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    ENGINE -3406

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    ENGINE -3406

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    27 views76 pages

    Senr6470 00 00 All

    Uploaded by

    Jaime castro
    ENGINE -3406

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 76
    CATERPILLAR’ cence Specitications 3406C Engine For Caterpillar Built Machines 11N3780-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 taining, skils 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 hhave read and understood the operation, lubrication, maintenance and repair information. ‘Safety precautions and wamings 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 folowed by a "Signal Word" such as “WARNING’ as shown below. The meaning of this safety alert symbol is as folows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning, explaining the hazard, can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this, publication. Caterpitar cannot anticipate every possible circumstance that might involve a potential hazard, The ‘warnings in this publication and on the product are therefore not all inclusive. Ifa tool, procedure, work ‘method or operating technique not specifically recommended by Caterpillar is used, you must satisfy ‘yourself that itis 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 avaliable 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 gven to the product. Obtain the complete and most current information before starting any job. Caterpillar dealers have the most current information available, For a ist of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F. Index Accessory Drive Group Aercooler Air Cleaner Alternator and Fan Support Alternator Mounting Group Alternator And Regulator Belt Tightonor Bolt Tension Chart Breather Cap Camshaft ‘Camshaft Bearings ‘Connecting Rod And Wain Bearing Journals ‘Connecting Rods ‘Coolant Conditioner Base ‘Coolant Fow Swatches ‘Coolant Temperature Sensor (Crankshaft (Cylinder Block Cylinder Heat Cylinder Liners Cylinder Liner Projection Dual Horsepower Solenoid (i Equipped) Dust Ejector Group Engine Design Engine Support Exhaust Manifold Exhaust Manifold Shield Exhaust Elbow Adapter Group Exhaust Extension Group Fan Drive Fan Group Flywheel Group Flywheel Housing Flywheel Housing Bore Flywheel Housing Cover Flywheo! Housing Funout Flywheel Runout Ful Fiter Base Fuel Injection Lines Fuel Injection Nozzle And Adapter Fuel injection Pump Fuel Injection Pump Housing Fup Pressure Gauge Fuel Ratio Control Fuel Transfer Pump Front Housing And Covers Front (Timing) Gear Group Governor Governor And Fuel Pump Orve Group Idler Gear Assembly For Front Gear Group) Idler Gear Shaft Plot Bore Magnetic Pickup Group ‘Muifer and Ejector Group 4 BRAG BS TSVRNovont2BSSSRRS BBVVBe B (04 Cooler Bypass Valve 31 4 Fiter 20 i Pan uw Ol Pump 22 Pistons And Rings 46 Primary Fuel Filter 4 Radiator a Fear Gear Group 2 Service Meter a Shutoff Solenoid n Starting Motor 2 Turbocharger cy Vaves 20 Valve Covers 20 Valve Rocker Aims, Liters And Bridges 2 Water Pune % Water Temperature Reguiator 0 Introduction \When the words ‘use again’ ate in the description, the ‘spectication given can be used to determine i apart can be Used again. I the part is equal lo or within the specication ‘given, use the part again. |When the word ‘permissible’ is inthe description, the specification given isthe ‘maximum or minimum” tolerance ‘permitted before adjustment, repair andjor now parts are needed ‘A comparison can be made between the measurements of a ‘worn part and the specifications of a new part to find the ‘amount of wear, A part thal is worn can be safe to use if an ‘estimate ofthe remainder of its service fe fs good. Ifa short ‘service eis expected, replace the part NOTE: For Systems Operation, Testing and Adjusting make teference to 8406C Engine For Caterpilar Bult Machines, ‘SENRG47 3406C Engine Index Engine Design 5 4 3 2 4 OOOO NOUS HAN © INTAKE VALVES © EXHAUST VALVES. 19646 (Gyiner and Valve Location Bore 137mm (6.4) Stroke 165 mm (6.5 in) Displacement 14 Biter (696 cvin) ‘Number and Arrangement of Cylinders 6.Inine Fring Order (injection Sequence) 1536.24 Valve lash setting with engine cold and stopped: Intake (0.38 mm 015 in) Exhaust (0.76 men (030 in) No. 1 Cylinder Location Front Rotation of Crankshaft (when seen from flywheel end) Counterciockwise Rotation of Fuel Puryp Camshaft (when seen from pump sive end) Counterciockwise NOTE: Front and of engine is opposite to flywheel end Left side and right side of engine are as seen from flywhee! end, No. 1 cylinder s the front cyinder. 3406C Engine Specifications Fuel Injection Ful ijection Line With Support Bracket Be sure the fuel injection line clamps are installed in the correct locations. incorrectly installed clamps may allow the fuel injection lines to vibrate and become damaged. The damaged lines may leak and cause a fi (1) Clamp location dimensions are in reteence to a vertical line (1) through the center ofthe number one fuel pump outlet Align brackets in postion to fue lines such that when the faslaners are tightened no stain will be added to the fuel lines while tightening fasteners. “ 353mm (1.38 12in) ® 165: 13mm (6.50.51 in) © 187+ 1 mm (7.6 + 04 in) o 187 3mm (7.6 12in) e 282-43 mm (11.10 12in) © 286 4:9 mm (11.26 12in) @ 529-43 mm (17.98 12in) Tighten metal-o-metal clamps to a torque of 23Nem (win) NOTE: The 6V4980 Torque Screweriver Tool Group is avaliable for applying the correct torque. 3406C Engine ‘Specifications Jnoun |] / (2) Tighten fuel injection ine nus to 4247 Nem (@I5mH) (@) Tighten ruts to 14£3Nem (1020811) (4) Tighten retainer on adaptor to .. 48: 7 Nem (85+ 5 1b) Fuel Injection Nozzle And Adapter SSS EIN a NS ccouezees (1) Torque for fuel injection tne nut 427 Nem @iz5in) (2) Torque for retainer 48: 7Nem (35 51) (@) Tighten bleed screw toa torque of 27£08Nem (23.89£7.081bin) Always use a now washer (Seal) anytime the bleed screw is removed. (4) Washer. Make sure the correct washer is used when the nozzle assembly is installed (6) Put liquid soap on the rubber Oring seal and in the bore in the head before assembly, (©) Put $9931 Ant'Seize Compound on the threads ofthe ‘adapter before instalation. Torque for the adapter 200 14 Nem (160+ 10 bt) Torque for the nut on the adapter assembly 727 Nem (63:5 1b) 3408C Engine ‘Specifications Fuel Transfer Pump Fuel Injection Pump 1 e102 (1) Clearance between guide and tappet (0.0028 t0 0.0101 mm (0001 to.0004 in) NOTE: The guide and tappet are a matched set one part is worn, anew guide and tappet assembly must be installed, (2) Bore in leave forthe piston 34.0004 0.015 mm (13386 + 0008 in) Diameter of piston 38.972 40.008 mm (13875 0003 in) (8) 70134 Spring: Length under test force 83.67 mm (1.328 in) Test force 2212 11N 097 £250) Free length after test 56.1 mm (221 in) Outside diameter 274mm (1.08 in) (4) Fel inlet port (8) Check valves, (© Fest outlet port Tighten the two 988007 Plugs in the engine side ofthe pump housing fo a torque of Sct 1 Nem (449 bin) (1) Torque for bushing 243.4 13Nem (179+ 1016) (2) 8N5993 Spring (everse flow check valve): Length under test force 11.50 mm (453 in) Test force 151+8N@424 180) Free length after test 15.81 mm ( 622in) Outside diameter 10.36 mm (408 in) (8) Thickness of 7£9907 Spacer 6.761 0.005 mm (2662 + 0002in) (4) Torque for cover bolts (6) Length of pump plunger (naw) 1424Nem (1043161) 77,423 + 0.013 mm (@10481 +0005 in) (©) 4P8704 Spring (tery Length under test force Test force Free length after test Outside diameter 48.87 mm (1.924 in) 460: 8N (25.97 + 1.8010) '52.16 mm (2.054 in) 84.21 mm (1.347 in) 3406C Engine ‘Specifications (7) Bowe forthe rack and diameter ofthe rack Bote in bearing (after instalation) in governor end of housing 12,746 + 0.045 mm (5018 +.0018in) Bore in bearing (atte instalation) in ckive end of housing 12.767 + 0.058 mm (5026 + .0023in) Diameter of rack (new) 12.662: 0.005 mm (4985 + 0005 in) (@) Bore in bearings for camshaft (after assembly)... 74.089 + 0.039 mm (2.9169 +0015 in) Diameter of bearing surfaces of the ‘camshaft 74,000 0.013 mm (2.9134 +0005 in) (9) Setscrew. Tighten the setscrews inthe drive end of ‘camshaft (10) toa torque of (10) Camshatt 217 Nem (155111) Fuel Injection Pump Housing (1). Distance from end of dowel tothe opposite wall of the bore 40.40: 0.18.mm (1.591 +007 in) (2) Dowel (@) Distance trom fat surface of rack bearing to opposite wal of the bore... 11.178 0.050 mm (4401 0020 in) (4) Rack bearing in dive end of fuel pump housing. (6) Install bearing with flat surface (as shown) to an angle of 1S degrees: NOTE: The 64824 Driver and 6V4825 Plate are avaiable to install the rack bearing tothe corect angle and depth. 3406C Engine SECTION AA soosere w AN, (©) Distance from the end of pin to the opposite wall ofthe bore 35.57 + 0.10mm (1.400.004 in) (7) Distance trom the governor end ofthe housing to the fend of the dowel 7.5 05mm (30+.02in) (8) Distance trom the dive end housing face to the drive fend rack bearing 83.0+05mm (327 + 02in) Inside diameter of bearing (after assembly) 12,767 + 0058 mm (5026 + 0023 in) (9) Distance trom the governor end housing face to the ‘governor end rack bearing 7.160.138 mm (282.005 in) Inside diameter ofthe bearing (ater assembly)..12.746 £0,045 mm (5018 + 0018 in) (10) Postion of ol supply hole for three camshaft bearings 30: Bdegrees (11) Inside dlameter of three fuel pump camshat bearings (alter assemy) 74,089 + 0.039 mm (29169: 0018 in) (12) Distance from surface of bore to end of camshaft bearing 4.00 + 0.50 mm (039 + 020 n) (19) Distance from surtace of bore to end of center camshaft bearing 218.0 0.3mm (8.58 + 01 in) ‘3406C Engine (14) Distance from governor end of housing to the end of the camshaft bearing... 1.00: 0.25 rm (039+ 010in) Specifications Governor (1) Setscrew. Adjustment for fuel ratio contro (2) Nut Tighten to a torque of 1.700.25Nem (1521bin) () Lover for manual shutot. (4) Setscrew. Adjustment for dimension (6) (8) Nut Tighten to a torque of 1.700.25Nem (182 1bin) (©) Dimension at shutoff. With manual shutoff lever (3) atthe ‘maximum shutoff positon, the distance ftom the end of the lever assembiy tothe face of the rear governor housing must be 28.805 mm (1.13+.02in) NOTE: Make sure setscrew (4s adjusted to give dimension (© at assembiy (7) Setscrew. This setscrew is used forthe adjustment of ‘dimension (6) on engines that use a shutoff detent Nut Tighten to a torque of 1.70:£0.25Nem (1522 1bin) (9) Broken link spring, See the Miscellaneous Spring Chart (10) Torque for screws 3.4£0.5Nem (31 +4 bin) (11) Spring to center or preload the fyweights, See the Miscellaneous Spring Chart. (12) Guide. The distance trom the end ofthe guide tothe housing gasket surface is dimension (4) 11,80 + 0.25 mm (464+ 010in) (18) Dashpot spring. See the Miscellaneous Spring Chat. (18) Governor spring. See the Governor Spring Chart (16) Tighten the insulated terminal in governor housing to a torque of 340.5 Nem (31 4b in) (17) Setscrew. Adjustment for torque rise setting (18) Setscrew. Adjustment for fuel setting. (19) Nut. Tighten the nut on setscrews (16) and (17) to @ torque of 1700.25 Nem (15% 21b in) (20) Bumper spxing. See the Miscellaneous Spring Chart. ersa7ere L (21) Lever. instal the shutoff lever as ilusrated. Angle (A) ‘and angle (8) trom the vertical centeine must be 0 degrees, 3406C Engine 10 ‘Specifications ‘MISCELLANEOUS SPRING CHART ‘Spring Type. (9) Broken Link (11) Centering (13) Dashpot (20) Bumper Part No. 22216 aKS733 4N6410 twa243 Length under 26.33 mm 193mm 26.16 mm 263mm test force (1.037 in) (760) {4.030 in) (1.049) Test force 73.34 066N S1t5N 4.45 £0.96 N 0.194N (3.002 * 148) (13.7 £ 1.110) (1.000 2 081 Ib) (0437 to) Free length 58.74 mm 312mm 31.26mm ‘32mm after test (231 in) (1:22 = 08 in) (1.230in) (1.3in) ‘Outside 11.32mm 14.35 mm 1483.mm, 83mm diameter (446 in) (565 in) (584 in) (33in) ‘Color Code (stripe) ‘none none ‘one pink ‘one yolow [ ‘GOVERNOR SPRING CHART (15) I ‘Spring Part No. su6445 ‘aL9790, ‘enoiat 2N2878 l ‘one blue |__ Color Code (stripe) fone yellow. ‘one end pink one purple cone brown Put a force on TSN 18N 18N 29N spring of: Bb) (4) (iby (65m) “Then add more force to 203mm 22.06 mm 22.86 mm 10.69 mm make spring shorter by: (799i) (900 in) {900 n) (421 in) Total Test Force: 43.95 1.33N S992 12N e6t2N a7 aN (9.876 + 29810) (13.45 + 0.27 b) (1480510) (105 £0.11) Free length after test 56.90 £0.76 mm 59.496 99.496 59.496 = (2.240 2 090 n) 1.016 mm 4.016 mm 4.016 mm (236 O4in) (2:34 O4in) (236 = On) ‘Outside diameter ‘94.88 + 0.38 mm 34.98 * 38mm 34.82 & 38mm 33.99 = 38mm (1.879: 018in) (1.377 £018 in) (1.371 015in) (9.938 +018 in) ‘GOVERNOR SPRING CHART (15) ‘Spring Part No. emo140 enss9¢ M3760, 718056 ‘one light blue | Color Code (stripe) ‘one green {Wo light bie ‘one end yellow two yellow uta force on 18N 222N 22.2N ‘35.6N spring of: ae) Gib) 6b) ib) “Then add more force to 22.88 mm 16mm 22.86 mm 20.82 mm _make spring shorter by: (900 in) 629 in) {.900in) {£800 in) Total Test Force: 742 14N 537 £094N 86 t23N ast11N (166+ 32m) (1207 211m) (194 521) (982 2410) Free length after test 59.4062 59.496 59.496 59.496 1.016 mm 4.016mm 1.016 mm 4.016 mm (2.38 O4in) (2:38 O4in) (236 © O4ie) (2:36 O4in) ‘Ouiside diameter 34.93 98mm 34.87 = 38mm 35.93 = 38mm 34.57 & 38mm (1.875 * 015 in) (1.373.015 in) (1.391 +015 in) (1.361 +015 in) 3406C Engine 1 Specifications "TOROUE CONTROL GROUP COMPONENTS Nome Part No. Thickness 0.4 003 mm Sering aN7519 (025 = 00r in 074 0.03 mm Serng an7s18 (026: 001m 031 = 009mm speng an7s23 (012 0011m 081 = 003mm Spring enzs17 (032 Oot) 0.56 = 0.09 mm sering en7s20 (22 001) 046 = 0.04 mm Contact woos (ove 002) 064 = 0.19mm Spacer 272605 (025 #005) 0,75 «0.007 Spacer 7x00 (aa0'= oor) 1553.05mm Spacer 71796 (081-002) 1.02303 mm shin su7205 (040° orm) Fuel Ratio Control 1 2 3 ccoezers (1) 792826 Spring Puta force on spring of 624N (18020) ‘The add mare force to make spring shorter by 368mm (.145 in) Total test force 77/484 45 N (17.400 101 b) Free length afte test ‘32.56 mm (1 282 in) Outside diameter 135.12 mm (1387 in) Color code (stipes) twored (2) 72828 Soring Put a fore on spring of TAN (17.401) ‘The add more force to make spring shorter by '3.68mm (.145 in) Total test force... 107.694 181 N (24.200: 33910) Free length ater test 46:40 mm (1.827 in) Outside diameter 24.45 mm ( 963 in) Color code (stripes) two yellow (@) aNS76S Sexing Length under test force 24.00 mm (948 in) Test force 2225+ 4N 60% 9) Free length afte test 80 5mm (3.17 in) (uiside diameter 35.57 mm (1.400 in), Color code (stipes) ‘wo pink Governor And Fuel Pump Drive Group Automatic Timing Advance Unit NOTE: For the correct iming specications to use for adjustment ofthe automatic timing advance unt, see the Engine information Plate, TMi (Technical Marketing Information), or Fuel Setting And Related information Fiche, (1) Spring. See Spring Chart (2) Torque forfour batts (8) Torque for plug (4) Torque for nut (8) Torque for nut (©) Spring, See Spring Chart. (7) Bolts that hold flyweight carriers. Apply 6V1541 Quick Cure Primer to bolt treads and let i ry, Put 983263 “Thread Lock on bot threads before instalation, @ Torque for four bolts 55: 7 Nem (40+ 1b 1) 12k 4Nem @+ 301) 70: 15Nem (50-411 Bf) 45:£05Nem (9982+ 443! in) 70: 15Nem (50-11 bt) 3406C Engine 12 Specifications ‘SPRING CHART ‘Spring PartNo. (W527 (6) 4PA365, (areas, (6 aPas67 Length under test force | 62.0 mm 2.4 in) 38.0 mm (1.545) 38.0 mm(1.54i9) BBO mm (154m) Test force ‘381 = 20 2.99045 111 206N 2192 11N @ezesy) (2007 = 101) 2914p) 82 250) Free length aftr test 31.96 7.31mm | 482mm (192616) 48.3mm(1.94in) | 68.28 mm 2687 i) (8.228 0521) Outside dameter 97 mm @.82in) 15.4 mm (61) $5.4 mm (61m) 15am (611) ‘Color code (srp=5) - one white ‘one ight green ‘one dark bive ‘one red ‘one 06 ‘one red Free length after test 41.52.nm (1.65 in) Outside diameter 15.40 mm (606 in) Color code (stripes) ‘one red and one purple (6) Torque for bolts that hold fyweight carr... 34Nem win) (©) Torque for four bolts 13: 4Nem (104301) NOTE: For the corect timing specifications to use for ‘adjustment of the automatic timing advance unit, see the Engine information Pate, TMi (Technical Marketing Information), or Fuel Setting And Related Information Fiche. (1) Torque for eight bats 55:47Nem (404511) (2) Torque for rut 45405Nem (6982: 4.431bin) (8) Torque for rut 70+ 15Nem (60:11 bt) (4) Spring: 10222 Test force 10224 51N 287 + 11515) Length unde est foxco '38.0mm (1.5419) Free length ater test 45.49. (1.791 in) Ouiside diameter 1540 mm (606in) Color code (st928) wo vilet 613665 Test force 8.4 4N (1.89: 091) Length under tes force 380mm (154in) Free length ate test 43.1 mm (1.70in) Oude diameter 15.40 mm (606in) Color code (stipes) ‘one orange and one red et00e2 Test force 8.46 42N (1.901 + 094) Length unde ost oreo 37 mn (1.48in) 3406C Engine 13 Specifications Dual Horsepower Solenoid (If Equipped) Fuel Filter Base — 1580 Operating voltage ange 181028800 Coil esistance at 25°C (77°F) ulin windings 16.1% 16ohms ——_BsHe08e1 Pushin windings ‘42: dohms (1) Shuto (2) Dual Horsepower. (1) Stud (two) Used when iter base is installed high on atic Symbol attercooler housing Insal stud so end of stud extends a ‘above surface of aftercooler housing boss to a ‘dimension of 243-£ 1.5 mm (96 + 06 in) (2) Put 983265 Retaining Compound on the tapered end of ; stud to a distance of 7.6mm (30in) Primary Fuel Filter (8) Sealing srace of stud NOTE: Do not damage this surface (4) Distance trom sealing surtace of base to end of 1 8 stud 248 13mm (87+ 05in) (8) Torque for stud 70+ 15Nem (60-11 oft) case 2 (1) Torque for nut 25E5Nem (189M) (2) 789028 Spring Length under test force 279mm (1.101n) Test force 12810 145 N (2810331) Froe length ator test 42.7 mm (1.68in) Outside diameter 473mm (68in) 3406C Engine 14 Specifications Idler Gear Shaft Pilot Bore Idler Gear Assembly (For Front Gear Group) (1) Distance trom vertical centerline of dowel hoe to vertical Ccenteine of plot bore 186.33 mm (7.396 in) (@) Bore in cylinder block for ier gear shatt pilot 31.750 0.025 mm (1.2500 + 0010 in) Depth of bore fram surlace of cylinder block 11925mm (47 + 101) 31.687 0.025 mm (1.2875 0010 in) (@) Tighten bolts that hold her gear shaft in postion to 55: 10Nem (407 bt) (4) Distance trom horizontal centerline of dowel and Diameter of idle gear shaft plot 2W7455 Gear Assembly Used For Water Pump and Camshatt Drive (1) Bore in bearing of gear (atter assembly)... 63.602:+ 0.038 mm (2.5040 +0015 in) Diameter of bearing surtace ofthe shaft 163.500 0.013 mm (2.5000 0008 in) (2) Install bearing from rear face of gear assembly oa depth of 11505 mm (06 O2in) (8) Length of gear...» 47.60: 0.05 mm (1.874 002n) Length of the bearing surface ofthe Crankshatt to horizontal centerline of plot shaft “47-85 £0.05 mm (1.864 002in) bore 247.02 mm (8.725in) 3406C Engine ‘Specifications Front Housing And Covers PE104, 2458, 245C & 375 “Typical lutration NOTE: Cut gaskets even with the bottom of front housing and front pate after the housing is installed onthe engine. (1) Tighten the two studs to a torque of... 65+ 10Nem (487 bt) (2) (PE104, 2456 & 245C Only) Tighten the two nuts to a torque of ‘65+ 10 Nem (48+ 7 bt) 1W1427 Front Housing buses 5545Nem 40418) (@) Put 953263 Thread Lock on the treads of the studs. Two studs must be installed to extend above the housing surface toa dimension of 285+ 15mm (112 08 in) (@) Put 983263 Thread Lock on the threads of the eight studs, The studs must be installed to extend above the housing surface to a dimension of 410 15mm (161 08 in) Tighten five studs marked "" toa torque of 35:5 Nem 26-4 bit) NOTE: Put 98326 Thread Lock on the stud serrations and leach side of the gasket prior to assembly NOTE: Heads of studs must not be moce than 4.5 mm ((18in) above the surface ofthe timing gear plate ater instatation, (1) Tighten two studs to @ torque of 7W3656 Front Housing ‘Typical stration NOTE: Cut gaskets even with the bottom of front housing and front plate after the housing is installed on the engine. (1) Tighten two studs to a torque of 55¢5Nem 404001) (2) Put 983263 Thread Lock on the threads of the studs. ‘Two studs must be installed to extend above the housing surface to a dimension of 285 15mm (112+ 08in) (@) Put 983268 Thread Lock on the threads of the stud, The stud must be installed to extend above the housing surface to @ dimension of 3702 1.5mm “Typical stration (1.46 06 in) NOTE: Cut gaskets even with the bottom of front housing and front plate after the housing is installed on the engine. ‘3406C Engine 16 ‘Specifications (4) Five studs marked #X" must be installed to extend above the housing surface to a dimension of... 285 1.5mm (1.12 08in) Tighten studs to a torque of... 352 SNem (26: 4 ft) NOTE: Put 983263 Thread Lock on the stud serrations and teach side of the gasket prior to assombly. NOTE: Heads of studs must not be more than 4.5 mm (18in) above the surface ofthe liming gear plate after Installation, Front (Timing) Gear Group (1) Drive gear for water pump, (@) Idler gear assembly. ler gear for water pump. (@) dle gear for camshaft Pat of idler gear assembly (2). (4) "°K marks must be seen from front of engine when (gears are in alignment as shown. Top center forthe No. 1 oyinder. (8) Camshatt gear. (© Air compressor drive gear Accessory Drive Group 8N9653 Accessory Drive Group crsaeort (1) Bore in bearing of gear (after assem)...» 63,602 + 0,098 mm (2.5040 0015 in) Diameter of bearing surface of the shaft £63 500 = 0.013 mm (2.5000: 0006 in) (2) Install bearing from face of gear to a depth of 1.50.5mm (06+ 02in) (3) Length of gear... $0.75 20,05 mm (1.996 + 002in) Length of bearing surface ofthe shaft 51.00: 0.05 mm (2.008 +002 in) (4) Front (spacey) plate between cylinder block and front housing, (6) Rear face of front housing. (7) ler goat fora compreesr ve (6) Tighten adapter studs to a torque of geese (@) Drive gear for fuel pump (9) Crankshatt gear (10) Drive gear for oil pump. (11) Torque for bott 55: 10Nem (407 1b) 3408C Engine ‘Specifications 1N3970 Accessory Drive Group alee 27220 (1) When sleeve for 17935 Hydraulic Pump Drive or the Adapter for 1W8585 Auxiliary Drive Group i installed, tighten the bolts to torque of 30:3Nem (@z2m1) Camshaft (1) Tighten stud to @ torque of. 85: 10Nem (40: 7 ft) 4W3123 Accessory Drive Group ms pais 27219 o Gear. It new gear is required, replace camshaft assembly. The heat treatment of the gea is damaged it heated. Diameter ofthe surtaces (journals) for the camshatt (1) Accessory Drive @ bearings (new). €8.850°+ 0.013 mm (2.7500 .000Sin) () Totten a compress crankshaft rut oa oun 150 ct 20 Nerm (110-4 15) Bern ont bering ft cansat ate it ond of at compressor crankshatt with harwmer an assent) 0.048 mn (2.7647 0018Ie) ‘ordi sn ete oe tage Nem Bore in the other six bearings for the camshaft (after (meee 88eMb) 68.982: 0.061 mm (27552 +.002¢in) (8) Thickness of thst plate (new) 465003mm (183: 001m) End ply ofthe camshat 0.10%0028 mm (0040 010%n) (4) Camshat 3408C Engine 18 ‘Specifications 4 74239P4 Camshaft Bearings 027361 0 is 1 z (6) Height of camshaft lobes. To find lobe height, use the procedure that follows: ‘A. Measure camshaft lobe height (6) B. Measure base circle (7). . Subtract base circle (STEP 8) from lobe height (STEP A). ‘The difference is actual lobe It (6) D. Specified camshat lobe it (6 is: 8N9245 Camshaft Assembly a. Exhaust lobe B. Intake lobe 100-7408 Camshaft Assembly a. Exhaust lobe 10.210 mm (4019in) . Intake lobe 10.212 mm (4021 in) “Maximum permissible ciference between actual abe it (STEP ©) and specified lobe it (STEP D) is 0.1mm (005 in) £8,100 mm (3189in) {8.783 mm (3458 in) Intake Valve Timing 41. Check the No. 1 intake valve lash with the engine stopped. The valve lash must be 0.30 to 0.48 mm (012 to (18 in). the valve lash is not in this range, adust the lash to.0:38 men (015 in). 2. Mark Top Center Position of the crankshaft on the vibration damper or pulley. 3. Use a dial indicator to measure the intake valve movernent 4, Rotate the crankshaft inthe direction of normal engine rotation, Stop when the intake valve is 1.81 mm (075 in) off its seat in the opening sequence. [A this point the crankshaft Top Center Position Mark must bein position as folows: Engines with the 8NG246 Camshaft ‘Assembly 32 degrees After Top Center Engines with the 100.7408 Camshaft Assembly 1 2 degrees After Top Center (1) Inside diameter of camshaft bearings 2 through 7 (after SSE)... 69.982 0.081 mm (2.7552 + 0024 in) (2) Centarine of No. 1 cylinder. (@) Inside diameter ofthe front camshaft bearing (ater assembiy) 69,969 + 0.048 (2.7547 +0019 n) (4) Front surtace of cyinder block Dimension from the front surface of the cylinder block to Install the camshaft bearings. “ 1099.1 + 0.5mm (40.91 + 02in) ® 867.7+05mm (34.16 02in) © 696.24 0.5mm (27.41 +.02in) © 524.8 0.5mm (20.66+.02in) © 353.3405 mm (19.91 +.02in) © 181905 mm (7.16+.02in) @ 2.805mm (11.02in) 3406C Engine 19 ‘Specifications Breather Cap arrears (1) Tighten clamp to a torque of 45£05Nem (4041 in) Valve Covers 7 H Y “ 4 Y Y Y Y q NOTE: Guidelines For Reusable Parts; Valves And Valve ‘Springs, SEBF8002 and SEBF8034 have the procedure and specications necessary for checking used valves and valve springs, (1) 4W2471 Spring for valves (outer) (new Length under test force {53.24 mm (2.096 in) Test foe 245 + 241 (65 +5 1b) Length of spring at vaive open position 380mm (154in) Use again minimum load at valve open position 805+ 40N (181 +916) Free length after test 159.5 mm (2.94 in) Outside diameter ‘37°31 mm (1.469 in) (1). 4W2872 Spring for valves (inner (new) Length under test force 50.24 mm (1.978 in) Test foce 178 18N 40x41) Length of spring at vaive open postion 36.01 (142in) Use again minimum load at valve open postion 343417 NO 441) “Typical Example Free length alter test 65,7 mm (260in) side diameter 25.13 (989 (1) Torque forthe bolts that hold valve covers and cover Ousie dames eee es bases in poston 14d aNem (1023161) NOTE: Cut valve cover seals and cover base seas tof at assembly. Coat joints with BT2022 sealant. 34066 Engine ‘Specifications (1). 4N5906 Spring fo valves (new) Length under test force {54.99 mn (2.165 in) Test force 344+ 34N (77 +8) Length of spring at valve open postion ...... 42.93mm (11690 in) Use again minimum load at valve open postion 880+ 44,N (198+ 101) Free length after test 62.74 mm (2.470'n) Outside diameter 381.75.m (1250 in) (2) Height to top of valve guide 323:+08mm (127£.03in) (3) Diameter of valve stem (new) 9.441 £0.010mm (3717 + 0004in) Use again minimum diameter of valve stems: Exhaust 9.408 mm (3704 in) Intake 9.408 mm (3704 in) ‘Bore in valve guide with guide installed in the head (oem) {9.487 + 0.025 mm (3735 +.0010in) Use again dimension for valve guide bore (measured 750 ‘rom end of guide) 9.538 mm (3755 in) (4) Diameter of valve head: Exhaust valve Intake valve 41.81 + 0.13 mm (1.646 +005 in) 44.98 + 0.13mm (1.771 + 005 in) 29% Vi dogroes 44% degrees: (6) Angle of intake valve face ‘Angle of exhaust valve face (® Angle of face of intake valve seat insert 30+ 1 degrees ‘Angle of face of exhaust valve seat insert 451 degrees (9) Dimension from end of closed valve to machined face of ead, Maximum permissible dimension: New 115-2368 inlet & 115-2067 Exhaust valves. Below (recessed from) machined face 122mm (048in) ‘Above (extended from) machined face 0.041 (0016in) All other new Inlet & Exhaust valves. Below (recessed from) machined face 122mm (048 in) ‘Above (extended from) machined face 020mm (008 in) Reconditioned 115-2968 Inlet & 115-2367 Exhaust valves, Below (recessed from) machined face 4.70.mm (067 in) ‘Above (extended from) machined face 004mm (0016) ‘Al other reconaltioned niet & Exhaust valves. Below (recessed from) machined face 1.70mm (087 in) ‘Above (extended from) machined face 020mm (008 in) (10) Outside dameter ofthe face of the valve seat insert: Exhaust seat... 9.268-+ 0.013 mm (1.5460 +.0005in) Intake seat... 40,894 + 0.013 mm (1.6100 + 0008 in) (11) "Use again thickness of valve lip: Exhaust valve 2.061mm (081 in) Intake valve 2.51 mm (099in) naer-1P1 (6) Depth of bore in head for valve seat insert 1301 0.35 mm ($12: 014in) (7) Diameter of valve seat insert fr intake valve 46.025 + 0.013 mm (1.8120:+.0005 in) Bore in head for valve seat insert fr intake valve 45.949 + 0.025 mm (1.8090-+.0010 in) Diameier of vaive seat insert fr exhaust valve 442.850 + 0.013 mm (1.6870 0005 in) ‘Bore in head for valve seat insert for exhaust valve 42.774 % 0.025 mm (1.6840 +0010 in) ‘3406C Engine ‘Specifications Valve Rocker Arms, Lifters And Bridges (1) Bore in rocker arm for shaft 24,808 + 0.013 mm ( 9765 + 0005in) Diameter of rocker arm shatt 24,752 0.013 mm (9745 + 0005in) DO+O+D+OHDYO s8 8 ayn aH Ho °° (2) Put P3931 AntiSeize Compound on all the threads of bolts that hold rocker arm shafts and tighten the bolts in the step sequence that folows: ‘Step 1. Tghen bots tom 1 trough 8 in number sequence 270 +27 Nem (20020 bt) Step 2. Then bats rom 1 trough 8m uber eouence 1450 + 20 Nem (830 + 15 ft) aa 3. Tighten botts from 1 through 6 in number sequence again to 1450 20 Nem (390 15 ft) (@) Torque for locknut for valve adjustment screw 30-4 Nem (22: Sib ft) (4) Torque for locknut for bxidge adjustment screw 30: 41Nem (22: 31D) (6) Valve Lash Intake valves (038mm (015 in) Exhaust valves (0.76 mm (080 in) (©) Height 1 top of dowel... 6380.6 mm (2.10 .02in) (7) Diameter of dowel 11,008 0.003 mm (4334 0001 in) Bore in bridge for dowel 11.13 005mm (438 002i) Bore in head for dowel 10.968 0.020 mm (4318 0008in) (®) Diameter of vatve iter 27.896 +: 0.013 mm (110983 +0005 in) Bote in block for vale iter 27.953 0.019 mm (11005 +0008 in) NOTE: See Guideline For Reusable Parts; Salvage Of Liter Bores in 3400 Family Engines, SEBFE0EY forthe procedure, tooling and spectications needed to install 44568 Sleeves for salvage ofthe Iter bores in the cylinder block. () Guide springs must not be used again, Aways install ew guide springs. fn por nza9ee 4 (10) 2N7228 Spring Length under test force 74.2 mm (2:92) Test force "4 to 53N (1010 1216) Free length after test 144.31mm (4.50 in) Outside diameter 29.7 mm (1.17 in) (11) Dowel length above top surface of rocker shaft support tobe 12.7 1.0mm (50.04 in) (12) Clearance for rocker arms (both ends)... 0:30 to 1.40 mm (012to 085 in) (13) Use 2N7228 Washer as needed to get clearance (12) 3408C Engine ‘Specifications caesar (A) Minimum dimension alter reconcitioning .... 16:51 mm (850 in) (8) Allowable wear before reconditioning 013mm (095in) Inspect the bridge seats for wear. Use the bridge again if the ‘wear is 0.13 mm (005 in) or less. When the wear seat is wor ‘ore than the allowable limt, the worn surface of the seat ‘can be ground flat. The maximum amount of material that ‘can be removed i 0:38 mm (.015 in). the seat cannot be ‘made fat, replace the bridge. Reconditioning of the wear seat ccan only be done once. 3406C Engine 23, Specifications Cylinder Head ap DODDS Oh OM @ ® ® @ ® ® a tr r — (1) Large bolts (%4 inch). Put 64876 Molycoat on all bolt threads and under al bolt heads. Tighten the bolts inthe {allowing step sequence: Step 1. Tighten bolts 1 through 14 in number sequence W_t to 27025 Nem (200 20 bt) ‘ep 2. Titan bot tough 4 rumba sequence 1 4870 20Nem (48 15M) | ore 3, Tighten bolts 1 through 14 in number sequence again H 470-4 20Nem (345+ 151b 1) ‘Step 4 Install the rocker arm shafts fr the engine valves. . ‘Step 5. Tighten bolts 15 through 26 in number sequence to 270+ 25 Nem (200+ 20 bt) ‘Sep 6. Tan bots 15 tough 25In ruber sequence 1450 20 Nem (330+ 15 1) (4) Thickness of cylinder head (new) ..... 112.78 0.25 mm (4.440 + 010in) a 7. Tighten bolts 15 through 26 in number sequence Ne ee again to 450+ 20 Nem (830+ 15 1b) rasa Tt me (4.900) Step 8. Tohton he wave smal Bots (2). At 7 Nem Ln erereneran ecires eae jatspn looks ATE 5Nem (13:44) eee aang acieage eens NOTE: Flatness ofthe cyinder head should be within (@) Torque for twelve studs in cylinder head... 95-5 Nem (0.13 mim (008 in) total, and a maximum of 0.03 mm (001 in) (264M) for any 762 mm (3.00 in) span. ‘3406C Engine 24 Specifications Turbocharger S4DS, S4DC, TD09 (1) End play for shaft (new) 0.114.0038mm (0045 +,0018in) ‘Maximum permissible end play (worn) 020mm (008 in) (2) Thickness of trust bearing (where thrust rings contact bearing) 5.36 0.08mm (211 + 001 in) (8) Diameter of shaft (new) 18.997 to 16.005 mm (6298 o 6301 in) Bore in the bearing (new) 16.035 to 16.043mm (63130 6316 in) ‘Maximum permissible clearance between beating and shaft (worn) (0.05 mm (002 in) (4) Maximum permissible gap of ol seal ring, measured in bbote of housing {0.251mm (010 in) (6) Turbocharger impeller instalation ‘a. Put impeller on shatt Put a small amount of clean ol on the threads and impeller face area that contacts the nut 6. Install and tighten the nut to 155215Nem (137 13. in) NOTICE Do not bend or add stress to the shaft when the nut is loosened or tightened, 1. Remove the nut trom the shaft 8, Use 6V1581 Quick Cure Primer on the treads of the shatt and nut, f. Put 953285 Retaining Compound on the threads of the shaft and nut {Install and tighten the nut to 4 2Nem (5 181bin) fh. Tighten the rut more 90 5 degrees (©) Thickness of each thrust ring 2.8530013mm (1005 + 0008n) (7) Bote in housing (new) 24,994 to 25.006 mm (9840 to 9845 in) Outside diameter ofthe bearing (new) 24,882 to 24.892 mm (9796 to 9800 in) Maximum permissible clearance between bearing and bore in housing (worn) (0.15 mm (006 in) Tighten both band clamps (that hold the compressor and turbine housings to the cartridge group) with procedure that follows: 2. Tighten to 1441.1 (125-10 1bin) . Tap (hit) clamp light al around! ©, Tighten again to 14 1.1m (125 101i) NOTICE Do not over tighten the clamps. “Torque for four nuts (put SP3981 AntiSeize Compound on tveads) and bolts that hold turbocharger to exhaust ‘manitold 55¢5Nm (40+ 4Ib ft) NOTE: Put clean engin ol in the ol inlet of the turbocharger after assembly or before instalation to provide start up lubrication andjor storage protection 3408C Engine ‘Specifications ‘TL78, UTV78, TV81 LOO] (1), Turbocharger impeter instalation: 4. Put impeler on shatt ». Put a small amount of clean engine oon the threads and imple face that wil be under the rut 6. Tighten the nut to Y7Nem (1316) 2050006 NOTICE Donotbend or add stress the shaft when the nutis loosened oF tightened, 6. Loosen the rut on the shat @. Tighten nut 1 Tighten the rt an ational 4g. Remove the nut fom the shalt Use 6V1541 Queck Cure Primer on the treads ofthe shal and nut |. Put 983285 Retaining Compound on the theads ofthe shaft and rut j. Again tren the nut to 35Nem 01 in) k. Agan tghten the nut and addhional... 120 degrees (@) Torque forthe bolts that hod the backplate 111 Nem (8 101bin) (@) Torque for the clamp bats 140 15Nem (120+ 131bin) Light hit al azound clamp wit a sot faced hammer and again tghten to. 140: 15 Nem (120: 131 n) (8) Bore in the bearings 18.921 to 15931 mm (6288 0 6272in) Diameter forthe surfaces (journals) on the shaft for the bearings...» 16.8750 16.885.mm (6250 to 6254 in) 35Nem (901 in) 120 degrees, 24.961 1024.973mm (9827 to. 9832 in) 24.846 10 24.859 mm (97820 9787 in) (© Clearance between the ends ofthe oll seal ring (when installed in ts bore)... 0.20 100.38 mm (008 0 015in) (7) Endpay forthe shaft. 0.08 0.0.25 mm (.003 0 .010in) (@) Torque for bolts and nuts that hald the turbocharger to the exhaust manifold (put SPG931 Anti Saze Compound ‘on the thveads) 55:5 Nem (40 4b ft) (6) Bore inthe housing Outside diameter ofthe bearing TL81, TL75 (1) Turbocharger impeller installation: ‘a. Put impeler on shaft '. Puta small amount of clean engine ol onthe threads {and impel face that wil be under the nut (Tighten the nut to Y7Nem (1310 ft) NOTICE, onot bend or add stress the shaft when the nutis loosened or tightened, 4. Loosen the nut on the shaft, fe. Tighten nut to 4. Tighten the nut an additional 4g. Remave the nut from the shaft. Fh. Use 6V1541 Quick Cure Primer on the threads of the 85 Nem (30! in) 120 degrees, shaft and nut |, Put 983265 Retaining Compound on the threads of the shaft and nut |. Again tighten the nut to 3.5Nem (30! in) Again tighten the nut and additonal... 120 degrees (2) Torque for the bolts that hold backplate... 10: 1 Nem (0+ 101bin) @) Torque for the clamp bolts 140:1.5Nem (120 13 bin) Lightly ital around clamp with a hammer and again tighten to 140: 1 5Nem (120 13 Ibi) 3406C Engine Specifications (4) Bote in the bearings 15.921 t0 15.931 mm (6268 10 6272 in) Diameter ofthe surtace on the shaft for the bearings 15.875 to 15,885 mm (6250 to 6254 in) (6) Bote in the housing 24961 024.973 mm (9827 to 9832 in) Outside diameter of the bearings .. 24.846 to 24.859 mm (978210 9787 in) (6) Clearance between the ends of the ol seal ring (when installed in its bore)... 0.20 0.0.8 mm (.008 0.015 in) (7). End play forthe shaft... 0.08 to 0.25 mm (003 0.010 in) (6) Torque for bolts and nuts that hold the turbocharger to the manifold (put SP3831 Anti Seize Compound on the ttveads) ‘55:7 Nem (40+ 5b ft) Exhaust Manifold ®ODD®O® Exhaust Manifold Shield Oo ‘Shield Position (1) Manifold shied (2) Installshield as shown with short end toward front of engine, but behind manifold bolts by a cimension of 503mm (1.97 + 12in) (8) Put P3931 AntiSeize Compound on the threads of the bolts an tghten the ts 10a torque of... 25:7 Nem (18584) (4) Front face of block 02045 Put SP3981 AntSeize Compound on threads of studs (1) Totten nuts in nae sequence shown fo a trae 4847 Nem B51) 3406C Engine Specifications Exhaust Elbow Adapter Group Dust Ejector Group ‘e041 143Nem (1) Tighten clamp nut to a torque of (W0t2b4) Exhaust Extension Group 015508 (1) Tighten two studs to a torque of 355Nem 26401 1 15509 Lubricate threads and bearing surface with SP3931 Anti ‘Seize Compound before assembly. (1) Tighten two bolts to a torque of 30£7Nem 4 (t5bn) sao ‘Typical tustration (1) Tighten bott on clam to a torque of {8NS677 Extension Group ... 13:=3Nem (10: 216 ft) ‘W507 Extension Group ... 25: 7Nem (18: 5 bf) 3406C Engine Specifications Muffler and Ejector Group Air Cleaner \_ arrose ‘Typical stration Put 8P3931 Ant: Seize Compound on threads of clamp bots before assembly. (1) Torque for ejector clamp .... 25: 7 Nem (18 5 bt) (2) Torque for mutter clamps: {6N2085 Mutter Group 257 Nem (18+ Sib ft) ‘2W0584 Mutler Group 9: 2 Nem (80 18 bin) W186 Mutter Group 6 Nem (639 bin) (8) Distance from end of muffier to clamp (GN2065 Matfer Group) 3.0mm (12in) YY “Typical tustration| (1) Torque for clamp bot (@) Torque for wing bots 254 7Nem (18+ 51b 1) 60+ 10Nem (63:91) 4 15815 (1) Torque for clamp bot (2) Torque for eight locknuts 90 7Nem (22:4 51 it) 907 Nem (224500 it) 3408C Engine 29 Specification Oil Filter s24ie4 (1). 4N8150 Spring for bypass valves for ol cooler and oi a Length under test force (55.25 mm (2.175 in) iss valves: cooler and oil ‘estore TEESN(17013—) (© _ABtS0 Spring fr bypass valves foro cooler and ol Fos ost 37 rm (a8 Leng under tc £5250 @.1780) Filter and cooler bypass valves to open with a pressure Test foros een rate Simcoe see oa) Eo i 837m 8B) (2) Torque for stud: Filter and cooler bypass valves to open with a pressure Put 953263 Thread Lock Compound on threads of the difference of (255 + 20 kPa (37 + 3 psi) Rion ao witNem ——@ Tones (60+ bf Put 983263 Thread Lock Compound on threads of the mfosapnovewoass eae Swen ‘3408C Engine 30 Specifications sas (1) 4N8150 Spring for bypass valves foro cooler and oi! filter: Length under test force {55.25 mm (2.175 in) Oil Cooler Bypass Valve Test foroe T6ESN(17 04130) (1) 4N8180 Spring fr bypass valve for ol cooler: Free length after test 937 mm (3.69in) Length under test force 85.25 mm (2.175in) make erneter 20.6 mm (81 in) Test force 765N (17041310) Fier and cooler bypass vaives to open with a pressure Froe length alter test 93,7 mm (369in) diference of 255 20 KPa (37 + 3ps) Outside diameter ‘206mm (81 in) Tighten four plugs to a torque of 100 15Nem (i cooler bypass valve to open with a pressure (411A) itference of 255 20 kPa (37 3p) (2) Torque for stud Put 983269 Thread Lock Compound on threads ofthe stud and tighton the stud to... 68: 7 Nem (50:5 bf) 3406C Engine Specifications Oil Pump One Section Gear 2 a {Aa 1 © Hilo 9 LN 2521 ° NOTICE, Before operation, the pump must be lubricated with clean {engine ol and the pump must turn freely by hand or damage to parts can be the result. Rotation (seen ftom the dive end) counterclockwise Tost on tost stand, with SAE 10W oll at 49°C (120°F) Output 272 ter/min (72U.S. gor) ‘Ata pressure of, 310 KPa (45 ps) With pump at| 2550 rpm Output 144 itermin (8 US. gpm) ‘Ata pressure of 560 KPa (81s) With pump at 22550 rpm (1) Diameter of rive shat 22.217 £0.005 mmm (8747 + .0002n) Bote in bearings for crve shaft... 22-258 + 0.008.mm (8763 +.0008in) Diameter of idler shaft 22.217 £0.005mm (5747 +.002in) Bote in bearings for idler shaft... 22.288 + 0.008 mm (8763 +.0003 in) (2) Length of gears 79375 0.025 mm (1250: 0010 in) Depth of bores for gears 79,502 + 0.020.mm {@.1300+.0008 in) (8) 282760 Spring (ol pressure ree): Length under test force Test force Free length ater test Outside diameter 117.9 mm (484in) 49027 N (10:61) 152.9mm (6.02in) 227.00. (1.063 in) (4) Bearing junction (6) Position of bearing junction from the centetine through bearing bores: ‘30 15 degrees Install bearings so they are even with outside of pump body. 3406C Engine ‘Specifications ‘Two Section Gear 1 SN 2 ™ ™ 3 ] © 4 6 o 4 — LJ —| 6 027330 ls ‘Scavenge pump end Rotation (s08n from the drive end) counterclockwise ‘Test on test stand, with SAE 10W oil at 49°C (120°F) Pump body assembly Rotation (seen from the crive end) Test on test stand, with SAE 10W oil at 49°C (120°F) ‘counterclockwise Output 272 ter/min (72 U.S. gpm) ata pressure of ‘310 kPa (45 ps) with pump at 2860 rpm Output +44 iterjmin 38 US. gpm) Ata pressure of ‘560 KPa (81 ps) ‘with pump at| 2850 rpm 79375+0.025mm (8.1250 0010 in) 79.502 + 0,020 mm (@-1900=+ 0008 in) (6) Diameter of ceive shatt and idler shaft (ren) 22.217 0.005 mm (8747 +.0002in) ‘Bote in bearings for dive and idler shaft (oe) £2288 + 0.008 mm (8763 +.0003n) (©) 252760 Spring (oll pressuce calle valve} (4) Length of gears Depth of bores for goars Length under test force 117.9mm (4.64in) Test fore 490+ 27 N (1106 b) Free length after test 1529 mm (6.02) Outside ciameter 27.00 mm (1.063 in) A Output 193 iter/min (61 US. gpm) with pump at 2550 pm (1) Diameter of rive shaft and idler shatt (new) £20320 + 0.005 mm (8000 0002 in) Bore in bearings for crive shaft and cer shaft ‘Scavenge Pump (nen) 20.361 20,008 mm (8016 +0003 in) {@) Length of gears (new) 57.158:+0.025 mm ie (@ 2503 +.0010in) {®) Position of bearing junction from the centerine through Depth of bores for gears (new)... 57-285 + 0.020 mm bearing bores 30: 15 degrees. (2.2553. 0008 n) (@) Insta bearings in bottom of gear bores to a depth ot 11524 0.25 mm (060+ 010in) ‘Spacer assembly (@) Diameter of chive shaft and idler shaft (new) 22.217 + 0.005 mm ( 8747 +0002 in) Bore in bearings for dive shaft and ier shaft (new) £22258 + 0.008 mm (8763 +,0003in) 3406C Engine Specifications Spacer assembly (10) Spacer assembty bearing junctions. (11) Slots must be in locaton shown when small hole in ‘bearing is algned with centerline of splash holes (12). (12) 01 splash holes (ubricating holes) (13) Install spacer assembly bearings from Face A toa depth of (0.76 0.25 mm (030+ 010in), Pump Body (14) Pump body bearing junctions. (15) Position of pump body bearing junction trom the Cconteriine through bearing bores ....... 30+ 15 degrees. Install bearings so they are even with outside of pump body. ‘Typical Example (1) Pipe plug. Put 853263 Thread Lock on the threads of ll Pipe plugs, and tighten to a torque of ... 80+ 11 Nem (O+8mt) (2) Magnetic plug, instal the gasket and/or Oring forthe ‘magnetic drain plug with the seam against the ol pan, Tighten magnatic dain lug to a torque of 70:t 15Nem (61 +11 Bt) (@) Tighten bots to a torque of... 55: 10NNem (40 7 ft) NOTE: Retorque all drain plugs with gaskets andjor Oving at ‘each ol change. 27878 {4P0519 Drain assembly (1) Lubricate with ol and tighten to a torque of 70: 13Nem (50+ 1011) E4613 Oi Pan Group requires 4P0519 Drain Assembly to be tightened to a torque of 952 15Nem (70211 bt) 3408C Engine Water Pump (@) Ring and water sea Use a 29102 Sea! instalation Tool and hand pressure to install the rubber seal and ceramic ring asa unt inthe pump housing bore. Make sure the identification mark (oles or groove) on the ceramic ring face is installed inside the rubber seal 1 2 3 (0) Seu anaes. — 2. Remove testing fom th el Bicentenary 0 tony \ Tlncatonc esos De ma er ny gee or rival icee Bator seel ener fhe al essen alain he ta ooctad be pone a Seneree «1 Boe Bo102 seat naan Toot se has sansa baal gat easy on amp Feralpetnanen non oe es comes oy Re cmom aces he coum ine NOTE: The ctor sal ase mut tov he water ovp oul De not oce en utente lean wlon Fartaltcuos re robo Banat navel oe tte cobon sal eboney apg. 4 5 (6) Ol seal. Put a small amount of clean engine oil on the lip oz0se elie bn een et wah sip rd fearngs as shown (6) Torque for bolt that holds the gear 215+ 40Nem_ (160 + 30 Ib ft), (1 Torque or bt at tpt $883 Bien (2) Silt clare cx sal soy eat wat eo "S10 Osten CIE Oooh) NOTE: Ue 6V 1541 Cuik Oe Prime olan te wae Noa on fe crass wy cou couicoae he arb rowing BELT TENSION CHART. SORROUGHS GAUGE WINGERS Ton GAUGE READING sett | ctr toe | "BECT TENSION] BELT TENSION ou NEw INITIAL Ys USED" ++ GAUGE NUMBER |GAUGE NUMBER| ae oe WEASURE TENSION OF BELT FARTHEST FROW ENONE sole se terfererctanterT eeaTionea 01509 34066 Engine % Specifications Fan Drive A 15220 (1) Torque for studs 65: 10Nem (4847 bt) {@) Position seal as shown and install even with end of pale, (@) Fill with muttpurpose grease at assembly. 015516 ‘Typical lustration| (1) App 988269 Tread Lock and gen bo to trae 212 12Nem (156916 ft) (9¥5649 Blower Fan (1) Tighten two botts to @ torque of 20 7Nem @ESbH) 3406C Engine ‘Specifications Belt Tightener paeziPs (1) Fit cavity with multipurpose grease. (2) Tighten nut to a torque Of 45 7 Nem (38:4: 51 ft) hd ‘Typical Top Tank With Pressure Relief Valve Assembly (1) Pressure Relief Cap or Pressure Relief Valve Assembly 551218 Pressure Role! Valve Assemby Pressure that opens relief valve assembly 195 to 125 KPa (14 10 18s) imum ‘necessary to make relief val (1) Tighten nut to a torque of 547 Nem (40+ 5 ib tt) See ee eee eels wFiPa (tps) (2) Tighten nut to a torque of... 102: 14 Nem (75+ 101) a a en ta Se ieee an een ae (@) Center the hump of the hose between the ends ofthe mating pipes. 3406C Engine 37 ‘Specifications NOTE: Use the tightening sequence shown to instal op and bottom tanks to radiator core oo 0 \ ile 06) bpeoce Le oe} pecce $ ‘ asia Lower Racator Tank Bots (upped) (8) Tighten bois to a torque of 1352 13Nem ——————————— (00 10mm) Teterng Procedure For Typical Three Row Tank 1 2 vosepeess eco ssoede 92221 Tightening Procedure Fr Typical Two-Row Tank ‘Brackot Assembly Bolts (f equipped) (4) Tighten bolts to a torque of... 55 7 Nem (40+ 5b ft) 34086 Engine 38 ‘Specifications Folded Core ‘Typecal Top Tank With Pressure Relot Valve Assembly (1) Pressure Relief Valve Assembly 581218 Pressure Rell! Valve Assembly: Pressure that opens rele valve assembly 195 to 1254Pa (140 18s) Maximum vacuum necessary to make reel valve assembly open 7 kPa (1 psi) Torque for stud for filer cap 55:7 Nem (40: Sib) “Typical Mustration| (@) Center the hump of the hose between the ends of the rating pipes. (4) Tighten the bots and bolt assembles that hold the four baffle strips in positon to @ torque of 25:7 Nem (i8£50N) ain FLOW. J ‘090871 (6) Trash gap. Betore bolts that hold core assembles in positon are tightened, trash gap must be 85+ 1.5mm (26+.06in) 3406C Engine 39 ‘Specifications Coolant Flow Switches Water Temperature Regulator z- p1sezs 44794 Water Temperature Regulator psoseo-1P1 Temperature when completely open 92°C (197°F) Minimum opening distance at 92°C (187°F) 104mm (atin) 9xs040 Cee 763095 Water Temperature Regulator (@) With paddle in vertical postion, the force (F) on rivet Temperature when completely open 96°C (206°F) head (2) necessary to lose contacts of Minimum opening distance at 96°C (208°F 104mm switch 87S grams (190+ 1002) i een (atin) ©) Length of pace 490 mm (1.83in) 362000 ‘Switch contacts are normally open. (@) With paddle in vertical position, the force (F) on rivet head (2) necessary to lose contacts of Switch 87 3grams (1.90 1002) (8) Length of paddle 58mm (228in) 3406C Engine 40 Specifications Aftercooler IPI (1) Bolts that hold the cover and core support pate Tighten the bolts 10a toque of 25:47 Nem (18501) ‘Alter the engine is operated, again tighten the bolts to a torque of 257 Nem (185i ft) (@) Put clean engine olor glycerin on all O-ring seals and in ther bores at assembly NOTE: Tighten all ott (1) through the core support plate ‘before bolts (3), through he waterline adapters, are tightened. (Tighten the bolts and nuts to a torque of ... 23: 4Nem (7£3bM) “Typical stration (4) Botts that old the waterline adapters (6) Put 983269 Thread Lock on the bolt threads at assembly, 3406C Engine a ‘Specifications Cylinder Block 759761 (1) Put 953263 Thread Lock on the tapered end of the stud toa distance of 10.0% 1.5mm (39+.06in) (2) Tighten the stu to a torque of 10+ 18Nem (O11 MN) (1) Thickness of spacer plate 8.585 +0025 mm (3379. 0008in) ‘Thickness of gaskot that is placed between spacer plate and cylinder block (0.208 + 0.025 mm (0081 + 0009 in) Height of liner over spacer plate, under instalation pressure 10.13 008mm (005 2 008in) (2) Height of four dowels above top surface of cylinder block End dowels (Put 7M7456 Bearing Mount Compound on two fend dowels at instalation)... 185-0.5mm (73 +,02in) Middle dowels 160+05mm (63+.02in) (@) Dimension (new) from centerline of crankshatt bearing bore to top of block (top deck)... 42545+0.15mm. (18.750 006in) Minimum dimension from centerline of crankshaft bearing ‘bare to top of Block (top dack) 425.02 mm (16.733in) NOTE: The fatness across the whole contact surface of the ‘black must be within 0.10 me (004 in and within 0.05 mm (002 in) fox any 177 mm (7.0 in) section ofthe surface. The surface finish specification is 3.2 micrometers (125 miczo- inches) maximum. 3406C Engine 42 Specifications (4) Bore in block for camshaft bearings "76.895 0.018 mm (3.0250 + 0007 in) Install bearings with the ol holes in the bearings on the horizontal center. Make sure the bearing joint position 's above the ol holes, (6) Bore inthe block for the main bearings: Standard, original size (new) 129891 +0.013mm (6.1138 + 0005 in) (0.64 mm (025 in) larger than original size "130.526 + 0.013 mm (5.1988 +0008 in) (©) Distance from front of rear face of cylinder block to end of dowels 19.1 +£0.05 mm (75 02in) (7) Width of main bearing cap 215.900-+ 0.025 mm (5000+ 0010 in) 215.900 0013mm (5000 0008 in) Clearance between main bearing cap and cylinder ‘look. 0.025 mm {.0010n) ight 00.025 mm (010 in) loose D\ \ \ [TURN 7 120° ‘Width of block for main bearing cap “Tightening Procedure For Main Beating Cap Bolts (8) Torque forthe bolts that hold the caps forthe main bearings: Install the main bearing caps withthe marks (arrow) toward the front ofthe engin. Install each cap in the ‘correct position by puting the number stamped on the bottom of the cap toward the corresponding number ‘cast on left se ofthe cylinder biock atthe pan ral €. Put 405593 Thread Lubricant on the threads ofthe bolts. b. Tighten the bots first on the bearing tab side ofthe cap to 258+ 141Nem (190 10 1b) €. Tighten the bolts on the opposite side ofthe bearing tab side to 258+ 14 Nem (190 10 1b) 4. Put armark on each bolt and cap. €. Tighten the bolls on the opposite side ofthe bearing tab ‘ide, from the mark 120 5 degrees 4 Tighten the bolts onthe bearing tab side ofthe cap, from the mark 120+ 5 degrees (9) Dimension (new) from centerine of crankshaft bearing ‘bore to bottom of block (pan rails)... 165.10 0.10mm (6500 +,004in) a re ‘View From Right Side Of Cyinder Block (10) Put 8P3414 Pipe Sealant on threads of plugs before installation in the eylinder block (11) Torque for bolts holding ol jt coating tubes: 307 Nem (22+ Sib ft) NOTE: Minimum permissible clearance between piston and ‘let cooling tube (0.64:mm (025 in) 3406C Engine ‘Specification Cylinder Liners A Cylinder Liner Projection NOTE: This procedure alleviates the need forthe “H’ bar to hold down liners during projection measurements. Tools Neoded I~ | | L A wll VIEW A-A piees2 For installation {2 Putliquid soap on the liner bore surfaces ofthe ‘tinder block and on the rubber seals installed on the lower part ofthe liner. ». Put the filer band completely in clean engine ol fora moment. Insta filer band (1) inthe groove under the ner flange, without delay 4. Insal the liner in the block immediatly, before ‘expansion of the flr band. (1) Fler Band (2) Ofing Seals (3) Thickness of flange on ner 889+ 002mm (350.001 in) ‘Use again’ minimum thickness (4) Bore in iner (now) £8,870 mm (3492 in) 137.185 + 0.025mm (6401 + 001 in) NOTE: Make reference to Guideline For Reusable Parts; Pistons And Cylinder Liners, SEBFB049 and SEBFEO6S, (870455 _Liner Projection Tool Group csenages LUner Projection Components (1) Bott. @) Washer. () Washer. ‘COMPONENTS NEEDED Hem] PartNo. |Description | Quantity For | Quantity For One Cylinder | Six Cylinders 7] 7ase8 [Bot 6 26 2 | eFr4ae | Washer 6 26 3 [e177 | Washer 6 26 "These are fabrlo material washers, an expendable item, therefore you may "wish to order more than the amount Incas, Install clean liners or cylinder packs (without the filer band or the rubber seals), spacer plate gasket and clean spacer plate, ‘3406C Engine ‘Specifications 3406 Liner Projection Measurements wey fa escineae 082r 0 FRONT DEON Liner Proj Mox Variation, Each Cylinder Max Variation of AVG er 248 mv (008) Mor 0.081 mom (002 Between Ly ‘Adjacent Liners Max: 1A~10 ox 0.051 mm (,002 in) * Min 1A-1D 8 Variation _[ WET i Wax 2A~20 AVG 2 aq — Min 24-20 Variation [-——————] Mi Variation —[ AVG 2 Wox 3 AVG 3 2K Min 3A~3D Variation _ [———} fe Variation —_[ we 3 20 ee Variation [————~} ave 3 Voriotion _[ AVG & Max SA-5D avers Ba —— Min 5A-5D Varietion _ [————} 8 —] Variation [—————} AVG 5 ES — Wax. 64-60 AVG 6 30 — Min 6A-6D Variation} yg [ioe —— 4A “e — Mor 0308 mm (004 in) 40 ———] Max AVG 5 — EMG Variation 5A 58 5c 50 —_ suas. | ———— wvG S| J oA 68 6c al 60 —_ suu6 | — oar777 3406C Engine 5 Specifications Install bolts and washers, as indicated previously in the holes. instal all bolts or the six bots around the lier. Tighten the bolts to a torque of 95 Nem (70 Use the 870455 Liner Projection Tool Group to measure liner projection at postions indicated with an A,B, C and D. Facord measurements Tor each cylinder. Add the four readings foreach cyinder and divide by four to find the average. ‘SPECIFICATIONS ner Projection 10.026 t6 0.152 mm (0.001 to 0.006 5) ‘aximam Variation (0.051 mm nach Une {2002 n) ‘Maximum Average Variation 0.051 mv Between Adjacent Liners (0.0020) ‘Maximum Variation 10.102 me Between All uners (@.004i0) I the liner projections are out of specication try rotating the liner or install the nr in anther bore to see if the ‘measurements improve. I the liner projections are all below the specifications or low in the range, 0.025 mm (0.001 in) or 0.051 mm (0.002 in), try Using a thinner spacer pate (613189 or 614903). These pates ‘are 0.076 mm (0.003 i) thinner than the regula plate and they wil increase the liner projection, thus increasing the fre ring crush, Use these spacer plates fo compensate for ow liner projections that are less than 0.076 mm (0.003 in) ori the Inspection ofthe top deck reveals no measurable damage dectly under the liner langes, but the average liner projection is lass than 0.076 mm (0.003 in) Do not exceed the maximum liner projection of 0.182 mm (2006 in). Excessive liner projection wil contribute toner flange cracking \With the proper liner projection, mark the liners inthe proper positon and set them ase When the engine is ready for inal assembly, the Oving seals, cylinder block and upper filer band must be lubricated before installation. ifthe lower O-rings are black in color, apply quid soap on the lower O-ing seals and the cylinder block. Use Clean engine ol on the upper filer band. Ifthe lower O-rings are brown in color, apply engine ol on the lower Ong seals, the cyinder block and the upper filer band, NOTE: Appi iqud soap andfor clean engine oil immediately before assembiy. I applied 00 ear, the seals may swell and be pinched under the liners during installation Pistons And Rings One Piece Pistons Make reference to Guideline For Reusable Parts; Pistons, ‘SEBF8049; Cylinder Liners, SEBFB0G8; and Piston Pins And Retaining Rings, SEBFBOS1 NOTE: For installation, number on tab groove side of ‘connecting od isto be positioned toward opposite side of ‘engine from camshaft Top And Intermediate Ring ‘The 106431 Keystone Piston Ring Groove Gauge is necessary for measuring ring grooves in keystone style pistons. For correct use of the gauge group, see the Instruction card that is withthe gauge group. Intal piston rings with "UP" side toward top of piston, (1) Top Rng has the mark "UP. (@) Intermediate ring has the mark "UP-2. Clearance between ends of piston ring when installed in a Cylinder liner with a bore size of 137.16 mm (5 400i): Top ring (0.724: 0.190 mm (.0285 + 0075 in) Intermediate ring 1.080 0.190 men (0425 + 0075in) Increase in clearance between ends of piston rings for each (0.03 mm (001 in increase in cylinder ner bore sze (0.08 mm ( 003 a) Oil Control Ring (9) Insti oi conto ing with the gap inthe spring 180

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