3412, 3412C, and 3412D Engines (A) Inlet valves (B) Exhaust valves (C) Fuel injection pump 3412 Engines and 3412C Engines Bore ... 137.2 mm (5.40 inch) Stroke ... 152.4 mm (6.00 inch) Displacement ... 27 L (1648 in 3) 3412D Bore ... 145.0 mm (5.71 inch) Stroke ... 162.0 mm (6.38 inch) Displacement ... 32 L (1953 cu in) Cylinder arrangement ... 65 degrees V12 In order to check the engine valve lash setting, setti ng, the engine must be cold and the engine must be stopped. Engine valve lash settings Inlet valves ... 0.38 mm (0.015 inch) Exhaust valves ... 0.76 mm (0.030 inch) Type of combustion ... Direct Injection Firing Order ... 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7, 12 The crankshaft rotation is viewed from the flywheel fl ywheel end of the engine. Direction of rotation ... counterclockwise The rotation of the fuel pump camshaft is viewed from the pump drive end of the fuel injection pump. Direction of rotation ... counterclockwise Number one cylinder is the front cylinder on on the left side of the cylinder block. Number two cylinder is the front cylinder on the right side of the cylinder block. Note: The front of the engine is opposite of the flywheel fl ywheel end of the engine. The left side of the engine and the right side of the engine are viewed from the flywheel end of the engine.
Valve Rocker Arms, Lifters, and Bridges
SMCS - 1102; 1121; 1209 Número de pieza - 4N-4298 S/N - 99U7599-UP Número de pieza - 4N-7352 S/N - 60M5161-UP
(1) Bore in the rocker arm for the rocker arm shaft ... 24.803 ± 0.013 mm (0.9765 ± 0.0005 inch) Diameter of new rocker arm shaft ... 24.752 ± 0.013 mm (0.9745 ± 0.0005 inch) (2) Refer to Specifications, "Cylinder Head" for information that is related to the tightening sequence of the cylinder head bolts. (3) Tighten the valve adjustment screw locknut after you set the valve lash. Torque for the adjustment locknut ... 47 ± 9 N·m (35 ± 7 lb ft) Inlet valve lash (4) ... 0.38 ± 0.10 mm (0.015 ± 0.004 inch) Exhaust valve lash (4) ... 0.76 ± 0.10 mm (0.030 ± 0.004 inch) (5) Diameter of new valve lifter lifte r ... 27.896 ± 0.013 mm (1.0983 ± 0.0005 0.0005 inch) Diameter of the valve lifter bore that is in the cylinder block ... 27.953 ± 0.019 mm (1.1005 ± 0.0007 inch)
(4) 6N-6872 Guide Spring Refer to Guideline for Reusable Parts, SEBF8069, "Salvage of Lifter Bores in 3400 Family Engines" for information that is related to r econditioning the valve lifter bores.
(7) 2N-7229 Spring Length under test force ... 74.2 mm (2.92 inch) Test force ... 45 to 53 N (10 to 12 lb) Free length after test ... 114.3 mm (4.50 inch) Outside diameter ... 29.7 mm (1.17 inch) (8) The protrusion of the dowel above the top surface of the rocker shaft support is the following value. ... 9.7 ± 1.0 mm (0.38 ± 0.04 inch) (9) Clearance for the rocker arms ... 0.30 to 1.40 mm (0.012 ± 0.055 inch) (10) Add or remove 2N-7228 Washers in order to adjust clearance (9). 1
0
Cylinder Head Valves SMCS - 1105 Número de pieza - 269-3676 S/N - 60M5161-UP Número de pieza - 4W-7007 S/N - 60M5161-UP Número de pieza - 273-9999 S/N - 99U7599-UP
1
/sisw eb/sisw eb/
/sisw eb/mediase
Note: The Reuse and Salvage Guidelines, "Valve and Valve Spring Specifications" has the necessary procedure and specifications for checking used valves and springs.
(1) 4N-5906 Spring Length under test force ... 54.99 mm (2.165 inch) Test force ... 344 ± 34 N (77 ± 7.6 lb) Free length after test ... 62.74 mm (2.470 inch) Outside diameter ... 31.75 mm (1.250 inch) (A) Height to top of valve guide ... 32.26 mm (1.270 inch) Note: Apply clean engine oil to the valve stems prior to i nstallation in the cylinder head.
(B) Diameter of new valve stem ... 9.441 ± 0.010 mm (0.3717 ± 0.0004 inch) The minimum diameter of the valve stems for use in the cylinder head Exhaust valves ... 9.309 mm (0.3665 inch) Inlet valves ... 9.309 mm (0.3665 inch) Bore in the new valve guide that is installed in cylinder head ... 9.487 ± 0.020 mm (0.3735 ± 0.0008 inch) (C) Diameter of valve head Exhaust valve ... 41.81 ± 0.13 mm (1.646 ± 0.005 inch) Inlet valve ... 44.98 ± 0.13 mm (1.771 ± 0.005 inch) (D) Angle of valve face
Exhaust valve ... 44.25 ± 0.25 degrees Inlet valve ... 29.25 ± 0.25 degrees
(E) Diameter of valve seat insert Exhaust valve ... 42.850 ± 0.013 mm (1.6870 ± 0.0005 inch) Inlet valve ... 46.025 ± 0.013 mm (1.8120 ± 0.0005 inch) (F) Depth of bore in cylinder head for new valve seat inse rt ... 15.7 ± 0.5 mm (0.62 ± 0.02 inch) Bore in cylinder head for valve seat insert Exhaust valve ... 42.774 ± 0.025 mm (1.6840 ± 0.0010 inch) Inlet valve ... 45.949 ± 0.025 mm (1.8090 ± 0.0010 inch) (G) Projection height of the valve Maximum permissible projection of the inlet valves and the exhaust valves from the face of the cylinder head ... −1.219 to 0.203 mm (−0.0480 to 0.0080 inch) (H) Angle of face of valve seat insert Exhaust valve ... 44.75 ± 0.50 degrees Inlet valve ... 30.25 ± 0.50 degrees (J) Outside diameter of the face of the valve seat insert Exhaust seat ... 39.268 mm (1.5460 inch) Inlet seat ... 40.894 mm (1.6100 inch) Altura de la culata 112.78+/- 0.25
Camshaft SMCS - 1210 Número de pieza - 4N-0965 S/N - 60M5161-UP
(1) Do not use a torch to heat the gear. Maximum temperature of the gear for installation on the camshaft ... 215 °C (419 °F)
(2) Fit between the gear and the camshaft ... 0.64 to 0.140 mm (.0252 to .0055 inch) (3) Diameter of the journals on a new camshaft for camshaft bearings ... 69.850 ± 0.013 mm (2.7500 ± .0005 inch) Bore in front and rear bearings for new camshaft ... 69.969 ± 0.048 mm (2.7547 ± .0019 inch) Bore in five inner bearings for new camshaft ... 69.982 ± 0.061 mm (2.7552 ± .0024 inch) (4) Thickness of new thrust plate ... 4.65 ± 0.03 mm (.183 ± .001 inch) End play of camshaft ... 0.10 to 0.25 mm (.004 to .010 inch)
(6) Procedure for camshaft lobe height 1. Measure the camshaft lobe height (6) . 2. Measure the base circle (7) . 3. Subtract the base circle (Step 2) from the camshaft lobe height (Step 1). The difference is the actual lobe lift. 4. Specified camshaft lobe lift (5)
Exhaust lobe ... 8.783 mm (.3458 inch) Inlet lobe ... 8.100 mm (.3189 inch) The maximum permissible difference between actual lobe li ft (Step 3) and the specified lobe lift (Step 4) is the following value. ... 0.13 mm (.005 inch)
Camshaft Bearings SMCS - 1211 Número de pieza - 117-9509
Note: Two different camshaft bearings are used. Install the wider camshaft bearings in the two outer bores. Install the narrow camshaft bearings in the inner bores.
(B) Bore in the camshaft bearings after installation Outer bearings ... 69.969 ± 0.048 mm (2.7547 ± 0.0019 inch) Inner bearings ... 69.982 ± 0.061 mm (2.7552 ± 0.0024 inch)
The camshaft bearings are installed from the front face of the cylinder block to the following distance. (C) ... 803.1 ± 0.5 mm (31.62 ± 0.02 inch) (D) ... 593.9 ± 0.5 mm (23.38 ± 0.02 inch) (E) ... 409.7 ± 0.5 mm (16.13 ± 0.02 inch) (F) ... 225.6 ± 0.5 mm (8.88 ± 0.02 inch) (G) ... 4.6 ± 0.5 mm (0.18 ± 0.02 inch)
Cylinder Block SMCS - 1201 Número de pieza - 1W-5082 S/N - 99U7599-UP Número de pieza - 4N-2624 S/N - 60M5161-UP Número de pieza - 4W-6144 S/N - 99U7599-UP
1
1
0
(1) Apply 6V-6640 Sealant to the outside diameter of the cup plugs before installation into the cylinder block. (2) Apply 5P-3413 Pipe Sealant to the threads of the plugs before installation into the front and rear of the cylinder block. (3) The dowels extend from the top deck of the cylinder block. ... 18.5 ± 0.5 mm (0.73 ± 0.02 inch) (4) Tighten the studs into the front of the cylinder block to the following torque. ... 35 ± 5 N·m (26.0 ± 4.0 lb ft) (5) The dowels project from the front of the cylinder block and from the rear of the cylinder block. Distance ... 19.0 ± 0.5 mm (0.75 ± 0.02 inch) (6) Main bearing caps Width of the main bearing caps ... 215.900 ± 0.025 mm (8.5000 ± 0.0010 inch) The width of the slot that is machined into the cylinder block for the main bearing caps ... 215.900 ± 0.013 mm (8.5000 ± 0.0005 inch) (7) Apply 5P-3413 Pipe Sealant on the threads of the plugs before installation into the front and the rear of the cylinder block. Tighten the plugs to the following torque. ... 80 ± 15 N·m (60 ± 10 lb ft)
(8) Use the procedure that follows in order to install the main bearing caps.
Index marks for the tightening procedure
1. Lubricate the threads of the bolts with engine oil prior to installation. 2. First, tighten the bolts that are on the bearing tab side of the cap. Torque for bolts ... 258 ± 14 N·m (190.0 ± 10.0 lb ft) 3. Tighten the bolts on the opposite side of the bearing tab. Torque for bolts ... 258 ± 14 N·m (190.0 ± 10.0 lb ft) 4. Use a paint stick in order to place an index mark on each bolt and each cap. Refer to Illustration 2. 5. Tighten the bolts that are on the opposite side of the bearing tab for an additional amount. Turn the bolt clockwise from the index mark. Angle ... 120 ± 5 degrees 6. Tighten the bolts that are on the bearing tab side of the cap for an additional amount. Turn the bolt clockwise from the index mark. Angle ... 120 ± 5 degrees
Front face of cylinder block Typical example
(A) Thickness of a new cylinder head gasket ... 0.208 ± 0.025 mm (0.0082 ± 0.0010 inch) (B) Thickness of the cylinder head spacer plate ... 8.585 ± 0.025 mm (0.3380 ± 0.0010 inch) (C) The size of the bore in the cylinder block for the camshaft bearings ... 76.835 ± 0.018 mm (3.0250 ± 0.0007 inch) (D) The size of the bore in cylinder block for the main bearings Standard size bearings ... 129.891 ± 0.013 mm (5.1138 ± 0.0005 inch) 0.64 mm (0.025 inch) larger than the standard size ... 130.526 ± 0.013 mm (5.1388 ± 0.0005 inch)
(E) The distance from the centerline of the crankshaft bearing bore to the top deck of the cylinder block ... 419.10 ± 0.15 mm (16.500 ± 0.006 inch) (F) The distance from the centerline of the crankshaft bearing bore to the pan rail ... 165.10 ± 0.10 mm (6.500 ± 0.004 inch)
Cylinder Liner SMCS - 1216 Número de pieza - 197-9322 Número de pieza - 2W-6000
1
1
0
(1) Filler band
(A) Bore in new cylinder liner ... 137.185 ± 0.025 mm (5.4010 ± 0.0010 inch) (B) Flange Thickness ... 8.890 ± 0.020 mm (0.3500 ± 0.0008 inch) Minimum thickness ... 8.870 mm (0.3492 inch) Use the following procedure to install the cylinder liner: 1. Put 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. 3. Immediately install the filler band in the groove that is under the cylinder liner flange. 4. Install the cylinder liner into the cylinder block before the expansion of the filler band. Note: Refer to Guideline For Reusable Parts and Salvage Operations, SEBF8068, "Cylinder Liners" for more information. Also, refer to Reuse And Salvage Guidelines,
SEBF8049, "Visual Inspection of the Piston" for more information. 1
0
1
Cylinder Liner Projection SMCS - 1216 Número de pieza - 197-9322 Número de pieza - 2W-6000 /sisw eb/sisw eb/
/sisw eb/fulltext/f
Refer to the Systems Operation, Testing and Adjusting manual for the complete procedure for the cylinder liner projection. Table 1
Cylinder Liner Projection
Cylinder liner projection
0.025 to 0.152 mm (0.0010 to 0.0060 inch)
Maximum variation in each cylinder
0.051 mm (0.0020 inch)
Maximum average variation between cylinders that are adjacent
0.051 mm (0.0020 inch)
Maximum variation between all cylinders
0.102 mm (0.004 inch)
Crankshaft SMCS - 1202 Número de pieza - 4N-0922 S/N - 60M5161-UP /sisw eb/sisw eb/
/sisw eb/mediase
Note: To measure a crankshaft that ma y be bent, a procedure must be followed. Refer to the Guideline for Reusable Parts for the correct procedure.
(1) The pin extends from the surface of the crankshaft face. Distance ... 8.4 mm (0.33 inch) (2) Thrust plates are used on the center main bearing only. Thickness of new thrust plate ... 5.74 ± 0.04 mm (0.226 ± 0.002 inch)
(3) End play New crankshaft ... 0.13 to 0.50 mm (0.005 to 0.020 inch) Maximum end play with used bearings ... 0.89 mm (0.035 inch)
(4) Oil gallery plugs Apply 5P-3413 Pipe Sealant to the threads of the oil gallery plugs prior to installation. Minimum torque for six plugs ... 23 N·m (17.0 lb ft)
(5) The dowel extends from the surface of the crankshaft. Distance ... 4.1 ± 0.5 mm (0.16 ± 0.02 inch) (6) Crankshaft gear
Note: The crankshaft gear must be installed on the crankshaft with the timing mark V on the outside of the crankshaft.
(7) The rear crankshaft seal is installed on the rear of the crankshaft. The seal driver can not contact the seal inside a 177.80 ± 0.25 mm (7.000 ± 0.010 inch) diameter. (8) (9) Refer to the Specifications, "Connecting Rod Bearing Journals" and Specifications, "Main Bearing Journal"for more information. There are two types of front crankshaft seals that are available for use: (10A) The lip type crankshaft seal is installed on the front of the crankshaft. (10B) The radial lip crankshaft seal is also installed on the front of the crankshaft. 1
1
0
Connecting Rod and Main Bearing Journals SMCS - 1230 Número de pieza - 211-0592 /sisw eb/sisw eb/
/sisw eb/fulltext/f
Refer to the Guideline for Reusable Parts for more information.
Connecting Rod Bearing Journals Table 1
Diameter of Crankshaft Journal (Bearing Surface) For Connecting Rod
Original Size
97.028 ± 0.020 mm (3.8200 ± 0.0008 inch)
Clearance between new bearing and new journal ... 0.070 to 0.178 mm (0.0028 to 0.0070 inch)
Main Bearing Journals Table 2
Diameter of Crankshaft Journal (Bearing Surface) for Main Bearings
Original Size 120.650 ± 0.020 mm (4.7500 ± 0.0008 inch)
Undersize Journal 0.63 mm (0.025 inch)
120.015 ± 0.020 mm (4.7250 ± 0.0008 inch)
Undersize Journal 1.27 mm (0.050 inch)
119.380 ± 0.020 mm (4.7000 ± 0.0008 inch)
Main bearing cap with two bolts Clearance between new bearing and new journal ... 0.076 to 0.186 mm (0.0030 to 0.0073 inch)
Main bearing cap with four bolts Clearance between new bearing and new journal ... 0.071 to 0.178 mm (0.0028 to 0.0070 inch)
Connecting Rod SMCS - 1218 Número de pieza - 160-8178
(A) Diameter of the connecting rod bore for the bear ing for piston pin ... 55.436 ± 0.013 mm (2.1825 ± 0.0005 inch) (B) Diameter of the connecting rod bore for the cr ankshaft journal without installing the bearing in the connecting rod and the bolts have been torqued. ... 103.500 ± 0.013 mm (4.0748 ± 0.0005 inch) (C) Distance between the center of the bore for the bearing for piston pin and the center of the bore for the crankshaft journal ... 261.62 mm (10.300 inch) (D) Dimensions for piston pin and bearing Bore of bearing for the piston pin ... 50.830 ± 0.008 mm (2.0012 ± 0.0003 inch) Average roughness of the finished bearing ... 0.8 Diameter of piston pin ... 50.795 ± 0.005 mm (1.9998 ± 0.0002 inch) (E) Inside diameter of connecting rod for the cran kshaft journal after the bearing for connecting rod has been installed and the bolts have been torqued. ... 97.095 to 97.153 mm (3.8226 to 3.8249 inch) Clearance between the new bearing and the crankshaft ... 0.070 to 0.178 mm (0.0028 to 0.0070 inch)
Position of the piston pin bearing
(F) Maximum angle of the bearing joint from the horizontal centerline ... ± 5 degrees (G) Maximum angle of the bearing joint from the horizontal centerline ... ± 5 degrees Note: Do not use a torch to heat the connecting rod.
(H) Maximum length for heating the connecting rod during installation of bearing for the piston pin ... 89 mm (3.5 inch)
Allowable temperature for heating of the connecting rod ... 175 to 260 °C (350 to 500 °F)
View A-A
Note: Install surface (2) of the connecting rod next to the crank pin thrust surface. Refer to Illustration 3. Surface (3) of the connecting rod is now next to surface (3) of the adjacent rod on the common crank pin.
(1) Use the following procedure to tighten the connecting rod nut : 1. Before assembly, lubricate the threads of the bolts and the seating face of the bolt heads with clean engine oil. 2. Tighten the connecting rod nuts to 82 ± 8 N·m (60 ± 6 lb ft).
3. After torquing the connecting rod nuts, tighten each nut for an additional angle (J) of 120 ± 5 degrees.
Piston and Rings SMCS - 1214; 1215 Número de pieza - 4P-1890
/sisw eb/sisw eb/
/sisw eb/mediase
Note: Refer to Guideline for Reusable Parts for information on the pistons, the piston pins, and the retaining rings. Note: Lubricate the piston body assembly with clean engine oil around the zone (A) and the top of the piston body assembly prior to assembly into the c ylinder block.
Top Piston Ring The 1U-6431 Piston Ring Groove Gauge Gp is used for measuring the ring grooves in keystone style pistons. Refer to the Special Instruction that is supplied with the piston ring groove gauge.
(1) Top piston ring Install the top piston ring with "UP-1" mark toward the top of the piston. There is a clearance between the ends of the top piston ring. When the top piston ring is installed in a cylinder liner with a bore of 137.16 mm (5.400 inch), the clearance is the following value. ... 0.55 ± 0.15 mm (0.022 ± 0.006 inch) There is an increase in the clearance between the ends of the top piston rings for each 0.030 mm (0.0012 inch) increase in the cylinder liner bore. Increase ... 0.08 mm (0.003 inch)
Intermediate Piston Ring The 1U-6431 Piston Ring Groove Gauge Gp is used for measuring the ring grooves in keystone style pistons. Refer to the Special Instruction that is supplied with the piston ring groove gauge. (2) Intermediate piston ring Install the intermediate piston ring with "UP-2" mark toward the top of the piston. There is a clearance between the ends of the intermediate piston ring. When the piston ring is installed in a cylinder liner with a bore of 137.16 mm (5.400 inch), the clearance is the following value. ... 1.080 ± 0.190 mm (0.0425 ± 0.0075 inch) There is an increase in the clearance between the ends of the piston rings for each 0.030 mm (0.0012 inch) increase in the cylinder liner bore. Increase ... 0.08 mm (0.003 inch)
Oil Control Piston Ring (3) Oil control piston ring Note: The spring ends of the oil control piston ring should be assembled 180 degrees from the ring end gap.
The 5P-3519 Piston Ring Groove Gauge Gp is available for checking the ring grooves with straight sides. Refer to the Guideline for Reusable Parts for instructions on using the piston ring groove gauge. Width of groove in new piston for oil control piston ring ... 3.190 ± 0.010 mm (0.1256 ± 0.0004 inch) Thickness of new oil control piston ring ... 3.137 ± 0.013 mm (0.1235 ± 0.0005 inch) There is a clearance between the ends of the oil control piston ring. When the oil control piston ring is installed in a cylinder liner with a bore of 137.16 mm (5.400 inch), the clearance is the following value. ... 0.57 ± 0.19 mm (0.022 ± 0.008 inch)
There is an increase in the clearance between the ends of the oil control piston rings for each 0.030 mm (0.0012 inch) increase in the cylinder liner bore. Increase ... 0.08 mm (0.003 inch)
Piston Pin Note: Lubricate the piston pin with clean engine oil before assembly.
(4) Piston pin Diameter of the bore in the piston for the piston pin ... 50.800 ± 0.005 mm (2.0000 ± 0.0002 inch) Diameter of the new piston pin ... 50.795 ± 0.005 mm (1.9998 ± 0.0002 inch) 1
1
0
/sisw eb/sisw eb/
/sisw eb/sisw eb/
/sisw eb/fulltext/f
