RENR3731-02

October 2004
4. Crankshaft Specifications

3512 & 3512B Engine Assembly

Procedure Wall Chart
3512 Engine

Bore

170 mm (6.7 inch)

Stroke

190 mm (7.5 inch)

As Used in

Number of Cylinders

12

785B Off-Highway

Cylinder Arrangement

V-12

Trucks & 3512B

Engine As Used in
785C Off-Highway
Trucks

Firing Order

Out of Round
Main

Fillet Radius

Taper
Rod

Min.

Main & Rod

Max.

Min.

Thrust Bearing
Width

Min.

Max.

Max.

Min.

159.339

159.390

134.341 134.389

(6.2732)

(6.2752)

(5.2890) (5.2909) (0.0008) (0.0008) (2.831)

Max.

Main & Rod

Min.

Journal
Hardness
Main

8. Fuel Injector

Rod

Note: Lubricate injector bore with 1P-0808 Grease prior

to assembly

Max.

1. Plug
2. Clamp
Note: Clamp must be used to draw injector into bore
3. Washer
4. Bolt. Tighten to 65 7 Nm (48 5 lb ft).
5. EUI Injector Group shown in the illustration.
A. Do not tap on this surface of injector during
installation.

All 3500 Remanufactured (POR) Prefix Forging Numbers

0.020 0.020

71.9

72.1
(2.838)

7/32

1/4

Rc48min.

7/32

1/4

$c48min.

All 3500 Production Forging Numbers

1-12-9-4-5-8-11

(Injection Sequence)

2-3-10-7-6

Direction of Rotation

Counterclockwise

159.974

160.025

134.976 135.024

(6.2982)

(6.3002)

(5.3140) (5.3159) (0.0008) (0.0008) (2.831)

0.020 0.020

71.9

72.1
(2.838)

9. Aftercooler Assembly

(When viewed from

flywheel end)

"Q" Denotes Critical Checkpoints

Engine Assembly Sequence
Sub-assembly
Parts

SubAssembly

Seq.

Engine Assembly Procedure

Clean block; refer to SMHS8418
Cylinder Block Cleaning
Procedure.

Q1

Block
Plugs
Seals
Priority Valves
Cam Bearings

Block
Assembly

Q2
3

Cylinder Liners

Q4

Crankshaft
Thrust Washers

Crankshaft

Counterweights

Assembly

Gears

Rings

Piston and

Pistons

Rod
Assembly

Install main bearing halves in

block and bearing caps. Oil main
bearings.

Oil crankshaft main bearing

journals.

Install crankshaft and thrust

washers.

Camshaft

Spacers

Assembly

Install rod bearing upper halves.

Lubricate liner bores, piston
rings, and rod bearing upper
halves.

10

11

Install piston and rod assemblies

in liner bores. (Use 1U-7616
Compressor.)

Q 12

Install rod bearings in rod caps &

install rod cap assemblies on
crank journals. Install & tighten
rod bolts & rotate crankshaft to
top dead center of #1 cylinder.

Cam Followers

Holddown

Install camshaft timing pins.

2. Lubricate piston assembly and bearings with clean engine oil.

Install roller injector lifters and

roller valve lifters.

4. Retainer ring end gap must be within zone "A".

17

Install spacer plate gaskets,

spacer plates, water seals, O-ring
seals & cylinder head gasket.

18

Install cylinder heads.

Fuel Injector
Q 22
23

Aftercooler
Housing

Aftercooler

Tubes

Assembly

Q 24

Lines

a. Top and intermediate ring. Install piston rings with "UP" side toward top of piston. Top of ring (1) has the
mark "UP-1" (yellow color strip to right of ring gap). Intermediate ring (2) has the mark "UP-2" (green color
strip to right of ring gap).

16

Q 20

Aftercooler Core

1. Install piston rings.

15

21

Clamps

Note: Installation requires 6V-4020 Ring Expander Group.

Oil bearing journals and install

camshaft.

19

Fuel Injector

Flywheel Housing Bolt Installation

14

Q 19
Inlet Elbow
Exhaust

5. Piston Group

13

Gaskets

26

(1) Location pin for correct installation of connecting rod cap.

Note: Bolts A and B are on same end of rod cap that has bearing tabs and location pin. Use new rod bolts
at the 2nd and 4th overhaul. Rod bolts can be reused at the 1st and 3rd overhaul. If bolt life is unknown, do
not use again. Refer to Guidelines for Reusable Parts SEBF8301 Inspection & Reuse of Critical Fasteners
in All Engines and SEBF8149 Specifications for Connecting Rods - 3500 Engines for additional information.

28

Install on stands.

Gears
Front

Shafts

Gear Gp

Q 31

Flywheel
Gp

Install flywheel.

Q
33

Torque bolts and check

flywheel runout.

50.8 (2.00)

1D-4574

152.4 (6.00)

5/8 in

5D-9514

158.8 (6.25)

5/8 in

1D-4597

165.1 (6.50)

5/8 in

5P-4626

266.7 (10.50)

Dia
(in.)

Bolt
Location

Part No.

Flywheel Housing Bolt

Installation (version 2)

Bolt Length
(excluding head)
mm

inch

Dia
(in.)

Bolt
Location

Part No.

Bolt Length
(excluding
head)
mm

inch

0S-1595

31.8

1.25

1/2

9X-8873

57.2

2.25

9X-8875

88.9

3.50

1/2

9X-8875

88.9

3.5

1/2

6M-9613

228.6

9.00

1/2

6M-9613

228.6

1/2

9S-1374

203.2

8.00

1/2

9S-1374

203.2

2. Sequentially tighten bolts A & B to 90 5 Nm (65 4 lb ft).

1/2

8S-9089

114.3

4.50

1/2

8S-9089

114.3

4.5

3. Sequentially tighten bolts C & D to 90 5 Nm (65 4 lb ft).

5/8

1D-4590

120.7

4.75

5/8

1D-4590

120.7

4.75

Piston Cooling Jets

10

a. 64.93 mm (2.556 inch)

b. 215 mm (8.46 inch)

b. 317 mm (12.48inch)

c. Angle of 12 degrees & 41 minutes

c. 309.22 mm (12.174 inch)

Tighten bolts and install rear oil

seals

32

1A-1460

a. 200 mm (7.87 inch)

Install flywheel housing.

1/2 in

Check piston cooling jets.

29

30

1/2 in

5. Torque-turn each bolt an additional 90o 5o.

Note: The rod & piston group is to be assembled in an engine with the chamfer side of rod adjacent to the
crank pin thrust surface. The opposite side is to thrust against the mating rod on same crank pin.

Bolts
Rear
Housing Rear Seal
Housing Gp

31.8 (1.25)

4. Sequentially retighten bolts C & D to 90 5 Nm (65 4 lb ft).

Install idler and cluster gears.

Bearings

0S-1595

Note: Make sure 6V-4876 Molykote Paste Lubricant is kept off of the bearing backs.

Install water lines, air tubes, and

adapters.

Remove long block assembly

from rollover stand.

1/2

1. Put 6V-4876 Molykote Paste Lubricant on the bolt threads, shank, and area under the head of each bolt.

Tighten bolts.

27

mm (inch)

1/2 in

1/2

Tighten connecting rod bolts as follows:

Adapters
Long Block
Assembly

Part No.

Flywheel Housing Bolt

Installation (version 1)

Install injectors.

Install aftercooler core and

housing.

Location

3. Ring gaps must be located 120o apart.

Install exhaust manifolds.

Tighten holddown bolts.

Bolt Length (excluding head)

Dia.

b. Oil control ring. Install oil control ring (3) with gap in spring 180o away from gap in ring. White portion of
spring must be visible at ring end gap.

Tighten cylinder head bolts.

Install inlet air elbows.

10. Flywheel Housing Group

NOTICE

Install piston cooling jets and

lower side covers.

Bolts

Prior to assembly, lubricate bore lightly with engine oil or glycerin and lubricate O-ring seals with water or
glycerin. Tighten cover assembly to core assembly bolts (1). Torque for bolts is 25 6 Nm (18 4 lb ft) (2).
Torque for bolts that hold the aftercooler housings to the cylinder block is 55 7 Nm (41 5 lb ft).

Each counterweight has a No. & must be installed in same position as corresponding No. on crankshaft
mounting pad. Not following this recommendation can cause damage to crankshaft when engine is run.

Check end play and rotate

crankshaft.

Cylinder
Head Gp

1. Before assembly, put 6V-4876 Molykote Paste Lubricant on bolt threads, shank & underside of bolt head.
2. Tighten bolts 70 5 Nm (50 4 lb ft).
3. Turn bolts an additional 120o 5o.

Q9

Seals

Note: Never reuse counterweight bolts. Always use new bolts when attaching counterweight segments.

Maximum surface finish for bearing journal for all 3500 Engines is 0.125 um (5 u in.). Thrust face surface finish
must be 0.45 um (18 u in.) or smoother. Ensure there are no wear steps or marks from grinding on surface.
Refer to Guideline for Reusable Parts, SEBF8043 Visual Inspection for Crankshafts, for additional info..

Lubricate bolt threads and install

main bearing caps and tighten
bolts.

Thrust Plates

O-rings

Procedure to tighten counterweight bolts:

2

Q8

Rod Bearings

Camshafts

Check liner projection.

Install camshaft bearings.

Connecting Rods

Cylinder Heads

(1) Thrust plates for center main bearing only.

(2) End play for the crankshaft (new) 0.17 to 0.63 mm (0.007 to 0.025 inch).
(3) Torque for straight thread plugs is 50 7 Nm (37 5 lb ft).
(4) Connecting rod bearing journals.
(5) Main bearing journals.
(6) Counterweight bolts.

Install liners.

Install cooling jet priority valves

For the aftercooler shown in the above illustration, torque for 3/8 inch bolts (1) is 47 9 Nm (35 7 lb ft).

Refer to the above illustration.

Clean oil passages.

Mount block on rollover.

Main Bearings

Pins

Step

d. 85.61 mm (3.370 inch)

11

1. Cylinder Liners
Cylinder Liner Installation

Flywheel Housing Bolt

Installation (version 1)
Dia
(in.)

Bolt
Location

1/2
1/2

Flywheel Housing Bolt

Installation (version 2)

Bolt Length
(excluding head)

Part No.

mm

0S-1595

31.86

1D-4574

152.4

inch

Part No.

Bolt Length
(excluding head)

Dia
(in.)

Bolt
Location

mm

inch

1.25

1/2

9X-8873

57.2

2.25

6.00

1/2

1D-4574

152.4

6.00

1/2

9X-8878

133.4

5.25

1/2

9X-8878

133.4

5.25

5/8

1D-4597

165.1

6.50

5/8

1D-4597

165.1

6.50
9.50

5/8

1D-4602

241.3

9.50

5/8

1D-4602

241.3

b. Momentarily submerge the filler band in clean engine oil.

5/8

1D-4593

139.7

5.50

5/8

1D-4593

139.7

5.50

Note: Once the filler band is soaked with oil it will begin to expand. Therefore, the
band must be installed in liner and liner installed in the block before the band expands.

1/2

2B-0947

57.15

2.25

1/2

1D-4574

152.4

6.00

a. Put liquid soap on the surfaces of cylinder block liner bore and rubber seals on the lower part of the liner.

c. Quickly install the filler band in the groove under the liner flange.

Flywheel Housing Installation:

d. Immediately install the liner in the block, before the filler band expands.

Cylinder Liner Projection

Refer to Cylinder Liner Projection in Testing & Adjusting module of Service Manual for complete procedure.

6. Cylinder Head Group

14 Nm (10 lb ft)
35 Nm (25 lb ft)
70 Nm (50 lb ft)
95 Nm (70 lb ft)

2. Install 3H-0465 Plate (1) & 8B-7548 Push-Puller

shown. Tighten bolts for crossbar evenly in 4 steps:
1st step
2nd step
3rd step
4th step

NOTICE
Plug at location (A) must be installed on these engines.

Crossbar (6) as

7 Nm (5 lb ft)
20 Nm (15 lb ft)
35 Nm (20 lb ft)
70 Nm (50 lb ft)

3. Measure cylinder liner projection with dial indicator (2) in 1P-2402 Gauge Body (3) as shown. Measure at
four places around each cylinder liner near the clamped area.
Average of 4 projection measurements from any cylinder must be 0.059 to 0.199 mm (0.0023 to 0.0078 inch).
Maximum permissible difference between all 4 measurements around each liner is 0.05 mm (0.002 inch).

2. Cooling Jet Sequence Valve

Spring Specifications
6B-9202 Spring for cooling jet sequence valve (one at each end of block):
Length under test force is 68.3 mm (2.69 inch).
Test force is 85 to 102 N (19 to 23 lb).
Free length after test is 112.7 mm (4.44 inch).
Outside diameter is 24.60 mm (0.969 inch).
Both cooling jet sequence valves must start
to open at a pressure difference of
130 30 kPa (19 4.5 psi).
Both cooling jet sequence valves must be fully
open at 200 30 kPa (29 4.5 psi).

1. Make sure height (3) of cylinder head (new) is

142.00 0.15 mm(5.591 0.006 inch).
Note: Apply 6V-6640 sealant in cup bores (2) & (4) before assembly.

1
4

6V-4003 Locator

(5) Tighten bolts holding flywheel housing to rear face of block.

2N-5006 Bolt 1"-14NF X 63.5mm (2.5) long

Torque for 1/2 in. - 13 NC bolts is 135 20 Nm (100 15 lb ft). Guide Bolts 5/16"-18NC X 101.6 mm (4) long
Torque for 5/8 in. - 11 NC bolts is 270 40 Nm (199 30 lb ft).

6V-4977 Installer

9S-8858 Nut

8T-3099 Installer

a. Remove seal from each end of engine.

Note: Seals & wear sleeves cannot be used again
after seals & wear sleeves are separated.

5. Install the spacer plate gasket, spacer plate, water seals, and
cylinder head gaskets. Use 6V-4876 Molykote Paste Lubricant.

b. Remove wear sleeves with 5P-7409 Distorter

and 6V-3143 Distorter Adapter.

6. Install cylinder heads.

Installation:

Crankshaft Wear Sleeves & Seals

a. Do not separate wear sleeves (6) from

crankshaft seals (3) & (4). Once they are
separated they cannot be used again.

(1) Flywheel housing. (2) Front housing.

b. Install sleeve & seal assembly with correct tools.

c. Clean outer surface of crankshaft and the inner

Quick Cure Primer (A surface of wear sleeve (6)
(5) Crankshaft seal installed from both ends of crankshaft 8.0 with 169-5464 erosol spray).
0.5 mm (0.315 0.020 in.). Crankshaft seals must be installed
with seals lip toward inside of engine as shown. Ensure correct d. Carefully put a thin coat of 4C-9507 Retaining
seals are installed. Use 113-8432 on front & 113-8433 on rear. Compound on the inner surface of wear sleeve (6)
and on crankshaft surface.
(6) Wear sleeve.
e. Install seals (3) & (4) with wear sleeve (6) as a
(7) Dimension installed from both ends of crankshaft 0.5 0.5
unit on the end of crankshaft with the correct tools
mm (0.020 0.020 in.).
(3) 113-8433 Seal Gp (rear). (4) 113-8432 Seal Gp (front).

11. Flywheel Group Installation and Bolt Torque

Note: When installing flywheel, put flywheels dash mark
in alignment with crankshafts dash mark.
(1) Put engine oil on all bolts holding flywheel to crankshaft
& tighten to a torque of 1150 60 Nm (848 44 lb ft).
(2) Locations of dash mark on flywheel and dash mark on
crankshaft.

Main Bearing Cap Bolt Torque

Note: Assemble main bearing caps with FRONT & cast part no. toward front of block.

Typical Example - Left exhaust manifold (1). Right exhaust manifold (2).

1. Completely lubricate bolt threads with SAE 30 engine oil before assembly.
2. Start bolts in tapped holes by hand.
3a. If the main bearing cap bolts are 19.05 mm (0.75 inch), then tighten in letter sequence to 136 14 Nm
(101 10 lb ft). Next, tighten bolts in letter sequence an additional 180 o 5.
3b. If the main bearing cap bolts are 22.23 mm (0.875 inch), then torque in letter sequence to 190 14 Nm
(140 10 lb ft). Next, tighten bolts in letter sequence an additional 180 o 5.

1. Put 5P-3931 Anti-Seize Compound on threads of all exhaust manifold bolts & nuts (3).
2. Locations of new Sleeves and Seals (4).

Turbochargers

3. Install bolts and nuts, then tighten to 55 5 Nm (40 4 lb ft).

1. If installing bolts and locknuts (hold turbocharger to exhaust manifold):
Lubricate threads of 3/8 inch bolts that hold turbocharger to exhaust manifold with 5P-3931 Anti Seize
Compound. Position turbocharger on exhaust manifold. Install bolts and locknuts, then torque to 54 5 Nm
(40 4 lb ft). Repeat for the other turbocharger.
2. If installing bolts and washers (hold turbocharger to exhaust elbow):
Lubricate threads and washer face of M10 bolts that hold turbocharger to exhaust elbow with 5P-3931 Anti
Seize Compound. Position turbocharger on exhaust elbow. Install washers on bolts, then insert each bolt
through the exhaust elbow and install in the turbocharger. Torque bolts to 45 10 Nm (33 7 lb ft). Repeat
for the other turbocharger.
3. If installing bolts and washers (turbocharger to bellows assembly):
Lubricate threads and washer face of 3/8 inch bolts that hold turbocharger to bellows assembly with 5P-3931
Anti Seize Compound. Position turbocharger on bellows assembly. Install washers on bolts, then insert each
bolt through the bellows assemblys flange and install in the turbocharger. Torque bolts to 54 5 Nm (40 4
lb ft). Repeat for the other turbocharger.

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All Rights Reserved

2
4

Removal:

4. Install roller injector and valve lifters. Reuse the lifter guide
springs if they meet the "Use again" specifications in SEBF8172
Visual Inspection of 7N-4782 Lifter Guide Spring - 3500 Family.

7. Exhaust Manifolds

6V-4001 Forcing Ring

(4) Put 6V-6640 Gasket Sealant on complete surface of

flywheel housing that makes contact with cylinder block.

3. Install remaining cup plugs (4) to 1.0 0.5 mm (0.04 0.02 inch)
below the bottom of chamfer in cylinder head.

3. Cylinder Block

Qty

6V-4002 Forcing Bracket

(3) Install 2 dowels to a height of 3.5 0.5 mm (0.14 0.02 in.). 1D-4716 Nut (5/16"-18 NC)

2. Install two cup plugs 9.0 0.5 mm (0.35 0.02 inch) deep (2)
in top of cylinder head.

7. Coat head bolt threads 1 thru 8 with engine oil.

8. Tighten bolts (1) as follows:
a. Tighten bolts 1 thru 8 in numerical sequence to
30 5 Nm (22 4 lb ft).
b. Tighten bolts 1 thru 8 in numerical sequence to
200 15 Nm (147 11 lb ft).
c. Retighten bolts 1 thru 8 in numerical sequence to
200 15 Nm (147 11 lb ft).
d. Turn bolts 1 thru 8 an additional 180o 5o.
e.Tighten bolts 9 thru 10 to 55 10 Nm (41 7 lb ft).

Tools needed to install Crankshaft

Wear Sleeves & Seals (front & rear)

(1) Plugs torque 70 15 Nm (50 11 lb ft).

(2) Install 3 dowels to a height of 6.0 0.5 mm (0.24 0.02 in.).

1. Install gasket and spacer plate (5). Install copper washers and bolts (4) to hold the spacer plate.
Tighten bolts (4) evenly in 4 steps:
1st step
2nd step
3rd step
4th step

Reference Flywheel Housing Runout & Flywheel Housing Bore

Runout for the correct methods of flywheel housing inspection.

Printed in U.S.A.