of the battery voltage shows that the problem is in
the motor. The motor must be removed for further testing. A zero reading on the multimeter shows that the
solenoid contacts do not close. Repair the solenoid if the contacts do not close. The clearance for the starter
motor pinion gear may also need adjusting.
Perform a test. Fasten one multimeter lead to the connecting (terminal) for the small wire to the solenoid and
fasten the other lead to the ground. Look at the multimeter and activate the starting solenoid. A voltage
reading shows that the problem is in the solenoid. A zero reading indicates that the problem is in the start
switch or in the wires for the start switch.
Fasten one multimeter lead to the start switch at the connection (terminal) for the wire from the battery.
Fasten the other lead to a good ground. A zero reading indicates a broken circuit from the battery. Check the
circuit breaker and wiring. If there is a voltage reading, the problem is in the start switch or in the wires for
the start switch.
Starting motors that operate too slowly can have an overload because of too much friction in the engine that
is being started. Slow operation of the starting motors can also be caused by the following conditions:
¡ A short circuit
¡ Loose connections
¡ Dirt in the motors
247
Pinion Clearance Adjustment
When the solenoid is installed, make an adjustment of the pinion clearance. The adjustment can be made with
the starting motor removed.
Connection for checking pinion clearance, (1) Ground terminal (2) SW terminal (3) Connector
1. Install the solenoid without connector (3) from the MOTOR connections (terminal) on the solenoid to the
motor.
2. Connect a battery, that has the same voltage as the solenoid, to "SW" terminal (2) .
3. Connect the other side of the battery to connector (3) .
4. For a moment, connect a wire from the solenoid connection (terminal), which is marked "MOTOR", to the
ground connection (terminal). The pinion will shift to the crank position and the pinion will stay there until
the battery is disconnected.
Pinion clearance adjustment, (4) Shaft nut (5) Pinion (6) Pinion Clearance
5. Push the pinion toward the end with the commutator in order to remove free movement.
6. Pinion clearance (6) must be 9.1 mm (0.36 inch).
7. In order to adjust the pinion clearance, remove the plug and turn shaft nut (4) .
248
SENR2382-00
INDEX
3500 MARINE ENGINES, SENR2382-00
Disassembly and Assembly
Alternator (An Attachment) INDEX 000

001 1
3
Manual Shutoff 002 5
Air Cleaner Housings 003 7
Exhaust Elbow 004 8
Gauge Panel 005 9
Junction Box 006 14
Air Intake Shutoff (3508) 007 17
Service Meter 008 24
Tachometer Drive 009 25
Water Temperature Regulators 011 29
Water Pump 012 31
Auxiliary Pump (Fresh Water) (An Attachment) 013 36
Fuel Filter Housing 014 48
Water Temperature Contactor 015 51
Fuel Priming Pump 016 52
Expansion Tank 018 57
Oil Pump 019 58
Oil Filter Housing 020 63
Oil Pan 021 68
Oil Sequence Valves 022 71
Oil Cooler 023 72
Oil Sump Pump And Check Valve (An Attachment) 024 78
Oil Sump Pump (An Attachment) 025 80
Governor 026 82
Governor Drive 027 83
Turbochargers 028 87
Turbochargers (3512) 029 89
Turbochargers (3508) 030 95
Exhaust Manifolds 031 100
Aftercooler 032 102
Hydramechanical Shutoff Control (An Attachment) 033 106
Hydramechanical Shutoff Drive (An Attachment) 034 117
Accessory Drive (Front) 035 120
Oil And Water Pump Drive 036 123
Crankshaft Vibration Damper 037 126
Crankshaft Front Seal And Wear Sleeve 038 127
Crankshaft Rear Seal And Wear Sleeve 039 130
Front Drive Housing 040 133
SENR2382-00
249
Air Starter 041 137

Air Starter (An Attachment) 042 138
Flywheel 043 149
Valve Covers 045 154
Rocker Shafts And Push Rods 046 155
Rocker Shaft Assemblies 047 157
Fuel Injectors 048 159
Fuel Injectors 049 161
Cylinder Heads 051 167
Piston Cooling Sets 052 172
Valves 053 173
Valve Lifters 054 175
Bridge Dowels 055 176
Valve Seat Inserts 056 177
Valve Guides 057 178
Connecting Rod Bearings 058 179
Front Balancer Group (3508) 059 181
Rear Gear Group 060 184
Spacer Plates 061 188
Crankshaft Main Bearings 062 190
Pistons 063 194
Cylinder Liners 064 197
Camshafts 065 200
Camshaft Bearings 066 205
Crankshaft 067 207
SENR2382-00
250
001 Disassembly and Assembly
Alternator (An Attachment)

Remove Alternator
1. Put identification on the electric wires as to their location on the alternator. Disconnect the wires and
ground wire (1) from the alternator.
2. Loosen the nuts on adjustment rod (3), to remove the tension on the vee belts.
3. Remove guard assembly (2) from the alternator.
4. Remove vee belts (6) from the alternator pulley.

5. Remove bolts (5) and (7) to remove alternator (4) from the bracket. The weight of the alternator is 14 kg
(30 lb.)
Install Alternator
NOTE: Make sure the nut that holds the alternator pulley in position is tightened to a torque of 100 ± 7 N·m
(75 ± 5 lb. ft.).
1. Put the alternator in position on bracket (3) and install the bolts and washers that hold it to bracket (3) and
adjustment rod (2).
2. Install the nuts and washers that hold the guard assembly in position at this time to hold the alternator.
251
3. Put vee belts (1) in position on the drive and alternator pulleys. Make an adjustment of the belt tension
with a belt tension gauge such as Borroughs Tool Company Part No. BT-33-95 or an equivalent. Measure the
belt farthest from the timing gear cover. Tighten new belts until the gauge indication is 120 ± 5. Operate the
engine at high idle for a minimum of 30 minutes after Step 4. Make another adjustment of the belt tension.
The correct gauge indication for used belts is 90 ± 10.
4. Connect the electric wires and ground wire (4) to their correct locations on the alternator.
5. Remove the two nuts and washers that hold the alternator in position and install guard assembly (5). Install
the two nuts and washers.
252
Manual Shutoff
Remove Manual Shutoff
1. Remove bolt (1) and the washer. Pull lever (2), the adapter and lever from the front drive housing. There is
an O-ring seal that holds the adapter in the front drive housing.
2. Remove bolt (3) and the washer to remove lever (2) from adapter (4).
3. Use tool (A) and remove the ring that holds lever (5) in adapter (4). Remove lever (5) from adapter (4).
4. Remove O-ring seal (6) from adapter (4).
5. Remove seal (7) from adapter (4).

253
Install Manual Shutoff
1. Use tool group (A) and install the seal in adapter (1) with the lip of the seal toward the inside as shown.
Put clean engine oil on the lip of the seal.
2. Install O-ring seal (2) on adapter (1) and put clean engine oil on it.
3. Put lever (4) in adapter (1) and use tool (B) to install ring (3) to hold the unit together.
4. Put lever (5) in position and install the washer and bolt to hold it to lever (4).
5. Install the levers and adapter in the front drive housing. Make sure lever (4) is under and in contact with
the governor stop lever. Install the bolt and washer to hold the unit in position.
6. To make an adjustment of the shutoff levers, loosen the locknut and screw on the adapter. Pull lever (5)
until the governor linkage makes contact with its stop and hold lever (5) in this position. Turn the adjustment
screw until it makes contact with lever (5) and then turn it one more complete turn. Tighten the locknut.
254
Air Cleaner Housings

Remove Air Cleaner Housings
1. Disconnect adapter (1) from the air inlet system.

2. Loosen the clamp that holds turbocharger hose (2) to air cleaner housing (4).
3. Disconnect filter element indicator hose (6) from the tube assembly.
4. Fasten a hoist to air cleaner housing (4) with tool (A) as shown.
5. Remove the bolts and washers that hold air cleaner housing (4) to support (3) and bracket (5). Remove air
cleaner housing (4) from the engine. The weight of air cleaner housing (4) is 29 kg (65 lb.).
Install Air Cleaner Housings
1. Fasten a hoist to air cleaner housing (4) with tooling (A) and put it in position. Install the bolts and washers
to hold air cleaner housing (4) to support (3) and bracket (6).
2. Tighten the clamp to connect hose (2) to air cleaner housing (4).
3. Connect filter element hose (5) to the tube assembly.
4. Connect the air inlet system to adapter (1).
255
Exhaust Elbow
Remove And Install Exhaust elbow
start by:
a) remove turbochargers
1. Disconnect temperature sending units (2) from exhaust elbow (1).

2. Fasten a hoist to exhaust elbow (1) as shown. Remove the bolts that hold the elbow to bracket (3) and
remove exhaust elbow (1). The weight of the elbow is 17 kg (38 lb.).
3. Fasten a hoist to exhaust elbow (1) and put it in position with gasket (4). Install the bolts that hold the
elbow to bracket (3).
4. Connect temperature sending units (2) to exhaust elbow (1).
end by:
a) install turbochargers
256
Gauge Panel
Remove Gauge Panel
1. Put identification marks on nine lines (2) for correct installation and disconnect lines (2) from block (1).
2. Remove the screws from panel (4) and fasten panel (4) to box assembly (3) as shown.
3. Put identification marks on six wires (5) for correct installation and disconnect wires (5) from tachometer
(7) and pyrometer (6). Remove the wires from the panel.
4. Put panel (4) in position in box assembly (3) and install two screws to hold the panel in position.
5. Disconnect wiring harness (10). Remove clamps (9) from gauge panel support assembly (8).
6. Remove water jacket sending unit (11) from the engine.
257
7. Remove oil temperature sending unit (12) from the engine.

8. Remove eight bolts (13) from gauge panel support assembly (8) and lower gauge panel (14) to the base of
the engine.
9. Fasten gauge panel (14) to the engine as shown.
NOTE: If the gauge panel has to be completely removed from the engine, the expansion tank has to be
removed to remove manifold air temperature sending unit (15).
Install Gauge Panel
1. Put gauge panel (1) in position on the engine and install the bolts that hold it in place.
NOTE: Make sure the capillary tubes from the sending units do not make direct contact with the engine.
2. Install oil temperature sending unit (2) in the engine.
258
3. Install water jacket sending unit (3) in the engine.

4. Connect wiring harness (6). Install clamps (5) that hold the fuel lines and wires to gauge panel support
assembly (4).
5. Remove the two screws that hold panel (8) to box assembly (7). Lower the panel to the position shown and
fasten the panel to the box assembly with wire.
6. Install six wires (9) to panel (8) and connect wires (9) to tachometer (11) and pyrometer (10).
7. Put panel (8) in position in box assembly (7) and install screws (12) that hold it in place.
8. Connect nine lines (14) to block (13).
Disassemble Gauge Panel
1. Remove the screws that hold panel (2) in box assembly (1). Lower panel (2) to position shown and fasten
259
panel (2) to box assembly (1) with wire.

2. Remove the five pressure gauges and two vacuum gauges from panel (2) as follows:
a) Disconnect line (3) from gauge (6).
b) Remove nuts (4) and bracket (5).
c) Remove gauge (6) from the front of the panel.
3. Put identification marks on wires (7) for correct installation and disconnect wires (7) from tachometer (8).
Remove nuts (9) to remove bracket (10) and remove tachometer (8) from the front of the panel.
4. Put identification marks on wires (12) for correct installation and disconnect wires (12) from pyrometer
(13). Remove nuts (11) to remove two brackets (14) and remove pyrometer (13) from the front of the panel.
5. Remove the four temperature gauges from panel (2) as follows:

a) Remove sending unit (15) from the engine.
b) Remove nuts (16) to remove bracket (17).
c) Remove gauge (18) from the front of the panel.
NOTE: The manifold air temperature sending unit can not be removed unless the expansion tank is removed.
Assemble Gauge Panel
1. Install the four temperature gauges in panel (3) as follows:

a) Put gauge (1) in position in panel (3).
b) Put bracket (2) in position on gauge (1) and install the nuts that hold the bracket and gauge to the
panel.
260
c) Install sending unit (4) in the engine.
NOTE: Make sure the capillary tube from the sending unit does not make contact with the engine.
2. Put pyrometer (7) and two brackets (6) in position in panel (3). Install the two nuts that hold brackets (6)
and pyrometer (7) to the panel. Connect wires (5) to the pyrometer.
3. Put tachometer (9) and bracket (10) in position in panel (3). Install the two nuts that hold bracket (10) and
tachometer (9) to the panel. Connect wires (8) to the tachometer.
4. Install the five pressure gauges and two vacuum gauges in panel (3) as follows:
a) Put gauge (13) and bracket (12) in position in panel (3).
b) Install the two nuts that hold bracket (12) and gauge (13) to panel (3).
c) Connect line (11) to gauge (13).
5. Put panel (3) in position in box assembly (14) and install screws (15) to hold panel (3) to box assembly
(14).
261
Junction Box
Remove Junction Box
1. Disconnect wiring harnesses (1) from the tachometer and service meter drive.
2. Disconnect wiring harness (2) from the shutoff solenoid on the air intake housing.
3. Disconnect wiring harness (3) from the shutdown solenoid on the governor.
4. Disconnect wiring harness (4) from the water temperature contactor.
5. Remove the screws from panel (5) and lower the panel to a horizontal position. Fasten panel (5) to box
assembly (6) with wire to hold the panel in the horizontal position.
6. Disconnect wires (7) from the tachometer and remove the wires from the panel.
262
7. Disconnect wiring harness (8) from the engine shutdown switch.

8. Disconnect strap assembly (9) from water line (11). Disconnect hose assembly (10) from the junction box.
9. Remove the three mounting nuts from junction box (12) and remove junction box (12) from the engine.
Install Junction Box

1. Put junction box (1) in position on its mounting brackets and install the three mounting nuts to hold the
junction box in position.
2. Connect hose assembly (2) to the junction box and connect strap assembly (4) to water line (3).
3. Connect wiring harness (5) to the engine shutdown switch.

4. Install wires (6) on panel (7) and connect wires (6) to the tachometer.
5. Remove the wire that holds panel (7) in its horizontal position and put the panel back in its original
263
position in box assembly (8). Install the screws that hold the panel in the box assembly.
6. Connect wiring harness (9) to the water temperature contactor.
7. Connect wiring harness (10) to the shutdown solenoid on the governor.

8. Connect wiring harness (11) to the shutoff solenoid on the air intake housing.
9. Connect wiring harnesses (12) to the tachometer and service meter drive.
264
Air Intake Shutoff (3508)

Remove Air Intake Shutoff
1. Disconnect the harness assembly to the shutoff solenoid.
2. Remove the bolts to remove shield (1) and pipes (2) from the engine.
3. Remove the bolts and remove air intake cover (3) from the air shutoff group.
4. Remove bolts (5) and remove air shutoff group (4) from the aftercooler housings.
Install Air Intake Shutoff

1. Put the gaskets and air shutoff group (1) in position on the aftercooler housings. Install the bolts to hold the
group in position.
2. Put the gasket and air intake cover (2) in position on the air shutoff group. Install the bolts to hold cover
(2) in position.
3. Put clean engine oil on the O-ring seals on pipes (4). Put pipes (4) and shield (3) in position on the engine
and install the bolts to hold these in position.
265
Disassemble Air Intake Shutoff
start by:
a) remove air intake shutoff
1. Remove the bolts from solenoid (1). Hold handle (2) in the position as shown by hand or with a wrench
and remove solenoid (1) from the air shutoff group. Slowly release handle (2) to the shutoff position.
2. Bend the locks away from bolts (3) and loosen all of bolts (3) that hold the plate assemblies to the shaft
assembly.
3. Move handle (2) back to the position as shown by hand or with a wrench and put solenoid (1) in position
in the shutoff housing assembly. Install the bolts and release the handle.
4. Remove the bolts, the locks, the plates and bushings from plate assemblies (4). Remove plate assemblies
(4) from the shaft assembly.
5. Do Step 1 again to remove solenoid (1).
6. Remove the bolt and remove handle (2) from the shaft assembly.
7. Remove the bolts and remove cover assembly (5) from the housing assembly.
8. Remove seal (6) from cover assembly (5).
266
9. Remove pin (8) to remove spacer assembly (7) from the housing assembly.
10. Remove shaft assembly (9), the spacer and spring from the housing assembly. Remove the spring and
spacer from the shaft assembly.
11. If necessary, remove the dowel and remove lever (10), spacer assembly (12) and pin (11) as a unit from
shaft assembly (9). Remove pin (11) from lever (10) to remove spacer assembly (12) from lever (10) if
necessary.
Assemble Air Intake Shutoff
1. If necessary, make a replacement of dowel (1) and make sure the end of the dowel as shown is 83.0 ± 0.5
mm (3.268 ± .020 in.) below surface (X).
2. If shaft assembly (2) was disassembled, put spacer assembly (5) in position on lever (3) and use a press to
install pin (4) until it is even (flush) with the surface of lever (3) as shown. Put lever (3), spacer assembly (5)
and pin (4) as a unit in position on shaft assembly (2). Install the dowel to hold the unit on shaft assembly (2)
and put marks (stake) the end of the dowel.
267
3. Install spacer (8) and spring (6) on shaft assembly (2). Install shaft assembly (2) in housing assembly (7).
Make sure spring (6) is correctly engaged with dowel (1) as shown.
4. Install handle (10) on the shaft assembly. Turn handle (10) up (upward) and install pin (11) so handle (10)
can be put in contact with pin (11). With handle (10) in contact with pin (11), install plate assemblies (9) on
the shaft assembly.
5. Release handle (10) from the pin and remove the pin so plate assemblies (9) can move to the "SHUTOFF"
position. A 0.076 mm (.003 in.) feeler gauge must not pass between plate assemblies (9) and the housing
assembly as shown. Remove handle (10) from the shaft assembly.
6. Put spacer assembly (12) in position and install pin (11) in the housing assembly through the spacer
assembly.
7. Use tool group (A) to install the seal until it is even (flush) with the inside surface of cover assembly (13).
Make sure the lip of the seal is toward the outside surface of the cover as shown.
8. Install cover assembly (13) on the housing assembly and the bolts to hold it.
9. Install handle (10) on the shaft assembly and the bolts to hold it.
268
NOTE: To make the installation of the bolts in the air shutoff group easier, the electric solenoid must be
installed before the air shutoff group is installed on the engine.
10. Turn handle (10) to the open position as shown and put the gasket and solenoid (14) in position on the
housing assembly. Release the handle and install the bolts to hold the solenoid in position.
end by:
a) install air intake shutoff
Remove Air Intake Shutoff
1. Disconnect shutoff solenoid wires (6) from wiring harness (7).

2. Remove bolts (3) that hold flanges (1) and (5) to shutoff housing (4) and the exhaust manifolds.
3. Remove bolts (2) and remove shield (8). Remove shutoff housing (4) from the aftercooler manifold.
Install Air Intake
1. Put the gasket and shutoff hosing (1) in position. Put the shield for the shutoff solenoid in position and
install the bolts to hold housing (1) to the aftercooler manifold.
2. Put the gaskets for the flanges in position on shutoff housing (1). Install the bolts to hold the flanges and
pipes (2) to the exhaust manifold and shutoff housing (1).
3. Connect wiring harness (4) to solenoid wires (3).
4. Make sure the air shutoff is in the "OPEN" position before the engine is started.
Disassemble Air Intake Shutoff
start by:
a) remove air intake shutoff
269
1. Remove the four bolts (1) to remove the spring and valve assembly (2) from the shaft.
2. Remove the bolts and nuts to remove valve (2) from spring (3).
3. Remove the bolts and remove arm (4) and latch (5) from the shaft.
4. Remove the two bolts (6) and the washers to remove knob (7), the cover and shaft from the shutoff
housing.
5. Remove bolt (10) and the washer to remove knob (7) and cover (9) from shaft (8).
6. Remove carrier (12) from the shutoff housing (11).
7. Remove plug (14), the spring and pin from carrier (2).
8. Remove seal (13) from the shutoff housing. If necessary, remove bushings (15) for shaft (8) from the
housing.
Assemble Air Intake Shutoff

270
1. Use tooling (A) to install the bushings and seal in the shutoff housing. Install the seal with the lip of the
seal toward the inside of the housing as shown. Check the inside diameter dimension of the bearings after
installation. The correct dimension is 19.050 ± 0.044 mm (.750 ± .002 in.).
2. Install the pin, the spring and plug (2) in carrier (1).
3. Install carrier (1) in the shutoff housing and tighten the carrier to a torque of 120 ± 15 N·m (90 ± 11 lb.ft.).
4. Put cover (4) and knob (5) on shaft (3) and install the bolt and washer to hold knob (5) on shaft (3).
5. Put shaft (3) in position through the seal in the shutoff housing and put bushing (7) and spring (6) over the
end of the shaft.
6. Push the shaft all the way in the housing and install the bolts and washers to hold cover (4) in position.
7. Make sure the end of spring (6) is engaged with the hole in the shutoff housing and install latch (9) to
connect spring (6) to the shaft. Install arm (8) on the shaft.
8. Put valve assembly (11) in position on spring (10) and install the bolts, washers and nuts to hold the unit
together.
9. Put spring (10) and valve assembly (11) in position and install the bolts and washer to hold the unit to shaft
(3).
end by:
a) install air intake shutoff
271
Service Meter
Remove And Install Service Meter
1. Remove bolts (1) and the clamps.

2. Remove service meter (2) from the tachometer drive adapter assembly.
3. Put clean engine oil on O-ring seal (3) and install it on the service meter.
4. Install the service meter in the tachometer drive adapter assembly. Make sure the shaft of the service meter
engages in the groove (slot) in the shaft of the tachometer drive.
5. Install the clamps and bolts (1) to hold service meter (2) in position.
272
Tachometer Drive
Remove Tachometer Drive
start by:
a) remove service meter
1. Disconnect harness assemblies (3) and remove bolts (2) and clamps from adapter assembly (1). Remove
adapter assembly (1) from the cover assembly.
2. Remove bolts (4) to remove cover assembly (5) from the flywheel housing.
3. Remove the dowels, lip type seal and bearing (6) from the cover.
4. Remove shaft (7) from the adapter assembly.
5. Remove bolts (8) to remove adapter assembly (9) from the camshaft.
6. If necessary, remove the dowels from adapter assembly (9).
273
Install Tachometer Drive
1. If necessary, install new dowels in adapter assembly (1). Make sure dowels (2) extend 9.5 ± 0.5 mm (.374
± .02 in.) above the surface of adapter assembly (1). Put adapter assembly (1) in position on the end of the
camshaft and install the two bolts to hold it in position. Tighten the bolts evenly to a torque of 100 ± 15 N·m
(75 ± 10 lb.ft.). Hit the adapter with a hammer and tighten the bolts again to the same torque. Do this until the
torque does not change.
2. Install shaft (3) in adapter assembly (1).
3. Use tooling (A) to install the bearing in cover (4) until it is 26 ± 1 mm (1.024 ± .04 in.) below surface (X).
4. Use tooling (A) to install the lip type seal in cover (4) until the seal makes contact with the bottom of the
bore in cover (4). Make sure the lip of the seal is toward the bearing and put clean engine oil on it.
5. Install the dowels in cover (4) until the dowels are 6.0 ± 0.5 mm (.240 ± .02 in.) above surface (Y).
6. Put cover (4) and gasket in position on the flywheel housing and install the bolts to hold the cover in
position.
7. Put clean engine oil on seal (6) and install adapter assembly (5) in the cover. Make sure the shaft of the
adapter assembly engages in the groove (slot) on the end of shaft (3). Install the two bolts and clamps to hold
adapter assembly (5) to the cover.
8. Connect harness assemblies (7).
end by:
a) install service meter
274
Crankcase Breather
Remove Crankcase Breather
1. Remove the four nuts and remove breather assemblies (1) from elbow (2).
2. Loosen the clamps and remove hoses (3), (4) and the tubes from breather assemblies (1).
3. Remove cover assembly (5) from each breather assembly (1).

4. Remove filter element (6) from each breather assembly (1).
5. Remove O-ring seals (7) from elbow (2).

6. Remove elbow (2) and gasket from the front drive housing.
275
Install Crankcase Breather
1. Install the gasket and elbow (1) on the front drive housing.
2. Install O-ring seals (2) on elbow (1) and put clean engine oil on the seals.
3. Install filter element (4) in each breather assembly (3).
4. Install cover assembly (5) on each breather assembly (3).

5. Put hoses (6) and (7) in position on breather assemblies (3) and tighten the clamps.
6. Put breather assemblies (3) in position on elbow (1) and install the four nuts to hold the assemblies in
position.
276
Water Temperature Regulators

Remove Water Temperature Regulators
1. Drain the cooling system until the level of the coolant is below the exhaust manifolds.
2. Remove the bolts that hold flanges (2) to the expansion tank.
3. Remove the bolts that hold housing (1) to the regulator housing. Remove housing (1), the two tubes and
flanges (2) as a unit from the engine.
4. If necessary, remove ferrule (3) and the ball from housing (1).
5. Remove regulators (4) from the regulator housing.

6. Remove the gaskets from the regulator housings, flanges and expansion tank.
7. If necessary, remove ferrule (5), the ball and lip type seals (6) from the regulator housing.
277
Install Water Temperature Regulators
1. Install the ball and ferrule (1) in the regulator housing. Make sure the end of ferrule (1) with the holes is
toward the inside. Install the ferrule until it makes contact with the bottom of its bore in the housing.
2. Use tool group (A) and install the water temperature regulator seals in the housing. Make sure the lips of
the seals are toward the inside as shown.
NOTICE
If the water temperature regulators are installed wrong, it will cause

the engine to overheat.
3. Install water temperature regulators (2) in the housing with the springs up as shown.
4. Install the ball and ferrule (3) in housing (4). Make sure the end of ferrule (3) with the holes is toward the
inside. Install ferrule (3) until it makes contact with the bottom of its bore in housing (4).
5. Put the gaskets for housing (4) and flanges (5) in position. Install housing (4), the tubes and flanges (5) on
the engine.
6. Fill the cooling system with coolant to the correct level.
278
Water Pump
Remove Water Pump
1. Drain the coolant from the cooling system.
2. Remove the bolts and remove damper guard (1) from the engine.
3. Remove bolts (4) and remove elbow (3) and tube (2) as a unit from the engine.
4. Remove bolts (5) that hold the water pump to the drive adapter.
5. Fasten a hoist to water pump (7) and remove bolts (6) to remove the water pump from the engine. The
weight of water pump (7) is 27 kg (60 lb.).
Install Water Pump
1. Make sure gasket (3) is in position on the water line adapter. Install O-ring seal (2) on the pump housing
and put clean oil on it.
2. Fasten a hoist to water pump (1) and put it in position in the pump drive. Make sure the splines on the
pump shaft are correctly engaged with the pump drive splines.
3. Install bolts (4) and (5) that hold the water pump to the water line adapter and the pump drive adapter.
279
4. Install O-ring seal (8) on the pump housing and put clean oil on it.
5. If necessary, make a replacement of the O-ring seals on each end of tube (6) and put clean oil on the seals.
6. Put tube (6) and elbow (7) as a unit in position and install the bolts to hold these in position.
7. Install damper guard (9) on the engine.

Disassemble Water Pump
start by:
a) remove water pump
1. Remove elbow (1) from housing assembly (2). Remove the O-ring seal from elbow (1).
2. Remove O-ring seal (5) from the back of housing assembly (2).
3. Remove washer (4) that holds shaft assembly (3) in housing assembly (2).
280
4. Remove cover (6) from housing assembly (2). Remove the O-ring seal from cover (6).
5. Loosen bolt (8) and the washer that hold impeller (7) to the pump shaft. Use tooling (A) to loosen impeller
(7) from the end of the pump shaft. Remove tooling (A), bolt (8), the washer and impeller (7) from the pump
shaft and housing assembly (2).
6. Remove spring (10) from seal assembly (9) and shaft assembly (3).
7. Use a soft faced hammer and push shaft assembly (3) out of seal assembly (9) and housing assembly (2).
Remove seal assembly (9) from housing assembly (2).
8. Remove ceramic seal (11) from the rubber ring. Remove the rubber ring from housing assembly (2).
9. Remove seal (12) from the back of housing assembly (2).

281
Assemble Water Pump
1. If necessary, make a replacement of the two filters in the pump housing at location (1).
2. If necessary, make a replacement of plug (2) and the seal.
3. Use tool group (A) to install the seal in the housing assembly. Make sure the lip of the seal is toward the
outside as shown. Put clean engine oil on the lip of the seal.
4. Install shaft assembly (3) in housing assembly (4). Install washer (5) and the bolts to hold shaft assembly
(3) in position.
NOTICE
Clean water only is permitted for use as a lubricant for assembly. Do

not damage or put hands on the water surface of the carbon ring or the
ceramic ring. Install the ceramic ring with the smoothest face of the
ring toward the carbon seal assembly.
5. Put ceramic seal (6) in position in the rubber ring. Use hand pressure and the tool (which is with the
replacement seal) to install the ceramic seal.
6. Remove spring from seal assembly (7). Use hand pressure and the tool (which is with the replacement
seal) to install the seal assembly. Push seal assembly on shaft until seal faces make light contact.
282
7. Install spring (8) on the carbon seal assembly.

8. Put impeller (9) in position on the pump shaft as shown.
9. Install washer (11) and bolt (10). Tighten bolt (10) to a torque of 90 ± 15 N·m (66 ± 11 lb.ft.). Hit the bolt
with a hammer and tighten it again to a torque of 90 ± 15 N·m (66 ± 11 lb.ft.).
NOTE: Make sure the studs for cover (12) are tightened to a torque of 27 ± 4 N·m (20 ± 3 lb.ft. in the pump
housing.
10. Put clean engine oil on O-ring seal (13) and install it on cover (12). Put cover (12) in position and install
the nuts to hold it to the pump housing.
11. Put clean engine oil on the O-ring seal and install it in elbow (14). Put elbow (14) in position on housing
assembly (4) and install the bolts to hold the unit together.
12. Put clean engine oil on the O-ring seal and install it on the back of housing assembly (4).
end by:
a) install water pump
283
Auxiliary Pump (Fresh Water) (An Attachment)

Remove Auxiliary Pump (Fresh Water)
1. Drain the coolant from the system and disconnect the inlet and outlet lines from pump (2).
2. Remove cover (1) and the O-ring seal from the pump drive adapter.
3. Remove the bolts and adapter (3) from the front drive housing.

5. If necessary, remove bearing (4) from adapter (3).
6. Fasten a hoist to pump (2) with tooling (A) as shown. Remove the bolts that hold pump (2) in position.
Pull the pump and drive gear out of the front housing and remove the unit from the engine. The weight of the
unit is 39 kg (85 lb.).
284
Install Auxiliary Pump (Fresh Water)
1. Install O-ring seal (1) around the pump body and put clean engine oil on it.
2. Use tool (A) to fasten a hoist to the pump and put it in position in the front drive housing. Install the bolts
and washers to hold the pump.
3. Make sure the oil hole in the bearing is in alignment with the oil passage in adapter (2). Use tool group (B)
and a press to push the bearing into adapter (2) until it is 1.5 ± 0.5 mm (.06 ± .02 in.) below the surface of
adapter (2). The inside diameter of the bearing must be 75.000 ± 0.055 mm (2.9528 ± .0022 in.) after
assembly.
4. Install O-ring seal (3) around adapter (2) and put clean engine oil on it. Install adapter (2) in the front drive
housing.
5. Install O-ring seal (4) around cover (5) and put clean engine oil on it. Install cover (5) on the adapter.
6. Connect the inlet and outlet lines to the water pump and fill the system with coolant to the correct level.
Disassemble Auxiliary Pump (Fresh Water)
start by:
a) remove auxiliary pump (fresh water)
285
1. Remove O-ring seals (3) and (4) from the pump housing.
2. Remove the bolts and gear (2) from shaft (1).
3. Remove the bolts and adapter (5) from the pump housing. Remove the O-ring seal from adapter (5).
4. Loosen bolt (6) and the washer that hold impeller (7) to the shaft.
5. Use tooling (A) to loosen impeller (7) from the end of the pump shaft. Remove tooling (A), bolt (6), the
washer and impeller (7) from the pump shaft and housing.
6. Remove spring (9) from carbon seal assembly (10). Remove carbon seal assembly (10) from the end of
shaft (8).
7. Remove the bolts that hold retainer washers (12) to the pump housing. Remove shaft (1) and washers (12)
from the pump housing.
8. Remove the bolts that hold the shims and retainer washers (13) to the pump housing. Remove shaft (8), the
shims and washers (13) from the pump housing.
286
9. Remove the rubber ring and ceramic seal (11) from the pump housing.
10. Remove lip type seal (14) from the pump housing.
11. Remove bearing (15) from the pump housing.
Assemble Auxiliary Pump (Fresh Water)
1. Make sure the oil hole in the bearing is in alignment with the oil passage in housing (1). Use tool group
(A) and a press to push the bearing in housing (1) until it is 1.5 ± 0.5 mm (.06 ± .02 in.) below the surface of
housing (1). The inside diameter of the bearing must be 75.000 ± 0.055 mm (2.9528 ± .0022 in.).
2. Use tool group (A) to install the lip type seal in housing (1). Make sure the lip of the seal is toward the
bearing as shown. Put clean engine oil on the lip of the seal.
3. Install shaft (2) in the pump housing. Install retainer washers (3), the shims and bolts to hold shaft (2) in
the pump housing.
4. Put clean engine oil on the bearing in the pump housing and install shaft (4) and retainer washers (5) over
shaft (2). Install the bolts to hold retainer washers (5) to the pump housing.
287
NOTICE
Clean water only is permitted for use as a lubricant for assembly. Do

not damage or put hands on the wear surfaces of the carbon ring or the
ceramic ring. Install the ceramic ring with the smoothest face of the
ring toward the carbon seal assembly.
5. Install ceramic seal ring (6) in the rubber seal. Put clean water on the rubber seal and ceramic seal ring for
lubrication. Use hand pressure and the tool (which is with the replacement seal group) to install the seal and
seal ring as shown.
6. Remove the spring from carbon seal assembly (7). Put clean water on the inside diameter of the seal
assembly for lubrication. Use hand pressure and the tool (which is with the replacement seal group) to push
seal assembly (7) on the shaft until seal faces make light contact.
7. Install spring (8) on carbon seal assembly (7).

8. Put impeller (9) in position on the pump shaft as shown.
9. Install the bolt and washer that hold impeller (9) to the pump shaft. Tighten the bolt to a torque of 38 ± 4
N·m (28 ± 3 lb.ft.).
10. Install O-ring seal (11) around adapter (10) and put a small amount of engine oil or glycerine on it.
11. Put adapter (10) in position and install the bolts to hold it to the pump housing.
288
12. Put gear (12) in position on shaft (4) and install the bolts to hold gear (12).
13. Install O-ring seals (13) and (14) in the pump housing and put clean engine oil on the O-ring seals.
end by:
a) install auxiliary pump (fresh water)
Remove Sea Water Pump
1. Remove the inlet and outlet water lines to pump (1).

2. Remove the oil supply to pump (1).
3. Fasten a hoist to sea water pump (1) as shown. Remove the bolts and nuts and remove the pump from
housing assembly (2). The weight of pump (1) is 32 kg (70 lb.).
4. Remove bolts (3) and the washers to remove housing assembly (2) from the front housing. If necessary,
remove the bearing from the housing assembly.
5. Remove the bolts and remove gear (4) from the accessory drive shaft.
Install Sea Water Pump

289
1. Install gear (1) and the bolts to hold it to the accessory drive shaft.
2. If the bearing in housing assembly (2) was removed, lower the temperature of the bearing and use tooling
(A) to install the bearing to a depth of 1.5 ± 0.5 mm (0.059 ± .002 in.) below the housing surface. Make sure
the oil hole in the bearing is in alignment with the oil passage in the housing assembly. Check the bore in the
bearing after assembly. The bore in the bearing must be 75.000 ± 0.055 mm (2.9528 ± .0022 in.).
3. Make sure the O-ring seals are in position on housing assembly (2) and put clean engine oil on the O-ring
seals and the bearing. Install housing assembly (2) and the bolts and washers to hold it in the front housing.
4. Fasten a hoist to sea water pump (3) and install the pump in the housing assembly. Install the bolts and
nuts to hold the pump to the housing assembly.
5. Install the oil supply line to the pump.
6. Install the inlet and outlet water lines to the pump.
Disassemble Sea Water Pump
start by:
a) remove sea water pump
290
1. Loosen bolt (3) approximately 3.0 mm (0.118 in.) and use tooling (A) to pull gear (2) from the pump shaft.
Remove tooling (A), bolt (3), the washer and gear (2) from the end of the pump shaft.
2. Remove clamp (1) from the pump.
3. Remove end body (6) from the drive body. Remove port plate (4) from the end body.
4. Remove the cotter pin. Remove nut (5) and the washer from the end of the pump shaft.
5. Use tooling (B) to remove impeller (7) from the pump shaft. Remove the shims from the pump shaft.
6. Remove O-ring seal (8) and ring (10) from the drive body.
7. Remove washer (9) and key (11) from the pump shaft.
8. Remove port plate (12) from the drive body.
9. Remove nuts (14) that hold drive body (13) to bearing housing (15).
291
NOTICE
Do not let bearing housing (15) fall when it is removed from drive body
(13).
10. Use a press to remove bearing housing (15) and pump shaft (16) from drive body (13). Remove seal (17).
NOTE: Make a replacement of both seal (17) and the ceramic rings if either is damaged or worn.
11. Remove the ceramic ring from drive body (13) with tooling (C) and a press.
12. Remove the water thrower from pump shaft (16). Remove seal (18) with tool group (H).
13. Remove snap ring (19) with tool (E).

14. Bend back the lock from nut (21). Remove nut (21) with tool (F). Remove the lock.
15. Remove spacer (20).
16. Remove pump shaft (16) from bearing housing (15) with a press. Do not let the pump shaft fall as it is
removed.
17. Remove the bearing from pump shaft (16) with a press.
18. Remove bearing retainer (22). Remove the bearing from bearing housing (15) with tooling (G) and a
press.
292
19. Remove bearing race (23) with tool (G).
Assemble Sea Water Pump
1. Install the bearing race in housing (1) with tooling (B). Install the bearing until is against the shoulder in
housing (1).
2. Install the double roller bearing (2) in housing (1) with tooling (C) and a press. Install the bearing until it is
against the shoulder in housing (1).
3. Install single roller bearing (4) on shaft (3) until it is against the shoulder of shaft (3).
4. Put 9S3265 Retaining Compound to the inside diameter of collar (5) and on shaft (3). Install collar (5)
until is makes contact with bearing (4). Remove any excess compound.
293
5. Install retainer (6) on housing (1) to hold the double roller bearing (2) in position.
6. Install shaft (3) and bearing (4) in housing (1) as a unit. Be sure that shaft (3) is in alignment with bearing
(2) and bearing (4) is also in alignment with its respective outer race.
7. Install snap ring (7) with tool (D).
8. Install seal (8) with tooling (F) until it makes contact with snap ring (7). Install rubber washer (9) (thrower)
on shaft (3).
9. Put clean water on the ceramic ring (10). Install ceramic ring (10) with tooling (A) and hand pressure.
Install the ring with the bevel side down.
10. Install body (13) on housing (1). Install nuts (15) and locks.
11. Install the spacer, lock and nut on the gear end of the pump shaft. Tighten the nut to a torque of 95 to 110
N·m (70 to 80 lb.ft.) and bend the tab of the lock in the groove of the nut.
12. Put clean water on seal (16). Install seal (16) on the pump shaft with the large sealing surface against the
ceramic ring. Use hand pressure only to install seal (16).
NOTE: Make a replacement of both seal (16) and ceramic ring (10) if either is damaged or worn.
13. Install washer (11) on the pump shaft.
14. Install plate (17) in body (13) with tabs (12) in alignment with the notches in body (13).
294
15. Use straight plate (18) and a feeler gauge as shown to find the distance between the shoulder on the pump
shaft and the face of plate (17).
16. Install shims (22) on the pump shaft with the thickness the same as the distance found in Step 15 plus the
clearance dimension for each side of the impeller. The clearance dimension is 0.20 ± 0.03 mm (.008 ± .001
in.).
17. Install ring (14) in body (13) and install O-ring seal (21) around ring (14).
NOTE: Install the impeller with the threaded puller holes toward the outside.
18. Install key (20) and impeller (19) on the pump shaft.
19. Install the washer and nut (24). Tighten the nut to a torque of 60 to 70 N·m (44 to 50 lb.ft.). Install the
cotter pin to hold the nut.
20. Install plate (23) in body (25) with the tabs of the plate in alignment with the notches of body (25).
21. Install body (25) on the pump and install clamp (28) to hold the body to the pump.
22. Install gear (27) and the washer and bolt (26). Tighten the bolt to a torque of 55 ± 7 N·m (41 ± 5 lb.ft.).
Use a hammer and punch and hit the bolt. Tighten the bolt again to the same torque.
end by:
a) install sea water pump
295
Fuel Filter Housing

Remove Fuel Filter Housing
1. Drain the coolant in the cooling system to a level below the exhaust manifolds.
2. Remove the bolts that hold housing assembly (1) to the expansion tank and the water regulator housing.
Remove housing assembly (1) from engine.
3. Close the fuel supply line to the engine.
4. Disconnect fuel lines (2), (3) and remove fuel line (4) from fuel filter housing (5).
5. Remove the eight bolts and fuel filter housing from engine. The weight of the fuel filter housing with no
fuel in it is 23 kg (50 lb.).
Install Fuel Filter Housing
1. Put fuel filter housing (1) in position and install the bolts that hold it to the engine.
2. Connect fuel lines (2) and (3) to fuel filter housing (1).
3. Install fuel line (4) on fuel filter housing (1).
4. Open the fuel supply line to the engine.
5. Put housing assembly (5) in position and install the bolts that hold it to the water regulator housing and the
expansion tank.
6. Fill the engine with coolant to the correct level.
Disassemble Fuel Filter Housing

296
start by:
a) remove fuel filter housing
1. Remove cover (1) from the end of the filter housing.

2. Use tool (A) to remove ring (2) from the cover.
3. Remove retainer (3), O-ring seal (4), spring (5) and O-ring seal (6) from cover (1).
4. Remove the five filter elements (7) from the filter housing.
5. Disconnect fuel line (9) from cover (8). Remove cover (8) from the filter housing and remove the O-ring
seal from the cover.
Assemble Fuel Filter Housing

297
1. Install O-ring seal (2) on cover (1) and put clean engine oil on the seal.
2. Install cover (1) on the end of the filter housing. Connect fuel line (3) to the cover.
3. Install the five filter elements (4) in the filter housing.
4. Put O-ring seal (6), spring (7) and retainer (5) in position on cover (9).
5. Use tool (A) to install ring (10) on the cover.
6. Install O-ring seal (8) on cover (9) and put clean engine oil on it. Install cover (9) on the end of the filter
housing.
end by:
a) install fuel filter housing
298
Water Temperature Contactor

Remove And Install Water Temperature Contactor
2. Disconnect wiring harness (1) from the contactor.

3. Remove contactor (2) from the water housing.
4. Install contactor (2) in the water housing.
5. Connect wiring harness (1) to the contactor.
299
Fuel Priming Pump

Remove And Install Fuel Priming Pump
1. Shut off the fuel supply to the engine.
2. Remove bolts (2) and remove fuel priming pump (1) from the fuel filter housing.
3. Put a gasket and fuel priming pump (1) in position on the fuel filter housing.
4. Install bolts (2) to hold the pump in position.
5. Open the fuel supply to the engine.
300
Fuel Transfer Pump

Remove Fuel Transfer Pump
1. Close the fuel supply to the engine and disconnect the fuel supply line from elbow (1).
2. Disconnect fuel line (3) and priming pump fuel line (2) from the fuel transfer pump.
3. Remove the four bolts (4) that hold fuel transfer pump (5) to the engine oil pump cover.
4. Pull fuel transfer pump (5), the O-ring seal and coupling from the engine oil pump and remove the unit
from the engine.
Install Fuel Transfer Pump
1. Install O-ring seal (2) on the pump body and put clean engine oil on it.
2. Install coupling (3) on the pump shaft and put fuel transfer pump (1) in position. Make sure coupling (3) is
engaged correctly with oil pump shaft (4).
3. Install the four bolts (5) to hold fuel transfer pump (1) to the engine oil pump cover.
4. Connect priming pump fuel line (7) and fuel line (8) to fuel transfer pump (1).
5. Connect the fuel supply line to elbow (6) and open the fuel supply to the engine.
301
Disassemble Fuel Transfer Pump

start by:
a) remove fuel transfer pump
1. Pull drive coupling (2) from the pump shaft.

2. Remove O-ring seal (1) from the pump.
3. Remove cap (6), seal washer (5), spring (4) and relief valve poppet (3) from the pump bracket assembly.
4. Remove bolts (7) and remove pump head (8) from plate (9).
5. If necessary, remove check valve (10) from head (8).
6. Remove plate (9) from the pump casing.

7. Remove gasket (11) and the O-ring seal from the opposite side of plate (9).
8. If necessary, remove the bearings from plate (9).
9. Remove gear assembly (12) and shaft assembly (13) from the pump bracket and casing (14).
10. Remove casing (14) and sleeves (15) from pump bracket (16).
11. Remove the O-ring seal from casing (14).
302
12. Remove outer seal (17) and inner seal (18) from bracket (16).
13. If necessary, remove the two bearings from bracket (16).
Assemble Fuel Transfer Pump
1. Use tool group (A) to install the inner and outer lip type seals in bracket (1). Make sure the lips of the seals
are in the position shown at assembly. Put clean engine oil on the lips of the seals.
2. Use tool group (A) to install bearings (2) 1.5 mm (.06 in.) below the surface of bracket (1).
3. Install sleeves (4) in bracket (1).

4. Install O-ring seal (5) in casing (3) and put casing (3) over sleeves (4) on bracket (1).
5. Install gear assembly (6) and shaft assembly (7) in the bracket and casing.
303
6. Use tool group (A) to install bearings (8) 1.5 mm (.06 in.) below the surface of plate (9).
7. Install O-ring seal (10) in plate (9) and put plate (9) in position on the pump casing.
8. Use tool group (A) to install the check valve in head (11) until it makes contact with the shoulder in its
bore. Make sure the spring on the check valve is toward the inside before it is installed.
9. Put gasket (12) and head (11) in position on the plate and install the two bolts that hold the pump together.
10. Install the relief valve poppet (13), spring (14), the seal washer and cap (15) in the pump.
11. Install O-ring seal (16) around the pump and put clean engine oil on it.
12. Install drive coupling (17) on the pump shaft.
end by:
a) install fuel transfer pump
304
Expansion Tank
Remove Expansion Tank
start by:
a) remove fuel filter housing
2. Remove the bolts and plate (1) from the expansion tank and the water regulator housing.
3. Remove the bolts from the flange that holds tube (2) to the bottom of the expansion tank (3).
4. Fasten a hoist to expansion tank (3). Remove the bolts that hold expansion tank (3) to the support assembly
and remove the tank. The weight of the expansion tank is 141 kg (310 lb.).
Install Expansion Tank
1. Fasten a hoist to expansion tank (1) and put the tank in position on the support assembly. Install the bolts
that hold expansion tank (1) to the support assembly.
2. Install the bolts on the flange that hold tube (2) to the bottom of expansion tank (1).
3. Install the bolts that hold plate (3) to the water regulator housing and the expansion tank.
end by:
a) install fuel filter housing
305
Oil Pump
Remove Oil Pump
start by:
a) remove fuel transfer pump
2. Drain the oil from the oil pan.
3. Remove fuel lines (1) and bracket (2) from the engine.
4. Remove bolts (3) and (5) to remove adapter (4) and tube (6) from the engine.
5. Remove bolts (7) to disconnect elbow (8) from the oil pump.
6. Remove bolts (9) to remove oil pump (10) and adapter (11) from the oil pump drive. The weight of the oil
pump is 39 kg (85 lb.).
Install Oil Pump
1. Make sure the O-ring seals are in position on adapters (3), (4) and elbow (2). Put clean engine oil on the
seals.
306
NOTE: The oil pump shaft must turn by hand and the pump must have oil for lubrication before it is
installed.
2. Put oil pump (1) and adapter (4) in position in the oil pump drive. Make sure the splines of the oil pump
are correctly engaged with the splines of the oil pump drive. Install the bolts that hold oil pump (1) and
adapter (4) in position.
3. Install the bolts that connect elbow (2) to oil pump (1).
4. Make sure O-ring seal (9) is in position on tube (8) and put clean engine oil on the seal.
5. Put tube (8) and adapter (6) with the gaskets for tube (5) and water pump (7) in position and install the
bolts.
6. Install fuel lines (10) and bracket (11) on the engine.
7. Fill the engine with oil to the correct level.
end by:
a) install fuel transfer pump
Disassemble Oil Pump
start by:
a) remove oil pump
1. Remove adapter assembly (1) from the pump.
Cover (2) has spring tension on it. Loosen the bolts that hold it slowly
and the same amount to remove the tension on the cover.
307
2. Remove the bolts, cover (2), gasket (3), spring (4) and valve spool (5) from the pump.
3. Remove cover assembly (6) and the gasket from the pump.
4. Remove cover assembly (7) from the pump.

5. Use tooling (A) to remove bearings (8) from cover assembly (7).
6. Remove shaft assemblies (10) from body assembly (9).

7. Use a press to remove gears (11) from the shaft assemblies.
8. Use tooling (A) to remove bearings (12) from body assembly (9).
308
Assemble Oil Pump
1. Make an alignment of bearings (1) so the joints are .45 ± 15° from a line through the center of the bearing
bores as shown.
2. Use tooling (A) to install bearings (1) in the body assembly until they are 1.5 ± 0.5 mm (.059 ± .020 in.)
below the gear bore in the body assembly. Check the inside diameter of the bearings after installation. The
diameter must be 31.837 ± 0.070 mm (1.2534 ± .0028 in.).
3. Heat gears (2) to a maximum temperature of 316°C (600°F).

4. Install the gears on shaft assemblies (3) until they are 34.0 ± 0.5 mm (1.34 ± .020 in.) from the cover end
of the shaft assemblies to the face of the gears and 47.0 ± 0.5 mm (1.85 ± .020 in.) from the fuel pump drive
end of shaft assembly (4).
5. Install shaft assemblies (3) and (4) in the body assembly.

309
6. Make sure dowels (5) and (8) are installed in cover assembly (6) so they extend 6 ± 0.5 mm (.236 ± .02 in.)
above the surface of the cover assembly.
7. Use tooling (A) and install bearings (7) in cover assembly (6) with the joints of the bearings in the
positions as shown.
8. Put cover assembly (6) in position and tighten the bolts to hold it to the body assembly.
9. Make sure the two pins in cover assembly (9) are installed so they extend 6 ± 1 mm (.236 ± .039 in.) above
the surface of the cover assembly. Install the gasket and cover assembly (9) on the pump.
10. Put clean engine oil on valve spool (13). Install valve spool (13), spring (12), gasket (11), cover (10) and
the bolts on the pump body.
11. Install the gasket and adapter assembly (14) on the pump body.
end by:
a) install oil pump
310
Oil Filter Housing

Remove Oil Filter Housing
start by:
a) remove expansion tank
1. Remove the bolts from adapter (1) to disconnect it from the oil filter housing.
2. Use tooling (A) to fasten a hoist to oil filter housing (2). Remove the bolts that hold the housing to the
support and remove the housing from the engine. The weight of oil filter housing (2) is 74 kg (165 lb.).
Install Oil Filter Housing
1. Use tooling (A) to fasten a hoist to oil filter housing (1). Put the housing in position on the support and
install the bolts to hold the housing in position.
2. Install the bolts to connect adapter (2) to the oil filter housing.
end by:
a) install expansion tank
311
Disassemble Oil Filter Housing

start by:
a) remove oil filter housing
1. Remove the bolts and remove cover (1) from the housing assembly.
2. Remove O-ring seal (2) from cover (1).
3. Remove ring (3) to remove retainer (4), the spring and the O-ring seal from cover (1).
4. Remove three element assemblies (5) from the housing assembly.

5. Remove O-ring seals (7) from housing (6) and remove the bolts to remove housing (6) from the housing
assembly. The weight of housing (6) is 25 kg (55 lb.).
6. Remove O-ring seal (8) from the housing.
Cover (10) has spring tension behind it. Slowly remove bolts (9) to
release the tension and prevent possible personal injury.
7. Slowly remove bolts (9) to release the spring tension behind cover (10) and remove cover (10) from the
housing.
8. Remove O-ring seals (11), spring (12) and the valve from the housing.
312
9. Remove the bolts and nuts to remove cover assembly (13) from the housing.
10. If necessary, remove pins (14) from cover assembly (13).
11. Remove O-ring seal (15) from the housing.

12. Remove plug (17) to remove valve (16) from the housing.
13. Remove adapter (18) from housing assembly (19).
Assemble Oil Filter Housing

1. Install O-ring seal (2) on adapter (1) and put clean engine oil on it. Install adapter (1) in the housing
assembly.
2. Install valve (3) in housing (4) as shown.

313
NOTE: If valve (3) has been installed wrong, plug (5) can not be installed correctly.
3. Put clean engine oil on the O-ring seal and install plug (5) in housing (4).
4. If pins (6) were removed, install the new pins in cover (7). Make sure they are 7 ± 0.5 mm (.275 ± .020 in.)
above the surface of the cover.
5. Install O-ring seal (8) on the housing and put clean engine oil on it.
6. Put cover (7) in position on housing (4) and make sure pins (6) are in alignment with the hole in housing
(4) and the groove (slot) in valve (3). Install the bolts and nuts to hold the cover in position.
7. Install valve (9) in housing (4). Install O-ring seals (10) in housing (4) and put clean engine oil on the
seals.
8. Put spring (12) in position and install cover (11) on housing (4).
9. Install O-ring seal (14) on housing (4) and put clean engine oil on it. Install housing (4) on housing
assembly (13).
10. Install O-ring seals (15) on housing (4) and put clean engine oil on the seals.
314
11. Put the O-ring seal, spring (17) and retainer (16) in position on cover (18).
12. Install ring (19) to hold the retainer and spring in position. Install O-ring seal (20) on cover (18) and put
clean engine oil on it.
13. Install three element assemblies (21) in housing assembly (13). Install cover (18) on housing assembly
(13).
end by:
a) install oil filter housing
315
Oil Pan
Remove And Install Oil Pan
1. Drain the oil from the engine.
2. Disconnect sump pump oil line (2) from the oil cooler.
3. Remove all the bolts that hold oil pan (1) to the engine. Lift the engine off of the oil pan or lower the oil
pan from the engine. The weight of the 3512 Oil Pan is 408 kg (900 lb.) and the weight of the 3508 Oil Pan is
240 kg (530 lb.). The weight of the 3512 Engine is approximately 5902 kg (13,000 lb.) and the weight of the
3508 Engine is approximately 4445 kg (9800 lb.).
4. Install two 3/8"-16 NC guide bolts (3) in each side of the oil pan. Put a gasket in position on the oil pan
and lift the engine on the oil pan or put the oil pan in position under the engine.
5. Remove the guide bolts and install all the bolts that hold the oil pan to the engine.
6. Connect sump pump oil line (2) to the oil cooler.

316
Disassemble Oil Pan

start by:
a) remove oil pan
1. Disconnect hose assembly (1) from the rear of the oil pan.
2. Remove bolts (2) and remove cover (3) from the front of the oil pan.
3. Remove screen assembly (4) and handle (6) from the oil pan and remove O-ring seals (5) from handle (6).
4. Remove bolt (7) and remove the handle from screen assembly (4).
5. Remove bolts (8) and remove oil level gauge (9) from the oil pan.
6. Remove bolts (12) to remove bell (11) from tube (10) and the oil pan.
7. Remove bolts (14) to remove housing (13) from tube (10) and the oil pan.
8. Remove tube (10) from the oil pan and remove O-ring seals (15) from the tube.
317
Assemble Oil Pan
1. Install O-ring seals (2) on tube (1) and put clean engine oil on the seals. Install tube (1) in the oil pan.
2. Install O-ring seal (4) on housing (3) and put clean engine oil on it. Put housing (3) in position and install
bolts and washers to hold it to the oil pan.
3. Push tube (1) into housing (3).
4. Push bell (5) in position over the end of tube (1) and install the bolts and washers to hold bell (5) in
position.
5. Put gasket (7) and oil level gauge (6) in position in the oil pan. Install the bolts and washers that hold
gauge (6) to the oil pan.
6. Put handle (10) in position on screen assembly (9) and install the bolt and washer to hold the handle in
position. Install O-ring seals (8) on handle (10) and put clean engine oil on the seals.
7. Install the screen assembly and handle in the oil pan.
8. Install O-ring seal (11) on cover (12) and put clean engine oil on the seal. Install cover (12) and the bolts to
hold it to the oil pan.
9. Connect hose assembly (13) to the oil pan.
end by:
a) install oil pan
318
Oil Sequence Valves

Remove And Install Oil Sequence Valves
start by:
a) remove front drive housing
b) remove flywheel housing
1. Remove cover (1) from the front of the cylinder block.

2. Remove plunger assembly (2) and spring (3) from the front of the cylinder block.
3. Remove the gear assembly, idler gear and shaft from over cover (4) on the rear of the cylinder block.
4. Remove cover (4) from the rear of the cylinder block.
5. Remove plunger assembly (5) and spring (6) from the rear of the cylinder block.
6. Put clean engine oil on spring (6) and plunger assembly (5) and install them as shown in the rear of the
cylinder block.
7. Install cover (4). Install the idler gear, shaft and gear assembly over cover (4) on the rear of the cylinder
block.
8. Put clean engine oil on spring (3) and plunger assembly (2) and install them in the front of the cylinder
block as shown.
9. Install cover (1) to hold the plunger assembly and spring in position.
end by:
a) install flywheel housing
b) install front drive housing
319
Oil Cooler
Remove Oil Cooler
1. Drain the coolant from the engine cooling system.
2. Drain the oil from the oil cooler.
3. Remove bolt (2) that holds the hose clip to the oil cooler.
4. Disconnect sump pump oil line (1) from the check valve.
5. Disconnect hose (3) from the gauge panel. Remove bolt (4) that holds the clip for hose (3) to the oil line
elbow.
6. Remove the bolts and retainers that hold tube (5) to elbow (6).
7. Remove the bolts and remove elbow (6) from the oil cooler.
8. Remove the four bolts to disconnect flange (7) and tube (8) from the water line adapter.
9. Remove the bolts to disconnect the oil cooler from bracket (9).
NOTE: Steps 10 and 11 are for the 3512 Engine.
3512 ENGINE
10. Remove the bolts to remove elbow (10) and the tube as a unit from oil cooler bonnet (11).
11. Fasten a hoist to oil cooler (13). Remove the two bolts from oil cooler bonnet (11) and pull oil cooler (13)
from oil tube (12). Remove the cooler from the engine. The weight of the oil cooler is 65 kg (145 lb.).
NOTE: Step 12 is for the 3508 Engines.

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12. Fasten a hoist to oil cooler (15). Remove the four bolts from oil cooler bonnet (16) and pull oil cooler
(15) from oil tube (14). Remove the cooler from the engine. The weight of the oil cooler is 50 kg (110 lb.).
Install Oil Cooler

NOTE: Step 1 is for the 3508 Engines.
1. Put clean engine oil on the O-ring seal on oil tube (2). Fasten a hoist to oil cooler (3) and put oil cooler (3)
in position on oil tube (2). Make sure the gasket is in place for oil cooler bonnet (1) and install the four bolts
to hold the oil cooler in position.
NOTE: Steps 2 and 3 are for the 3512 Engines.
3512 ENGINE
2. Put clean engine oil on the O-ring seal on oil tube (5). Fasten a hoist to oil cooler (6) and put oil cooler (6)
in position on oil tube (5). Install the two bolts in oil cooler bonnet (4) to hold the oil cooler in position.
3512 ENGINE
3. Put clean engine oil on the O-ring seal on tube (7). Put elbow (8) on tube (7) and install the tube and elbow
as a unit in oil cooler bonnet (4). Make sure the gasket is in place for elbow (8) and install the bolts to hold
the elbow to the engine.
4. Install the bolts that hold the oil cooler to bracket (9).
5. Make sure the gasket is in place and install the bolts to hold flange (11) and tube (10) to the water line
adapter.
321
6. Install the ring and O-ring seal on oil line (15). Install the O-ring seal on elbow (14). Put clean engine oil
on the O-ring seals.
7. Install elbow (14) on the oil cooler. Install the bolts and retainers to hold oil line (15) and the ring in elbow
(14).
8. Connect hose (12) to the gauge panel and install bolt (13) to hold the hose clip in position.
9. Install bolt (17) to hold the oil line clip to the oil cooler.
10. Connect oil sump pump oil line (16) to the check valve.
11. Fill the cooling system with oil to the correct level.
Disassemble Oil Cooler
start by:
a) remove oil cooler
1. Remove the bolts from elbow (1) and remove elbow (1) and tube (2) as a unit from the oil cooler.
2. Remove tube (2) from elbow (1) and remove the O-ring seals from tube (2) and elbow (1).
322
3. Put marks on bonnet (3) and core assembly (4) for correct alignment at assembly. Remove bonnet (3) from
core assembly (4).
4. Remove flange (7) and tube (6) as a unit from bonnet (5). Remove the O-ring seals from tube (6).
5. Remove the bolts and remove elbow (8) from core assembly (4).
6. Remove the bolts and remove cover (9) from elbow (8). Remove the O-ring seal from cover (9).
7. Remove spring (10) and plunger (11) from elbow (8).

8. Remove the bolts to remove cover (13) and remove O-ring seals (12) from elbow (8).
9. Put marks on bonnet (5) and core assembly (4) for correct alignment at assembly. Remove bonnet (5) from
core assembly (4).
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Assemble Oil Cooler

1. Make sure the tubes in core assembly (1) are clean and free of dirt and foreign material.
2. Put the gasket and bonnet (2) in position on core assembly (1) and install the bolts.
3. Install O-ring seals (4) on elbow (3) and put clean engine oil on the seals. Install cover (5) on elbow (3).
4. Put plunger (7) and spring (8) in position in elbow (3). Install the O-ring seal in cover (6) and put clean
engine oil on it. Install cover (6) on elbow (3).
5. Put elbow (3) in position on the core assembly and install the bolts.
6. Install the O-ring seals on tube (9) and put clean engine oil on the seals. Install tube (9) and flange (10) as
a unit in bonnet (2).
7. Put the gasket and bonnet (11) in position on core assembly (1) and install the bolts.
8. Install the O-ring seals on tube (13) and put clean engine oil on the seals. Install tube (13) in elbow (12).
9. Install the O-ring seal on elbow (12) and put clean engine oil on it. Put elbow (12) and tube (13) as a unit
324
in position and install the bolts in elbow (12) to hold the elbow and the tube in position.
end by:
a) install oil cooler
325
Oil Sump Pump And Check Valve (An Attachment)

Remove Oil Sump Pump And Check Valve
1. Disconnect hose assembly (1) from the adapter and engine oil cooler bypass elbow (2).
2. Remove bolts (3) that hold adapter (5) and hose assembly (4) in position. Remove adapter (5) from the
engine oil cooler bypass elbow.
3. Use a hammer and punch to push spring pin (9) out of pin (8) and adapter (5). Remove pin (8), spring (7)
and valve (6) from adapter (5).
4. Disconnect hose assembly (1) from the valve assembly. Disconnect hose assembly (12) from the elbow.
5. Remove the bolts that hold pump (10) to bracket (11) and remove pump (10).
Install Oil Sump Pump And Check Valve
1. Put pump (1) and the oil lines in position. Install the bolts to hold the unit to bracket (5).
2. Connect hose (4) to elbow (3). Connect hose (6) to valve assembly (2).
3. Install spring (8) and valve (7) on pin (9). Make sure the tapered end of valve (7) is toward adapter (10).
326
4. Put pin (9) in position in adapter (10) and install spring pin (11) to hold the unit together. Push pin (11)
through pin (9) until pin (9) is in the center of the bore in adapter (10).
5. Make sure O-ring seal (12) is in position on the engine oil cooler bypass elbow and put clean engine oil on
it.
6. Put adapter (10) in position and install the bolts to hold it and the clip for hose assembly (13).
7. Connect hose assembly (6) to adapter (10).

8. If necessary, add clean engine oil to the correct level in the engine.
327
Oil Sump Pump (An Attachment)

Disassemble Oil Sump Pump
start by:
a) remove oil sump pump
1. Remove nut (1) and handle assembly (2) from the pump shaft.
2. Remove plastic packing nut (4), two bolts (3) and head (5) from the pump cylinders.
3. Remove shaft (6) from head (5).

4. Remove packing (7) from head (5).
5. Remove rotor (8), vanes (9) and the springs from the pump cylinder.
328
Assemble Oil Sump Pump

1. Put clean engine oil on the parts of the pump at assembly.
2. Install shaft (2) in pump head (1).

3. Install rotor (3) in pump cylinder (4) with the grooves for the pin in shaft (2) up as shown.
4. Install springs (5) and carbon vanes (6) in rotor (3).

5. Install head (1) and gasket (of the correct thickness) on cylinder (4). Make sure pin (7) engages correctly
with one of the notches (8) in the rotor. Install the two bolts that hold head (1) to cylinder (4).
NOTE: A new gasket set has three thicknesses of gasket. The identification is as follows: no holes or two
punched holes for 0.05 mm (.002 in.), three punched holes for 0.08 mm (.003 in.), four punched holes for
0.10 mm (.004 in.). For replacement, use a gasket of a thickness that will let the pump rotor turn freely. If a
too thick gasket is used, the pump can lose its vacuum or priming ability.
6. Install packing (10) around the pump shaft. Install nut (9) in the pump head to hold packing (10) in place.
7. Put handle assembly (11) in position and install the nut to hold it to shaft (2).
end by:
a) install oil sump pump
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Governor
Remove Governor
1. Remove manual shutoff (3) from the drive housing. See REMOVE MANUAL SHUTOFF.
2. Disconnect wiring harness (1) and hose assemblies (2) from the governor.
3. Remove the bolt and washer to remove clip (4) from the drive housing.
4. Remove bolts (5) that hold cover (6) to the drive housing.
5. Remove bolts (8) to remove governor (7) and cover (6) from the governor drive and drive housing. The
weight of the governor is 23 kg (50 lb.).
Install Governor
1. Put gaskets (1) and (3) in position. Use a hoist or two men to put governor (5) in position. Make sure the
pin in the lever assembly engages the groove (slot) of lever (2) for the fuel control. Make sure the splines on
the governor drive shaft are engaged correctly in the governor drive and install the bolts to hold governor (5)
and cover (4) in position.
2. Put clip (8) in position and install the bolt and washer to hold it to the drive housing.
3. Install the manual shutoff in the drive housing. See INSTALL MANUAL SHUTOFF.
4. Connect wiring harness (6) and tube assemblies (7) to the governor.
330
Governor Drive
Remove And Install Governor Drive
start by:
a) remove governor
1. Remove bolts (2) and pull governor drive (1) from the front drive housing.
2. Make sure the O-ring seals are in position on the front of governor drive (1) and put clean engine oil on the
seals.
3. Put governor drive (1) in position and install bolts (2) to hold it to the front drive housing.
end by:
a) install governor
Disassemble Governor Drive
start by:
a) remove governor drive
1. Remove O-ring seals (1), (2) and (3) from the front of the governor drive housing.
2. Remove the bolts that hold adapter (4) in position and pull adapter (4) from the housing.
3. Remove pinion (5), shims (6), seals (7) and (8) from adapter (4). Make a measurement of the thickness of
shims (6) and put identification on them for assembly purposes.
331
4. Remove hose assembly (9), cover (11) and the gasket from governor drive housing (10).
5. Remove gear (13) and coupling (12) from housing (10) as a unit.
6. Remove ring (14) to remove coupling (12) from gear (13).

7. If necessary, remove bearing (15) from housing (10).
Assemble Governor Drive
1. Make an alignment of the oil hole in the bearing with the drilled oil passage in governor drive housing (1).
Use tool group (A) and install the bearing in housing (1) until it is 1.0 ± 0.5 mm (.039 ± .020 in.) below the
inside surface of the housing.
332
2. Put coupling (3) in position in gear (2) and install ring (4) to hold the gear and coupling as a unit.
3. Install coupling (3) and gear (2) as a unit in housing (1).
4. Install pinion (5) in adapter (6).

5. Put adapter (6) and shims (7) of the original thickness in position and install the bolts to hold the unit
together.
6. Make an adjustment of the gear clearance (backlash) between gear (2) and the pinion as follows:
a) Install tool group (B) on gear (2) as shown to check the gear clearance (backlash) at four locations
around gear (2) 90° apart.
b) Hold the pinion in position and push down while gear (2) is moved back and forth. Make a record of
the indications on tool group (B) and use the lowest indication as the correct gear clearance (backlash)
value. The correct gear clearance (backlash) is 0.100 + 0.050 or - 0.025 mm (.0039 + .0020 or - .0010
in.).
c) Add or subtract shims (7) as necessary until the gear clearance (backlash) is correct.
7. Remove tool group (B), the adapter and pinion from the housing.
333
8. Connect hose assembly (8) to housing (1). Put the gasket and cover (9) in position and install the bolts and
washers to hold them to housing (1).
9. Install seals (10) and (11) on adapter (6) and put clean engine oil on them.
10. Install the correct amount of shims (7) and adapter (6) with the pinion in housing (1) and tighten the bolts.
11. If necessary, make a replacement of pins (14). Make sure the pins are 14 ± 1 mm (.55 ± .04 in.) above the
surface of the housing.
12. Install O-ring seal (12) and seals (13) on the front of the housing. Put clean engine oil on the seals.
end by:
a) install governor
334
Turbochargers
Remove Turbochargers
start by:
a) remove air cleaner housings
1. Remove air cleaner housing support (1) from the back of the exhaust elbow.
2. Drain the coolant from the engine cooling system.
3. Disconnect water lines (4) from the bottom of the turbochargers.
4. Remove oil drain lines (5) and oil supply lines (2) from the engine.
5. Remove clamps (3) and the seals that connect the turbochargers to the exhaust elbow.
6. Disconnect water lines (7) and (9) from the top of the turbochargers.
7. Remove all of bolts (6) and bolts (8) that hold two pipes (10) to the air shutoff housing and exhaust
manifolds. Remove pipes (10) from each side of the engine.
8. Fasten a hoist to turbocharger (11). Remove the locknuts that hold turbocharger (11) to exhaust manifold
(12).
9. Pull turbocharger (11) out of the exhaust elbow. There is an adapter that connects turbocharger (11) to the
exhaust elbow and can be removed with the turbocharger. Remove turbocharger (11) from the engine. The
weight of the 3512 Turbocharger is 59 kg (130 lb.). The weight of the 3508 Turbocharger is 34 kg (75 lb.).
335
Install Turbochargers
1. Make sure the studs for turbochargers (1) are tightened to a torque of 30 ± 5 N·m (22 ± 4 lb.ft.).
2. Install the gaskets on the ends of exhaust manifolds (2) and put 5P3931 Anti-Seize Compound on the
threads of the studs.
3. Fasten a hoist and put turbocharger (1) and the adapter in position in the exhaust elbow and on exhaust
manifold (2). Install the locknuts to hold the unit in position.
4. Connect upper water lines (3) and (5) to the turbochargers.

5. Make sure the O-ring seals are installed on the ends of pipes (4). Put clean engine oil or glycerine in the
bores for the O-ring seals for installation.
6. Put pipes (4) and the gaskets in position. Install the bolts to hold pipes (4) and the flanges to the air shutoff
housing and exhaust manifolds.
7. Install oil supply lines (6) and oil drain lines (8) with the gaskets.
8. Connect lower water lines (7) to the turbochargers.
9. Install seal (10) and clamp (9) around each exhaust elbow adapter.
10. Install the support for the air cleaner housings.
end by:
a) install air cleaner housings
336
Turbochargers (3512)
Disassemble Turbochargers (Airesearch TW81)
start by:
1. Put the turbocharger in position on tool group (A) as shown. Put marks on the three housings of the
turbocharger for correct installation and alignment at assembly.
2. Loosen clamp (2) and remove compressor housing (1) and the clamp from the cartridge assembly.
3. Loosen clamp (5) and remove cartridge assembly (3) from turbine housing (4).
NOTICE
To prevent a bent shaft, do not put a side force on the turbine shaft
when the compressor wheel nut is loosened.
4. Put the end of the turbine shaft in tool (B). Use a universal joint and socket of the correct size to remove
the nut that holds compressor wheel (6) on the turbine shaft.
5. Use a press and push the turbine shaft out of compressor wheel (6) and the cartridge housing. Remove
compressor wheel (6) from the cartridge housing.
337
6. Remove seal ring (8) and shroud (9) from turbine shaft (7).
7. Bend the tabs of the locks from bolts (10) and remove the bolts.
8. Remove backplate assembly (11) from the cartridge housing. Make a note of the position of the oil holes in
the backplate assembly and cartridge housing for correct alignment at assembly.
9. Remove spacer (12) from backplate assembly (11).

10. Remove seal rings (13) from spacer (12).
11. Remove thrust collar (14) and seal ring (15) from the cartridge housing.
12. Remove thrust bearing (16) from the cartridge housing.
NOTE: If the bearings are to be used again, put identification on them as to their location for correct
assembly.
13. Remove bearing (17) and the washer below the bearing from the cartridge housing.
338
14. Use tool (C) and remove snap rings (18) and (19) from the cartridge housing.
15. Remove bearing (20) and washer (21) from the cartridge housing.
16. If necessary, use tool (C) and compress the end snap ring and push it out of the bearing bore toward the
compressor end of the cartridge housing to remove it.
Assemble Turbochargers (Airesearch TW81)
1. Make sure all of the oil passages in the turbocharger cartridge housing, backplate assembly and bearings
are clean and free of dirt and foreign material.
2. Put clean engine oil on all parts of the cartridge at assembly.
NOTE: Make sure the round edge of the snap rings are toward the bearings when the snap rings are installed.
3. Use tool (A) and install snap ring (1) in the turbine end of the cartridge housing.
4. Install washer (2) and bearing (3). Use tool (A) to install snap ring (4) to hold the washer and bearing in
position.
5. Use tool (A) and install snap ring (5) in the cartridge housing.
339
6. Install washer (7) and bearing (6) in the cartridge housing until washer (7) makes contact with snap ring
(5).
7. Install thrust bearing (8) over the dowels in the cartridge housing. Make sure the grooves in bearing (8) are
toward the outside as shown.
8. Install seal ring (9) in the groove of the cartridge housing.

9. Put thrust collar (10) in position on the thrust bearing with the counterbore for the spacer up.
10. Install seal rings (11) on spacer (12) so the gaps in the rings are 180° apart.
11. Install spacer (12) in backplate assembly (13).
12. Make sure oil passage (14) in the cartridge housing and oil passage (15) in the backplate assembly are in
340
alignment. Put backplate assembly (13) in position on the cartridge housing. Make sure the spacer fits
correctly in the counterbore of the thrust collar.
13. Install the locks and bolts to hold backplate assembly (13) to the cartridge housing. Tighten the bolts to a
torque of 10 ± 1 N·m (7 ± 1 lb.ft. and bend the tabs of the locks on the bolts.
14. Put the turbine shaft in position in tooling (B). Put 6V2055 High Vacuum Grease in the groove for seal
ring (16). Make sure the grease fills the groove approximately one half or more of the groove depth for the
complete circumference of the groove to help make a carbon dam under the seal ring. Install seal ring (16)
and shroud (17) on the turbine shaft.
15. Install the cartridge housing on the turbine shaft while spacer (12) is held in position. Make sure the seal
ring on the turbine is fitted correctly in the cartridge housing.
16. Put compressor wheel (18) in position on the turbine shaft.
NOTICE
Do not put a side force on the turbine shaft when the nut is tightened
or a bent shaft will be the result.
17. Put a small amount of oil on the turbine shaft threads and the compressor wheel face that will be under
the nut. Install the nut and tighten it to a torque of 14 to 17 N·m (124 to 150 lb.in.) to push the compressor
wheel (18) on the shaft. Loosen the nut and tighten it again to 3.5 N·m (31 lb.in.). Tighten the nut 120° of a
turn more.
18. Put the cartridge housing in a vise as shown. Check the shaft end play with tool group (C). The shaft end
341
play must be 0.08 to 0.25 mm (.003 to .010 in.).
19. Install turbine housing (19) on tool group (D) as shown. Put the cartridge and clamp (20) in position in
turbine housing (19). Make sure the marks on the housing and cartridge are in alignment and tighten clamp
(20) to a torque of 14.0 ± 1.5 N·m (124 ± 13 lb.in.). Lightly hit all around the clamp with a soft faced
hammer and again tighten clamp nut to same torque.
20. Install clamp (22) and compressor housing (21) on the cartridge in the correct position. Move clamp (22)
into position and tighten the nut to a torque of 14.0 ± 1.5 N·m (124 ± 13 lb.in.). Lightly hit all around the
clamp with a soft faced hammer and again tighten clamp nut to the same torque.
end by:
342
Turbochargers (3508)
Disassemble Turbochargers (Airesearch TW61)
start by:
1. Put the turbocharger in position on tool group (A). Put marks on the three housings of the turbocharger for
correct installation and alignment at assembly.
2. Loosen clamp (2) and remove compressor housing (1) and the clamp from the cartridge assembly.
3. Loosen clamp (3) and remove cartridge assembly (5) from turbine housing (4).
NOTICE
To prevent a bent shaft, do not put a side force on the turbine shaft
when the compressor wheel nut is loosened.
4. Install tool (C) in tool (B) and put the cartridge assembly in tool (C) as shown. Use tool (D) to remove the
nut that holds compressor wheel (6).
343
5. Use a press to push the turbine shaft out of compressor wheel (6) and the cartridge housing. Remove
compressor wheel (6) from the cartridge housing.
6. Put the turbine shaft in tool (C). Remove seal ring (8) and shroud (7) from the shaft.
7. Use tool (E) to make sure the turbocharger shaft is straight. See SPECIAL INSTRUCTION Form No.
SMHS6998.
8. Bend the tabs of the locks from bolts (10) and remove the bolts and locks.
9. Remove backplate assembly (11) from the cartridge housing. Remove spacer (9) from backplate assembly
(11).
10. Remove seal rings (12) from spacer (9).

11. Remove thrust collar (13) from the cartridge housing.
12. Remove seal ring (14) and thrust bearing (15) from the cartridge housing.
NOTE: If the bearings are to be used again, put identification on them as to their location for correct
assembly.
13. Remove bearing (16) and the washer below the bearing from the cartridge housing.
344
14. Use tool (F) to remove snap rings (17) and (18) from the cartridge housing.
15. Remove bearing (19) and washer (20) from the cartridge housing.
16. Use tool (F) to remove snap ring (21) from the cartridge housing if necessary.
17. Check all the parts of the turbocharger for damage. If the parts have damage, use new parts for
replacement. See SPECIAL INSTRUCTION Form No. SMHS6854 for TURBOCHARGER
RECONDITIONING. Also see GUIDELINE FOR REUSABLE PARTS Form No. SEBF8018.
Assemble Turbochargers (Airesearch TW61)
1. Make sure all of the oil passages in the turbocharger cartridge housing, backplate assembly and bearings
are clean and free of dirt and foreign material.
2. Put clean engine oil on all parts of the cartridge at assembly.
NOTE: Make sure the round edge of the snap rings are toward the bearings when the snap rings are installed.
3. If necessary, use tool (A) to install snap ring (1) in the turbine end of the cartridge housing.
4. Install washer (2) and bearing (3). Use tool (A) to install snap ring (4) to hold the washer and bearing in
position.
5. Use tool (A) and install snap ring (5) in the cartridge housing.
345
6. Install the washer and bearing (6) in the cartridge housing until the washer makes contact with snap ring
(5).
7. Install thrust bearing (8) over the dowels in the cartridge housing. Make sure the grooves in bearing (8) are
toward the outside as shown.
8. Install seal ring (9) in the groove of the cartridge housing.
9. Put thrust collar (7) in position on the thrust bearing with the counterbore for the spacer up.
10. Install seal rings (10) on spacer (11) so the gaps in the rings are 180° apart.
11. Install spacer (11) in backplate assembly (12) with the chamfer end of the spacer toward the cartridge
housing.
12. Make sure the oil passage in the cartridge housing and the backplate assembly are in alignment. Put the
backplate assembly (12) in position on the cartridge housing.
13. Install the locks and bolts to hold backplate assembly (12) to the cartridge housing. Tighten the bolts to a
torque of 10 ± 1 N·m (90 ± 10 lb.in.) and bend the tabs of the locks on the bolts.
14. Put the turbine shaft in position in tooling (C). Put 6V2055 High Vacuum Grease in the groove of seal
ring (14). Make sure the grease fills the groove approximately one half or more of the groove depth for the
complete circumference of the groove to help make a carbon dam under the seal ring. Install seal ring (14)
and shroud (15) on turbine shaft (13).
15. Install the cartridge housing on the turbine shaft while spacer (11) is held in position. Make sure the seal
ring on the turbine is fitted correctly in the cartridge housing.
16. Put compressor wheel (16) in position on the turbine shaft.
346
NOTICE
Do not put a side force on the turbine shaft when the nut is tightened
or a bent shaft will be the result.
17. Put a small amount of oil on the turbine shaft threads the compressor wheel face that will be under the
nut. Install the nut and tighten it to a torque of 13.6 N·m (120 lb.in.) to push the compressor wheel (16) on
the shaft. Loosen the nut and tighten it again to 3.4 N·m (30 lb.in.). Tighten the nut 120° of a turn more.
18. Put the cartridge housing in a vise as shown. Check the shaft end play with tool group (D). The shaft end
play must be 0.08 to 0.25 mm (.003 to .010 in.).
19. Install turbine housing (17) on tool group (E) as shown. Put the cartridge and clamp (18) in position in
turbine housing (17). Make sure the marks on the housing and cartridge are in alignment and tighten clamp
(18) to a torque of 13.6 ± 1.1 N·m (120 ± 10 lb.in.). Lightly hit all around the clamp with a soft faced
hammer and again tighten clamp nut to same torque.
20. Install clamp (20) and compressor housing (19) on the cartridge in the correct position. Move clamp (20)
into position and tighten the nut to a torque of 13.6 ± 1.1 N·m (120 ± 10 lb.in.). Lightly hit all around the
clamp with a soft faced hammer and again tighten clamp nut to the same torque.
end by:
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Exhaust Manifolds
Remove Exhaust Manifolds
start by:
1. Fasten a hoist to the exhaust manifold with tooling (A).

2. Remove bolts (1) that hold the front of the manifold to the water lines housing.
3. Remove bolts (2) that hold the water lines to the manifold.
4. Remove bolts (3) that hold the manifold to the cylinder heads. Most of the upper bolts (3) can not be
removed for lack of clearance to the aftercooler housing; make sure these bolts are completely loosened
before the manifold is lifted.
5. Remove exhaust manifold (4) from the engine. The weight of the 3512 Exhaust Manifold is 96 kg (212
lb.). The weight of the 3508 Exhaust Manifold is 68 kg (149 lb.).
348
Install Exhaust Manifolds
1. Install O-ring seal (2) in the water lines housing. Install O-ring seals (4) in the water line elbows. Put a
small amount of engine oil or glycerine on all of the O-ring seals as lubrication.
2. Put 5P3931 Anti-Seize Compound on the threads of all manifold bolts (5). Put the upper manifold bolts
and washers in position in manifold (1).
3. Put manifold gaskets (3) in position on the cylinder heads.
4. Fasten a hoist to manifold (1) and put it in position.
5. Install bolts (5), (7) and washers to hold the manifold to the cylinder heads and water lines housing.
6. Install bolts (8) to hold the water line elbows to manifold (1).
7. Put 5P3931 Anti-Seize Compound on the threads of studs (6) and make sure they are tightened to a torque
of 30 ± 5 N·m (22 ± 4 lb.ft.) in the ends of manifolds (1).
end by:
349
Aftercooler
Remove Aftercooler
2. Remove fuel lines (1) from the engine.

3. Disconnect junction box (2) from the brackets that hold it to the engine and fasten it to the engine as shown
in illustration B36292X1.
4. Remove oil tube (3) from the engine.
5. Remove water tube (4) and remove bolts (5) that hold water line (6) to adapter (7).
6. Remove bolts (8) and remove water line (6) from the engine.
7. Remove elbow (9) from the aftercooler housings.

8. Remove bolts (10) and remove adapter (7) from the aftercooler housings.
350
9. Remove sleeve (11) and adapter (12) from both ends of the aftercooler housings.
10. Remove bolts (13) to disconnect air lines (16) from air intake shutoff housing (15) and exhaust manifolds
(17). Disconnect wiring harness (14).
11. Use tooling (A) to fasten a hoist to aftercooler housings (18). Remove the bolts that hold the aftercooler
housings to the engine and remove aftercooler housings (18). The weight of the 3512 Aftercooler Housings is
82 kg (180 lb.). The weight of the 3508 Aftercooler Housings is 36 kg (80 lb.).
NOTICE
Be careful when the aftercooler core assembly is removed the lower

part of the core is held in position by a connector and O-ring seals.
12. Fasten a hoist to aftercooler core assembly (19). Remove bolts (20) and remove the core assembly. The
weight of the 3512 Core Assembly is 52 kg (115 lb.) and the weight of the 3508 Core Assembly is 29 kg (65
lb.).
13. Remove pipes (21) from both ends of the aftercooler core. Remove the O-ring seals from the pipes.
14. Remove O-ring seals (22) from each end of the core assembly.
351
15. Remove ring (23) to remove connector (24) from the core assembly. Remove the O-ring seals from
connector (24).
Install Aftercooler
NOTE: Clean and inspect all of the O-ring seals and gaskets. Make a replacement of any worn or damaged
seals and gaskets.
1. Install the O-ring seals on connector (2) and put clean engine oil on the seals. Put connector (2) in position
and install ring (3) to hold the connector in the core assembly.
2. Install O-ring seals (1) on the ends of the core assembly and put clean engine oil on the seals.
3. Install the O-ring seals on pipes (4) and put clean engine oil on the seals. Install pipes (4) on the ends of
the aftercooler core assembly.
4. Fasten a hoist to the aftercooler core assembly as shown and put it in position on the engine. Make sure
connector (2) is correctly engaged with adapter (5) in the cylinder block. Install the bolts to hold the core
assembly in position.
NOTE: If the aftercooler housings were taken apart and new gaskets installed, cut the gaskets even with the
bottom of the housings.
352
5. Fasten a hoist to aftercooler housings (6) with tooling (A). Put housings (6) and the gasket in position and
install the bolts to hold the housings in position. Tighten the bolts to a torque of 55 ± 7 N·m (40 ± 5 lb.ft.).
6. Connect air lines (8) to the air intake shutoff housing and install the bolts to connect the air lines to exhaust
manifolds (9). Connect wiring harness (7).
7. Put clean engine oil on O-ring seal (10) and install adapter (11) in both ends of the aftercooler housings.
8. Install sleeve (12) in adapter (11) at both ends of the aftercooler housings.
9. Put clean water on the O-ring seal and install elbow (13) in the aftercooler housings.
10. Put clean water on O-ring seal (15) and install adapter (14) in the aftercooler housings.
11. Put clean water on the O-ring seals and install water line (16) on the engine.
12. Install oil tube (18) on the engine. Connect junction box (19) to brackets (17) with the bolts that hold it to
brackets (17).
13. Install water tube (21) on adapter (14) and regulator housing (20).
14. Install fuel lines (22) on the engine.
15. Fill the engine with coolant to the correct level.
353
Hydramechanical Shutoff Control (An Attachment)

354
Remove Hydramechanical Shutoff Control
1. Disconnect tube assemblies (2) from diverter valve (3) and disconnect tube assemblies (1) from the shutoff
control.
2. Remove the bolts to remove cover (5), tube (4) and the diverter valve as a unit from the shutoff drive
housing assembly and the shutoff control.
3. Disconnect tube assemblies (6), (7) and (9) from the shutoff control. Remove the bolts and
hydramechanical shutoff control (8) from the shutoff drive housing assembly.
4. Remove coupling (10) from the end of the shutoff drive gear.
Install Hydramechanical Shutoff Control
1. Install coupling (2) on the end of the shutoff drive gear.

2. Put hydramechanical shutoff control (1) and the gasket in position on the shutoff drive housing assembly.
Make sure the shaft of the shutoff control is correctly engaged with the coupling and install the bolts to hold
the shutoff control in position.
3. Connect tube assemblies (3), (4) and (5) to the shutoff control.
355
4. Put clean engine oil on the O-ring seals and install tube (6) in the bottom of the shutoff control. Put cover
(7) and the diverter valve as a unit in position on tube (6) and the shutoff drive housing assembly. Install the
bolts to hold these in position.
5. Connect tube assemblies (8) to the shutoff control and connect tube assemblies (9) to the diverter valve.
Disassemble Hydramechanical Shutoff Control
start by:
a. remove hydramechanical shutoff control
1. Remove the bolts and remove actuator valve (1) from the pressure control valve.
NOTICE
There is spring pressure on cover (2).
2. Remove the bolts and remove cover (2) from the actuator valve body.
356
3. Remove springs (4), spacer (5) and valve assemblies (3) from the valve body.
4. Remove tube assembly (7) from the shutoff control.

5. Remove pressure control valve (6) from the shutoff control.
6. Put identification marks on valve assemblies (12) and (13) for assembly purposes. Remove rack shutoff
valve (12) and air inlet shutoff valve (13) from the pressure control body assembly. Remove three O-ring
seals from each valve.
7. Remove plug (11) to remove pilot valve (10) and spring (9) from the pressure control body assembly.
8. Remove manual shutoff valve (8) as a unit from the pressure control body assembly.
9. Loosen nut (16) to remove knob (17) and nut (16) from valve (14). Remove adapter (18) and spring (19)
from valve (14). Remove O-ring seal (15) from adapter (18).
10. Remove seal (20) from adapter (18).
11. Remove eight bolts (22) to remove gerotor pump group (21) from the shutoff control housing assembly.
12. Use tool (A) to remove ring (24) and the washer from the carrier assembly shaft.
NOTE: Do not remove bolts (23) at this time.

357
13. Remove carrier assembly (25) from the gerotor pump group.
14. Remove dowels (27) to remove weights (26) from carrier (25). Remove pin (28) and use a press to
remove shaft (29) from carrier (25).
15. Remove washer (30) from the pump group.

16. Remove the two bolts (23) to remove cover assembly (31) from the plate.
17. Remove gasket (32) from the plate.

18. Remove plate (33) from the housing assembly.
19. Remove seal (34) from plate (33).
NOTE: Carefully remove driven gear (36) from sleeve (35) so brush (39) and spring (38) do not become
lost.
358
20. To remove the gerotor assembly, remove drive gear (37), driven gear (36) and sleeve (35) from the
housing assembly.
21. Remove brush (39) and spring (38) from driven gear (36).
22. Use tool (B) to remove snap ring (43) and remove seat (42), spring (41) and plunger assembly (40) from
the housing assembly.
23. Remove O-ring seal (44) from the housing assembly.

24. Remove speed sensing valve (46), spring (45) and the seat from the housing assembly guide.
25. Remove ring (50) to remove race (49), bearing (51) and race (48) from seat (52). Loosen nut (47) to
remove seat (52) and nut (47) from speed sensing valve (46).
26. Remove shaft (53) to remove lever (54) from the housing assembly.
359
27. Remove the wire seal and bolts (55) to remove cover (56), the two seats and the spring from the housing
assembly.
28. Use tool group (C) to remove the guide from the housing assembly.
Assemble Hydramechanical Shutoff Control
1. If necessary, make a replacement of dowels (2) and make sure they are 3.0 ± 0.5 mm (.118 ± .020 in.)
above the surface of the housing assembly.
2. Put guide (1) in position in the housing assembly and make sure the dash mark on the end of the guide is in
alignment with hole (3). Use tool group (A) to install guide (1) in the housing assembly.
3. Put lever (5) in position in the housing assembly as shown and install shaft (4) to hold lever (5) in position.
Make sure the end of the shaft is even (flush) ± 0.25 (.010 in.) with the housing assembly.
4. Put the seat, spring (7) and seat (6) in position in cover (8) and put cover (8) and the gasket in position on
the housing assembly. Install the bolts to hold the cover in position.
5. Install nut (15) and seat (10) on speed sensing valve (9). Make sure the dimension between the end of the
valve and the nut face of the seat is 117.21 ± 0.25 mm (4.614 ± .010 in.) and tighten the nut. Put race (14),
bearing (11) and race (13) in position on seat (10) and install ring (12) to hold these in position.
360
6. Install seat (16), spring (17) and speed sensing valve (9) on the housing assembly guide.
7. Put clean engine oil on O-ring seal (18) and put O-ring seal (18), plunger assembly (19), spring (20) and
seat (21) in position in the housing assembly. Use tool (B) to install snap ring (22) to hold the plunger
assembly, the spring and seat in position.
8. If necessary, make a replacement of pin (24) and make sure pin (24) is 3.96 ± 0.50 mm (.156 ± .020 in.)
above the bottom surface of the bore.
9. Install the gerotor assembly as follows:
a) Install sleeve (23) and make sure the groove (slot) on sleeve (23) is in alignment with pin (24).
b) Put the spring and brush (26) in position in the driven gear (25). Install driven gear (25) in the sleeve.
c) Install drive gear (27) in the driven gear.
10. Install seal (29) on plate (28) and put clean engine oil on it.
11. Install plate (28) on the housing assembly.
above the surface of the cover assembly.
361
13. Put gasket (32) in position and install cover assembly (30) on the plate.
14. Use a press to install shaft (37) in carrier (35) until dimension (X) is 84.08 ± 0.25 mm (3.310 ± .010 in.).
NOTE: If either or both the shaft and the carrier are new, a hole 3.175 + 0.051 - 0.000 mm (.125 + .002 -
.000 in.) in diameter must be drilled through either or both the shaft and the carrier at location (Z) and
dimension (Y) must be 5.0 ± 0.5 (.197 ± .020 in.). This must be done before Step 15 can be done.
15. Install pin (36) to hold the shaft and carrier in position.
16. Put weights (33) in position on carrier (35) and install dowels (34) to hold the weights. Each weight must
move freely on its dowel and must have 0.02 to 0.18 mm (.001 to .007 in.) end play after assembly. Put
marks (counterpunch) four places around both ends of the dowels.
17. Install washer (38) on the cover assembly and put carrier assembly (35) in position in the gerotor pump
group.
18. Put the washer in position and use tool (C) to install snap ring (39) on the carrier assembly shaft.
19. Install two bolts (40) to hold the gerotor pump group together as a unit.
20. Put gerotor pump group (41) in position on the housing assembly. Make sure the speed sensing valve is
correctly engaged with the carrier assembly and install the eight bolts to hold the pump in position.
above the surface of the valve body.
22. Put spring (44) and pilot valve (43) in position in the valve body. Put clean engine oil on the O-ring seal
and install plug (42) to hold the spring and pilot valve in position.
362
23. Install three O-ring seals on air inlet shutoff valve (46) and put clean engine oil on the seals. Install valve
(46) in the valve body and tighten it to a torque of 58 ± 4 N·m (43 ± 3 lb.ft.).
24. Install three O-ring seals on rack shutoff valve (47) and put clean engine oil on the seals. Install valve
(47) in the valve body and tighten it to a torque of 58 ± 4 N·m (43 ± 3 lb.ft.).
25. Install the seal in adapter (48) with tool group (A). Make sure the lip of the seal is toward the valve body
as shown.
26. Install O-ring seal (50) on adapter (48) and put clean engine oil on it. Install spring (53), adapter (48), nut
(51) and knob (52) on manual shutoff valve (49). Tighten the nut to hold the knob on the valve.
27. Install manual shutoff valve (49) as a unit in the valve body.
28. Put pressure control valve (55) and the gasket in position on the shutoff control.
29. Install tube assembly (54) on the shutoff control.
30. Put four valve assemblies (56), three springs (57) and spacer (60) in position in the actuator valve body.
Install gasket (58), cover (59) and the bolts to hold the valves, the springs and spacer in position.
363
31. Put the gasket, actuator valve (61) and the bolts in position on the pressure control valve. Tighten the
bolts to hold the actuator valve and the pressure control to the shutoff control.
32. See CATERPILLAR FUEL INJECTION TEST BENCH, Form No. SEHS7465 Section IV, X for the
correct procedure to adjust the hydramechanical shutoff control after assembly.
end by:
a) install hydramechanical shutoff control.
364
Hydramechanical Shutoff Drive (An Attachment)

Remove Hydramechanical Shutoff Drive
start by:
a) remove hydramechanical shutoff control
b) remove tachometer drive
1. Remove tube assemblies (1) and (2) from the shutoff drive housing assembly and the engine.
2. Remove the bolts and remove shutoff drive housing assembly (3) from the flywheel housing.
3. Use tool (A) to remove snap ring (5) and the washer from the end of drive gear (4). Remove drive gear (4)
from the housing assembly.
4. If necessary, remove dowels (6) from the housing assembly.
5. Remove bearing (9) and seal (7) from the housing assembly. The bearing can be used to push the seal out
of the bore.
6. Remove two bearings (8) from the drive gear bore.
7. If necessary, remove dowels (10) from the housing assembly.
8. Remove gear assembly (11) from the end of the crankshaft.

365
Install Hydramechanical Shutoff Drive
1. If necessary, make a replacement of dowels (1) in gear assembly (2). The dowels must extend 9.5 ± 0.5
mm (.374 ± .020 in.) from the gear. Put gear assembly (2) in position on the end of the camshaft and install
the bolts to hold it. Tighten the bolts evenly to a torque of 100 ± 15 N·m (75 ± 10 lb.ft.). Hit the gear
assembly with a hammer and tighten the bolts again to the same torque. Do this until the torque does not
change.
2. If dowels (5) were removed, install the new dowels until the extend 6.0 ± 0.5 mm (.236 ± .020 in.) from
the housing assembly.
3. Use tool group (A) to install two bearings (4) in the drive gear bore until they are 1.5 ± 0.5 mm (.059
± .020 in.) from the ends of the bore.
4. Put drive gear (3) in position in the housing assembly.
5. Put washer (8) in position and use tool (B) to install snap ring (7) to hold the washer and drive gear in
position.
6. Use tool group (A) to install bearing (6) in the housing assembly until it is 26 ± 1 mm (1.02 ± .04 in.)
below surface (X). Use tool group (A) and install seal (10) to the bottom of the bore. Make sure the lip of the
seal is toward the engine as shown and put clean engine oil on the lip.
7. If dowels (9) were removed, install the new dowels until they extend 6.0 ± 0.5 mm (.236 ± .020 in.) from
the housing.
8. Install shutoff drive housing assembly (13) and the bolts to hold it on the flywheel housing. Make sure the
teeth of drive gear (3) are correctly engaged with the teeth of gear assembly (2).
366
9. Install tube assemblies (11) and (12) on the housing assembly and the engine.
end by:
a) install hydramechanical shutoff control
b) install tachometer drive
367
Accessory Drive (Front)

Remove Accessory Drive (Front)
start by:
a) remove alternator (if so equipped)
b) remove governor drive
1. If the engine is equipped with an alternator, remove the bolts to remove the alternator pulley from the drive
shaft.
2. Remove bolts (1) and cover (2) from adapter assembly (3). Remove bolts (4) and use two 1/2"-13 NC
forcing screws to remove adapter assembly (3) from the drive housing.
3. Remove bolts (6) to remove adapter assembly (5), the drive gear and shaft as a unit from the drive housing.
Install Accessory Drive (Front)
1. Put clean engine oil on the two O-ring seals on adapter assembly (1).
2. Install the drive gear, shaft and adapter assembly (1) in the drive housing. Make sure the drive gear teeth
are in alignment with the teeth of the oil and water pump drive gear. Install the bolts that hold adapter
assembly (1) in the drive housing.
3. Put clean engine oil on the two O-ring seals on adapter assembly (2). Put adapter assembly (2) in position
in the drive housing and install the four bolts that hold it in position. Put the cover with a gasket in position
on adapter assembly (2) and install the two bolts that hold the cover and gasket in position.
4. If the engine is equipped with an alternator, put the alternator pulley in position on the drive shaft and
install the bolts that hold it in position.
end by:
a) install alternator (if so equipped)
b) install governor drive
368
Disassemble Accessory Drive (Front)
start by:
a) remove accessory drive (front)
1. Remove O-ring seals (2) and (3) from the adapter.

2. Remove seal (4) from adapter (1). Use a press and tool group (A) to remove bearing (5) from adapter (1).
3. Remove bolts (7) to remove gear (8) from shaft (6).

4. Remove bolts (9) and the retainer washer to remove shaft (6) from adapter (10).
5. Remove O-ring seals (12) and (13) from adapter (10).

6. Use a press and tool group (A) to remove bearing (11) from adapter (10).
Assemble Accessory Drive (Front)

369
1. Make an alignment of the oil hole in the bearing and the oil hole in adapter (1). Use a press and tool group
(A) and install the bearing in adapter (1). Check the bore in the bearing after assembly. The bore in the
bearing must be 75.000 ± 0.055 mm (2.9528 ± .0022 in.).
2. Install the two O-ring seals in adapter (1).
3. Put clean engine oil on the bearing and install shaft (3) in adapter (1). Install retainer washer (2) to hold the
shaft and adapter together.
4. Put gear (4) in position on shaft (3) and install the bolts to hold them together.
5. Make an alignment of the oil hole in the bearing and the oil hole in adapter (5). Use a press and tool group
(A) and install the bearing in adapter (5). Check the bore in the bearing after assembly. The bore in the
bearing must be 75.000 ± 0.055 mm (2.9528 ± .0022 in.).
6. Use tool group (A) to install the seal in adapter (5). Make sure the lip of the seal is toward the bearing as
shown.
7. Install O-ring seals (6) and (7) on adapter (5) and put clean engine oil on them.
end by:
a) install accessory drive (front)
370
Oil And Water Pump Drive

Remove Oil And Water Pump Drive
start by:
a) remove oil pump
b) remove water pump
1. Remove bolts (1) and pull adapter assembly (2) and the gears from the front drive housing as a unit. The
weight of the unit is 23 kg (50 lb.).
2. Remove bolts (4) and pull adapter assembly (3) from the front drive housing.
Install Oil And Water Pump Drive
1. Make sure the O-ring seal is installed in the groove of adapter assembly (1) and put clean engine oil on it.
2. Put adapter assembly (1) in position and install the bolts to hold it to the front drive housing.
3. Make sure the O-ring seals are installed on the grooves of adapter assembly (2) and have clean engine oil
on them.
4. Put the gears and adapter assembly (2) in position as a unit. Make sure the drive gear is engaged correctly
with the idler gear and tighten the bolts to hold adapter assembly (2) in position.
end by:
a) install oil pump
b) install water pump
371
Disassemble Oil And Water Pump Drive
start by:
a) remove oil and water pump drive
1. Remove oil pump O-ring seal (4) from adapter (3).

2. Remove washers (2). Remove adapter (3) from shaft assembly (1).
3. Remove O-ring seals (6) and (7) from adapter (3).
4. Use a press and tool group (A) to remove bearing (5) from adapter (3).
5. Remove bolts (9) to remove gears (8) and (10) from shaft assembly (1).
6. Remove O-ring seal (13) from the water pump adapter assembly (12).
7. Use a press and tool group (A) to remove bearing (11) from adapter assembly (12).
Assemble Oil And Water Pump Drive
1. Lower the temperature of the bearing for water pump adapter (1). Use tool group (A) and install the
bearing in adapter (1). Check the bore in the bearing after assembly. The bore in the bearing must be 75.00 ±
0.06 mm (2.953 ± .002 in.). Install O-ring seal (2) on adapter (1).
372
2. Put gears (3) and (4) in position on the shaft assembly as shown and install the bolts to hold the unit
together.
3. Lower the temperature of the bearing for adapter (5). Make an alignment of the oil hole in the bearing with
the oil hole in adapter (5) and use tool group (A) to install the bearing. Make sure the bearing does not extend
beyond the surface shown and the inside diameter is 75.00 ± 0.06 mm (2.953 ± .002 in.) after installation.
4. Install O-ring seals (6) and (7) on adapter (5).
5. Put adapter (5) in position on shaft assembly (8) and install washers (9) to hold the unit together.
6. Install the oil pump O-ring seal (10) on adapter (5).
end by:
a) install oil and water pump drive
373
Crankshaft Vibration Damper

Remove Crankshaft Vibration Damper
1. Remove the bolts and remove damper guard (1) from the engine.
2. Remove two bolts (2) and install two 1"-14 NF guide bolts 11 in. long. Fasten a hoist to the damper with
tool (A) and remove the remainder of bolts (2). Remove vibration damper (3) from the engine. The weight of
the damper is 79 kg (175 lb.).
Install Crankshaft Vibration Damper
1. Install two 1"-14 NF guide bolts 11 in. long in the end of the crankshaft. Fasten a hoist to vibration damper
(1) with tool (A). Put the damper in position on the guide bolts and make sure the mark on the damper is in
alignment with the mark on the end of the crankshaft. Install four of the bolts to hold the damper in position
and remove tool (A). Remove the guide bolts and install the remainder of the bolts.
2. Put damper guard (2) in position and install the bolts to hold it in position on the engine.
374
Crankshaft Front Seal And Wear Sleeve

Remove Crankshaft Front Seal And Wear Sleeve
start by:
a) remove crankshaft vibration damper
NOTE: Any time the crankshaft seal is removed from the wear sleeve, a new sleeve and seal must be
installed as a unit. If the seal is put back on the sleeve, the seal will leak.
1. Remove the bolts from adapter (1) and install two 5/16"-13 NC forcing screws in the adapter to remove it
from the drive housing.
2. Remove O-ring seal (3) and crankshaft seal (2) from adapter (1).
3. Install tool (B) in adapter bore as shown.
4. Install tool (A) between tool (B) and wear sleeve (4). Turn tool (A) until the edge of the tool makes a flat
plate (crease) in the wear sleeve. Do this several places around the wear sleeve until the sleeve can be
removed from the end of the crankshaft by hand.
375
Install Crankshaft Front Seal And Wear Sleeve
installed as a unit. If the seal is put back on the sleeve, the seal will leak.
1. Install adapter (3) on tooling (A) as shown.
NOTICE
If the crankshaft seal and wear sleeve come apart during installation,
the seal and sleeve become scrap and a new seal and sleeve must be
used as a replacement.
NOTE: The front seal and wear sleeve can not be exchanged with the rear seal and wear sleeve. There are
grooves in the sealing lip of the seals that direct the oil back into the crankcase as the crankshaft turns. An
exchange of front and rear seals would pump the oil out of the crankcase.
2. Put crankshaft seal (1) and wear sleeve (2) as a unit in position on adapter (3). Make sure the lip of the seal
is up as shown.
3. Install tool (B) over the studs of tooling (A). Install nuts (C) and tighten the nuts evenly until the seal is
against the bottom of the adapter bore.
4. Remove nuts (C), tool (B) and tooling (A) from the adapter.
376
NOTE: Do not put engine oil on the lip of the seal during installation. Lubrication of the seal at installation
can be a wrong indication for linkage at a later time.
5. Put clean engine oil on the O-ring seal and install the seal on the adapter.
6. Install tooling (D) on the end of the crankshaft.

7. Install guide bolts (E) in the drive housing. Put adapter (3) in position on guide bolts (E) and over tooling
(D). Make sure the wear sleeve makes contact with the end of the crankshaft.
8. Install tool (B) over the small outside diameter of tool (F) until tool (B) is against the shoulder on tool (F).
9. Install tooling (B) and (F) as a unit on the guide bolts and over the locator.
10. Put clean engine oil on the face of nut (G) and install nut (G) on the locator. Tighten nut (G) until the
wear sleeve and adapter are in position.
11. Remove the tooling from the engine.
12. Install bolts (4) to hold adapter (3) in position.
end by:
a) install crankshaft vibration damper
377
Crankshaft Rear Seal And Wear Sleeve

Remove Crankshaft Rear Seal And Wear Sleeve
start by:
a) remove flywheel
installed as a unit. If the seal is put back on the sleeve, the seal will be damaged.
1. Remove the bolts from adapter (1) and install two 5/16"-18 NC forcing screws in the adapter to remove it
from the drive housing.
2. Remove O-ring seal (3) and crankshaft seal (2) from adapter (1).
3. Install tool (B) in adapter bore as shown.
4. Install tool (A) between tool (B) and wear sleeve (4). Turn tool (A) until the edge of the tool makes a flat
place (crease) in the wear sleeve. Do this several places around the wear sleeve until the sleeve can be
removed from the end of the crankshaft by hand.
378
Install Crankshaft Rear Seal And Wear Sleeve
installed as a unit. If the seal is put back on the sleeve, the seal will be damaged.
1. Install adapter (3) on tooling (A) as shown.
NOTICE
If the crankshaft seal and wear sleeve come apart during installation,
the seal and sleeve become scrap and a new seal and sleeve as a unit
must be used as a replacement.
NOTE: The rear seal and wear sleeve can not be exchanged with the front seal and wear sleeve. There are
grooves in the sealing lip of the seals that direct the oil back into the crankcase as the crankshaft turns.
An exchange of front and rear seals can cause the oil to come out of the crankcase.
2. Put crankshaft seal (1) and wear sleeve (2) as a unit in position on adapter (3). Make sure the lip of the seal
is up as shown.
3. Install tool (B) over the studs of tooling (A). Install nuts (C) and tighten the nuts evenly until the seal is
against the bottom of the adapter bore.
4. Remove nuts (C), tool (B) and tooling (A) from the adapter.
379
NOTE: Do not put engine oil on the lip of the seal during installation. Lubrication of the seal at installation
can be a wrong indication for linkage at a later time.
5. Put clean engine oil on the O-ring seal and install the seal on the adapter.
6. Install tooling (D) on the end of the crankshaft.

7. Install guide bolts (E) in the drive housing. Put adapter (3) in position on guide bolts (E) and over tooling
(D). Make sure the wear sleeve makes contact with the end of the crankshaft.
8. Install tool (B) over the small outside diameter of tool (F) until tool (B) is against the shoulder on tool (F).
9. Install tooling (B) and (F) as a unit on the guide bolts and over locator.
10. Put clean engine oil on the face of nut (G) and install nut (G) on the locator. Tighten nut (G) until the
wear sleeve and adapter are in position.
11. Remove the tooling from the engine.
12. Install bolts (4) to hold adapter (3) in position.
end by:
a) install crankshaft vibration damper
380
Front Drive Housing

Remove Front Drive Housing
start by:
a) remove oil and water pump drive
b) remove accessory drive (front)
c) remove vibration damper
d) remove oil filter housing
e) remove crankshaft front seal and wear sleeve
1. Remove bolts (1) and (4) to remove water line (2) from the engine.
2. Remove tube assemblies (3) from the engine.
3. Remove bolts (6) to remove crankcase breather (5) and elbow (7) as a unit from the drive housing.
4. Remove bolts (8) and remove cover (9) from the drive housing.
5. Remove bolts (10) from shafts (11) and use tooling (A) to remove shafts (11) and gears (12) from the drive
housing.
6. If necessary, remove bearings (13) from gears (12).
381
7. Remove washer assemblies (14) from the drive housing.

8. Fasten a hoist to support (15) with tooling (B). Remove bolts (17) to remove support (15) and support
assembly (16) as a unit from the drive housing. The weight of the supports is 102 kg (225 lb.).
9. Remove bolts (18) and remove governor control lever (19) from the injector control shaft.
11. Remove all the bolts that hold the oil pan to the engine. Install two 3/8"-16 NC guide bolts in each side of
the oil pan. Fasten a hoist to the engine and lift the engine approximately 12 mm (0.5 in.) off of the oil pan.
Put two 50 mm wide x 100 mm long x 6 mm thick (2" wide x 4" long x 1/4" thick) plates in position between
the cylinder block and the oil pan on each side of the engine. Lower the engine on the plates and remove the
hoist. The weight of the 3512 Engine is approximately 5902 kg (13,000 lb.) and the 3508 Engine is
approximately 4445 kg (9800 lb.).
NOTICE
Fuel control linkage (21) must be moved for clearance to pull the front
drive housing from the engine or damage to parts can be the result.
12. Fasten a hoist to front drive housing (20) with tooling (B). Remove all the bolts that hold the drive
housing to the cylinder block and install two 5/8"-11 NC guide bolts. Remove front drive housing (20) from
the engine. The weight of the drive housing is 209 kg (460 lb.).
382
Install Front Drive Housing
1. Fasten a hoist to front drive housing (1) with tooling (A). Install two 5/8"-11 NC guide bolts in the end of
the cylinder block. Put the gasket and housing in position on the guide bolts. Install the bolts and tighten all
evenly. Remove the guide bolts. Install the remainder of the bolts. Cut the gasket even with the bottom of the
drive housing.
2. Fasten a hoist to the engine and lift the engine enough to remove the plates between the cylinder block and
the oil pan. If the oil pan gasket is damaged, the engine will have to be removed from the oil pan to make a
replacement of the gasket. Lower the engine on the oil pan and remove the guide bolts from the oil pan.
Install all the bolts that hold the oil pan in position.
3. Install governor control lever (2) and the bolts that hold it to the injector control shaft.
4. Install a hoist to support (3) with tooling (A). Put support (3) and support assembly (4) as a unit in position
on the drive housing and install the bolts that hold the supports in position.
5. Install washer assemblies (5) in the drive housing.
6. Use tooling (B) and a press to install the bearings in gears (6). Check the bore in the bearings after
assembly. The bore in bearings must be 90.00 ± 0.06 mm (3.543 ± .002 in.).
7. Install O-ring seals on shafts (7) and put clean engine oil on the seals. Put gears (8) in position and install
shafts (7) in the drive housing.
8. Put clean engine oil on the O-ring seal and install cover (11) in the drive housing.
383
9. Put a gasket and elbow (10) with crankcase breathers (9) in position and install the bolts to hold these in
position.
10. Install tube assemblies (12) and water line (13) on the engine.
end by:
a) install oil and water pump drive
b) install accessory drive (front)
c) install vibration damper
d) install oil filter housing
e) install crankshaft front seal and wear sleeve
384
Air Starter
Remove Air Starter
1. Make sure the air supply is shut off and the pressure is drained from the system.
2. Disconnect the air lines from starter (1).

3. Remove clip (2) and sump pump oil line (3) from the engine.
4. Fasten a hoist to starter (1). Remove bolts (4) and remove starter (1) from the flywheel housing. The
weight of starter (1) is 54 kg (120 lb.).
Install Air Starter
1. Fasten a hoist to starter (1) and put it and the gasket in position. Install the bolts that hold the starter to the
flywheel housing.
2. Install sump pump oil line (2) and clip (3) on the engine.
3. Connect the air lines to the starter.
4. Open the air supply to the engine.
385
Air Starter (An Attachment)
Disassemble Air Starter
start by:
a) remove air starter
386
NOTE: Make sure there is a complete set of new gaskets, vanes, seals and O-ring seals before the air starter
is disassembled.
1. Remove elbow (1) from cover assembly (2).

2. Remove silencer group (4) from motor housings (3).
3. Make marks to show the position of motor housing (3) in relation to gear case (7) for assembly purposes.
Remove bolts (4) to remove gear case (7) and drive housing (6) as a unit from motor housing (3).
4. Use tool (A) to remove ring (9) from drive gear (8).
NOTE: This air starter is a right hand model and bolt (10) has left hand threads. The bolt for a left hand
model starter has right hand threads.
5. Remove bolt (10) and washer (11) to remove drive pinion (12), a sleeve and spring from the end of the
drive shaft.
6. Make marks to show the position of drive housing (6) in relation to gear case (7) for assembly purposes.
Remove bolts (13) and remove drive housing (6) from gear case (7).
7. Remove O-ring seal (14) from drive housing (6).
The drive shaft assembly, the piston and drive gear are under a spring
force.
387
8. Install tooling (B) between drive gear (8) and piston (15). Use a press to make a compression of the piston
return spring and remove the ring that holds the drive shaft assembly and piston in the drive housing.
9. Slowly release the press to remove the force of piston return spring (17). Remove tooling (B) from
between the drive gear and piston and remove ring (16) from the piston. Remove the drive gear, the piston
and drive shaft assembly as a unit from the drive housing. Remove piston return spring (17) from the drive
housing.
10. Use a 5/16" hex wrench to loosen the drive gear bolt until the threads are free and remove drive shaft
assembly (18) and piston (15) as a unit from drive gear (8).
11. Remove bulkhead (19) from piston (15).
12. Remove O-ring seals (20) from bulkhead (19).

13. Remove ring (21) from piston (15) and remove the piston from drive shaft assembly (18).
14. Remove O-ring seal (24), bumper (23) and seal (22) from piston (15).
388
15. Remove ring (33), cup (32), spring (31), driven clutch jaw (30), driving clutch jaw (29), bearing (28),
washer (27), lockwasher (26) and bolt (25) from drive shaft assembly (18).
NOTE: Any time ring (34) is removed a replacement must be made.
16. Remove ring (34) to remove bearing (35) from drive shaft (18).
17. Use tool (C) to remove ring (37) and remove bearing (36) from gear case (7).
18. Remove bumper (38) from drive housing (6).

19. Remove backup ring (39) from drive housing (6).
20. Remove seat (40) and bearing (41) from drive housing (6).
21. Remove seal (42) from drive housing (6).
389
22. Make marks to show the position of cover assembly (2) in relation to motor housing (3) for assembly
purposes. Remove cover assembly (2) and an O-ring seal from motor housing (3).
23. Remove bolt (44) to remove rotor pinion (43) from rotor shaft.
24. Loosen setscrew (46) and remove nut (45) from the rotor shaft.
25. Remove bearing (47) from end plate (48).
26. Remove O-ring seal (49) and end plate (48) from the end of the rotor.
27. Remove vanes (50) from rotor (51).

28. Remove rotor (51) from motor housing (3).
29. Use a press to remove bearing (52) and end plates (53) from rotor (51).
390
30. Remove bearing (52) from end plate (53).
31. Remove washers (54) from end plate (53).

32. Remove O-ring seals (55) from cylinder (56).
33. Remove cylinder (56) from motor housing (3). Remove the remainder of the O-ring seals from the
cylinder.
Assemble Air Starter
NOTE: Clean all parts thoroughly. Put 2S3230 Bearing Lubricant on all bearings and the drive assembly. Put
a thin layer of SAE 10W oil on all other parts before assembly.
1. Install O-ring seals (1) on cylinder (2) and install the cylinder in housing (3). Make sure pin (5) is in
391
alignment with opening (slot) (4) in housing (3).

2. Install O-ring seals (6) on cylinder (2).
3. Install end plate (7) on rotor (8).

4. Install O-ring seal (9) on the rotor shaft.
5. Install bearing (10) over the rotor shaft and in the end plate.
6. Install nut (11) on the rotor shaft with the shoulder toward the bearing.
7. Tighten the nut until there is .02 mm to .07 mm (.001 in. to .003 in.) clearance between the end plate and
the rotor. Use a feeler gauge to check the clearance. Tighten bolt (12) and check the clearance again.
NOTE: Step 8 is for right hand rotation starters only. For the left hand rotation starters, the rotor is installed
with the pinion end of the rotor away from the cylinder alignment pin.
8. Install rotor (8) in motor housing (3) with the pinion end of the rotor toward the cylinder alignment pin.
Make sure pin (13) is in alignment with the hole in the end plate.
392
9. Install vanes (14) in the rotor.

10. Install end plate (15) on the rotor and make sure hole (16) in the end plate is in alignment with pin (17).
11. Install washers (18) in the end plate.

12. Put bearing (19) in position on the end plate.
13. Use tooling (B) and a press to install bearing (19) on the rotor shaft and in the end plate.
14. Install rotor pinion (20) and the bolt that holds it to the rotor shaft. Tighten the bolt to a torque of 120
N·m (90 lb.ft.).
15. Install O-ring seal (22) around the rotor bearing and put cover assembly (21) in position on motor
housing.
16. Put bearing (25) and ring (23) in position on drive shaft (24).
393
17. Use a press and tool (A) to install the ring on the drive shaft.
18. Put bolt (30), lockwasher (31), washer (32), bearing (33), driving clutch jaw (34), driven clutch jaw (26),
spring (27) and cup (28) in position in drive shaft assembly (24) and install ring (29) in the drive shaft
assembly.
19. Use tooling (B) to install the seal in piston (35). Make sure the lip of the seal is toward the outside of the
piston as shown.
NOTE: Later model air starters will not have bumper (36).
20. Install O-ring seal (37) and bumper (36) on piston (35).
21. Install piston (35) on drive shaft assembly (24) and install ring (38) that holds the piston to the shaft
assembly.
22. Install O-ring seals (39) on bulkhead (40).
23. Install bulkhead (40) on piston (35).

24. Install drive gear (41) on drive shaft (24) and use a 5/16" allen wrench to install the drive gear bolt that
394
holds the drive gear to the drive shaft. Tighten the bolt to a torque of 77 N·m (57 lb.ft.).
25. Use tooling (B) to install the seal in drive housing (42). Make sure the lip of the seal is toward the outside
of the housing as shown.
26. Install bearing (43) in the drive housing.
27. Install seat (44) in the drive housing.
NOTE: Later model air starters will not have backup ring (45) and bumper (46).
28. Install backup ring (45) and bumper (46) in the drive housing.
29. Install piston return spring (47) in the drive housing.

30. Put the drive gear, the piston and drive shaft assembly as a unit in position on the piston return spring.
31. Put ring (48) in position over the piston and install tooling (C) between the drive gear and piston. Use a
press to make a compression of the piston return spring and install ring (48) in the groove of the drive
housing. Release the press and remove tooling (C).
395
32. Install bearing (49) in gear case (50) and use tool (D) to install the ring that holds the bearing in the gear
case.
33. Install drive housing (42) in gear case (50). Make sure the shaft on the end of the drive gear is correctly
engaged with the bearing in the gear case. Install the bolts that hold the drive housing to the gear case and
tighten the bolts to a torque of 38 N·m (28 lb.ft.).
34. Use tool (E) to install ring (51) on the end of the drive gear shaft.
NOTE: This is a right hand rotation starter and bolt (52) has left hand threads. The bolt for a left hand
rotation starter has right hand threads.
35. Install spring (55), sleeve (54), drive pinion (53), bolt (52) and the washer on the end of the drive shaft.
Tighten bolt (52) to a torque of 108 N·m (80 lb.ft.).
36. Install gear case (50) and drive housing (42) as a unit on motor housing (3). Install bolts (56) and tighten
each bolt a little at a time to a torque of 81 N·m (60 lb.ft.).
37. Install silencer group (58) and a gasket on the motor housing.
38. Install elbow (57) and a gasket on the cover assembly.
39. To check the operation of the air starter, use the following procedure:
a) Turn drive pinion (53) by hand in the direction of the starter rotation. The drive clutch must operate
with a smooth (clicking) action.
b) Turn drive pinion (53) in the opposite direction of the starter rotation. The drive pinion must turn by
hand.
c) Put 345 kPa (50 psi) of air pressure in the inlet opening of the drive housing. Drive pinion (53) must
move away from the drive housing and air must come out of the outlet opening of the drive housing.
d) Put a plug in the outlet opening of the drive housing and put 1034 kPa (150 psi) of air pressure in
the inlet opening of the drive housing. Make sure there are no air leaks and measure the dimension
from the face of drive pinion (53) to the mounting face of the drive housing. The dimension must be 73
± 2.0 mm (2.874 ± .08 in.). Remove the air pressure from the inlet opening and measure the same
dimension again. The dimension must be 44.5 ± 2.0 mm (1.75 ± .08 in.).
e) Put 620 kPa (90 psi) of air pressure in the inlet opening of the motor housing. The motor must run
smoothly.
end by:
a) install air starter
396
Flywheel
Remove Flywheel
1. Fasten a hoist to the flywheel with tooling (A).

2. Remove two of bolts (1) and install two 1"-14 NF guide bolts 6 in. long in their place. Remove the
remainder of bolts (1).
3. Install two 5/8"-11 NC eyebolts in each side of flywheel (2) and use a pry bar to remove flywheel (2) from
the end of the crankshaft.
4. Remove flywheel (2) from the engine. The weight of the 3512 Flywheel is 168 kg (370 lb.). The weight of
the 3508 Flywheel is 126 kg (278 lb.).
397
Install Flywheel
1. Install two 1"-14 NF guide bolts 6 in. long in the end of the crankshaft.
2. Fasten a hoist to the flywheel with tooling (A) and put it in position on the guide bolts. Make sure the mark
on the flywheel is in alignment with the mark on the crankshaft.
3. Put clean engine oil on the threads of the bolts and install the bolts in flywheel (1). Remove the hoist and
tooling (A) from flywheel (1). Install the remainder of the bolts and tighten all of the bolts to a torque of 1150
± 60 N·m (850 ± 45 lb.ft.).
398
Flywheel Housing
Remove Flywheel Housing
start by:
a) remove exhaust elbow
b) remove tachometer drive
c) remove crankshaft rear seal and wear sleeve
d) remove air starter
1. Use tooling (A) to remove two camshaft drive gears (1) from the ends of the crankshaft.
2. Remove bolts (3) to remove bracket (2) from the flywheel housing.
3. Remove bolt (4) and disconnect marine gear oil pressure line (5) and air restriction line (6).
4. Remove bolts (7) to remove housing (8) with three water lines (11) from the engine.
5. Remove three bolts (9) to disconnect marine gear oil pressure line (5), air restriction line (6) and two
temperature sending unit wires (10) from the flywheel housing. Put the lines and wires out of the way of the
housing.
399
7. Remove all the bolts that hold the oil pan to the engine. Install two 3/8"-16 NC guide bolts (12) in each
side of the oil pan. Fasten a hoist to the engine and lift the engine approximately 12 mm (0.5 in.) off of the oil
pan. Put two 50 mm wide x 100 mm long x 6 mm thick (2" wide x 4" long x 1/4" thick) plates (13) in
position between the cylinder block and the oil pan on each side of the engine. Lower the engine on plates
(13) and remove the hoist. The weight of the 3512 Engine is approximately 5902 kg (13,000 lb.) and the
3508 Engine is approximately 4445 kg (9800 lb.).
8. Use tooling (B) to fasten a hoist to flywheel housing (14). Remove two of the bolts that hold flywheel
housing (14) in position and install two 1/2"-13 NC guide bolts (15). Remove the remainder of the bolts that
hold flywheel housing (14) and pull it from the dowels in the cylinder block. Remove the flywheel housing
from the engine. The weight of the 3512 Flywheel Housing is 245 kg (540 lb.). The weight of the 3508
Flywheel Housing is 202 kg (445 lb.).
Install Flywheel Housing
1. Put the flywheel housing gasket in position on the rear of the cylinder block.
2. Install two 1/2"-13 NC guide bolts in the rear of the cylinder block. Fasten a hoist to flywheel housing (1)
with tooling (A).
3. Put flywheel housing (1) in position on the guide bolts. Install the bolts in the housing and tighten the bolts
evenly. Remove the guide bolts and install the remainder of the bolts.
4. Cut the flywheel housing gasket even with the bottom of the bolts.
400
5. Fasten a hoist to the engine and lift the engine enough to remove the plates between the cylinder block and
the oil pan. If the oil pan gasket is damaged, the engine will have to be removed from the oil pan to make a
replacement of the gasket. Lower the engine on the oil pan and remove the guide bolts from the oil pan.
Install all bolts (2) that hold the oil pan in position.
6. Install housing (3) with the three water lines on the engine.
7. Put air restriction line (6), marine gear oil pressure line (5) and two sending unit wires (4) in position on
the flywheel housing. Connect the two lines and install the bolts that hold the lines and wires in position.
8. Install bracket (7) and the bolts that hold it to the flywheel housing.
9. Put drive gears (8) in position on camshafts (9) and install the plates and bolts that hold drive gears (8) in
position. Tighten the bolts evenly to a torque of 100 ± 15 N·m (75 ± 10 lb. ft.). Hit the plates with a hammer
and tighten the bolts again to the same torque. Do this until the torque does not change.
end by:
a) install exhaust elbow
b) install tachometer drive
c) install crankshaft rear seal and wear sleeve
d) install air starter
401
Valve Covers
Remove Valve Covers
1. Remove bolts (1) and remove valve cover (2) from the valve cover base.
2. If necessary, remove the seal from valve cover (2).
Install Valve Covers
1. Make sure seal (1) is installed in the groove of valve cover (3). Cut new seals to fit at assembly.
2. Put valve cover (3) in position on valve cover base (2) and install the four bolts to hold it. Tighten the bolts
to a torque of 14 ± 3 N·m (10 ± 2 lb.ft.).
402
Rocker Shafts And Push Rods

Remove Rocker Shafts And Push Rods
start by:
a) remove valve covers
1. Remove bolts (1) and lift shaft (2) and the rocker arms off the valve cover base and the push rods.
2. Remove push rods (3) from the valve lifters and valve cover base.
3. Remove bridge assemblies (4) from the dowels.
Install Rocker Shafts And Push Rods

1. Loosen the adjustment nuts and screws (1) on valve bridges (2).
2. Put clean engine oil on the bridge dowels, the inside diameter of valve bridges (2) and on the top pad of the
valve bridge. Install valve bridges (2) on the bridge dowels as shown.
3. While bridges (2) are pushed straight down with a force of 25 ± 20 N (5.6 ± 4.5 lb.) on the top contact
surface, turn adjustment screw (1) until it makes contact with the valve stem. Turn screw (1) another 20° to
30°. This will straighten the dowel in the guide and make compensation for clearance (slack) in the threads.
4. Hold adjustment screw (1) in position and tighten the nut around screw (1) to a torque of 30 ± 4 N·m (22 ±
3 lb.ft.).
403
5. Put push rods (3) in position in the valve lifters and valve cover base.
NOTICE
Make sure the crankshaft and camshafts are in time with each other
and that adjustment screws (5) are turned all the way out before the
rocker shaft bolts are tightened or damage to the valves or pistons can
be the result. See INSTALL CAMSHAFTS for the procedure to time
the engine.
6. Put the rocker arms and shaft (4) in position on the valve cover. Make sure the rocker shafts and push rods
are in alignment and install the bolts to hold shaft (4).
7. Make an adjustment of the valves to have a clearance of 0.40 mm (.016 in.) for intake and 0.76 mm (.030
in.) for exhaust. See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING section for the
complete procedure.
end by:
a) install valve covers
404
Rocker Shaft Assemblies

Disassemble Rocker Shaft Assemblies
start by:
a) remove rocker shafts and push rods
1. Slide shaft assembly (1) out of rocker arms (2). If necessary, remove the dowel from shaft assembly (1).
2. Remove adjustment screw (4) and the nut from rocker arm (2).
3. Use a hammer and punch to push socket (3) out of rocker arm (2).
4. Remove the ring that holds button (5) in socket (3) and remove the button from the socket.
5. Use tool group (A) to remove bearing (6) from rocker arm (2).
6. Do Steps 2 through 5 for the other two rocker arms.
405
Assemble Rocker Shaft Assemblies
1. Make an alignment of the oil hole (slot) in the bearing with the oil passage in rocker arm (1). Use tool
group (A) to install the bearing in rocker arm (1) with the joint in the bearing toward the top of the rocker
arm. The bore in the bearing must be 37.140 ± 0.015 mm (1.4622 ± .0006 in.) after assembly.
2. Make an alignment of the scribe mark on socket (2) with the mark on rocker arm (1) and install the socket
in the rocker arm.
3. Put button (3) in socket (2) and install ring (4) to hold the unit together.
4. Install adjustment screw (5) and nut (6) on rocker arm (1).
5. Do Steps 1 through 4 for the other two rocker arms.
6. If the dowel was removed from shaft assembly (7), install the new dowel in the shaft until it is 7.7 ± 0.5
mm (.303 ± .020 in.) above the surface of the shaft.
7. Put clean engine oil on the rocker arm bearings and shaft assembly (7). Install rocker arms (1) on shaft
assembly (7).
end by:
a) install rocker shafts and push rods
406
Fuel Injectors
Remove Fuel Injectors
start by:
1. Close the fuel supply to the engine.
2. Remove inlet fuel tube (1) and outlet fuel tube (2) from the cylinder head. Put caps on the fuel openings.
NOTE: Step 2 must be done to prevent fuel leakage into the combustion chambers and the crankscase.
3. Remove locknut (4) and the washer. Disconnect lever assembly (3) from the control rod.
4. Remove bolts and remove lever assembly (3) from the cylinder head.
5. Remove bolt (6) and clamp (5) that hold the fuel injector in position.
NOTICE
Do not put a force on the fuel injection rack or cause damage to it

when the injectors are removed from the cylinder head.
407
6. Use a pry bar and loosen injector (7) from the cylinder head. Pull injector (7) out of the cylinder head and
remove it from the engine.
7. Remove O-ring seals (8) from the injector.
8. If necessary, remove the plug for clamp (5) from the cylinder head.
408
Fuel Injectors
Install Fuel Injectors
1. Use tool (A) as shown to make sure the fuel injection rack will move freely by its own weight when
injector (1) is turned a total of 180° in both directions. Check the rack movement with the injector spring
under compresion in several positions.
NOTE: To prevent a carbon deposit between the injector and the injector bore, make sure the injector body
(especially the tapered area) and the injector bore are clean and free of foreign material.
2. Make sure the three O-ring seals (2) are installed on injector (1) and put clean engine oil on the seals and
in the bore for the injector.
3. Make sure the plug that the anvil of clamp (5) sets on is installed in the top of the cylinder head.
NOTICE
Do not tap or hit on the injector follower to install the injector. Damage
and failure of the injector can be the result.
409
4. Put injector (1) in position in the cylinder head. Install clamp (5) and tighten the bolt and washer to push
injector (1) all the way into its bore. Tighten the bolt to a torque of 65 ± 7 N·m (48 ± 5 lb.ft.).
5. Check to make sure the fuel injection rack moves freely by hand in the injector after the injector is
installed.
6. Put lever assembly (6) in position. Connect the lever assembly to control rod (7) and make sure lever
assembly (6) is engaged correctly with the fuel injection rack. Install the two bolts to hold the lever assembly
in place.
7. Remove the caps from the fuel openings and install inlet fuel tube (3) and outlet fuel tube (4) on the
cylinder head. Open the fuel supply to the engine.
8. See TESTING AND ADJUSTING section for the correct adjustment of the fuel injection of the fuel
injection control group. Make sure the control group can move to the fuel off position with the governor
linkage disconnected.
end by:
410

Remove Fuel Injection Control Linkage
start by:
b) remove front drive housing
1. Remove the bolts that hold the brackets for shaft (2) to the front of the cylinder block. Disconnect the
levers on shaft (2) from the levers on shafts (1) and remove shaft (2) from the engine.
2. Remove levers (4) and (5) and brackets (3) from shaft (2).
3. Remove bearings (6) from brackets (3) with tool group (A).
4. Remove access covers (7) from over the camshafts.
5. Remove bolts (9) and the caps that hold the levers of rod assemblies (8) to the fuel control rod.
6. If necessary, remove the cover from the front right side of the flywheel housing and use tool (B) to turn the
411
engine flywheel until the camshaft is moved in a position so the levers of rod assemblies (8) can be removed
between the cylinder block and camshaft.
7. Remove bolts (11) and remove lever assemblies (10) and fuel control rod assemblies (8) as a unit from the
cylinder heads. See Step 6 if the levers on the lower ends of rod assemblies (8) do not have enough clearance
to be removed from the engine.
8. Remove locknut (12) and the washer to remove rod assembly (8) from lever assembly (10).
9. Remove levers (14) from control shafts (1).
10. Remove the bolts and supports (13) from each side of the engine.
11. If necessary, remove bearings (15) from supports (13) with tool group (A).
12. Pull control shaft (1) out of each side of the engine block.
13. Remove the bolts and remove two bracket assemblies (16) on each side of the 3512 Engine. The 3508
Engine has only one bracket assembly (16) on each side.
14. If necessary, use tool group (A) to remove bearings (17) from bracket assemblies (16).
Install Fuel Injection Control Linkage

412
1. Use tool group (A) to install the bearings in bracket assemblies (1) until they are in the center of their
bores. Check the bore in the bearings after assembly. The bearing bores must be 21.925 ± 0.015 mm (.8632
± .0006 in.).
2. Install two bracket assemblies (1) on each side of the 3512 Engines. Install one bracket assembly (1) on the
3508 Engines.
3. Install control shaft (2) on each side of the engine block.

4. Use tool group (A) and install the bearings in the center of the bores in supports (3). Check the bore in the
bearings after assembly. The bearing bores must be 21.925 ± 0.015 mm (.8632 ± .0006 in.).
5. Install supports (3) to hold the front of the control shafts. Install levers (4) on each of the control shafts.
6. Connect lever assembly (6) to rod assembly (5).
7. Install lever assembly (6) and rod assembly (5) as a unit in each cylinder head. If necessary, use tool (B) to
turn the engine flywheel until the camshaft moves enough to permit the lever of the rod assembly to move
into position.
413
8. Make sure lever assembly (6) is engaged correctly with the fuel injection pump rack and install the two
bolts to hold it in place.
9. Make sure the lever for the fuel control and assembly is in position on the control shaft and install the bolt
and cap (7).
10. Install access covers (8) and seal over the camshafts and control rods.
11. Use tool group (A) and install the bearings in the center of the bores in front control shaft brackets (9).
Check the bore in the bearings after assembly. The bearing bores must be 21.925 ± 0.015 mm (.8632 ± .0006
in.). If necessary, make a replacement of the pins in brackets (12). The pins must extend 8.0 ± 0.5 mm (.315
± .020 in.) above the surface of brackets (9).
12. Install brackets (9) and levers (10) on the ends of front control shaft (11).
13. Put shaft (11) in position on the front of the engine. Make sure levers (10) and (4) are engaged correctly
and install the bolts to hold the brackets and shaft (11) to the engine.
NOTE: After assembly the control shafts must turn freely by hand and the linkage must return to the
"SHUTOFF" position when it is turned and released. See TESTING AND ADJUSTING section for the
correct adjustment of the fuel injection control group.
end by:
a) rocker shafts and push rods
b) front drive housing
414
Cylinder Heads
Remove Cylinder Heads
start by:
a) remove exhaust manifolds
NOTE: The exhaust manifolds do not have to be removed unless all of the cylinder heads are to be removed.
2. Shut off the fuel supply to the engine.
3. Remove the bolts and remove intake elbow (1) from the cylinder head.
4. Disconnect fuel lines (2) and (4) from fuel manifold (3). Remove bolts (5) and remove fuel manifold (3).
5. Remove rocker shaft and push rods. See REMOVE ROCKER SHAFTS AND PUSH RODS for this
procedure.
6. Remove the bolts and cover (6) from under the cylinder head to be removed.
7. Remove bolt (8) and cap (7) that hold the fuel control lever to the fuel control shaft.
415
8. Remove bolts (13) to remove lever assembly (9) and rod assembly (14) as a unit from the cylinder head.
9. If necessary use tool (A) to turn the flywheel until the camshaft is moved in a position so rod assembly
(14) can be removed between the engine block and camshaft.
10. Remove bolt (10) and clamp (12) from fuel injector (11).
NOTICE
Do not put a force on the fuel injection rack or cause damage to it

when the injectors are removed.
11. Use a pry bar to remove injector (11) from the cylinder head.
12. Remove fuel lines (17), bracket (16) and elbows (15) from the cylinder head.
13. Remove bolts (18) and (20) to remove valve cover base (19) from the cylinder head.
14. Use tooling (B) to fasten a hoist to cylinder head (22). Remove bolts (21) and (23) to remove cylinder
head (22) from the engine. The weight of the cylinder head is 45 kg (100 lb.).
Install Cylinder Heads
1. Thoroughly clean the spacer plates and bottom surface of the cylinder heads. Install a new head gasket and
seals. Do not use any adhesives.
NOTE: A new spacer plate gasket must be installed when the cylinder head is removed. See REMOVE AND
INSTALL SPACER PLATE.
416
2. Fasten a hoist and tooling (A) to the cylinder head with two 3/8"-16 NC bolts and washers as shown. Put
the cylinder head into position on the spacer plate.
3. Put clean engine oil on the threads of the cylinder head bolts. Install the cylinder head bolts and washers.
Tighten the bolts in the following sequence:
a) Tighten all of the bolts to a torque of 30 ± 5 N·m (22 ± 4 lb.ft.).
b) Tighten bolts 1 through 8 in number sequence to a torque of 270 ± 35 N·m (200 ± 25 lb.ft.).
c) Tighten bolts 1 through 8 in number sequence to a torque of 450 ± 20 N·m (330 ± 15 lb.ft.).
417
4. Install bolts (3) and the washers to hold the cylinder head to the engine.
5. Make sure the O-ring seals are installed around the two dowels in the bottom of valve cover base (2). Put
the gasket and base (2) in position and install the bolts to hold them to the cylinder head.
6. Install elbows (1) with a gasket on he cylinder head.
7. Install bracket (5) and fuel lines (6) on the cylinder head.
8. Make sure the three O-ring seals are installed on injector (4) and put clean engine oil on them and in the
bore for the injector.
NOTICE
Do not tap or hit on the injector follower to install the injector. Damage
and failure of the injector can be the result.
NOTE: To prevent a carbon deposit between the injector and the injector bore, make sure the injector body
(especially the tapered area) and the injector bore are clean and free of foreign material.
9. Put the injector (4) in position. Install the clamp, washer and bolt. Tighten the bolt to push injector (4) all
the way in its bore. Tighten the bolt to a torque of 65 ± 7 N·m (48 ± 5 lb.ft.).
10. Check to make sure the fuel injection rack moves freely by hand in the injector after the injector is
installed.
11. Install fuel control rod assembly (7) in the cylinder head and engine block. If necessary, use tool (B) to
turn the engine flywheel until the camshaft moves enough to permit the lever of rod assembly (7) to move
into position.
12. Connect lever assembly (8) to the control rod assembly. Make sure lever assembly (8) is engaged
correctly with the fuel injection rack and install the two bolts and washers to hold it in place.
13. See TESTING AND ADJUSTING section for the correct adjustment of the fuel injection control group.
14. Make sure the lever for the fuel control rod assembly is in position on control shaft (9) and install the bolt
and cap (10).
418
15. Install cover (12) and seal (11) over the camshaft and control shaft (9).
16. Install the rocker shafts and push rods. See INSTALL ROCKER SHAFTS AND PUSH RODS for this
procedure.
17. Put clean engine oil on the O-ring seals and install fuel manifold (14). Connect fuel lines (6) and (13) to
fuel manifold (14).
18. Put the gaskets and intake elbow (15) in position and install the bolts to hold intake elbow (15) in place.
19. Turn on the fuel supply to the engine.
419
Piston Cooling Sets

Remove And Install Piston Cooling Jets
1. Remove the cover from side of the engine block.
2. Remove bolts (1) and retainer (2).

3. Pull cooling jet (3) out of its bore in the engine block from the inside to remove it.
4. Put cooling jet (3) in position in the engine block. Make sure the oil holes in the end of the jet are toward
the piston.
5. Install retainer (2) and bolts (1) to hold jet (3) in position.
6. Install the cover on the side of the engine block.
420
Valves
Remove Valves
start by:
a) remove cylinder heads
1. Use tool (A) to put valve springs (1) under compression.

2. Remove locks (2) from the valve stem.
3. Release the tension on springs (1) with tool (A) and remove tool (A), the rotor coil assembly, springs (1)
and washer from the valve stem and guide.
4. Remove the valves from the cylinder head.
NOTE: If the valves can be used again, put identification on them as to their location for installation
purposes.
5. Check the valve spring force with tool (B). See SPECIFICATIONS for the correct spring force values.
6. Do Steps 1 through 5 again for the remainder of the valves.
421
Install Valves
1. Put clean engine oil on the valve stem and install valve (4) in the cylinder head.
2. Put washer (2), the inner spring, outer spring (1) and rotocoil assembly (3) over the valve stem and valve
guide.
3. Put the valve springs under compression with tool (A) and install locks (5).
The locks can be thrown from the valve when the spring compressor is
released if they are not in their correct position on the valve stem. To
prevent possible personal injury be sure to stay away from in front of
the valve retainer and springs.
4. Remove tool (A) and hit the top of the valve with a plastic hammer to be sure the locks are in their correct
position on the valve stem.
5. Do Steps 1 through 4 again for the remainder of valves.
end by:
a) install cylinder heads
422
Valve Lifters
Remove And Install Valve Lifters
start by:
NOTICE
The lifter guide springs can be assembled on the lifter assembly or

installed in the cylinder head lifter bore only once. If a lifter assembly
is removed from the cylinder head or a lifter guide spring is removed
from a lifter assembly, a new lifter guide spring must be installed at
assembly.
1. Pull lifter assemblies (1) out of the cylinder head lifter bore.
2. Remove the guide springs from the lifter assemblies.
3. Install guide spring (2) on each of the lifter assemblies (1).
4. Put lifter assemblies (1) in a container of clean engine oil before they are installed. Install lifter assemblies
(1) in the lifter bore of the cylinder head.
end by:
423
Bridge Dowels
Remove And Install Bridge Dowels
start by:
a) remove valves
1. If necessary, use tooling (A) to remove bridge dowels (1) from the cylinder head.
2. Use tool (B) and a hammer to install dowels (1) in the cylinder head. The dowels must extend 66.5 ± 0.5
mm (2.62 ± .02 in. above the head surface.
end by:
a) install valves
424
Valve Seat Inserts

Remove Valve Seat Inserts
start by:
a) remove valves
1. Remove the valve seat inserts from the cylinder head with tooling (A).
2. Clean and remove any burrs from the valve seat bores.
Install Valve Seat Inserts
1. Lower the temperature of valve seat inserts (1) and install them with tooling (A).
NOTICE
Do not make the diameter of the extractor larger when the insert is
installed or damage to the insert and cylinder head can be the result.
2. Grind valve seat inserts (1) as to the values given in SPECIFICATIONS.
end by: a) install valves

425
Valve Guides
Remove Valves Guides
start by:
a) remove valves
1. Use tool (A) and a hammer to push the valve guides out of the cylinder head as shown.
Install Valve Guides
1. Put clean engine oil on the outside diameter of the valve guides.
2. Use tooling (A) and install the valve guides until they extend 26 mm (1.024 in.) from the surface of the
cylinder head. See SPECIFICATIONS for the correct values for the inside diameters of new and used valve
guides.
end by:
a) install valves
426
Connecting Rod Bearings

Remove And Install Connecting Rod Bearings
start by:
a) remove piston cooling jets
1. Use tool (A) and turn the engine flywheel to move the connecting rod cap bolts into a position for removal.
2. Remove bolts (1) to remove bearing caps (2) from the crankshaft and connecting rod. Remove the lower
half of the bearings from caps (2).
3. Push the connecting rods away from the crankshaft and remove the upper halves of the bearings from the
rods.
NOTE: Install rod bearings dry when the clearance checks are made. Put clean engine oil on the rod bearings
for final assembly.
4. Clean the surfaces where the bearing halves fit. Install bearing halves (3) in the rods and caps (2). Put
2P2506 Thread Lubricant on the bolt threads and contact surfaces of the bolts and caps.
5. Make a check of the bearing clearance with Plastigage. Put caps (2) in position on the connecting rods and
make sure the number on the side of the cap is next to and respective with the number on the side of the
connecting rod. Tighten the bolts in the number sequence shown as follows:
NOTICE
Do not use an impact wrench to tighten the bolts the additional 90 ± 5°

of a turn more.
427
NOTE: Bolts (6) and (7) are on the end of the rod cap opposite the end that has the location pin for correct
installation.
a) Tighten bolts No. 4 and 5 to a torque of 90 ± 5 N·m (65 ± 4 lb.ft.).
b) Tighten bolts No. 6 and 7 to a torque of 90 ± 5 N·m (65 ± 4 lb.ft.).
c) Tighten bolts No. 6 and 7 again to a torque of 90 ± 5 N·m (65 ± 4 lb.ft.).
d) Tighten each bolt 90 ± 5° of a turn more.
6. Remove the cap and measure the Plastigage. The rod bearing clearance must be 0.107 to 0.218 mm (.0042
to .0086 in.).
7. Put clean engine oil on both halves of the rod bearings. Put caps (2) in position and tighten the bolts as in
Step 5.
end by:
a) install piston cooling jets
428
Front Balancer Group (3508)

Remove Front Balancer Group
start by:
a) remove front drive housing
1. Remove the bolts that hold the brackets for shaft (2) to the front of the cylinder block. Disconnect the
levers on shaft (2) from the levers on shafts (1) and (3) and remove shaft (2) from the engine.
2. Use tool (A) to make an alignment of the marks on balancer gear (4) and crank gear (6) according to the
rotation of the engine as shown.
429
3. Remove the bolts and remove plate (5) from balancer gear (4). Remove balancer gear (4) from the shaft.
4. Use tool group (A) and a press to remove bearing (7) from balancer gear (4).
5. Remove shaft (8) from the end of the cylinder block.
6. Remove crank gear (6) from the end of the crankshaft.
Install Front Balancer Group
1. Put crank gear (2) in position on the end of the crankshaft and install the bolts.
2. Install shaft (1) on the end of the cylinder block.
3. Use tool group (A) and a press to install the bearing in balancer gear (3). Make sure the bearing joint is in
the center of the heavy section in gear (3). The bore in the bearing must be 75.00 ± 0.053 mm (2.9528
± .0021 in.) after assembly.
430
4. Put balancer gear (3) in position on the shaft. Make sure the marks on the balancer gear and the crank gear
are in alignment according to the rotation of the engine as shown.
5. Install plate (4) and the bolts to hold it on the balancer gear.
6. Put shaft (7) in position on the cylinder block. Make sure the levers on shaft (7) are correctly engaged with
the levers on shafts (5) and (6) and install the bolts to hold the brackets and shaft (7) to the cylinder block.
end by:
a) install front drive housing
431
Rear Gear Group

Remove Rear Gear Group
start by:
a) remove flywheel housing
3508 ONLY
NOTE: Before the flywheel housing is removed, the 3508 engine must be put in time to make sure the rear
gear group is in alignment according to the rotation of the engine as shown.
1. Remove plate (1) to remove gear assembly (2) from the shaft.
2. Use tool group (A) and a press to remove bearing (3) from gear assembly (2).
3. Use tool group (A) and a press to make a separation of the gears for gear assembly (2).
432
4. Remove the bolts to remove the shafts, gears (4) and the washers from the cylinder block.
5. Remove washers (6) and shafts (5) from gears (4).
6. Use tool group (A) and a press to remove the bearings from gears (4). Remove shaft (7) from engine.
7. Remove the bolts and remove gear (8) from the end of the crankshaft.
Install Rear Gear Group
1. Put gear (1) in position on the end of the crankshaft and install the bolts.
2. Install shaft (2) on the cylinder block.
433
3. Use tool group (A) and a press to install the bearings in both gears (3) until the bearings are in the center of
their bores. The bore in the bearing must be 75.00 ± 0.053 mm (2.9528 ± .0021 in.) after assembly.
4. Put clean engine oil on the bearings and install shafts (5) in gears (3). Install washers (4) on the shafts.
5. Put gears (3) in position on the cylinder block and install the bolts to hold the gears in position.
6. Use tool group (A) and a press to install bearing (6) in gear assembly (7). The bore in bearing (6) must be
75.00 ± 0.053 mm (2.9528 ± .0021 in.) after assembly.
7. Heat the larger gear of gear assembly (7) to a maximum temperature of 400° C (752° F) and install it on
the smaller gear as shown.
8. Put clean engine oil on the bearing and install gear assembly (7) on the shaft.
NOTE: Step 9 is for the 3508 Engine.

9. Put clean engine oil on the bearing and install the gear assembly on the shaft. Make sure the marks on the
gear assembly and the crankshaft gear are in alignment according to the rotation of the engine as shown.
434
3508 ONLY
10. Put plate (8) in position on gear assembly (7) and install the bolts.
end by:
a) install flywheel housing
435
Spacer Plates
Remove Spacer Plates
start by:
1. Remove gasket (4), seals (1), seals (2) and O-ring seal (3) from the spacer plate.
2. Remove spacer plate (5) from the dowels in the cylinder block.
3. Remove gasket (6) from the dowels.

4. Remove the O-ring seal from around dowel (7).
Install Spacer Plates

1. Make sure the spacer plate and the machined surface of the cylinder block are clean and free of dirt and
foreign material.
2. Install the O-ring seal around dowel (2).

436
NOTICE
Both surfaces of the spacer plate gasket and the top of the cylinder
block must be clean. Do not use a gasket adhesive on these surfaces.
3. Install new spacer plate gasket (1) over the dowels in the cylinder block.
4. Install spacer plate (3) on the dowels.

5. Install the O-ring seal around dowel (5).
6. Install new water seals (4) and (6) in spacer plate (3).
7. Install new cylinder head gasket (7) on the spacer plate.
8. Check the cylinder liner projection. See INSTALL CYLINDER LINERS.
end by:
437
Crankshaft Main Bearings

Remove Crankshaft Main Bearings
start by:
a) remove piston cooling jets
2. Use tool (A) to turn the engine flywheel to move counterweights (1) in position for removal. Remove
counterweights (1) from the crankshaft through the side of the cylinder block.
3. Use tool (A) and turn the engine flywheel to move the connecting rod bearing surface (journal) to the top
center position.
4. Use tool (B) and loosen the four bolts that hold the main bearing cap in position.
5. Hold the main bearing cap in position with a pry bar and remove the bolts and lower the bearing cap from
the cylinder block.
6. Remove the bearing caps from the side of the engine. The weight of the bearing cap is 16 kg (35 lb.).
7. Remove the lower bearing half (2) from bearing cap (3).
8. Remove thrust plates (4) from each side of the center main bearing.
NOTICE
If the crankshaft is turned in the wrong direction, the tab of the

bearing will be pushed between the crankshaft and cylinder block. This
438
can cause damage to either or both.
NOTE: On the center main journal that has no oil hole, put a thin piece of soft material that will not damage
the crankshaft journal against the end of the bearing, opposite the tab. Hit the bearing with the soft material
until the tab of the bearing is free from the cylinder block. Remove the upper half of the main bearing.
9. Install tool (C) in the oil hole in the crankshaft journal and remove upper main bearing halves (5) as the
crankshaft is turned and the bearing is moved out of the cylinder block.
Install Crankshaft Main bearings
NOTICE
Make sure the upper and lower halves of bearings are installed so the
bearing tabs fit into the notch in cylinder block and bearing caps.
NOTE: Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main
bearings for final assembly.
1. Install tool (B) in the oil hole of the crankshaft. Put the upper bearing half (half with oil hole) in position
on the crankshaft. Use tool (A) to turn the engine flywheel and push the bearing half in position with tool (B).
2. Make sure the bearing caps are clean and install the lower bearing halves in the caps.
439
NOTICE
Do not use an impact wrench to tighten the bolts the additional 180 ±
5° of a turn more.
NOTE: When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle,
the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct
measurement with the Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct
indication. If the engine is in a horizontal position, it is not necessary to hold the crankshaft up. Do not turn
the crankshaft when the Plastigage is in position to check clearance.
3. Check the bearing clearances with Plastigage as follows:
a) Put a piece of the Plastigage on the surface of the lower bearing half.
b) Install the main bearing caps with the word "FRONT" and the cast part number toward the front of the
cylinder block. Each cap has a number on the bottom surface and must be installed in the same position as
the correct number on the right side of the block pan rail.
c) Put 2P2506 Thread Lubricant on the main bearing cap bolts and tighten them in the number sequence
shown with tool (D) to a torque of 136 ± 14 N·m (100 ± 10 lb.ft.). Then tighten the bolts in the number
sequence shown 180 ± 5° of a turn more.
d) Remove the caps and measure the Plastigage. The main bearing clearance must be 0.122 to 0.241 mm
(.0048 to .0095 in.).
4. Put clean engine oil on thrust plates (5) and install them on each side of the center main bearing with the
grooves in the plates against the crankshaft.
5. Put clean engine oil on bearings (7) and put bearing caps (6) in position and tighten the bolts as in Step 3.
NOTICE
Each counterweight has a number and must be installed in the same

position as the correct number on the crankshaft mounting pad to
prevent damage to the crankshaft when the engine is run. Also do not
use an impact wrench to tighten the bolts the additional 120 ± 5° of a
turn more.
440
6. Make sure the dowels are in position and install counterweights (8) on the crankshaft. Put 2P2506 Thread
Lubricant on the bolts and tighten them evenly to a torque of 50 ± 5 N·m (37 ± 4 lb.ft.). Then tighten the
bolts 120 ± 5° of a turn more.
7. Check the crankshaft end play with tooling (C). The end play is controlled by the thrust plates on the
center main bearing. End play with new bearings must be 0.15 to 0.50 mm (.006 to .020 in.).
end by:
a) install piston cooling jets
441
Pistons
Remove Pistons
start by:
a) remove spacer plates
b) remove piston cooling jets
1. If necessary, remove the cover from the front right side of the flywheel housing and use tool (A) to turn the
engine flywheel until all four of bolts (1) can be removed.
2. Remove bolts (1) and bearing cap (2) from the connecting rod.
3. Push the piston up until the piston rings are clear of the cylinder liner. Remove pistons (3) and the
connecting rods.
NOTE: Put identification on each piston as to its location for correct installation and alignment. Keep each
bearing cap with its connecting rod.
4. Use tool (B) and remove the rings that hold piston pin (4) in position. Remove pin (4) and remove piston
(3) from connecting rod (5).
5. Remove the bearings from the bearing cap and connecting rod (5).
6. Use tool (C) to remove piston rings (6) from piston (3).
442
Install Pistons
1. Clean the ring grooves in the piston.
2. Use tool (A) to install the oil ring on piston (1). Make sure the oil ring spring ends are 180° apart from the
ring end gap.
3. Use tool (A) to install the two compression rings on piston (1). Make sure the sides with the "UP" marks
are toward the top of the piston and all three ring end gaps are 120° apart after installation.
4. Put clean engine oil on pin (3), the pin bearing in rod (2) and the pin bore in piston (1). Put rod (2) in
position in piston (1) and install pin (3). Use tool (B) to install rings (4) on each side of pin (3).
5. Install the upper half of the connecting rod bearing in the connecting rod and put clean engine oil on it.
Make sure the tab on the back of the bearing fits in the groove of the rod.
6. Put clean engine oil on the piston rings and cylinder liner bore. Use tool (D) to put the piston rings under
compression and install the pistons and connecting rods in the cylinder liners.
NOTICE
Make sure the piston is installed with the side of the connecting rod
that has the chamfer in the rod bearing bore next to the crankshaft
thrust surface. The side with the square shoulder for the connecting
rod bearing bore must be next to the other connecting rod on the same
crankshaft journal.
443
7. Install the lower half of the connecting rod bearing in cap (5) and put clean engine oil on it. Make sure the
tab on the back of the bearing fits in the groove of the cap.
8. See INSTALL CONNECTING ROD BEARINGS for the procedure to install the connecting rod caps and
to check the bearing clearance.
9. Check the side clearance between two connecting rods on the same crankshaft journal. The clearance must
be 0.85 ± 0.23 mm (.335 ± .0091 in.) for the 12 cylinder and 0.900 ± .282 mm (.0354 ± .0111 in) for the 8
cylinder.
end by:
a) install cooling jets
b) install spacer plates
444
Cylinder Liners
Remove Cylinder Liners
start by:
a) remove piston
1. Drain the coolant from the cooling system and cylinder block.
2. Put covers on the crankshaft journals for protection from dirt and coolant.
3. Remove the cylinder liner with tool (A).

4. Remove seals (1) and filler band (2) from the cylinder liner.
Install Cylinder Liners
1. Install the gasket and spacer plate.

2. Clean the cylinder liners and liner bores in the cylinder block.
3. Install the cylinder liners in the cylinder block without seals or bands.
445
4. Check the cylinder liner projection as follows:

a) Install four bolts (4) and washers from tooling (A) around each cylinder liner as shown. Tighten the
bolts evenly to a torque of 95 N·m (70 lb.ft.).
b) Install crossbar (2), plates (3) and bolts (1) from tooling (A). Be sure the crossbar is in position at
the center of the liner and the liner surface is clean. Tighten bolts (1) evenly to a torque of 70 N·m (50
lb.ft.).
c) Check the distance from the bottom edge of crossbar (2) to the top edge of the spacer plate. The
distance on each end of the crossbar must be the same.
d) Check the liner projection with tool (B) at four locations around the liner. Liner projection must be
0.059 to 0.199 mm (.0023 to .0078 in.). The difference between the four measurements on the same
liner must not be more than 0.05 mm (.002 in.).
NOTE: If the liner is turned in the cylinder block, it can make a difference in liner projection.
5. If the liner projection is not 0.059 to 0.199 mm (.0023 to .0078 in.), check the thickness of the following
parts:
a) Spacer plate (X): 10.313 ± 0.025 mm (.4060 ± .0010 in.).
b) Spacer plate gasket (Y): 0.208 ± 0.025 mm (.0082 ± .0010 in.).
[All surfaces must be clean and dry when gaskets are installed].
c) Cylinder liner flange (Z): 10.65 ± 0.02 mm (.419 ± .001 in.).
6. Put a mark on the cylinder liners and block so the liners can be installed in same position.
7. Remove tooling (A) and tool (B). Remove the liner.
446
8. Put liquid soap on seals (5), grooves of the liner and the bore of the block. Install the seals on the cylinder
liner.
9. Put the filler band completely in clean engine oil for a moment. Install filler band (6) in the groove under
the liner flange without delay.
10. Install the liner immediately after the filler band is installed before expansion of the band. Make sure the
mark on liner is in alignment with the mark on the block. Use tooling (C) to push the liner into position.
11. Use Steps 7 through 10 for the remainder of the liners.
end by:
a) install pistons
447
Camshafts
Remove Camshafts
start by:
b) remove crankcase breathers (left side only)
c) remove tachometer drive (right side only)
d) remove governor (right side only)
1. Remove access covers (1) from the sides of the engine.

2. Remove bolt (3) and cap (4) that hold fuel rod assembly (2) to the fuel control shaft.
3. Remove bolts (5) to remove lever assembly (6) and fuel rod assembly (2) as a unit from the cylinder heads.
If necessary, use tool (A) to turn the flywheel until the camshaft is moved in a position so that the fuel rod
assembly can be removed between the engine block and camshaft.
4. Remove cover (7) from the left side of the flywheel housing.
448
5. Remove the bolts and remove plate (8) from the end of the camshaft on the left side of the engine.
6. Use tooling (B) to remove drive gear (9) from the end of the camshaft on each side of the engine. Remove
the drive gears from the flywheel housing.
7. Remove the bolts and remove washer (10) from the end of the camshaft on each side of the engine.
8. Push valve lifters (11) up away from the camshaft into the cylinder heads and hold the lifters in this
position. An O-ring seal can be used to hold the valve lifters up.
9. Install the pilot assembly part of tool group (C) on one end of the camshaft.
10. Install the handle part of tool group (C) on the other end of the camshaft.
11. Pull camshaft (12) out of the engine block until a hoist can be fastened to it.
12. Put identification on the camshafts as to their location in the engine so they can be installed correctly.
13. Remove camshaft (12) and tool group (C) from the engine. The weight of the 3512 camshaft is 63 kg
(140 lb.). The 3508 Camshaft weight is 43 kg (95 lb.).
449
14. If necessary, remove bolts (13) to make a separation of the 3512 Camshaft only.
Install Camshafts
1. If the 3512 Camshafts were taken apart, make sure spacer (2) is in position between the camshaft and
camshaft assembly. Put 9S3263 Thread Lock on the threads of bolts (1) and tighten the bolts by hand only to
a torque of 45 ± 7 N·m (33 ± 5 lb.ft.).
NOTE: Make sure the camshafts are installed respective to the marks (Rear L.H., Rear R.H.) on the ends of
the camshafts.
2. Install the pilot assembly port of tool group (A) to one end of the camshaft and the handle part of tool
group (A) to the other end.
3. Fasten a hoist to camshaft (3) and put the camshaft in position and push it into the engine block. Remove
the hoist and tool group (A).
4. Install washers (4) on each side of the engine to hold the camshafts in position.
5. Remove timing pins (5) from their storage positions on each side of the engine.
450
6. Turn the camshafts until timing pins (5) can be installed through the engine block and into the grooves
(slots) in the camshafts.
7. Remove cover (6) and plug (7) from the right front side of the flywheel housing.
8. Put timing bolt (8) in position in the flywheel housing. Use tool (B) and a ratchet wrench to turn the
flywheel until the timing pin engages with the hole in the flywheel. The No. 1 cylinder is now at top center.
9. Put drive gears (9) in position on the end of the camshaft on each side.
10. Install plate (11) and the bolts to hold the drive gear to the camshaft. Tighten the bolts evenly to a torque
of 100 ± 15 N·m (75 ± 10 lb.ft.). Hit the plate with a hammer and tighten the bolts again to the same torque.
Do this until the torque does not change.
11. Install the gasket and cover (10) over the camshaft.
12. Install the tachometer drive adapter on the other camshaft to hold the drive gear in position. See
INSTALL TACHOMETER DRIVE.
13. Remove the timing pins for the camshaft and inltall the pins in their storage positions.
14. Remove the timing bolt from the flywheel and install the plug in the timing hole in the housing. Remove
tool (B) and install the cover on the housing.
451
15. Remove the O-ring seals from valve lifters (12) and push the lifters down against the camshaft.
16. Install fuel rod assembly (14) and lever assembly (13) as a unit in the cylinder heads. If necessary use tool
(B) to turn the flywheel until camshafts move enough to permit the fuel rod assembly to move into position.
17. Make sure lever assembly (13) is engaged correctly with the fuel injection pump rack and install the
bolts.
18. Install the bolt and cap (15) to hold the fuel rod assembly to the fuel control shaft.
19. Install access covers (16) on each side of the engine.
20. See TESTING AND ADJUSTING section for the correct adjustment of the fuel injection control group.
end by:
a) install governor
b) install crankcase breather
c) install rocker shafts and push rods
d) install tachometer drive
452
Camshaft Bearings
Remove And Install Camshaft Bearings
start by:
a) remove camshafts
1. Install tooling (A) as follows:

a) Install the cam bearing pilot in the camshaft bearing.
b) Put the backup plate in position so the bearing is between the parts.
c) Install the bolt to hold the tooling together.
NOTE: Tooling (D) is used in place of tooling (B) and (C) to remove and install the camshaft bearings when
the flywheel and front drive housings have been removed from the cylinder block.
453
2. Install tool (B) on the flywheel housing as shown or install tooling (B) and (C) on the front drive housing.
Tooling (C) must be used behind the bolt holes for clearance to install tool (B) on the front drive housing.
3. Use tooling (E) as needed to get the correct length. Connect the extensions to the stud on tooling (A).
NOTE: The threaded shaft, thrust bearing assembly and nut (all part of 8S2241 Tool Group) can be used
with an 8H684 Ratchet Box Wrench in place of tooling (F) if a hydraulic puller is not available.
4. Connect tooling (F) to extensions of tool group (E) and pull the bearing from its bore in the cylinder block.
NOTE: When the bearings are installed in the bore of the block, the bearing joint must be on the horizontal
centerline of the bore and the upper oil hole of the bearing toward the vee of the block. The upper bearing oil
hole must be put 20 ± 5° above the horizontal centerline of the bore in the block and the location of the lower
(outside or outboard) bearing oil hole will be (and must be) 20 ± 5° below the horizontal centerline of the
bearing bore as shown. Also, the bearing joint of the right side bearings must be toward the vee of the block
and the left side bearings must be toward the outside of the block.
5. Install the camshaft bearings as follows:

a) Install camshaft bearing (1) on tooling (A) as shown and put unit (2) in position in the bearing bore.
b) Follow Steps 2, 3 and 4 to install the tooling and pull the bearing into the center of its bore.
c) Check the bore in bearing (1) after it is installed. The bore must be 86.00 ± 0.06 mm (3.386 ± .002 in.).
end by:
a) install camshafts
454
Crankshaft
Remove Crankshaft
start by:
b) remove front drive housing
c) remove front balancer group (3508)
d) remove rear gear group (Step 1 only)
e) remove piston cooling jets
NOTICE
The rocker shafts and push rods do not have to be removed to remove
the crankshaft but bent push rods can be the result if they are not
removed.
1. Put the engine in the position as shown. The weight of the 3512 Engine is approximately 5902 kg (13,000
lb.). The weight of the 3508 Engine is approximately 4445 kg (9800 lb.).
2. Remove counterweights (1) from the crankshaft.
3. Remove bearing caps (2) from the connecting rod and push the connecting rods away from the crankshaft.
Use wire to hold the upper half of the connecting rods away from the crankshaft.
4. Remove the center main bearing cap and remove two thrust plates (3) from each side of the main bearing.
5. Use two of the bolts that hold the flywheel to the crankshaft and install a bolt in each end of the crankshaft.
Fasten a hoist to the crankshaft as shown.
6. Remove the remainder of main bearing caps (5) and remove crankshaft (4) from the engine block. The
weight of the 3512 Crankshaft is 409 kg (900 lb.). The weight of the 3508 Crankshaft is 299 kg (660 lb.).
455
7. If necessary, remove bolts (7) to remove gears (6) from each end of the crankshaft.
Install Crankshaft
1. If gears (1) were removed, install gears (1) on each end of the crankshaft and install the bolts to hold the
gears.
2. Make sure the upper halves of main bearings (2) (bearings with oil holes) are in position in the cylinder
block. Put clean engine oil on the bearings.
3. Fasten a hoist to crankshaft (3) with two flywheel bolts and put it in position. Make sure the word
"FRONT" on the end of the crankshaft is toward the front of the cylinder block.
4. Make sure the lower halves of the main bearings are in position in the main bearing caps. Put clean engine
oil on the bearings and install all but the center main bearing cap on the cylinder block. The caps must be
installed with the word "FRONT" and the cast part number toward the front of the cylinder block. Each cap
has a number on the bottom surface and must be installed in the same position as the correct number on the
right side of the block pan rail.
NOTICE
456
Do not use an impact wrench to tighten the bolts 180° ± 5° of a turn

more.
5. Put 2P2506 Thread Lubricant on the main bearing cap bolts and tighten the bolts in the number sequence
as shown to a torque of 136 ± 14 N·m (100 ± 10 lb.ft.). Then tighten each bolt in the number sequence as
shown 180° ± 5° of a turn more.
6. Put clean engine oil on the thrust plates and install thrust plates (8) on each side of the center main bearing.
Install the center main bearing cap and the bolts to hold it. Use the same procedure in Step 5 to tighten the
bolts.
NOTE: See INSTALL CRANKSHAFT MAIN BEARINGS for the correct bearing clearance check and
crankshaft end play.
7. Remove the wire that holds the upper half of the connecting rods in position. Make sure the upper and
lower halves of the bearings are in position on the connecting rods and the rod caps. Put clean engine oil on
the bearings.
NOTICE

more.
8. Put the connecting rods in position on the crankshaft. Install caps (9) in the same location as they were
removed from with the number on the side of the cap next to the number on the side of the connecting rod.
Put 2P2506 Thread Lubricant on the bolt threads and contact surfaces of the bolts and caps and tighten the
bolts in number sequences as follows:
457
NOTE: Bolts (12) and (13) are on the end of the rod can opposite the end that has the location pin for correct
installation.
a) Tighten bolts No. 10 and 11 to a torque of 90 ± 5 N·m (65 ± 4 lb.ft.)
b) Tighten bolts No. 12 and 13 to a torque of 90 ± 5 N·m (65 ± 4 lb.ft.).
c) Tighten bolts No. 12 and 13 again to 90 ± 5 N·m (65 ± 4 lb.ft.).
d) Tighten each bolt 90 ± 5° of a turn more.
NOTE: See INSTALL CONNECTING ROD BEARINGS for the correct bearing clearance check.
NOTICE
Each counterweight has a number and must be installed in the same

position as the correct number on the crankshaft mounting pad to
prevent damage to the crankshaft when the engine is run.
9. Make sure the dowels are in position and install counterweight (14) on the crankshaft.
NOTICE

more.
10. Put 2P2506 Thread Lubricant on the counterweight bolts and tighten the bolts to a torque of 50 ± 5 N·m
(37.5 ± 4.0 lb.ft.). Then tighten the bolts 120° ± 5° of a turn more.
11. Put engine in a vertical position.
end by:
b) install front drive housing
c) install front balancer (3508)
d) install rear gear group
e) install piston cooling jets

CAT 3512 Service Manual 66Z SENR2382

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CAT 3512 Service Manual 66Z SENR2382

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SENR2373-07

General Information (Fuel System) - Diesel 165

Engine Design INDEX 000

Engine Oil Pan 039 64

Engine Coolant Temperature Sensor 075 119

3500 Marine Engines, SENR2373-07

Number and arrangement of cylinders ... 60 degree V-8

3500 Marine Engines, SENR2373-07

Number and arrangement of cylinders ... 60 degree V-12

3500 Marine Engines, SENR2373-07

Fuel Filter (Primary)

3500 Marine Engines, SENR2373-07

Fuel Pressure Regulator

3500 Marine Engines, SENR2373-07

Fuel Transfer Pump

3500 Marine Engines, SENR2373-07

Fuel Injector Mechanism

3500 Marine Engines, SENR2373-07

Bore diameter of drive housing (D) is

3500 Marine Engines, SENR2373-07

Fuel Injection Control Linkage

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

Camshaft Bearing Position

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

Installation depth for cup plug is

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

131-0421 Cylinder Head 270 ± 35 N·m (200 ± 26 lb ft).

3500 Marine Engines, SENR2373-07

Cylinder Head Valves

Bore in head for valve seat inserts

3500 Marine Engines, SENR2373-07

Cylinder Head Valves

12.619 ± 0.025 mm (0.4968 ± 0.0010 inch).

Stem diameter (C) is

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

Air Inlet and Exhaust Lines

3500 Marine Engines, SENR2373-07

3500 Marine Engines, SENR2373-07

Engine Oil Pump

Bore in the bushing for idler shaft assembly is

31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).

3500 Marine Engines, SENR2373-07

Engine Oil Pump

3500 Marine Engines, SENR2373-07

Engine Oil Pump

3500 Marine Engines, SENR2373-07

Engine Oil Cooler Bypass and Cooling Jet Sequence Valves

Use the following tightening sequence for the clamp bolts:

3500 Marine Engines, SENR2373-07

Engine Oil Cooler Bypass and Cooling Jet Sequence Valves

Tightening sequence for the clamp bolts