RENR1230-02

May 2004

Engine Design
3116 & 3126 HEUI 3116 & 3126 HEUI Diesel Truck Engine Specifications
Cylinders and Arrangement 6 In-Line
Diesel Truck Engine Bore 3116 105 mm (4.1 inch)
Bore 3126 110 mm (4.3 inch)
Stroke 127 mm (5.0 inch)
Firing Order 1-5-3-6-2-4
Rotation (viewed from flywheel) Counterclockwise

In-Frame
Overhaul Procedure
Q-Denotes Critical Checkpoint Steps Procedures
Q – 21 Remove side covers and lifter assemblies as a unit.
Literature References Inspect lifter assemblies and camshaft for reuse.

Form No. Title Note: When removing the main bearing top halves, both the
SEBF8211 3116 Reuse & Salvage Guidelines Reference Manual center and two end crankshaft main journals have no
SELD0018 Core Acceptance-Cylinder Heads oil hole. To remove these upper main bearing halves,
SENR6553 3100 HEUI Diesel Truck Engine Disassembly & put a thin piece of soft material (that will not damage
Assembly Manual (8WL, 1WM, 4ES, 2CW, 8HW, 7LZ)
SENR6558 3100 HEUI Diesel Truck Engine Systems Operation
the crankshaft journal) against the end of the bearing
Testing & Adjusting (8WL, 1WM, 4ES, 2CW, 8HW, half, opposite the tab. Tap the bearing with the soft
7LZ) material until the tab of the bearing half is free from the
SENR6557 3100 HEUI Diesel Truck Engine Specifications groove in the cylinder block. When removing the
(8WL, 1WM, 4ES, 2CW, 8HW, 7LZ) remaining four bearing halves using the 2P-5518
SEBF8167 Reconditioning Procedures 3114 and 3116 Engines
(Part of SEBF8211)
Bearing Removal & Installation tool, if the crankshaft is
SEBF8261 Installing a 7C-6208 Cylinder Sleeve in 3114 and turned in the wrong direction, the tab of the bearing will
3116 Engines be pushed between the crankshaft and the cylinder
block. This can cause damage to either or both the
crankshaft and cylinder block.
Initial Disassembly
Q – 22 Remove main bearing caps and bearings from No. 2, 3, 4, 5
Note: EXTRA ATTENTION should be given to cleanliness, as and 6. No. 4 will not have a hole in the journal.
built in dirt is a major cause of engine failure following Q – 23 Clean No. 2, 3, 4, 5 and 6 main bearing journals and caps.
rebuild. Q – Note: Lubricate journal surface of main bearing ONLY.
DO NOT put oil on back side of bearings.
Steps Procedures
1 Steam clean engine.
Q – Note: Ensure main bearing caps are installed correctly.
2 Disconnect batteries. Install main bearing caps with sequence number
3 Drain engine oil facing towards turbocharger side.
4 Drain coolant.
Q – 24 Install upper halves of No. 2 and 6 main bearings. Install
lower halves in main bearing caps and install No. 2 and 6
caps. This will provide support for crankshaft during main
Disassembly bearing replacement. No. 6 main bearing is thrust. Install
thrust bearing at this location. Put clean engine oil on bolt
5 Remove fan drive.
threads and washer contact face. Torque No. 2 and 6 main
6 Remove water temperature regulator.
bearing bolts to a torque of 54 ± 7 N·m (40 ± 5 lb ft). Tighten
7 Remove valve cover. bolts an additional 90 ± 5 degrees (1/4 turn).
8 Remove fuel jumper tubes, seals and loose seat from fuel Q – 25 Remove No. 1 and 7 main bearing caps and bearings.
injection pump. These two journals do not have oil holes, so it will be
9 Disconnect wiring harness plug from fuel injectors. necessary to tap the top bearing halves out with a soft
10 Remove rocker arm assemblies and pushrods. material.
Note: DO NOT pry on the hydraulic fuel injection solenoid Q – Note: Lubricate journal surface of bearing ONLY.
assembly. Pry only on the fuel injector body using the Q – 26 Install upper halves to No. 1, 3, 4, 5 and 7 main bearings.
1U-7587 Removal Service Tool. Damage to the fuel Install main bearing caps.
injector can occur. Q – 27 Put clean engine oil on bolt threads and washer contact face.
Install bolts and washers.
11 Remove fuel injectors. Q – 28 Tighten bolts of each main bearing cap to a torque of 54 ± 7
12 Remove inlet manifold. N·m (40 ± 5 lb ft).
13 Remove the turbocharger and the exhaust manifold. Q – 29 Tighten main bearing bolts an additional 90 ± 5 degrees (1/4
14 Remove cylinder head and cylinder head gasket. turn).
15 Remove crankshaft damper and pulley. Check alignment Q – 30 Check end play of crankshaft with a dial indicator. End play
marks on damper. Replace if necessary. must be 0.07 to 0.32 mm (0.003 to 0.013 inch).
16 Remove crankshaft seal (front) and install new seal with Q – 31 Check clearance between ends of piston rings. See topic,
shipping sleeve in position. “Piston and Rings” in the Specification Manual, SENR6557.
17 Remove engine oil pan. Q – Note: The oil ring is to be installed over the spring with
18 Remove oil discharge tube, oil pump and piston cooling jets. the end gap 180 degrees from the oil spring joint. After
Q – 19 Mark connecting rods, rod caps and main bearing caps
before removing. During assembly it is mandatory that all
installing of all three piston rings, put the piston rings in
rod and main caps be installed in the same location as position so the end gaps are 120 degrees apart.
removed. Q – Note: The connecting rods were marked with the number
Note: To protect the crankshaft journals from the threaded of the cylinder they were removed from. Reinstall the
portion of the connecting rod bolts, cut short pieces of rod and piston in the same location as removed. Be
rubber hose and install them over the connecting rod sure the short pieces of rubber hose are installed on
bolt threads. the rod bolt threads to protect the journals from
damage.
Q – 20 Remove piston and rod assemblies. Take care to prevent Q – Note: Engines using one piece pistons have the word
damaging the crankshaft journals. “FRONT” on the crown. The word “FRONT” must be
facing toward the front of the engine. The two piece
Q – Measuring Cylinder Bores piston is not stamped with the word “FRONT”. The
piston orientation to the rod is not necessary on the two
Refer to Guideline For Reusable Parts and Salvage
piece piston.
Operations, SEBF8211, for information and procedures.
Measure all cylinder bores with the 4C-4377 Stress Plate Q – 32 Install ring compressor tool group.
Group and a cylinder head gasket over each cylinder to Q – 33 With number one crankshaft throw at bottom center, carefully
simulate accurate bore conditions. The crosshatch remaining install piston and connecting rod assembly into cylinder block.
and bore diameter determines if honing or installing sleeves is Q – 34 Put connecting rod in alignment with crankshaft journal. Using a
required. Refer to SEBF8261, “Guideline for Reusable Parts rubber mallet, tap piston into cylinder bore until ring compressor
comes off piston.
and Salvage Operations for additional information. The Q – 35 Before connecting rod comes in contact with crankshaft, install
4C-4377 Stress Plate Group is ONLY used when measuring upper half of rod bearing. Be sure bearing tab engages with
the bores and honing. It is NOT used when boring the groove in connecting rod.
cylinders. Cylinder bores which show at least 75% of Q – 36 Apply clean engine oil on JOURNAL SURFACE ONLY of upper
crosshatch pattern and have only light vertical scratches can rod bearing. Continue tapping piston down, guiding connecting
rod onto crankshaft.
be restored by flexible honing. Refer to SEBF8167, Guideline Q – 37 Position lower half of rod bearing in corresponding numbered rod
for Reusable Parts and Salvage Operations for additional bearing cap. Be sure bearing tab engages with groove in rod
information. Cylinder bores with less than 75% should be bearing cap.
reconditioned with a rigid hone. Bores larger than maximum Q – 38 Apply clean engine oil on JOURNAL SURFACE ONLY of lower
dimensions require sleeving. bearing surface. Install rod bearing cap on connecting rod with
number on bearing cap on same side and same number as on
connecting rod.
Maximum Cylinder Bore Size As Measured With Stress Plate Q – 39 Apply clean engine oil on bolt threads and all surfaces that make
Installed: contact between bolts and caps. Tighten each rod cap nut to a
torque of 54 ± 5 N·m (40 ± 4 lb ft). Put a reference mark on each
rod cap nut. Tighten each nut an additional 60 ± 5 degrees (1/6
3116 Engine 105 mm (4.134 inch) 8WL
turn).
Q – 40 Install remainder of pistons and connecting rod assemblies using
3126 Engine 110 mm (4.331 inch) 1WM above procedures and torques.
Steps Procedures Steps Procedures
Q – 41 Check the piston cooling jets and then install them. Tighten the Q-50 Install gasket and turbocharger. Apply 5P-3931 Anti-Seize
cooling jet bolt to a torque of 28 ± 7 N·m (21 ± 5 lb ft). Compound to turbocharger studs. Install locknuts. Tighten
Install the oil pump. locknuts to a torque of 54 ± 5 N·m (40 ± 4 lb ft).
Q – 42 If new or exchange cylinder head is being installed, transfer all Q – 51 Make sure mating surface of cylinder head and cylinder block are
components to replacement head. thoroughly clean.
Piston Cooling Jets for 3116 HEUI
a. 120.6 ± 0.3 mm (4.75 ± 0. inch) Note: To prevent damage to the two cylinder head-to-cylinder
b. 110.2 ± 0.3 mm (4.34 ± 0.010 inch) block dowels, keep the cylinder head assembly level
c. 114.1 ± 0.3 mm (4.49 inch) during installation.
d. 120.3 ± 0.3 mm (4.74 ± 0.010 inch)
e. 22.6 ± 0.3 mm (0.890 ± 0.010 inch)
Q – 52 Put new cylinder head gasket in position on cylinder block. Be
f. 9.7 ± 0.3 mm (0.382 ± 0.010 inch) sure head gasket is DRY. Fasten hoist to cylinder head, and put
g. 41.5 mm (1.63 inch) in position on cylinder block.
Note: Dimensions b, d and e are for the spray for one orifice;
dimensions a, c and f are for the other orifice’s spray.

Cylinder head bolt tightening sequence

Q – 53 Tighten bolts 1 thru 14 in number sequence to a torque of 300 ± 15

N·m (220 ± 11 lb ft).
Q – 54 Loosen bolts 1 thru 14 to a torque of 0 N·m (0 lb ft).
Q – 55 Tighten bolts 1 thru 14 in number sequence to a torque of 130 ± 15
N·m (95 ± 11 lb ft).
Q – 56 Retorque bolts 1 thru 14 in number sequence to a torque of 130 ±
15 N·m (95 ± 11 lb ft).
Q – 57 Turn bolts 1 thru 14 by a numerical sequence an additional 90º (1/4
turn).
Piston Cooling Jets for 3126 HEUI Q –58 Apply 4C-5593 Anti-Seize Compound on the threads and under bolt
a. 108.01 ± 0.25 mm (4.25 ± 0.010 inch) head of bolts 15 thru 20.
b. 121.30 ± 0.25 mm (4.78 ± 0.010 inch) Q – 59 Tighten bolts 15 thru 20 in number sequence to a torque of 55 ± 7
c. 38.5 mm (1.52 inch) N·m (41 ± 5 lb ft).
d. 24.32 ± 0.25 mm (0.957 ± 0.010 inch) Q – 60 Install HEUI Injectors as shown in Disassembly & Assembly
e. 121.30 ± 0.25 mm (4.78 ± 0.010 inch) Manual, SENR6553.
Q – 61 Adjust valves according to procedures listed in System Operation
Testing & Adjusting , SENR6558.

Cylinder and valve location

Crankshaft Positions For Valve Lash Setting

SAE Standard (Counterclockwise) Rotation Engines As Viewed
From the Flywheel End
Exhaust Manifold Check/Adjust With No.1 Piston On TC Compression Stroke*
Inlet Valves 1-2-4
Exhaust Valves 1-3-5
Check/Adjust With No. 1 Piston On TC Exhaust Stroke*
Inlet Valves 3-5-6
Exhaust Valves 2-4-6
Firing Order 1-5-3-6-2-4
*Put No. 1 piston at top center (TC) position and make identification for the
correct stroke. Make reference to Finding Top Center Position For No. 1
Piston in 3100 HEUI Diesel Truck Engine Systems Operation Testing &
Adjusting, SENR6558. After top center position for a particular stroke is
found and adjustments are made for the correct cylinders, remove the top
center (TC) bolt and turn the flywheel counterclockwise 360 degrees. This
Typical example of a three-piece exhaust manifold will put No. 1 piston at top center (TC) position on the other stroke. Install
the top center (TC) bolt in the flywheel and complete the adjustments for the
NOTICE cylinders that remain.
If 2P-2333 Sealer is left on the inside of the exhaust manifold
after assembly, it may cause damage to the turbocharger. Valve Lash Setting: Engine Stopped
Inlet Valves 0.38 ± 0.08 mm (0.015 ± 0.003 inch)
Q – 43 Coat inside diameter of female ends of manifold with clean Exhaust Valves 0.64 ± 0.08 mm (0.025 ± 0.003 inch)
engine oil. Note: After setting valve lash, tighten adjusting screw locknut to 30 ± 7 N·m
Q – 44 Apply thin coat of 2P-2333 Sealer to outside diameter of male (22 ±5 lb ft).
ends of manifold before assembly. Remove excess sealer from
assembled joint. Q – 62 Finish assembling engine components.
Q – 45 Continue with procedure given for one-piece exhaust manifold.
Q – 63 Fill engine with oil.
Q – 64 Fill engine with coolant.
Q – 65 Connect batteries.
Q – 66 Start engine and check all operating systems.
Q – 67 Check for fuel and oil leaks before road testing vehicle.

Typical example of a one-piece manifold

Q – 46 Check condition of exhaust manifold gaskets. If gaskets are

damaged, replace with new parts.
Q – 47 Apply 5P-3931 Anti-Seize Compound on threads of bolts that
hold exhaust manifold in position.
Q – 48 Put gaskets and exhaust manifold in position on cylinder head
assembly. Install locks and bolts that hold it. Tighten bolts 1 thru
12 in numerical sequence shown to an initial torque of 4 ± 1 N·m
(3 ± 1 lb ft). Tighten bolts 1 thru 12 in numerical sequence to a
final torque of 45 ± 5 N·m (33 ± 4 lb ft). Bend lock tab over flat of
each bolt head. If necessary, loosen to tighten bolt to align flat of
bolt head with lock tab.
Q – 49 If four turbocharger mounting studs were removed from exhaust
manifold, apply 5P-3931 Anti-Seize Compound on studs, install,
and tighten to a torque of 35 ± 5 N·m (26 ± 4 lb ft).

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