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® SENR1143

September 1996

3406C Marine Engine


1SS1-UP
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you
have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“WARNING” as shown below.

WARNING

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.

Operation that may cause product damage are identified by NOTICE labels on the product and in this
publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warning in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by Caterpillar is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged
or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information
available at the time it was written. The specifications, torques, pressures, measurements, adjustments,
illustrations, and other items can change at any time. These changes can affect the service given to
the product. Obtain the complete and most current information before starting any job. Caterpillar
dealers have the most current information available. For a list of the most current publication form
numbers available, see the Service Manual Contents Microfiche, REG1139F.
Oil Filter Base .......................................................... 82
Index Oil Filter Base, Disassemble & Assemble ................. 83
Oil Pan ................................................................... 131
Accessory Drive ....................................................... 23 Oil Pump ............................................................... 132
Accessory Drive, Disassemble & Assemble ............. 24 Oil Pump, Disassemble & Assemble ...................... 133
Aftercooler Housing ................................................. 75
Air Cleaner ................................................................. 5 Piston & Connecting Rod Assemblies .................... 140
Piston & Connecting Rod Assemblies, Disassemble
Bridge Dowels ....................................................... 129 & Assemble ........................................................... 142
Piston Cooling Tubes ............................................ 135
Camshaft ............................................................... 153
Camshaft Bearings ................................................ 148 Raw Water Pump .................................................... 15
Connecting Rod Bearings ...................................... 136 Raw Water Pump, Disassemble & Assemble ........... 16
Crankshaft ............................................................. 144 Rocker Shaft Assemblies & Push Rods ................. 108
Crankshaft Front Seal & Wear Sleeve .................... 149 Rocker Shaft Assemblies, Disassemble &
Crankshaft Rear Seal & Wear Sleeve ..................... 151 Assemble .............................................................. 113
Crankshaft Main Bearings ...................................... 138
Crankshaft Vibration Damper & Pulley ....................... 5 Service Meter .......................................................... 10
Cylinder Head Assembly ........................................ 123 Spacer Plate .......................................................... 126
Cylinder Liners ....................................................... 157 Sump Pump ............................................................ 12
Sump Pump, Disassemble & Assemble ................... 12
Dipstick Assembly ..................................................... 4
Tachometer Drive .................................................... 10
Electric Starting Motor ............................................. 11 Timing Gear Cover ................................................ 159
Engine Front Support ................................................ 7 Timing Gears & Plate ............................................. 155
Engine Rear Support ................................................. 7 Turbocharger ........................................................... 90
Engine Lifting Brackets .............................................. 4 Turbocharger, Disassemble & Assemble ................. 93
Engine Oil Cooler ..................................................... 85
Exhaust Manifold ................................................... 100 Valves .................................................................... 127
Expansion Tank ....................................................... 77 Valve Covers ......................................................... 107
Valve Guides ......................................................... 130
Flywheel ................................................................ 162 Valve Lifters ........................................................... 114
Flywheel Housing ................................................... 163 Valve Seat Inserts .................................................. 128
Fuel Filter Base ........................................................ 14
Fuel Injection Nozzles ............................................ 118 Water Pump .......................................................... 102
Fuel Injection Nozzle Adapters ............................... 121 Water Pump, Disassemble & Assemble ................. 104
Fuel Injection Lines .................................................. 46 Water Temperature Regulator .................................. 79
Fuel Injection Line Adapters ..................................... 47
Fuel Injection Pump Housing, Disassemble &
Assemble ................................................................ 71
WARNING
Fuel Injection Pump & Governor .............................. 49
Fuel Injection Pump & Governor Drive ..................... 30
Fuel Injection Pumps ............................................... 65 Disconnect batteries before performance of any
Fuel Injection Pumps, Disassemble & Assemble ...... 68 service work.
Fuel Priming Pump .................................................. 14
Fuel Ratio Control .................................................... 41
Fuel Ratio Control, Disassemble & Assemble .......... 42 FLUID SPILLAGE CONTAINMENT
Fuel Transfer Pump ................................................. 25
Fuel Transfer Pump, Disassemble & Assemble ........ 25 Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
Governor & Fuel Pump Drive ................................... 33 testing, adjusting and repair of the machine. Be
Governor & Fuel Pump Drive, Disassemble & prepared to collect the fluid with suitable containers
Assemble ................................................................ 37 before opening any compartment or disassembling any
Governor, Disassemble & Assemble ........................ 51 component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
Instrument Panel ........................................................ 8 supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
Marine Gear Oil Cooler ............................................ 89 regulations and mandates.
Marine Gear Oil Cooler Core .................................... 88

3406C Marine Engine 3 Disassembly & Assembly


Disassembly & Assembly Dipstick Assembly
Remove & Install Dipstick
Engine Lifting Brackets Assembly 1326-010
Remove & Install Engine Lifting
Brackets 1122-010

1. Remove bolt, nut, washer and spacer (1).

2. Remove bolt and washer (3).


1. Remove four bolts and washers (1). Remove
retainer (4). 3. Remove dipstick assembly (2).

2. Remove four bolts and washers (3). Remove front


engine lifting bracket (2).

4. Remove O-ring seal (4) from the dipstick assembly.

NOTE: For installation of the dipstick assembly,


3. Remove eight bolts and washers (5). Remove rear reverse the removal steps.
engine lifting bracket (6).

NOTE: For installation of the engine lifting brackets,


reverse the removal steps.

3406C Marine Engine 4 Disassembly & Assembly


Air Cleaner Crankshaft Vibration Damper &
Pulley
Remove & Install Air
Cleaner 1051-010 Remove Crankshaft Vibration Damper
& Pulley 1205-011

1. Remove three bolts (1).


1. Remove the top bolt from pulley (2), and install a
5/8-18 NF Guide Bolt (1) in the crankshaft.

2. Remove the remainder of the bolts and pulley (2)


from the vibration damper.

2. Loosen hose clamp (2).

3. Remove three bolts (4), and remove air cleaner (3).

NOTE: The following steps are for installation of the air


cleaner.
3. Remove vibration damper (3) from the adapter.
4. Put air cleaner (3) in position on the turbocharger
and bracket.

5. Install three bolts (4) that hold the air cleaner to the
bracket. Tighten bolts (4) to a torque of 25 %
7 N•m (18 % 5 lb ft).

6. Tighten hose clamp (2) to a torque of 4.5 %


0.5 N•m (39.82 % 4.42 lb in).

7. Install three bolts (1). Tighten bolts (1) to a torque of


25 % 7 N•m (18 % 5 lb ft).

3406C Marine Engine 5 Disassembly & Assembly


4. Remove adapter (4) from the crankshaft.
NOTICE
The vibration damper has marks (3) on the hub and
Install Crankshaft Vibration Damper & ring. These marks show an indication of the condition
Pulley 1205-012 of the vibration damper. If the marks are not in align-
ment, install a new damper.

1. Install a 5/8-18 NF Guide Bolt (2) in the


crankshaft. 3. Put vibration damper (4) in position on the adapter.
2. Put adapter (1) in position on the crankshaft.

NOTE: Lubricate the threads of the bolts that hold the


crankshaft vibration damper and pulley in place with
clean engine oil.

4. Put pulley (5) in position on the vibration damper,


and install the bolts.

3406C Marine Engine 6 Disassembly & Assembly


Engine Front Support Engine Rear Support
Remove & Install Engine Front Remove & Install Engine Rear
Support 1154-010 Support 1154-010

Tools Needed A
8T5255 Hydraulic Jack 1

1. Fasten a lifting sling and a hoist to the front lifting


bracket.

2. Remove the bolts that hold the engine front support Typical Example
to the frame rails. Loosen the bolts that hold the
engine rear support to the frame rail.
1. Put Tooling (A) in position under the flywheel
3. Use the hoist or and raise the front of the engine. housing to support the rear of the engine. Loosen
The weight of the front of the engine is the bolts that hold the engine front support to the
approximately 998 kg (2200 lb). frame rail.

4. Remove eight bolts (1), and remove engine front 2. Remove the bolts that hold the engine rear support
support (2). The weight of the engine front support to the frame rail, and raise the engine approximately
is approximately 32 kg (70 lb). 6.35 mm (.250 in) with Tooling (A). The weight of
the rear of the engine is approximately 624 kg
NOTE: The following steps are for installation of the (1375 lb).
engine front support.
3. Remove bolts (1) that hold the engine rear support
5. Put engine front support (2) in position on the to the flywheel housing, and remove the engine rear
engine, and install eight bolts (1). support.

6. Lower the engine to the frame rails, and install the NOTE: The following steps are for installation of the
bolts that hold the engine front support to the frame engine rear supports.
rails. Tighten the bolts in the engine rear support.
4. Put the engine rear supports in position on the
flywheel housing, and install bolts (1).

5. Lower the engine with Tooling (A), and install the


bolts that hold the engine rear supports to the
frame rail. Tighten the bolts that hold the engine
front support to the frame rail.

3406C Marine Engine 7 Disassembly & Assembly


Instrument Panel
Remove Instrument Panel 7450-011

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in 4. Turn the fuel supply to the “OFF” position.
Caterpillar machines. Dispose fluids according to local
regulations and mandates. 5. Disconnect fuel pressure line (4). Cap and plug all
openings immediately.

6. Disconnect oil pressure line (5). Cap and plug all


openings immediately. Remove the bolt and
disconnect clips (3) and the line from the engine.

1. Drain the coolant from the engine below the level of


water temperature gauge line (1) into a suitable
container for storage or disposal.

2. Disconnect water temperature gauge line (1) from


the cylinder head. Cap and plug all openings 7. Remove bolts (6) and spacers (7). Remove
immediately. instrument panel (8) from the aftercooler housing.

3. Remove the bolts, and disconnect clips (2) and the


line from the aftercooler housing.

3406C Marine Engine 8 Disassembly & Assembly


Install Instrument Panel 7450-012

4. Connect water temperature line (6) to the cylinder


head.

1. Put instrument panel (1) in position on the 5. Put the line and clips (5) in position on the
aftercooler housing, and install the spacers and aftercooler housing, and install the bolts.
bolts.
6. Turn the fuel supply to the “ON” position.

7. Fill the cooling system to the correct level. See the


Operation & Maintenance Manual.

2. Connect fuel pressure line (3).

3. Connect oil pressure line (4), and put clip (2) in


position, and install the bolts.

3406C Marine Engine 9 Disassembly & Assembly


Service Meter Tachometer Drive
Remove & Install Service Remove & Install Tachometer
Meter 7478-010 Drive 7462-010
Start By:

a. remove service meter

1. Disconnect the tachometer cable from the


tachometer drive.

1. Remove two bolts and clamps (1), and remove


service meter (2).

2. Remove two bolts and clamps (2), and remove


tachometer drive (1).

Typical Example

2. Remove coupling (4) and O-ring seal (3) from


service meter (2).

NOTE: The following steps are for installation of the


service meter.

3. Put O-ring seal (3) and coupling (4) in position on


service meter.

4. Put clean engine oil on the coupling and O-ring


seal.

5. Put service meter (2) in position, and install two


bolts and clamps (1).

3406C Marine Engine 10 Disassembly & Assembly


Electric Starting Motor
Remove & Install Electric Starting
Motor 1453-010

3. Remove coupling (4) and O-ring seal (3) from


tachometer drive (1).

NOTE: The following steps are for installation of the


tachometer drive.

4. Put coupling (4) and O-ring seal (3) in position on


tachometer drive (1). 1. Disconnect the wires from the starting motor. Put
identification on the wires for correct installation.
5. Put clean oil on the coupling and O-ring seal.
2. Fasten a hoist to the starting motor, and remove
6. Align coupling (4) with the shaft in the governor, and three bolts (1) that hold the starting motor to the
install tachometer drive (1). flywheel housing. Remove the starting motor. The
weight of the starting motor is 32 kg (70 lb).
7. Install bolts and clamps (2) that hold the tachometer
drive to the governor. NOTE: The following steps are for installation of the
starting motor.
8. Connect tachometer cable to the tachometer drive.
3. Use a hoist, and put the starting motor in position
End By: on the flywheel housing, and install three bolts (1).

a. install service meter 4. Install wires in the correct location on the starting
motor.

3406C Marine Engine 11 Disassembly & Assembly


Sump Pump Disassemble Sump Pump 1319-015
Start By:
Remove & Install Sump
Pump 1319-010 a. remove sump pump

FLUID SPILLAGE CONTAINMENT FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local Caterpillar machines. Dispose fluids according to local
regulations and mandates. regulations and mandates.

1. Disconnect oil lines (3) and (4). Cap and plug all 1. Remove pipe assembly (2) from the sump pump.
openings immediately.
2. Remove the three bolts, cover assembly (1) and the
2. Remove three bolts (2) that hold the sump pump to gasket from the sump pump.
the bracket, and remove sump pump (1).

NOTE: The following steps are for installation of the


sump pump.

3. Put sump pump (1) in position on the bracket, and


install three bolts (2).

4. Connect oil lines (3) and (4).

3. Remove the nut that holds handle assembly (3) to


the shaft. Remove the handle assembly and nut (8)
from shaft (5).

4. Remove nut (4), packing (6) and shaft (5) from cover
(7).

3406C Marine Engine 12 Disassembly & Assembly


5. Remove rotor (12), vanes (10) and springs (11) from 2. Install shaft (7), packing (8) and nut (6) in cover (9).
housing (9).
3. Install nut (10) on shaft (7). Put handle (5) in position
on the shaft, and install the nut that holds the
handle on the shaft.
Assemble Sump Pump 1319-016

4. Put the gasket and cover assembly (11) in position


on the housing, and install three bolts.
1. Install rotor (3), springs (4) and vanes (2) in housing
(1). 5. Install pipe assembly (12) on the sump pump as
shown.

End By:

a. install sump pump

3406C Marine Engine 13 Disassembly & Assembly


Fuel Priming Pump Fuel Filter Base
Remove & Install Fuel Priming Remove & Install Fuel Filter
Pump 1258-010 Base 1262-010

FLUID SPILLAGE CONTAINMENT Tools Needed A


2P8250 Strap Wrench 1
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be Start By:
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any a. remove fuel priming pump.
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
FLUID SPILLAGE CONTAINMENT
Caterpillar machines. Dispose fluids according to local
regulations and mandates. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
1. Turn the fuel supply to the “OFF” position.
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

2. Remove two bolts (2), and remove fuel priming


pump (1) from the fuel filter base.

3. Remove the gasket from the fuel priming pump.

NOTE: The following steps are for installation of the


fuel priming pump.

4. Put the gasket and fuel priming pump in position on 1. Use Tool (A) to remove filter assembly (1).
the fuel filter base, and install two bolts (2).

5. Turn the fuel supply to the “ON” position.

3406C Marine Engine 14 Disassembly & Assembly


Raw Water Pump
Remove Raw Water Pump 1371-011

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
2. Disconnect three lines (3) from the fuel filter base. supplies suitable to collect and contain fluids in
Cap and plug all openings immediately. Caterpillar machines. Dispose fluids according to local
regulations and mandates.
3. Remove the two nuts that hold fuel filter base (2) to
the aftercooler housing, and remove the fuel filter 1. Drain the coolant from the cooling system into a
base. suitable container for storage or disposal.

4. If necessary, remove the stud on the fuel filter base.

NOTE: The following steps are for installation of the


fuel filter base.

5. Replace the stud on the fuel filter base if it was


removed. Tighten the stud to a torque of 70 %
15 N•m (50 % 11 lb ft).

6. Put fuel filter base (2) in position on the aftercooler


housing, and install the nuts.

7. Connect three lines (3) to the fuel filter base.

8. Install a new filter assembly (1) on the fuel filter 2. Remove bolts (2), elbows (1) and the gaskets from
base. Follow the installation instructions on the filter the raw water pump.
assembly. See the Operation & Maintenance
Manual.

NOTE: For more detailed information on the fuel filter


base, refer to the topic “Fuel Filter Base” in the
Specifications Manual.

End By:

a. install fuel priming pump

3. Remove nuts (4), raw water pump (3) and the


gasket from the front timing gear cover.

3406C Marine Engine 15 Disassembly & Assembly


Install Raw Water Pump 1371-012 Disassemble Raw Water
Pump 1371-015

Tools Needed A B C
1P1855 Pliers 1
1P1861 Pliers 1
9S9152 Bearing Puller 1

Start By:

a. remove raw water pump

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
1. Put the gasket and raw water pump (1) into position during performance of inspection, maintenance,
on the front timing gear cover and install the nuts testing, adjusting and repair of the machine. Be
that hold them. prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

2. Install the gasket, elbows (2) on the raw water


pump with bolts (3).

3. Fill the cooling system with coolant to the correct


level. See the Operation & Maintenance Manual.

1. Remove screws (1) and cover assembly (2) from


body assembly (3).

3406C Marine Engine 16 Disassembly & Assembly


2. Remove plate (5) and gasket (4) from the cover 5. Use Tool (A) and remove ring (10) from the shaft.
assembly.
6. Remove cover (9) (part of the seal assembly) from
the body assembly.

3. Remove seal (6) and impeller assembly (7) from the


body assembly.
7. Remove spring (11) (part of seal assembly) from the
NOTE: Make a note of the direction of the impeller body assembly.
blades for correct assembly.

8. Remove carbon seal (12) (part of the seal assembly)


4. Remove seal (8) from the shaft. from the body assembly.

3406C Marine Engine 17 Disassembly & Assembly


9. Remove bolts (14) and remove housing (13) from 12. Remove seal (18) from the shaft.
body assembly (3).

13. Use Tool (B) and remove ring (19) from the
10. Remove cam (15) and ceramic seal (16) (part of housing.
the seal assembly) from body assembly (3).

14. Use a press and remove shaft (20) and the


11. Remove plate (17) from the body assembly. bearings from housing (13).

3406C Marine Engine 18 Disassembly & Assembly


A02077P2*

Assemble Raw Water Pump 1371-016

Tools Needed A B C D E
1P510 Driver Group 1
9S9152 Bearing Puller 1
1P1861 Pliers 1
1P1855 Pliers 1
1U6684 Compressor 1

15. Use a press and Tool (C) to remove bearings (21)


from shaft (20).

1. Use Tooling (A) and install seal (1) in housing (2).


Make sure the lip of the seal is toward the bearing
bore as shown. Put 1P-0808 General Purpose
Lubricant on the lip of the seal.

16. Remove seal (22) from housing (13).

3406C Marine Engine 19 Disassembly & Assembly


2. Use a press and Tool (B) to install bearings (4) on 6. Inspect seal (6) for wear or damage and make a
shaft (3). replacement if necessary.

7. Put clean engine oil on seal (6) and install the seal
on the shaft as shown.

3. Put 1P-0808 General Purpose Lubricant on the


bearings and in the bearing bore of housing (2).

4. Use a press and install shaft (3) and the bearings in 8. Put plate (8) in position in body assembly (7) as
housing (2). shown.

5. Use Tool (C) and install ring (5) in the housing. 9. Make an alignment of the dowel (10) in body
assembly (7) with cam (9). Install cam (9) in body
assembly (7).

3406C Marine Engine 20 Disassembly & Assembly


10. Install housing (2) on body assembly (7) and install 13. Install seal (12) in the body assembly with the
the bolts that hold the two together. polished carbon seal face of the seal toward the
ceramic seal.

NOTE: Parts (11), (12), (13) and (14) come as a seal


assembly only. 14. Install spring (13) and cover (14) in the body
assembly.

11. Put clean engine oil on the rubber part only of


ceramic seal (11).

12. Put clean engine oil in the seal bore of the body
assembly and install ceramic seal (11), polished
surface toward the impeller. If the face of the seal
is damaged (marked, scratched) a replacement
must be made.

15. Use Tool (D) and install ring (15) on the shaft that
holds the seal assembly in place.

3406C Marine Engine 21 Disassembly & Assembly


16. Inspect seal (16) for wear or damage and make a 21. Install seal (18) in the impeller assembly.
replacement if necessary.

17. Put clean engine oil on seal (16) and install on the
shaft.

22. Install gasket (19) and plate (21) on cover


assembly (20).

23. Make an alignment of the dowel in cover assembly


18. Put a small amount of 1P-0808 General (20) and the dowel hole in the cam and install
Purpose Lubricant in the impeller bore. cover assembly (20) with the screws that hold it.

19. Make sure all impeller blades are bent in the same End By:
direction and in the correct direction of rotation.
a. install raw water pump
20. Use Tool (E) and install impeller assembly (17) in
the body assembly.

3406C Marine Engine 22 Disassembly & Assembly


Accessory Drive Install Accessory Drive 1206-012

Remove Accessory Drive 1206-011

1. Put gasket (2) and accessory drive (1) in position on


the front timing gear plate and install the bolts that
hold them. Make sure the accessory drive gear is in
1. Remove nuts (1), cover (2) and the gasket from the alignment with the camshaft gear.
accessory drive.

2. Put gasket (4) and cover (3) in position on the


2. Remove bolts (3), accessory drive (4) and the accessory drive and install the nuts that hold them.
gasket from the front timing gear plate.

3406C Marine Engine 23 Disassembly & Assembly


Disassemble Accessory Assemble Accessory Drive 1206-016
Drive 1206-015
Start By:

a. remove accessory drive

1. Install cover (1) and bolts (2) on gear (3).

1. Remove bolts (1), plate (2) that hold the gear to the
bearing.

2. Install gear (3) in bearing (4) as shown.

2. Remove gear (4) from bearing (3).

3. Install cover (5) and the bolts that hold the gear in
the bearing.

End By:

a. install accessory drive


3. Remove bolts (5), cover (6) from gear (4).

3406C Marine Engine 24 Disassembly & Assembly


Fuel Transfer Pump NOTE: The following steps are for installation of the
fuel transfer pump.

Remove & Install Fuel Transfer 4. Put the O-ring seal in position on the fuel transfer
Pump 1256-010 pump. Put clean engine oil on the O-ring seal.

FLUID SPILLAGE CONTAINMENT 5. Put fuel transfer pump (2) in position, and install
bolts (1).
Care must be taken to ensure that fluids are contained 6. Remove the caps from the fuel lines, and connect
during performance of inspection, maintenance, fuel lines (3) to the fuel transfer pump.
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers 7. Turn the fuel supply to the “ON” position.
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND 8. Prime the fuel system. See the Operation &
SHOP PRODUCT GUIDE, NENG2500", for tools and Maintenance Manual for the proper procedure.
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local NOTE: For more detailed information regarding the
regulations and mandates. fuel transfer pump, see the topic “Fuel Transfer Pump”
in the Specifications Manual.
1. Turn the fuel supply to the “OFF” position.

Disassemble Fuel Transfer


Pump 1256-015
Start By:

a. remove fuel transfer pump

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
2. Disconnect two fuel lines (3) from the fuel transfer component containing fluids. Refer to "TOOLS AND
pump. Cap and plug all openings immediately. SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
3. Remove two bolts (1), and remove fuel transfer Caterpillar machines. Dispose fluids according to local
pump (2). Remove the O-ring seal from the fuel regulations and mandates.
transfer pump.

1. Remove seal (1) from the fuel transfer pump.

3406C Marine Engine 25 Disassembly & Assembly


WARNING NOTICE
Mark the orientation of valve (8) as to its location in the
Cover (2) is under spring tension. Remove the bolts housing.
that hold cover (2) slowly to prevent injury.
5. Remove washer (7), valve (8) and the seal from the
housing.
2. Remove bolts (3) and cover (2) from the housing.

6. Remove piston (9) and sleeve (10) from the housing.


3. Remove seals (4) and valve (5) from cover (2).

7. Remove seal (11) from sleeve (12).


4. Remove spring (6) from the piston.

3406C Marine Engine 26 Disassembly & Assembly


8. Remove guide and tappet assembly (13) from the 11. Remove the bolts and cover (18) from the
housing. housing.

9. Remove seal (14) from guide (15). 12. Remove seal (19) from cover (18).

13. Remove valve (20) from the housing if necessary.


NOTICE
If tappet (17) or the guide are damaged or worn, they
must be replaced as a unit.

10. Remove ring (16) from tappet (17) and the tappet
from guide (15).

3406C Marine Engine 27 Disassembly & Assembly


B50041P2*

Assemble Fuel Transfer


Pump 1256-016

2. Put clean fuel on seal (4), and install it on cover (3).

3. Install cover (3) on the housing.

1. Install valve (2) in housing (1) as shown.

3406C Marine Engine 28 Disassembly & Assembly


7. Put clean fuel on seal (10), and install it on sleeve
NOTICE (11).
The tappet and guide must be serviced as a unit.
8. Install sleeve (11) in the housing.

4. Install tappet (6) in guide (5). Install ring (7) on


tappet (6) to hold the tappet in the guide.

9. Install piston (12) in the housing.

5. Put clean fuel on seal (8), and install it on guide and


tappet assembly (9).

6. Install guide and tappet assembly (9) in the housing


as shown.

10. Install seal valve (14) and washer (13) in the


housing as shown. Be sure valve (14) is the
correct position in the housing.

3406C Marine Engine 29 Disassembly & Assembly


Fuel Injection Pump &
Governor Drive
Remove Fuel Injection Pump &
Governor Drive 1288-011

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
11. Install spring (15) in the piston. component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

12. Install valve (18) in cover (16) as shown.

13. Put clean fuel on seals (17), and put them in


position on cover (16).
1. Remove nuts (1), and move clip (2) and the hose
14. Install cover (16) on the housing.
away from cover (3).

2. Remove cover (3) and the gasket.

15. Put seal (19) in position on the fuel transfer pump.

End By:
3. Remove the bolts that hold cover (4) to the ring,
and remove the cover.
a. install fuel transfer pump

3406C Marine Engine 30 Disassembly & Assembly


Install Fuel Injection Pump & Governor
Drive 1288-012

Tools Needed A B
6V4186 Timing Pin 1
9S9082 Engine Turning Tool 1

4. Remove the four bolts and ring (5).

1. Remove the plug from the timing pin hole, and put
Tool (A) in the timing pin hole.

2. Install two 7/16-20 NF x 102 mm (4 in) long bolts


in fuel injection pump camshaft (1). Slowly rotate
the fuel injection pump camshaft until Tool (A) goes
into the groove in the fuel injection pump camshaft.
Remove the bolts.
5. Remove gear (7) from the front of fuel injection
pump camshaft (6).

3. Put No. 1 piston at the top center compression


position (TC) with the following procedure.

a. Remove the plug and cover from the left side of


the flywheel housing, and install Tool (B) in the
flywheel housing.

b. Use Tool (B) to slowly rotate the engine in the


direction of normal rotation (counterclockwise as
seen from the flywheel end of the engine) until
timing bolt (2) [the long bolt that holds the cover
to the flywheel housing] can be installed in the
flywheel housing and into the hole in the flywheel.

3406C Marine Engine 31 Disassembly & Assembly


c. Remove the valve cover from the valve cover 6. Put ring (5) in position on the fuel injection pump
base. Check to see if both rocker arms (3) for camshaft and install the four bolts that hold it.
the No. 1 cylinder can be moved backward and Tighten the bolts to a torque of 3 N•m (27 lb in).
forward.
7. Use Tool (B) and slowly rotate the engine in the
NOTE: The No. 1 piston is at the top center direction of normal rotation until the timing bolt can
compression stroke when the timing bolt is installed in be installed in the flywheel.
the flywheel and both rocker arms for the No. 1
cylinder can be moved backward and forward. If both 8. Tighten the bolt that holds ring (5) to the fuel
rocker arms can not be moved, the No. 1 piston is not injection pump camshaft to a torque of 55 %
at the top compression position. Remove the bolt from 7 N•m (41 % 5 lb ft).
the flywheel and rotate the engine in the direction of
normal rotation (counterclockwise as seen from the 9. Remove Tool (A) from the fuel injection pump, and
flywheel end of the engine) one full turn 360 degrees , the timing bolt from the flywheel.
and install the timing bolt again.
10. Check the timing as follows:
4. Remove the timing bolt and rotate the engine
opposite the direction of normal rotation (clockwise a. Rotate the engine in the direction of normal
as seen from the flywheel end of the engine) for a rotation (counterclockwise as seen from the
minimum of 30 degrees. flywheel end of the engine) two full turns, and
install Tool (A) and the timing bolt again.

b. The timing is correct if Tool (A) and the timing


bolt can be installed at the same time. The
timing procedure must be done again if the
timing bolt and Tool (A) can not be installed at
the same time.

c. Remove Tool (A), and install the plug in the fuel


injection pump housing. Remove the timing bolt
and Tool (B), and install the cover and plug in
the flywheel housing.

5. Put gear (4) in position on the fuel injection pump


camshaft.

3406C Marine Engine 32 Disassembly & Assembly


Governor & Fuel Pump Drive
Remove Governor & Fuel Pump
Drive 1272-011

11. Put O-ring seals (7) on cover (6). Put clean engine
oil on the O-ring seals.

12. Install cover (6) on the ring, and install the bolts
that hold it.

1. Remove nuts (1), cover (2), and the gasket.

13. Put the gasket and cover (8) in position on the


timing cover. Put the hose and clip (9) in position,
and install the bolts that hold the cover and clip to
the timing cover. 2. Remove four bolts (3). Remove governor and fuel
pump drive (4). Remove the O-ring seals from the
governor and fuel pump drive.

3. Remove gear (6) from fuel injection pump camshaft


(5).

3406C Marine Engine 33 Disassembly & Assembly


Install Governor & Fuel Pump
Drive 1272-012

Tools Needed A B
6V4186 Timing Pin 1
9S9082 Engine Turning Tool 1

b. Install Tool (B) in the flywheel housing. Use Tool


(B) to slowly rotate the engine in the direction of
normal rotation (counterclockwise as seen from
the flywheel end of the engine) until timing bolt
(4) can be installed in the flywheel housing and
into the hole in the flywheel.

1. Remove the plug from the timing pin hole in the fuel
injection pump housing, and install Tool (A) in the
timing pin hole.

2. Install two 7/16-20 NF x 102 mm (4 in) long bolts


in fuel injection pump camshaft (1). Slowly rotate
the fuel injection pump until Tool (A) goes into the
groove in the fuel injection pump camshaft. Remove
the bolts from the camshaft.

c. Remove the valve cover from the valve cover


base. Check to see if both rocker arms (5) for
the No. 1 cylinder can be moved backward and
forward.

NOTE: The No. 1 piston is at the top center


compression position (TC) when the timing bolt is
installed in the flywheel and both rocker arms for the
No. 1 cylinder can be moved backward and forward. If
both rocker arms cannot be moved, the No. 1 piston is
not at the top center compression position (TC)
Remove the timing bolt from the flywheel and rotate
the engine in the direction of normal rotation
3. Put No. 1 piston at the top center compression (counterclockwise as seen from the flywheel end of the
position (TC) with the following procedure: engine) one full turn 360 degrees , and install the
timing bolt again.
a. Remove plug (3), timing bolt (4) and cover (2)
from the flywheel housing. 4. Remove the timing bolt, and use Tool (B) to rotate
the engine in the opposite direction of normal
rotation (clockwise as seen from the flywheel end of
the engine) a minimum of 30 degrees.

3406C Marine Engine 34 Disassembly & Assembly


11. Check the timing as follows:

a. Rotate the engine in the direction of normal


rotation (counterclockwise as seen from the
flywheel end of the engine) two full turns, and
install Tool (A) and the timing pin again.

b. The timing is correct if Tool (A) and the timing


bolt can be installed at the same time. The
timing procedure must be done again if the
timing bolt and Tool (A) can not be installed at
the same time.

c. Remove Tool (A), and install the plug in the fuel


injection pump housing. Remove the timing bolt
5. Put gear (6) in position on the fuel injection pump and Tool (B), and install the plug and cover on
camshaft. the flywheel housing.

6. Put two O-ring seals (8) in position on governor and 12. Put the gasket and cover (9) in position on the
fuel pump drive (7). timing gear cover, and install the nuts.

7. Put the governor and fuel pump drive in position on


the fuel injection pump camshaft, and install the
four bolts. Tighten the bolts to a torque of 3 N•m
(27 lb in).

8. Use Tool (B) and slowly rotate the engine in the


direction of normal rotation until the timing bolt can
be installed in the flywheel.

9. Tighten the bolts that hold the governor and fuel


pump drive to the fuel injection pump camshaft to a
torque of 55 % 7 N•m (41 % 5 lb ft).

10. Remove Tool (A) from the fuel injection pump


housing, and remove the timing bolt from the
flywheel.

3406C Marine Engine 35 Disassembly & Assembly


B89846P2*

3406C Marine Engine 36 Disassembly & Assembly


Disassemble Governor & Fuel Pump
Drive 1272-015
Start By:

a. remove governor and fuel pump drive

4. Remove springs (6) and ring (5) from retainer


assembly (7).

1. Remove seals (1) from the body.

WARNING

Spring force is present behind carrier (3). Put down-


ward pressure on carrier (3) when bolts (2) are
removed.

5. Remove the locknut and setscrew (8). Remove the


2. Remove bolts (2) from ring (4). locknut and screw (9) from the retainer assembly.

3. Remove ring (4) and the carrier from ring (5). 6. Remove ring (4) from carrier (3).

7. Remove seal (10) from carrier (3).

3406C Marine Engine 37 Disassembly & Assembly


8. Remove bolts (11) and carrier (12) from carrier (3). 11. Remove ring (16) and race (17) from spool (18),
and remove spool (18) from the carrier.

9. Remove lockring (13) and body (14) from the


carrier. 12. Remove dowels (19) and flyweights (20) from the
carrier.

10. Install two 3/8-16 NC Bolts into the body as


shown. Clamp the bolt heads in a vise, and
remove plug (15) from body (14).

3406C Marine Engine 38 Disassembly & Assembly


Assemble Governor & Fuel Pump
Drive 1272-016

4. Install body (7) into carrier (8), and install lockring


(9).

1. Put flyweight (1) in position on carrier (2), and install


dowels (3) that hold the flyweights in position.

5. Put carrier (2) in position on carrier (8), and install


the bolts that hold it.

2. Put spool (4) in position on the carrier, and install


race (5) and ring (6) on the end of spool (4).

6. Install seal (9) on carrier (8). Put clean engine oil on


the seal, and install ring (10) on carrier (8).

3. Install two 3/8-16 NC Bolts into body (7) as


shown. Clamp the bolt heads in a vice, and install
plug (8). Tighten plug (8) to a torque of 70 %
15 N•m (50 % 11 lb ft).

3406C Marine Engine 39 Disassembly & Assembly


7. Install setscrew (11) and the locknut. Install the 10. Use two 3/8-16 NC x 89 mm (3.5 in) long bolts,
screw and locknut (12) into the retainer assembly. washers and nuts to compress the spring. Install
Tighten locknut (12) to a torque of 70 % 15 N•m four bolts (17), and tighten bolts to a torque of
(50 % 10 lb ft). 12 % 4 N•m (9 % 3 lb ft).

8. Place ring (13) and two springs (14) in position on 11. Install seals (18) on body (7).
retainer (15).
End By:
9. Place ring (16) and the carrier in position on ring
(13). Make sure that the small spring fits over the a. install governor and fuel pump drive
end of the spool in the carrier assembly.

3406C Marine Engine 40 Disassembly & Assembly


Fuel Ratio Control NOTE: The following steps are for installation of the
fuel ratio control.
Remove & Install Fuel Ratio 4. Put the O-ring seals in position on the rear governor
Control 1278-010 housing. Put the O-ring seal in position in the fuel
ratio control. Put clean engine oil on the O-ring
FLUID SPILLAGE CONTAINMENT seals.

Care must be taken to ensure that fluids are contained 5. Put fuel ratio control in position on the governor.
during performance of inspection, maintenance, Make sure the flange on the end of the fuel ratio
testing, adjusting and repair of the machine. Be control is behind the groove (slot) in the lever.
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any 6. Install the two bolts that hold the fuel ratio control to
component containing fluids. Refer to "TOOLS AND the governor.
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in 7. Install tube (1).
Caterpillar machines. Dispose fluids according to local
regulations and mandates.
NOTE: See the Systems Operation Testing &
Adjusting Manual for the adjustment of the fuel ratio
control.

1. Remove tube (1). Cap and plug all openings


immediately.

2. Remove the two bolts that hold fuel ratio control to


the governor. Disconnect the fuel ratio control from
the lever in the governor, and remove the fuel ratio
control (2).

3. Remove the O-ring seal from the fuel ratio control.


Remove the O-ring seals from the rear governor
housing.

3406C Marine Engine 41 Disassembly & Assembly


Disassemble Fuel Ratio
Control 1278-015

Tools Needed A B
FT1820 Fixture Assembly 1
1P1855 Retaining Ring Pliers 1

Start By:

a. remove fuel ratio control

FLUID SPILLAGE CONTAINMENT


2. Put Tooling (A) in a vise as shown so that the
Care must be taken to ensure that fluids are contained station being used is not over the vise jaw. Place
during performance of inspection, maintenance, the fuel ratio control over the pins in Tooling (A).
testing, adjusting and repair of the machine. Be Remove cover (2) and the gasket from fuel ratio
prepared to collect the fluid with suitable containers control.
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

WARNING

There is spring force behind cover (3). Hold cover (3)


in position, and slowly remove the bolts that hold it
1. Remove O-ring seal (1) from the fuel ratio control. to release the spring force.

3. Remove cover (3) from housing (4).

3406C Marine Engine 42 Disassembly & Assembly


4. Remove O-ring seals (5) and (6) from the governor 7. Remove spring (18), retainer (17) and spring (19)
housing. from the housing.

5. Remove spring (9), washer (7), and diaphragm (10) 8. Remove piston assembly (20) from the housing.
from retainer (8). Remove retainer (8) from housing
(11).

9. Use Tooling (B), and remove snap ring (21) and the
wave washers from valve assembly (22). Remove
6. Remove nut (16) from extension (15), and remove piston assembly (23) from the valve assembly.
the extension from retainer (8). Remove valve (12),
spring (13) and O-ring seal (14) from the extension. 10. Remove seal (24) from piston (23).

3406C Marine Engine 43 Disassembly & Assembly


11. If necessary, remove stem (26) from valve (25). 2. Put seal (4) on piston (3), and put piston (3) on valve
assembly (5).
12. Clean and inspect all parts. Make a replacement
of all parts that are worn or damaged.

Assemble Fuel Ratio


Control 1278-016
Tools Needed A B C

1P1855 Retaining Ring Pliers 1


FT1820 Fixture Assembly 1
6V9072 Guide 1

3. Put two wave washers in position on valve (5), and


use Tooling (A) to install the snap ring on the valve
assembly.

1. Assemble stem (2) to valve (1) using 9S-3265


Retaining Compound.

4. Place housing (7) on Tooling (B), and put Tooling (C)


into the bore of the housing. Lubricate Tooling (C)
with clean engine oil.

5. Put a small amount of clean oil on the seal of the


piston assembly, and push piston assembly (6) into
position with a smooth swift motion.

3406C Marine Engine 44 Disassembly & Assembly


6. Place spring (8) and retainer and spring (9) in 10. Install O-ring seals (19) and (20) on the governor
position in housing (7). housing.

7. Put O-ring seal (12) on extension (13). Put spring 11. Hold retainer (14) in position, and install cover (21)
(11) and valve (10) in position on the extension. on the housing. Install the bolts that hold the
cover, and tighten them to a torque of 9 % 3 N•m
8. Lubricate O-ring seal (12) with clean engine oil. (81 ± 27 lb in).
Install extension (13) in retainer (14). Install nut (15).

12. Make a replacement of the gasket for cover (22),


9. Put diaphragm (18), washer (17) and spring (16) in and install the cover.
position on retainer (14). Install retainer (14) in
housing (7).

3406C Marine Engine 45 Disassembly & Assembly


Fuel Injection Lines
Remove Fuel Injection
Lines 1252-011

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
13. Put O-ring seal (23) in position on the fuel ratio SHOP PRODUCT GUIDE, NENG2500", for tools and
control. supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
End By: regulations and mandates.

a. install fuel ratio control

1. Disconnect line (1) from the cylinder head and the


fuel ratio control, and remove the line. Cap and plug
all openings immediately.

2. Disconnect front fuel injection lines (2) and rear fuel


injection lines (3) from the fuel injection pump and
cylinder head, and remove the lines. Cap and plug
all openings immediately.

3406C Marine Engine 46 Disassembly & Assembly


Install Fuel Injection Lines 1252-012 Fuel Injection Line Adapters
Tools Needed A
Remove Fuel Injection Line
5P0144 Fuel Line Socket 1
Adapters 1711-011

Tools Needed A B
5P0144 Fuel Line Socket 1
5P5195 Fuel Line Wrench 1

Start By:

a. remove valve covers

b. remove fuel injection lines

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
1. Put front fuel lines (1) and rear fuel lines (2) in testing, adjusting and repair of the machine. Be
position, and connect them to the fuel injection prepared to collect the fluid with suitable containers
pump and cylinder head. Use Tool (A), and tighten before opening any compartment or disassembling any
the fuel injection line nuts to a torque of 42 % component containing fluids. Refer to "TOOLS AND
7 N•m (31 % 5 lb ft). SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

2. Connect line (3) to fuel ratio control and cylinder


head.

NOTICE
Do not let the tops of the fuel nozzles turn when the
fuel lines are loosened. The nozzles will be damaged
if the top of the nozzles turn in the body.

1. Use Tool (A) and a 5P-0328 Crow Foot Wrench


(7/8 in) to loosen the fuel injection line nut at the
nozzle end.

3406C Marine Engine 47 Disassembly & Assembly


Install Fuel Injection Line
Adapters 1711-012

Tools Needed A
5P5195 Fuel Line Wrench 1
5P0144 Fuel Line Socket 1

2. Use Tool (B) to loosen the nut at the fuel injection


line adapter end. Remove inner fuel injection lines
(1). Install plugs in the fuel injection nozzles.

1. Check the condition of O-ring seal (1) on fuel


injection line adapter (2) for damage. Make a
replacement if necessary.

2. Lubricate O-ring seal (1) with clean engine oil. Install


fuel injection line adapter (2). Tighten the retaining
nut to a torque of 13.6 % 2.7 N•m (10.00 %
2.00 lb ft).

3. Remove the nut that holds the adapters to the


cylinder head assembly. Remove fuel injection line
adapters (2).

3. Check the condition of the O-ring seal on inner fuel


line (3) for damage, and make a replacement if
necessary. Install inner fuel line (3).

3406C Marine Engine 48 Disassembly & Assembly


Fuel Injection Pump &
Governor
Remove Fuel Injection Pump &
Governor 1286-011
Start By:

a. remove fuel injection lines

b. remove fuel injection pump and governor drive

FLUID SPILLAGE CONTAINMENT


NOTICE Care must be taken to ensure that fluids are contained
Do not let the tops of the fuel nozzles turn when the during performance of inspection, maintenance,
fuel lines are tightened. The nozzles will be damaged testing, adjusting and repair of the machine. Be
if the top of the nozzles turn in the body. prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
4. Use Tooling (A) to tighten the inner fuel line nuts to SHOP PRODUCT GUIDE, NENG2500", for tools and
a torque of 40 % 7 N•m (30 % 5 lb ft). supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
End By: regulations and mandates.

a. install fuel injection lines

b. install valve covers

1. Remove fuel line (2). Remove fuel line (1) from the
fuel injection pump. Cap and plug all openings
immediately.

3406C Marine Engine 49 Disassembly & Assembly


Install Fuel Injection Pump &
Governor 1286-012

2. Remove bolt, nut and washer (3). Remove fuel line


(4). Cap and plug all openings immediately.

1. Put the three O-ring seals in position on fuel


injection pump and governor (1). Put clean engine
oil on the O-ring seals.

2. Install fuel injection pump and governor (1) on the


engine, and install the nuts that hold it to the timing
gear plate.

3. Install three bolts (2) that hold the fuel injection


pump and governor to the cylinder block.

3. Fasten a strap and a suitable lifting device to the


fuel injection pump, and remove the nuts that hold
the fuel injection pump to the timing gear plate.
Remove bolts (5) and (6), and remove fuel injection
pump and governor (7) from the engine. The weight
of the fuel injection pump and governor is 57 kg
(125 lb).

5. Remove the three O-ring seals from the fuel


injection pump.

4. Install two lines (4) on the engine. Install fuel line (4)
to the fuel injection pump.

End By:

a. install fuel injection pump and governor drive

b. install fuel injection lines

3406C Marine Engine 50 Disassembly & Assembly


Governor
Disassemble Governor 1264-015

Tools Needed A B C
FT1251 Pump Housing Stand 1
6V2163 Clamp Assembly - Spring Compressor 1
1P1855 Pliers 1

Start By:

a. remove fuel injection pump and governor


4. Remove governor spring (3), the two wave washers,
b. remove fuel transfer pump one flat washer and the seat from the guide in the
rear governor housing.
c. remove service meter

d. remove fuel ratio control

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.
5. Remove the bolts that hold cover (4) to the rear
governor housing, and remove the cover and
gasket.

1. Install the fuel injection pump and governor on Tool


(A) as shown.

2. Remove the two bolts and clamps, and remove 6. Remove locknut (6) and low idle adjustment screw
service meter (2). (7) from cover (4).

3. Remove the bolts that hold the rear governor 7. Remove seal (5) from the cover.
housing in place, and remove rear governor housing
(1) and the gasket from the front governor housing.

3406C Marine Engine 51 Disassembly & Assembly


8. Remove bolt (8) that holds lever (10) to the shaft 12. Remove plug (18) from the rear governor housing.
assembly.

NOTE: There is a key in the (slot) groove of the shaft


assembly that must be removed before the shaft
assembly is removed from the rear governor housing.

9. Remove shaft assembly (9), lever (10) and lever (11)


from the rear governor housing.

NOTE: Spacers (19) and (21) are different sizes. Make


sure they are assembled in the correct position.

13. Use needle nose pliers (22), and remove the shaft.
Remove spacer (19), lever (20) and spacer (21)
from the rear governor housing.

10. Remove the rings, pins (13), stop (14) and two
plates (12) from the shaft assembly.

14. Remove lever (24) and spring (23) from lever (20).

15. Remove the nuts and set screws from the lever if
necessary.
11. Remove dowel (16), pin (17) and spring (15) from
the shaft assembly.

3406C Marine Engine 52 Disassembly & Assembly


NOTE: Step 16 is only for governors equipped with a 19. Remove lip seal (32) and insulator (33) from the
manual shutoff. rear governor housing.

16. Release spring (26) from the notch in the rear 20. Remove cover (31), and remove the high idle
governor housing. Remove snap ring (25), and screw.
remove shaft (27) from the housing. Remove lever
(28) and spring (26). 21. If necessary, remove the remaining three covers.

17. Remove two lip seals (29) from the rear governor 22. Remove two bolts (34), housing (35) and the
housing. gasket from the fuel injection pump housing.

18. If necessary, remove the four screws and plate


(30) from the rear governor housing.

3406C Marine Engine 53 Disassembly & Assembly


25. Remove the bolt that holds collar (39) to bolt (41).
NOTICE
Depending on the different engine applications, torque 26. Remove collar (39) and spring (40) from bolt (41).
control groups will vary. Inspect all parts for wear and Remove bolt (41) from the block.
damage, and make a note of the correct sequence of
the parts for assembly purposes. 27. If necessary, remove the stop screw and power
setting screw from collar (39).

23. Remove two bolts (36), and remove torque control


group (37).

NOTE: It may be necessary to turn the piston to


remove the servo from the rack.

24. Remove two bolts and block (38) from housing 28. Remove the three bolts and governor servo (42)
(35). from the fuel injection pump housing.

3406C Marine Engine 54 Disassembly & Assembly


29. Remove ring (48), seat (45), spring (47) and sleeve 32. Use Tool (B) to hold spring (56) under
(44) from valve (43). Remove ring (46) from the compression so the ring on the governor shaft can
valve. be removed.

33. Remove the ring, and carefully remove Tool (B).

34. Remove bearing (55), the sleeve and spring (56)


from the governor shaft.

30. Remove sleeve (49), valve (43) and piston (50)


from cylinder (53). Remove O-ring seal (52) from
sleeve (49).

31. Remove pin (51) and lever (54) from the cylinder.
35. Remove ring (57) and dashpot assembly (58) from
the governor shaft.

3406C Marine Engine 55 Disassembly & Assembly


36. Use Tool (C), and remove ring (64) from seat (59). 41. Remove the bolts and carrier assembly (71) from
the fuel injection pump housing.
37. Remove ring (60) and spool (63) from seat (59).

38. Remove seat (59) and spring (62) from shield (61).

42. Remove governor shaft (74) from the carrier


assembly. Remove dowel (75) from the governor
shaft.
39. Remove spring (66) and riser (65) from the
governor shaft. 43. Remove dowels (72) and flyweights (73) from the
carrier assembly.

40. Remove ring (68), races (69) and bearing (67) from
the riser. 44. Remove races (76) and (78) and bearing (77) from
the fuel injection pump housing.

3406C Marine Engine 56 Disassembly & Assembly


Assemble Governor 1264-016

Tools Needed A B C D
FT-1251 Pump Housing Stand 1
1P-1855 Snap Ring Pliers 1
6V-2163 Clamp Assembly Spring Compressor 1
1P-0510 Driver Group 1

5. Install dowel (7) in the governor shaft (6), and install


the governor shaft in carrier assembly (5).

6. Install carrier assembly (5) and the bolts on the end


of the camshaft.

1. Put the fuel injection pump housing in position on


Tool (A).

2. Install race (3), bearing (2) and race (1) on the end
of the camshaft in the fuel injection pump housing.

7. Install race (10), bearing (12), race (9) and ring (11)
on riser (13).

NOTICE
Make sure the flyweight toes are under the bearing
race.

3. Put flyweight (4) in position on carrier assembly (5),


and install the dowels.

4. Use a feeler gauge to check flyweight end play. The


flyweights must move freely on the dowels and
have 0.010 to 0.230 mm (.0004 to .0090 in) end
play.

3406C Marine Engine 57 Disassembly & Assembly


8. Install riser (13) and spring (14) on the governor 12. Install the ring in the lower groove in the governor
shaft. shaft. Install sleeve (22), spring (24), sleeve (23)
and bearing (25) on the governor shaft.

13. Use Tool (C) to hold spring (24) in compression,


and install the ring in the groove in the governor
shaft.

9. Install spool (18) and ring (19) on seat (17), and use
Tool (B) to install ring (20) to hold them in place.

10. Install seat (17) on spring (16) and spring (16) on


shield (15).
14. Put lever (30) in position on governor servo (26),
and install pin (27) to hold the lever in place. Use a
hammer and chisel to move the metal (stake) four
places 90 degrees apart on the outside surface
on both legs of the governor servo to hold pin (27)
in place.

15. Install the O-ring seal on sleeve (28). Install piston


(29) and sleeve (28) in the governor servo as
shown.

11. Install dashpot assembly (21) on the governor


shaft as shown.

3406C Marine Engine 58 Disassembly & Assembly


16. Install valve (31) in the governor servo as shown. 19. If the dowel was removed from block (38), install it
in the block to a dimension of 31 % 0.5 mm (1.22
% .02 in) above the outside surface of the block.

20. Install bolt (39) in block (38). Install spring (37) on


bolt (39).

21. Install the stop screw, power setting screw and


locknut in collar (36).

22. Put collar (36) in position on bolt (39), and install


the bolt that holds the collar to the bolt.

17. Install one lockring (35) in the groove near the


center of valve (31). Put sleeve (32), spring (broken
link spring) (33) and seat (34) in position on valve
(31), and install the other lockring (35) to hold
them in place.

23. If dowels (41) were removed from the front


governor housing, install them 4.0 % 0.5 mm (.16
% .02 in) above the outside surface of the front
governor housing.

24. Put block (38) in position on the front governor


housing, and install the bolts that hold it.

25. If dowels (40) were removed from the front


governor housing, install them 6.0 % 0.5 mm (.24
% .02 in) above the outside surface of the front
18. Put governor servo (26) in position on the fuel
governor housing.
injection pump housing with piston (29) engaged
over the rack and the lever engaged in the groove
in riser (13).

3406C Marine Engine 59 Disassembly & Assembly


WARNING

To avoid possible personal injury and damage to the


engine when front governor housing (43) is installed
on the fuel injection pump housing, make sure the
flange on bolt (39) is behind the shield of the dash-
pot. If the flange on the bolt is installed on the wrong
side of the shield, the riser in the governor will be
held in the maximum fuel delivery position.

27. Install the gasket and front governor housing (43)


26. Assemble torque spring group (42) in the correct on the fuel injection pump housing. Make sure the
sequence as shown, and install it on block (38). flange on bolt (39) is behind the shield of dashpot
assembly (21).

28. Install the gasket and cover (44) in the rear


governor housing.

3406C Marine Engine 60 Disassembly & Assembly


29. Install the gaskets and covers (45) and (46). Put 34. Use Tool (E), and install lip seal (52) 2.00 % 0.25
the O-ring seals in place, and install cover (47). mm (.079 % .025 in) below the outer service of
the rear governor housing. Install seal (53) 4.0 %
30. Install high idle screw (48). 1 N•m (.157 % .039 in) below the surface of the
rear governor housing. Put clean engine oil on the
lip of the seals.

31. Install the gasket and cover (49).

32. Install insulator (51). Tighten the insulator to a NOTE: Steps 36-38 are only for governors equipped
torque of 4.5 % 0.5 N•m (40.00 % 4.40 lb in). with a manual shutoff.

33. Use Tool (D), and install lip seal (50) with the lip 35. Put clip (57) in position on shaft (56), and install
toward the inside. Put clean engine oil on the lip of shaft (56) into the rear governor housing through
the seal. spring (55) and lever (54). Put the key in the lever
in alignment with the keyway in the shaft.

3406C Marine Engine 61 Disassembly & Assembly


36. Install clip (58) on the shaft. 39. Install shaft (65) in the rear governor housing.
Install long spacer (63), lever assembly (64) and
37. Put the end of spring (55) in position in notch of short spacer (62) on shaft (65).
the rear governor housing as shown.
40. Check the condition of the O-ring seal on the
plug. Put clean engine oil on the O-ring seal, and
install the plug to hold shaft (65) in position.

38. Install the setscrews and locknuts in lever (61).


Tighten the locknuts to a torque of 1.70 %
0.25 N•m (15 % 3 lb in). Put spring (59) and lever
(60) in position on lever (61). Form the sleeve out 41. Install spring (69) in shaft assembly (67). Install pin
against the chamfer in lever (60) all around. The (66) in shaft assembly (67) with the tip of the pin
lever must move freely after forming. engaged in the hole in spring (69). Install dowel
(68) to hold pin (66) in place.

3406C Marine Engine 62 Disassembly & Assembly


42. Put stop (71) and plates (70) in position on shaft 45. Install low idle adjustment screw (78) and the
assembly (67), and install pins (73). Install rings locknut in cover (77).
(72) that hold pins (73) in place.
46. Use Tool (E), and install the seal in cover (77) with
the lip of the seal toward the inside and 1.5 %
0.15 mm (.06 % .006 in) below the outside
surface.

43. Put shaft assembly (67) in position in the rear


governor housing. Install shaft assembly (67) into
the first hole of lever (74). Install the key in shaft
assembly (67), and make an alignment of the
groove in the second hole in lever (74) and the 47. Install gasket (79) and cover (77) on the rear
groove in lever (76). governor housing, and install the bolts.

44. Install bolt (75) into lever (76) through the notch in
shaft assembly (67).

3406C Marine Engine 63 Disassembly & Assembly


48. Put the throttle lever and manual shutoff lever (54)
in the maximum shutoff position, and measure the NOTICE
distance between the face of lever (61) and the Be sure the flyweight toes are under the bearing race
outer surface of the rear governor housing with a before installing the rear governor housing.
depth micrometer (80). Adjust the setscrew on
lever (61) so that the measurement is 28.80 %
0.50 mm (1.134 % .020 in). Tighten the locknuts 50. Install gasket (83) and rear governor housing (82)
to a torque of 1.7 % 0.3 N•m (15.00 % on the front governor housing.
3.00 lb in).
51. Make the governor adjustments. See the topic
“Governor Adjustments” in Systems Operations
Testing & Adjusting.

End By:

a. install fuel ratio control

b. install service meter

c. install fuel transfer pump

d. install fuel injection pump and governor

49. Put the seat, two wave washers, one flat washer
and spring (81) in position on the guide in the rear
governor housing.

3406C Marine Engine 64 Disassembly & Assembly


Fuel Injection Pumps 2. Put Tooling (B) except for the 8T-5287 Wrench in
position on the fuel pump housing as shown. Lower
the handle to center the adjusting screw with the
Remove Fuel Injection fuel line seat. With the handle down in the locked
Pumps 1251-011 position, the adjusting screw must just be in
contact with fuel line seat (1). If force is needed to
Tools Needed A B C lower the handle or there is a gap, remove the
6V4186 Timing Pin 1 tooling, and make an adjustment to the screw.
9U5692 Compressor Group 1
3. Loosen bushing (2) 1/4 of a turn.
8T5287 Wrench 1
8S2244 Extractor 1 4. Put Tooling (B) in position on the pump housing
with the handle down in the locked position as
shown.
Start By: 5. Remove bushing (2) from the pump housing.

a. remove fuel injection lines 6. Carefully and slowly lift the handle to release the
spring force. Remove the tooling.
b. disassemble governor *

* Only disassemble the governor enough so that


Tooling (D) of Install Fuel Injection Pump can be
installed.

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates. 7. Install Tool (C) on fuel pump (4) as shown.

8. Remove seal (3) and fuel pump (4) from the fuel
pump housing.

1. Remove the plug, and move the rack until Tool (A)
can be installed to hold the rack in the center
position. The rack must be in the center position to
remove the fuel injection pump. 9. Remove spacers (5) from the pump housing.

WARNING

To prevent possible personal injury carefully follow


the steps below.

3406C Marine Engine 65 Disassembly & Assembly


NOTE: There must be a pump installed on either side NOTE: Spacers (5) are the same thickness for each
of the pump to be removed to install Tooling (B). If fuel injection pump so they can be mixed. The fuel
there is no pump, take a pump already removed, and injection pump plungers and barrels are sets and
remove the spring so there will be no spring force, and cannot be mixed.
install it in the pump housing. See Install Fuel Pump.

3406C Marine Engine 66 Disassembly & Assembly


Install Fuel Injection Pumps 1251-012
Tools Needed A B C D
6V4186 Timing Pin* 1
8S2244 Extractor 1
6V7050 Compressor Group 1
8T5287 Wrench 1
9S0225 Bracket 1
6V6106 Dial Indicator 1
5P2393 Contact Point 1

4. Install Tool (B) on the bonnet of the fuel pump as


shown.

5. Install the fuel pump in the pump housing with the


saw cut (slot) (5) in the gear in alignment with small
pin (1) in the lifter assembly and groove (4) in the
barrel in alignment with large pin (3) in the pump
housing.

1. Install spacers (2) in the fuel pump housing.

2. Move the rack until Tool (A) can be installed to hold


the rack in the center position. The rack must be in
the center position to install the fuel injection
pumps.

3. Install a fuel pump without its spring so that Tool (C)


can be installed. See Step 5 for correct fuel pump
installation.
6. Install the seal and bushing (6) on the fuel pump.

7. Put Tooling (C) in position on the fuel pump housing


as shown.

8. Lower the handle slowly and carefully. If the fuel


pump is not installed correctly, the handle will not
go all the way down. Do not try to use force on it.
Remove and install the tooling and the fuel pump
again.

9. Make sure the seal is in its correct position, and


start to tighten bushing (6). Remove the tooling, and
tighten the bushing to a torque of 220 % 15 N•m
(160 % 11 lb ft).

3406C Marine Engine 67 Disassembly & Assembly


Disassemble Fuel Injection
Pumps 1251-015

Tools Needed A B
6V7870 Fixture Group * 1
8T5116 Pliers 1
*See SMHS8378 for tool usage.

Start By:

a. remove fuel injection pumps

10. After each fuel pump has been installed, follow the FLUID SPILLAGE CONTAINMENT
steps below to check total rack travel to make
sure each pump has been installed correctly. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
a. Remove Tool (A) from the fuel pump housing. testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
b. Install Tooling (D) on the fuel pump housing as before opening any compartment or disassembling any
shown. component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
c. Move rack (7) in and out of the fuel pump housing supplies suitable to collect and contain fluids in
to measure total rack travel. Total rack travel must Caterpillar machines. Dispose fluids according to local
be approximately 19.7 mm (.78 in). If this regulations and mandates.
measurement is not obtained, center the rack,
install Tool (A), and remove and install the fuel
pump again.
NOTICE
End By: Be careful when the injection pumps are disassem-
bled. Do not damage the surfaces of the plungers,
a. assemble governor barrels and bonnets. Any scratches will cause leakage
inside the fuel injection pump. The plunger and barrel
b. install fuel injection lines for each pump are made as a set. Do not put the
plunger of one pump in the barrel of another pump. If
one part has wear, install a complete new pump
assembly. Be careful when the plunger is put into the
bore of the barrel.

3406C Marine Engine 68 Disassembly & Assembly


1. Pull plunger (4) and washer (3) out of barrel (1) and
spring (2). 3. Use the following procedure to put the fuel pump in
position on Tooling (A):
2. Remove spring (2) from barrel (1). Do not remove
the gear from the plunger. The gear and plunger are a. Select the correct turret position.
assembled and adjusted at the factory.
b. Place a barrel assembly into the turret.

c. Loosen the nut on the clamp.

d. Adjust clamp end (6) until the bonnet is almost


touching the barrel when the clamp handle is in
the locked position.

e. Tighten the nut on the clamp.

4. Use Tool (B) to expand ring (5), and carefully lift it


off the fuel pump.

5. Slowly release the clamp handle of Tooling (A), and


remove the lockring.

6. Remove bonnet (7), spring (8) and valve (9) from


barrel (1).

3406C Marine Engine 69 Disassembly & Assembly


Assemble Fuel Injection
Pumps 1251-016
Tools Needed A B
6V7870 Fixture Group * 1
8T5116 Pliers 1
*See SMHS8378 for tool usage.

6. Install spring (7) on barrel (4).

7. Install washer (8) on plunger (9). Make sure the


spring seat on the washer is away from the gear on
the plunger.

8. Install plunger (9) in barrel (4). Make sure spring (7)


is engaged in the spring seat on washer (8).

End By:
1. Put spring (2) and valve (5) in barrel (1).
a. install fuel injection pumps
2. Put bonnet (4), barrel (1) and ring (3) in position on
Tool (A).

3. Put the barrel assembly in position on Tooling (A).


Lower the handle on Tooling (A) to hold the fuel
pump together.

4. Use Tool (B), and lower ring (3) on to the barrel and
the bonnet to hold them together.

5. Remove the barrel assembly from Tooling (B).

3406C Marine Engine 70 Disassembly & Assembly


Fuel Injection Pump Housing
Disassemble Fuel Injection Pump
Housing 1253-015
Tools Needed A
8S2241 Camshaft Bearing Installation And Removal Group 1
8B7548 Push-Puller 1

Start By:

a. disassemble governor
2. Remove six lifters (2) from the fuel pump housing.
b. remove fuel injection pumps Put identification marks on the lifters for installation
purposes.
FLUID SPILLAGE CONTAINMENT
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

3. Remove camshaft (3) from the fuel pump housing. It


may be necessary to use a soft hammer to push
the camshaft out of the governor end of the fuel
pump housing.

1. Remove rack (1) from the fuel pump housing.

4. Remove races (4) and bearing (5) from the


camshaft. Remove ring (6) if necessary.

3406C Marine Engine 71 Disassembly & Assembly


5. Remove rack bearing (7) from both ends of the 7. Remove the bolts, cover (10) and the gasket.
housing and dowel (8) if necessary.

8. Remove pins (12), the seal and dowels (11) if


6. Use Tooling (A), and remove three camshaft necessary. Pins (12) must be pushed from the
bearings (9). inside out.

3406C Marine Engine 72 Disassembly & Assembly


Assemble Fuel Injection Pump
Housing 1253-016

Tools Needed A B C
6V4824 Drive 1
6V4825 Plate 1
1P0510 Driver Group 1
8S2241 Camshaft Bearing Installation And 1
Removal Group

1. Clean and inspect all parts. Make a replacement of


all parts that are worn or damaged.
5. Install the rack bearing with Tooling (A). Install the
bearing until the installer comes in contact with the
plate. The bearing should be installed to a depth of
83.0 % 0.5 mm (3.27 % .02 in) from the fuel
pump mounting face.

2. Lubricate the seal with clean engine oil, and install


pin (1). Pin (1) must protrude into the pump bore
2.15 % 0.05 mm (.085 % .002 in).

3. Install dowel (2) so that it protrudes into the pump


bore 1.93 % 0.05 mm (.076 % .002 in). 6. Measure rack bearing (4). Dimension (X) must be
11.178 % 0.05 mm (.4400 % .002 in). Diameter
(W) must be 12.767 % 0.058 mm (.5026 %
.0023 in).

4. Install the gasket, cover (3) and the bolts.

3406C Marine Engine 73 Disassembly & Assembly


NOTE: Oil holes (7) in the camshaft bearings must be
positioned 30 % 3 degrees above the horizontal
centerline toward the engine side of the fuel pump
housing. The outer bearings must be installed 1.0 %
0.5 mm (0.04 % 0.02 in) below the surface marked
(Z). The inner bearing must be installed 218.0 % 0.3
mm (8.58 % .012 in) below the front surface (Y).
Diameter (XX) must be 68.339 % 0.038 mm (2.6905
% .0015 in) after assembly.

7. Install dowel (5). Dowel (5) must protrude 6.0 %


0.5 mm (.24 % .02 in) from the fuel pump housing
face.

8. Install the rear rack bearing with Tooling (B) to a


depth of 7.16 % 0.13 mm (.282 % .005 in) below
the fuel pump housing surface. The inside diameter
of the rear rack bearing must be 12.746 %
0.045 mm (.5018 % .0017 in).

10. Install ring (8), races (10) and bearing (9) on the
camshaft.

11. Lubricate cam bearings (6) and the camshaft


bearing journals with clean engine oil.

12. Install camshaft (11) into the fuel pump housing.

9. Use Tooling (C), and install three camshaft bearings


(6).

3406C Marine Engine 74 Disassembly & Assembly


Aftercooler Housing
Remove Aftercooler
Housing 1063-011
Tools Needed A
6V2156 Link Brackets 2

Start By:

a. remove fuel filter base

FLUID SPILLAGE CONTAINMENT


NOTICE
The notch in the lifter must be in line with the dowel in Care must be taken to ensure that fluids are contained
the lifter bore. The lifter must slide up and down freely during performance of inspection, maintenance,
in the bore. If it does not, check the dowel for proper testing, adjusting and repair of the machine. Be
installation depth. prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
13. Lubricate lifters (12) with clean engine oil, and SHOP PRODUCT GUIDE, NENG2500", for tools and
install them in their original lifter bores. supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

1. Drain the coolant from the engine into a suitable


container for storage or disposal.

14. Lubricate the rack bearings and rack (13) with


clean engine oil.

NOTICE
The rack must slide freely in the rack bearings after 2. Remove tube (1). Cap and plug all openings
installation. immediately.

3. Remove the four bolts and washers that hold


15. Install rack (13). The flat on the rack must line up adapter (2) to the aftercooler housing. Move the
with the flat on the front rack bearing. elbow away from the aftercooler housing.

End By:

a. install fuel injection pumps

b. assemble governor

3406C Marine Engine 75 Disassembly & Assembly


Install Aftercooler Housing 1063-012

Tools Needed A
6V2156 Link Brackets 2

4. Remove five bolts and washers (3) that hold air inlet
pipe (4) to the aftercooler housing. Move the air inlet
pipe away from the aftercooler housing.

1. Put the six gaskets in place on the cylinder head.

2. Put a new O-ring seal in position on pipe (3). Put


clean oil on the O-ring seal.

3. Fasten a hoist and Tool (A) to aftercooler housing


(1).

4. Put the aftercooler housing in position on the elbow


and cylinder head.

5. Put 9S-3263 Thread Lock on the threads of the


5. Disconnect tube assembly (7). bolts, and install the bolts that hold aftercooler
housing (1) to the cylinder head.
6. Fasten a hoist and Tool (A) to aftercooler housing
(5). Remove twelve bolts (6), that hold aftercooler 6. Connect tube assembly (2) to the aftercooler
housing (5) to the cylinder head and remove the housing.
aftercooler housing. The weight of the aftercooler
housing is 34 kg (75 lb).

7. Remove the six gaskets from the cylinder head.

8. Remove the O-ring seal from the water outlet tube


(8).

3406C Marine Engine 76 Disassembly & Assembly


Expansion Tank
Remove Expansion Tank 1354-011
Tools Needed A
6V2156 Link Brackets 2

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
7. Put the gasket and air inlet pipe (4) in position on prepared to collect the fluid with suitable containers
the aftercooler, and install five bolts (3) that hold the before opening any compartment or disassembling any
air inlet pipe to the aftercooler housing. component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

1. Drain the coolant from the engine into a suitable


container for storage or disposal.

2. Disconnect the water line from the water


temperature regulator housing. Cap and plug all
openings immediately.

8. Put the gasket and elbow (6) in position on the


aftercooler housing, and install the four bolts that
hold them in place.

9. Install tube (5).

10. Fill the engine with coolant to the correct level.


See the Operation & Maintenance Manual.

End By:

a. install fuel filter base 3. Remove tube (3). Cap and plug all openings
immediately.

4. Remove three bolts and washers (1). Remove cover


(2).

3406C Marine Engine 77 Disassembly & Assembly


Install Expansion Tank 1354-012

Tools Needed A
6V2156 Link Brackets 2

5. Remove the bolt that holds clamp (4) to the


expansion tank.

6. Remove the two bolts that hold adapter (5) to the


water regulator housing.

1. Fasten a hoist and Tooling (A) to expansion tank (1).


Put the expansion tank in position on the engine,
and install the four bolts that hold it.

7. Remove four bolts (7), and disconnect elbow (6)


from the expansion tank.

2. Put the gasket and elbow (2) in position on the


expansion tank, and install four bolts (3).

8. Fasten a hoist and Tooling (A) to the expansion


tank. Remove four bolts (9), and remove expansion
tank (8) from the engine. The weight of the
expansion tank is 43 kg (95 lb).

3406C Marine Engine 78 Disassembly & Assembly


Water Temperature Regulator
Remove Water Temperature
Regulator 1355-011

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
3. Put clamp (4) in position on the expansion tank, and SHOP PRODUCT GUIDE, NENG2500", for tools and
install the bolt that holds it. supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
4. Put the gasket and adapter (5) in position on the regulations and mandates.
water regulator housing, and install bolts (6).
1. Drain the coolant from the engine into a suitable
container for storage or disposal.

5. Install the gasket and filler neck (8) on the


expansion tank. Connect hose (7) to the filler neck.
2. Remove bolts (1), and move adapter (2) away from
6. Install tube (9). the cover assembly and into pipe (3).

7. Connect the water line to the water temperature


regulator.

8. Fill the cooling system with coolant to the correct


level. See the Operation & Maintenance Manual.

3406C Marine Engine 79 Disassembly & Assembly


3. Remove bolts (4), and move cover assembly (5) 8. Remove cover assembly (5).
away from the expansion tank.

9. Remove water temperature regulators (11) from


4. Remove bolt (6) that holds tube (7) to the expansion cover assembly (5).
tank.

5. Remove bolt and washers (8).

10. Remove seals (12) from cover assembly (5).

6. Remove tube (9).

7. Remove the four bolts that hold elbow (10) to the


aftercooler housing, and remove the elbow and
tube (7) as an assembly.

3406C Marine Engine 80 Disassembly & Assembly


Install Water Temperature
Regulator 1355-012

Tools Needed A
1P0510 Driver Group 1

3. Put the gasket, bolts (3) and cover assembly (1) in


position near the expansion tank. Do not install the
bolts into the expansion tank.

1. Use Tool (A), and install the seals in cover assembly


(1) with the lips of the seals down. Put clean oil on
the lips of the seals.

4. Put the O-ring seal on the end of tube (4).

5. Put tube (4) and elbow (5) in position in elbow (6) as


an assembly.

2. Install water temperature regulators (2) in cover


assembly (1) as shown.

6. Put the gasket and elbow (5) in place on the


aftercooler housing, and install the bolts.

7. Install tube (7).

3406C Marine Engine 81 Disassembly & Assembly


Oil Filter Base
Remove Oil Filter Base 1306-011

Tools Needed A
2P8250 Strap Wrench 1

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
8. Put cover assembly (1) in position on the expansion prepared to collect the fluid with suitable containers
tank, and tighten bolts (3). before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
9. Install bolt (8). SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

10. Install the bolt that holds clip (9) to the expansion
tank.

11. Install the gasket, and connect adapter (10) to the 1. Remove filter assembly (1) with Tool (A).
cover assembly.

12. Fill the engine with coolant to the correct level.


See the Operation & Maintenance Manual.

3406C Marine Engine 82 Disassembly & Assembly


2. Remove the two bolts that hold tube (3) to the oil 3. Put the gasket and tube (4) in position on oil filter
filter base, and move the tube away from the oil base (2), and install the bolts that hold the tube in
filter base. Cap or plug all openings immediately. place.

3. Remove the two bolts that hold tube (4) to the 4. Put clean oil on the gasket on filter assembly (5),
cylinder block. and install the filter assembly on the oil filter base.
Tighten the filter assembly 3/4 of a turn after the
4. Remove the bolts that hold oil filter base (2) to the gasket makes contact with the oil filter base.
cylinder block, and remove the oil filter base and
tube (4) as an assembly. Cap or plug all openings
immediately.
Disassemble Oil Filter Base 1306-015
Start By:
Install Oil Filter Base 1306-012
a. remove oil filter base

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

1. Put oil filter base (2) and tube (3) in position on the
cylinder block as an assembly, and install four bolts
(1) to hold the oil filter base to the cylinder block.

2. Put the O-ring seal in position in tube (3), and install


the two bolts that hold the tube to the cylinder
block.

3406C Marine Engine 83 Disassembly & Assembly


Assemble Oil Filter Base 1306-016

1. Remove tube (3) from oil filter base (1).

2. Remove the O-ring seals from tube (3).


1. Put plunger (2) and spring (1) in position in oil filter
3. Remove stud (2) from the oil filter base. base (3), and install the gasket and cover.

4. Remove the cover that holds spring (4) and plunger 2. Put 9S-3263 Thread Lock on the tapered threads
(5) in the oil filter base. of stud (4), and install the stud in oil filter base (3).
Tighten the stud to a torque of 83 % 13 N•m
5. Remove the spring and plunger from oil filter base (62 % 10 lb ft).
(1).
3. Put O-ring seal (5) on tube (6), and install the tube
in the oil filter base.

End By:

a. install oil filter base

3406C Marine Engine 84 Disassembly & Assembly


Engine Oil Cooler
Remove Engine Oil Cooler 1378-011

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in 5. Remove clip (8).
Caterpillar machines. Dispose fluids according to local
regulations and mandates. 6. Remove the bolts that hold elbow (6) and bypass
valve body (7) to the cylinder block, and remove
1. Drain the coolant from the engine into a suitable them as an assembly with engine oil cooler (9).
container for storage or disposal.
7. Remove the bolts that hold elbow (6) and bypass
valve body (7) to the oil cooler, and remove the
elbow and the bypass valve body.

8. Use a 3.17 mm (.125 in) diameter rod to clean


each tube of the engine oil cooler.

2. Remove the bolts that hold tube (1) to the oil filter
base and bypass valve body, and remove the tube.
Cap or plug all openings immediately.

3. Remove clip (3) and bolts (2), and remove bonnet


(4) and the adapter as an assembly.

WARNING

Spring force is present behind cover (10). Remove


the bolts slowly and evenly that hold cover (10) in
position to avoid possible personal injury.

9. Remove cover (10).

10. Remove spring (11) and the plunger from bypass


valve body (7).

4. Remove adapter (5) from bonnet (4), and remove


the O-ring seals from the adapter.

3406C Marine Engine 85 Disassembly & Assembly


11. Remove elbow (6) from tube (12), and remove the 3. Install plunger (5) and spring (4) in bypass valve
tube from bypass valve body (7). body (2), and install the gasket and cover.

12. Remove the O-ring seal from tube (12).

Install Engine Oil Cooler 1378-012


1. Replace all O-ring seals that are worn or damaged,
and put clean engine oil on them.

4. Put the O-ring seals in position in elbow (1) and


bypass valve body (2), and install them on engine oil
cooler (6).

2. Install the O-ring seal on tube (3), and install the


tube in elbow (1) and bypass valve body (2).

3406C Marine Engine 86 Disassembly & Assembly


5. Install O-ring seal (7) on the flange. 9. Put a new gasket in place on the water pump and
elbow (10).
6. Put engine oil cooler (6) in position on the flange.
Make sure the O-ring seal is in place in elbow (1), 10. Install bonnet (8) on the engine oil cooler, and
and install the bolts that hold the elbow and bypass install the bolts that hold the bonnet to the water
valve body (2) to the cylinder block. pump and elbow (10).

7. Install the clip that holds the engine oil cooler to the 11. Install the clip that holds the bonnet to the engine
flange. oil cooler.

8. Install the O-ring seals on adapter (9), and install the 12. Put the O-ring seal in place on tube (11), and
adapter in bonnet (8). install the tube in the bypass valve body.

13. Put the gasket on the oil filter base, and connect
tube (11).

14. Fill the cooling system to the correct level. See the
Operation & Maintenance Manual.

15. Check oil level in the engine. See the Operation &
Maintenance Manual.

3406C Marine Engine 87 Disassembly & Assembly


Marine Gear Oil Cooler Core
Remove & Install Marine Gear Oil
Cooler Core 3320-010

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and 4. Remove core assembly (3) and gasket (4) from the
supplies suitable to collect and contain fluids in housing.
Caterpillar machines. Dispose fluids according to local
regulations and mandates. NOTE: The following steps are for installation of the
marine gear oil cooler core.
1. Drain the coolant from the engine into a suitable
container for storage or disposal. 5. Put gasket (4) and core assembly (3) in position in
the housing.
2. Disconnect the oil inlet and outlet lines. Cap or plug
all openings immediately. 6. Install the two O-ring seals in cover (2). Put cover
(2) in position on the housing, and install bolts (1).

7. Connect the oil inlet and outlet lines.

8. Fill the cooling system with coolant to the correct


level. See the Operation & Maintenance Manual.

3. Remove eight bolts (1) and cover (2) from the


housing, and remove the two O-ring seals from the
cover.

3406C Marine Engine 88 Disassembly & Assembly


Remove & Install Marine Gear Oil
Cooler 3320-010

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates. 4. Remove the bolts that hold clip (4) to the oil cooler,
and remove the clip.
1. Drain the coolant from the engine into a suitable
container for storage or disposal. 5. Remove four bolts (2), and remove marine gear oil
cooler (3).
2. Disconnect the oil inlet and outlet lines. Cap or plug
all openings immediately. 6. Remove the gasket and O-ring seal from oil cooler
(3).

NOTE: The following steps are for installation of the


marine gear oil cooler.

7. Put the gasket and O-ring seal in place on the


marine gear oil cooler. Put clean engine oil on the
O-ring seal.

8. Put marine gear oil cooler (3) in position on the


engine, and install bolts (2).

9. Put clip (4) in position on the oil cooler, and install


the two bolts that hold it.

10. Install tube (1) between the turbocharger and the


marine gear oil cooler.
3. Disconnect tube (1) from the turbocharger and
marine gear oil cooler, and remove the tube. Cap or 11. Connect the oil inlet and outlet lines.
plug all openings immediately.
12. Fill the cooling system with coolant to the correct
level. See the Operation & Maintenance Manual.

3406C Marine Engine 89 Disassembly & Assembly


Turbocharger
Remove Turbocharger 1052-011

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in 4. Remove the bolts that hold tubes (5) and (6) to the
Caterpillar machines. Dispose fluids according to local turbocharger. Disconnect tube (5) from the cylinder
regulations and mandates. block, and remove the tube and gasket.

1. Drain the coolant from the engine into a suitable


container for storage or disposal.

5. Remove the bolts that hold elbow (7) to the


aftercooler housing, and remove the elbow and
pipe (8) from the turbocharger as an assembly.
2. Remove the four bolts and clips (1), and remove
exhaust elbow (2).

6. Loosen clamp (9).

3. Remove water lines (3) and (4). 7. Fasten a hoist to the turbocharger. Remove four
nuts (11), and remove turbocharger (10) and the
gasket from the exhaust manifold. The weight of the
turbocharger is 39 kg (86 lb).

3406C Marine Engine 90 Disassembly & Assembly


8. Remove tube (6) from the engine, and remove the 4. Put turbocharger (4) in position on the engine, and
gasket and O-ring seal from the tube. install the nuts that hold it. Tighten the nuts to a
torque of 54 % 5 N•m (40 % 4 lb ft).

Install Turbocharger 1052-012

5. Put the O-ring seal in position on pipe (6). Put clean


oil on the O-ring seals, and install the pipe and
elbow (5) in the turbocharger as an assembly.

1. Put gasket (1) in position on the exhaust manifold. 6. Put the gasket and elbow (5) in place on the
aftercooler housing, and install the bolts.
2. Put 5P-3931 Anti-Seize Compound on studs (3).

3. Install the gasket and O-ring seal on tube (2). Put


clean oil on the O-ring seal, and install tube (2) in
the flywheel housing.

3406C Marine Engine 91 Disassembly & Assembly


7. Tighten clamps (8). 11. Put exhaust elbow (11) in position on the
turbocharger.
8. Install the bolts that hold tube (2) to the
turbocharger. 12. Put 5P-3931 Anti-Seize Compound on the
threads of bolts (13). Install clips (12) and bolts
9. Put the gasket and tube (7) in position on the (13) to hold the exhaust elbow in place.
turbocharger, and connect the tube to the cylinder
block. Install the bolts that hold tube (7) to the 13. Fill the cooling system with coolant to the correct
turbocharger. level. See the Operation & Maintenance Manual.

10. Install water lines (9) and (10).

3406C Marine Engine 92 Disassembly & Assembly


Disassemble Turbocharger 1052-015

Tools Needed A B C D E F G
9S6363 Turbocharger Fixture Group 1
9S6343 Fixture Group 1
5S9566 T-Wrench 1
FT168 Fixture Adapter 1
1P1861 Snap Ring Pliers 1
1P0074 Slide Hammer 1
2P2312 Leg 3
FT0745 Modified Pliers 1

Start By: 3. Loosen “V” clamp (3), and remove cartridge


housing (4) from turbine housing (5).
a. remove turbocharger

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

4. Put the cartridge assembly in Tool (B) as shown.

NOTICE
When the nut is loosened, do not put a side force on
the shaft.

5. Use Tool (C) and a universal socket, and remove


the nut that holds compressor wheel (6).

1. Install the turbocharger on Tooling (A). Put marks


on the three housings of the turbocharger for
correct installation and alignment at assembly.

2. Loosen “V” clamp (2), and remove compressor


housing (1).

3406C Marine Engine 93 Disassembly & Assembly


8. Use Tool (E), and remove ring (11) that holds insert
(12) on the cartridge housing.
WARNING

Compressor wheel (6) has sharp edges and can


cause personal injury if not handled carefully.

6. Put the cartridge assembly in Tool (D), and use a


press (if necessary) to remove compressor wheel (6)
from turbine wheel and shaft assembly (7). Do not
let the turbine wheel and shaft assembly fall during
removal of the compressor wheel.

9. Remove insert (12) with Tooling (F).

WARNING

The turbine wheel has sharp edges and can cause


personal injury if not handled carefully.
10. Remove O-ring seal (14) and sleeve (13) from
insert (12). Remove the seal ring from sleeve (13).
7. Remove seal ring (8) and shroud (10) from turbine
shaft (9).

3406C Marine Engine 94 Disassembly & Assembly


11. Remove deflector (16) and ring (15) from the 13. Use Tool (G), and remove ring (20). Remove
cartridge housing. bearing (19), and put a long dye mark on the top
of the bearing.

12. Remove bearing (18), sleeve (17) and the ring from
the cartridge housing. 14. Turn the cartridge assembly over. Use Tool (G),
and remove ring (21). Remove bearing (22) from
the cartridge housing, and put a short dye mark
on the top of the bearing.

NOTE: The dye marks are used for identification of the


bearings when they are installed.

15. If necessary, remove the two rings that hold the


bearings in position from the cartridge housing
with Tool (F).

16. Check all the parts of the turbocharger for


damage. If the parts have damage, use new parts
for replacement. See Special Instruction,
SMHS6854, for Turbocharger Reconditioning.
Also see Guideline For Reusable Parts,
SEBF8018, and Analyzing Turbocharger Failure,
FEG45138.

3406C Marine Engine 95 Disassembly & Assembly


A02801P1*

3406C Marine Engine 96 Disassembly & Assembly


Assemble Turbocharger 1052-016

Tools Needed A B C D E
FT0745 Modified Pliers 1
1P1861 Pliers 1
9S6363 Fixture Assembly 1
8T5096 Dial Test Indicator Group 1
9S6363 Turbocharger Fixture Group 1

1. Make sure all of the oil passages in the


turbocharger cartridge housing are clean and free
of dirt and foreign material.
6. Turn the cartridge assembly over, and install
2. Put clean engine oil on all parts of the cartridge bearing (4). Use Tool (A), and install ring (3) to hold
assembly. the bearing in position.

3. Make a replacement of the two inside rings that


hold the bearings in position in the cartridge
housing if necessary.

NOTE: Install the rings that hold the bearings in


position with the round edges of the rings toward the
bearings.

7. Install ring (7), sleeve (6) and bearing (5) in the


cartridge housing.

NOTE: Make sure the oil hole in bearing (5) is open


and clean to prevent a bearing failure.

4. Install bearing (2) in the cartridge housing.

5. Use Tool (A) to install ring (1) in the cartridge


housing.

3406C Marine Engine 97 Disassembly & Assembly


8. Install ring (9) and deflector (8) in the cartridge 12. Install insert (11) in the cartridge housing. Use Tool
housing. (B), and install the ring to hold the insert in
position.

9. Install O-ring seal (12) around insert (11).


13. Put turbine shaft (14) in position in Tool (C). Put
10. Put 6V-2055 High Vacuum Grease on the seal 6V-2055 High Vacuum Grease in the groove for
ring. seal ring (15). Make sure the grease fills the
groove approximately one half or more of the
11. Install sleeve (10) in insert (11) from the bottom groove depth for the complete circumference of
side. the groove to help make a carbon dam under the
seal ring. Install seal ring (15) and shroud (13) on
turbine shaft (14).

3406C Marine Engine 98 Disassembly & Assembly


14. Put the turbine shaft in Tool (C), and install the 17. Put the cartridge housing in a vise as shown.
cartridge housing on turbine shaft (14). Make sure Check the shaft end play with Tool (D). The end
seal ring (15) is fitted correctly in the cartridge play must be 0.114 % 0.038 mm (.0045 %
housing. .0015 in) (new) 0.20 mm (.008 in) maximum
permissible (worn). If the shaft end play is not the
correct dimension, the inside parts of the cartridge
NOTICE housing must be checked for too much wear.
Do not put a side force on the shaft when the nut is
tightened.

18. Install the turbine housing on Tooling (E). Put the


cartridge assembly in position in the turbine
housing. Make sure the marks on the housings
15. Install compressor wheel (16) on the turbine shaft. are in alignment with each other. Put 5P-3931
Put a small amount of 4C-9507 Retaining Anti-Seize Compound on the threads of the “V”
Compound and the nut and the shaft. Install the clamp that holds the cartridge assembly to the
nut that holds the compressor wheel on the turbine housing. Install the “V” clamp, and tighten
turbine shaft. Use a torque wrench and a universal the bolt to a torque of 13.6 % 1.1 N•m (120 %
socket of the correct size, and tighten the bolt to a 10 lb in). Tap (hit) clamp lightly all around, and
torque of 60 % 3 N•m (44 % 2 lb ft). tighten again to a torque of 13.6 % 1 N•m (120
% 10 lb in).
16. Make sure the compressor wheel is clean and dry.

3406C Marine Engine 99 Disassembly & Assembly


Exhaust Manifold
Remove Exhaust Manifold 1059-011
Start By:

a. remove turbocharger

19. Install the compressor housing to the cartridge


assembly. Install the “V” clamp that holds the
compressor housing to the cartridge housing, and
tighten the bolt to a torque of 13.6 % 1.1 N•m
(120 % 10 lb in). Tap (hit) clamp lightly all around,
and tighten again to a torque of 13.6 % 1.1 N•m
(120 % 10 lb in).

End By:

a. install turbocharger 1. Remove bolts (1), and disconnect flange (2) from
the exhaust manifold.

2. Remove tube (6) from the engine.

3. Remove the bolts that hold adapter (4) to the


regulator housing, and move the adapter into pipe
(5).

4. Remove six bolts (3), and remove pipe (5) from the
engine.

3406C Marine Engine 100 Disassembly & Assembly


5. Remove nuts (8) and spacers (7), and remove
exhaust manifold (9).

6. Remove the gaskets from the cylinder head. 5. Tighten the nuts in the number sequence shown to
a torque of 38 % 5 N•m (28 % 4 lb ft).

Install Exhaust Manifold 1059-012


1. Replace all seals that are worn or damaged, and
put clean engine oil on them.

Typical Example

6. Put the gasket and pipe (6) on the cylinder head,


and install bolts (4).

7. Connect adapter (5) to the regulator housing.

2. Make sure the seal is in position on elbow (1). 8. Install tube (7) on the engine.

3. Put 5P-3931 Anti-Seize Compound on the studs.

4. Put gaskets (3) and exhaust manifold (2) on the


cylinder head, and install the spacers and nuts that
hold the exhaust manifold to the cylinder head.

3406C Marine Engine 101 Disassembly & Assembly


Water Pump
Remove Water Pump 1361-011

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
9. Connect flange (8) to the exhaust manifold with supplies suitable to collect and contain fluids in
bolts (9). Caterpillar machines. Dispose fluids according to local
regulations and mandates.
End By:
1. Drain the coolant from the engine into a suitable
a. install turbocharger container for storage or disposal.

2. Remove clip (1).

3. Remove the bolts that hold bonnet (3) to the water


pump and elbow (2), and remove the bonnet.

3406C Marine Engine 102 Disassembly & Assembly


Install Water Pump 1361-012
1. Inspect the seals for wear or damage, and replace if
needed. Put clean engine oil on the seals.

2. Put the O-ring seal on the front of the water pump.

4. Remove tube (4) from the engine. Cap or plug all


openings immediately.

5. Remove the bolts that hold cover (5) to the water


pump and elbow (6), and remove the cover.

6. Remove the O-ring seal from the rear of the water


pump.
3. Put water pump (1) in position on the timing gear
plate, and install the bolts and nuts that hold it.
Make sure that the water pump gear and the gear
in the front cover are in alignment.

7. Remove two nuts (9) and five bolts (8) that hold the
water pump to the timing gear plate, and remove
water pump (7).

8. Remove the O-ring seal from the front of the water 4. Put the O-ring seal in position on the rear of the
pump. water pump.

5. Put the gasket and cover (3) in position on elbow


(4), and install the bolts that hold the cover to the
elbow and water pump.

6. Install tube (2) on the engine.

3406C Marine Engine 103 Disassembly & Assembly


Disassemble Water Pump 1361-015

Tools Needed A B C
8S-2264 Puller Group 1
4B-3903 Bolt 5/16-18 NC X 102mm (4 in) Long 2
1P-0456 Plate 1
4B-4277 Washer 2
1P-0510 Driver Group 1
2W-9102 Seal Installation Tool 1

Start By:

7. Make sure the O-ring seal is in place on adapter (6). a. remove water pump

8. Install the gaskets on the water pump and elbow FLUID SPILLAGE CONTAINMENT
(5).
Care must be taken to ensure that fluids are contained
9. Put bonnet (7) in position on the adapter, and install during performance of inspection, maintenance,
the bolts that hold the bonnet to the water pump testing, adjusting and repair of the machine. Be
and elbow (5). prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
10. Install the clip that holds the bonnet to the oil component containing fluids. Refer to "TOOLS AND
cooler. SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
11. Fill the cooling system to the correct level. See the Caterpillar machines. Dispose fluids according to local
Operation & Maintenance Manual. regulations and mandates.

NOTE: The water pump seal can be replaced without


removing the water pump from the engine.

An intermittent leakage of a small amount of coolant


from the hole in the water pump housing is not an
indication of a water pump seal failure. This is required
to provide lubrication for the seal. Replace the water
pump seal only if a large amount of leakage or a
constant flow of coolant is observed draining from the
water pump housing.

3406C Marine Engine 104 Disassembly & Assembly


1. Remove O-ring seal (3) from adapter (4). Remove 5. Remove gear and shaft assembly (17) from the
the adapter from housing (7). Remove the O-ring housing. Remove bolt (15), retainer (14), and
seal from the outside of the adapter. retainer (12) from the shaft assembly.

2. Remove bolt (1) and washer (2). Use Tool (A) to 6. Use a press to remove shaft (13) from the gear.
remove impeller (6) from shaft (13). Remove bearing (9), spacer (10), and bearing (11)
from the shaft.
3. Remove spring and seal (5) from the shaft.
7. Remove lip seal (8) from the housing.
4. Remove four bolts (16) from retainer (12) that hold
the shaft assembly to the pump housing. Remove 8. Turn the housing over, and remove ceramic ring
O-ring seal (18) from housing (7). (20) and seal (19) from the housing.

NOTE: The following steps are for the assembly of the


water pump.
3406C Marine Engine 105 Disassembly & Assembly
9. Use 6V-1541 Quick Cure Primer and clean shaft NOTE: The carbon seal assembly must rotate with the
(13) and the seal counter bore in the pump housing water pump shaft after installation.

10. Install bearing (9), spacer (10), and bearing (11) on 16. Separate spring from seal (5). Use hand pressure
shaft (13). and Tool (C) to install the seal on the shaft of gear
and shaft assembly (17). Push the seal on the
11. Put retainer (12) and gear (17) on the shaft shaft until the seal faces make light contact. Install
assembly. Install retainer (14) and bolt (15) on the the spring on the shaft.
shaft.
17. Put impeller (6) in position on the shaft. Install
12. Use Tool (B) to install lip seal (8) in housing (7). washer (2) and bolt (1) that hold the impeller.
Install seal with the lip toward the inside of the Tighten the bolt to a torque of 39 % 3 N•m (29 %
housing. Put a small amount of clean engine oil on 2 lb ft).
the lip of the seal.
18. Install the O-ring seal on the outside diameter of
13. Install a new O-ring seal (18) on the housing. adapter (4). Put a small amount of clean SAE 30
oil on the O-ring seal.
14. Put gear and shaft assembly (17) in position in the
housing. Install bolts (16) that hold retainer (12) to 19. Install O-ring seal (3) on the adapter.
the housing.
20. Put adapter (4) in position on the housing.

NOTE: For more detailed information regarding the


NOTICE water pump, see the topic “Water Pump” in the
Clean water only is permitted for use as a lubricant for Specifications Manual.
assistance at installation. Do not damage or put hands
on the wear surface of the carbon ring or the ceramic End By:
ring. Install the ceramic ring with the smoothest face
of the ring toward the carbon seal assembly. a. install water pump

15. Put ceramic ring (20) in position in seal (19). Use


hand pressure and Tool (C) to install the ceramic
ring in the housing.

NOTICE
Avoid contaminating the seal faces with grease or oil.
Also, avoid stretching the rubber seal during installa-
tion.

3406C Marine Engine 106 Disassembly & Assembly


Valve Covers Install Valve Covers 1107-012
1. Put a new seal in position in the valve cover, and
Remove Valve Covers 1107-011 cut it to length after installation.

1. Loosen clamps (1), and disconnect the hose from 2. Put valve cover (1) in position on the valve cover
the breather cap. base. Install the bolts that hold the valve cover in
place. Tighten the bolts to a torque of 18 % 3 N•m
(13 % 2 lb ft).

2. Remove the bolts that hold the valve cover to the


valve cover base. Remove valve cover (2).
3. Connect hose (2) to breather cap (3), and tighten
3. Check the condition of the valve cover seal. If the clamps that hold the hose.
necessary, replace the seal.

3406C Marine Engine 107 Disassembly & Assembly


Rocker Shaft Assemblies &
Push Rods

88249P3*

3406C Marine Engine 108 Disassembly & Assembly


Remove Rocker Shaft Assemblies &
Push Rods 1102 & 1208-011

Tools Needed A B
5P0144 Socket 1
5P5195 Fuel Line Wrench 1

Start By:

a. remove valve covers

1. Remove four bolts (1) from the turbocharger tube


adapter to the aftercooler housing. Loosen the
turbocharger compressor housing clamp, and
B50069-1P2*
rotate turbocharger tube (2) out of the way of the
cylinder head assembly.

NOTICE
To prevent damage to the fuel injection nozzle, hold
adapter assembly (5) in position at the top of injection
nozzle (6) when fuel line nut (7) is loosened or tight-
ened.

2. Remove bolts (3) that hold the valve cover bases to


the cylinder head assembly. Remove valve cover
bases (4).

3406C Marine Engine 109 Disassembly & Assembly


3. Use Tool (A) and a 5P-0328 Crow Foot Wrench 7. Put identification marks on the push rods as to their
(7/8 in) to loosen the fuel injection line nut at the location in the engine. Remove push rods (11).
nozzle end.

8. Put identification marks on the bridges as to their


4. Use Tool (B) to loosen the nut at the fuel injection location in the engine. Remove bridges (12) from
line adapter end. Remove inner fuel injection lines the dowels on the cylinder head assembly.
(8). Install caps and plugs on all fuel injection line
openings to keep dirt out of the fuel system.

5. Remove bolts (9) that hold the rocker shaft


assemblies to the cylinder head assembly.

6. Remove rocker shaft assemblies (10).

3406C Marine Engine 110 Disassembly & Assembly


Install Rocker Shaft Assemblies &
Push Rods 1102 & 1208-012

Tools Needed A B
5P5195 Fuel Line Wrench 1
5P0144 Socket 1

NOTE: Install original push rods in their respective


locations in the engine. New push rods can be mixed.

3. Install push rods (2).

1. Put clean engine oil on the bridges and dowels.

NOTE: Install the original bridges in their respective


locations. New bridges can be mixed.

2. Install bridges (1) on the bridge dowels. While firmly


pressing 0.5 to 4.5 kg (1 to 10 lb) straight down
on the top contact surface of the bridge, turn the
adjusting screw clockwise until contact is made
with the valve stem. Turn the screw an additional
20 to 30 degrees (1/3 to 1/2 of 1 hex on nut). This
4. Put rocker shaft assemblies (3) in position on the
will straighten the dowel in the guide and
cylinder head assembly.
compensate for the slack in the threads. Hold the
adjusting screw in this position, and tighten the
5. Put clean engine oil on the threads of the bolts that
locknut to a torque of 30 % 4 N•m (22 % 3 lb ft).
hold the rocker shaft assemblies in place. Tighten
the bolts first to a torque of 270 % 25 N•m (200 %
18 lb ft). Start with the bolt in the center of the
rocker shaft assembly. Tighten the bolts again to a
torque of 450 % 20 N•m (330 % 15 lb ft). Tighten
the bolts again by hand to a torque of 450 %
20 N•m (330 % 15 lb ft).

3406C Marine Engine 111 Disassembly & Assembly


9. Install valve cover bases (7) on the cylinder head
NOTICE assembly. Install bolts that hold the valve cover
Do not cause damage to the O-ring seals on the inner bases in place. Tighten the bolts to a torque of
fuel lines. 14 % 3 N•m (10 % 2 lb ft).

6. Install inner fuel injection lines (4). Tighten the fuel


injection line adapter nuts (5) to a torque of 40 %
7 N•m (30 % 5 lb ft) with Tool (A).

NOTICE
Do not let the tops of the fuel nozzles turn when the
fuel lines are tightened. The nozzles will be damaged
if the top of the nozzles turns in the body.

7. Tighten fuel injection line nut (6) to a torque of 40 %


7 N•m (30 % 5 lb ft) with Tool (B) and a 5P-0328
Crow Foot Wrench (7/8 in).
10. Rotate turbocharger tube (8) into position. Place a
8. Make adjustments to the valves until the inlet valve gasket between the aftercooler housing and
clearance is 0.38 mm (.015 in) and the exhaust adapter, and install four bolts and nuts that hold
valve clearance is 0.76 mm (.030 in). See the topic the tube to the aftercooler housing.
“Valve Clearance Setting” in Systems Operation
Testing & Adjusting. Tighten the locknut to a torque 11. Tighten turbocharger clamp nut (9) to a torque of
of 30 % 4 N•m (22 % 3 lb ft) and check the 18 % 3 N•m (13 % 2 lb ft). Lightly hit all around
adjustments. the clamp with a soft faced hammer, and tighten
the clamp nut again to the same torque value.

End By:

a. install valve covers

3406C Marine Engine 112 Disassembly & Assembly


Disassemble Rocker Shaft Assemble Rocker Shaft
Assemblies 1102-015 Assemblies 1102-016
Start By:

a. remove rocker shaft assemblies and push rods

1. Put clean engine oil on the shaft.

2. Install the bracket and rocker arms for the center


bracket.
1. Remove retainer (2) from the end of the shafts.
3. Install spring (1), rocker arm (2) and bracket (3).
2. Remove the washers and rocker arms (1). Install the pin that holds the brackets on each end
of the rocker shaft. Install the pin until it extends
12.7 % 1.0 mm (.50 % .04 in) from the surface of
the bracket.

3. Remove pins (6) that hold the brackets to each end


of the shaft.

NOTE: The center bracket does not have a pin. 4. Install rocker arm (4) on each end of the shaft.
Install washers (5) as needed to get an assembled
4. Remove bracket (3), rocker arm (4) and spring (5). clearance of .03 to 1.40 mm (.012 to .055 in) at
each end of the shaft. Install the retainer on each
end of the shaft.

End By:

a. install rocker shaft assemblies and push rods

3406C Marine Engine 113 Disassembly & Assembly


Valve Lifters
Remove Valve Lifters 1209-011

Tools Needed A B C D E
5P0144 Socket 1
5P5195 Fuel Line Socket 1
FT1322 Lever Assembly 1
9S9082 Engine Turning Pinion 1
5P7433 Valve Lifter Tool Group 1

Start By: NOTE: If necessary, use Tooling (D) to turn the engine
so the valves do not make contact with the pistons
a. remove valve covers when the valves are opened with Tool (C) to remove
the push rods.

3. Put compression on the valve springs with Tool (C),


and remove push rods (2). Put identification marks
on the push rods as to their location in the engine.

4. Push the push rod end of the rocker arms down.

NOTICE
Do not let the tops of the fuel nozzles turn when the
fuel lines are loosened. The nozzles will be damaged
if the top of the nozzles turns in the body.

1. Loosen the fuel injection line nut at the nozzle end 5. Remove the inlet valve lifter with Tooling (E) as
with Tool (A) and a 5P-0328 Crow Foot Wrench follows:
(7/8 in).
a. Install 5P-2685 Nut (3) and 5P-6601 Collet (4)
2. Loosen the fuel line nut at the fuel injection line on 5P-2408 Outer Handle Assembly (5).
adapter with Tool (B). Remove inner fuel injection
lines (1). Install caps and plugs on all fuel line b. Install 5P-6599 Inner Handle Assembly (6) in
openings to keep dirt out of the fuel system. 5P-2408 Outer Handle Assembly (5).

3406C Marine Engine 114 Disassembly & Assembly


NOTE: The opening in the cylinder head assembly for
the inlet valve lifter is larger than the opening in the
exhaust valve lifter side. The tooling and each valve
lifter must be installed and removed from the inlet valve
lifter side.

b. Install the outer handle assembly in the inlet


valve lifter side of the cylinder head assembly.
Slide the flat area of 5P-2408 Outer Handle
Assembly (5) through the head casting, and
install the 5P-6601 Collet in the exhaust valve
lifters.

c. Install Tooling (E) in the inlet valve lifter. Hold the


5P-2408 Outer Handle Assembly , and
tighten the 5P-6599 Inner Handle Assembly
until the 5P-6601 Collet is tight against the
inside of the inlet valve lifter.

c. Install 5P-6599 Inner Handle Assembly (6) in


5P-2408 Outer Handle Assembly (5). Hold the
5P-2408 Handle Assembly , and tighten the
5P-6599 Handle Assembly until the 5P-6601
Collet is tight against the inside of the exhaust
valve lifter.

d. Pull the exhaust valve lifter up until the spring on


d. Remove inlet valve lifters (7) from the cylinder the exhaust valve lifter is free from the cylinder
block with Tooling (E). Put identification marks block.
on the lifters as to their location in the engine.
e. Remove the 5P-6599 Inner Handle Assembly.
Slide the 5P-2408 Outer Handle Assembly
through the head casting, and remove it from
the inlet valve lifter side of the cylinder head.

6. Remove the exhaust valve lifters with Tooling (E) as


follows:

a. Install 5P-2685 Nut (3) and 5P-6601 Collet (4)


on 5P-2408 Outer Handle Assembly (5).

3406C Marine Engine 115 Disassembly & Assembly


f. Use a magnet, and remove exhaust valve lifters 2. Put the inlet or exhaust valve lifter in position in 5P-
(8) from the inlet valve lifter side of the cylinder 2395 Holder (5) of Tooling (A). Install 5P-2685 Nut
head assembly. Put identification marks on the (4) and 5P-2400 Compressor (3) on 5P-2408
lifters as to their location in the engine. Outer Handle Assembly (2). Install the 5P-2400
Compressor on the lifter over the guide spring.
7. Remove the guide springs from the lifters.
NOTE: Immerse the lifter assembly in engine oil before
installing it in the cylinder block lifter bore.

NOTE: The opening in the cylinder head assembly for


Install Valve Lifters 1209-012 the inlet valve lifter is larger than the opening in the
exhaust valve lifter side. All tooling and valve lifters
Tools Needed A B C D E must be installed and removed from the inlet valve lifter
5P7433 Valve Lifter Tool Group 1 side.
FT1322 Lever Assembly 1
9S9082 Engine Turning Pinion 1
5P0144 Socket 1
5P5195 Fuel Line Socket 1

NOTE: Steps 1 and 2 must be done to install inlet or


exhaust valve lifters.

3. Install the exhaust valve lifters with Tooling (A) as


follows:

NOTICE
When a valve lifter is removed, a new guide spring
must be installed.

1. Install a new guide spring (1) on the valve lifters.

3406C Marine Engine 116 Disassembly & Assembly


NOTE: Be sure to install original valve lifters in their
respective bores. New valve lifters can be mixed.

a. Install exhaust valve lifter (6) and the handle


assembly in the cylinder head opening on the
inlet valve lifter side. Slide the flat area of the
5P-2408 Outer Handle Assembly through the
casting in the cylinder head assembly.

NOTICE
If necessary, use Tool (C) to turn the engine so the
valves do not make contact with the pistons when the
valves are opened with Tool (B) to install the push
rods.

5. Turn the rocker arms up, and use Tool (B) to install
b. Put the exhaust valve lifter in the valve lifter bore push rods (9).
of the cylinder block. Install 5P-6599 Inner
Handle Assembly (7) in the 5P-2408 Outer
Handle Assembly , and push the exhaust valve
lifter from Tooling (A).

c. Remove the 5P-6599 Inner Handle Assembly


from the 5P-2408 Outer Handle Assembly.
Slide the 5P-2408 Outer Handle Assembly to
the inlet valve lifter side of the cylinder head, and
remove it.

4. Install the inlet valve lifters with Tooling (A) as


follows:

NOTE: Be sure to install original valve lifters in their


respective bores. New valve lifters can be mixed.

a. Install 5P-6599 Inner Handle Assembly (7) in


the 5P-2408 Outer Handle Assembly. NOTICE
Do not let the tops of the fuel nozzles turn when the
b. Install the inlet valve lifter into the valve lifter bore fuel lines are tightened. The nozzles will be damaged
of the cylinder block with Tooling (A). Use the if the top of the nozzles turn in the body.
5P-6599 Inner Handle Assembly to push the
lifter from Tooling (A). Remove Tooling (A).
6. Install inner fuel lines (10). Use Tool (D) to tighten
the nuts on the adapter assemblies in the cylinder
head assembly, and use Tool (E) to tighten the nuts
on the fuel injection nozzles to a torque of 40 %
7 N•m (30 % 5 lb ft).

End By:

a. install valve covers

3406C Marine Engine 117 Disassembly & Assembly


Fuel Injection Nozzles
Remove Fuel Injection
Nozzles 1254-011
Tools Needed A B
5P0144 Socket 1
5P5195 Fuel Line Wrench 1
6V6981 Nozzle Puller Group 1

Start By:
2. Remove seal (2) from fuel injection line (1) if
a. remove valve covers necessary.
FLUID SPILLAGE CONTAINMENT
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

3. Remove screw (3) from clamp (4) that holds fuel


injection nozzle (5) in position. Clamp (4) cannot be
removed until the fuel injection nozzle is lifted
approximately 25.0 mm (1.00 in).

NOTICE
Do not let the tops of the fuel nozzles turn when the
fuel lines are loosened. The nozzles will be damaged
if the top of the nozzles turn in the body.

1. Use Tooling (A), and remove inner fuel injection lines 4. Remove the fuel injection nozzles with Tooling (B)
(1). Install caps and plugs on all fuel injection line as follows:
openings to keep dirt out of the fuel system.
a. Install 6V-6983 Adapter (6) and 6V-4152
Screw (7) into nozzle assembly (5).

3406C Marine Engine 118 Disassembly & Assembly


Install Fuel Injection
Nozzles 1254-012

Tools Needed A B C D
6V4979 Carbon Stop Seal Tool 1
5P0144 Socket 1
5P5195 Fuel Line Wrench 1
8S2245 Cleaning Tool Group 1
6V4089 Reamer * 1
*Part of 6V7020 Nozzle Puller Group.

b. Install 6V-6982 Tube Assembly (8) over the


6V-4152 Screw. Use 2S-5658 Washer (9) and
1B-2406 Nut (10) on the 6V-4152 Screw to
pull the fuel injection nozzle from the adapter.

NOTICE
A replacement of compression seal washer (11) and of
carbon dam seal (12) must be made each time the fuel
nozzle is removed. Be sure that the replacement com-
pression seal washer (11) is the same color code and
part number as the original compression seal washer.
If the wrong thickness washer is used, engine damage
could occur. See the topic “Fuel Injection Nozzle And
Adapter” in the Specifications Manual for more
detailed information. 1. Install compression seal washer (1), and use Tool
(A) to install carbon dam seal (2) on the fuel injection
nozzle.

2. Make reference to Special Instruction SEHS7292


for the use of Tooling (C).

5. Remove compression seal washer (11) and carbon


dam seal (12) from fuel injection nozzle (5).

3. Use Tool (D) to clean adapter bore (3) for the fuel
injection nozzle. Use an open end wrench or a tap
driver to turn Tool (D).

3406C Marine Engine 119 Disassembly & Assembly


4. Install fuel injection nozzle (4) and clamp (5) as a
unit. Install the bolt in the clamp to hold it in place. NOTICE
Do not let the tops of the fuel nozzles turn when the
fuel lines are tightened. The nozzles will be damaged
if the top of the nozzles turn in the body.

6. Install inner fuel injection line (7). Use Tooling (B) to


tighten the inner fuel line nuts to a torque of 40 %
7 N•m (30 % 5 lb ft).

NOTE: For more information regarding the fuel


injection nozzles, see the topic “Fuel Injection Nozzle
And Adapter” in the Specification Manual.

End By:

a. install valve covers


5. Install O-ring seal (6) on the inner fuel injection line.

3406C Marine Engine 120 Disassembly & Assembly


Fuel Injection Nozzle Adapters
Remove Fuel Injection Nozzle
Adapters 1106-011

Tools Needed A B
FT1887 Compressor Plate Group 1
5P0125 Precombustion Chamber Wrench 1

Start By:

a. remove valve covers


a. Install adapter plate (1) with two 0S-1618 (5/16-18 x
b. remove rocker shaft assemblies and push rods 1 in) bolts.

c. remove fuel injection nozzles b. Install stud (2) and nut (3). Tighten the nut.

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

NOTICE c. Install plate (4), washer (5) and nut (6). Tighten the
Be sure that the piston is at Top Center (TC) so that nut until the locks are free.
the valves will be held in position when the springs are
removed. d. Remove locks (7), and remove the nut, washer and
plate from the stud. Remove the stud and adapter
plate from the fuel injection nozzle adapter.
1. Remove the valve cover bases.

2. Remove the valve stem locks with Tooling (A) using


the following procedure:

3. Remove rotocoil (8), spring (9) and washer (10).

3406C Marine Engine 121 Disassembly & Assembly


Install Fuel Injection Nozzle
Adapters 1106-012

Tools Needed A B
5P0125 Precombustion Chamber Wrench 1
FT1887 Compressor Plate Group 1

4. Use Tool (B) to remove fuel injection nozzle adapter


(11) from the cylinder head assembly.

1. Inspect seals (3) for damage or wear, and make a


replacement if necessary.

2. Install washers (1) and seals (3) on adapters (2).

3. Put liquid soap in the bores of the cylinder head


and on the seals of the fuel injection nozzle
adapters.
5. Remove washers (12) and seals (13) from adapters
4. Put 5P-3931 Anti-Seize Compound on the
(11).
threads of adapter (2), and install the adapters in
the cylinder head assembly.

5. Use Tool (A), and tighten the adapters to a torque


of 205 % 14 N•m (150 % 10 lb ft).

3406C Marine Engine 122 Disassembly & Assembly


Cylinder Head Assembly
Remove Cylinder Head
Assembly 1100-011
Start By:

a. remove rocker shaft assemblies and push rods

b. remove aftercooler housing

c. remove fuel injection lines

d. remove exhaust manifold


6. Install washers (6), springs (5) and rotocoils (4).

1. Remove bolts (1) from the alternator bracket (if


7. Use Tool (B), and compress the springs until locks
equipped).
(7) can be installed. Install locks (7) on the valve
stems, and remove Tool (B).
2. Remove the bolts that hold plate (3), and remove
the plate.
NOTE: For more information regarding the fuel
injection nozzle adapters, see the topic “Fuel Injection
3. Disconnect water line (2) from the air compressor (if
Nozzle And Adapter” in the Specification Manual.
equipped).
8. Install the valve cover base. Tighten the valve cover
NOTE: Turn the water line tee toward the lifting
base mounting bolts to a torque of 14 % 3 N•m
bracket in order to provide clearance to remove the
(10 % 2 lb ft).
head bolt.
End By:

a. install fuel injection nozzles

b. install rocker shaft assemblies and push rods

c. install valve covers

3406C Marine Engine 123 Disassembly & Assembly


Install Cylinder Head
Assembly 1100-012
NOTE: Be sure a new gasket has been installed
between the spacer plate and the cylinder block. See
the topic “Remove & Install Spacer Plate”.

4. Remove bolts (4) and (5) that hold the cylinder head
assembly to the cylinder block.

5. Fasten a hoist, and remove the cylinder head


assembly. The weight of the cylinder head
assembly is approximately 135 kg (300 lb).

NOTICE 1. Thoroughly clean the spacer plate and the bottom


Do not put the cylinder head assembly down on a flat surface of the cylinder head assembly. Install a new
surface. This can cause damage to the fuel injection head gasket, new seals (1) and two O-ring seals (2).
valves.

6. Remove the gasket and seals from the spacer


plate.

2. Fasten a hoist, and put cylinder head assembly (3)


in position on the cylinder block.

3. Put 6V-4876 Molycoat Paste Lubricant on the


threads of the cylinder head bolts and between the
washer and the underside of the bolt heads. Install
the cylinder head bolts and washers. Tighten the
cylinder head bolts in the sequence shown in
illustration D11970.

3406C Marine Engine 124 Disassembly & Assembly


(1) Large bolts (3/4 in). Put 6V-4876 Molycoat Paste Lubricant on bolt threads and between washer and underside of bolt heads. (2) Small bolts
(3/8 in). See Step h.

a. Tighten bolts 1 through 14 in number sequence 5. Install the valve cover bases and the inner fuel lines.
to a torque of 270 % 25 N•m (200 % 20 lb ft). See the topic “Install Rocker Shaft Assemblies &
Push Rods”.
b. Tighten bolts 1 through 14 in number sequence
to a torque of 470 % 20 N•m (345 % 15 lb ft).

c. Tighten bolts 1 through 14 in number sequence


to a torque of 470 % 20 N•m (345 % 15 lb ft)
by hand.

d. Install the rocker shaft assemblies and push


rods. See the topic “Install Rocker Shaft
Assemblies & Push Rods”.

e. Tighten bolts 15 through 26 in number


sequence to a torque of 270 % 25 N•m (200 %
18 lb ft).

f. Tighten bolts 15 through 26 in number


sequence to a torque of 470 % 20 N•m (345 %
6. Install plate (4).
15 lb ft).
7. Connect the water line to the air compressor (if
g. Tighten bolts 15 through 26 in number
equipped).
sequence to a torque of 470 % 20 N•m (345 %
15 lb ft) by hand.
8. Install bolts (5) for the alternator bracket (if
equipped).
h. Tighten the (3/8 in) bolts to a torque of 45 %
7 N•m (33 % 5 lb ft).
End By:
NOTE: If the studs for the exhaust manifold were
a. install exhaust manifold
removed, install new studs, and tighten them to a
torque of 25 % 4 N•m (18 % 3 lb ft).
b. install fuel injection lines
4. Make an adjustment to the valves to have a
c. install aftercooler housing
clearance of 0.38 mm (.015 in) for inlet and
0.76 mm (.030 in) for exhaust. Tighten the
d. install rocker shaft assemblies and push rods
locknuts for the valve adjustment screws to a
torque of 28 % 4 N•m (21 % 3 lb ft).

3406C Marine Engine 125 Disassembly & Assembly


Spacer Plate Install Spacer Plate 1221-012

Remove Spacer Plate 1221-011


Start By:

a. remove cylinder head assembly

1. Thoroughly clean the spacer plate and cylinder


block surface. Install two O-ring seals (1) in the
cylinder block.

1. Remove spacer plate (1) from the cylinder block.

NOTICE
Do not cause damage to the dowels.

2. Remove the spacer plate gasket and two O-ring


seals.

NOTICE
Both surfaces of the spacer plate, top of cylinder
block and both sides of the spacer plate gasket must
be clean and dry. Gasket adhesives or other sub-
stances must not be used on these surfaces.

2. Install a new gasket between the spacer plate and


cylinder block. Put spacer plate (2) in position on
the cylinder block.

3. Check cylinder liner projection. See the topic “Install


Cylinder Liners” in this Manual.

End By:

a. install cylinder head assembly

3406C Marine Engine 126 Disassembly & Assembly


Valves
Remove Valves 1105-011

Tools Needed A B
5S1330 Pneumatic Valve Spring Compressor 1
8S2263 Valve Spring Tester 1

Start By:

a. remove cylinder head assembly

4. Use Tool (B) to check spring force. The


specifications for the spring force are given in the
Specifications Manual.

5. Do Steps 1 through 4 again for the remainder of


valves.

Install Valves 1105-012

Tools Needed A
5S1330 Pneumatic Valve Spring Compressor 1

1. Use Tool (A) to compress springs (1).

WARNING

The locks can be thrown from the valve when the


spring compressor is released if they are not in their
correct position on the valve stem. To prevent pos-
sible personal injury, be sure to stay away from in
front of the valve retainer and springs.

2. Remove the locks.

3. Remove Tool (A), the valve, the rotocoil and the


spring. 1. Put clean engine oil on the valve stem. Install
washer (3), spring (2), rotocoil (1) and the valve.
NOTE: If a valve can be used again, put identification
on the valve for location at installation.

3406C Marine Engine 127 Disassembly & Assembly


Valve Seat Inserts
Remove Valve Seat Inserts 1103-011

Tools Needed A
9S3095 Handle Assembly 1
9S3081 Extractor Inlet 1
9S3086 Extractor Exhaust 1

Start By:

a. remove valves
2. Use Tool (A) to compress the spring.

3. Install locks (4) with the thick end up.

WARNING

Locks can be thrown from valve when compressor


is released, if they are not in their correct position
on the valve stem.

4. Remove the compressor and hit the valve with a


soft faced hammer to be sure locks are in their
correct position on the valve.

5. Do Steps 1 through 4 again for the remainder of the 1. Use Tooling (A) to remove the valve seat inserts.
valves.
2. Clean and remove the burrs from the valve seat
End By: bore.

a. install cylinder head assembly

3406C Marine Engine 128 Disassembly & Assembly


Install Valve Seat Inserts 1103-012 Bridge Dowels
Tools Needed A
Remove Bridge Dowels 1121-011
9S3095 Handle Assembly 1
9S3081 Extractor Inlet 1
Tools Needed A
9S3086 Extractor Exhaust 1
5P0944 Dowel Puller Group 1
5P0942 Extractor 1

1. Use Tooling (A) to install valve seat inserts.


Start By:
NOTICE a. remove valves
Do not increase the diameter of the extractor in the
valve seat insert when the insert is installed in the
cylinder head.

2. Grind the valve seat insert according to


specifications given in the Specifications Manual.

End By:

a. install valves

1. Use Tooling (A) to remove bridge dowel (1).

3406C Marine Engine 129 Disassembly & Assembly


Install Bridge Dowels 1121-012 Valve Guides
Tools Needed A
Remove Valve Guides 1104-011
5P2406 Dowel Driver 1

Tools Needed A
7S8859 Driver 1

Start By:

a. remove valves

1. Use Tool (A) to install the bridge dowel.

End By:

a. install valves

1. Use Tool (A) to remove the valve guides.

3406C Marine Engine 130 Disassembly & Assembly


Install Valve Guides 1104-012 Oil Pan
Tools Needed A
Remove Oil Pan 1302-011
7S8859 Driver 1
5P2396 Bushing 1
FLUID SPILLAGE CONTAINMENT
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

1. Put clean engine oil on the outside of the valve


guide.

2. Use Tooling (A) to install the valve guides.

3. After installation, the inside diameter of the valve


guide must be 9.487 % 0.025 mm (.3735 %
.0010 in). The maximum diameter of used guides is
8.538 mm (.3755 in).

End By: 1. Remove the magnetic drain plug and drain the oil
from the oil pan into a suitable container for storage
a. install valves or disposal.

2. Disconnect sump pump line (1) from oil pan (if so


equipped). Cap or plug all openings immediately.

3. Remove bolts (2) that hold the oil pan to the


cylinder block.

4. Remove the oil pan and gasket from the cylinder


block.

3406C Marine Engine 131 Disassembly & Assembly


Install Oil Pan 1302-012 Oil Pump
Remove Oil Pump 1304-011
Start By:

a. remove oil pan

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
1. Put the gasket and oil pan (1) in position on the SHOP PRODUCT GUIDE, NENG2500", for tools and
engine, and install the bolts that hold the oil pan to supplies suitable to collect and contain fluids in
the engine. Tighten the bolts that hold the oil pan to Caterpillar machines. Dispose fluids according to local
the engine to a torque of 55 % 10 N•m (40 % regulations and mandates.
7 lb ft).

2. Connect sump pump line (if so equipped).

3. Install the magnetic drain plug and tighten the plug


to a torque of 70 % 15 N•m (50 % 10 lb ft).

4. Fill engine with oil to the correct level. See the


Operation & Maintenance Manual.

1. Remove oil supply tube (1), suction bell (2) and


suction bell tube (3).

2. Remove three bolts (4) that hold oil pump to


cylinder block, and remove oil pump (5).

3406C Marine Engine 132 Disassembly & Assembly


Install Oil Pump 1304-012 Disassemble Oil Pump 1304-015

Tools Needed A B
1P2321 Puller Assembly 1
1P0458 Plate * 1
1P0510 Driver Group 1
*Part of 1P-0510 Driver Group.

Start By:

a. remove oil pump

FLUID SPILLAGE CONTAINMENT


Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
1. Put the oil pump in position on engine. Install three testing, adjusting and repair of the machine. Be
bolts that hold pump to cylinder block. prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
2. Put clean engine oil on O-ring seals of tubes. component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
3. Install suction bell tube (1), suction bell and oil supplies suitable to collect and contain fluids in
supply tube (2). Caterpillar machines. Dispose fluids according to local
regulations and mandates.
End By:
1. Remove the bolt and washer that hold the gear on
a. install oil pan the shaft.

2. Use Tooling (A), and remove drive gear (1) from the
shaft. Remove the key from the shaft.

3406C Marine Engine 133 Disassembly & Assembly


Assemble Oil Pump 1304-016

Tools Needed A
1P0510 Driver Group 1

3. Remove retainer (3) for the bypass valve.

4. Remove the spring and bypass valve.

5. Remove cover (2) from the pump body.

1. Use Tooling (A) to install the bearings in the pump


body. Install the bearings so the joint in the bearings
is 30 % 15 degrees from the center line of the oil
pump outlet passage (2).

6. Use Tooling (B), and remove the bearings from the


cover.

2. Install idler gear (1) and drive gear (3) in the oil
pump body. Put clean engine oil on the bearings
and the gears.

7. Remove gears (5) from pump body (4).

8. Use Tooling (B), and remove the bearings from


pump body (4).

3406C Marine Engine 134 Disassembly & Assembly


Piston Cooling Tubes
Remove & Install Piston Cooling
Tubes 1307-010

Tools Needed A B
9S-9082 Engine Turning Tool 1
5P-8709 Piston Cooling Jet Alignment Tool Group 1

Start By:

a. remove oil pump


3. Use Tooling (A), and install the bearings in cover (4).
Install the bearings so the joint in the bearings is
30 % 15 degrees from the center line of the
bearing bores toward oil pump outlet passage (2).

4. Install bypass valve (5), spring (6) and the retainer.

5. Install the key on the shaft.

1. Remove bolts (1). Remove piston cooling tubes (2)


from the engine. Use Tool (A) to turn the crankshaft
in a clockwise direction as seen from the front of
the engine to get access to all of the piston cooling
tubes.

NOTE: The following steps are for installation of the


piston cooling tubes.
6. Install gear (7) on the shaft. Install the washer and
bolt that hold the gear on the shaft. 2. Check the alignment of the piston cooling tubes
with Tool (B). See Use of 5P-8709 Tool Group for
NOTE: Before running, lubricate the oil pump with Alignment of Piston Cooling Jets, SMHS7267, for
clean engine oil. After assembly, be sure the pump the correct alignment procedure.
rotates freely by hand .
3. Install piston cooling tubes (2) on the engine. Use
End By: Tool (A) to turn the crankshaft clockwise as seen
from the front of the engine to get access for the
a. install oil pump installation of the piston cooling tubes.

End By:

a. install oil pump.

3406C Marine Engine 135 Disassembly & Assembly


Connecting Rod Bearings
Remove & Install Connecting Rod
Bearings 1219-010

Tools Needed A
Plastigage *

Start By:

a. remove oil pump

1. Check the connecting rods and caps for their NOTE: Install the bearings dry when the clearance
identification and location. checks are made. Put clean engine oil on the bearings
for final assembly.

5. Install the upper half of the bearing in the


connecting rod.

6. Pull the connecting rod slowly on to the crankshaft.

7. Install the lower half of the bearing in the cap.

NOTICE
Be sure the tabs in the back of bearings are in the tab
grooves of the connecting rod and cap. The service-
man must be very careful to use Plastigage, Tool (A)
correctly. The following points must be remembered.

2. Turn the crankshaft until the connecting rod caps


.........Make sure that the backs of the bearings and
are in position.
bores are clean and dry.
3. Remove two bolts (1) and the cap from the
....Make sure that the bearing locking tabs are properl
connecting rod. Remove the lower half of the
seated in their slots.
bearing from the cap.
The crankshaft must be free of oil where the Plastigage
4. Push the connecting rod away from the crankshaft.
touches it.
Remove the upper half of the bearing from the
connecting rod.
..........Put a piece of Plastigage (A) on the crown o
bearing half that is in the cap. Do not allow the
Plastigage to extend over the edge of the bearing.

....... Install the bearing cap using the correct torque-tur


specifications. Do not use an impact wrench. Be
careful not to dislodge the bearing when the cap is
installed.

Do not turn the crankshaft with the Plastigage


installed.

3406C Marine Engine 136 Disassembly & Assembly


Carefully remove the cap but do not remove the
Plastigage. Measure the width of the Plastigage while it
is in the bearing cap or on the crankshaft journal. Do
this by using the correct scale on the package. Record
the measurements.

Remove the Plastigage before reinstalling the cap.

When using Plastigage, the readings can sometimes


be unclear. For example, all parts of the Plastigage are
not the same width. Measure the major widths to make
sure that they are within the specification range. Also,
experience has shown that when checking clearances
tighter than 0.10 mm (.004 in) the readings may be
low by 0.013 to 0.025 mm (.0005 to .0010 in). Out-
of-round journals can give faulty readings. Also, journal 11. Install rod caps (2). Install the two bolts. Tighten
taper may be indicated when one end of the Plastigage each bolt to a torque of 90 % 8 N•m (67 %
is wider than the other. 6 lb ft). Put a mark on the nuts and cap, and
tighten the nuts an extra 90 % 5 degrees from
For complete details concerning measuring bearing the mark. Remove the rod cap. Remove
clearances. See Engine Bearings and Crankshafts, Plastigage (A), and check the bearing clearance.
SEBD0531. The bearing clearance must be 0.071 to
0.168 mm (.0028 to .0066 in) for new bearings.
Maximum clearance with used bearings is
0.25 mm (.010 in).

12. Put clean engine oil on lower half of the bearing.


Install the rod cap again. Tighten each nut to a
torque of 90 % 8 N•m (67 % 6 lb ft). Put a mark
on the nuts and cap, and tighten the nuts an extra
90 % 5 degrees from mark.

13. Do steps 1 through 12 for the remainder of the


connecting rod bearings.

End By:

a. install oil pump

8. Use Plastigage (A) to check the bearing clearance.

9. Put Plastigage (A) on the bearing.

10. Put 4C-5593 Thread Lubricant on the threads of


the rod bolts and seat surfaces of the nuts.

NOTE: Be sure the cylinder numbers on the rod cap


and rod are the same and are on the same side of
connecting rod. Numbers are on the same side of the
rod and cap as are the bearing tab slots. If new rods
are installed, put the cylinder number on the rod and
cap.

NOTE: Do not turn the crankshaft when Plastigage


(A) is in position.

3406C Marine Engine 137 Disassembly & Assembly


Crankshaft Main Bearings
Remove & Install Crankshaft Main
Bearings 1203-010
Tools Needed A B C
2P5518 Bearing Removal And Installation Tool 1
Plastigage *
8T5096 Dial Indicator Test Group 1

Start By:

a. remove oil pump


3. Remove the upper halves of the main bearings by
1. Check the main bearing caps for identification for putting Tool (A) in oil hole (2) in the crankshaft. Turn
their location and direction in the block. The caps the crankshaft in the direction which will push the
must be installed in the same location and direction end of the bearing with a tab out first.
from which they were removed.
4. Remove the lower halves of the bearings from the
caps.

NOTE: Install the bearings dry when the clearance


checks are made. Put clean engine oil on the bearings
for final assembly.

5. Install the new bearings in the caps.

6. Install the upper halves of the bearings in the


cylinder block with Tool (A).

2. Remove No. 2 through No. 6 bearing caps (1).


Remove thrust plates from the No. 4 main bearing.

NOTICE
If the crankshaft is turned in the wrong direction, the
tab of the bearing will be pushed between the crank-
shaft and cylinder block. This can cause damage to
either or both.

NOTE: Be sure tabs (3) on the back of the bearings fit


in the tab slots of the caps and cylinder block.

7. Check the bearing clearance with Plastigage (B).


Put Plastigage (B) on the bearings.

NOTE: Do not turn the crankshaft when Plastigage


(B) is in position.

3406C Marine Engine 138 Disassembly & Assembly


8. Install the bearing caps for No. 2 through No. 6
main bearings. Put 4C-5593 Thread Lubricant on
the threads of the bolts.

a. Install the bolts, and tighten the bolts on the


bearing tab side first to a torque of 258 %
14 N•m (190 % 10 lb ft).

b. Tighten the bolts on the opposite side to a


torque of 258 % 14 N•m (190 % 10 lb ft).

c. Put a mark on each bolt and cap.

d. Tighten the bolts on the opposite side of the


mark 120 % 5 degrees

e. Tighten the bolts on the bearing side of the mark


120 % 5 degrees

f. Remove the bearing caps for No. 2 through No.


6 main bearings. Remove Plastigage (B) from
the caps. Check the thickness of Plastigage (B)
to find the bearing clearance. The bearing
clearance must be 0.091 to 0.185 mm (.0036
to .0073 in) with new bearings. Maximum
clearance with used bearings is 0.25 mm
(.010 in).

9. Install the bearing caps for No. 2 through No. 6


main bearings. Put 4C-5593 Thread Lubricant on
the threads of the bolts.

NOTICE a. Install the bolts, and tighten the bolts on the


Be sure the main bearing caps are installed so the bearing tab side first to a torque of 258 %
numbers on the side of the cylinder block are the 14 N•m (190 % 10 lb ft).
same as the numbers on the bearing caps, and the
arrows (4) on the bearing caps are toward the front of b. Tighten the bolts on the opposite side to a
the cylinder block. torque of 258 % 14 N•m (190 % 10 lb ft).

c. Put a mark on each bolt and cap.


NOTE: When the bearing clearance is checked and
the engine is in a vertical position, such as in the d. Tighten the bolts on the opposite side of the
vehicle, the crankshaft will have to be lifted up with a mark 120 % 5 degrees
force equal to the weight of the crankshaft and held
against the upper halves of the main bearings to get a e. Tighten the bolts on the bearing side of the mark
correct measurement with Plastigage (B). The 120 % 5 degrees
Plastigage will not hold the weight of the crankshaft
and give a correct indication. If the engine is in a 10. Remove the No. 1 and No. 7 main bearing caps.
horizontal position, such as on an engine stand, it is Do Steps 3 through 9 for the No. 1 and No. 7
not necessary to hold the crankshaft up. Do not turn caps.
crankshaft when Plastigage is in position to check
clearance. 11. Install the thrust plates for the No. 4 main bearing.

NOTICE
Do not use an impact wrench to tighten the bolts the
additional 120 % 5 degrees (1/3 turn) when the bear-
ing clearance is being checked.

3406C Marine Engine 139 Disassembly & Assembly


Pistons & Connecting Rod
Assemblies
Remove Pistons & Connecting Rod
Assemblies 1225-011
Start By:

a. remove cylinder head assembly

b. remove piston cooling tubes

1. Remove the carbon ridge from the top inside


NOTE: Install the thrust plates with the identification surface of the cylinder liners.
“BLOCK SIDE” toward the cylinder block.

12. Check the end play of the crankshaft with Tooling


(C). Be sure the dial indicator is against a
machined surface. The end play is controlled by
the thrust plates of No. 4 (center) main bearing.
The end play with new thrust plates must be 0.15
to 0.51 mm (.006 to .020 in). The maximum
permissible end play with used thrust plates is
0.89 mm (.035 in).

End By:

a. install oil pump

2. Turn the crankshaft until two pistons are at bottom


center.

3. Remove bolts (1) and the bearing caps. Push the


rods and pistons up until the rings are out of the
cylinder liners.

3406C Marine Engine 140 Disassembly & Assembly


2. Use Tool (A), and install piston (2) and the
connecting rod in the cylinder liner. Be sure the
WARNING number of the tab groove side of the connecting
rod is on the opposite side from the camshaft.
If more than one piston is to be removed, the crank-
shaft can turn because of the weight of the remain- 3. Install the bearing cap on the connecting rod with
ing pistons. Lock the position of the crankshaft to the number on the side of the bearing cap on the
prevent unexpected movement and personal injury same side and same number as on the connecting
or component damage. rod.

4. Put 4C-5593 Thread Lubricant on the threads of


4. Remove the pistons (marked x) and the connecting the bolts. Install the bolts, and tighten them to a
rods from the cylinder liners. torque of 90 % 8 N•m (67 % 6 lb ft). Put a mark
on the bolts and cap, and tighten the bolts an extra
5. Do Steps 1 through 4 for the remainder of the 90 % 5 degrees.
pistons and connecting rods.
5. Do Steps 1 through 4 for the remainder of the
pistons and connecting rods.

End By:
Install Pistons & Connecting Rod
Assemblies 1225-012 a. Install piston cooling tubes

Tools Needed A b. install cylinder head assembly


5P-3526 Piston Ring Compressor 1

1. Put clean engine oil on piston rings, connecting rod


bearings and cylinder liners.

3406C Marine Engine 141 Disassembly & Assembly


Disassemble & Assemble
Pistons & Connecting Rod
Assemblies 1225-017

Tools Needed A B C
1P1858 Retaining Ring Pliers 1
7M3978 Piston Ring Expander 1
5P8639 Press Group 1
8F0024 Hose Assembly 1
1P2375 Coupler Assembly 1
1P2376 Coupler Assembly 1
5P9725 Cylinder Group 1
5P8651 Spacer 1
5P8649 Adapter 1
5P8650 Adapter 1

Start By:
WARNING
a. remove pistons and connecting rod assemblies
Piston rings (5) may break apart during removal
from the pistons. If the rings are to be removed,
wear eye protection to prevent possible personal
injury from flying parts.

4. Remove piston rings (5) from the piston with Tool


(B). Clean the piston ring grooves on the pistons
with an acceptable ring groove cleaning tool.

NOTE: See Use Of Piston Pin Bearing Removal &


Installation Tools, Special Instructions, SMHS7295.

5. Heat connecting rod (4) in an oven to a temperature


of 177° to 260°C (350° to 500°F). Never use a
direct flame to heat a connecting rod.

1. Remove bearings (3) from the connecting rod and


connecting rod cap.

2. Remove retainer ring (1) with Tool (A).

3. Remove pin (2) and connecting rod (4) from the


piston.

3406C Marine Engine 142 Disassembly & Assembly


11. Install the oil ring on the piston with Tool (B).

12. Install the second (intermediate) piston ring with


the side that has the identification “UP-2” toward
the top of the piston. Use Tool (B) to install the
ring.

13. Install the first (top) piston ring with the side that
has the identification “UP-1” toward the top of the
piston. Use Tool (B) to install the ring.

NOTE: After the installation of all three piston rings,


6. Put connecting rod (4) in position on the base plate put the piston rings in position so the end gaps are
of Tooling (C). Put a new rod pin bearing (6) on the 120 degrees apart.
adapter part of Tooling (C).

NOTE: The old bearing is pushed out by Tooling (C)


as the new bearing is installed.

7. Use Tooling (C) to push the new bearing into the


connecting rod until the push adapter of Tooling (C)
makes full contact with the connecting rod surface.

8. Use a pin boring machine to make the rod pin


bearing the correct size. The bore in the new rod
pin bearing must be 50.830 % 0.008 mm (2.0012
% .0003 in).

9. Check the clearance between the ends of the


piston rings. See the topic “Pistons & Rings” in the
Specifications Manual.
14. Put the piston in position on connecting rod (4).
Put clean engine oil on pin (2), and install the pin.
10. Install the oil ring spring in the oil ring groove of
Install retainer rings (1) with Tool (A). Make sure
the piston.
the retainer rings are in the grooves of the piston.
NOTE: The oil ring is to be installed over the spring
15. Install bearings (3) in the connecting rod and
with the oil ring end gap 180 degrees from the oil ring
connecting rod cap.
spring joint.
NOTE: Be sure the tabs in back of the bearings are in
the tab slots of the connecting rod and connecting rod
cap.

End By:

a. install pistons and connecting rod assemblies

3406C Marine Engine 143 Disassembly & Assembly


Crankshaft
Remove Crankshaft 1202-011

Tools Needed A B
1H-3110 Bearing Puller Attachment 1
8B-7560 Step Plate 1
6U-6600 Hand Pump (Or Electric) 1
1H-3108 Leg 2
1H-3107 Puller Assembly 1
3H-0468 Plates 5
3H-0465 Nuts 2
1P-0820 Hydraulic Puller Group 1 2. Install one of the bolts from the front pulley in each
5B-0637 Nut 1 end of the crankshaft.
8S-6586 Screw 1
3. Fasten a hoist to crankshaft (3), and remove
5P-0944 Dowel Puller Group 1
crankshaft (3) from the block. The weight of the
5P-0939 Extractor 1 crankshaft is 159 kg (350 lb).

NOTE: If new main bearings are not to be installed,


Start By: keep old bearings with identification as to their location
in cylinder block.
a. remove timing gear cover

b. remove flywheel housing

c. remove pistons and connecting rod assemblies

NOTE: Check the bearing caps for a number as to


their location. If a number can not be seen, put a
number on the left side of cylinder block and bearing
cap.

4. Use Tool (A) to remove the crankshaft gear.

5. Use Tool (B) if necessary to remove the dowel and


the pin.

1. Remove bolts (1) that hold main bearing caps (2) to


the block, and remove main bearing caps (2).

3406C Marine Engine 144 Disassembly & Assembly


Install Crankshaft 1202-012 Do not turn the crankshaft with the Plastigage
installed.
Tools Needed A B
Carefully remove the cap but do not remove the
8T-5096 Dial Indicator Test Group 1 Plastigage. Measure the width of the Plastigage while it
Plastigage * is in the bearing cap or on the crankshaft journal. Do
this by using the correct scale on the package. Record
the measurements.
If the crankshaft journals and bores for the block and
rods were measured at disassembly and found to be Remove the Plastigage before reinstalling the cap.
within specifications, no further checks are necessary.
However, if the serviceman still wants to measure the When using Plastigage, the readings can sometimes
bearing clearances, Plastigage is recommended. Lead be unclear. For example, all parts of the Plastigage are
wire, shim stock or use of a dial bore gauge can not the same width. Measure the major widths to make
damage the bearing surface. sure that they are within the specification range. Also,
experience has shown that when checking clearances
The serviceman must be very careful to use Plastigage, tighter than 0.10 mm (.004 in) the readings may be
Tool (B) correctly. The following points must be low by 0.013 to 0.025 mm (.0005 to .0010 in). Out-
remembered: of-round journals can give faulty readings. Also, journal
taper may be indicated when one end of the Plastigage
is wider than the other.
Make sure that the backs of the bearings and the
bores are clean and dry.
For complete details concerning measuring bearing
Make sure that the bearing locking tabs are properly clearances, see the topic “Engine Bearings And
seated in their slots. Crankshafts”, SEBD0531.

The crankshaft must be free of oil where the Plastigage


touches it.

If the main bearing clearances are checked with the


engine upright or on its side, the crankshaft must be
supported. Use a jack under an adjacent crankshaft
counterweight and hold the crankshaft against the
crown of the bearing. If the crankshaft is not
supported, the weight of the crankshaft will cause
incorrect readings.

Put a piece of Plastigage on the crown of the bearing


B73707P2*
half that is in the cap. Do not allow the Plastigage to
extend over the edge of the bearing.

Install the bearing cap using the correct torque-turn


specifications. Do not use an impact wrench. Be 1. Install pin (5) in the crankshaft end until it is
careful not to dislodge the bearing when the cap is extended from the surface 6.4 % 0.5 mm (.25 %
installed. .02 in).

2. Install dowel (6) until it is extended from the surface


4.1 % 0.5 mm (.16 % .02 in).

3406C Marine Engine 145 Disassembly & Assembly


3. Heat crankshaft gear (4) to a maximum temperature 6. Install one bolt for the flywheel on each end of the
of 232°C (450°F). Install gear (4) on the crankshaft crankshaft.
with the keyway in alignment with dowel (6) and the
“V” mark to the outside. 7. Fasten a hoist, and put crankshaft (3) in position in
block. Be sure the “V” mark on the crankshaft gear
NOTE: The dowel in the crankshaft must be in is in alignment with “V” mark on the idler gear. The
alignment with the keyway in crankshaft gear (4). “K” marks on the camshaft gear can be seen at the
outer edges of the idler gear when the timing gears
4. Clean the cylinder block and main bearing caps are in the correct position.
thoroughly.
8. Install main bearings in bearing caps.
NOTE: Install the bearings dry when the clearance
checks are made. Put clean engine oil on the bearings
for final assembly.

NOTE: Be sure tabs (8) on back of the bearings fit in


the tab slots of the caps and cylinder block.
Typical Example

9. Use Plastigage (B) to check bearing clearance.


5. Install upper half of main bearings (7) in the block.
10. Put Plastigage (B) on the bearing.

3406C Marine Engine 146 Disassembly & Assembly


NOTICE
Be sure main bearing caps (2) are installed so the
numbers on the side of the cylinder block are the
same as the numbers on the bearing caps, and the
arrows on the caps are toward the front of the cylin-
der block. 15. Check the end play of the crankshaft with Tool (A).
Be sure the dial indicator is against a machined
surface. The end play is controlled by the thrust
11. Install the main bearing caps. Install bolts (1), and bearings of No. 4 (center) main bearing. The end
tighten the bolts at the end with tab first to a play with new bearings must be 0.15 to 0.51 mm
torque of 260 % 14 N•m (190 % 10 lb ft) put a (.006 to .020 in). The maximum permissible end
mark on the bolts and caps. Turn the bolts at the play with used bearings is 0.89 mm (.035 in).
opposite end of the tab first an extra 120 %
5 degrees from the mark. End By:

12. Remove the main bearing caps. Remove a. install pistons and connecting rod assemblies
Plastigage (B) from the caps. Check the width of
Plastigage (B) to find the bearing clearance. The b. install flywheel housing
bearing clearance must be 0.091 to 0.185 mm
(.0036 to .0073 in) with new bearings. Maximum c. install timing gear cover
clearance with used bearings is 0.25 mm
(.010 in).

13. Install the thrust bearings for No. 4 main bearing.

NOTE: Install the thrust bearings with the side


identification “BLOCK SIDE” toward the cylinder block.

14. Put 4C-5593 Thread Lubricant on the threads of


the bolts. Install the main bearing caps. Install the
bolts, and tighten the bolts at the end with the tab
first to a torque of 260 % 14 N•m (190 %
10 lb ft). Put a mark on the bolts and caps. Turn
the bolts opposite end of the tab first, an extra
120 % 5 degrees from the mark.

3406C Marine Engine 147 Disassembly & Assembly


Camshaft Bearings
Remove Camshaft Bearings 1211-011
Tools Needed A
8S2241 Camshaft Bearing Installation And 1
Removal Tool Group
8S8293 Extension 1

Start By:

a. remove camshaft
1. Use Tooling (A) to install the camshaft bearings in
b. remove flywheel housing the cylinder block.

c. remove pistons and connecting rod assemblies 2. All camshaft bearings must be installed so that the
holes in the bearings are 90 % 15 degrees from
d. remove timing gears and plate the oil holes in the cylinder block. Make sure the
bearing joint position is above the oil holes.

1. Use Tool (A) to remove the camshaft bearings from


the cylinder block starting with the rear bearing. 3. The installation depth of dimension A of the front
bearing from the front face of the block is 2.8 %
0.5 mm (.11 % .02 in).

4. Install the remainder of the bearings to the


Install Camshaft Bearings 1211-012 dimensions given from the front face of the block:

Tools Needed A B. 181.9 % 0.5 mm (7.16 % .02 in).


8S2241 Camshaft Bearing Installation And 1
Removal Tool Group C. 353.3 % 0.5 mm (13.91 % .02 in).
8S8293 Extension 1
D. 524.8 % 0.5 mm (20.66 % .02 in).

E. 696.2 % 0.5 mm (27.41 % .02 in).

F. 867.7 % 0.5 mm (34.16 % .02 in).

G. 1039.1 % 0.5 mm (40.91 % .02 in).

3406C Marine Engine 148 Disassembly & Assembly


Crankshaft Front Seal & Wear
Sleeve
Remove Crankshaft Front Seal & Wear
Sleeve 1160-011

Tools Needed A B C
1U7600 Puller Group 1
5P7312 Distorter 1
5P7314 Ring 1

5. After assembly, the inside diameter of bearings (1) Start By:


must be 69.969 % 0.048 mm (2.7500 %
.0019 in). The remainder of the bearing must have a. remove vibration damper and pulley
an inside diameter of 69.982 % 0.061 mm (2.7552
% .0024 in). FLUID SPILLAGE CONTAINMENT
End By:
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
a. install timing gears and plate
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
b. install pistons and connecting rod assemblies
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
c. install flywheel housing
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
d. install camshaft
Caterpillar machines. Dispose fluids according to local
regulations and mandates.

B82546P2*

NOTICE
The crankshaft front seal and wear sleeve come as a
set and must be installed as a set. If a replacement of
the seal is to be made, a replacement of the wear
sleeve must also be made.

3406C Marine Engine 149 Disassembly & Assembly


Install Crankshaft Front Seal & Wear
Sleeve 1160-012

Tools Needed A
5P1733 Locator 1
5P1737 Bolt 3
9S8858 Nut 1
6V6142 Installer 1

1. Make at least three holes in seal (1) with a hammer


and a sharp punch.

1. Install the front crankshaft seal and wear sleeve with


Tooling (A). Use the procedure which follows:

a. Clean and make a preparation of the wear


sleeve inside diameter and crankshaft outside
diameter with 6V-1541 Quick Cure Primer.
2. Use Tool (A) to remove seal (1). Make an application of 9S-3265 Retaining
Compound to the crankshaft outside diameter
before the wear sleeve is installed on the
crankshaft. Do not let any Quick Cure Primer
or Retaining Compound get on the lip of the
seal.

b. Install locator (1) and bolts (3) on the crankshaft.

c. Seal (6) and wear sleeve (2) must be installed


dry.

3. Install Tool (C) in the seal bore.

4. Install Tool (B) between Tool (C) and wear sleeve


(2). Turn Tool (B) until the tool makes a dent
(crease) in wear sleeve (2). Do this in three or more
places until the wear sleeve is loose.

5. Remove Tools (B) and (C), and remove wear sleeve


(2) from the crankshaft.

3406C Marine Engine 150 Disassembly & Assembly


NOTICE Crankshaft Rear Seal & Wear
Make sure the seal is installed with the part number Sleeve
and the arrows showing crankshaft rotation toward
the outside.
Remove Crankshaft Rear Seal & Wear
Sleeve 1161-011
NOTICE Tools Needed A B C
The front and rear seals and wear sleeves have differ- 1U7600 Puller Group 1
ent spiral grooves in the seal. Because of this type of
5P7312 Distorter 1
design, the front seal group for an engine is different
from the rear seal group. If a seal group is installed on 5P7313 Ring 1
the wrong end of the engine, oil can actually be taken
out of the engine instead of moving the oil back into
the engine. Start By:

a. remove flywheel
d. Put wear sleeve (2) and seal (6) as a unit in
position on locator (1). FLUID SPILLAGE CONTAINMENT
e. Put installer (4) in position on locator (1).
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
f. Put clean engine oil on the face of nut (5) and its
testing, adjusting and repair of the machine. Be
contact area on installer (4). Install nut (5) on
prepared to collect the fluid with suitable containers
locator (1).
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
g. Tighten nut (5) until the inside surface of installer
SHOP PRODUCT GUIDE, NENG2500", for tools and
(4) comes in contact with locator (1).
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
h. Remove Tooling (A) from the crankshaft seal and
regulations and mandates.
wear sleeve. Tooling (A) will install the seal and
wear sleeve to the correct depth on the
crankshaft.

End By:

a. install vibration damper and pulley

B82546P2*

NOTE: The crankshaft rear seal and wear sleeve come


as a set and must be installed as a set. If a
replacement of the seal is to be made, a replacement
of the wear sleeve must also be made.

3406C Marine Engine 151 Disassembly & Assembly


Install Crankshaft Rear Seal & Wear
Sleeve 1161-012

Tools Needed A
5P1733 Locator 1
5P1737 Bolt 3
6V6143 Installer 1
9S8858 Nut 1

1. Make at least three holes in seal (1) with a hammer


and a sharp punch.

1. Install the rear crankshaft seal and wear sleeve with


Tooling (A). Use the procedure which follows:

a. Clean and make a preparation of the wear


sleeve inside diameter and crankshaft outside
diameter with 6V-1541 Quick Cure Primer.
2. Use Tool (A) to remove seal (1). Make an application of 9S-3265 Retaining
Compound to the crankshaft outside diameter
before the wear sleeve is installed on the
crankshaft. Do not let any Quick Cure Primer
or Retaining Compound get on the lip of the
seal.

3. Install Tool (C) in the seal bore.

4. Install Tool (B) between Tool (C) and wear sleeve


(2). Turn Tool (B) until the tool makes a dent
(crease) in wear sleeve (2). Do this in three or more
places until the wear sleeve is loose.

5. Remove Tools (B) and (C), and remove wear sleeve


(2) from the crankshaft.

3406C Marine Engine 152 Disassembly & Assembly


Camshaft
2 1 Remove Camshaft 1210-011
4 Tools Needed A
8B7561 Step Plate 1
8B7551 Bearing Pulling Attachment 1
3 1P0820 Hydraulic Puller Group 1
5 8B7549 Leg 1
3H0465 Plate 4
1B4207 Nut 2
6 B84143P1*

Start By:

a. remove timing gear cover

b. remove valve lifters

b. Install locator (1) and the bolts on crankshaft (3). FLUID SPILLAGE CONTAINMENT
c. The seal and wear sleeve must be installed dry. Care must be taken to ensure that fluids are contained
Make sure the seal is installed with the part during performance of inspection, maintenance,
number and the arrows showing crankshaft testing, adjusting and repair of the machine. Be
rotation toward the outside. prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
NOTICE SHOP PRODUCT GUIDE, NENG2500", for tools and
The front and rear seals and wear sleeves have differ- supplies suitable to collect and contain fluids in
ent spiral grooves in the seal. Because of this type of Caterpillar machines. Dispose fluids according to local
design, the rear seal group for an engine is different regulations and mandates.
from the front seal group. If a seal group is installed on
the wrong side of the engine, oil can actually be taken 1. Turn the engine to top center compression stroke
out of the engine instead of moving the oil back into for the No. 1 piston.
the engine.

d. Put wear sleeve (2) and seal (6) as a unit in


position on locator (1).

e. Put installer (4) in position on locator (1).

f. Put clean engine oil on the face of nut (5) and its
contact area on installer (4). Install nut (5) on
locator (1).

g. Tighten nut (5) until installer (4) makes contact


with locator (1).

h. Remove Tooling (A) from the crankshaft seal and


wear sleeve. Tooling (A) will install the seal and
2. Remove four bolts (2) and plate (1) that hold the
wear sleeve to the correct depth on the
idler gear in place.
crankshaft.

End By:

a. install flywheel

3406C Marine Engine 153 Disassembly & Assembly


Install Camshaft 1210-012

3. Remove idler gear (3).

1. Heat camshaft gear (1) to a maximum temperature


of 315°C (600°F).

2. Put the key in the camshaft in alignment with the


groove (keyway) in gear (1). Install gear (1) on the
camshaft.

3. Put clean engine oil on the lobes and journals of the


camshaft.

4. Remove two bolts (4) and retainer (5) that hold the
camshaft to the cylinder block.

5. Carefully remove the camshaft assembly from the


cylinder block.

4. Carefully install camshaft assembly (2) in the


cylinder block.

5. Install the retainer that holds the camshaft in the


cylinder block.

6. Remove camshaft gear (6) from the camshaft with


Tooling (A).

3406C Marine Engine 154 Disassembly & Assembly


Timing Gears & Plate
Remove Timing Gears &
Plate 1206 & 1162-011

Tools Needed A B
1P2321 Puller Assembly 1
1P0474 Plate * 1
1P0510 Driver Group 1
*Part of 1P-0510 Driver Group.

6. Install idler gear (3) on its shaft. Be sure the “V” Start By:
mark on idler gear (3) is in alignment with the “V”
mark on the crankshaft gear. The “K” marks on the a. remove timing gear cover
camshaft gear can be seen at the edge of the idler
gear. b. remove fuel injection pump housing and governor

7. Install plate (4) and the bolts that hold the idler gear 1. Remove four bolts (2), plate (3) and idler gear (1).
in place.

NOTE: It will be necessary to check the timing of the


governor and fuel pump drive. See the topic “Camshaft
Timing For Fuel Injection Pump” in Systems Operation
Testing & Adjusting Manual.

End By:

a. install valve lifters

b. install timing gear cover

2. If the camshaft is not going to be removed, use


Tooling (A) to remove camshaft gear (4).

3406C Marine Engine 155 Disassembly & Assembly


NOTICE
Install Timing Gears &
Do not turn the crankshaft with the camshaft gear Plate 1206 & 1162-012
removed. Damage can be caused to the pistons and
valves or both. Tools Needed A
1P0510 Driver Group 1

3. Remove bolts (5) that hold timing gear plate (6) to


the cylinder block.
1. Install a new gasket on the timing gear plate.
4. Remove timing gear plate (6).
2. Put timing gear plate (1) in position on the cylinder
block, and install the bolts that hold the timing gear
plate to the cylinder block.

5. Use Tooling (B) to remove the bearing from the idler


gear.
3. Heat camshaft gear (2) to a maximum temperature
of 315°C (600°F) , and install it on the camshaft.

3406C Marine Engine 156 Disassembly & Assembly


Cylinder Liners
Remove Cylinder Liners 1216-011

Tools Needed A
5P8665 Cylinder Liner Puller 1

Start By:

a. remove pistons

b. remove spacer plate

1. Put covers on journals of crankshaft for protection


4. Use Tooling (A), and install the bearing in the idler
from dirt or water.
gear.

NOTE: Set the gear on the front face (the face with
the timing marks). Drive the bearing from the rear face
toward the front face of the gear. Install the bearing to
a depth of 1.5 % 0.5 mm (.06 % .02 in) below the
rear face of the idler gear.

5. Install the idler gear, plate and bolts.

2. Remove the cylinder liners with Tool (A) as shown.


NOTE: Be sure No. 1 cylinder is at top center on the
compression stroke. Install the idler gear so “V” mark
(4) on the idler gear is in alignment with the “V” mark
on the crankshaft gear. “K” marks (3) of the camshaft
gear can be seen at the outer edges of the idler gear.

End By:

a. install fuel injection pump housing and governor

b. install timing gear cover

3406C Marine Engine 157 Disassembly & Assembly


Install Cylinder Liners 1216-012

Tools Needed A B C
7H-3598 Bolt 6*
8F-1484 Washer (Steel) 6*
7K-1977 Washer (Fiber) 6*
8T-0455 Liner Projection Tool Group 1
2P-8260 Liner Installation Group 1

* Quantity of six each required for one cylinder on any engine.

3. Install Tool (A) around the cylinder liner as shown.


Tighten the six bolts from Tool (A) evenly in four
steps to a torque of 95 N•m (70 lb ft).

4. Use Tool (B) to measure the liner projection at


positions indicated with A, B, C, and D in the
illustration above.

NOTE: If the liner projection changes too much from


point to point around the liner, turn the liner to a new
position in the bore. If the projection measurements are
still not within specifications, move the liner to a
different bore in the cylinder block and check the
projection again.
5. If a liner does not measure within the correct
1. Install clean liners or cylinder packs (1) in the engine projection specifications, the projection can be
block, (without the filler band or the rubber seals). changed with a counterbore operation to the top
surface of the cylinder block. The counterbore
2. Install the spacer plate gasket and the spacer plate. depth must be in a range from a minimum of
0.76 mm (.030 in) to a maximum of 1.14 mm
(.045 in). Shims are available to then adjust the liner
to the correct projection.

NOTE: See Special Instruction, FMO55228-03, for


procedure to use the 8S-3140 Cylinder Block
Counter-boring Tool Arrangement. See the topic
“Cylinder Liner Projection” in the Testing & Adjusting
section of Service Manual to find shim thickness, part
number and installation procedure.

6. Put a mark on cylinder liner (1) and the spacer plate


so the cylinder liner can be installed in the same
position. Remove Tools (A) and (B). Remove
cylinder liner (1).

3406C Marine Engine 158 Disassembly & Assembly


Timing Gear Cover
Remove Timing Gear Cover 1166-011
Start By:

a. remove water pump

b. remove expansion tank

c. remove raw water pump

d. remove accessory drive

e. remove crankshaft front seal and wear sleeve


NOTICE
Apply liquid soap and/or clean engine oil immediately f. remove engine front support
before assembly. If applied too early, the O-rings seals
and the filler bands may swell and be pinched under g. remove oil pan
the liners during installation.

NOTE: If the O-ring seals are black in color apply


liquid soap on O-ring seals (2) and the bore of the
cylinder block. Use clean engine oil on filler band (3). If
the O-ring seals are brown, brown with blue coating or
black with blue coating, apply clean engine oil on the
O-ring seals, the bore of the cylinder block and the filler
band.

7. Install O-ring seals (3) and filler band (2) on the


cylinder liner. Install the cylinder immediately into the
cylinder block.

1. Remove expansion tank support (1) from the timing


gear cover.

2. Remove the bolts, and remove bracket (2) from the


engine.

8. Use Tool (C) to install cylinder liner (1) in the block.


Make sure the mark on the cylinder liner is in
alignment with the mark on the spacer plate.

NOTE: For more information regarding installation of


the cylinder liners see the topic “Cylinder Liner
Projection” in Special Instruction SEHS9564-01.

End By:

a. install spacer plate

b. install pistons
3406C Marine Engine 159 Disassembly & Assembly
3. Remove the bolts that hold tube assembly (3) to the 6. Remove bolts (6) that hold the accessory drive
timing gear cover, and remove the tube from the cover to the timing gear cover.
aftercooler elbow.
7. Remove two bolts (7) that hold the fuel injection
pump to the timing gear cover.

8. Remove two bolts (8) that hold the timing gear plate
to the timing gear cover.

4. Disconnect oil pressure line (4) from the timing gear


cover.

5. Remove the nut that holds clamp (5) to the timing


gear cover, and move the clamp and hose away
from the timing gear cover. 9. Remove the bolts that hold the timing gear cover to
the cylinder block, and remove timing gear cover
(9).

10. Remove the gasket and O-ring seal from the


timing gear plate.

3406C Marine Engine 160 Disassembly & Assembly


Install Timing Gear Cover 1166-012

6. Connect oil pressure line (3) to the timing gear


cover.

1. Put O-ring seal (1) in position on the dowel in the 7. Put the hose and clamp (4) in position on the timing
timing gear plate. gear cover, and install the nut that holds them in
place.

2. Install a new gasket and timing gear cover (2) on


the dowel pins in the cylinder block, and install the 8. Install bracket (6) on the engine.
bolts that hold the timing gear cover to the cylinder
block. 9. Put expansion tank support (5) in position on the
timing gear cover, and install the bolts that hold it.
3. Install the bolts that hold the accessory drive cover
to the timing gear cover.

4. Install the bolts that hold the fuel injection pump


and the timing gear plate to the timing gear cover.

5. Cut the timing gear cover gasket to make it even


with the surface on the bottom of the cylinder block
and timing gear cover.

3406C Marine Engine 161 Disassembly & Assembly


Flywheel
Remove & Install Flywheel 1156-010

Tools Needed A
FT0120 Lifting Bracket 1

10. Put a new O-ring seal on tube assembly (7). Put


clean oil on the O-ring seal.

11. Put tube assembly (7) in position in the aftercooler


elbow, and install the bolts that hold the tube
assembly to the timing gear cover.

End By:

a. install oil pan

b. install engine front support

c. install crankshaft front seal and wear sleeve

d. install accessory drive

e. install raw water pump


1. Fasten a hoist to Tooling (A), and install Tooling (A)
f. install expansion tank to the flywheel with bolt (1).

g. install water pump 2. Remove bolts (2) that hold the flywheel to the
crankshaft, and remove the flywheel. The weight of
the flywheel is 59 kg (130 lb).

NOTE: The following steps are for installation of the


flywheel.

3. Fasten a hoist and Tooling (A) to the flywheel with


bolt (1).

4. Put the flywheel in position on the dowel of the


crankshaft, and install the bolts that hold it. Tighten
the bolts to a torque of 270 % 25 N•m (200 %
18 lb ft).

NOTE: For more detailed information regarding the


flywheel, refer to the topic “Flywheel” in the
Specifications Manual.

3406C Marine Engine 162 Disassembly & Assembly


Flywheel Housing
Remove & Install Flywheel
Housing 1157-010

Tools Needed A
5P9736 Link Bracket 1

Start By:

a. remove turbocharger

b. remove electric starting motor 2. Install Tool (A) on the flywheel housing, and fasten a
hoist as shown.
c. remove sump pump (if so equipped)
3. Remove the bolts (3) that hold the flywheel housing
d. remove oil pan to the cylinder block.

e. remove crankshaft rear seal and wear sleeve 4. Remove the flywheel housing from the cylinder
block.

5. Thoroughly clean the contact surfaces of the


cylinder block and flywheel housing. Install a new
gasket between the block and housing.

6. Put the flywheel housing in position on the cylinder


block.

1. Remove two bolts (2) and cover (1) from the


housing.

3406C Marine Engine 163 Disassembly & Assembly


NOTE: For more detailed information regarding the
flywheel housing, refer to the topic “Flywheel Housing”
in the Specifications Manual.

End By:

a. install crankshaft rear seal and wear sleeve

b. install oil pan

c. install sump pump (if so equipped)

d. install electric starting motor

e. install turbocharger

7. Use the following procedure to tighten the bolts that


fasten the flywheel housing to the cylinder block.

a. Tighten bolts 1 through 24 in numerical sequence


to a torque of 40 % 10 N•m (30 % 7 lb ft).

b. Tighten bolts 1 through 24 again in number


sequence to a torque of 55 % 10 N•m (40 %
7 lb ft).

8. Install cover (1) with two bolts and lockwashers.

9. Apply 8T-9022 Silicone Sealant to fill the space at


the cylinder block, flywheel housing and oil pan
joint.

3406C Marine Engine 164 Disassembly & Assembly


©1996 Caterpillar
All Rights Reserved Printed in U.S.A.

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