GAIERPII.

TAB'

Specifications
34OOE and 3456 Engines

Built Machines

AEfl-Up

for Gaterpillar

4nhbtErbow.....,............ ...............,,..........
E.rct Mnirotd ._........,,..............

EnSie Oil

Pn

19

.....

$hPup','''.'''.''''''''''..'.'''''-..'-

cdncting Rd Beann! Jouht

r&

B.rino

Jdmd

..

35

Specif ications Secton

3456

Engne Desgn
3406E

(AIdd.
()

Bft

1B)

e&r

(c)

d 4 rs.lF)

bi

!*

Filhd6

dde

d4tu

cr @ ubei
GIFDd ed
(D)

...........-........................... 137.0 mm (5.40 rnch)

strcke .................................... 165.0 mm (6.50 inoh)

Dbprennl -................................. 143

L (3e0

rn)

Cynder Aftnqment .......,.... ...... ln-ne s rylinde

Valvs

ps cyind*

.........-......... ..,

lnlel varve hsh ......... .............. 0.3! mm (0.01s nch)

Exhast %lve

l6h .......,,.,...,,. 0.76

mm (0.030irch)

Finns order (injeclion sequene) ..

cnlchan bialion

lrm

lhe iyrheel

Fuel Transfer Pump

Type

FisftfoFh..1h1tsP

tol

tE h01s to te
ing
iotque. ..........._........._...._ 30 r 5 N (22 14 b n)
lEtan

Type 2
(2i P.$su eoulalinq

|re

(2) P''ersuE resubiilns wN

Electronic Unt Inector

Mechansm

fshlen lhe ns lo rhe rollowitrs

torqoe. ...........-.............3015N m (22 r 4lbfr)

Fuel Filter Base

l
fshc lhe p nut3 io $ tunwio
Irqu. ......... 2 sr 0.25 N m (2212|b in)

\2)
fighign l djosrinO screw rooloul lo lhe
fon@insrrque. ........1ml 10 N.m(74 17 rb)
(3)
Adjusr 'e unir anj.{tr hiqht ro the forr@ine
direm. ...... 7a.0 ! 0.2 mm {3.07 ! 0.01 incrr)

\4) unit injecbr clmp Brinhq bon

f ) ft *rin!
srud is lh

fghin nit injectw damp rning bdr t

3're o rh bs b m nd of $e
fllwins dimension. ... 24.6 ! 1.3 mm
(0.e7

5s

o.o5 inch)

10 N.m (40.6 7.4 lb ).

L@sn

(2) Appry 1 s5 - 0695 Thad Lock Compound on

rhe lapeEd end of rhe srud io rhe lollowing

tl iinifE b.lt

fghisn $ iainis

dmnsro.. ........................... 7.7 mm (o.30 inch)

(5)
']lghrn rh stud io

l drwio

tque. ......,.,, ....,......

70 1 15 N m (50

11 lb

,t)

(6)
(7) Ong

**

unl

$e

bolt is ncr

boft asain ro 55

r l0

Nm

BloB insbnion ot le un[ ir]edor tubrit th

wls silh so/50 mixru ol dsn

iop re o{ing
ngn oir and

3f-2993Lubn@nr

Valve Mechansm

: R.lr to fsrins and Adtsro, .Etecroric Unil

hrdor . adju{ lol fl 6recr prc
_

ot

dr rsh on t6

re.troic unir

iDaciof

Electronic Unt lnector Rocker

Arm

(1) Vlw r.ker m a*mbry

(l) 8oEnlheoc*ersmbadnqrdthercckorm
r

0.015 mn
(1.s774r0.0006 rnh)
Mdimu di'mensim fof dM pans .40.193mm
O.$24 inch)

.......... 40.065

TrE

rlr

beainq musl nd

r he

m.br

ded bMnd

(2) Adj$ihq screw ochd

fghrn the.djlsiis sEw tocknt to le

fn4in! lorqu. ...........30! 7 N m (22 f5 tbfr)

xor.: rflhe eisine .cuipped wth noGsion

bEk6 tle mouniino botts for th domores;on
brk red66 bons l3). Rr lo secirirns
cdpEes'n
&ke".

Tqffn rh botb ro lhe lbntuins

bque.

........_ .109rlsNm(30!f

Oiamder or

bn)

Ecksr am

shai1.....-...

...............,,,.... 0.00o1o.olo mm

Bm

kr,er m

in a nw

shn

11s743r000 in.hr
rorthe,ockr '
.. ..... ..40ir6s!o0r5mm
(r.5774 r 0.00m nr
srino

Mdlmum d m6N,on rd bd. "--a";

mbeanngtorlheookrmshafi .. 40.193mm

(1 s324 inoh)

hl Elves ......... ..,................,.

0.38 ! 0.03 hm
'10.01510.003 ind,l

(0.030

* 0.003 irch)

Cylinder Head

a)oO@(D

"r

21s mm (3.5 inoh)

The bo[s ihal are adied
rhe
bolls
194 mm
rong. Th6 Bmainde. ol

appry 6v -4a76 Lubfiff b rh6 boll lhcads and

bolh sid6 ot le Mshec. fohte th bolE n fl

l.

2.

ln numeri@l sequetue,

tqhle bolts 1 lh@ugh

Torlue for bohs ,...... 270

ln

n a

5 N m (200 1 11 rb

f)

un'tl @uen@, liqhlen bolis 1 thouch

torque lor bolls .......450i

3.

l5N

(330

11

lb)

numedclsequrG. q6i lighn blt3 I

Torqua lor borrs

......450+ 15N

(330

11

lb)

(A) Cylinder Hd Tltichess

of a lw .rrifde
hed.,,,,. 120.0010 15mm (4.72.11 0.006incn)
Tht

*n*

Mjmun l.h* of. used rylndr

hd .........-......-............. 11e.50 mm (a 70s inch)

Nor: The frabess or rhe cyiinder head should b

wn nrorlot0 13mm(.005n).also,rheiar.ss
ofihe ryfnder h.d sh@rd b wiln. mdjmum of
0 05 mm I 002 inch) ror ary 150 m (s.e icl') stn.

11

9C)';

\Q\

NOftcE

C.rddr b.'inss musl b. istued

,I

inl! $en corcr

FailuE io do so wl resuh in nodne daaqe

r) fIrereroreruhbofe

ffin

ot beain! joht

t-...--.................

..

20'15'bdho'izni.r

t
./

ol rlie
rha deih o!
'n{anaon
h'ralrb
;;ry ilD.'tant

comPression Brake
(F EduiPPed)

'gs
(30

*sha be d ns5 )
t 0 50 m (0 75 ! 0 02 inoh
c ... ... 19'12
oo'?
.. .... ..... i-1'.'d;' i9:9 '
""n
P......1 .,....
F... ........ ;;;;i;;.i1,'s'g'o'.'?i^"r'
i' *o oz
1 ......... ....
0,
i$ "
9?

rstrlat'on

de Prh

lor

3it'.-os*li:9:i:$ll*
i6.i;;;;;
"n
j;;';;;
'9 ilt

l'- - ,il)iii

iga"ooz'o

1\
1(
::ilIJr.T"Jtr f t':"$ilT'""
(2)
1. rishbn tuo @nler bolls

"

54(401bli)

T'stfen monns

dld

nul (5).

Toqu. ior mourfing stud nt .....

Tofqu

rr

oule b.ris

rghin ^o enrer

....

b Tsng nd Adjs1ine, :alre pislo

adjust for $ omplee F.edufe for
.djusrq rhe srv piion ra3h.
Nor: R.rer

Lsh -

N.m (0 tb )

.. 54 N.m (40

tb

f)

botrs (2) aqain.

(3) Fmr idrque for srav pislcnr dtwlins $rew

l@rnd ......... ........ ............. 34 N.m (25 tb lr)
(4) Finliorcu ro sotenod vtk

(e.22 b n)

To.!ulorenirbols,........... 109N(30lbn)
Iohlen the mounng slud nul

(5) agan.

Torqolormoundnssludnul... 10sN.(30tb)

rshlen 1so dlBr b.[s

asin.

Torleroroulerbois............. 109N.m(30|bft)

Pnofb

NOTICE

adusrins rh. l.eh s.fins ror the.ngtno

cmpre.sio br.ke, hck tho idotlric.tlon pl8b

thr

5 or lh. coPession br.k

.r.r ro drmie thc mod.t th.r i. insrald on
yor ensin. You mu.t h.w rhis nod. numhr
.d thc ensin6's ..lal nlnbs pGfir n od.r to
dem rh. l.h settins tor your .ngn..

(6) Fna rofque fof

of th mouffino stud

'nr,ndion
htlU'ecvlindrhed
......... 33Nmt65.0tb)

Turbocharger
Pl Num6. AE Forlh Fott.wtnqtlustiio.s:
2221753, 2221751, Zn4t56. 2221757. nd

123-0460, 132-3163, 14,r.m16. 143-2016. 151-3026.

1s4-36t7, 1s5301, 155-79s3, t637t0, 165-7311,

r39.9172, 19l. 009s, 19r-2S2s, 19

l.--

roshlen

,f]ghlen

cramps (1)onlhe tuocharsr, us th

lhe clamp lo the fo lNins

.................. 14 r 1 N m (10.31

brqe.

2. Genuy lap rhe clamp

w rh a sofr taced

o 7 lb

fi)

To r ohren

dmps

I )d

dr

rdharsei

use the

hamer

3. Aqain liqhrn [re clP.

nghEn Ihe crmp !o lhe lollowinq

lorque ... .......... .. 1a 1 N.m (10.3 r0.7 rbtt)

I
ghls

rhe daDp io le lorr ino

tfque........................ 1411 N m l0 310.7 rb fr)

2. Gently bp n'e danp *i' a $fr la@d hammer

ope ing pssr or lhe waslsaG

....

133kPa
(20 psi)

i4tfs fE d.fp.
rEften n crep b t tuleins

3. again

ro lshlen rbe clamp (6) on rhe ocharler, 0se the

ro tshten lhe clamp (3)on ihe turbcharce4 use lhe

nqhrn lhe cmp nur ro the fonowinq

... l3Nm(133lbn)

Loosen rbe c amp nur to rh iollwing

Loosn rhecramp io le ionowng tolque. ..6 N m

(53 1 rb n)

qhten the clamp nut lo rhe lollow ns

rorque....................135r1 N.m(ss10.7rblt)

Tishle rh dlap ro rhe rol ow ns

6Nm(531bin)

Tshren rhe bolls (4 ror lh cop.essr c!p

assby i ppii pans. fghlr rh b b if rh
@mpfessof c mp ssemb y lo rhe fonNins lorque

175i r N.m (12.s01070rbft).

Appy5P-3931 Anr seizecomp!

.B used io mounl ihe luboch.4er qhlen le nuls
rorhelorowns tofqueT0 I 15 N m (51.6 I 11 0 rb).
Parl umb.rs Ar. For Th. Followa s lllustaton:
62-7603. 1 64693. 1 64490, 164-91s6, 1 69-1675,
1694271, 173-002, 139-S2f 0, 139-9211, 1A9-9212,
1

190.6210, r90-621r, 1902r2. rS0-6213, 190-6215,

1

l33lblt)

91

-2926,

19

2-207 7, 19 4 -1 115, 19 4 -111 1, 196 -21 7 5,

lo4ue

...

.. .... 13.sl r

N m (e

ghlen the boli to [ie rliowins

rcfqoe. ................ 13 5 r 1 N m

(9

s10.7

b )

9!

b fi)

0.7

Paft Nunb.6 a For Th Forrowins frusrion:

r 5s-79s2, r 64-9490, r 6+993, 1 64-9496, r 39-921 0
r64.94S0, r39-9210, 139,9211, 13
1904210, 190-6211, 1905212, r90{2r3, and

nd ondad3 ruffiqen aud4b

To lrshren rh

dp {r0t on

lhe lonowio pmceduE

Irr

fyi$npbdalleoqa6'wa9a6

tuo.ha@i

u*

ro llshFn Ihe cramp (13)

'le

tu'bochf!4 use

rghn\eclamptotheloltowins!rque... 1aN.m
(133

rrqhcnrhclan!btl.fon inqtoEue... 13N.

Loo*n the d.mp

Locenlhecramprorfolt inotofque...6N.m

b0

r lhe tottoving

tolqo.. .. 6 N.n
(53.1lb ln)

fghlen rh6 dap to the tdtowfiq

rorqo. ............,......... 13.5 r 1N.m (9.9

0.7 tbfr)

o3.3

tb

f)

(53.1tbin)

ghrd rr .

bfque

amp io

....

...

[ie rolwing
13511N.(S9r07rbii)

I11) wasteqie
Opmg

plsuE

of trl w6resEte ....... 156

kpa

(23 Ps)

Tjgn

[le

cramp

(t2l b the fotrd'ng

t3.5r tN.m 199r0

tb)

Pat Numb are Fd nE Folldi. fitudrio:

162-7303, 190520s, t90206, t90-si0?, t9o-6203,

openins pbssu ollh6 Mrsate ....... 135 kfh

(24 p0

TiqhGn th ctamp to

rolque

..........

rie

13

folsh!

51

1 N.m (9

910.7lbfrJ

{umb.B Arc For Th. Foltowtno tuslroni

1134321.1l,l-ar6.drc.?r Pd

Pll

To

Numt) A@ For Th

tqhin th8 damp (16) on the turocnaEol lso

. 13N
(l3.3lb rl)

r'shlenrhecramprrhlollowingtoque

Les.n

mE dmp t('

e tollNins lorqu.

.. 6 N m
(53 1 lb i)

IOhten th cLmp io Ih tunowing

rolque. ..................,..... 1311N m (9.6

To tighrn rhe Boll (17) on rhe

fgtfen

r0.7|b)

1uel'arge.

f33

lo lh

follNinglolque.

nghin b.ll lo the tollwins

rorque.,.......-...............

13i1

Trghla l @cser clap pll b.ll3 09)

h oppoil palE. ligtfen te @mp'esr dlp
plate blts l lh folleing L.que. ... l7-5 ! 1 N.m

f2.s 10.7D

re

the boll io rhe onng roqu. .... 13 N m

Les6 lhs b[

IEhin rh6 tuine clmp plale bofs (13) to trr

follMinOlorAue.-. 15310.6Nn(11.6r0.4bn)

lbn)

...... 6 N m

(s3.1rbin)

h (9.6.0.7|bft)

n)

- 3 931 Arls.iza Cmpound lo le n uls ihal

e use lo ounl tte iochargei liqht$ lha nds
t lh lclldlnq toque ?0 t 15 N m (515 i 1l.0 lb fr).

Apply 5P

Air lnlet Elbow

oo oo oo

o(D oG)

Apply

(1) LuMere t bore riohty ith

srrl ing th. o{ins sts.

Exhaust Manifold

5F -

3931 Anli-seize Compound to the

tlcds of fts studs lat ngag.

stfen lhe 3tuds n tE cytindr
lollowing

(d)

iorqu

........ 35

the tocknuts.
had ro rhe
. 4 tb )

s N. {26

Appry nqn rr to the Gmat ends of lh manlds

blG assenbly Apdy 2P,2333 Hoh TempeEtu6
&aler b $e mare nds ot th6 mntrolds bfo6
asffibly. Rmore x@ss slerlrom i Asehbted

qtfen he
ll

i3

rocLts in

tle numnetsedu.nd

r.rk;ho
33r5N(2S!4i)

shtun rn ll usrron 4t ro rhe

ioqu,............

Exhaust Manifold Shield

O) rshlen the nuls i tun ino

roque. ............,............25i 7 N.m 03tr5 tbfr)

spcid

rob

r r

Err,usrbb........-....... 3.5rs mm(0.3352rnch)

lll lob ...... .... ......... s.,431mm(0.3713inch)
hiecltr be...,......,....., 10.451 m (0.4115 inch)

Camshaft
Type

shafi

I
Io

frnd rh6 rob ri, us r

i,

MeasuE

ruhat

pmedu rh

ror

M:

lobe heighl {7),

2. Mu bas. crrcb (3).

3. Subtor 'e base @.le neasuEmenl (sip
2) from lhe enshfr h heighl (Slep 1). The

diffeee

s rh

.crur rob rft

Mxlmm pemissible diersce benrn he actual

bbe fin {Siep 3) nd r 3pdd lob llt ol a nw
013 mm (0.005 ich)

o@shaft

[or.: LLbdd

th8 mshaft lbs with 50/50

mirlure ol aT 2993 Lubrint d cr@n engh. or.

Diamers of 'e barinq

loum|s .. 3.35i0.02mm{3.341.0-001 in.h)

b.nr$

rh crn
ord: Lubr t'e mshfr
o pnd lo inslallins lhe @nshafr.

engine

fshlen tE bohs lhal taslen $le rer io lhe

cyrndrh.dbtfon ingtoqu. .. t3r3N

2 b

ff)

f0 t

Z_\

21

fype 2
Io find lhe lob.

rrfr, use th

pb@du $t

fIm:

Msue nBhn tbe heiqhr (7).

2. M*3ur6 bse cn b (3).

3. sdbract lhe b* cale mesumr rsib
2) rion rh shantob. h'shrlsleD i). ihs
diBnce is me sdur rb. ri
Mxium lemissbt dtfieren@ bet*i e actuat
lobe li (Scp 3) nd rhe speoitid tob rifr of a new
@nsh.....-......,,,.......-.......-.. 0.13 mo (0.005 hch)

xotc Lubri16 I6 mshait

n

ue

tobs eith 50/s0

ol 3T- 2993 Lubdcr and ctn nge o

Diamebr or the beadns

joumb.. 343510.02

mm(3.341

0.001 in.rr)

Nor: Lub.i@1. rh kmshafi bnnds w rh .ren

enqine

pde to insrr ns rh6

eroiir

lighln re botts tht hsrn rhe 6wr lo ihe

ctllhdgrheadtothfI@insrorqu. .. 13.3N.m

0012 br)

Slecid nsha o6 tin

Exhsusr rob.................. 3.515
lnlr robe........_............. s.702 hm

ljeclorlobe...........,,. 10.451 mm

fype 2

Engine Oil Flter Base

Type

(1) Apply 9l 3263 ThHd Look Compound on

tle rpercd end of le stud io rh. lorlovno
drnnsion. ...... 1o.5 ! 1 .5 nm (01 r 0.06 not)

IhlnlhestudlDletol

ing irqu6. ..

66I7

(50i5rbn)

t)
t6t fo@ .., 55.25 (2,175 inch)
........--.......... ... ?6 1 5 N (17.0 ! l.1 lb)
Fe bngrh fler test .......... 93.7 mn (3.69 irch)
ou6ide diamecr .--............. 20.6 mm (0.31inch)
Th6 iirt..nd th @or.f bypass larves
rrr pn wit) rh lrrejng pG$B
Lngih under
Tesl

fo@

dlie6ce,,,,.,,,.......-.... 255120 kPi37l 3psi)

2) s-lud
appyss-3263 Thresd Lod( comoound d
e lapeEd qd ot rhe srd r h6 forrMiis
dmnsd. ...........--.............,, 3.0 mm (0.32 inch)
]lohrn rhe shrd ro nle fdlowing
trqle.,,....,,.,...,..-,.....30. 14N m (601 10 lbfrl

Lnglh lndr 16r

re

.., 55,25 mm (2.175 inch)

N f7 t 1,30 tb)
Gr .......... s3.7 mm {3.69 inch)
::sidedisrei6................ 20.6mn (0.31 inch)
4,-. fihd d i er. bypass qtves
,:rr ! $tl me ftlwins ptsr6

Fe

.......76r5.3

lensih ae.

25s

tr!.n tlE

prug

20 kPa {37

io fle forfjis

113. .....-...............100r 15 N.n (74

3 psD

11 lb

Engne Oil Coole Bypass

Valve

Engine Oil Pump

Type

Lngh drlstfor@... 55.25 mm (2.175 inch)

rstrorce ...................7615 N (17.0 t 1.l3lb)
Ffee renqlh ale1esr.......... 93 7m {3.6s inch)
Oulsidedmt.r................ 20.6 {0,31 inch)
Th fllr ad lh cader bypass vatvs

willops wid1 lhe follodinq lGsuG

direre@ ................. zss120kPa(37r3ps0

NOTICE
Belore operaton, th pmp nur be lub rd

lith

clen onginir andrhepumpmusttumffeetybyhand

of daaqe to oans e be rh suh.

(1) Damf of shafrs......_....... 22.217

(0.374?

o_a05

0.0002 irch)

Dmrf of boes in

shafrs

cdr fr
r 0.003 n (0.3763

22.253

1 0.0003 iddh)

(2) Lndhoroea6,......_._......... 7s37510.025m

(31250 t 0.0010 inch)
Dprh ol

bo6

ror

Lngrh uder

Fe

ensh

!ea6

............ 79.502 + 0020mm

(3.1300

0.0003 indh)

lsrfoG..... ri7 9mn (4 3.4 hch)

150!3Nml 0r3tbfrr

firr8sr 152 9mm fo 02in.h)

. .. .... 27 m {1 063 inohj

ours d d,amerer

Type 2

(@
l.sr me badOs s lheb@inge: v.n wi
fl oside ol e pup body.
(A) Pcr o or bdnq joinl from th6 enirriie
tlrcugh beains bocs ........ 30! l5 dqrees

NOTICE

Br opelion, th pump nusl ba tubrited wh

.rnssineondEpumpmu6lrumrreetybyhad
o' dm.s r Fds can bo P 6u r

T6t

Rottror

lst srand with sAE 10W oit a! 4s

llm

the dre nd

"c

Pupsped..................................2550RpM
Oulrt ......... ..........., ..... 193 Umtr (51 US gpm)

Oimrr or lhe ddv shafr

(nw).....................

..

Dameler of ddve

(n4)

...... 20.32010.005mm
(0.3000 + 0 0002 inch)

shatr

r a :'

'.-'.'--.-----'.- (0

22.211

374t r

a.oa'

0 ooo2 inch)

Bre in bed nss ror dnre shfr

(new)................................. 22.25310.003m
(0.3763 t 0.0003 inoh)

(nw)..............:.............. .. 20.361 0.00shm

(0.3016r0.0003inch)
(3)

Dameteroridlrshafi

(ns)..

B.E in beann$ fof

tdtr sha

(new).................

Lngd

20.320r0.00smm

(03000r00002n.h)

.....20.36110.003mm
(0.3016100003inch)

DiamtafidreIshafr(n
Bo/ in

bein6 lo, dbr

) . 22.217 lo.aos
(0 374710.0002 incht

sh6

(new) ........................,,..... 22.25310003mm

(0.3763

0.0003 inch)

ofsea6 (new) ........ s7.153r0.025mm

(2 2503 ! 0.0010 inch)

Deplhof b.srorgars..... 57.235r0.020mm
(2.2s531 0.0003 in)

Test on t.r

rad wil saE low

.i ii c ".

Rolaton iiom $ drive end ..... counrrc

Pum! rp

..

d.li*

................ ............... 2550 lpm

FIM specieuons lor row pessuE

ouhul ..,.............. .......... 272 L,tnin (72 uS spm)
PHsure ............ ............. ........ 310 kPa (a5 psi)
Flry 3pcficions tor hish pBssu
ourput................ ..... 1r4Llmn(33usqpm)
Pressu .................................. 560 kpa (31 ps)

ol ddve shafr
(nw).....:............................ 22 217
Diameler

(0 3747
drive shfr

I 0.005 mm
0.0002 ncht

BoE in benos rtr

nwl...........,....,,.................. 22253 r 0 003 mm
(0.3763 ! 0.0m3 in)

t:)
Diamereroridbsha(new).. 22 217i0.00sm

(0377r00002inch)
Bo in barinst rrr idler shn
('e*)-.. -'..---.----. 22.2531 0.003 mn
(0.3763

0.0003 inch)

()
Lonslh

(n

rq6ln*)........

. 79.375 r 0.02s mn
(3.t25o!0001Oimh)

).....,..............................

79502I0.020

(3.1300i0.0003inch)

Terfo@... .. ..439!24Nl11o.0rsslbr
Lonor unds les fo@ .117.s;m1464 ni
Fe rens{ fi6f resr .... rs29mm(6.02'n.ht
oursided'mrer ............. 27mn(1.063inchj

@ffedine
o4 ) Posiri of benns lolnr lon
l@sh bennq b6 ..............''e30 r l5 dess

fype 2

Nol: rstfi rh6 barings so tal lhe beaifos f6

ih lhe olsid of lhe pump body.

fiush

Engine Oil Pan

Type {

f'ghn oB oa p4 bdls lo e
loaue. ...---...---......-.......-47 1 9

fshl

tr ptug r. ilF folwins

.....701 l0N m (5217 lb fr)

9S-32$ Ed L@k Compund 10 th

lrcads ol.ll piF p&gp d le oil pan.
fghlen ot nt tp plugs lo tle rolNinq
Appy

fghrn rhe oil pn bolts io lh

iorqu ...... ... ... .47r9

rorqu. ......-................-- a1

11N-m (60

t S lbl)

Typ 3
Lub cE the plug liqhy s'l ngh of.
ohlen lhe plus lo lhe llllng
rorque..................... 95rlsNm(70r11lb)

Ighn the bdb io *E folowjns

lqque, ....,......-............. 55 1 10 N,m (41
(2) Pip plus

7 lb

ii)

Apply 5P- 3413 Pipe Selnt to rh rhreds r rhe

liqhren lhe vr bds io

]johin rhe dEn pruq ro t forwhq
roque......................, 70!10Nm(5017tb)

lighten ih

Ioqu.

Crankcase Breather
appry rglf

hN

....,,.

*l

tle

dp lo lhe fot wing

..........__913 N m (30r27 tbin)

ololy@nn io lhe

*t boi

Water Temperature Regulalor

l-'

----r

(2) woter iempetu reouraior

Water Lnes

cmplelelyopenFmpdu 92'ct193"F)

isln......
Minmu oreninq

................. 92.C093.F)
disln ..
(o.41 inoh)

2A

Water Pump

f,shrs fr6 bol th

tollding

hotds ihe lmpler to

rdqu .. .. 39 r 3 N {29 t 2 tb ff)

*t

(2) rha shafr dim.i ar rhe rhon

asmbly er aBa E th lonNino

dnn50n..,, ................. 191010.01m

{0.7520

tt*

E .ear s*mbty odo e

unr lh

shion.ry p

s tut y

@lr

*id

in

0.0004 inch)

pufiD shfr

tE NmD

(a) oirs@r

stsih

lnsl l or
wir purp dnre

sr

lrl.

prtmary tip io@rd fte

Press
oit @t nto ih

'l.

Cylinder Block

'-'.

tl
I

L.
|.,.
L.l

Appry 7r- 7456 Compound to rr dowet

befo6

Th dorernsds sbov6 fl iop $t@

r rhe crnder block by rhe ronrynq
d slano. ....... 13 5t0 5 mm {0.73r002 inch)

rshlen $ ptug b the loll ing

ldque- ............. .....70110 N.m (52 iT tblr)

dsts irend p$ tha nd or lhe cyt'nder

brdr by ie forld'no dir@. ... tg.t r0 5mm
T1

(0.7s

fhickiess ofrh 3prptale .. 3.53510.025 n

(0.3330! 0.0010 inch)
Thrckness of the !5skt tEt is ph6d
bel$en l. spcar prale and h cyti.der
blor. 0.233r0 032 mm (0.0094 i 0 0013mch)

cynnder riner prcjecllor abow lhe sDae

prare....................._.....,......... 0.025 ro 0.152 mm
(0.0010 to 0.0060 inch)

dMrxrends abd rh 14 suta

rtu cylinder bo.r by rhe roons
ditan@ ........ t6o+o5 nm (0 63 r 0 02,ncn)
Th
of

Apply 7rr- 7456

Cmpdnd

io

ra ddel betoE

rh d@teends.bM th bp $la6
f rhe cyindor btoc* by $e rolw ns
disEnce. ..... 20 0r 0 5mm (0 79i 002 inchl

0,02 inch)

Nol: Th ttr i1ns or tle lp MEol suda@

of Ih cylinder bloc* musl be wihi 0 10 mm
t0.0o4 mch). Th fldnte mur aLsewfhn

00s

rn

(s) ede

0 002 rncn) for anv

in

tle

"".

mm

99 in.h)

16

oylindr bl.k for the main beanigs

Manbannqrridrh..
W_ri*l or

1t.s

. 215.90010.025mm
(3.5000t00410nch)

ih. drinder block lr lhe main beadno

..:................. 2r5.s0010013
13

50oo

o ooo5

'nch)

(11) Main barins Qp bofts

of lheprus..........

2.012.0 mm

(0.03

0.03 nch)

6' ruh bii! 6p bts

r4!*m !di!h! dd

use rhe fonowlng prc@du in

l.

dd

lo stfer lh

Appt clan ensine oil l th thds ol the bohs

2. nshbn he bo[s fit

on

tl.

bein!

side

'roueforb.lts.......260i14Nml90!10|b)
3. liqhlen lhe holls
Tofqu rof

bo[s

Pd a malk

on

le opp6ie

....... 260

14

(2

).

N. (190

sd

10 lb fr)

eadh bolt nd eadr @P.

the opposile sid (3) ftom

lt'e

l rledine ol th cnlshafi
bennq borc iD le rp of lhe tylinde' block

rshlen rh bolls

N4

Aisl(a).....-................ 120!5ds@s(2rat5)

(3) D'mension rro

(16.75 !0.006inoh)
.......... 425 02 l1a.rc3inoh)

...42s.45r0.15 m

nohGn lhe b.lrs r be.nno iab gde (41 ol lhe

rom rhe ma'r l. El ro'ownq rue.

ansre (a)...,.,................

120i5d6ss (2nals)

(12) Nw dhensin iom le @nt8rh frhe

dfnkshan befins bore to ln bon of the

cyliderblockpnEft ....... 16510r0.10hm

(6.s00

15) Prs
fshren lh

prus b ihe tonowing.

rolqu.........,.................3517N.m

0.004 inch)

Cylinder Liner
3406E

Apply 5P 3413 Pipe Sernt on rhe drreads orle

pipe plugs bef@ n.lni in the cylinder block.

To p'evenr dqe to $e pislon .oor,ns rers

du ng storc, rhe pison @ol'nslt ust be

fghten tl bris rhai hod the pEion cootiq jels

ro rh6 bnryins lorqu. ..40r 3 N.n (30 i6 tb)
Mininum pemisrbl cleaane betw3a
'e p,eron, 116 p Ern @oths let, nd rh
.. . 0.63 mm (0 025 in.ht

@nksh

The follow ns deps

ac

ror

hta

no rhe cyinder I nr

l.

appt 5P-3975 Rubbq Lobnr n th sutcs

of fr cyrinder liner boc. appty 5P 397s Rubbf
Lrbrjcanton rh. tubbr sats on th tNrFd of

2.

Pur rhe

3.

rslafl finer bnd (3) n me srcore ondr the tiner

. rnr

fer band.ompterety

rhe riner

'n

cen snqine o

h th b.G mrFdErri beroc

16

(1) 806 in nw lin. .....-.....,.,.. 137.135 I 0.025 mm

(s.4010i 0.0010 inch)
(2) Thicknss orfang on re ,.. 3.390
(0.3s00

0.020 nm
0.0oo8 inch)

The minimm rhic*n$ of rh8 pan lhal e b used

agin rhrorrwins
............. 3.370 mn
(0.3492 inoh)

var..

Nd: Rerer

1o

Guidlln For Reusablo Prts,

ne6 lor mo

SEBF3063, 'Cvlhdr L

also, rer lo rad nq nd adrins, 'c,'ntomdion

nder Line
. Projdion for F prc(duE fof inspcrng h
orolecon or the c'ndr ineE

3456

The

forr

ina steps

lhe cvllnder linef

fof

'nslallg
b sFcll
hrn rhc turnder bloc{. Relf
REHso272 for no inlbmalin

Inrrudon,

Rubbr Lubdnl lhe crl rder

bor suraces and on 16 rubber se13
l@s Pa ol lhe crlinder liner

r- Aorv 5P 397s

bi llF
m s

Pt rhe lld band @pLelelv in dean nsii .r

3. lmlll fler bnd (3) in the sod undef rh linr

4. hshll

th6 liner n th bo imtudlelv bero lhe

(r) Ns cJ'nder

nerbore

r3s.635r 0025 mm

154S94

0 0010 ich)

\2')

Minimu mmended lhdoess or lne ovlindr

Lhriianqe..............,,

...

3370mm(03492inch)

Nor.: Refe {o Guideline ior Reusable Prs,

Crankshaft Seals
Durjns imianafion, rhe *atdnvet shoutd
nor ild e st wirh'n lhe tunN no

d'mrer

......... ..

... r77304025m
{700010.010in(ht
Ale imlandon lh le r he sett waar sl*v
shdrd be w tlin t'le tuneins dimonsion fiom th
ff r@ of rE nkshafr. ............ 1 .5 r 0.5 m

6ha

lhe l or
ser'e
'nslrrion,
3hourd
be kith n h lonMins dimeiof f.om rhe
@rraceotlhecrnkshn .... 5.4+0.0 0.6mm

ar

(02s

+000 003mchl
s.a

Atter insiallrion rhe rad i rh. *er

nn , t
b pand w h rhe Ef fe or h cEn|sf1
rin rhe lollwng rorece. ............

{r

Vibration Damper

x6re

Rerer ro sp*rrishorion, sMHs35o3,

'spe.tal Handrng rni'@lion and tmlztion
nslruclions for cBnkshafr s.t Gbops lhar Hv.
HyddFaic G@Ns h ihe seatins LD.for lne
6fct pmcedurc o the tsbllion of h irod nd

No.: Do not sepale lh sd fiom lhe ste.v. ff

l. *al is seeaEtd no ihe sred. sl set nusi

NOTICE

Dufis insra ton, rhe seardfivf shoutd

nol ontacl t'e sea sithrn rhe fonM'nd

...........

1t.s0 r-o 2s

mm

17.00orooro,nhr

Aer nstann rhe tac ot lh ser's

wer slv should be frush lh lhe front
fa or re cnksha wih he f.tdtno

........ -o13do 13m

l-0.005 o 0.00s inchr

Aar ms1l arion rh ront .e or ih.

s sin! shuld be wih n th tttNLno
dimssron rrom he tom ae or

*l

ihe

@nkshan,.....................s.23+000-0.60mm
(0.203 + 0.000.0024
After insiandon. e e ofih *t s es'nd 'n.hr
nsi
b pafnerwih me fd race ot [e rks-hfi
wilhin re tollhg roleEnce.

Thdouoh|yinspectlev|'eusd
re.kse or for rsns of d6nid ld;maoedt-c*e
Eilher or rh6* @ditios en Gus lh f,taht lo
ake @nlct wilh tl6 * This can ffed lh6 vs-

appry4c 5593 arfisoze compound lo rhe

botrs.

Connecting Rod Bearng

Journal

sMcScod.:

'l

ffid.,&;-

To..ds-.r*s..TP,sir-i-i;t
(5 f3s 0.0005 ii.h)
h E sod(
lhoB-

1202: 12191 1225

Refef io Guidelie Fof Resable Ptu, SEBFP,009,

"Mai ad connciins Rdd Bnnss'd Guld8line
-CEnkshaft
For Rlsbre Pas, SEBF3041,

roor5b

r5.ts4 o.ooo5 rmhr

C.nnectng Rod
Rid to Sr@l l6tudDn, sMHs7l66, 'Usins
dE sP-2o5O cffino Rod CheO Fnu

g"ffi:}ffi :'3[",fl :fi r""lfi:'"""

Parrr sBF3oer, -srtEge ot Non smld

oeane belw* lh n4

Lumal. .........

1_

beafing nd lhe

0 062 n k,0 10 mm
(0 0024 mch ro o 0063ln.h)

M&u omissible dEn@ ber*en n6 beadns

n t. .'lmr..... .... ... .. o.2omm (0003 ln.h)

-------------::-l

l--ffi-1-'
I ; I \\4-r
I

Man Bearng Journal

Rerer lo Gdline For Resabl PalE, sEBFsooS,

in and comcling Rod Bsfi$ and Guideline

F R.@ble Prs, sEBF3Ml, 'Cnksh.n

\T'fV \

i /[["

t/"
M

| _,/ !2 \=

cr*nce berv@n

lhe

beding and

t'e

0091mmloO.l6rm

Mdimum pfrsrble de@n biden ule

and

hel(unal

\ -,.
b- r!

..... .. 025mm10.01' ;)

;ll

lrr Bo'e'n

l\

_Jl

6nnec0no rcd tor r psion prn

59640r0.013mm

'

(2.340

O,OO05 nch)

I 6medlq d must be hiEd fo. ihe

insbnidnoldpfupinbeadngDonotusea

ansre(A) ....................e0r5dba.{1/4tum)

Nor:

te @nkshgfr @nneclinq rcd

nedi's d

musr be hsled from

175 rd 260 'C (3,r7 b 463 'F) lor the insiantun
of rhe
Fn b.ring. Mdiom d sbnce ror
35 0mm (3.35 inch)

(2) rh

rilo

(3) Pton pn bedinq bof

......... 55.035!0.003mm
(21657 r 0.0003 in.i')
Thooqhly lub'iL4 m pisrn pt u(h dean engine
oil Dor io asmblv of 'e piro and lhe .dneclinq

(4) The beinna ioinr mur be wirhin

5 deo@es

"Pislons' nd Gudnne rr Rusabr

SEBF3051,

"Pilon Pis and Relainnq

inch)

(6) Etch rhe cylinds u nber on t'e mnneoli ns rod

and ihe 6p an lh s l@lion Ma( rhe @nneclng
rcd and le p wil a umber i lhrcugh 6. Malk
I6 nub66 n rh sa sid or ih conne.lnq
rod as rhe beains lab slob.

use th

3406E

al

(5) Dki?ne beMq r},e oentec of

beadnqs.............................. 261.620.05mm

f0.30010.0m

Pislon and Rinqs

lllNins prcedufe in ofder lo I qhten lhe

tubnie the out6r soffe ol lhe piston

and rhe pdton fnqs w crsn ensin oitbef@
indana in rhe cytinds btock.
ThorouqhLy

listll lhe

rwad
l@ldumfghbngmedbf@me]Edphd6
1- Lbfire lhe boll threads nd re sear no res
the @ps wilh 4c- 5s9s Antl-s?e compound.

ot

lqhlen n'e @nnec$na rcd bolts

Toque fof bons ............,.9013 N.n

(65r6lb)

3. Pd a mr* on 8ch bon nd dh p.

rqhren

eaoh bolt

fom lhe

rol

lo anqle lA).

iop

ng w'lh rh side marked'UP-1'

rhe rop f lhe

sion.

yvhen lhe piston dng is rndned in a cytinder trcr

lht has bo size ot 137.16 mm (5.400 tnch),
lh creaEe belween tle nds l lh pi$n nns

isrherolowing v|oe. ................ 055r 0.'15m

10 022 1 0.006 inch)

lsrrr lhe

t{h lhe side a.ked

r1@ of rhe oion.

inremdile dc

UP2 io@d

when lhe DBlon dno E inrLl8d n a cvrndd ljner

h*

boc siz ol 137 16 mm (s.400 iich),

ll cleac bMen lh dds or lhs pglo nnq
1030r0190mm
is [l roll@inq vrue
l0 042510 0o7s ircn)
har

sde orrhe ollcontrolfing should b6

as*mbrd 1s0 ddE* fom lhe nng end sap
w dlh .r rhe dd in n pislon lor lhe oil
Mrdmo.:. -....... ......... 321 r00tm
{0 126410 0004
Th6 sDnno

'nch)

ino

1137 r 0.013 mm10.1235t 00005 inch)

cr6aE*. bts*n

lh

srcd. dd lhe is dl
00s010 020
'''''
(0 0020 r 0 0003 i^ch)

nDdgdy lubE

le odr sulfa@
sid'
.lean ng'ne
rir4 'ngs
tlE qlinder botk.
'nsEllad '

nd d

(r)

Fisroi'

own aslmbt

M,rimum oamEs'bL deEnc bhden

. dmdd nd the oil rc|nnser
'' 0 15 m 10 006 inch)

Whs th. ol @nlrol nno is imlalled ii a

drndef I nd tlal hs bo siz 0l 137 16 m
,in , . derac berween ihe
;ds of h osron nnq 6 rh tunon!

v'iue

.....

.57i0.1emn(0022100$rnd'l

For ach o.o3 10.001 inch) n@M h lhe

cvxnder lirr boE 5, den@ beton
; ds or rh plslon rin! lncreas6 bv 0 03 m

Nd:
Dored w n the qaps ol
rh nss appmcry 120 deslg ffom each lhr
Th nos should b

lhorcoghly tubnb ll pidor ph wilh clean

ngne oil Pdor lo

on

55

*bly

M7 rO.OO3 m (2.1672r0 0@3 inchl

h ilr pisbn k'.1 for lh piels

oin 55.0r9t 0 004 mm{2166l r 0 CO02 indr)

Bof

Dm.lgoflnew9is|0n
p

55.000

0.005 mm 12 1654 1 0 0002 ncn)

113rOrO15m
L.nolhofrhaodonp'n......
(4 45?

lvw

0 005

ind')

Rler !o Guld.Iine tof Rd*ble PafE, SEBF3049

?'dns and Gu'dxne for R.usble Prrg,
sFFFAosl -Pidon P' and Rts'n'nq Ris'

lnstd tl iop nng *il m stde marxd

rhe b0 ot tte Pi$on.

"UPrr

trrrd

wB E r*i .ins instId n ovlindar lner

tlai hs . bde . ot 137 16 r (5'100 idh)
beEn tl nds ot rh p3ton nnq
le d6.E

lle fooriis Etue.

.... ..... 045!010mn

(0.01310.004inch)

hstar E hEffist dns wilh ttr sade nadcd

'uP,z btmd e rop l1h pision.
ws tlE Fidn 'i4 i!; 'sned in a cvl'nd4 linef
M lul 9zr 137.r6 mm {54m,ncn),
tn d bd, tle ends orti pislon nq
dEtuadE rdE ........ ..033r015mn
(0 033 I 0 006 hn)

TIE sp.liq

d.

ot the oil clrol dng should b6

er$ld l3o dg lom lhe nng nd gap

wdth d ql@ r ns p'don for tle oil
403'001nm
dEltE - 'n
(0.lss100004inch)

0E lw oil @tbl
333 1 O01 Fm (0 1567

Itl-b.a
g

-----...

Cl'E befiE,
dtdriE...--,

1 0.0004 inch)

grwe

and l new oil

0.05 r 002mm
l0 0020 0.0003 inch)

.......

[rximum pmsibre deaEn@ ber*en

[i gr6ve ad the ol @nircl n9 alter
use... ...................... ..... 0.15mm(0.006inch)

(3) Top pision fs

nsiarr th lop fins wirh th side malked 'uP-1'
lNard the iop of tl pirn.
whaf rh pision nng b n$ned in cytinde tnef
lhat h6 a borc size or 139.66 mm (5.4S3 inch),
rhe dean bhr*n rhe ends ol lh psln rjia

vlhen th oir nbor s is insrrLed in a

cylindrlin*lhl has a bore size of137.16 m
(5400 inch),Ihce.Ene bstuer lhe
ends ol th pision dno is rhe fbn@inq

lh ronMins va ue. ............... 0.50

vlu.... 0.55!015mm(0.022t00059hch)

(0.020

For ach 0.03 (0.001 inch) n@se in the

cyliide. ner bore siq lhe dean@ bete.6n
lhe nds oflhe pston nng imass by 0.03

ensi ir pfiof

! 0.10 mm
0.004 inoh)

ln.ian $e remediate rins witr rh srd mrxd

'UP'2'roward tle lop of lho prsl.
wh lh pron jns is insrIen i cyrlndr rhsr
t'al has a borc size ol 139.66 mm (s.493 idrh),
tle .leane btw*n trl6 ends or rhe p sron ns
is th lrleirg varue. ............... 0.3310.15 mm
(0.m3 l 0.003 nch)

Nole: The dngs should b p*ond wilh l gaps or

lh dngs pporimtly 120 dgre6 nm ch other

fhobughry robel8 ih pisidn pin w

crean

assembry

cM

Bore in lh. psion

bring ror rhe pislon
pin... s5.047 r 0.003 mm (2.16720.0003 inch)

ft

Bore lhe pislon sk for lhe pston

pn .. 55.01s10.004mm(2.13610.0002inch)

@fdnns...........................4.033!0.013mm

spnns ends ot the or 6ntror dng sh d be

ssembled 130 dsres 16 $e nna end qaD.
widrh ol rhe gbde h . nw pisrn ror le oil
(0.r533 1 0.000s nch)

pin... 55.000!0.005 mm (2.16910.0002inch)

Legth

ollh.

ing....

pslon pin ..........113.20 i0.15mm

(4.457 I 0.006 inch)

3.930

!0.010 mn (0.1567r0.0004

nch)

cLeaEn@ bel*en rhe gbow d the nry oit

@nrcl ins ........ . .................. 0053t 0.023 mn
(0.0021 r 0.0000 inch)

3456

Mdiun pemissibrecrafndebh'*n
*'e srcove and lh 6naolnns as

Reler ro cuderi fr Rusabte Pads. SEBF3049.

"Psions" and Guidene for Reusable P,ts,
sEBF305l,'Pisbn Pins and Rrinho Rinqs".

......... . 0.15mm(0.006 iich)

whe rhe oil @rd nng is insEled n a

cylinder iner rhr has a blc gze of 139.66 m
(5.4s3 nch), te deaEn blwe the
ends ofrhe ldon ng is rhe bno{ng
(0.0177 + 0.0059 tnch)
For each 0.03 mm (0.001 inchi incres in l
cylinder liner bo size, lhe oleaEn been
rhe

ds of tl pision nnq n@ses by 0.03 mm

Not: Th dss shourd be

pc'i

s trom earh

't'roushly lubnele lhe ouls suac

and lhe piston r ngs wlll dean eng ne
insr.rraton h th dyrinder brock

Thoroohly

lubiie

ol
olhsr

ed wiih rhe qp3

the psion pin wiih dean

sine ol por lo .smbly.

Bof in rhe piron qoM bfing for ire p slon

pin ................. .................. s5 0355 !0.m55 mm

{2.166710.0002

rndh1

ir rhe pislon skil fd th piston

pin... s5 020I0.00s (2.1661.0.0002 nch)
Bor

ol lhe new !slon

prn.. 55.000r0.00sm(2.165.410.0002inch)
Damerer

.
14

r13.201015mn
457 r 0.006

rrfd ro.k cmpo to rh

ffirioru dt te (2) p'ior b indllan.
apdy 155-06S5

s.:i's d

(3)

'nch)

Housng (Front)

u*

th

fdrdiE Flaft a oder ro shln tl

*, ,E Plrlle b dE cylinder b ook.

bdrs lt

1.

U* httd b* b tqhrF

trr b.h.

fEa o: b.lE io 0E lollo*inq

.....55r5Nml4Ot4lbfr)
dcE....
2, Ue hid

b.t

b tghien t'e b.lls

gin.

TdEr E bG b l lob{ing
lolq@ .,.-....--.......-.-..... 5s r s N m (40 }

4 lb

f)

Nor.: aldv aT-9{t22 se Gasket in order i0 fin

e sp drrE drE frg jonl of lhe fonr plate, oil
Fn q4rGr, ad qftrq tod(

Front Housng and Covers

Tqhle lh ttuds har

idw'ns b'que

aon rhe blod\ o the

! 10 N m 175 t 7 lb fi)

... .. 102

Gear Group

(Front)

fohren i6 bd had s@G ontv er

lhldn'no he oH bole nd nurs
ln 6 uturical seqwne, tightn {.e buron hd
s)@ lo thelollMng rofqe. .........13 4 3 N.m

(f0r2rbfr)

apply 155 0695 ThEad tock

lhEds ol fl. d thai ens.s.
Agply 95-3263 Thcd Lock ComDound
lve bolE ror rh srub +er

rhe

fshren rh. bohs lor ihe stub

shl n lhe folldinq sqd@. s@
rrrusrrarion e for lE nunbro of E
1.3,4.5 2.1.2.3.4.s.

Apply

95

3263 ThFad

b.l

compound to the

oiing *al on lhe oGd ol

*ins dab *i[l a 50/50 mi{lure of
3T'2993 Lubfinl ad d ngine oil Applv
95 - 3263 Thd Lod( cdpound l lh the
bolb r le rdn sng Plate.
foht re the reh wlinq p t !
boills ro rh6 dt*n blqE. see llu#lion
39....... ...............-... 1213N m(9i2lb)
Lrohtv lbn@le th

rrhhn rhe r.ur bh8 rhal fasre th6 clustef

dr b fi 3lub shalt io lhe lol owiq

qre.

...............

30t7Nm(22i5 blt)

lrre @msha

Tlehl6n ule dlqd b.is in 'e rollNng

+ouen. s lstr.ton 90 fof lhe numben q
........... 1.4.2,5 3,6, r.4
fii borr.

fomen*le*Fhafrqealbo[910lhe
roiNiq lac. .. 2.or40 N m (ln 1 30 |b fl l
u PrtE st $e oir qrev t(Mrd
Thread Loc(
cdmd to oE o b.lrs lhal hsren lh
LnEt.n

lhe@rh@ Ardy9s.3263
N,isu. id6 9.r

lo

t'e sr, sa

fstller tE oE bdrs ror lh dluslable

idr.r b $b sha lo lh iclloMnq

r-i
..3or7Nmr22islbfir

rot *, i,"tns, "e"". e.,P

(Frorq
rr iB b.cldash djtnent
-

Ire-

t'elEr dE mh. gear aid lhe

0.21610.114 m
diusrtle'ddes ..
Bcd6h

100035r00u5inch)

AFdy 9s-326 lrE-ad Lock Compound

b.l l
TEhlen tE
$ ro F
(6) air

fE ds lq

the slub

10

lhe

.hil.

ho and five nuc tor lhe slb

............ 55 r 10 N m

badrq tr.que.

dlpre* qd

(41r7rb)

f'r quipeed)

@"o

A,pt 9S-3263

oo

Atply 9s-326ts Tn:Fd Ldk compound 10 lhe

l@ b.rs rEl ian le idler sear io tha Errb

oe

ItFi

Lk

Compound to lh

-d fE sUds ror rh stb shft

f-tu tu dE bdr nd ff\ uc for lhe stub
s5 1 10 N m
sfi-aff b iE adg L.que
(4r r 7rb)
ore bo

E bdE ar fasbn lhe

tE s&b shn to e fol owinq
'drr
.30I7Nm(22*5lbil)
brqG..---..
rEhEn E

@'

g4r *iln
tu h

(41 Al'sn rhe lrm'ng mari [ie msha

ls im nq m n the fronl housng
o. 1 pislon is al rop 6nie.

(3) Gr

ro

b.tE l

(9) alqn E

FEcl

PumP driv

nE * d tle

the riig nst o

@nkshafi sr wlh
tlE s:t gr

Flywheel Housing
Tighren rh b.rr rr 1e oit

follwlnq

lump
lque. .........55 1 10

3406E

Flywheel

lloi.:

Oudng ssembly, anspoct th rottM]ns

compels tor ay foEigi mate'ias: th6 frdt

rce of rhe iyrher housins, lle rro sids of lhe

fryrheel ho$ng gasker, and lh r f@ ot lhe

cylindd brd.r( These 6mponnrs nust b fr* of
lh toneins subGtanes oit, tuet, wl. asker
dhesive asblv conDounds. and antoher

rorcrsn minar. Appty in mou oisr-90p2

Silimne Gsk h rer lo llrthe pce be{rm $e
cylinds bl@[, lhe flyvheet hous'no, and e of Dan
berorc
he o on asier and fl or oin

'nsbniq

xore

Do nol h6t ih dns

qr

wrh tofch,

Apply ngne oir to fe lhads ol the bdts.

TEhre l brts ro le fott ing

iorqlo. .....,,............270r40 N.m (200 r30 tb)

To ghrn

t.

$e nrahet housins botrs,

ln nned@tsequne. tishle bo[

foque lor bofts ......... 100

2. h

1t\muqh9.

20 N m (74 1 15 tb tr)

nuen sauce, riqhren botr

Toquo rorbds.............40

the

10

rh'@qh

r0 N.m (30

17b

l a nunsicar sqenoe, aqain rsht bott

lhrcugh bort L

n)

135120Nm(l00r1slbfr)

,r, ln a rm'l@r sequsn@. &ari dlen boll

bo[ 10

ln numdlsequn@, gan liqhlen

Torq iorbohs.............5str r0 m

To$ufo.bolb ........... 55r l0N m(4017lbfi)

(40l

'9..
9

ro

1'?

o5

t)

rqht6n lhe Pluo to lhe lolldins

ssi 14 N m (414
roE@ ...... .

oui.o semby' hsped 6 fondng

ffionsc r.f anv fofEn marnls: lhe ftonl
b;or . wer hesino. rie " sdes or ft6
wheel hou;hs $s[, and l reaf fc. of ihe
.;[nd.. block. These moonnc musr b or
ie rdlNinq $b3lnos oll tuer l6i s*rl

zl,^'

fb'on mbd1. AaDlv . small moun' of 3r_ s022

sil;n Gaslt h order io fll e epae b6l*n the
cdinder bloc{, dr n$heel hdsing nd he oil pan
M insbl||m lhe o I Fn askl nd [l oil psn

To

gtfen l tyvrheel housino boltr' u$ lh

l.

ln a

nuMi@lssquene,

ghten boh

TtquelorbolE...,... 1m l20
ln a numel

re

N m (74

sq@@. ligftei

fofqueforbolls....,,.......40+

1[rrcush9-

15 !b

boh 10 rugh

10 N m

(30r7 lbfr)

@l ssauence, asin tshis bolt

forque lor botts

...

l3S+20Nm(100t15lbn)

a
I'

Nor.: Dufno

asbrx

inspecl

E ldnMins

6pnenb ltrny fo'qn ruinb rhe rronl

rc r rhe nr'heet houdiq rhe o sdes ot the
f,yeerhoushs osrr and rhe Earlca orrhe
cylnd.f brock. rhese conponenlg musr b nee oi
fr iollNins subshns: of lul wel saske
dhesire asse mbly r mp.und s, and.ny dhsr
ibian tnr ADDrv snal amountorsT s022
srrlce Gaskel in o.der r iI rh spae be4en th
ylindrbr4r $e rrheer housinq, nd iha tpn

3456

ro lighren le lnhlhoGng b.rt6, use le

l.

uefil*quen, fghlen

Torqu lor borts ........

2.

Ln

[rfoush

100120 N m (74115 rb)

z numefil seq ue@, ightan boft 10 {hrcush

Tofq

3. ln

bort 1

i'f

bdrb .....

a nuned@l

40 1 10 N.m (30

squen6, aga rigtfen botr

7 tb )
1

foqefrbls...... 135120N.l0ai15tb)
21, ln

umdca squne, asain tghln botr 10

Torqueforbolts............s5 1 10

Nm

(4017 tbfr)

Nor.: Dunng **bty, inspe.l th r tdins

mmpotunrs for any loreiqn mreda s: rhe
fce of the ll,lh.r hosins, rhe lwo sidos or rr
flywheel housing gaskeL and lhe br fce or the
cyihdr bbcr. These compdnls musl be free of
Me tunowins subsrnG oit, tuet, sats, oastel

fdr

*sMbry (mpNnds, and antote

fo'qn mtenl AoDrv a smn mud or 3r . so22
sr rcon Gaskel n ofdr b n dre sp.ce b.twn rhe
adhesive.

cylinde bl@k, $6 fiwheel housins, nd $ oit oan

beloB istarng the oit pn gsket nd lle or p.

To iight rhe frynht hosg

l.

n numed@t

bo[s, us. th

s6qune. tighten bot I rhmush 9.

rorquelorbons.........100120
2.

rn

numei6l $quenG,

N m (74

riorrln otr

1s tb fr)

r0 urrcuoh

Iolqforbolrs...........40rl0N.m(30i7tb)
3, ln a umrica sequ6nc6, aoai shlen bon
TEtfen lhe lh bohs ror tle @wr to the

tollwngtorqoe....,,.l15.20N(35r15tb)

Tofque for bofts

ln

..

135120N.(100115tb)

nair sequn*,

Tolue

gai tqhlen b.tr 10

orbls.. ......55i 10N

(40

!7 tbf)

Belt Tension chart

Not : D or u* the bell len6h chLs
iansioM il E apring lodod

for bell wilh

for oAYco uF[d B.rb

ont

Mounting Gp-Fan Drve

Alternator and Regulator

114-2401 Alternator Gp

trn
,Et

ll$

E
.....................2516Nn(13r4|bfi)

Engne Support (Front)

Nolo: L@d t'e batrery wit' a '.n pile aC a91
Ba{ery Ld Tler in dd to get lle maximum

)-

P.r.i'v................................. ........ Nesrive Gfound

Minium

ouFn

t rld

rb!

lftnr

al 2000 rpm

........ ......

T'grn rE b.

E gound temna io lhe

to[orn'gtdq........6.2]06N (5s1slbin)
].ishbn lhe elght bolls lo lhe
roque. ......... . 135 r 20

fshien e n on lhe output

shfr or ih
lienalor Io rhe followng to4- ... 102r7Nm

(755tbtt)

fghGn rhe nd on rh pos(ive teminat lo lhe

forlowino rofqe. .... .7.110.3 N.m (5 1 0.6 lb fr)

Voltase sefiing................. ....-..... No

adj.tnt

Pmsibrgvorra! fnoe....,......,.... 27to29v

liqhien lhe not o rhe positve lm{nIs th

forro*rngtofqe. ...... 13.21 2.4 N m f13r 2lbfi)

fshGn le nut or 1e opur sha o,

rh

llmcrto'ero(winqioeu...i27110Nm

(94i7lb)

Tiohten lhe n on th qrcund lmna t rh

ror*inslorqoe........4.4r1.0N.m(3ererbin)

169-3345 Allernator Gp
vohase sins .......................... No adjusLft nt
Pemissible vorras6 En$ .................. 27 t 29 v

Electrc Starting Motor

Type

ilA
!".s
Nor: Lad the batey wirh a eon pt. 4c- 491
Baery L@d T6le. i .rne l(l g11he naximum

P.|arily . .,,. ............ ......-....... ........ Nqive c@nd

Rota n ................................................. CtoclMts
Minlmom lull lod

drenr

Minimum tull load

orenr .t

ar 5000 pm ......... 50
1500

Am

......... 3o

o&utvftg ...,,,,.................................. 23

Anp
Ap
1.0 V

tle electic aiho odr is ewed from

rh. ddv nd, rhe moror @lales i tho ioning
When

No rod

trdriom d x"c

(77"F)

.............. .... 76,131 1633 Dm

corenr dr.w ....... ............. ... 67.5 r7.s amp
vollag.................................................23V
Speed....

rhe not on the banery lemna io lhe

t) nghlen
tollowins brq. ..... 30.5a3.5 N m (22 3 rb)

t2)

rght ! th ot on th gbnd lmnal lo lhe

tolowinqiorlue.....30.5r3.5N m2r3lbn)

(3) rshln th ut on the gmund lminal io lhe

tol ownq iorque. ... 22s 1 0.25 N m (20 1 2 lb in)

'fishln ltu nut

rotowins ro!u.

le swiich leminal lo rhe

... 2.25 1 0.2s N m (20 1 2 lb n)

ihe
(22
brqu.
......30.513.5
N
m
r 3!b
followis

(s) fshrn rh nol on rhe moror teminal

1o

f)

(3) fghtn rh. nul on lhe mor rne bminal to

ilre rllwin! lorlue. .....313 N m {71127 bin)

whn m. bcrric sNajng morof is vised rrcm

lhe dive end, t mobr robres in t'e loll@ing
dnedion. ....................................... ......... Clockwise
No load condirions

Spd ............. .......... ........ 5500 lpm minimum

.... 140 AnP mdlhm

9x-gsrl Slarlins ororsolnoidAssbly

crntm.

on 125'c (77'F)

. ............56.5i4.s4mp
tlold-inwdingsa120V. ......... ..... 14.6Amp
Purl n windinss ar 20v

Type 2

d 25'c O7'F)

Vohase
(r

) rhtn il'6 n',

for wing

.... .-....-....--.-.........-- .-.24y

on lh

brqu

(2) fshtn in

...

sod tehinl to th8

30.5 1 3 5 N.m (22

3 tb fr)

on rhe bah'y rem nar to rhe

follNingro'que... ..30.5t3.5N(2213|b)

(3) rshle l,'e not on lli sbnd teminal to t'e

fnMi! idrque. .. 2.2510.25 N m (20! 2 lbin)
(4) fg'rlen lhe nut on il' sw .h teminar to tle
irnNingrrqu ... 2.2510.25 N m (20! 2 lb n)

(5) rsrrlen rhe nur on otd reminar ro rhe

i'nMiq rqu ... . 30.5 r 3 5 N m (22 r 3 tb ft)
(6) Iishlen r'e on rh moro' .ame reminar lo the

turNisrorque ... 305!3.5N.m(22r3rbfr)

cfff

dosumpon ar 25"c (77.F)

Pulliln *ind.g at

24V .. ........ ........ 51 Ap

........-...... ...... 7 Amp

Coolant Temperature Ssor

Fuel Pressure Sensor

dtf,: #il
fqhlen lh
lotque......
hshren trle

*ntr

a$embly ro the rlldlg

ssor .s*mbly
.

{2) Pr0o w lr

edcr a. wker

t514rb)

Engine Ol Pressure Sensor

Fuel Temperature sensor

I'lrlld *| .sy

lo lhe ibnding

rdqe......-..............-.......... 1012N.m (3 1 13 rbin)

rghtn rh s6mor assembly !o

brqu......--...................20r5

Atmospheric Pressure Sensor

)

]lohbn ulle snsor asembty b lhe b r.wha

roque ........ _. _. 1012 N.m (s3113tb ln)

lnlet Atr Temperature Sensor

Type

Type 2

IEhten rh

qsor asnbty

c rhe

fond,nc

....... .. ..20rsN.m(t5!4rbn)

Speed and Timng Sensor

'-\e.'

(1) Pluo wirh eokt A, ed(t

l-Bhten Ih sesor a*brv r.

r.rcue. .... ...................... 1dr 3

B,

ad tutet

C.

P'n clen nsine ot on rh crim 3ea . pur 4p -s5e7

compond
te thds ohin ilp
tunborassembty b lh6 fonNino ioque _ 40i 5N.m

anii*i}

(30

.4

r! i)

lndex
Ens'ne SuPPod lFront)

ExhstMnito|d

- .. ..-- ...
11.2401 Alma@rGP
16e.334s almror Gp

arLnrdErbow-

Armosphec Pfssu'e

.... ..

Exhaust Manlld shi6ld

1!

"

"

49

1!
Jr

Sen$f

Housin9......

.........

34068......................... ....
3456...... .........-.'-.
"
FntHoinsandcov.6..
.
.
...
Bse..
Fifter
Fuel
F0el PEssu Sensor .
" "
FuelTeplure Sesr" ...
Fuel T6nsler PumP ... .

...

..

"
'

camshaft..........

lrT31--- - -----

co;'essDn Brre

(lr Equ'pped)

c,nnoljngRod'''''''''''''
"
coolan TempeElu sensor
.
Breler'
Crnkse
__ --cEkshan....... .. .'........"
.
.
"
crankshalt seals.
cindef Blo.[ ....

cirderH6ad
cvlinder Head

Hsins (Frcnt).....

...

Valves

lmFriad sr! hrmstn

51

ElMc Sbrtiq Motor

Fbnarcunds'ud

.....

Min Brins

Elecvnc unit rnieclor Mechnism .

Erscrfonic unil lnjedar Rockeram -.. _Enohe

osgn

....... ..

Eie oilFrcl Ba*...

TYP

1,

fype

Dnw

'

340 .................
3456............. .... ........

Fnine orcoolf Bvoass

Joumal....

Monlinq GPFa

. . .
Valv . .

..
.

35

23

--..- -----, --Ensine OilPn.. .

s@6t'JGsdd.
spd dd

Tms SlB

-1

Tbl olCdtenls.--.............,,..,,,,,.,............_...._......

3
TurboctEQr-.....-...............--...........-......,...,,,.,..... 13

\llw

M.anilm.............--...,,,,.,,,
VE M.nlsm Co6r..-............-...........,,,.,,,...... 3
Mb.rro oanrpr,,,,,,...-...-......-......

Wr.rUn*.--..............

...........-...................,..,.,,. 27

wai.rPump....,,,,,,.........-...........-............

wf.rfmp.EtuB

_._....._.

2a

Rguraior.....,,,,..,,,,......._....._.. 27