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3306 Engine Manual - Assembly & Disassembly

The document provides detailed instructions for the disassembly and assembly of engine components, specifically focusing on the rocker shaft assembly, push rods, cylinder head assembly, and crankshaft main bearings. It includes step-by-step procedures for removing and installing various parts, along with torque specifications and necessary precautions to prevent damage during the process. Additionally, it emphasizes the importance of maintaining the original positions of components and using new seals and gaskets during reassembly.

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Tarsis Felipe Souza
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3K views18 pages

3306 Engine Manual - Assembly & Disassembly

The document provides detailed instructions for the disassembly and assembly of engine components, specifically focusing on the rocker shaft assembly, push rods, cylinder head assembly, and crankshaft main bearings. It includes step-by-step procedures for removing and installing various parts, along with torque specifications and necessary precautions to prevent damage during the process. Additionally, it emphasizes the importance of maintaining the original positions of components and using new seals and gaskets during reassembly.

Uploaded by

Tarsis Felipe Souza
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
Engine Disassembly and Assembly Rocker Shaft Assembly And Push Rods Remove Rocker Shaft Assembly And Push Rods 1102 & 1208-11 START BY: a. remove valve cover 4, Put the gasket and pipe (4) in position, and install the bolts that hold them, 5. Put O-ring seal (6) and breather cap (6) in position. Install bolt (3), and tighten it to'a torque of 14 + 3Nm (10 x 2 [Link]). : 6, Slide the hose into position on the 1, Remove bolts (1) and the washers that Preather cap, and lighten the clamp that holds hold rocker shaft Gacembly (2) in position, i 2. Remove rocker shait assembly (2) Remove the O-ring seal from the rear rockér arm support bracket, 38. Put identification marks on push rods (3) as to their location in the engine. Remove the push rods. 73 Engine Disassembly and Assembly Rocker Shaft And Push Rods Install Rocker Shaft Assembly And Push Rods 1102 & 1208-12 18006 Enna Sequence 4. Install push rods (1). Make sure they ar . in their original location in the engine and in 5 Tighten the bolts thet hotd the rocker position in the valve lifters. shaft as follows: a. Tighten the boits in number sequence to a torque of 156 Nan (115 [Link]). NOTICE b. Tighten the bolts in number sequence to a torque of 250 17Nm (185 + 13 Ibt.). Loosen the adjusting screws on the rocker , Tighten the bolts again in number arms. This will prevent a bent valve or push sequence to a torque of 260 = 17 Nm (185 rod during installation of the rocker shaft as- = 13 bit), sembly, 6. See Valve Clearance Setting in Testing And Adjusting. Make an adjustment to the valves so the intake valves have 0.38 mm si i (.015 in.) clearance and the exhaust valves 2. Install a new O-ring seal in the rear co aa rearance and Me ewraus a rocker arm support bracket. Put 2°2506 Thread Lubricant on all of the bolts that ¢ hold the rocker shaft assembly in position END BY: except for the bolt that goes through the i rear rocker arm support bracket. a install valve cover 3, Put rocker shaft assembly (2) in position (on the engine. Make sure the dowels in the support bracket are in alignment with the dowel holes in the cylinder head. Make sure the rocker arms are engaged with the push rods. 4, Install the bolts and washers that hold the rocker shaft assembly in position, and tighten them until they are finger tight. 14 Engine Rocker Shaft Assembly Disassemble Rocker Shaft Assembly 1102-15 START BY: a. remove rocker shaft assembly and push rods 4. Remove O-ring seal (1) from the rear support bracket. NOTE: A replacement of the O-ring seal must be made each time the head boll is removed from the rear support bracket. 2. Remove retainer ring (6), washer (5), spring (4) and washers (3) from each end of the rocker shaft, Make @ note of the number of washers (3) used at each end of the shaft. Remove rocker arms (2) from each end of the rocker shatt. All the rocker arms, springs, washers and brackets, except the rear support bracket, can be removed from the shaft. 75 Disassembly and Assembly 8. Remove the pin from the rear support bracket with a hammer and punch. Remove Tear support bracket (7) from the shatt 4, Remove the plugs from each end of the shaft if necessary. Assemble Rocker Shaft Assembly 1102-16 1. Install rocker arms (5), brackets (1), washers (4) and springs (2) on the rocker shaft, 2, Install rear support bracket (6) on the rocker shaft. Make sure the hole in the rear support bracket is in alignment with the hole in the rocker shaft. 3. Put pin (3) in position in the bracket: Engine Disassembly and Assombly Rocker Shaft Assembly Cylinder Head Assembly And Spacer Plate Remove Cylinder Head Assembly And Spacer Plate 1100 & 1221-11 Tools Needed ‘SPOTSG_Unk Bracket 2 pH START BY: @. remove rocker shaft assembly and push rods meee “ b. remove exhaust manifold 4, Install pin (3) through the bracket and c. remove air cleaner group shait with a hammer, . d, remove aftercooler 5, Pin (3) must extend 9.60 mm (.978 in.) NOTE: The procedure which follows was above the bracket. done on a 3306 Engine. ®. dels} Sains 6. Install O-ring seal (7) in the rear support 4. Remove bolts (1), mounting bracket and bracket. install rocker arm (8), the original pipe assembly (2) and ling bracket (3) from number of washers, spring, washer and the the cylinder head assembly. retainer ring on the rocker shaft. 7. Install the front support, rocker arm, original number of washers, spring, washer and the retainer ring on the rocker shatt. 8. Install the plugs in each end of the rocker shatt if they were removed. END BY: a. install rocker shaft assembly and push rods from elbow (4). _ 768 Engine 3, Loosen clamp (6), and remove the bolts that hold elbow (4) to the water pump and cylinder head assembly. Remove the elbow and gaskets from the engine. 4, Install tooling (A) on the cylinder head assembly as shown, and fasten a hoist on it. NOTICE Do not set the cylinder head assembly on a flat surface because of possible damage to the fuel injection nozzle tips. 5. Remove all bolts (7) and (8) that hold the cylinder head assembly to the cylinder block. Remove the cylinder head assembly. The weight of the cylinder head assembly (3304) is 64 kg (142 Ib.). The weight of the cylinder head assembly (3806) is 96 kg (210 lb.). Disassembly and Assembly 6. Remove head gasket (9), water seals (11) and the O-ring seal from dowel (10). Remove spacer plate (12), the spacer plate gasket and the O-ring seal from dowel (10). Install Cylinder Head Assembly And Spacer Plate 1100 & 1221-12 Too Needed |] ‘GPOTSE_ Link Bracket 2 NOTE: The procedure which follows was done on a 3306 Engine. NOTICE When the cylinder head assembly is removed a new spacer plate gasket and @ new cylinder head gasket must be installed, Do not use any adhesive or other substances on these gas- kets or the surfaces they contact, 4. Thoroughly clean the spacer plate, oylinder head and cylinder block surfaces. Engine Cylinder Head Assembly And Spacer Plate Disassembly and Assembly NOTE: If dowel (1) was removed for any reason, install a new dowel until it extends 16.0 + 0.5 mm (.63 + .02 in.) from the cylinder block. 2, install the O-ring seal on dowel (1) against the cylinder block, Install spacer plate gasket (2) and spacer plate (3) on the cylinder block., 3. Check the cylinder liner projection height. See Install Cylinder Liners. 4, Install the O-ring seal dn top of the: spacer plate around, dowel (1). Install cylinder head gasket (4) and water seals (5). 78 5. Install tooling (A) on the cylinder-head assembly as shown, and fasten a hoist to it. Put the cylinder head assembly in position on the engine. 8. Put 2P2506 Thread Lubricant on all the cylinder head bolts, and install them until they are finger tight. Remove tooling (A) from the engine. Fk 7. install push rods (6). Make sure they are installed in their original locations. Be sure the push rods are in position in the valve lifters. 8, Loosen the adjusting screws on the rocker arms for valve clearance. This will prevent a bend valve or push rod during installation [Link] rocker shaft assembly. 9. Install a new’ O-ring seal in the rear rocké[Link] support bracket. 10, Put 222508 Thread Lubricant on all of the rocker shaft bolts except the one that goes through the rear rocker arm support bracket, Engine 11. Put rocker shatt assembly (7) in position on the cylinder head assembly. Make sure the dowels in the support brackets are in the dowel holes%in'the cylinder head assembly and the rocker arms are engaged awith the push rods. Install the bolts thal hold the rocker shaft assembly until they are finger tight. . {3804 Engine Shown 2, Hand tighten the large size cylinder head and rocker shaft bolts in the numbered sequence, shown for each engine as follows: a. Tighten the boits in the numbered sequence to a torque of 156 N-m (115 [Link],) . Tighten the bolts in the numbered sequence to a torque of 250 + 17 N-m (185 #19 [Link]). . Tighten the bolts in the numbered sequence again to @ torque of 250 + 17 Nm (jes = 18 Ios) . Hand tighten the small size cylinder Head bolts, in the lettered sequence shown for each engine to a torque of 43. 7 Nm (32 + 5 Ibi) 44. See Valve Clearance in Testing And Adjusting, and make an adjustmentrto the valves. The intake valves must have a clearance of 0.38 mm (.015 in,). The exhaust valves must have a clearance of 0.64 mm (.028 in.). 79 Disassembly and Assembly 18. Remove bolt (11). Pul ling bracket (8) and mounting bracket and pipe assembly (9) in position, and install bolts (10). Install bolt (11), and tighten it to a torque of 43 + 7 Nm (32 + 5 iit), 16. Put the gaskets and elbow (12) in position and install the bolts thal hold them. Tighten the hose clamp on the back side of the elbow. 12. Install temperature sending unit (13) in the elbow. END BY: a. install valve cover b. install exhaust manifold c. install air cleaner group d, install aftercooler Engine Disassembly and Assombly Water Directors Pistons And Connecting Rods Remove And Install Water Directors Remove Pistons And Connecting 1115-10 Rods 1225-11 START BY: START BY: a, remove cylinder head assembly and a, remove cylinder head assembly and spacer plate spacer plate b. remove oll pan plate c. remove oi! pump 4. Remove the carbon ring and tip trom the inner surface of the cylinder liner. a 1. Remove old water directors (1) from the cylinder head. 2. Clean the cylinder head. 3. Install new water directors in the cylinder j head with the notch in the water director in 2 Turn the crankshaft unti two of the aight with the "\V" mark on the cylinder pistons are at bottom center. Remove the nuts head, Install the water director to a depth of and bolts (1) from the connecting rods that 0.8 + 0.6 mm (.03 + .02 in.) below the are a bottom canter connecting rod i caps (2), and put identificati surface of the cyinder head. them for installation purposes. op ENO BY: a. install cylinder head assembly and spacer plate 84 Engine Disassembly and Assembly Pistons And Connecting Rods Disassemble Pistons And Connecting Rods 1225-15 ‘Tools Needed [8 750470 _ fing Expander f ‘SP8659 Press Group v2049 Adapter 6v8029_ Spacer ‘P6845 Adapter "202825 Hand Purp : EF24 Hose Assonibly {P2876 Coupior Aecombiy ~ B. Pull the connecting rod into position on 12376 Coupler Assembly crankshaft as shown. Install connecting — rod bolts (1) in the connecting rods. ' START BY: 7. Put clean engine-oil dn the lower halt of a. remove pistons the connecting rod bearing, Put 2P2506 Thread Lubyjcant on the Bolt threads and on . the surfaces of the nuts that make contact ith the connecting rod caps. NOTICE When the connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the. number on the side of the connecting rod. 4. Remove the rings from the pistons with tool (A). S 8, Install connecting rod caps (2) and the nuts that hold them, Tighten the nuts to a torque of 40 + [Link] (30 + 3 [Link]). Puta ‘mark on each nut as to its location, and tighten them 90° more. 9. Do §teps 1 through 8 for the remainder of the pistons, . END BY: a. install oil pump b. install oil pan plate , . install cylinder head assembly and spacer plate 2. Remove retaining ring (3), piston pin (1) and connecting rod (2) from the piston. 86 Engine Disassembly and Assembly Crankshaft Main Bearings Remove And Install Crankshaft Main 3, Remove crankshaft thrust bearings (3) » Bearings 1203-10 from the rear main bearing. ‘Tools Needed a[eye NOTE: install the main bearings dry when BPS51@ Baring Tool 1 the clearance checks are made. Put clean Piastioage 7 engine oil on the main bearings tor final 1882328 _ Dial Indicator Test Group + assembly. START BY: NOTICE a. remove oi pump b. remove oil pan plate Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and the main bearing caps. Cok 1, On 3304 Engines remove No. 1, 3, and 5 main bearing caps (1). On 3306 engines remove No. 1, 3, 5 and 7 main bearing caps (1). Remove the lower halves of the main bearings from the main bearing caps. NOTICE If the crankshaft is turned in the wrong direc- tion, the tab on the bearing will be pushed be- tween the crankshaft and the bearing area in the cylinder block. This can result in damage to the cylinder block and/or the crankshaft. 2. Install too! (A) in the hole in the crankshaft journal, and turn the crankshaft to remove the upper halves of main bearings (2). 91 Engine Crankshaft Main Bearings 4. Use tool (A), and install new upper halves of main bearings (2) in the cylinder block. Install new lower halves of main bearings (2) in main bearing caps (1) * NOTICE -

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