SENR2028-02

May 2004

3306
Engine Design
Bore 120 mm (4.75 inch)
Stroke 152 mm (6.00 inch)
Number of Cylinders 6
Cylinder Arrangement *In-line
Firing Order (Injection Sequence) 1, 5, 3, 6, 2, 4
Direction of Rotation Counterclockwise
(Viewed from flywheel end)

Engine Assembly Procedure

Spacer Plate Engines
Q - Denotes Critical Checkpoints
Sub Assembly Installation Parts Assembly Sub Assembly Sub Assembly Installation Parts Assembly
Sub Assembly
Parts Sequence Procedure Parts Sequence Procedure
Clean oil passages. a. Time fuel pump camshaft
Q–1 Q – 26
Block Check liner projection. Fuel Injection with timing pin.
Pump
Covers Assembly b. Install fuel injection pump
Position block on engine Governor
Plugs Block (Sleeve housing assembly and fuel
2 stand with accessory drive Fuel Filter
Liners Assembly Metering filter.
side up. Gear
Camshaft Fuel System) c. Install fuel pump drive
Bearings Install main bearings to
3 gear and torque.
block and caps.
27 Install valve filters.
4 Oil main bearings.
Install gasket and spacer
Install crankshaft and 28
5 plate.
thrust plates.
Install gasket and cylinder
Crankshaft Crankshaft Install and torque main 29
Q–6 head.
Gear Assembly bearing caps. Plate
30 Install push rods.
Rotate crankshaft and Cylinder Head Cylinder Head
Q–7 31 Install rocker arm assembly.
check end play. Push Rods Assembly
Rocker Arm Torque cylinder head and
Connecting Oil liners, rings and Q – 32
8 Assembly rocker arm bolts.
Rods bearings.
Rings Piston & Rod Q – 33 Adjust valve lash.
Install pistons and rod
Pistons Assembly caps. Check alignment of Install valve cover, breather
Q–9 34
Pins "V" marks on pistons and and glow plug leads.
Bearings cylinder block. Front Housing Install front housing.
Housing 35
Q – 10 Torque rod nuts. Assembly

Rotate crankshaft and 36 Install trunnion.

Q – 11
recheck end play. Install wear sleeve and seal
37
Flywheel 12 Install flywheel housing. to crankshaft and trunnion.
Housing Check flywheel housing 38 Install front support.
Covers Flywheel Q – 13
bore and face runout. Install crankshaft damper
Housing Q – 39
Plugs and pulley and torque.
Assembly Install wear sleeve and
Seals 14 seal to crankshaft and Pump Install water pump, regulator
Sleeve flywheel housing. Water Pump and elbows.
Regulator 40
Assembly
Q – 15 Install flywheel and torque. Elbows
Check flywheel bore and Install exhaust manifold and
Q – 16 41
face runout. turbocharger.
17 Install front timing plate. 42 Install engine oil cooler.
Pump, 18 Install oil pan plate. 43 Install oil filter base and filter.
Gears Oil Pump 19 Install oil pump. Install transmission oil
Assembly 44
Tube Assembly cooler.
20 Install oil pan.
Suction Bell 45 Install tube assemblies.
21 Set engine upright. 46 Install air compressor.
Put No. 1 piston at top 47 Install fuel lines.
22 center. Put timing bolt in
flywheel. 48 Install starter motor.
Install camshaft, thrust 49 Install alternator.
Camshaft Camshaft Q – 23
washers, gear & torque. Install miscellaneous covers,
Gear Assembly lines, and accessories.
24 Install fuel pump idler gear. 50
Compare completed engine
Accessory Drive a. Install accessory drive with photos.
Q – 25
Assembly housing assembly.
Pump Fuel Injection b. Time accessory drive
Governor Assembly shaft with timing plate. Torque Procedure
Gear (Scroll Fuel c. Install fuel pump drive Connecting Rod Nut
Fuel Filter System) gear and torque.
a. Put SAE 30 oil on threads and nut seat.
Fuel Transfer d. Install fuel pump and
b. Tighten both nuts to 40 ± 4 N-m (30 ± 3 lb ft).
Pump governor assembly.
c. Mark each nut and end of bolt.
d. Tighten both nuts from mark 90o ± 5 o.
Crankshaft
Note: There are holes in the bores for the main bearings, between Main Bearing Bolt
cylinders 1 and 2, 3 and 4, 5 and 6 for piston cooling orifices. These a. Put SAE 30 oil or 6V-4876 Molykote Paste Lubricant on threads and
holes must have either orifices or plugs installed. Find this information washer face.
in OIL LINES in the parts book for your engine arrangement.
b. Tighten all bolts to 40 ± 4 N·m (30 ± 3 lb ft).
Note: If a turbocharger is installed on engine, be sure to install orifices.
Note: If orifices are installed in engine, then install engine oil cooler. c. Mark each bolt and cap.
1. Connecting Rod Journal 76.180 ± 0.020 mm (2.9992 ± 0.0008 inch) d. Tighten all bolts from mark 90o ± 5 o.
Diameter
Connecting Rod Journal -to - 0.057 to 0.155 mm (0.0022 to .0061 inch)
Bearing Clearance
2. Main Bearing Journal 88.880 ± 0.020 mm (3.4992 ± 0.0008 inch)
Diameter
Main Bearing Journal - to - 0.037 to 0.135 mm (0.0015 to .0053 inch)
Bearing Clearance
3. Do not heat gear or wear sleeve to more than 315oC (600oF) before Wear Sleeve and Seal Installation Tools Required
installation. Part No. Description Part No. Description
4. Crankshaft End Play 0.122 to 0.579 mm (0.0048 to .0228 inch) 9S-8871 Locator 9S-8858 Nut
5. Clearance between main bearing cap and cylinder block - 0.033 mm 9S-8890 Bolt (three) 5P-7299 Installer
(0.0013 inch) Tight to 0.043 mm (0.0017 inch) Loose. 5P-7298 Installer 7F-8022 Bolt

Main bearing cap width 165.095 ± 0.020 mm (6.4998 ± 0.0008 inch)

Width of cylinder block for 165.100 ± 0.018 mm (6.5000 ± 0.0007 inch)
main bearing cap
Note: If the width between the shoulders of the rear main bearing
(journal) is 40.411 to 40.615 mm (1.5910 to 1.5990 inch) install
100-3652 Thrust Plate. If the width is 42.799 to 43.003 mm
(1.685 to 1.6930 inch) install 7N-9343 Thrust Plate.
Special Instruction SMHS7100 gives the procedure for using the
installation tools.
Cylinder Liners
Bore in liner (New)
Use again maximum
Liner flange thickness
Spacer plate thickness
Spacer plate gasket
thickness
Liner projection
Note: Projection of adjacent liners must be within 0.05 mm (0.002 inch)
of each other.
Timing Gears
1. Fuel Pump Drive: Torque for 1/2” bolt 105 ± 20 N·m
120.68 ± 0.03 mm (4.751 ± 0.001 inch) (Sleeve Metering Fuel System) (77 ± 15 lb ft)
120.78 mm (4.755 inch) Torque for 5/8” bolt (Scroll Fuel System) 215 ± 40 N·m
10.282 ± 0.020 mm (0.4048 ± 0.0008 inch) (158 ± 30 lb ft)
9.970 ± 0.025 mm (0.3925 ± 0.0010 inch) 2. Fuel pump Idler: End Play (new) 0.10 to 0.40 mm
(0.004 to 0.016 inch)
0.196 ± 0.025 mm
(0.0077 ± 0.0010 inch) Maximum permissible end play (worn) 0.86 mm (0.034 inch)
0.033 to 0.175 mm (0.0013 to 0.0069 inch) 3. Camshaft: End Play (new) 0.18 ± 0.08 mm
(0.007 ± 0.003 inch)
Note: Marks on camshaft and crankshaft gear must be in alignment.

Maximum permissible end play 0.64 mm (0.025 inch)

4. Crankshaft
5. Oil Pump Idler
6. Oil Pump Drive

Torque spacer plate in four steps:

Step 1 - 14 N·m (10 lb ft)
Step 2 - 35 N·m (25 lb ft)
Step 3 - 70 N·m (50 lb ft)
Step 4 - 95 N·m (70 lb ft)
Torque liner clamping arrangement in four steps:
Step 1 - 7 N·m (5 lb ft)
Step 2 - 20 N·m (15 lb ft)
Step 3 - 35 N·m (25 lb ft)
Flywheel
Step 4 - 70 N·m (50 lb ft) 1. Maximum permissible "run out" (radial eccentricity) 0.15 mm
off center of bore (total indicator reading) (0.006 inch)
Installation Tool Required
Part No. Description Part No. Description 2. Maximum permissible "run out" (axial eccentricity) 0.15 mm
2P-8260 Cylinder Liner Installer of face (total indicator reading) (0.006 inch)
Inspection Tool Required 3. Maximum permissible "run out" (radial eccentricity) 0.13 mm
1P-2394 Puller Plate 8B-7548 Puller Crossbar for pilot bearing off center of bore (total indicator (0.005 inch)
3H-0465 Plates 8T-0455 Indicator Tool Gp reading)
Put liquid soap on bottom liner bore in block, on grooves in lower liner, 4. Torque for flywheel bolts 215 ± 40 N·m
and on o-rings. Install o-rings on liner. Put filler band in engine oil. (158 ± 29 lb ft)
Immediately install filler band on liner and install liner in cylinder block.

Piston, Rings and Connecting Rods

Installation Tool Required
Part No. Description
5P-3525 Piston Ring Compressor
Lubricate Piston Assembly and bearings with clean engine oil.
Ring gaps must minimum of 90o apart.
Note: Put connecting rod in the piston with the slot for the bearing tab
on the same side as the "V" mark on the piston. Put piston in cylinder
block with "V" mark in alignment with "V" mark on cylinder block.
Crankshaft Pulley and Vibration Damper
1. Tighten bolt holding pulley to crankshaft to 370 ± 50 N·m
(270 ± 35 lb ft)
Hit bolt with hammer and again tighten bolt to 370 ± 50 N·m
(270 ± 35 lb ft)

Cylinder Head
Note: Put 6V-4876 Molykote Paste Lubricant on threads and washer
faces of bolts 1 thru 26. Tighten bolts in the following Step sequence: Valve Clearance
Step 1. Tighten bolts 1 thru 26 in a numerical 150 ± 15 N·m
sequence to (110 ± 11 lb ft)
Step 2. Again tighten bolts 1 thru 26 in a 250 ± 17 N·m
numerical sequence to (185 ± 13 lb ft)
Step 3. Again tighten bolts 1 thru 26 in a 250 ± 17 N·m
numerical sequence (hand torque only) to (185 ± 13 lb ft)
Step 4. Tighten bolts A thru G in letter 43 ± 7 N·m
sequence (hand torque only) to (32 ± 5 lb ft) Exhaust 0.64 ± 0.08 mm (0.025 ± 0.003 inch)
Intake 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

Adjust following valves at No. 1 TC Adjust following valves at No. 6 TC

Valves Cylinder Valves Cylinder
Intake 1,2,4 Intake 3,5,6
Exhaust 1,3,5 Exhaust 2,4,6
View from right side of engine
Valve Cover
Flywheel Housing Tighten all bolts in number sequence to 16 ± 3 N·m
1. Maximum permissible "run out" (radial 0.30 mm (12 ± 2 lb ft)
eccentricity) of the flywheel housing bore. (0.012 inch)
2. Maximum permissible "run out' (axial 0.30 mm
eccentricity) of the flywheel housing face. (0.012 inch)

Exhaust Manifold
Note: Put 5P-3931 Anti-Seize Compound on threads of bolts and studs.
1. Torque for studs 25 ± 4 N·m
(20 ± 3 lb ft)
2. Torque for nuts holding exhaust manifold 47 ± 9 N·m
(35 ± 7 lb ft)
3. Torque for bolts holding turbochargers 47 ± 9 N·m
(35 ± 7 lb ft)

Turbocharger
1. Put turbocharger gasket on exhaust manifold.
2. Put 5P-3931 Anti-Seize Compound on bolt’s threads that hold
turbocharger to exhaust manifold.
3. Install turbocharger on exhaust manifold. Tighten nuts to a torque of
55 ± 10 N·m (40.5 ± 7 lb ft).

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