3500 ENGINE SPECIFICATIONS

WATER PUMP

EARLIER WATER PUMP ILLUSTRATED

(1) Oil seal. Put glycerin or clean engine oil on the the bore for the seal.
lip of the seal. Assemble with the lip toward the
splined end of the pump shaft as shown. (5) Earlier water pumps:

(2) Ceramic ring and rubber water seal. Torque for bolt that holds
impeller ........90 ± 15 N•m (65 ± 11 lb. ft.)
a. Put clean water on the seal and ring.
Hit bolt with hammer and again
b. Use the seal installation tool (part of the tighten bolt to................. 90 ± 15 N•m (65 ± 11
replacement seal assembly) and hand lb. ft.)
pressure to install the rubber seal and
ceramic ring as a unit in the housing bore. *Later water pumps:
Make sure the identification groove of the
ceramic ring is installed inside the rubber Torque for nut that holds
seal. impeller ........200 ± 25 N•m (150 ± 18 lb. ft.)
(3) Seal Assembly: (6) Torque for the three studs in pump
housing ........27 ± 4 N•m (20 ± 3 lb. ft.)
a. Remove the spring from the seal assembly.
(7) Clearance between impeller and cover:
b. Put clean water inside the seal assembly.
Earlier water pumps ...................... 0.12 to 0.89
c. Use the seal installation tool (part of the
mm (.005 to .035 in.)
replacement seal assembly) and hand
pressure to install the seal assembly on the
*Later water pumps ...................... 0.62 to 1.39
shaft until the carbon face makes light
mm (.024 to .055 in.)
contact with the shiny face of the ceramic
seal.
*NOTE: Later water pumps have a nut that
holds the impeller on the pump shaft.
d. Install the spring.
(4) Seal. Put a light amount of clean engine oil in

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST PAGE OF SPECIFICATIONS FOR
GENERAL TIGHTENING TORQUES
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3500 ENGINE SPECIFICATIONS

AFTERCOOLER

(3512 AFTERCOOLER ILLUSTRATED)

(1) Put clean engine oil or glycerin on all O-ring seals and in their bores at assembly.

(2) Cut the ends of the gaskets even with the bottom of the housings for assembly.

(3) Torque for all the bolts that hold the aftercooler housings to the cylinder block........55 ±7 N•m (41 ±5 lb. ft.)

WATER CONNECTION GROUP - OUTLET

(1) Tighten bolts to a torque of...135 ±15 N•m (100 ± 11 lb. ft.)

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3500 ENGINE SPECIFICATIONS

WATER TEMPERATURE REGULATORS

Temperature when completely open ......... 2° C (197° F)

Minimum opening distance at

92° C (197° F) ....... 9 53 mm (.375 in.)

V-BELT TENSION CHART

BELT BELT BORROUGHS GAGUE NUMBERS
TENSION TENSION
“INITIAL”* “USED”**
BELT WIDTH BELT WIDTH TOP GAUGE GAUGE
SIZE TOP OF PULLEY READING READING
GROOVE
mm in. mm. in. N lb. N lb. OLD GUAGE NEW GAUFE NO
NO.
3/8 10.7 .422 9.65 .380 445±2 100± 400±2 90±5 BT-33-73F BT-33-95
2 2 5 2
½ 13.8 .547 12.70 .500 534±2 120± 400±4 90±1 BT-33-96-4-16 BT-33-95
9 2 5 4 0
5V 15.8 .625 15.24 .600 534±2 120± 400±4 90±1 BT-33-72-4-15 BT-33-72C
8 2 5 4 0
11/16 17.4 .688 15.88 .625 534±2 120± 400±4 90±1 BT-33-72-4-15 BT-33-72C
8 2 5 4 0
¾ 19.0 .750 17.53 .690 534±2 120± 400±4 90±1 BT-33-72-4-15 BT-33-72C
5 2 5 4 0
15/16 23.8 .938 22.30 .878 534±2 120± 400±4 90±1 BT-33-72-4-15 BT-33-72C
3 2 5 4 0
MEASURE TENSION OF BELT FARTHEST FROM THE ENGINE
"'INITIAL" BELT TENSION is for a new belt.
**""USED" BELT TENSION is for a belt which has more than 30 minutes of operation at rated speed of engine. A10232-1
X1

NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST 33 PAGE OF SPECIFICATIONS FOR
GENERAL TIGHTENING TORQUES

33
3500 ENGINE SPECIFICATIONS
CYLINDER BLOCK

(1) Thickness of spacer plates....................2.313 ±0.025 Install main bearing caps with "FRONT" and cast part
mm (.4848 ± .0010 in.) number toward front of the block. Each cap has a
number and must be installed in the same position as
(2) Thickness of gasket between the cylinder block the correct number on the side of the cylinder block
and spacer plates ................ 0.208 ± 0.025 mm (.0082 pan rail.
± .0010 in.)
a. Before assembly, put Fel-Pro C100 Lubricant (if
(3) Distance all dowels extend above block not available, use 2P2506 Thread Lubricant) on
face.........20.0 ± 0.5 mm (.79 ±.02 in.) the bolt threads and all surfaces that make
contact between the bolt and the cap.
(4) Torque for plugs....100 ± 15 N-m (75 ± 11 lb. ft.)
b. Tighten the bolts in letter sequence
to............. 136 ± 14 N•m (100 ± 10 lb. ft.)
(5) Make reference to CYLINDER LINER PROJECTION,
for the height of the liner.
c. Tighten the bolts in
(6) Bore in the block for the camshaft letter sequence more 180±50
bearings ........92.000 ± 0.020 mm (3.6220 ± .0008
(14) Distance dowel extends from rear face
in.)
of block.............. 6.0 ± 0.5 mm (.24 ±.02 in.)
(7) Camshaft bearing junction.
(15) Torque for adapter ................... 100 ± 15 N-m (75 ±
(8) Centerline through oil holes in camshaft 11 lb. ft.)
bearings. Oil holes must be positioned from
horizontal at angle "X" 20 ± 5° (16) Distance dowels extend from front face
of block.............. 6.0 ± 0.5 mm (.24 ± .02 in.)
NOTE: All bearing oil hole centerlines (8) and bearing
junctions (7) must be in position shown for each side of
cylinder block.

(9) Dimension (new) from centerline of crankshaft

bearing bore to top of block
(top deck) ........ 586.00 mm (23.071 in.)

(10) Width of main bearing

cap.....................340.000 ± 0.015 mm (13.3858 ±.
0006 in.)

Width of cylinder block for main

bearing cap........340.000 ± 0.015 mm (13.3858 ±
.0006 in.) FRONT VIEW OF CYLINDER BLOCK
Clearance between the sides of the main bearing cap
and the cylinder
block ..................0.030 mm (.0012 in.) tight to 0.030
mm (.0012 In.) loose

(11) Bore in the block for the main bearings:

Standard, original size

(new)..................69.742 ± 0.020 mm (6.6828 ±.0008
in.)

0.63 mm (.025 in.) larger than original

size. ...................170.372 ± 0.020 mm (6.7076 ±.
0008 in.) (17) Distance dowels extend from rear face of block...19.0
± 0.5 mm (.75 ± .02 in.)
(12) Dimension (new) from centerline of crankshaft
bearing bore to bottom (18) Distance dowels extend from front face of
of block (pan rails) .............................. 230.00 mm
block.......40.0 ± 0.5 mm (1.58 ±.02 in.)
(9.055 in.)

(13) Tighten the bolts that hold the caps for the main
bearings as follows:
34
3500 ENGINE SPECIFICATIONS

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

b. Put the filler band completely in clean

engine oil for a moment.

c. Install filler band (3) in the groove under the

liner flange, without delay.

d. Install the liner in the bore immediately,

before expansion of the filler band.

(1) Bore in liner

(new)....................... 170.025±0.025 mm (6
6939 ± 0010 in.)

(2) Thickness of flange

on liner............ 12.65 ± 0.02 mm (.498 ± 001 in )

(3) Filler Band.

CYLINDER LINER PROJECTION

liner must be.......................... 0.059 to 0
Make reference to CYLINDER LINER PROJECTION in 199 mm (.0023 to .0078 in.)
Testing and Adjusting for the complete procedure.
Maximum permissible difference between
1. Install the gasket and spacer plate (5). all four measurements .......... 0.05 mm
Install copper washers and bolts (4) to hold (.002 in.)
the spacer plate Tighten bolts (4) evenly in
four steps. (1) 3H465 Plate
1st step .................. 14 N•m (10 lb. ft.)
(6) 8B7548 Push-Puller Crossbar.
2nd step................. 35 N•m (25 lb. ft )

3rd step................... 70 N•m (50 lb. ft )

4th step................... 95 N•m (70 lb. ft )

2. Install tooling as shown. Tighten bolts for

crossbar evenly in four steps.

1st step ..................... 7 N•m (5 lb ft.)

2nd step....................... 20 N•m (15 lb ft )

3rd step.......................... 35 N•m (25 lb ft.)

4th step........................ 70 N•m (50 lb ft.)
3. Measure cylinder liner projection with dial
indicator (2) in 1P2402 Gauge Body (3) as
shown Measure at four places around each
cylinder liner near the clamped area
Average of four projection measurements
from any cylinder
NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRST35 PAGE OF SPECIFICATIONS FOR
GENERAL TIGHTENING TORQUES
35