3500 ENGINE SPECIFICATIONS
PISTONS AND RINGS
PISTONS AND PISTON RINGS
(1) TOP RING* (2) INTERMEDIATE (3) OIL CONTROL (3) OIL CONTROL
RING* RING**(with 17 oil RING**(with 12 oil
slots) slots)
Width of groove in __ __ 5.050 ± 0.013 mm 5 050 ± 0.013 mm
piston for piston ring
(new)
(.1988 ± .0005 in ) (.1988 ± .0005 in.)
Thickness of piston __ __ 4.968 ±0.013 mm 4.954 ± 0 019 mm
ring (new).
(.1956 ± 0005 in.) (.1950 ±0007 In )
Clearance between __ __ 0.082 ±0 013 mm 0 064 to 0 128 mm
groove and piston ring
(new).
(0032 ±.0005 In.) ( 0025 to .0050 in.)
Clearance between 0.80 ± 0.20 mm 0 80 ± 0.20 mm 0 56 ±12 mm 0 70 ± 0.19 mm
ends of piston ring (.031 ± .008 In, ) (.031 ± 008 in.) (.022 ±005 In.) (.028 ± 007 in )
when installed in a
cylinder liner with a
bore size of 170 mm
(6.694 in )
Increase in clearance (.0010 08 mm ( 003 in )
between ends of
piston ring for each 0
03 mm in ) increase in
cylinder liner bore size
*Install piston ring with "UP" side toward top of piston.
NOTE: Top Ring (1) has the mark "UP-1." Intermediate Ring (2) has the mark "UP-2."
**Install Oil Control Ring (3) with the gap in the spring 180° away from the gap in the ring.
White portion of spring must be visible at the ring end gap.
(4) Bore in piston
for pin ............................... 69.983 + .008 mm (2.7552 + .0003 in.)
Clearance between pin and bore
in piston ............................ 0.008 to 0.034 mm (.0003 to .0013 in.)
Pin diameter ........................ 69.962 ±.005 mm (2.7544 ±.0002 in.)
36
3500 ENGINE SPECIFICATIONS
CONNECTING RODS Diameter of piston
(1) Distance between center of pin (new) ........69.962 ± 0.005 mm (2.7544 ±.
bearings.................. 380.00 mm (14.961 in.) 0002 in.)
NOTE: Connecting rod must be heated for installation of
(2) Distance that locating pin extends piston pin bearing. Do not use a torch. Heat connecting
from rod cap ..... 4.0 ± 0.5 mm (.16 ±.02 in.) rod to a temperature of 177 to 204° C (350 to 400°
F)
(3) Bore in connecting rod for bearing
with bolts tightened to specifications Side clearance between two connecting rods on
(6) ........... 143.028 ± 0.015 mm (5.6310 ± .0006 same crankshaft pin (new):
in.) 3508 ............ 0.900 ± 0.282 mm (.0354 ±
.0111 in.)
(4) Take the connecting rod bearing measurements 3512 .......... 0.850 ± 0.232 mm (.0335 ±
on the centerline of the connecting rod bores. .0091 in.)
3516 .......... 0.850 ± 0.332 mm (.0335 ±
Bore in bearing for .0131 in.)
crankshaft....... ............................. 135.133 to
135.194 mm (5.3202 to 5.3226 in.)
Clearance between bearing and crankshaft
(new)............ 0.107 to 0.218 mm (.0042 to
.0086 in.)
(5) Side of connecting rod with chamfer.
(6) Tighten connecting rod bolts as follows:
NOTE: Bolts A and B are on the same end of
the rod cap that has bearing tabs and location
pin (7).
a. Before assembly, put Fel-Pro C100
Lubricant (if not available, use 2P2506
Thread Lubricant) on the bolt threads and
all surfaces that make contact between the
bolt and the cap.
b. Tighten bolts A and B
to .................... 90 ± 5 N•m (65 ± 4 lb. ft.)
c. Tighten bolts C and D
to ....... 90 ± 5 N•m (65 ±4 lb. ft.)
d. Tighten bolts A and B
again to...... 90 ±5 N•m (65 ± 4 lb. ft.)
e. Tighten bolts C and D
again to........... 90 ± 5 N•m (65 ± 4 lb. ft.)
f. Tighten each bolt more......... 90 ± 5°
(7) Location pin for correct installation of connecting
rod caps.
(8) Bore in bearing for piston pin
(new)....... 70.000 ± 0.008 mm (2.7559 ±.0003
in.)
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR
GENERAL TIGHTENING TORQUES
37
3500 ENGINE SPECIFICATIONS
CONNECTING ROD AND MAIN
BEARING JOURNALS
CONNECTING ROD BEARING JOURNALS
0.63 mm (.025 in.) 1.27 mm (.050 in.)
UNDERSIZE UNDERSIZE
ORIGINAL SIZE (SMALLER) (SMALLER)
JOURNAL JOURNAL JOURNAL
Diameter of
crankshaft
journal (bearing 135 000 ± 0.025 mm 134.370 ± 0.025 mm 133.730 ± 0 025 mm
surface)
for connecting rod (5.3150 ± 0010 in.) (5.2902 ± .0010 in.) (5.2650 ±.0010 in.)
Clearance between 0.107 to 0.218 mm
bearing
and journal (new). (.0042 to 0086 in.)
MAIN BEARING JOURNALS
0.63 mm (.025 in.) 1.27 mm (.050 in.)
UNDERSIZE UNERSIZE
ORIGINAL SIZE (SMALLER) (SMALLER)
JOURNAL JOURNAL JOURNAL
Diameter of crankshaft
journal
(bearing surface) for main 160.000 ± 0.025 mm 159.370 ± 0 025 mm 158 730 ± 0 025 mm
bearings. (6.2992 ± 0010 in.) (6.2744 ± .0010 in.) (6.2492 ± .0010 In.)
Clearance between 0.122 to 0.241 mm
bearing and
journal (new) (.0048 to .0095 in.)
38
3500 ENGINE SPECIFICATIONS
CRANKSHAFT
(3508)
(3512 & 3516)
(1) Thrust plates for center bearing only.
(5) Make reference to Main Bearing Journals.
(2) End play for the crankshaft
(new) ...... 0.170 to 0.630 mm (.0067 to (6) Procedure to tighten counterweight bolts:
.0248 in.)
a. Before assembly, put Fel-Pro C100
(3) Plugs. Lubricant (if not available, use 2P2506
Thread Lubricant) on the bolt threads,
Earlier: shank, and underside of bolt head.
Torque for 1/4 pipe thread b. Tighten the bolts evenly to ......... 50 ±5
plugs ....... 25 N•m (20 lb. ft.) min N•m (37 ± 4 lb. ft.)
"Stake" (make a mark with a punch) the c. Tighten each bolt more ......... 120 ± 5°
crankshaft to hold the pipe plugs tight.
NOTICE
Later:
Each counterweight has a number and must be
installed in the same position as the correct number
Torque for straight thread
on the crankshaft mounting pad to prevent damage
plugs ....... 50 ± 7 N•m (37 ± 5 lb. ft.)
to the crankshaft when the engine is run.
(4) Make reference to Connecting Rod Bearing
Journals.
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR
GENERAL TIGHTENING TORQUES
39
3500 ENGINE SPECIFICATIONS
CRANKSHAFT WEAR SLEEVES
AND SEALS
(1) Adapter.
NOTE: For complete procedure with illustrations, make
(2) Crankshaft seals: reference to Disassembly and Assembly section of this
Service Manual.
Crankshaft seals must be installed with the lip of
the seal toward the inside of the engine as b. Install sleeve and seal assembly into
shown. Make sure the correct seal is installed adapter (1) with correct tools.
on each end of the crankshaft. For SAE
Standard Rotation engines use 1W6974 Seal c. Clean the outer surface of the crankshaft
Group on the front and 1W6977 Seal Group on and the inner surface of wear sleeve (4)
the rear. For SAE Opposite Rotation engines with 6V1541 Quick Cure Primer.
use 1W6977 Seal Group on the front and
1W6974 Seal Group on the rear. d. Carefully put a thin coat of 9S3265
Retaining Compound on the inner surface
(3) Put clean engine oil on the O-ring seals at of wear sleeve (4) and on crankshaft
assembly. surface.
(4) Wear sleeve. e. Install adapter (1), seal (2) and wear sleeve
(4) as a unit on the end of the crankshaft
Removal: with the correct tools.
a. Remove the seal adapters from each end of Tools Needed
the engine and remove the seals from the
adapters. 6V4002 Forcing Bracket (2)
6V4001 Forcing Ring (1)
NOTE: Seals and wear sleeves can not be used again, 1B4330 Nut (5/16"-18 NC) (4)
after the seals and wear sleeves are separated.
6V4003 Locator (1)
b. Remove wear sleeves with 5P7409 2N5006 Bolt (1"-14 NF x (2)
Distorter and 6V3143 Distorter Adapter. 2 5 in. long)
Guide Bolts (5/16"- (2)
Installation: 18 NC x 4 in. long)
6V4977 Installer (1)
a. Do not separate wear sleeves (4) from 9S8858 Nut (1)
crankshaft seals (2). Once they are
separated, they can not be used again.
40
