Product: MARINE ENGINE

Model: 3516B MARINE ENGINE S2X

Configuration: 3516B Marine Engine S2X00001-UP

Testing and Adjusting

3500B and 3500C Marine Engines
Media Number -RENR5078- 05 Publication Date -01/11/2006 Date Updated -11/11/2006

Finding the Top Center Position for the No. 1 Piston

SMCS - 1105-531

Table 1

Tools Needed Quantity

9S-9082 Engine Turning Tool 1

Illustration 1 g01193047

Timing bolt location (typical example)

(1) Cover
(2) Timing bolt

(3) Plug

1. Remove cover (1) and plug (3) from the right front side of the flywheel housing.

Illustration 2
Timing bolt installation (typical example)

(2) Timing bolt

(4) 9S-9082 Engine Turning Tool

2. Put timing bolt (2) through the timing hole in the flywheel housing. Use the 9S-9082 Engine
Turning Tool (4) and a ratchet wrench with a 1/2 inch drive in order to turn the flywheel in the
direction of normal engine rotation. Turn the flywheel until the timing bolt engages with the hole
in the flywheel.

Note: If the flywheel is turned beyond the point of engagement, the flywheel must be turned in the
direction that is opposite of normal engine rotation. Turn the flywheel by approximately 30
degrees. Then turn the flywheel in the direction of normal engine rotation until the timing bolt
engages with the threaded hole. This procedure will remove the play from the gears when the No.
1 piston is on the top center.

3. Remove the valve cover for the No. 1 cylinder head.

4. The inlet and exhaust valves for the No. 1 cylinder are fully closed if the No. 1 piston is on the
compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be
moved and the valves are slightly open, the No. 1 piston is on the exhaust stroke. Find the
cylinders that need to be checked or adjusted for the stroke position of the crankshaft after the
timing bolt has been installed in the flywheel. Refer to Testing and Adjusting, "Crankshaft
Position for Fuel Injector Adjustment and Valve Lash Setting".

Note: When the actual stroke position is identified and the other stroke position is needed, remove
the timing bolt from the flywheel. Turn the flywheel by 360 degrees in the direction of normal
engine rotation.
 Product: MARINE ENGINE
Model: 3516B MARINE ENGINE S2X
Configuration: 3516B Marine Engine S2X00001-UP

Testing and Adjusting

3500B and 3500C Marine Engines
Media Number -RENR5078- 05 Publication Date -01/11/2006 Date Updated -11/11/2006

Crankshaft Position for Fuel Injector Adjustment and Valve

Lash Setting
SMCS - 1202

Table 1

Counterclockwise Rotation (Standard) from the Flywheel End of the Engine

Cylinders to Check/Adjust
Engine Correct Stroke For No. 1 Piston At Exhaust Valves
Inlet Valves Injectors
Top Center Position (1)

Compression 1-2-6-8 1-2-3-7 2-3-4-7

3508
Exhaust 3-4-5-7 4-5-6-8 1-5-6-8
1-3-6-7-10-12
Compression 1-4-5-6-9-12 2-4-5-8-9-11
3512
2-4-5-8-9-11 1-3-6-7-10-12
Exhaust 2-3-7-8-10-11

1-2-5-7-8-12- 1-2-3-4-5-6-8-9 3-4-6-9-10-11-

Compression
13-14 15-16
3516
3-4-6-9-10-11- 7-10-11-12-13- 1-2-5-7-8-12-
Exhaust
15-16 14-15-16 13-14
(1) Put the No. 1 Piston at the top center (TC) position and identify the correct stroke. Refer to Testing and Adjusting,
"Finding the Top Center Position for the No 1 Piston". Find the top center position for a particular stroke and make the
adjustment for the correct cylinders. Remove the timing bolt . Turn the flywheel by 360 degrees in the direction of
normal engine rotation. This will put the No. 1 piston at the top center (TC) position on the other stroke. Install the
timing bolt in the flywheel and complete the adjustments for the cylinders that remain.
 Clockwise Rotation (Reverse) from the Flywheel End of the Engine
Cylinders To Check/Adjust

Engine Correct Stroke For No. 1 Piston At Exhaust Valves

Inlet Valves Injectors
Top Center Position (1)
Compression 1-3-4-8 1-2-7-8 2-6-7-8
3508
Exhaust 2-5-6-7 3-4-5-6 1-3-4-5

2-5-8-9-10-11
Compression 1-3-4-6-7-12 1-4-5-8-9-12
3512
2-5-8-9-10-11
Exhaust 2-3-6-7-10-11 1-3-4-6-7-12

1-2-5-6-7-8- 1-2-3-4-5-6-9- 3-4-9-10-11-12-

Compression
13-14 10 15-16
3516
3-4-9-10-11- 7-8-11-12-13- 1-2-5-6-7-8-13-
Exhaust
12-15-16 14-15-16 14
(1) Put the No. 1 Piston at the top center (TC) position and identify the correct stroke. Refer to Testing and Adjusting,
"Finding the Top Center Position for the No 1 Piston". Find the top center position for a particular stroke and make the
adjustment for the correct cylinders. Remove the timing bolt . Turn the flywheel by 360 degrees in the direction of
normal engine rotation. This will put the No. 1 piston at the top center (TC) position on the other stroke. Install the
timing bolt in the flywheel and complete the adjustments for the cylinders that remain.
 Product: MARINE ENGINE
Model: 3516B MARINE ENGINE S2X
Configuration: 3516B Marine Engine S2X00001-UP

Testing and Adjusting

3500B and 3500C Marine Engines
Media Number -RENR5078- 05 Publication Date -01/11/2006 Date Updated -11/11/2006

Valve Lash and Valve Bridge Adjustment

SMCS - 1102-036

Illustration 1
(1) 147-2060 Wrench

(2) 147-2059 Torque Wrench

(3) 148-7211 Bridge Nut Socket

(4) 145-5191 Gauge Support

(5) 147-2056 Dial Indicator

(6) 147-5536 Indicator Contact Point

(7) 147-2057 Indicator Contact Point

(8) 147-2058 Indicator Extension

 Table 1

Tools Needed Quantity

147-2060 Wrench 1

147-2059 Torque Wrench 1

148-7211 Bridge Nut Socket 1

145-5191 Gauge Support 1

147-2056 Dial Indicator 1

147-5536 Indicator Contact Point 1

147-2057 Indicator Contact Point 1

147-2058 Indicator Extension 1

147-5537 Dial Indicator (not shown) 1

Note: The 145-5191 Gauge Support (4), the 147-2057 Indicator Contact Point (7), the 147-2058
Indicator Extension (8), and the 147-5536 Indicator Contact Point (6) are included in the 147-5482
Valve Lash Gauge Group .

Note: The 147-2056 Dial Indicator or the 147-5537 Dial Indicator (Metric, not shown) can be used with
the 147-5482 Valve Lash Gauge Group .

There are two different design of valve bridges that are used. If the engine is equipped with an
adjustable valve bridge (Illustration 2), proceed to the "Valve Bridge Adjustment". If the engine is
equipped with a nonadjustable valve bridge (Illustration 3), proceed to the "Valve Lash Adjustment".
Illustration 2
Adjustable valve bridge
Illustration 3
Nonadjustable valve bridge

Valve Bridge Adjustment

The Electronic Control Module produces high voltage. To prevent

personal injury make sure the Electronic Control Module is not
powered and do not come in contact with the fuel injector solenoid
terminals while the engine is running.

Note: When the 147-5482 Valve Lash Gauge Group is used, it is not necessary for you to remove the
rocker arm shaft assemblies. The valves must be fully closed when the adjustment is made. Refer to
Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".

Installation
1. Assemble the 147-2058 Indicator Extension and the 147-5536 Indicator Contact Point on the 147-
2056 Dial Indicator or on the 147-5537 Dial Indicator .
Illustration 4
145-5191 Gauge Support

(1) Knurled knob

Illustration 5
(2) Valve cover base rear bolt hole
 Illustration 6
(3) 147-5536 Indicator Contact Point

(4) Top edge of the valve bridge

2. Install the 145-5191 Gauge Support in the rear bolt hole (2). The rear bolt hole is located in the
valve cover base. Adjust contact point (3) on the top edge of valve bridge (4) .

Illustration 7
(5) Adjustment screw

3. Loosen the locknut for the adjustment screw. Loosen the adjustment screw (5) by several turns.

4. Apply a force of 5 N (1 lb) to 45 N (10 lb). Push down on the top contact surface of the valve
bridge. Zero the indicator.

5. Turn adjustment screw (5) in the clockwise direction until the dial indicator reads 0.038 mm
(0.0015 inch). This measurement is equal to turning the adjustment screw 20 to 30 degrees
clockwise after the screw contacts the end of the valve.
 Illustration 8
(6) 148-7211 Bridge Nut Socket

6. Hold the adjustment screw with the 148-7211 Bridge Nut Socket (6) in order to tighten the
locknut to 30 ± 4 N·m (22 ± 3 lb ft). You may use a sliderule torque computer in order to
determine the torque wrench dial reading for the different extensions. Refer to Special Instruction,
SEHS7150, "Snap On Torque Computer".

Valve Lash Adjustment

The Electronic Control Module produces high voltage. To prevent

personal injury make sure the Electronic Control Module is not
powered and do not come in contact with the fuel injector solenoid
terminals while the engine is running.

Note: Adjust the valve bridges before you make the valve lash adjustments.

Table 2

Valve Lash Setting: Engine Stopped

Valves Gauge Dimension

Inlet
0.50 mm (0.020 inch)

Exhaust
1.00 mm (0.040 inch)

1. Ensure that the number 1 piston is at the top center position. Refer to Testing and Adjusting,
 "Finding the Top Center Position for the No. 1 Piston".

2. The number 1 piston should be at the top center position of the correct stroke. Make adjustments
to the valves according to the chart: Refer to Testing and Adjusting, "Crankshaft Positions for
Fuel Injector Adjustment and Valve Lash Setting".

Note: Tap each rocker arm on the top of the adjustment screw before you make any adjustments.
Use a soft hammer. Make sure that the lifter roller is seated against the base circle of the camshaft.

Illustration 9
(1) 145-5191 Gauge Support

(2) 147-2057 Indicator Contact Point

3. Install the 145-5191 Gauge Support (1). Use the 147-2056 Dial Indicator or use the 147-5537 Dial
Indicator. Use the 147-2057 Indicator Contact Point (2). Install the tool in the rear bolt hole. The
rear bolt hole is located on the valve cover base.
 Illustration 10
(3) 147-2060 Wrench

(4) 147-2059 Torque Wrench

Illustration 11 g00286367
(3) 147-2060 Wrench

(4) 147-2059 Torque Wrench

4. Move the rocker assembly upward and move the rocker arm assembly downward. Move the
rocker assembly several times. The oil film is removed in order to get a true zero reading on the
dial indicator. Use the 147-2060 Wrench (3) and use the 147-2059 Torque Wrench (4). Install the
socket wrench and install the torque wrench on the nut of the rocker arm. Apply upward pressure
to the front of the rocker assembly. Set the dial indicator to zero. The weight of the torque wrench
(4) allows the valve lash to be read. Do not apply any pressure on the torque wrench.

5. Loosen the locknut. The locknut is located on the adjustment screw of the pushrod. Turn the
adjustment screw until the valve lash is set to specifications. Tighten the nut for the adjustment
screw to 70 ± 15 N·m (50 ± 11 lb ft ). The 147-2059 Torque Wrench is preset to the torque that is
required. Check the adjustment again.
 Product: MARINE ENGINE
Model: 3516B MARINE ENGINE S2X
Configuration: 3516B Marine Engine S2X00001-UP

Testing and Adjusting

3500B and 3500C Marine Engines
Media Number -RENR5078- 05 Publication Date -01/11/2006 Date Updated -11/11/2006

Fuel Injector Adjustment

SMCS - 1290-025

Table 1

Tools Needed Quantity

9U-5132 Engine Timing Tool Group 1

6V-3075 Dial Indicator 1

8S-3675 Indicator Contact Point 1

9U-5138 Setting Gauge 1

9U-5137 Magnetic Fixture 1

122-0451 Timing Fixture Rod 1

122-0449 Rod Sleeve Extension 1

9U-6272 Nylon Screw 1

NOTICE
The camshafts must be correctly timed with the crankshaft before an
adjustment of the unit injector lash is made. The timing pins must be
removed from the camshafts before the crankshaft is turned or
damage to the cylinder block will be the result.
 The Electronic Control module produces high voltage. To prevent
personal injury make sure the Electronic Control Module is not
powered and the unit injector solenoids are disconnected.

Note: Calibration of the engine speed/timing sensor is not required unless the timing wheel has been
removed from the camshaft or the Electronic Control Module (ECM) has been changed.

This adjustment is critical. Ensure that the adjustment of the fuel injector is made properly.

1. Refer to Testing and Adjusting, "Crankshaft Position for Fuel Injector Adjustment and Valve Lash
Setting". All of the injectors can be checked or adjusted with the two crankshaft positions in the
chart. This will make sure that the pushrod lifters are off of the lobes and on the base circles of the
camshaft.

Before a check or an adjustment can be made, the tooling must be set to the correct dimension.

Illustration 1
(1) 9U-5137 Magnetic Fixture

(2) 122-0451 Timing Fixture Rod

(3) 122-0449 Rod Sleeve Extension

(4) 9U-5138 Setting Gauge

(5) 6V-3075 Dial Indicator

(6) 8S-3675 Indicator Contact Point

2. Place rod (2) in fixture (1) . Install extension (3) on fixture (1) . Install contact point (6) on dial
indicator (5) . Install dial indicator (5) in extension (3) .

3. Make sure that the surfaces of the fixture (1) and gauge (4) are clean and dry.
 Illustration 2
Adjustment of the fuel timing tools

(1) 9U-5137 Magnetic Fixture

(2) 122-0451 Timing Fixture Rod

(4) 9U-5138 Setting Gauge

(5) 6V-3075 Dial Indicator

4. Place dial indicator assembly from Step 2 on the top surface of gauge (4) . Rod (2) must be on the
top step of gauge (4) .

Note: Gauge (4) has two steps. Make sure that the step designation is for the 64.34 mm (2.53
inch) dimension.

5. Loosen the nylon screw for the dial face of dial indicator (5) . Move the dial face of the dial
indicator (5) in rod sleeve extension (3) until all of the pointers indicate zero. Tighten the nylon
screw for the dial face of dial indicator (5) .

6. Make sure that the top surfaces of injector follower (7) and shoulder (8) are clean and dry.
 Illustration 3
Fuel timing tools in position

(1) 9U-5137 Magnetic Fixture

(5) 6V-3075 Dial Indicator

(7) Injector follower

(8) Shoulder

7. Place dial indicator (5) and fixture (1) in position on the injector that will be checked. Make sure
that the magnetic base of the fixture is on the top surface of injector follower (7) . Rod (2) must be
on the top surface of shoulder (8) .

8. The dial indicator pointers must indicate 0.00 ± 0.20 mm (0.000 ± 0.008 inch).

9. If the dial indicator pointers indicate 0.00 ± 0.20 mm (0.000 ± 0.008 inch), no adjustment is
necessary. Proceed to the next injector to be checked. Repeat the procedure from Step 4. If the dial
indicator pointers do not indicate 0.00 ± 0.20 mm (0.000 ± 0.008 inch), proceed to Step 10 and
Step 11.

10. Loosen the adjustment screw locknut for the injector that is being adjusted.
 Illustration 4
The installed timing and fuel setting tool group

11. Turn the adjustment screw until the dial indicator pointers indicate 0.00 ± 0.20 mm (0.000 ± 0.008
inch). Tighten the adjustment screw locknut to the torque that is listed in the engine's
Specifications manual. Then check the adjustment in order to be certain that the adjustment has
not changed. If necessary, repeat this procedure until the adjustment is correct. When the
adjustment is correct, proceed to the next injector to be checked. Repeat the procedure from Step
3.

12. After all injectors are checked and/or adjusted, remove the timing bolt from the flywheel.
 Product: MARINE ENGINE
Model: 3516B MARINE ENGINE S2X
Configuration: 3516B Marine Engine S2X00001-UP

Testing and Adjusting

3500B and 3500C Marine Engines
Media Number -RENR5078- 05 Publication Date -01/11/2006 Date Updated -11/11/2006

Camshaft Timing
SMCS - 1210

Timing Check
Table 1

Tools Needed Quantity

9S-9082 Engine Turning Tool 1

Illustration 1
Location of timing pins (typical example)

(1) Timing hole

(2) Timing pin

1. Remove the rear camshaft covers from both sides of the engine.
2. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".

Note: When the timing bolt is installed in the flywheel, it is not necessary to remove the No. 1
valve cover in order to find the compression stroke. Both of the rear camshaft covers must be
removed in order to check the timing.

3. When the timing bolt is installed in the flywheel, look at the rear end of the camshaft. If the timing
ring is visible, then the No. 1 piston is on the compression stroke. If the timing ring is not visible,
then feel the back of the camshaft for the groove. If the groove is at the back of the camshaft, then
the flywheel must be turned by 360 degrees in order to put the No. 1 piston on the compression
stroke.

Illustration 2
Installation of timing pins (typical example)

(2) Timing pin

(3) RH Camshaft

4. When the timing bolt is installed in the flywheel and the No. 1 piston is on the compression
stroke, remove timing pins (2) from the storage positions.

5. Install timing pins (2) through timing holes (1) in the engine block. Install timing pins (2) into the
groove in camshaft (3) on each side of the engine. In order to time the engine correctly, the timing
pins must fit into the groove of each camshaft.

6. If timing pins (2) do not engage in the grooves of both camshafts, then the engine is not in time,
and one or both camshafts must be adjusted.

7. Both camshafts are adjusted in the same manner. See "Timing Adjustment" for the procedure to
put the camshafts in time with the crankshaft.

NOTICE
 If a camshaft is out of time more than 18 degrees (approximately 1/2
the diameter of timing pin out of groove), the valves can make contact
with the pistons. This will cause damage that will make engine repair
necessary.

Timing Adjustment
Table 2

Tools Needed Quantity

9S-9082 Engine Turning Tool 1

6V-3010 Puller Group 1

8S-9089 Bolts 2

5P-1076 Hard Washers 2

Note: The timing must be checked before the timing adjustments are made. See "Timing Check" for this
procedure.

After the Timing Check procedure is complete, the timing bolt will be engaged in the flywheel. The No.
1 piston will be at the top center (TC) position.

Illustration 3
Rocker shafts (typical example)

(1) Bolt

(2) Rocker shaft

Illustration 4
Camshaft drive gears (RH side)

(3) Drive gear

(4) Plate

(5) Bolt

1. Remove all of the valve covers on the side for the camshaft adjustment. Loosen bolts (1) that hold
rocker shafts (2) to the valve cover bases until all rocker arms are free from the injectors and the
valves.

Note: The above procedure must be done before camshaft drive gear (3) is pulled off the camshaft
taper.

2. Remove the covers from the flywheel housing.

Illustration 5

Camshaft drive gears (LH side)

 (5) Bolt

(7) Timing ring

3. Remove bolts (5) and plate (4) on the RH side, and timing ring (7) on LH side.

Illustration 6
Storage position for timing pins (typical example)

(6) Timing pin

4. Install the 6V-3010 Puller Group, two 8S-9089 Bolts, and two 5P-1076 Hard Washers. Loosen
drive gears (3) from the taper on the camshafts. Remove the engine turning tool and the gears.

5. Remove timing pins (6) from the storage position on each side of the engine.

Illustration 7

Installed camshaft timing pin (typical example)

 (6) Timing pin

6. Turn the camshafts until timing pins (6) can be installed through the engine block and into the
grooves (slots) in the camshafts.

7. Clean the camshaft taper and the inside diameter of the camshaft gear in order to remove any oil
that may be present.

8. Put camshaft drive gears (3) in position on the camshafts.

9. Use hand pressure to turn and hold the camshaft drive gears in the opposite direction of the
rotation. This removes all gear clearance (backlash) between the camshaft drive gears (3) and the
idler gears.

10. Install plate (4) on the RH side. Install timing ring (7) on the LH side in order to hold camshaft
drive gears (3) to each camshaft.

11. Tighten bolts (5) in steps to a torque of 360 ± 40 N·m (270 ± 30 lb ft).

12. Tap bolts (5). Tighten the bolts (5) to a torque of 360 ± 40 N·m (270 ± 30 lb ft).

Note: If necessary, repeat Step 12 until the torque does not change.

13. Install the gaskets and covers on the flywheel housing.

14. Remove timing pins (6) from the camshafts. Install timing pins (6) in the storage positions. Install
the covers over the camshafts and timing pins (6) .

15. Remove the timing bolt from the flywheel housing. Install the 8T-6765 Pipe Plug in the flywheel
housing timing hole. Remove the engine turning tool. Install the cover and the gasket.

16. Be certain that the rocker arms are correctly engaged with the pushrods. Tighten the bolts in order
to hold all of the rocker shafts in position.

17. Make adjustments to the valves and to the lash of the electronic fuel injector. See Testing And
Adjusting, "Valve Lash and Valve Bridge Adjustment" and Testing And Adjusting, "Fuel Injector
Adjustment" for the correct procedures.