Caterpillar3412 Manual Disassembly&Assembly PDF

CATERPILLAR" SENR1133
June 1996
3408C & 3412C Marine Engines
3 Marine Auxiliary & Generator Set Engines

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 resutt in injury or death.
Safety precautions and warnings are provided in this manual and on the product.
warnings are not heeded, bodily injury' or dedth could occur to you or other perso
"WARNING" as shown below.
A WARNING I
Operation that may cause product damage are identified by N

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. W 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 darnage@
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 Bypass Valves ..................................................................... 20
Oil Cooler ..................................................................................... 24
Oil Filters ..................................................................................... 20
\ Aftercooler ................................................................................... 25 Oil Filter Base .............................................................................21
Air Filter ................................................................................... 27 Oil Filter Base. Disassemble & Assemble ....................... 22
Air Cleaner Assembly ............................................................. 28 Oil Level Gauge ......................................................................... 23
Oil Pan ....................................................................................... 161
Bridge Dowels ........................................................................ 159 Oil Pump ................................................................................... 162
Oil Pump. Disassemble & Assemble ............................. 163
Camshaft ..................................................................................113
Camshaft Bearings ...............................................................115 Piston Cooling Tubes ........................................................... 169
Connecting Rod Bearings ............................................. 167 Pistons (Earlier .Rod Pin Bearing With Straight
Crankcase Breather .............................................................. 13 Sides). Disassemble & Assemble .................................... 171
Crankshait ............................................................................... 180 Pistons (Later .Tapered Rod Pin Bearings).
Crankshaft Front Seal & Wear Sleeve ........................... 110 Disassemble & Assemble ...................................................173
Crankshaft Main Bearings .................................................. 178 Pistons ....................................................................................... 170
Crankshaft Pulley & Damper ............................................... 14 Precombustion Chambers ................................................. 144
Crankshaft Rear Seal & Wear Sleeve ............................ 123
Cylinder Head Assemblies ................................................. 152 Radiator ..........................................................................................
5
Cylinder Liners ........................................................................ 175 Rocker Shaft Assembly ....................................................... 149
Rocker Shaft Assembly. Disassemble &
-'
Direct Injection Adapters ................................................. 146 Assemble .................................................................................. 151
Raw Water Pump ..................................................................... 98
Engine Lifting Brackets ........................................................ 12 Raw Water Pump (Earlier Engines). Disassemble &
Engine Support ......................................................................... 12 Assemble ..................................................................................... 99
Exhaust Manifold (Rear) ...................................................... 128 Raw Water Pump (Later Engines). Disassemble &
Exhaust Manifold (Water Cooled) .................................... 130 Assemble .................................................................................. 104
Expansion Tank & Water tines ........................................ 107
Service Meter .............................................................................38
Fan .................................................................................................... 6 Spacer Plates ..........................................................................160
. Fan Belts ....................................................................................... 7
). Fan Drive ........................................................................ 8 Timing Gears ........................................................................... 116
Fan Drive. Disassemble & Assemble ..................................8 Turbocharger ............................................................................. 29
Fan Guard .....................................................................................4 Turbocharger. Disassemble & Assemble ....................... 31
Flywheel ..................................................................................... 117
Flywheel Housing .................................................................. 125 Valve Covers ........................................................... .......... 133
Front Housing ......................................................................... 112 Valve Guides ........................................................................... 158
Front Housing Cover ..............................................................16 Valve Lifters & Push Rods ..................................................148
Fuel Filter .....................................................................................18 Valve Seat Inserts .................................................................. 157
Fuel Injection Lines ..................................................................33 Valves .........................................................................................
156
Fuel lnjection Nozzles & Adapters (Later 7000 Vibration Damper & Pulley .................................................109 .
1- Series) ........................................................................................ 143

Fuel Injection Nozzles (Earlier 7000 Series) ................. 139 Water Pump ............................................................................... 92
Fuel Injection Pump Housing & Governor ...................... 52 Water Pump. Disassemble & Assemble ......................... 95
Fuel lnjection Pump Housing. Disassemble & Water Temperature Regulators .......................................... 87
Assemble ..................................................................................... 78
Fuel Injection Pumps ............................................................. 44
Fuel Injection Valves (Direct Injection)............................ 138
Fuel Injection Valves (Precombustion Chamber) ....... 136
Fuel Priming Pump & Filter Base ....................................... 19
Disconnect batteries before performance of any
Fuel Ratio Control (If Equipped) ......................................... 35
service work
Fuel Ratio Control. Disassemble & Assemble ..............36
Fuel Transfer Pump ................................................................ 39
Fuel Transfer Pump. Disassemble & Assemble ........... 40
Generator ................................................................................. 118

Glow Plugs (Precombustion Chambers) ...................... 135
Governor. Disassemble & Assemble ................................ 55
--
Governor & Fuel Pump Drive ............................................... 47
/I
Governor & Fuel Pump Drive. Disassemble &
Assemble .....................................................................................50
3408C & 3412C Marine Engines 3 Index

Disassembly & Assembly
Fan Guard
Remove & Install Fan Guard 1360-010
3. Remove twenty two bolts and washers (3) and

remove two fan guards (4).
NOTE: To install the fan guards, reverse the removal

steps.
-,
1. Remove two bolts and strap (1) from the fan guard
assembly.
2. Remove two bolts and strap (2) from the fan guard
assembly.
3408C & 3412C Marine Engines 4 Disassembly & Assembly

Radiator
-1
\ Remove & Install Radiator 1353-010

Start By:
a. remove fan guard
FLUID SPILLAGE CONTAINMENT
Care must be taken to ensure that fluids are con-

tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the machine.
Be prepared to collect the fluid with suitable con- 3. Loosen two hose clamps (3).
tainers before opening any compartment or disas-
sembling any com~onentcontainina fluids. Refer to 4. Remove radiator tube (2) from the radiator.
1 1 ~ SHOP
~ PRODUCT
~ ~ GUIDE,
~ NENG250OW,
- ~ ~ ~
. for tools and supplies suitable to colle& and contain

- / fluids in Caterpillar machines. Dispose fluids
according to local regulations and mandates.
1. Drain the radiator into a suitable container for

storage or disposal.
5. Loosen two hose clamps (5) on the water

temperature regulator housings.
6. Remove two radiator braces (4).
2. Loosen two hose clamps (1).
7. Attach .lifting slings and a suitable lifting device to

radiator (6). Radiator (6) weighs approximately
186 kg (410 Ib).

Fan
Remove & Install Fan 1356-010
Start By:
a. remove radiator
8. Remove four bolts (7) fastening radiator (6) to the

radiator support.
9. Remove radiator (6).
1. Attach a lifting sling and a suitable lifting device to

fan (1). Fan (1) weights 34 kg (75 Ib) .
2. Remove six bolts and washers (2).
3. Remove fan (1).
NOTE: To install the fan, reverse the removal steps.
End By:
10. If necessary, remove four rubber mounts (8). a. install radiator
NOTE: To install the radiator, reverse the steps for
removal.
End By:
a. install fan guard

Fan Belts Install Fan Belts 1357-012
. Tools Needed A
-) Remove Fan Belts 1357-011
BT-33-72C Borroughs Belt Tension Gauge 1
Start By:
a. remove fan NOTE: Inspect the fan belts for damage, cracks or
wear. Replace with new belts if necessary.
1. Loosen four nuts (1) fastening the fan drive bracket

to the engine. 1. Install three fan belts (2) on the pulleys.
2. Tighten bolt (3) until fan belts (2) are tightened.
3. If belts are new, tighten bolt (3) until fan belts (2)
reach a tension of 534 + 22 N (120 k 5 Ib). Use
Tool (A) to determine the belt tension.
4. If belts are used, tighten bolt (3) until fan belts (2)
+ +
reach a tension of 400 44 N (90 10 Ib). Use
Tool (A) to determine the belt tension.
2. Loosen bolt (3) to loosen fan belts (2).
3. Remove three fan belts (2).
5. Tighten four nuts (1)fastening the fan drive to the

front housing.
End By:
a. install fan

Fan Drive Disassemble & Assemble Fan
Drive 1359-017
Remove & Install Fan Drive 1359-010 Tools Needed A
1P-0510 Driver Group 1
Tools Needed A
85-1378 Stud Remover and Resetter Group 1
Start by:
Start By:
a. remove fan drive
a. remove fan belts

fan drive (1) as shown.
2. Remove four nuts and washers (2).
3. Remove fan drive (1). Fan drive weighs 23 kg

(51 Ib) .
1. Remove two bolts and bracket (4) from the fan

drive bracket assembly.
2. Remove six bolts (1) that fasten fan adapter (3) to

pulley (2).
4. Remove bracket assembly (3).
5. If necessary, remove four studs (4) with Tool (A).
NOTE: To install the fan drive, reverse the removal

steps.
End By:
a. install fan belts

3. Remove two bolts and washer (5) from the fan drive 7. Remove lip seal (11) from hub (7).
hub.
18. ~ e m o v epulley (2) from fan bracket assembly (12). '

4. Remove O-ring seal (6) from the fan drive hub.
5. Remove hub (7) from the fan drive.
9. Remove spacer (13) from fan bracket assembly

112).
6. Remove bearing (8), spacer (9) and bearing (10)

from hub (7).

10. If necessary, remove plug (14) inside fan adapter 13. Instdl pulley (2) on bracket assembly (12).
(3).
NOTE: The following steps are for the assembly of the
fan drive.
14. Use Tool (A) to install lip seal (11) into hub (7).
-Lubricatethe sealing Ilp of lip seal (11) with 1P-
0808 Lithium Grease .
1 11. If removed, install plug (14) inside fan adapter (3).
15. Install bearing (8), spacer (9) and bearing (10) into
hub (7).
12. Install spacer (13) on fan bracket assembly (12).

* ..* I
16. Install hrrBq(T)in jhs fan d$$k. W. Install six bolts (1) fastening pulley (2) to hub (7).
e m ,
(@I dl hub m.
F
17. Install 0kr7g ae& 20. lnstalibracket and tyro bolts (4) on the fan drive
-"
bracket assembly.
21. Fill jhe fan drive at the grease fitting with 1P-0808
Lithiirm Grease.
End By:
a. install fan drive
18. Instatl washer $ndbof b.~h

(5) in hub (7).

Engine Lifting Brackets Engine Support
Remove & Install Engine Lifting Remove & Install Engine
Brackets 1122-010 Support 1154-010
Start By: Start By:
a. remove exhaust manifolds a. remove crankshaft pulley & damper
1. Remove four bolts and washers (2). 1. Loosen bolt (1) closest to the engine on each side
of the generator.
2. Remove right side engine lifting bracket (1).
2. Attach two lifting slings and a suitable lifting device

3. Remove four bolts and washers (4). to radiator support (2) as shown.Remove eight
bolts, washers and nuts (4) fastening radiator
4. Remove left side engine bracket (3). support (2) to engine support (3).
NOTE: For installation of the engine lifting brackets, 3. Remove radiator support (2). The weight of radiator
reverse the steps for removal. support (2) is 25 kg (55 Ib).
End By:
a. install exhaust manifolds
, 3408C & 3412C Marine Engines 12 Disassembly & Assembly
I
Crankcase Breather
Remove & Install Crankshaft
Breather 1317-010
NOTE: The crankcase breather removal and
installation is the same for both crankcase
breathers.For simplicity, removal and installation is
shown for only one crankcase breather.
4. Attach chains and a suitable lifting device to the

engine lifting brackets as shown. The weight of the
engine is approximately 3629 kg (8000 Ib).
1. Loosen hose clamp (2).
2. Remove breather (1).
5. Support the engine with the chains and the suitable

lifting device.
6. Remove four bolts, washers and nuts (6).
7. Remove eight bolts (5).
8. Remove engine support (3).The weight of engine

support (3) is 25 kg (55 Ib) .
9. If necessaw, dace wood blocks under the enaine

where the front housing and the oil pan are mvated
to support the engine. 3. Remove O-ring seal (3).
NOTE: To install the engine support, reverse the NOTE: For installation of the crankshaft breather,
removal steps. reverse the removal steps.
End By:
a. install crankshaft pulley & damper

Crankshaft Pulley & Damper
Remove & Install Crankshaft &
Damper 1205-010
Tools Needed A
88-1378 Stud Remover and Resetter Group 1
Start By:
a. remove fan belts

4. Move dam~er(41forward far enough to attach a
lifting sling 'as s'hbwn. Attach the l'Sng sling to a
suitable lifting device.
5. Remove damper (4). Damper (4) weighs 29 kg

(64 Ib).
L
1. Remove twelve nuts (2).
2. Use two people to remove pulley (1). Pulley (1)

weighs approximately 21 kg (46 Ib).
NOTE: Adapter (6) is held in place by twelve bolts

@).Whenremoving twelve bolts (5) hold adapter (6) by
hand to prevent it from falling. -
6. Hold adapter (6) by hand, remove twelve bolts (5). kc
3. Remove pulley (3).
7. If necessary, remove twelve studs (7) with Tool (A).

C
The following steps are for the instdIatioTof
nkshaft pulley and damper.
+%
-
12. Install pulley (3) on the adapter.

-
8. If removed, install twelve studs (7) in adapter (6)

with Tool (A).
13. Place pulley (1) in position on the adapter.
14. Install twelve nuts (2). Tighten twelve nuts (12) to a

torque of 65 +- 10 N*m (48 & 7 Ib ft).
9. Place adapter (6)in position on the crankshaft.
F
End By:
10. Install twelve bolts (5). a. install fan belts
11. Install damper (4) on the adapter.

~ro-sing Cover
Remove & Install Front Housing
Cover 1151-010
I
C
Tools Needed A
85-1 378 Stud Remover and Resetter Group 1
Start By:
a. remove fan drive

3. If necessary, remove four studs (6) with Tool (A).
4. If necessary, remove three bolts and cover (5).
5. Remove nut (7).

w
6. Remove ten bolts (3) and cover (4).
1
1. Remove bolt and hose clip (1).

(-L
7. Remove gasket (9).
8. If necessary, remove stud (8) with Tool (A). f
L ?
2. Remove nut and washer (2).
i
9. If necessary, remove five nuts (1O), cover (11) and 13. If removed, apply 4C-4032 Thread Sealant to
the gasket. the threads of stud (8) and install with Tool (A).
10. If necessary, remove five studs (12) with Tool (A). 14. lnstall gasket (9).
NOTE: The following steps are for the installation of

u
the front housing cover.
15. If removed, install four studs (6) with Tool (A).
16. lnstall cover (4).

11. If removed, install five studs (12) with Tool (A).
-
' 12. Install the gasket, cover (1I), and five nuts (10).
(15 f 2 Ib ft).
+
Tighten five nuts (10) to a torque of 20 3 N-m
17. Install nut (7) and ten bolts (3).
18. If removed, install the gasket and cover (5).

Fuel Filter
Remove & Install Fuel Filter 1261-010
Tools Needed A
C
-
2P8250 Strap Wrench 1

19. lnstall nut and washer (2). nance, testing, adjusting and repair of the machine.
Be prepared to collect the fluid with suitable con-
sembling any component containing fluids. Refer to
1 "TOOLSAND SHOP PRODUCT GUIDE, NENG2500".
for tools and supplies suitable to collect and contail
fluids in Caterpillar machines. Dispose fluids
20. lnstall bolt and hose clip (1).
End By:
a. install fan drive
1. Turn the fuel supply valve to the "OFF" position.
2. Use Tool A to remove fuel filter (1).

the fuel filter.

Fuel Priming Pump 8 Filter
Base
Remove & Install Fuel Priming Pump &
Filter Base 1258 & 1262-010
Start By:
a. remove fuel filter

3. Lubricate the seal of.fuel filter (1) with clean engine Care must be taken to ensure that fluids are con-
oil prior to installation. tained during performance of inspection, mainte-
4. Use Tool (A) to install fuel filter (I). Tiqhten fuel filter Be prepared to collect the fluid with suitable con-
(I) 3/4 to I turn after contact with the filter base. tainers before opening any compartment or disas-
,- sembling any component containing fluids. Refer to
u
' 5. Turn the fuel'supply valve to the "ONn position. "TOOLS AND SHOP PRODUCT GUIDE, NENG25W1',
for tools and supplies suitable to collect and contain
1. Turn the fuel supply valve to the "OFF" position.
2. Remove two bolts (2). Remove fuel priming pump

(1) and the gasket.
3. Mark two hoses (3) for identification. Disconnect

two hoses (3) from filter base (5). Cap and plug all
openings immediately.
4. Remove two bolts and nuts (4) from the filter base.
Remove filter base (5).
NOTE: For installation of the fuel priming pump and

filter base, reverse the removal steps.
End By:
a: install fuel filter

Oil Bypass Valves Oil Filters
:
Remove & Install Oil Bypass
Valves 1314-010
Remove & Install Oil Filters 1318-010
Tools Needed A
c
Tools Needed A 2P-8250 Strap Wrench 1
2P8250 Strap Wrench 1

"TOOLS AND SHOP PRODUCT GUIDE, NENG25001',
1. Remove two oil filters (2) from oil filter base (1) with
Tool (A).

the oil filters.
-
2. Lubricate the seals of two oil filters (2) with clean
engine oil.
C
3. lnstall two oil filters (2) until contact is made with oil
filter base (1).
4. Tighten two oil filters (1) an additional 3/4 turn after

contact with the oil filter base is made.
2. Remove the filter bypass valve from the filter base.
3. Use Tool (A) to remove 011 filter (2).
NOTE: Upon installation, install oil filter (2) according

to the instructions given on the filter.
4. Remove cover (3).
5. Remove the oil cooler bypass valve from the cooler

bypass line.
NOTE: For installation of the oil bypass valves, reverse

the removal steps.
6. Check the engine oil for the corred level. See the
Operation & Maintenance Manual. - - - -- .-- --- -- -
L
3408C & 3412C Marine Engines 20 isa assembly & Assembly
Oil Filter Base
Remove & Install Oil Filter
Base 1306-010
Start By:
a. remove oil filters
FLUID SPILLAGE CONTAINMENT I

tained during performance of inspection, mainte- 1. Remove bolt (2) holding hose clip (3) in place.
nance, testing; adjusting and repair of the machine.
Be-preparedto collect the fluid with suitable con- 2. Remove eleven bolts (1) holding oil filter base (4) to
tainers before opening any compartment or disas- oil cooler (5) and cylinder block (6).
"TOOLS AND SHOP PRODUCT GUIDE, NENG2500I1, 3. Remove oil filter base (4).
,. for tools and supplies suitable to collect and contain
fluids in Caterpillar machines. Dispose fluids 4. Remove the four O-ring seals from oil filter base (4).
NOTE: For installation of the oil filter base, reverse the
removal steps. A -
End By:
a. install oil filters
6. Check the enaine oil for the correct level. See the
Operation & ~aintenanceManual.
3408C & 3412C Marine Engines 21 ' Disassembly & Assembly

Disassemble & Assemble Oil Filter
Base 1306-017
Start By:
a. remove oil filter base

tainers-before opening any compartment or disas-
"TOOLS AND SHOP PRODUCT GUIDE, NENG250OU,
fluids in caterpillar machines. Dispose fluids There is a small amount of spring force behind cover -
according to local regulations and mandates. (4). When two bolts (3) are loosened, the spring force
will be released. To prevent possible personal
'--'y
u
,rn
ji
loosen bolts (3) slowly and evenly to release the
spring force.
2. Remove two bolts (3) slowly and evenly to release

the spring force behind cover (4).
1. Remove four O-ring seals (1) from oil filter base (2).
4. Remove two springs (5) from oil filter base (2).

Oil Level Gauge
Remove & Install Oil Level
Gauge 1326-010
5. Remove two plungers (6) from oil filter base (2).
6. Remove two plugs (7) from oil filter base (2).
NOTE: For assembly of the oil filter base, reverse the

disassembly steps.
d'
End By: 1. Remove bolt, two washers and nut (1).
a. install oil filter base 2. Remove tube (2) from the engine block.
3. Remove the O-ring seal from tube (2).
NOTE: For installation of the oil level gauge, reverse

the steps for removal.

Oil Cooler
Remove & Install Oil Cooler 1378-010
Start By:
a. remove oil filter base

NOTE: The oil cooler is held in place by six bolts (2).
Hold the oil cooler in place by hand while removing six
bolts (2) to prevent the oil cooler from falling.
2. Hold oil cooler (3) in place by hand, remove six
bolts (2).
7
fluids in Caterpillar machines. Dispose fluids L

3. Remove oil cooler (3).
4. Remove the two O-ring seals from the end of oil

cooler (3).
5. Remove the gasket where six bolts (2) fasten the oil
cooler to the cylinder block.
NOTE: The following steps are for installation of the oil

cooler.
NOTE: Check the O-ring seals for damage or wear

C
prior to assembly. Replace with a new gasket if
necessary.
NOTE: Lubricate the O-ring seals with clean engine oil

prior to installation.
1. Disconnect tube (1). Cap and plug all openings

immediately.
3408C & 3412C Marine Engines 24 Disassembly 81Assembly
I
SS Aftercooler
Remove & Install
Aftercooter 1063-010
lgl tained during performance of inspection, mainte-

nance, testing,-adjusting and repair of themachine.
Be prepared t o collect the fluid with suitable con-
6. Install the gasket between the oil cooler and the sembling any component containing fluids. Refer to
cylinder block. "TOOLS AND SHOP PRODUCT GUIDE, NENG250ON,
7. Install the two O-ring seals on the end of the oil fluids in Caterpillar machines. Dispose fluids
cooler. Lubricate the two O-ring seals with clean according to local regulations and mandates.
engine oil prior to installation of the oil cooler.
u
8. Place oil cooler (3) in ~ositionand install six bolts Start By:
(2)-
a. remove fuel injection lines
9. Connect tube (1).

- 1. Remove plug (5) and drain the coolant from the
End By: aftercooler into a suitable container for storage or
disposal. Reinstall plug (5).
a. install oil filter base
2. Remove four bolts and washers (2).
3. Remove eighteen bolts (3).
4. Remove bracket (4).
5. Remove aftercooler housing (1).

6. Remove gasket (6) from cover (1). 9. Remove two O-ring seals (9).
10. Remove two adapters (10).
17. Remove four bolts and washers (7).

. ,
b 8. Remove two elbows (8).

1 11. Remove eight bolts (12).
12. Remove cooler element (11).
13. Remove two O-ring seals (13).
14. Remove eight bolts (15), aftercooler housing (14)

and the gasket.

Air Filter
Remove & Install Air Filter 1054-010
15. Remove four O-ring seals (16).
NOTE: The following steps are for installation of the

aftercooler.
NOTE: Prior to installation, check all O-ring seals for

.- damage or wear and replace if necessary. Coat the 1. Unlatch six latches (2) and remove cover (1).
seals with clean engine oil.
NOTE: For installation of the aftercooler, reverse the

removal steps.
End By:
a. install fuel injection lines
. ,
2. Remove air filter elekent (3) from the air cleaner

assembly. -
NOTE: To install the air filter element, reverse the

removal steps.

Air Cleaner Assembly
Remove & Install Air Cleaner
Assembly 1051-010
Start By:
a. remove air filter
6. Remove four bolts and washers (8) fastening air

cleaner support (7)to the flywheel housing.
NOTE: To install the air cleaner assembly, reverse the

removal steps.
\
End By:
a. install air filter
1. Remove bolt, washers and nut (1) from the bracket

fastening air cleaner assembly (2) to the engine.
2. Loosen two hose clamps (3).
3. Remove bolt, washers and nut (4) from the bracket

fastening air cleaner assembly (2) to the engine.
4. Remove three bolts (6)fastening air cleaner housing

(5) to air cleaner support (7).During assembly,
tighten three bolts (6)to a torque of 24 m 7 Nm
+
(18 5 Ib ft).
5. Remove air cleaner housing (5).

sembling any component containing fluids. Refer to 8. Attach lifting slings and a suitable lifting device to
"TOOLSAND SHOP PRODUCT GUIDE, NENG25008', the turbocharger as shown.
fluids in Caterpillar machines. Dispose fluids 9. Remove four nuts (8).
- d
Start By:
a: remove air cleaner
1a. Disconneat.tube [B]; Cap and plug all openings

irntvW/&ely.
d 1. Remove four bolts (1).

immediately.

immediately.
4. Remove two bolts (4).

immediately.

immediately.

11. Remove bolt and clip (11). 15. Install gasket (13) and gasket (14)
12. Remove tube (12) and the gasket. Cap and plug
all openings immediately.
13. Remove turbocharger (10). The weight of the

turbocharger is 47 kg (104 Ib).
16. Attach lifting slings and a suitable lifting device to

the turbocharger as shown. Install turbocharger
(10) in its original location. The weight of the
turbocharger is 47 kg (104 Ib).
17. Place tube (12) in position and install bolt and clip
14. Remove gaskets (13) and (14). (11).

the turbocharger.
18. Connect tube (9) to the cylinder block.
19. lnstall four nuts (8). Do not tighten nuts (8) at this
time. C
Disassemble & Assemble
Turbocharger 1052-017
Start By:
a. remove turbocharger
20. Install four bolts (1) connecting the elbow to the

aftercooler.
21. Loosen the V-band clamps attaching the

compressor housing and turbine housing to the
cartridge enough to allow housings to rotate.
J,
22. Position the housings with the air pipes, exhaust

'
pipes, the oil and the water lines so they are all 1. Loosen clamp (4) and retiiove hose (5).
aligned without binding.
2. Loosen clamp (2). Upon assembly tlghten ckam~t[2)
(3), (5) and (7).
23. Connect tube (2), toatorq~eofi4&IN*ni'(iQ&fI~~)~
24. Install two bolts (4) and (6) connecting the tubes to 3. Remove compreksor i3) from the cartridge
the turbocharger. assembly 'and.turbine (I),
25. Tighten the V-band clamps to 14 & 1 N*m (10 +
) 1 Ib ft).
26. Tap the V-band clamps all the way around and
retighten to 14 & 1 Nem (10 r 1 Ib ft). Do not
overtighten the clamps.
27. Tighten the four nuts (8) fastening the

turbocharger to the rear exhaust manifold to a
torque of 55 & 5 N-m (41 & 4 Ib ft).
I
w
End By:
a: install air cleaner
4. Remove pipe (6) and the two O-ring seals from

compressor (3).
5. Remove adapter (7) and the two O-ring seals from

pipe (6).

I
o. Loosen elq-np (Q).Upori a ~ e ~ b ltighten

y, clamp (9) 10. Remove three adapters (12).
to atutque of 14 +, 1 N~rn (10 % 1 Ib ft).
7. Remob catn'dge assembly (&)from turbine (1).
12. Remove adapter (14).
8. Rernave four bolts and clip^ (I 1).

13. Remove two plugs (15) from exhaust elbow (lo)
9. Remove exhaust elbow (10).
NOTE: Check all O-ring seals for wear or damage and
replace with new parts if necessary.
NOTE: For assembly of the turbocharger, reverse the

disassembly steps.
-
End By:
a. install turbocharger
.I
Fuel Injection Lines
- ,
') Remove Fuel Injection
Lines 1252-011
Tools Needed A B
5P-4996 Plug 16
5P-0405 Cap 16
4. Remove tie wraps (4).

tained during performance of inspection, mainte- 5. Remove bolt, clamps, washers and nuts (5).
L sembling any component containing fluids. Refer to
"TOOLS AND SHOP PRODUCT GUIDE, NENG2500M,
e.
6. Loosen eight nuts (6)and eight nuts (7).
7. Remove fuel injection lines (8) as a unit.
1. Remove bolt, clamps, washers and nut (1).
2. Remove bolt, clamps and washers (2).
3. Remove two bolts, clamps, washers and nuts (3).
8. lnstall Tooling (A) in the fuel injection line openings.
9. Install Tooling (6)in the openings of the fuel

injection pump and the valve covers.
3 -----
lnstall Fuel Injection Lines 1252-012
Tools Needed A B C
5P-4996 Plug 16
5P-0405 Cap 16
5P-0144 Socket 1
5. Install tie wraps (4).

wrc 3 ~ ~ 3
6. lnstall bolt, clamps, washers and nut (5).
1. Remove Tooling (A) from the fuel injection line

openings.
2. Remove Tooling (B) from the openings of the fuel

injection pump and the valve covers.
7. Install two bolts, clamps, washers and nuts (3).
8. lnstall bolt, clamp and washers (2).
9. lnstall bolt, clamps, washers and nut (1).
NOTE: If replacement lines are installed, alway:

remove the metal identification tags so vibration or
tags will not cause worn through fuel lines.
3. lnstall fuel injection lines (8) as a unit.
4. Use Tool C to tighten eight nuts (6) and eight nuts

+
(7) to a torque of 40 +. 7 N-m (30 5 Ib ft).
i
Fuel Ratio Control lnstall Fuel Ratio Control
(If Equipped) 1278-012
) Remove Fuel Ratio Control (If
Equipped) 1278-011

"TOOLS AND SHOP PRODUCT GUIDE, NENG2500n,
1. Put fuel ratio control (1) into position on the

governor housing.Make sure bolt (3) engages with
stop collar (4) in the governor housing.
1. Disconnect line (3) to fuel ratio control (1). 2. Install the bolts that hold fuel ratio control (1) to the
governor housing.
2. Remove bolts (2). Remove fuel ration control (1).
3. Connect the air line at fitting (2).
L,

Disassemble Fuel Ratio
Control 1278-015
Start By:
a. remove fuel ratio control

tainers before opening any compartment or disas- 5- Remove the three bolts (9) and cover (10).
"TOOLS AND SHOP PRODUCT GUIDE, NENG250OW, 6. Remove valve (7),diaphragm (8), retainer and
for tools and supplies suitable to collect and contain spring
7. Remove pin (12) from valve (7).
8. Remove cover (I 1) from the valve.

1. Remove two bolts (1) and the housing (2).
9. Remove the seal fromcover (1I).
2. Remove valve assembly (3).
3. Remove seal (4) and O-ring seal from valve.
4. Remove the retainer (5) and two springs (6).

Assemble Fuel Ratio
Control 1278-016

"TOOLS AND SHOP PRODUCT GUIDE. NENG2500".
4.' 'I'&&ll spring md retdner (6)in cover (8).
I@) an valve assembly (4) and in
!f& Instiall 'dkphF-kgrn
thecover. -
1. Put clean engine oil on the lip of seal (1). lnstall seal
(1) in cover (2). Install the seal so the lip is toward 6. Install covw and three bolts (I 1) that hold covers
the inside of the cover. together.
7. Put clean engine oil on seal and ring seal. lnstall the
seals (10) on valve.
8. lnstall the two springs (13), retainer, and valve

assembly (12).
9. Install housing (9) and two bolts.
NOTE: Correct adjustment must be made to the fuel

ratio control before installation. See the Systems
Operation, Testing & Adjusting Manual.
End By:
a. install fuel ratio control

2. lnstall valve (3) into cover (2).
3. lnstall the pin that holds the cover on the valve.

Service Meter
Remove & Install Service
Meter 7478-010
NOTE: Lubricate the O-ring seal with clean diesel fuel

3. Lubricate the O-ring seal with clean diesel fuel prior

to installation. Install the O-ring seal on service -
meter (1). 1
NOTE: The fuel injection lines have been removed for 4. Install service meter (1) on fuel transfer pump (3).
picture clarity.The fuel injection lines do not have to be Position service meter (1)for viewing from right
removed in order to remove the service meter. hand side of the engine.
1. Remove two bolts and clamps (2) that hold service 5. Install two bolts and clamps (2) securing service
meter (1) to fuel transfer pump (3). Remove service meter (1) to fuel transfer pump (3).
meter (I).
2. Remove the O-ring seal on service meter (1).

the service meter.
I
Fuel Transfer Pump Install Fuel Transfer Pump 1256-012
Remove Fuel Transfer

Pump 1256-011
Start By:
a. remove service meter

tainers before opening any compartment or disas- 1. Install the gasket on fuel transfer pump (2).
"TOOLS AND SHOP PRODUCT GUIDE, NENG25001', 2. Put fuel transfer pump (2) in position on the
for tools and supplies suitable to collect and contain governor.
according to local regulations and mandates. 3. Install two bolts (3).
4. Connect two fuel lines (1)to the transfer pump.
End By:
I
a. install service meter
NOTE: The fuel injection lines have been removed for

picture clarity.The fuel injection lines do not have to be
removed in order to remove the service meter.
1. Disconnect and cap two fuel lines (1) from fuel

transfer pump (2).
3. Remove fuel transfer pump (2) and the gasket.
9%
Disassemble Fuel Transfer
Pump 1256-015
Start By:
a. remove fuel transfer pump
FLUID SPILLAGE CONTAINMEN1

tainers before opening any compartment or disas- 4. Remove O-ring seal (7) from fitting (3).
"TOOLSAND SHOP PRODUCT GUIDE, NENG25001',
5. Remove three socket head bolts (8).
6. Remove cover (9) from the fuel transfer pump.
1. Remove fittings (3) and (4) from fuel transfer pump

(5).
2. Remove gasket (1) and O-ring seal (2) from fuel
transfer pump (5).
7. Remove lip seal (10) from cover (9).
3. Remove O-ring seal (6) from fitting (4).

8. Remove plug (11) from cover (9). 16. Remove gear (23) from shaft (21).
9. Remove O-ring seal (12) from plug (11).
10. Remove plug (17), two washers (16), seal (15),

, spring (14) and plunger (13) from cover (9).
11. If necessary, remove the ferrule.
17. Remove Bearing (24) from body assembly (18).
18. Remove two lip seals (25) from body assembly

(18)
12. Remove nut (20) from the shaft.

I '
13. Remove gear (19) and the key from the shaft.
19. Remove valve (26), idler shaft (28), and bearing

(27) from body assembly (18).
) 14. Remove shaft assembly (21) from body assembly

-- 1
(18).
15. Remove gear (22) from body assembly (18).

Assemble Fuel Transfer
Pump 1256-016
4. lnstall first lip seal (25) with Tooling (C). lnstall first lip
seal (25) until it is 26.19 k 0.13mm (1.031 k
.OW in) from the bottom (drive gear) surface and
with the lip facing toward bearing (27).
5. lnstall second lip seal (25) with Tooling (D). lnstall

second lip seal (25) until it is 14.2 +
0.5 rnm (.559 '-'
k .020 in) from the bottom (drive gear) surface and
with the lip facing away from bearing (27).
6. lnstall bearing (24) in body assembly (18) with

Tooling (E). The bearing (24) must be even with the
bottom (drive gear) surface of the pump body.
1. Install valve (26) with Tooling (B).
2. lnstall idler shaft (28) until flush with bottom of body

assembly (18).
3. Install bearing (27) with Tooling (A). Bearing (27)

must not extend above the (gear) surface of body
assembly (18).
7. Heat gear (23)to a maximum of 315" C (600" F).

lnstall gear (23) on shaft (21) until dimension (X) is
49.71 k 0.25 mm (1.957 +. .010 in).

2 + < ' ,,. . ...: .I"- " - . *
'b%x~lshcdt @~)k-@&i
+... ~ 9 m b j g m b b (18): 15. Install lip seal (10) in cover (9) with Tooling (C).
+
lnstall the seal until it is 22.61 0.05 mm (.890
a Ir&all gear (22) on idls~ahaft(28). + .W2 in) from the top surface of cover (9) and
with lip facing toward gears (22) and (23).
NOTlCE
Do not let the liquid gasket enter the pump during
application or assembly.
. ,
10. lnstall gear (193 on the&%,-rn~~.
8
11. Iristall rmf (20)on the sb&&Edy. T1ghBn nut

RQ)'to a torque 6 4i@% T Nm@[# f $ bft).
16. Put 7M-7260 Liquid Gasket Material on the

surface of cover (9).
17. Install cover (9) on body assembly (18).
18. lnstall three socket head bolts (8).
NOTE: The drive shaft must turn freely after sower

head bolts (8) are tightened.
12. lnstall O-ring (12) on plug (11).
13. lnstall plug (11) in cover (9).
- 14. lnstall plunger (13), spring (14). seal (15), two

washers (16) and plug (17) in cover (9).
3498C 8 3412G Marine Engines 43 Disassembly & Assembly

Fuel lnjection Pumps
Remove Fuel Injection
Pumps 1251-011
Tools Needed A B C
6V6019 Timing Pin 1
8T5287 Wrench 1
852244 Extractor 1
19. lnstall O-ring (7) on fitting (3).

20. lnstall O-ring on fitting (4).
1. Remove the plug from location (1). lnstall Tool (A) in

the hole with the square end down. Move the
governor control to the "ON" position until the rack
stops against Tool (A). The racks are now in center
(zero) position.
21. lnstall fittings (3) and (4) in the fuel transfer pump.
22. lnstall gasket (1) on the fuel transfer pump.
23. lnstall O-ring seal (2) on the fuel transfer pump.
End By:
a. install fuel transfer pump

2. Disconnect lines (2) from the fuel injection pumps. 8. Remove spacer (8)from the fuel injection pump
Remove washers (3). Put caps on all fuel openings. bore. Keep spacer (8)with respective fuel injection
pump.
3. Remove bushings (4) with Tool (6).
4. Remove fuel injection pump with Tool (C). Remove

spacer (8).
Install Fuel Injection Pumps 1251-012
NOTE: When injection pumps, spacers and lifters are
removed from the injection pump housing, keep the Tools Needed A B C
parts of each pump together so they can be installed 6V6019 Timing Pin 1 b
back in their original location. 8T5287 Wrench 11
882244 Extractor 1
5. Disassemble the fuel injection pump. Remove ring
(6). Make a separation of bonnet (5) from the
plunger and barrel assembly (7).
NOTICE
Be careful when the injection pumps are disassem- Care must be taken to ensure that fluids are con-
bled. Do not cause damage to the surface on the tained during performance of inspection, mainte-
plunger. The plunger and barrel for each pump are nance, testing, adjusting and repair of the machine.
made as a set. Do not put the plunger of one pump in Be prepared to collect the fluid with suitable con-
the barrel of another pump. If one part has wear, install tainers before opening any compartment or disas-
a complete new pump assembly. Be careful when the sembling any component containing fluids. Refer to
-, pCunger is put into the bore of the barrel. "TOOLS AND SHOP PRODUCT GUIDE, NENG2500t1,
6. Remove the gear segment, washer and spring from according to local regulations and mandates.
the barrel.
7. Remove the ring, spring, collar, and valve from the NOTE: Make sure the fuel racks are in the center
barrel. (zero) position before the fuel injection pumps are
installed.

5. Install seal (1)and bushing (15) in the pump housing
bore. If the pump is in the correct position, bushing
(15) will turn into the threads of the pump housing
with the fingers until it is even with the housing.
Tighten bushing (15) to a torque of 205 + 14 N-m
(lS0 + 10 lbaft),
/
L
6. Install washers (16).
7. Connect the fuel lines to the injection pumps and
tighten the fuel line nuts to a torque of 40 +: 7 Nwm
+
(30 5 Ib ft) with Tool (D).
8. Check for correct installation of the injection pumps

with the engine stopped. See Injection Pump
1. Put plunger (1O), washer (5)and spring (9) in
Installation in the Systems Operation, Testing &
position on barrel (4). Put check valve assembly (7),
spring (3) and collar (8) in position in bonnet (6). Adjusting Manual.
Connect bonnet (6) and barrel (4) together with ring
(2). Keep seal (1) with bonnet for use at installation.
NOTICE
2. Put spacer (13) into position in the pump housing If one or more of the injection pumps have been
bore. Make sure the correct spacer is with each installed wrong, damage to the engine is possible if
P'J"P. cautions are not taken when the engine is first start-
ed.Make preparation to close off the air intake to stop
3. Put the space in gear segment (11) in alignment the engine, if necessary.
with the groove in barrel (4).
9. Remove Tool (A) and install the plug in the pump
housing.
4. Put the injection pump straight down into the

housing bore so the space in gear segment (11) is
in alignment with pin (12) and the groove in barrel
(4) is in alignment with dowel (14). Use Tool (C) to
install the pump.
Governor & Fuel Pump Drive
\
I
Remove & Install Governor & Fuel
Pump Drive 1288-010
Tools Needed A B
98-9082 Engine Turning Pinion 1
0s-1619 Bolt 3/8-16 NC x 76 mm (3 in) long 1
Start By:
a. remove front housing cover

2. Install Tool (A).
3. Remove plug (2).
), 1. Remove cover (1).
4. Install Tool (B).
5. Turn the engine counterclockwise (as seen from the

flywheel end of engine) with Tool (A) until No. 1
piston is at top center (TC)on the compression
stroke and Tool (B) can be installed in the flywheel.
See Top Center (TC) for No. 1 piston in Testing &
Adjusting.
-- ..-- -.----
---< MA-
6. Put alignment mark on governor and fuel pump 9. Remove cover (1).
drive (3).
7. Remove four bolts (4) and retainer (5).
10. Install Tool (A).
11. Remove plug (2).

8. Remove governor and fuel pump drive (3).

the governor and fuel pump drive.
12. Install Tool (6).
13. Turn the engine counterclockwise (as seen from

the flywheel end of engine) with Tool (A) until No. 1
piston is at top center (TC) on the compression
stroke and Tool (6) can be installed in the
flywheel.See Top Center (TC) for No. 1 piston in
Testing and Adjusting.
34086 & 3412C Marine Engines 48 Disassembly 81Assembly

NOTE: Lubricate the weights and slides inside the
governor and fuel pump drive with clean engine oil
NOTE: Inspect gasket (6) for damage or wear, if

necessary replace with a new gasket.
15. Install retainer (5) and four bolts (4). Tighten four
+
bolts (4) to a torque of 136 7 N=m(101 +-
5 Ib ft).
16. Install plug (2) and cover (1).
End By:
14. Install governor and fuel pump drive (3) in position a. install front housing cover
according to the alignment mark.

Disassemble Governor & Fuel Pump
Drive 1288-015
Start By:
a. remove governor and fuel pump drive
2. Remove two springs (2) and two weights (3) from

drive gear assembly (4).
1. Remove flange assembly (I),

- -
50 Disassembly & Assembly
3. Remove two slides (5)from pistons (6).
- .
4. Separate drive gear assembly (4)from advance Install s l i w (5) on pistons (6K
sleeve (71-
5. Install advance sleeve (7) to drive gear assembly (4).
Assemble Governor & Fuel rump

Drive 1288-016 1288-016
6. Install drive gear assembly (4)on flange assembly

(1). Make sure slides (5) fit in grooves of the
weights.
,- End By:
-
. 1. Put weights (3) in position in flange assembly (1)as
shown. a. install governor and fuel pump drive
2. Install springs (2) in flange assembly (1).
3408C & 3412C Marine Engines 51 Disassembly & ~ssembly

Fuel lnjection Pump Housing &
Governor
Remove Fuel Injection Pump Housing
& Governor 1253 & 1264-011
Start By:
a. remove fuel injection lines
b. remove governor & fuel pump drive
FLUID SPILLAGE CONTAINMENT 2. Remove two bolts, washers and spacers (2).

"TOOLS AND SHOP PRODUCT GUIDE, NENG2500I1,
3. Remove two bolts, washers and spacers (3).

L
1. Disconnect two fuel lines (1) to the fuel transfer

pump. Cap or plug immediately
4. Remove three bolts and washers (4).
5. Remove bracket (5).
3408C & 3412C Marine Engines 52 Disassembly & Assembly .I

6. Remove two bolts and washers (6). 9. Attach a lifting sling and a suitable lifting device to
fuel injection pump housing &governor (9) as
7. Remove bracket (7). shown.
10. Move fuel injection pump housing & governor (9)

back towards the rear of the engine until clear of
w the governor and fuel pump drive housing.
11. Remove fuel injection pump housing & govemor

(9). The weight of the fuel injection pump housing
& governor is 56 kg (125 Ib).
.Lr
12. Remove the two O-ring seals on the bottom of the
fuel injection pump housing & govemor.
13. Remove the O-ring seal on the front of the fuel -'?
injection pump housing & governor.
8. Disconnect two hoses (8). Cap and plug all

openings immediately.
3408C & 3412C Marine Engines Disassembly & Assembly

Install Fuel Injection Pump Housing &
Governor 1253 & 1264-012
NOTE: Inspect all O-ring seals prior to installation for
wear or damage. If necessary, replace with new O-ring
seals.
NOTICE
Make sure there is no paint, dirt or other foreign mate-
rial on the machined surfaces of the engine or fuel
injection pump housing. Be careful not to damage the
O-ring seals for the oil inlet and oil outlet as the pump
is put into position on the engine.
6. Connect two hoses (8) to the fuel injection pump
housing.
1. Install the O-ring seal located on the front of the fuel

injection pump housing and govemor. 7. Put bracket (7) in position and install two bolts and
washers (6).
2. Install the two O-ring seals located on the bottom of
the fuel injection pump housing and governor.
3. Put a light layer of 5P-0960 Multi-Purpose

Grease on the O-ring seal located at the front of
the fuel injection pump housing and governor and
on the two O-ring seals found on the bottom of the
fuel injection pump housing and governor (oil inlet
and oil outlet).

fuel injection pump housing and govemor (9) as
shown.
5. Put fuel injection pump housing and governor (9) in

position on the cylinder block.
8. Put bracket (5) in position and install three bolts and
washers (4).

Governor
Disassemble Governor 1264-015
Tools Needed A 6 C
6V-6019 Timing Pin 1
1P-1856 Retaining Ring Pliers 1
1P-1855 Retaining Ring Pliers 1
9. Install two bolts, washers and spacers (3).

nance, testing,-adjusting and repair of the machine.
"TOOLS AND SHOP PRODUCT GUIDE, NENG2500N,
according to local regulations and manbates.
NOTE: The fuel injection pump housing & governor

does not have to removed from the engine to
disassemble the governor. The fuel injection pump
1 10. Install two bolts, washers and spacers (2).
housing & governor have been removed from the
engine to disassemble the governor for photographic
1.-
1
1
purposes. I.
"
11. Connect two fuel lines (1) to the fuel transfer

1. Remove plug (1) from the fuel injection pump
Pump. housing.
End By:
a. install governor & fuel pump drive
b. install fuel injection lines
34086 & 3412C Marine Engines 55 Disassembly & Assembly

2. Install Tool (A) into the fuel injection pump housing 5. Remove gasket (6) from housing assembly (5).
with the square end down. Use a small amount of
hand force to push down on Tool (A) while the fuel
control lever is moved forward to the "FUEL ON"
position until Tool (A) seats itself. The fuel rack will
stop in the center "zero" position.
L
6. Remove seven bolts (7) fastening housing assembly
(5) to plate group (8).
3. Remove wire tie (2).
4. Remove five bolts and washers (3) fastening

adapter group (4) to housing assembly (5).

10. Remove gasket ( I3) from the bottom af housing
(5).
There is spring force under collar (9). Remove sock-

et head bolt (10) slowly while holding collar (9) in
place to allow the spring force to be released grad-
ually.
7. Remove socket head bolt (10) from collar (9) while

holding collar (9) in place to prevent sudden release
of the spring force.
8. Remove spring (11).
11. Remove locknut (14).
9. If necessary, remove nut and screw (12) from collar

(9).
12. Remove cotter pin and pin (15).

13. Remove throttle control rod (16) from bracket (17).
Shaft (20) is under spring force. Remove shaft (20)

from handle (21) slowly while holding shaft (29) in
place to prevent possible personal injury. ..
-/
16. Remove shaft (20) from handle (21) by turning

counterclockwise.
17. Remove the spring from shaft (20).
18. Remove handle (21) from guide (22).

-
14. Remove locknut (18) from throttle control rod (16).
19. Remove two screws (23) from bracket (17).
C
15. Fiemove spacer and spring (19) from throttle
cantrol rod (16).
20. Remove guide (22), quadrant control (24), hub

(25), ratchet (26) and bracket (17) from the shaft.

NOTE: Mark locations af idle screws (39) and (41)

prior to removal from the housing.
33. Make alignment mark an high idle screw (39) and

remove high idle screw (39) counting the number
of turns until removed.
34. Makg qrirnent mark oQ~;ltw/dlescrew (41) and

rern6~~.5&~~&&fBwr$lJcounting the number
', '
of turn@k@i iemb@d.
. .
21. Remove two socket head bolts (27).
22. Remove lock (28).

-'
23. Remove retainer (29).
35. Remove two socket head screws (44) fastening
24. Remove insulator (30). bracket (43) to the housing.
25. Remove contact (31). 36. Remove felt washer (42) from the shaft.
26. Remove retainer (32).
27. Remove shim (33).
28. Remove bar (34).
29. Remove insulator (35).
-331. Remove bolt (37) and cover (38).

37. Remove bolt (45). 41. Remove two seals (49) from both sides of the
housing.
38. Remove shaft (47) and lever assembly (46).
42. If necessary, remove plug (50) and the O-ring seal.
Pin (48) has a large amount of spring force behind it.

The spring force will not release slowly during
removal of pin (48). Remove pin (48) very carefully to
avoid possible personal injury.
39. Remove pin (48) slowly and carefully due to the

large spring force behind it.
40. Remove the spring and the stop plunger inside

lever assembly (46).
45. Remove valve (55) from valve body (53).
46. Remove O-ring seal (54) from valve (55).
47. Remove O-ring seal (56) from valve body (53).

C
!
48. Remove seat (57) and spring (58). 52. Use Tool (6)
to remove retaining ring (63).
,A'
49. Use Tool (B) to remove retaining ring (59). 53. Remove spring seat (65) and bolt stop (64) from
the governor.
50. Remove spacer ring (60).
51. Remove spool (61) and spring (62).

56. Remove governor weight (69) from the governor.
54. Disassemble spring seat (65) and bolt stop (64) as

follows:
L
a. Remove retaining ring (68) from spring seat (65). 57. Remove four bolts (72).
b. Remove bearing (67) from spring seat (65). 58. Remove adapter plate (71)from the fuel injection
pump housing.
c. Remove bolt stop (64) from spring seat (65).
d. Remove spacer (66)from spring seat (65).
59. Remove pin assembly (74) fastening drive

assembly (73)to gear (75).
55. Remove lockring (70) from governor weight (69). 60. Remove drive assembly (73) from gear (75)

NOTE: Make a note of alignment marks on stop (76) 65. Turn adapter plate (71) over
used for installation purposes.
66. Use Tool (C) to remove retaining ring (81) from
61. Remove stop (76) from gear (75). gear (75).
67. Remove three bolts (79) and bracket assembly

(80) from adapter plate (71). -
62. Remove dowel (78) from guide (77).
63. Remove guide (77) from adapter plate (71).

68. Disassemble bracket assembly (80) as follows:
64. Remove the O-ring seal inside guide (78).
a. Remove piston (88).
b. Remove valve (87).
c. Remove pin (86).
d. Remove sleeve (85).
e. Remove O-ring seal (84)from sleeve (85).
f. If necessary, remove dowel (83) and lever (82).
-- --
3408C & 3412C Marine Engines 63 isa assembly& Assembly

69. Remove gasket (89) from adapter plate (71). 76. Remove four bolts (96) from adapter group (4).
70. Remove plug (91) from adapter plate (71). 77. Remove two covers (97) from adapter group (4).
71. Remove two dowels (90) from adapter plate (71).
72. Remove cylinder (92) from adapter plate (71).
73. Remove dowel (94) from adapter plate (71).
74. Remove bearing (93) from adapter plate (71).
78. Remove two gaskets (98) from adapter group (4).
75. Remove two O-ring seals (95) from cylinder (92).
79. Remove cover (99) from adapter group (4).

a1
80. Remove wire tie (102) from bolt stop (100). 87. If necessary, remove dowel (106) and plug (107)
*. from plate assembly (105).
81. Remove nut and washer (101) from bolt stop
82. Remove bolt stop (100) from cove; (99).

)i: ~
aa. Remove gasket ( T I 0) f r h adapter. group (4).

L
89. Remove four sbcket head bolts (108).
83. Remove gasket (103) from adapter group (4). 90. Remove lever (107) and (109).
84. Turn adapter group (4) over. 91. Remove bolt (112), lever (113) and the woodruff
key.
85. Remove bolt and washer (104) from adapter
group (4). 92. Remove shaft (111) from adapter group (4).
-4
--i 86. Remove plate assembly (105) from adapter group
(4).
a d 8 a~341% Marine Engines 65 Disassembly & Aseembly

Assemble Governor 1264-Of 6
Tools Needed
6\1-6019 Timing Pin
1P-1856 Retaining Ring Pliers
1P-1855 Retaining Ring Pliers
1P-0510 Driver Group
NOTE: Inspect all parts of governor for wear of

damage prior to assembly. If necessary, replace any
worn or damaged part with a new part. Lubricate all
O-ring seals with clean engine oil prior to assembly.
93. Remove insulator (114) from adapter group (4).
94. Remove two bearings (115) and (118) from

adapter group (4).
95. Remove two lip seals (116) and (119) from adapter
group (4).
96. Remove valve (117). Remove the 0;ring seal from
valve (117). -
-
1. Install valve assembly (120) in adapter group (4).
97. Remove valve assembly (120).

2. Install insulator (114) in adapter group (4). Tighten NOTE: Lubricate two lip seals (116) and ( I19) with
insulator (114) to a torque of 4.52 r 0.60 Nm clean engine oil prior to installation of shaft (111).
(40.000 r 5.000 Ib in).
7. lnstall shaft (111).
NOTE: All measurements involving bearing (115) are
taken at the cen'ter of the bearing. 8. Install the woodruff key and lever (1 13) on shaft
3 (11I),
3. Use Tool (D) to instatf (115) to a depth of
2.13 & 0.10 h m l0.084 .004 in) from the a. Instal bolt (112) in lever (113). -. ,
outside face of adapter group (4). . .
4. Use Tool (D) to install bearing (118) until outward

facing surface of bearing (118) is 110.84 &
0.50 mm (4.340 & .020 in) from the bottom of
bearing (115).
5. Use Tool (D) to install lip seal (116) until seated

. )
I firmly against the counterbore face with lip facing
the counterbore surface.
6. Use Tool (D) to install lip seal (119) until seated

firmly against barina (118) with lip seal facing away
from bearing ($18).
10. Install lever (107) and (109).
11. Install four socket head bolts (108) fastening levers

(107) and (109) to shaft (111).
12. lnstall gasket (110) on adapter group (4).

13. If removed, install dowel (106) in plate assembly 17. Put gasket (103) in position on adapter group (4).
(105).
14. Install plug (107)
18. Install bolt stop (100) in cover (99).

L
19. Install washer and nut (101) on bolt stop (100).
15. Put plate assembly (105) in position on adapter
group (4)- NOTE: Wire tie (102) can only be installed after final
adjustments have been made to the governor.
16. Install bolt, washers and nut (104).

21. lnstall two O-ring seals (95) on cylinder (92).
I NOTE: Lubricate the entire cvlinder and the 0-rina v
seals with 1P-0808Lithium Grease prior to

installation in plate group (71).
22. lnstall cylinder (92) in plate group (71).
23. lnstall plug (91) in plate group (71).

24. Use Tool (D)to install bearing (93) until it is 0.51 +
0.25 mm 1.0204 2 .0100in) below the top
surface & plate group (71).
20. lnstall two gaskets (98), two covers (97), cover
(99) and four bolts (96). 25. lnstall gasket (89) on plate group (71).

.22 in.
(5.58 mm)
1.
33. Put bracket (80) in position on plate group (71).
34. lnstall three bolts (79) fastening bracket (80) to

26. If a replacement of the dowels in plate group (71) plate group (71).
is necessary, see the illustration for correct
installation dimensions. 35. lnstall gear (75).
36. Use Tool (C) to install retaining pin (81) on gear
27. Put lever (82) in position on bracket (80).
28. lnstall pin (83) in bracket (80).

37. lnstall guide (77) on plate group (71).
rv. lnstall O-ring seal (84) on sleeve (85).
38. lnstall dowel (78) in guide (77).
30. lnstall valve (87) in piston (88).
31. lnstall pin (86) in bracket (80) and engage with

lever (82).
32. Engage piston (88) with pin (86).
i
NOTE: Make sure to align marks on stop (76) and NOTE: Make sure the rack is held in the "zero"
gear (75) during assembly. position with Tool (A) during installation of plate group
(71). Make sure lever (82) engages with the rack during
39. Install stop (76) in gear (75). Align alignment marks installation.
to ensure proper assembly
42. Place plate group (71) in position on the fuel
injection pump housing.
43. lnstall four bolts (72) fastening plate group 71) to

the fuel injection pump housing.
40. lnstall drive assembly (73) in gear (75).
41. lnstall pin assembly (74) in gear (75). Ensure the

ends of pin assembly (74) are engaged in the
grove of the gear.
J 44. lnstall governor weight (69) on plate group (71).
45. Install lockring (70) on governor weight (69).

Ensure the ends of lockring (70) are engaged in
the governor weight.

51. Use Tool (B) to install retaining ring (63) securing
the spring seat to the guide.
46. lnstall bolt stop (64) in spring seat (65).
47. lnstall bearing (67) in spring seat (65).
48. lnstall retaining ring (68) in spring seat (65). 52. lnstall spring (62) on the bolt stop.
49. lnstall spacer (66) in spring seat (65). 53. lnstall spool (61) on the bolt stop.
50. Install spring seat (65) and bolt stop (64) on the 54. lnstall spacer ring (60) on the bolt stop.
plate group as shown.
55. Use Tool (B) to install retaining ring (59) fastening
spacer ring (60) to the spool.
L
56. lnstall spring (58) and spring seat (57).
60. lnstall valve (53) in the housing.
61. Use Tooling (D) to install bearing (52). Dimefision

'$7is 43.38 & 0.015 rnrn (1.708 2 .0006 in).
62. Use Tooling (D) to install bearing (51). Dimension

X' is 25.35 & 0.13 rnm (.998 & .005 in).
,) 63. Check dimension "r'. Dimension "Y" must be
57. lnstall O-ring seal (54) on valve (55).
60.58 & 0.13 rnrn (2.385 & .005 in).
58. Install O-ring seal (56) on valve body (53).
59. lnstall valve (55) in valve body (56).
64. Use Tool (D) to install two lip seals (49) until they
are flush with the outside face of the housing and
with the lips of both seals facing towards the
inside.
NOTE: ~ubricatethe bore with clean engine oil before

installing plug (50).
65. lnstall plug (50) and the O-ring seal.

66. Install the stop plunger, spring and pin (48) in lever 69. Install felt washer (42) on the shaft.
assembly (46).
70. lnstall bracket (43) and two socket head bolts (44).
67. Put lever assembly (46) in position in the housing

and install shaft (47). 71. lnstall high idle screw (3)
the Same number of
turns as during removal.
68. lnstall bolt (45) in lever assembly (46)
72. Install low idle screw (41) the same number of
turna w during removal.
73. lnstall gasket (40) an the housing,

85. lnstall guide (22), quadrant control (24), hub (25),
ratchet (26) and bracket (17) on the shaft.
86. lnstall two screws (23)fastening bracket (17),to

the housing.
064050
87. lnstall the spring,<govemorcontrol shaft (20) and
handle (21).
74. lnstall cover (38) and bolt (37).
75. lnstall cover (36).
76. lnstall insulator (35).
77. lnstall bar (34).
78. lnstall shim (33).
19. lnstall retainer (32).
80. lnstall contact (31).
81. lnstall insulator (30).
82. lnstall retainer (29). 88. lnstall spring (19) and locknut (18) on throttle
control rod (16).
83. lnstall lock (28).
3
--./
84. lnstall two socket head bolts (27).
3408C & 3412C Marine Engines 75 Disassemblv & Assembly

89. Install throttle control rod (16) in bracket (17). 92. Install gasket (13) on the bottom of housing (5).
90. Install pin and cotter pin (15) fastening the throttle 93. Install screw and nut (12) in collar (9).Tighten nut
L
control rod to the quadrant. +
(12) to a torque of 12 4 Nm (106.8 +
35.6 Ib in).
91. lnstall locknut (14) on the throttle control rod.

94. lnstall spring (1I), collar (9) and socket head bolt
(10).
3408C & 3412C Marine Engines 76 Disassembly & Assembly - !'

95. Put housing (5) in position on plate group (8). NOTE: Do not install wire tie (2) until after
adjustments to the governor have been made.
96. Install seven bolts (7) fastening housing (5) to plate
100. Remove Tool (A).
97. Install gasket (6) on top of housing (5).
101. Install plug (I).
98. Put adapter group (4) in position on housing (5).
99. Install five bolts and washers (3).
. 3408C & 34126 Marine Engines Disassembly & Assembly
-------. .-
Disassemble Fuel Injection Pump
Housing 1253-015
Start By:
a. remove fuel injection pump housing and governor 2. Remove shafl(6) from rear cover (2). Remove the
gear from shaft (6). Remove the bushing from rear
b. remove governor cover (2).
3. Remove retainer (4). Remove gear (5).

4. Remwe oil pump cover (3).
NOTICE
Be careful not to damage the inlet and outlet ports on
the bottom of the pump housing. The pump housing
A13CIJJl?lnbly.
must be put on blocks before c';c-reab 5. Remove idler gear (7)-Remove pinion gear
l yfrom tha pump housing with a soft
a ~ ~ m b(3)
/
hammer eras shown. Remove drive gear (8).
u
Nm C W e n piniofl gear assembly @) iis removed,
make a repkmsment af drive gear (8)with a new part.
1. Remove bolts (1) from rear cover (2). Remove cover

(2) and the gasket.

7. Remove the bolts from levers (14) and (11). Remove 10. Install Tool (D) in the pump housing with the
shaft (16), lever (14), lever (1I), bearing (15) and square end down (end with taper will be up). Hold
spring washer (12). the racks against Tool (D) and remove each of the
injection pumps (18) with Tool (B). For more
NOTE: Step (7) is only necessary on earlier fuel details, see the topic "Remove Fuel Injection
,-
systems. Later systems have shutoff in governor Pumps*.
housing.
8. Remove bypass valve (13). Remove the O-ring seal,

pin, piston, and spring from the valve body.
11. Remove bolt (19) that holds bracket (23) to the

fuel injection pump housing. Remove bracket (23)
and link (20).
-
._ 9. Remove the felt washer from bushing (17). Remove 12. Put identification on the left rack (21) and right
bushing (17) from each of the injection pumps with rack (22).Remove racks (21) and (22).
Tool (A).

13. Ranowe!sp&c.ere t24) an& IIWrs' (25) from the 15. Remove dowel (27), shaft (28) and dowel (29) with
injsdbn p m p hoU&ng; P u t k3#%R@tion.oneach Tool (C).
' csP the spmers and liftdm as toa"'th3rdw&imln the
pump hoosit-f~. 16. Remove lower and upper bearings (30) that are
supports for the pinion assembly.
--.
17. Remove bearing (31) and the lip seal. Remove 0
bearing (32) andthe lip seal.
NOTICE
Be careful not to damage the camshaft bearings as 18. Remove the rack bearings from locations (33).
the camshaft is removed.
19. Remove the camshaft bearings with Tool (E). 4

Assemble Fuel Injection Pump
Housing 1253-016
1. Put fixture assembly (3) (part of Tool (A)) on the

pump housing with the dowels in fixture (3)
engaged in the right ~ a c kbore. Install bolt (4).
2. Put a new bearing (2) in position between fixture (3)

and the rack bore with..the tab of the bearing up.
Install the bearing with driver (1) until the shoulder of
the driver makes contact with the fixture.
3. Turn the fixture and make alignment of the dowels

on the fixture with the left ra~k~bore.Install the right
wek'bedng ack@&Qg ..i to * the instk~ctions 2.
. :,." .--
i *.

4. Install O-ring seal (5).

5. lnstall the camshaft Tront bearing (7) with Tool (6). 8. Install the lower and upper bearings for the pinion
+
lnstall the bearing until tt is 1.02 0.51 mm (.040 gear assembly with Tool (C). lnstall the upper
r .020 in) from front surface (6)of the pump bearing until it is even with the top of the bearing
housing. bore and the bottom bearing until it is even with the
bottom of the bearing bore.
NOTE: lnstall a camshaft beadngs with the bearing
joint in area 'X".
This will put the oil hole in area "Y". 9. Install shaft (11) in the pump hausing until it is
For more complete illustration of bearing installation, extended 16.76 r 0.51 mm (.SO & ,020 in) from
make reference to the Specifications Manual. the top of the pump housing.lnstal1 dowel (12) until
it is extended 11.18 r 0.51' mm (A40 r .026 in)
from the top of the pump housing.
NOTE: Steps 10 thru 13 and Step 24 apply only to

earlier fuel systems with fuel shutoff shaft in injection
pump housing.
6. lnstall center bearing (9) with Tool (6)until the rear

edge of the bearing is 127.00 r 0.51 mm (5.000
r .020 in) from rear surface (8) of the pump
housing.
7. lnstall rear bearing (I 0) with Tool (B) until it is 4.83

r 0.51 mm (.I90 2 .020 in) from rear surface (8).

14. Put clean engine oil on the camshaft bearings and
on camshaft (17),lnstall camshaft (17) as shown.
10. lnstall bearing (13) with Tool (D) until dimension "Z"
is 38.23 & 51 mm (1.505 & .MO in) Dimension
) "Z" is taken from the end of bearing (13) to the
outer face of the pump housing boss.
15. Put clean engine oii on lifters (19.). lnstall lifters (19)
11. lnstall seal (14) with Tool (D). lnstall the seal even and spacers (18) for each af'the injection pumps.
with the surface of the housing and with the lip Be sure the lifters and spacers are put in their
toward the outside as shown. original location in the pump housing.
12. lnstall bearing (15) with Tool (D) until dimension 16. Put clean engine oil fuel racks (20) and (22). Install
"R" is 34.80 & 0.51 mm (1.370 & .020 in). left rack (22) in the pump housing with the groove
Dimension "R" is the distance between bearings. in the rack engaged with the tab of the rack
bearing. lnstall right rack (20) with the groove in
the rack engaged with the tab of the rack bearing.
NOTE: The right rack has a notch (21) cut into the
rear end of the rack:
13. lnstall seal (16) with Tool (E). lnstall the seal until it
is even with the surface of the pump housing and
with the lip toward the outside as shown.

17. lnstall dowel (23) in the pump housing until it is 20. lnstall pinion gear (29) in the pump housing. Use
+
extended 12.2 +. 0.5 mm (.48 .02) from the an 11/16".Socket and a "C" clamp with a '
surface of the pump housing. minimum opening of 22.9 cm (9 inches) and

install pinion gear (29) until the pump drive gear
18. lnstall link (25) and brac'ket (26). Tighten bolt (24) makes contact with the shoulder of the pinion -.
to standard torque. Be careful so bracket (26) gear shaft. / 7
does not turn as bolt (24) is tightened. L
21. lnstall spring (30) and piston (32) in valve body

19. lnstall idler gear (27) on the shaft. Put drive gear (34). lnstall pin (33). lnstall seal (31).
(28) in position with the bevel side of the gear
down. Make sure the teeth of the idler gear and NOTE: Pin (33) must not extend out from either side "
drive gear are in alignment and install the pump of valve body (34). L
cover.
22. Put clean engine oil on valve body (34) and seal
(31). lnstall the oil bypass valve in the pump
housing.
L
26. Install cover (45).
27. Install Tool (F) in the injection pump housing with

the fat end down. Use a punch or a screwdriver
to push the rack into housing. At the same time,
push down on Tool (F) until it engages in slot
(groove) in the rack. The rack is now centered (in
the zero position) and the fuel injection pump can
he installed.
23. Remove pump cover (40) and clean the metal

clips from the fuel injection pump housing. lnstall
pump cover (40).
24. Put lever (35) bearing and spring washer (37) into
position in the pump housing. lnstall shaft (38).
lnstall lever (39). lnstall bolts (41).
25. Put gear (42) and retainer (43) into position in the
pump housing.lnstall bolts (44) and tighten to
standard torque.
28. Put the space in gear segment (47) alignment with
V the groove in pump barrel (46). Put the injection
pump straight down into the housing bore with the
space in gear segment (47) engaged with the pin
in the lifter and the groove in barrel (36) engaged
with the dowel in the pump housing. Use Tool (H)
to install the pumps.

29. Install bushing (48) in the pump housing bore. If 33. Heat gear (52) t~a ~ i m u temperature
m of
the injection pump is in the correct position, 2SaC(45O0F).lnsWIthe gear on shaft (51) until it
bushing (48) will turn into the threads of the pump makes contact with the shoulder of the shaft.
housing with the fingers until it is even with The
housing. 34. Put rear cover (4 )position on the pump
into -,
houshg with sh&-f6t) in alignment with hole (53).
30. Tiahten bushinas 1481to 205 k 14 Nem (150 +-
16 lb ft) with ~&l'
(G;).Install the felt wasier for
each injection pump. For more detail see Install
Fuel Injection Pumps.
31. Check the rack movement {lmvel)bwith Tool (K)

after each pump b installedeSee Injection Pump
Installation in the Systems Qperattan, Testing &
Adjusting Manual.
35. Install bolts (54).
End By:
a. install governor
b. install fuel injection pump housing and governor
32. Install bearing (50) in rear cover (49) with Tool (J).

Water Temperature Regulators
Remove Water Temperature
Regulators 1355-011

nance, testing, adjusting and repair of the machine.. <
sembling any component containing fluids. Refer to 5. Remove two gaskets (7).
for tools and supplies suitable to collect and contain 6. Remove two bolts (5).
according to local regulations and mandates. 7. Remove water temperature regulator housing (6).
.EF
1. Drain the coolant from the radiator until the coolant
level is below the water temperature regulator
housings.
8. Remove tube (8).
9. Remove two gaskets (9).
10. Remove two bolts (1I ) , water connector (10) ana

2. Loosen the hose clamp and disconnect radiator the gasket.
hose (1).
3. Remove four bolts (2) and tube (4).
4. Remove tube (3).
-- -
11. Loosen the hose clamp and disconnect hose (12). 17. Remove two gaskets (19).
12. Remove two bolts (13) and disconnect tube (14) 18. Remove two bolts (21), water connector (20) and
from water temperature regulator housing (15). the gasket.
13. Remove tube (16).
-
NOTE: The removal of the water tem~eraturereaulator
from the regulator housing is the same for both
14. Remove two gaskets (17). housings (7) and (15). For simplicity, only the removal
of one water temperature regulator from the regulator
15. Remove three bolts (18). housing is shown. ,
16. Remove water temperature regulator housing (15). 19. Remove gasket (22) from the water temperature
regulator housing.

Install Water Temperature
Regulators 1355-012
1 FLUID SPILLAGE CONTAINMENT

20. Remove water temperature regulator (23)from the fluids in Caterpillar machines. Dispose fluids
water temperature regulator housing. according to local regulations and mandates.
NOTE: The installation of the water temperature

regulator is the same for both water temperature
regulator housings. For simplicity, the installation of
only one water temperature regulator is shown.
NOTE: Ensure all gasket material is removed and all

mating surfaces are free of dirt, oil and grease. R~place
any damaged or worn gaskets or O-ring seals with a
new part if necessary.
21. Remove O-ring seal (24) from water temperature

regulator (23).
1. Install O-ring seal (24) on water temperature

regulator (23).

5. Put the gasket and water connector (20) in position
NOTICE on the cylinder head.
If the water temperature regulator is installed incor-
rectly, the engine will over heat. 6. Install two bolts (21) fastening water connector (20)
to the cylinder head.
2. Install water temperature regulator (23) in the water 7. Put two gaskets (19) into position on water j-'
temperature regulator housing. connector (20).
3. Install gasket (22) on the water temperature 8. Put water temperature regulator housing (15) in <
regulator housing. position on the water connector.

V
4. Repeat steps 1 through 3 for the other water 9. Install three bolts (18) fastening water temperature
temperature regulator housing. regulator housing (15) to the water connector.
10. Put two gaskets (17) into position on water

temperature regulator housing (15).
I
11. Put tube (14) into position on water ternpe~ature 16. Put water temperature regulator housing (7) in
regulator housing (15) and install two bolts (13). position on the water connector.
12. Connect radiator hose (12) and tighten the hose 17. lnstall two bolts (5) fastening water temperature
clamp. regulator housing (6) to the water connector.
4-
13. Put the gasket and water connector (10) in 18. Install tube and two bolts (3).
/ ,position on the cylinder head. lnstall two bolts (11)
fastening water connector to the cylinder head. 19. Put tube (4) and the gaskets in position and install I
four bolts (2).

-- \14. Install two gaskets (9) on the watek connector.
'd 20. Connect radiator hose (1) and tighten the hose
15. Connect tube (8)to the water connector. clamp.
-
--.-. ---
-. - - -
Water Pump
Remove Water Pump 1361-011

"TOOLS AND SHOP PRODUCT GUIDE, NENG2500", 3. Remove four bolts (3) and tube (4).
NOTE: For clarity, the radiator has been removed for

removal of the water pump. The radiator does not have
to be removed to remove the water pump.
4. Remove two gaskets (5).
1. Drain the coolant from the cooling system into a

suitable container for storage or disposal.
2. Remove two hose clamps (1) and hose (2).
5. Remove five bolts (7) and water pump cover (8).
C '
3408C & 3412C Marine Engines 92 Disassembly & Assembly -

Install water Fump 1361--012
6. Remove four bolts (9).
7. Remove two O-ring seals (10).

I. Put water pump (14) in position on the front
housing. Install the nuts and one bolt (13) that hold
pump (14) to the front housing.
8. Remove two bolts (1I), elbpw (12) and the gaskets.

..
2. Put clean engine oil on the O-rings inside elbow
(12). Install the gaskets on elbow (12).
3. Install elbow (12) in the oil cooler.
4. Install two bolts (11).
9. Remove one bolt and four nuts (13).
10. Remove water pump (14) from the front housing.
z 5
3408C & 3412C Marine Engines 93 ~ i s a s s e m b l bly

$ ~ ~
-.
--- j- ---A-
- -... . -
-
- <- .,-A
----wp
5. Install four bolts (9) fastening the water pump to 9. Install two gaskets (5).
elbow (12).
6. lnstall two O-ring seals (10). Lubricate two O-ring

seals with clean engine oil.
10. lnstall tube (4) and four bolts (3).

L
7. Put water pump cover (8) in position.
8. lnstall five bolts (7).
11. lnstall tube (2) and two hose clamps (1).
. .
- .
3408e & 3412C Marine Engines 94 Disassembly & Assembly

Disassemble Water Pump 1361-015
Tools Needed A B
892264 Puller Group 1
1PO456 Drive Plate 1
4B3903 Bolt 2
9M1974 Flat Washer 4
1P2320 Puller Assembly 1
9S9155 Step Plate 1
Start By:
a. remove water pump 4. Remove impeller (4)from the water pump housing
with Tool (A).

5. Remove seal assembly (5). Remove rirrg and seal

(6).
1. Remove O-ring seal (1) from adapter (2).
2. Remove ada~ter(2) with a screwdriver. Remove the

seal from the edgk 'of adapter (2).
6. Remove the bolt and washer that hold gear (7) on
3. Remove bolt (3) and the washer. the water pump shaft.
7. Remove gear (7) with Tool (B).
8. Remove bolts and retainer (9).
9. Remove O-rings seal (8).

10. Remove shaft (10) and bearings ae a unit. 1. Put clean oil or glycerin on the lip of seal (1). Install
seal (1) as shown with Tool (A).
11. Remove bearing - .(1I), - (13)
. spacer (12) and bearing
from shaft (10).
12. Remove the R p seal from the gear side of the

water pump, Fiemtive.flng grid mal from the
impeller side of the wa* pump.
Assemble Water Pump -1361-016
Tools Needed A
1PO529 Handle 1
2. lnstall bearing (4), spacer (3) and bearing (5) on
shaft (2). lnstall shaft (2) in the pump housing.

3. lnstall retainer (7) and O-ring seal (8).
4. lnstall gear (6). lnstall the washer and bolt that hold
gear (6) to shaft (2).

7. Install impeller (14) and the washer and nut (13)that
hold 'the inpell6r to tfe'pump 9ha:ft.
5. Put clean water on seal (9). Install seal (9) and ring 8. Tighten nut (13) tb a torque of 39 i N-rn (28 +
(10) together in the housing bore with the shiny face 1 Ib ft).
of ring (10) toward the outside.
d
9. Put clean engine oil or glycerin on O-ring seals (15).

6. Remove spring (1I ) from seal (12). Put clean water Install the O-ring seals on adapter (16).
on the inside of seal (12). Push the seal on the shaft
until the carbon face makes contact with the shiny 10. Install adapter (16) in the pump housing with the
a face or ring (10). Install spring (11). notch in alignment with dowel (17).
End By:
a. install water pump

Raw Water Pump Install Raw Water Pump 1371-012
Remove Raw Water Pump 1371-011

Care must be taken to ensure that fluids are con- Be prepared to collect the fluid with suitable con-
tained during performance of inspection, mainte- tainers before opening any compartment or disas-
nance, testing, adjusting and repair of the machine. sembling any component containing fluids. Refer to
Be prepared to collect the fluid with suitable con- "TOOLS AND SHOP PRODUCT GUIDE, NENG2500H,
tainers before opening any compartment or disas- for tools and supplies suitable to collect and contain
sembling any component containing fluids. Refer to fluids in Caterpillar machines. Dispose fluids
"TOOLS AND SHOP PRODUCT GUIDE, NENG250O1', according to local regulations and mandates.
1. Put raw water pump (2) into position on the engine.

Install the nuts and washer for studs (1).
1. Remove the inlet and outlet water lines to pump (1). 2. Install the oil supply line between raw water pump
(2) and the side of the cylinder block.
2. Remove oil supply line (2).
3. Connect the inlet and outlet water lines to raw
3. Remove nuts (3). Remove raw water pump (1).The water pump (2). L
weight of the raw water pump is 27 kg (60 Ib).

Disassemble Raw Water Pump (Earlier
Engines) 1371-015
1. Remove bolt and washw @I from raw water pump

shaft. Remove gear 43)).with Tool (F).
2. Remove housing (q,. =
\ 3, Remove cFmp (1): t%mov& md cpver (7). Remove

-J Tools Needed H plate (5) fr@mthe en&wvkr.
1U7600 Puller Group 1
4. Remove the auer pin, nut (6)and &&her. Remove
impeller with Tool (A) h d tho 8 mm bolts
a
5b.8 m e, [S~bI)long or tap the hole9 and u$e two

Start By: "P1@
5116-4%' nc 5Q1 mm (2 in) la@ bolts.
*'"
,*
a. remove raw water pump

"TOOLS AND SHOP PRODUCT GUIDE, NENG2500",
5. Remove O-ring seal (8) and ring (10).
Remove washer (9) and key (11). Remove plate

(12).
- -
11. Remove snap ring (19) with Tool (D).
7. Remove nuts (14) that hold body (13) to housing

(15).
8. Use a press to remove housing (15) and shaft (16) 12. Bend back the l o ~ fram
k nut (21). Remove nut. L
from body (13).Remove seal (17). (21) with Tool (C). Remove the bck.
9. Remove the ceramic ring from the body (13) with 13. Remove spacer (20).
Tool (B) and a press.
14. Remove shaft (16) from housing (15) with a press.

10. Remove the rubber washer from shaft (16). Do not let the shaft drop as it is removed.
Remove seal (18) with Tool (H).
15. Remove the bearing from shaft (16) with a press.
16. Remove bearing retainer (22). Remove the bearing

from housing (15) with Tool (E) and a press.
17. Remove bearing race (23) with Tool (G).

2. Install the double roller-bearing (2) in housing (1)
with Tool (C) and a press. Install the bearing until it
is against the shoulder in housing (1).

- Care must be taken to ensure that fluids are con-
I * $
3. lnstall single roller $&ring (4) on shaft (3) until it is

against the should of shaft (3).
4. Put 9s-3265 Retaining Compound to the inside

diameter of collar (5) and on shaft (3). Install collar
(5) until it makes contact with bearing (4). Remove
any excess compound.
1. Install the bearing race in housing (1) with Tool (B).

Install bearing until it is against the shoulder in
housing (1).

5. lnstall retainer (6) on housing (I
ta
)hold the double
roller bearing (2) in position.
6. Install shafi (3)and bearing (4) in housing (1) as a

unit. Ee sure that shaft 43) is in alignment with
bearing (2)and bearing ((4)is also in alignment with
it respective outer rmG.
8. lnstall seal (8) With Tool (F) until it makes contact

with sndp ring (7). lnstall rubber washer (9) (thrower)
on shaft (3). C
7. lnstall snap ring (3with Tool (D).
9. Put clean water on the ceramic ring (10). lnstall

ceramic ring (10) with Tool (A)and hand pressure.
lnstall the ring with the bevel side down.
1
10. lnstall body (13)on housing (1).lnstall nuts (15) 16. Instdl the original shims (20)if available or shims
,. ,ma-lpcks.'*J , +;; a .
' .%; %
-**, - * ,% =.T+ of a thickness of 0.51 mm (.(MO in) as a place to
start.
' , . " I -
ll.'lktan t h i sfiacsr, lodk amfnt$bn'tl% g & ~ of iki

the pump shaft.Tighten tha nut to a torque of 17. Use a micrometer and measure the thickness of
95 to I t 0 N e r n (70 to 1bfi), and bend the tab the impeller (18) and the width of ring (14) to find
of the look in the groDve.of the.nut. the difference in dimensions. This difference is
used to flnd the ahims needed to get the same
12. Put @lean,wateron seal (16). Install seal,,(l6)on amount of clearance on each side of the impeller
the pump shaft with large seaG suhce against the when it is installed in the pump.
ceramic ring. Use hand prrssure-only to install
seal (16). . a . - -. 18. Install key (19) and impeller (181.0~ the pump
shaft.
NOTE: Make a replacement d both seal (16) and
ceramic ring (10) if either is damaged or worn. NOTE: lnstall the impeller with the threaded puller
holes toward the outside.
13. lnstall washer (I 1)on the pump shaft.
./
14. lnstall plate (17) in body (13) with tabs (12) in
alignment with the notches in body (13).
15. Install the O-ring seal around ring (14).

Disassemble & k m b l e Raw Watet
Pump (Later Engines) 1371-017
Start By:
a. remove raw water pump

19. Install the washer and nut (22). Tighten the nut to
a torque of 6P qo 70 N N (45. ~ to 5;0 Ib ft). lnstall
the cotter pin to hold the nut after Step 20.
20. Use a feeler gauge to check the clearance behind Care must be taken to ensure that fluids are con-
the impeller at four locations the same distance tained during performance of inspection, mainte-
apart. Use the average of the four measurements. nance, testing, adjusting and repair of the machine.
+
The correct clearance is 0.20 0.03 rnm (.008 Be prepared to collect the fluid with suitable con-
-t- ,001 in). Make an adjustment to the shims if tainers before opening any compartment or disas-
necessary. sembling any component containing fluids. Refer to
21. Install plate (21) in cover (24) with the tabs of the for tools and supplies suitable to collect and contain
plate in alignment with the notches of cover (24). fluids in Caterpillar machines. Dispose fluids
22. lnstall ring (14) and O-ring seal (23) in cover (24).
1. Prior to disassembly, mark all components for the

assembly procedure. C
23. lnstall housing (26) on the pump.
24. lnstall gear (27) and the washer and bolt (28).
Tighten the bolt to a torque of 55 r 7 Nem (40 &
2. Remove two bolts (1) and nuts.
5 Ib ft). Use a hammer and punch and hit the
bolt. Tighten the bolt again to the same torque.
3. Remove clamp assembly (2).
25. lnstall cover (24) and clamp (25) on the pump.
4. Separate body (3) from body (4).
End By:
a. install raw water pump

5. Remove ring (5).
6. Remove seal (6).
NOTE: Check seal (6) for damage or wear. Replace if

necessary.
L
9. Bend tab on lockwasher (10) for removal.
10. Use Tool (6)

to remove nut (9).
NOTE: Whem installing nut (9), tighten to a torque of

135 to 200 Nern (100 to 150 Ib ft).
11. Remove lackwasher (10).

7. Use Tool (A) to remove impeller (7).
12. Remove collar (1I ) and seal (12).
8. Remove washer (8).
1.3. Remove four bolts (13) and washers.
NOTE: Keep washer (8) free of ail and grease .% .
contaminates. NOTE: Wheq hsta!lin$ balts (13), tighten to a torque
of 34 N-rn p 3 Ibi
*i
fi& '
14. Separate hoking(14) from body (3).

19. Use Tool (D) to remove snap ring (18).
15. Remove plate (15).
16. Remove seal group (16).

20. Place housing (14) in a press @ndremove shaft
NOTE: Seal group (16) may separate when plate (15) (19).
is removed. .. .
17. Inspect seal (17) for damage or wear. Replace if
necessary.
.
M Remove bearing (20) from shaft (19) if necessary.
. .
NOTE: If bearing (20) is removed, upon installation

heat bearing in oven to 117 "C (275 "F).
18. Use Tool (C) to remove seal (16).
NOTE: Seal (16) in the step above is part of the seal

group in Step (16).

Expansion Tank & Water Lines
R e ~ w e r ~ ~ t l sTank
i o n& WLMr
Lines 12@4-011

. s . . tainers before opening any compartment or disas-
22. Remove bearing (21) if necmary. sembling any component containing fluids. Refer to
NOTE: lf bearing (21) is removed, upon installation for tools and supplies suitable to collect and contain
cool the bearing and insure it is seated against the fluids in Caterpillar machines. Dispose fluids
counterbore in housing (14). according to local regulations and mandates.1.
Drain the coolant from the expansion tank into a suitable
container for storage or disposal.
NOTE: If race (22) is removed, up@ninstallation cool

the race and tnsurcii it is seated against the counterbore
in housing (14). 2. Fiemove the four botts from the tank drain.elbow.
%$
NOTE: Be sure all parts of the mw water pump are
thorou~hlyclean and free of d ' i and debris prior to
assembly.
-1 NOTE: For assembly of the raw water pump, reverse

the dSassembly steps.
End By: '
a. install raw water pump
3. Remove hose (1) from the top of the expansion

tank. Disconnect llne (2) to the turbocharger cooling
line. Remove bolt (4).
4. Remove bolts (3) from the temperature regulator

housings.
5. Fasten a hoist to the expansion tank. Remove bolts

(5). Remove bolts (5). Remove expansion tank. The
weight of the tank is 77 kg (170 b).

lnstall Expansion Tank & Water
Lines 1354-012

I Be DreDared to collect the fluid with suitable con-
tainers' before opening any compartment or disas-
6. Remove water line (6) and elbows. Remove fluids in Caterpillar machines. Dispose fluids
tem erature re ulator housi according to local regulations and mandates.
nHammLAeLI- ?meT b C ?'%a
&&%- m r n :,'.$i,&
7. Remove elbows (8).

1. lnstall water line (2) and elbows, lnstall elbows (3).
8. Remove water line (11) and elbows. Remove water
line (9) and elbows. Remove elbows (10).
2. lnstall water line (4) and elbows.
3. lnstall elbows (1).
4. lnstall water temperature regulator housing (6).

lnstall water line (5) and elbows.

Vibration Damper & Pulley
Remove Vibration Damper &
Pulley 1205-011
Tools Needed A
Guide Bolt1/2-13 NC x 127 mm (5 in) long 2
5. Fasten a hoist to the expansion tank. Put the tank

into position on the engine. Install four bolts (10).
6. Install bolts (11) into the temperature regulator

housings.
d 7. Connect hose (7) to the expansion tank and line (8)

to the turbocharger cooling line.
8. l n e l l hose clhnlp a i d bolt (9).

.$it.
1. Remove four nuts (2)that hold pulley (1) to the
vibration damper adapter. Remove pulley (1).
Q 9. Install four bolts (12).
10. Fill the cooling system with coolant to the correct

level.
2. Remo* two of the bolts that hold vibration damper
(3) to damper adapter (5). Install Tool (A). Remove
the remainder of the bolts that hold damper (3) to
adapter (5).
3. Fasten a hoist to damper (3). Remove damper (3).

The weight of the damper is 31 kg (68 lb).
4. Remove spacer (6).
5. Remom bolts (4) that hold adapter (5) to the

crankshaft. Remove adapter (5).

lnstall Vibration Damper & Crankshaft Front Seal & Wear
Pulley 1205-012 Sleeve
Tools Needed A
Guide Bolt 2 Remove Crankshaft Front Seal & Wear
1/2-13 NC x 127 mm (5 in) long Sleeve 1160-011
Tools Needed A B C
5P7312 Distorter 1
5P7314 Ring 1
Start By:
a. remove vibration damper and pulley
1. Put 5P-3931 Anti-Seize Compound on bolts (1).

lnstall vibration damper adapter (2) and bolts (1).
2. Install spacer (3) on adapter (2).
3. Put Tool (A) into position in adapter (2). REAR FRONT
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.
J
4. Put damper (4) into position on Tool (A). lnstall bolts

(5). Remove Tool (A) and install the last two bolts
(5). Tighten bolts (5) to 135 k 14 N-m (100 +
10 Ib ft).
5. Put the pulley into position on studs (6). lnstall the

nuts that hold the pulley to adapter (2).
1. Make at least three holes in seal (1) with a hammer

and sharp punch. C
2. Use Tool (A) to remove seal (1).

3. Install Tool (C) in the seal bore. 1. Install the front crankshaft and wear sleeve with
Tooling (A). Use the procedure that follows.
4. Install Tool (6)between Tool (C) and wear sleeve
(2). Turn Tool (B) until the tool makes a dent a. Clean and prepare the inside diameter of the
(crease) in wear sleeve (2).Do this in three or more wear sleeve and the outside of the crankshaft by
places until the wear sleeve is loose. appling 6\1-1541 Quick Cure Primer. Apply
9s-3265 Retaining Compound to the outside
5. Remove Tools (6) and (C), and remove wear sleeve diamter of the crankshaft before the wear sleeve
(2) from the crankshaft. is installed on the crankshaft. Do not let any
Quick Cure Primer or'Retaining Compond get
on the lip of the seal.
b. Install locator (3) and bolts (4) on the crankshaft.

Install Crankshaft Front Seal & Wear
Sleeve 1160-012 c. Seal (1)and wear sleeve (2) must be installed
dry.
Tools Needed
5P-1733 Locator
5P-1737 Bolt NOTICE
98-8858 Nut Make sure the seal is installed with the part number
6\1-6142 Installer
and the arrows showing crankshaft rotation toward
the outside.
d. Put wear sleeve (2) and seal (1) as a unit in
- NOTICE
The crankshaft seal and wear sleeve come as a set
and must not be separated from each other at any
position on locator (3).
e. Put installer (5) in position on locator (3).

time. Carefully read Special Instruction, SMHS8508,
that is included with each seal and wear sleeve before f. Put clean engine oil on the face of nut (6) and its
any handling of the seal group is made. contact area on installer (5). Install nut (6) on
locator (3).
g. Tighten nut (6) until the inside surface of installer

(5) comes in contact with locator (3).
NOTICE
The front and rear seals and wear sleeves have differ-
h. Remove Tooling (A) from the crankshaft seal and
ent sprial grooves in the seal. Because of this type of wear sleeve. Tooling (A) will install the seal and
design, the front seal group for an engine is different wear sleeve to the correct depth on the
from the rear seal group. If a seal group is installed on crankshaft.
the wrong end of the engine, oil can actually be taken
out of the engine instead of moving the oil back into End By:
the engine.
a. install vibration damper and pulley

Front Housing lnstall Front Housing 1151-012
Tools Needed A B
Remove Front Housing 1151-011
88-1378 StudPuller 1
5P-9736 Link Bracket 2
Tools Needed A 6
85-1378 StudPuller 1
5P-9736 Link Bracket 2
NOTE: Thoroughly clean the mating surfaces of botn
the front cover and the cylinder block of any old gasket
material. The mating surfaces must be free of all oil, dirt
Start By: or other contaminants prior to assembly.
a. remove crankshaft front seal & wear sleeve
b. remove governor & fuel pump drive
c. remove water pump
d. remove oil pan
e. Remove the engine front support.
1. If removed, put 9s-3265 Retaining Compound on

the front housing and cylinder block studs and
install with Tool (A).
2. Put clean engine oil on the O-ring seal for the fuel
injection pump housing.
3. lnstall Tool (B) on front housing (1).
4. Put a new gasket and front housing (1) into position

1. lnstall Tool (B) as shown. Attach a suitable lifting on the front of the cylinder block.
device to Tool (B).
. 5. lnstall bolts (4) that hold front housing (1) to the
2. Remove five nuts (2) and cover (3). cylinder block. -
3. Remove five bolts (4) that hold front cover (1) to the 6. lnstall cover (3) and nuts (2) on the front housing.
cylinder block.
7. Remove Tool (B).
4. Remove front cover (1) and the gasket.
8. Cut the front housing gasket even with the bottom
5. Use Tool (A) to remove the studs from the front of the cylinder block.
cover and the cylinder block.
End By:
a. install front engine supprt
b. install oil pan
c. install water pump
d. install governor & fuel pump drive
e. install crankshaft front seal & wear sleeve.
L
Camshaft
Remove Camshaft
Tools Needed
4B4277 Washers (5116 in)

989082 Engine Turning Pinion
1PO478 Driver Plate
Start By:
2. Turn the engine with Tool (B) until the bolts in
a. remove front housing camshaft rear gear (3) are visible. Remove the four
bolts.
b. remove valve lifters
3. Tum the engine until the "V" marks on the fron?
timing *gearsare in alignment. Install Tool (A)
through the flywheel housing and into gear (3).
NOTE: Tool (A) must be used to keep the rear

camshaft gear in position when the camshaft is
removed.
:?
4. Tighten Tool (A) evenly to free the rear camshaft

gear from the camshaft.
1. Remove turbocharger drain tube (1) and elbow from

the flywheel housing. Remove two studs (2).
5. Remove two bolts (5) and plate (4).
6. Remove camshaft and gear from the cylinder block.

The weight of the camshaft is approximately 26 kg
(58 Ib).
NOTICE
Be careful not to cause damage to the camshaft bear-
ings as the camshaft is removed.
7. If necessary, remove camshaft gear with Tool (C)

and a press.
- . - - ,---- - -- -- *- -
Install Camshaft 1210-012
Tools Needed
484277 Fiat Washer (5/16 in)

885467 Dial Test Indicator Group
4. Loosen the two bolts from Tool (A) to make

alignment of gear (5) and the camshaft. lnstall one
bolt through gear (5) to hold the gear in
position.Remove Tool (A).
1. Heat gear (2) to a maximum temperature of 315C

(6WF).lnstall gear (2) on camshaft (1).
5. Turn the engine with Tool (B) until all of bolts (7) are
+
installed.Tighten the bolts evenly to 25 4 W-m
+
(20 30 Ib ft). Tighten the bolts again to 25 +
4 N-m (20 k 3 Ib ft).
6. Check the camshaft end play with Tool (C). End

play must be 0.10 to 0.25 mm(.004 to .010 in). L/
7. lnstall two studs (6) until they are extended 25.4 +

2. Put clean engine oil on the lobes and journals of 1.5 mm (1.00 & .06 in) from the surface of the
camshaft (1) and on the camshaft bearings. lnstall flywheel housing. Put 95-3263 Thread Lock on
the camshaft with the "V" mark on gear (2) in the studs before installation.
alignment with the 'V mark on gear (4).
8. lnstall the oil drain tube for the turbocharger.
3. lnstall plate (3) and bolts.
End By:
a. install valve lifters
b. install front housing

Camshaft Bearings lnstall Camshaft Bearings 1211-012
Tools Needed
) Remove Camshaft Bearings 1211-011
832241 Camshaft Bearing Removal &
InstallationTool Group
Tools Needed
858293 ~xtenion
882241 Camshaft Bearing Removal 8 5P1667 Spacer Tube
InstallationTool Group
888293 Extension
5P1667 Spacer Tube
Start By:
a. remove camshaft
b. remove flywheel housing
c. remove pistons
1. Install the rear camshaft bearing and three internal

camshaft bearings with Tool (A). lnstall the bearings
from the rear of the block bore. lnstall the bearings
until the front edge of the bearing is even with the
front surface (1) of the block bore.
NOTICE
Be sure each bearing is in alignment with the cylinder
block before the bearing is installed. lnstall the bear-
ing with the oil hole in the bearing 90 + 15 degrees
1
1. Remove the rear camshaft bearing with Tool (A).
from the oil hole in the block bore.
2. Remove the remainder of the camshaft bearings
with Tool (A). Start at the rear of the engine block
and move toward the front.

Timing Gears
Remove Timing Gears 1206-011
Tools Needed
c
L1774 Spacer
1P2321 Puller Assembly
1PO531 Handle
Start By:
a. remove front housing
b. remove camshaft
Install the front camshaft bearing with Tool (A) until
it is 7.34 r 0.10 mm (.2%9 r .004 in) from the
machined surface on the front of the cylinder block
as shown.
End By:
a. install pistons
b. install camshaft
c. install flywheel housing
1. Remove four bolts (1) and plate (2). Remove front

idler gear (3).
2. Remove bearing from gear (3) with Tool (B) and a

press.
3. Remove crankshaft gear (4) with Tool (A).
I
lnstall Timing Gears 1206-012 Flywheel
Tools Needed A
Remove Flywheel 1156-011
Tools Needed
1PO531 Handle 1
6V2157 Lifting Bracket
081624 Bolt 518-1 1 NC x 25 mm (1 in) long
Guide Bolt 5/8-18 NF x 203 mm (8 in) Long
-- , .
1. lnstall the bearing' in front idler gear (1) with Tool (A)
as shown.
1. Remove two flywheel bolts from the crankshaft.
lnstall Tool (B) in the crankshaft.
2. lnstall Tooling (A) in flywheel (2). Attach a suitable

lifting device to Tooling (A). Remove the remainder
of bolts (1).
3. Remove flywheel (2). The weight of flywheel (2) is

84 kg (185 Ib).
4. If necessary, remove the ring gear from flywheel (2)

using a punch and hammer.
2. Heat crankshaft gear (2) to a maximum temperature

of 204C (400F). lnstall gear (2) with notch (4) in
alignment with the pin on the crankshaft.
3. lnstall gear (1). Make sure the "V" mark on gear (1)
is in alignment with the "V" mark on gear (2).
4. lnstall plate (3) with the groove towards gear (1).

lnstall the four bolts that hold plate (3).
End By:
a. install camshaft
b. install front housing

.-- \
-
Install Flywheel 1156-012 Generator
6V2157
OS1624
Tools Needed
Lifting Bracket
Bolt 518-11 NC x 25 mm (1 in) Long
Guide Bolt 5/8-18 NF x 203 mm (8 in) Long
A 6
1
1
2
Remove Generator 1404-011
Tools Needed A
c
Eyebolt (7/8 in) 1
2J-3505 Nut (718 in) 1
1. Heat rina aear (3)to a maximum temperature of

315" C (660" i) 'and install it on flywheel (2), so the
chamfer of the gear teeth will be toward the starter 1. Remove five bolts and spacers (1).
pinion when the flywheel is installed.
1. Install Tool (B) in the crankshaft.

3. Remove four bolts (3) and two guards (4).
2. Fasten a hoist and Tool (A) to flywheel (1). Put
flywheel (1) into position on Tool (B).
3. Put clean engine oil or 5P-0960 Multipurpose

Grease on the threads of bolts (2). Install bolts (2).
Remove Tool (B). Install the last two bolts. Tighten
bolts (2) to a torque of 270 +: 40 N-m (200 &
30 Ib ft).
4. Check the run out (eccentricity) of the flywheel. See

the topic "Flywheel & Flywheel Housing" in the
Systems Operation, Testing & Adjusting Manual.

4. Attach lifting chains and a suitable lifting device to 7. Install Tool (A) to generator (5). Attach a lifting sling
the engine lifting brackets as shown to support the and a suitable lifting device to Tool (A). The
engine. The weight of the 3408 Engine is generator weighs approximately 1270 kg (2800 Ib).
approximately 3629 kg (8000 Ib). The weight of the
3412 Engine is approximately 5443 kg (12,000 Ib).
Y
\
8. Remove sixteen bolts (7) that hold generator (5) to

the flywheel housing. ,.
5. Remove, four bolts, washers and nuts (6) that hold
geneiator (5) to the frame. , 9. Remove six bolts (8) that hold generator fan-(9) to
' the flywheel.
lo. Remove generator (5) from the engine by moving

the generator away from the engine.
6. Support the engine and put blocks underneath the

oil pan to support the engine's weight as shown.
11. Remove eight bolts (11) and shim pack (10).
3408C & 3412C Marine Engines 119 ' Disassembly & Assembly
lnstall Generator 1404-012
Tools Needed A B
Eyebolt (718 in) 1
2J-3505 Nut (718 in) 1
83-5467 Dial Indicator Test Group 1
NOTICE
Do not start the alignment procedure until the electric
set is permanently installed. If the electric set is moved
to a different location, check the alignment and make
any necessary corrections. Alignment between the 2. Position shim pack (10) in the bore of.the flywheel
generator and the engine must be correct to get the housing to check for clearance before installing on
maximum performance and the longest life from the generator (5). There must be clearance between the
electric set. outside of the shim pack and the inside diameter of
the bore in the flywheel.
??-,
--.
NOTE: Remove all dirt, burrs and paint from the 3. lnstall a full shim pack (10) on generator (5).
contact sufaces of the generator supports and the
base. All contact surfaces of the engine, the coupling 4. lnstall six bolts (11) holding the shim pack to the
and the generator must be completely clean. generator.
Typical Example
5. lnstall two 5/8-11 NC Guide Bolts in the flywheel u
1. lnstall Tool (B) on the crankshaft pulley as shown. as shown.

The tip of the indicator must touch the face of
crankshaft pulley (12). Use a bar placed between
the flywheel and the flywheel housing to push the
crankshaft toward the flywheel to remove all the
end play. Put the dial indicator in the "zero"
position. Move the crankshaft to its forward position
and make a record of the total indicator reading
FIR). The TIR is the end play of the crankshaft.
NOTICE
Damage to the engine and-or generator can result if
the electric set is run with a shim pack that does not
have the proper clearance as described in Step 2.

11. Use Tool (B) to check the crankshaft end play (do
not use force to hold the crankshaft in position if
the original crankshaft TIR is not the same. If the
TIR is less than the original value, remove the
generator and remove only enough shims (10) to
- get the original amount of end play as shown in
Step 1.
12. If adjustments were made to the shim pack, initall

the generator and again check the crankshaft end
play-
(I"?
.?
6. Attach Tool (A) to generator (5). Attach lifting strap

to Tool (A). Attach appropriate lifting device to the
) lifting strap. The generator weighs 1270 kg
(2800 Ib).
7. Install the generator. Use the guide bolts to align

shim pack (lo), generator fan (9) with the flywheel.
8. Install four bolts (8). Remove the guidebolts and

install the last two bolts (8).
9. Install sixteen bolts (7) holding the generator to the

, , flywheel housing.
10. Remove Tool (A).
NOTE: The total thickness of shim pack (10) must not

cause a reduction of crankshaft end play as measured
in setp (1).

16. Install two guards (4).
17. Install four bolts (3).
13. Support the engine from the engine lifting brackets

with chains and a suitable lifting device. The
weight of the 3408 Engine is approximately
3629 kg (8000 Ib). The weight of the 3412 Engine
is approximately 5443 kg (12,000 Ib).
18. lnstall guard (2) and five bolts, spacers and
14. Remove the wood blocks from under the oil pan. washers (1).
15. Install four bolts, washers and nuts (6) holding

generator (5) to the frame.
5
Crankshaft Rear Seal & Wear
- ,
Sleeve
'
Remove Crankshaft Rear Seal & Wear
Sleeve 1161-011
Tools Needed A B C
5P7312 Distorter 1
5P7314 Ring 1
Start By: 2. Install Tool (C) in the rear seal bore.
a. remove flywheel 3. Install Tool (B) between Tool (C) and the wear
sleeve. Turn Tool (B) until the edge of the tool
makes a flat plate (crease) in the wear sleeve. Do
this in two or more places until the wear sleeve is
loose.
4. Remove Tool (C) and the wear sleeve by hand.
1. Put holes (2) evenly around seal (1) with a sharp

punch as shown. Remove seal (1) and Tool (A).
NOTE: When a replacement of the earlier type rear

seal is made, a replacement of the wear sleeve is to be
made also. Later type seals and wear sleeves come as
a set and must be replaced as a set.
./

Install Crankshaft Rear Seal & Wear c. For ,earliertype seals, put clean engine oil on the
Sleeve 1161-012 seal lip of the seal and on the outside diameter
on wear sleeve. Make sure the lip of the seal is
5P1733 Locator
Tools Needed A B
1 1
toward the inside of the engine and the outside
diameter bevel of wear sleeve is toward the
outside of the engine.
C
5P1737 Bolt 3 3
1 6V6143 Installer 111 1 NOTE: Later type seals and wear sleeves cannot be
used again after the seals and wear sleeves are
988858 Nut 1 1
separated.
6V6142 Installer 1
d. Put the wear sleeve and seal in position on
locator (2) as a unit.
NOTICE
On later type seals,make sure the seal is installed with
the part number and the arrows showing crankshaft
rotation toward the outside.
NOTICE
On later type seals, the front and rear seals and wear
sleeves have different spiral grooves in the seal.
Because of this type of design, the front seal group for
an engine is different from the rear seal group. If a seal
group is installed on the wrong end of the engine, oil
can actually be taken out of the engine instead of
moving the oil back into the engine.
e. Put the correct installer (4) in position on locator

(2).
f. Put clean engine oil on the face of nut (3) and its
contact area on installer (4). Install nut (3) on
locator (2).
g. Tighten nut (3) until the inside surface of installer

(4) comes in contact with locator (2).
1. Install earlier crankshaft rear seals and wear sleeves W
with Tool (A) or later crankshaft rear sleeves with
Tool (A) or later crankshaft rear seals and wear NOTICE
sleeves with Tool (B) as follows: On some early engines with lip seals, if the seals goes
against the bottom of the bore, a resistance (increase
a. Install locator (2) and the bolts on the rear of the in torque) will be felt on nut (3). Do not tighten nut (3)
crankshaft. too tight or the case (body) of the seal will be dam-
aged.
b. Clean and prepare the wear sleeve inside
diameter and crankshaft outside diameter with
6\1-1541 Quick Cure Primer. Apply 98-3265 h. Remove Tool (A) or (B).
Retainer Compound to the crankshaft outside
diameter and wear sleeve inside diameter before NOTE: For more information on the crankshaft seal
wear sleeve is installed on the crankshaft. installation, see Special Instruction, SMHS7100 (for
earlier lip seals), and SMHS8508 (for later seal groups
with hydrodynamic grooves).
End By:
a. install flywheel

Flywheel musing
7 Remove Flywheel Housing 1157-011
Tools Needed A
5P9736 Lifting Bracket 2
OS1594 Bolt 3/8-16 NC x 25 mrn (1 in) long 2
Start By:
a. remove rear exhaust manifold

4. Remove four bolts and washers (5) and fuel filter
b. remove crankshaft rear seal bracket (6).
c. remove oil pan
I.Remove six bolts (2) and turbocharger mounting

bracket (1).
2. Remove turbocharger drain line (3).
5. Attach Tooling (A), lifting slings and a suitable lifting

device to the flywheel housing as shown. The
weight of the flywheel housing is approximately
191 kg (425 Ib).
6. Remove eight bolts (7),two nuts (8), two covers (9)

and the gaskets.
7. Remove twenty bolts (10).

3. Remove two bolts and washers (4).
8. Remove flywheel housing (1 1) and the gasket.
---- - -
$
--
-aL
--
-
Install Flywheel Housing 1157-012
Tools Needed A
5P9736 Lifting Bracket 2
OS1594 Bolt 3/8-16 NC x 25 mm (1 in) long 2
NOTE: Ensure front face of the flywheel housing, both

sides of the flywheel housing gasket and the rear face
of the cylinder block are completely free of all oil, fuel,
water, gasket adhesive, assembly compounds and any
other contaminants prior to assembly.
NOTE: See the topics "Flywheel Housing Runout" and

"Flywheel Housing Bore" in the Specifications Manual 1. Install the flywheel housing and cylinder block
for the correct methods of flywheel housing inspection. gasket.
2. Apply 8T-9022 RTV Silicone-Blue sealant to fill

the space at the cylinder block, flywheel housing
and oil pan joint.
.
'
3. Attach Tooling (A), lifting slings and a suitable lifting
device to the flywheel housing as shown. The
weight of the flywheel housing is approximately
191 kg (425 Ib).
4. Install flywheel housing (11).
5. Apply 4C-4030 Thread Sealant to the threads' of

twenty bolts (10).
f

11. lnstall two bolts and washers (4).
6. lnstall twenty bolts (10). Tighten in numerical

') sequence as shown to a torque of 40 + 10 N=m
12. lnstall turbocharger drain line (3).
(30 +- 7 Ib ft).
7. Tighten twenty bolts (10) again in numerical 13. lnstall turbocharger mounting bracket (1) and six
bolts (2).
sequence shown to a torque of 40 + 10 Nem
(30 r 7 lb ft).
End By:
8. lnstall two covers (9) and the gaskets.
a. install oil pan
9. lnstall eight bolts (7) and two nuts (8).
V b. install crankshaft rear seal
c. install rear exhaust manifold
10. Place fuel filter bracket (6) in position and install

-3 four bolts and washers (5).

Exhaust Manifold (rear)
Remove Exhaust Manifold
(rear) 1059-011

nance, testing, adjusting and repair of he machine.
sembling any component containing fluids. Refer to 3. Remove eight bolts, washers and nuts (3).
for tools and supplies suitable to collect and contain 4. Remove two elbows (4) and the gaskets.
Start By:
a. remove turbocharger
5. Remove six bolts, washers and nuts (7) securing

rear exhaust manifold (5) to both water cooled
exhaust manifolds.

the rear exhaust manifold.
1. Remove four bolts (2) that secure two elbows (1) to 7. Remove four nuts (6). v
the cylinder heads. Some of the bolts (2) are too
long to be removed completely, ensure they will not 8. Remove rear exhaust manifold (5) and the gaskets.
bind on the cylinder head during removal of the rear
exhaust manifold.
2. Remove the two gaskets from two elbows (1).
i
4. Install two elbows (4).
. ,
5. ,
,,eigM bo&,washergand OjS 131securvxJ
I
.two &ows ($)to the exhaust manifold. L,
.
-GF==?,
a
-- k tbe.s~skefb dat~isg6or wear prior
- f&
14 any gasket is damaged worn. 0'
a new gasket.
End By:
<. '
a. install turbocharger ,'

,
_ h a \ \ six bolts and nuts m. /

Exhaust Manifold (Water
Cooled)
Remove Exhaust Manifold (Water
Cooled) 1059-011
-
Start By:
1
-
a. remove rear exhaust manifold

"TOOLS AND SHOP PRODUCT GUIDE, NENG250On,
3. Remove O-ring s e a l
cooled exhaust r
4. Attach lifting slings a-

- xe
the water cooled
5. Remove eight nuts, vr

- n
-
a
-
a

fluids in Caterpillar machines. Dispose fluids 6. Remove left side w
-at
1 according to local regulations and mandates. and the gaskets.
7. Loosen bolt (6) to allow

-ca
1. Remove two bolts (1) and tube (21.
., 8. Loosen two bolts (7).
2. Remove the gasket and the O-ring seal from tube
(2). 9. Disconnect tube (8) fromh
-t
exhaust manifold.
3408C & 3412C Marine Engines 130 Disass
-
-3C -.--- ---- 5 -.-
--_I
Cooled) 1059-012
I FLUID SPILLAGE CONTAINMENT

nance, testing,-adjusting and repair of the machine.
tainers'before opening any compartment or disas-
sembling any component containing fiuids. Refer to
"TOOLS AND SHOP PRODUCT GUIDE. NENG2500n,
for tools and supplies suitable to collect and contain i:.
10. Remove O-ring seal (I 1)from water cooled fluids in Caterpillar machines. Dispose fluids d
3'
exhaust manifold (10). according to local regulations and mandates. r
2-

the water cooled exhaust manifold as shown.
NOTE: Inspect all gaskets and O-ring seals for gd
damage or wear. Replace with a new gasket or a new
u 12. Remove eight nuts, washers and spacers (9).
O-ring seal if necessary.
11. Remove right side exhaust manifold (10) and the
gaskets.
NOTE: Ensure all of the old gasket material is

removed prior to installation of the new exhaust
manifold gaskets.
1. Put the new gaskets in place and install right side

exhaust manifold (10).
2. Put 4C-5598 Anti-Seize Compound on the studs.

Install eight spacers, washers and nuts (9).
-
- ----.
,, ---
- - - .---- &--- +----
.- -- - -
----
. I
3. Tighten nuts (9) in the number sequence shown to 9. Tighten nuts (4) in the number sequence shown to
a torque of 38 r 6 N-m (28 r 4 Ib ft). +
a torque of 38 -1- 6 N-m (28 4 Ib ft). -
4. lnstall O-ring seal (11). 10. Install O-ring seal (3). -,
5. lnspect gasket (12) for damage or wear, replace

with a new gasket if necessary. ,
11. lnspect the gasket for tube (2) for damage or

wear, replace with a new gasket if necessary.
-.
4. Apply clean engine oil to O-ring seal (10) on the 12. Apply clean engine oil to O-ring (3) prior to w
right side exhaust manifold prior to installation of installation of tube (2).lnstalltube 2.
tube (7). lnstall tube (7).
13. lnstall two bolts and washers (1).
5. If necessary, install new gasket (12) prior to
installation of the elbow and bolts (7). Install two End By:
bolts (7)
a. install rear exhaust manifold
6. lnstall bolt (6).
NOTE: Ensure all of the old gasket material is

removed prior to installation of the new exhaust
manifold gaskets.
7. Put the new gaskets in place and install left side

exhaust manifold (5).
8. Put 4C-5598 Anti-Sieze Compound on the studs.

lnstall eight spacers, washers and nuts (4).
- b
3. Remove bolt, washer and clip (5) from right side
valve cover (4).
1. Remove nine bolts (1) from left side valve cover (2).
Remove left side valve cover (2).
4. Remove eight remaining bolts (6).
I
5. Remove right side valve cover (4).
6. Remove the gasket from right side valve cover (4);
'd
2. Remove gasket (3) from left side valve cover (2).

lnstall Valve Covers 1107-012
1. lnstall the gasket in the right side valve cover.
6. lnstall gasket (3) in left side valve cover (2).
2. lnstall right side valve cover (4).
3. lnstall eight of the nine bolts (6) leaving one opening

where the fuel line is clamped to the valve cover.
L
7. Install left side valve cover (2).
8. lnstall nine bolts (1) and tighten to a torque of 14 &

+
4 N-m (10 3 Ib ft).
1 End By:
a: install instrument'panel
4. lnstall bolt, washer and clamp (5).
5. Tighten eight bolts (6) and bolt (5) to a torque of

+ +
14 4 N-m (10 3 Ib ft).

Glow Plugs (Precombustion Install Glow Plugs 1412-012
Tools Needed A
i Chambers'
Remove Glow Plugs 1412-01 1
5P0127 Socket 1
Tools Needed A 1. Put 5P-3931 Anti-Seize Compound threads of

5P0127 Socket 1 glow plug (1).
2. lnstall glow plug (I) and tighten to a torque of 14 a

Start By
+
3 N-m (10 2 Ib ft).
a. remove valve covers

NOTICE
Be sure glow plug wire is away from the valve spring
when it is installed on the glow plug.
End By:
a. install valve covers.
-
- . 1. Disconnect glow plug wire (1) from the glow plug.
., i 2. Remove the glow plug with tool (A).
3408C 8.3412C Marine Engines Disassembly & Assembly

=uel Injection Valves
:PrecombustionChamber)
Remove Fuel Injection Valves
(Precombustion Chamber) 1254-011
Tools Needed A B
5P0144 Socket 1
5P6229 Extractor 1
Start By:
1. Disconnect the glow plug wire from the glow plug
a. remove valve covers and clip (2) from fuel line (1). Remove line (1) with
Tool (A).
1 FLUID SPILLAGE CONTAINMENT 1

NOTICE ,-
Care must be taken to ensure that fluids are con- Put protective caps on all fuel line openings. L
Be prepared to collect the fluid with suitable con- 2. Remove nut (5) that holds valve (3) in
tainers before opening any compartment or disas- precombustion chamber (4).
"TOOLS AND SHOP PRODUCT GUIDE, NENG2500", 3. Remove valve (3) with Tool (B).

lnstall Fuel Injection Valves
(Precombustion Chamber) 1254-012
Tools Needed A
5P0144 Socket 1

Be prepared to collect the fluid with suitable con- 3. lnstall nut (3) in the precombustion chamber and
+ +
tighten to 75 7 N-m (55 5 Ib ft).
"TOOLS AND SHOP PRODUCT GUIDE, NENG2500i1, 4. Install fuet line (5). Tighten the fueGline?nGts to 40,f
for tools and supplies suitable to collect and contain 7 N-m (30 f 5 Ib ft) witR Tool (A).
,. according to local regulations and mandates. 5. Connect the glow plug wire to the glow plug and
clip (4) on the fuel line. Be sure the wire is clear of
the valve spring.
End By:
a. install valve covers
1. lnstall nozzle (2) on valve body (1) finger tight.

<
' -L '2. lnstall the valve body in the precombustion

chamber. Be sure the grooves (serrations) on body
(1) are in alignment with the grooves (serrations) in
the precombustion chamber.

Fuel lnjection Valves (Direct Install Fuel lnjection Valves (Direct
Injection) Injection) 1254-012
P
Tools Needed
Remove Fuel lnjection Valves (Direct 5P0144 Socket
Injection) 1254-011 5P6229 Extractor
6W025 Sleeve
Tools Needed A B
5P0144 Socket 1
5P6229 Extractor 1
start By: Care must be taken to ensure that fluids are con-
a. remove valve covers nance, testing, adjusting and repair of the machine.
FLUID SPILLAGE CONTAINMENT sembling any component containing fluids. Refer to
"TOOLS AND SHOP PRODUCT GUIDE, NENG2500"
Care must be taken to ensure that fluids are con- for tools and supplies suitable to collect and contain-
tained during performance of inspection, mainte- fluids in Caterpillar machines. Dispose fluids
nance, testing, adjusting and repair of the machine. according to local regulations and mandates.
1. If the seal on the direct injection valve has been

removed, install a new seal as follows:
..,/
%
- M
a. Put a new seal on Tool (C).
b. Put Tool (C) over valve body (1).
1. Remove fuel line (1) with Tool (A). c. Push the seal into position on the valve body
NOTICE
Put protective caps on all fuel line openings.
2. Remove nut (3) that holds the fuel valve in adapter

; (2).
3. Remove the fuel injection valve with Tool (6).
!
Remove Fuel Injection Nozzles (Earlier
7000 Series) 1254-011
Tools Needed A B
5P0144 Socket 1
5P5195 Fuel Line Wrench 1
6V6070 Nozzle Puller Group 1
NOTE: This procedure is for earher 7000 series fuel

2. Install nozzle (2) on valve body (1) finger tight.
injection nozzles with 55.12 mm (2.170 in) adapter
bores.
Start By:

\

' 3. mshei tfi6fhel injeation MI* h dhed injection

adlawer p).Make sur6?tTe.grodves (seifationsjon according to local regulations and mandates.
, valve body 11) are in alignment with the grooves
,. , +
(&$$t@wfi
.
gckafiter (3).
L ' k . c
++*
.. .. a*
s : .*, - .
a ,
4. Installc>fienut that hold the fuel injection valve in

' . . . CI-B ~WWI76 ~
*&aqIwhten * ~ ~ -
.+: r n NOTICE
~cl&
.@$$ . Do not let the tops of the fuel nozzles turn when the
- % "
fuel lines are loosened.The nozzles will be damaged if
j (4)?,~ i $ b p nihe
, t ~ 6 o f i eline otiitl$ezide~line the top of the nozzles turn in the body.
to a t 6 7 l of 48.,& -%:m&.@8 '16 lb ft] with Tdol
(4.
End By:
a. in&aIl valve covers
1. Use Tool (A) to loosen fuel injection line (1)at the

fuel injection nozzle.

2. Disconnect fuel injection line nut (2) from head 6. Remove bolt (7) that holds clamp (6).
adapter nut (3).
7. Remove fuel injection nozzle (8) with Tool (6)as
3. Remove adapter nut (3) and the O-ring seal. follows:
4. Move adapter (4) out of valve cover base, and

remove fuel injection line (1).
3. If necessry, remadf'M[5] fromYud in]ection.lihe

- '{4.
" , . 3iS,-";2;<3,-+
4.*, .. :- &:,/ 1 *-
- + -5
,/
?.
\
1,.
NOTE: Clmp (6)")"- B & q e W d U i ~ fGel
fl
injediori n-6 (@'is lR-Z%iipSiimdTy 25:O min *
(1*00in).
" .*
-9. - -:, .%Y$- 3,s=.J-7fgv
--%,. -
.
<?, %
', *' i,
, . 8e-,;2y ;.#-+J.&&&C:..;
a. Install 6\1-6983 Adapter and 6\1-4152 Screw

(9) part of Tool (B) into fuel injection nozzle (8).
b. Install 6\1-6982 Tube Assembly (11) over the

6\1-4152 Screw. Use 28-5658 Washer and
18-2406 Nut (10) on the 6\1-4152 Screw to
pull fuel injection nozzle (8) from the adapter.
Items (10) and (1 1) are part of Tool (B).

NOTE: Earlier fuel injection nozzles are installed in
I
adapters that are below the surface of the cylinder
head.
NOTICE
-
A replacement of compression seal washer (13) and of
carbon dam seal (12) must be made each time the fuel
injection nozzle is removed.Be sure that the replace- 1. Use Tool (A) to clean adapter bore (1) for fuel
.merit compression seal washer (13) is the same color injection nozzle. Use a tap driver to turn Tool (A).
code and part number as the original compression
seal washer. If the wrong thickness washer is used,
engine damage could occur. See the Specifications
Manual for more detailed information.
8. Remove carbon dam seal (12) and compression

seal washer (13) from fuel injection nozzle (8).
Install Fuel Injection Nozzles (Earlier

7000 Series) 1254-012
Tools Needed l ~ l ~ l c l ~ l
6V4979 Seal Tool* 1
2. Install compression seal washer (3) on fuel injection
5P0144 Socket 1
nozzle (41.
.,
,- 5P5195 Fuel Line Wrench 1
4 -852245 Cleaning Tool Group 1 3. Use Tool (A) to install carbon dam seal (2) on fuel
6V4089 Reamer Assembly 1 injection nozzle (4). Refer to Special Instruction
SEHSl292 for the use of Tool (C).
* Part of 88-2245 Cleaning Tool Group

"TOOLS AND SHOP PRODUCT GUIDE, NENG250On,
for tools and supplies suitable t o collect and contain
' fluids in Caterpillar machines. Dispose fluids
, according to local regulations and mandates.
3408C & 3412C Marine Engines 141 Disassembly & Assemblv

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.
7. Use Tool (6)to tighten the inner fuel line nuts to a

+
torque of 41 +. 7 N-m (30 5 Ib ft).
4. lnstall fuel injection nozzle (4) and clamp (5) as a

unit. lnstall the bolt through the clamp into the
adapter.
8. Put clean diesel fuel oil on O-ring seal (10). lnstall

O-ring seal (10) and nut (9). Tighten nut (9) to a
torque of 30 r 5 N-m (22 r 4 Ib ft).
#k the
lnstall nut (8) for the fuel injection line, and tighten
&A . fuel injection line nut to a torque of 41 rt 7 N-rn
(30rt5Ibft).
5. lnstall O-ring seal on fuel injection line (6), and put 10. After installation of the valve covers, bleed remove
clean diesel fuel on it. the air from the fuel system. See the Systems
Operation, Testing & Adjusting Manual for the
correct procedure.
End BY:
6. lnstall fuel injection line (6). Move adapter (7) into

position in the rocker a n cover base.
-- 3408C & 3412C Marine Engines 142 Disassembly & Assembly

Fuel Injection Nozzles 8
Adapters (Later 7000 Series)
Remove & Install Fuel Injection
Nozzles & Adapters (Later 7000
Series) 1254 & 1106-010
-
NOTE: This procedure is for later 7000 Series Fuel
Injection ~ozzleswith 40.45 mm (1.593 in) adapter
bores.
Start By:

-
Care must be taken to ensure that fluids areRmn-

tained during performance of inspection, r n s t e -
tainers before opeqing any compartment or disas-
- . sembling any component containing fluids. Refer to
"TOOLS AND SHOP PRODUCT GUIDE, NENG2500H,
1. Use Tool (A), and discohect fuel line (1) at both
ends. Remove the fuel line from the engine. Cap
,, for tools and supplies suitable to collect and contain and plug all openings immediately.
according to lbcal regulations and mandates. 2. Use Tool (B) and remove retainer (2)from the d
adapter. 1
&J
3. Remove the fuel injectio" nozzles with Tool (C) as : 1
follows.
a. lnstall the 6\1-6983 Adapter and the 8T-3199

I
Screw into nozzle assembly (3).
b. Install the 8T-3198 Tube over the 8T-3199

Screw.
- ._
a c. Use the 18-4206 Nut on the 8T-3199 Screw
k
to pull the fyel injection noqle from the adapter

6 .
a
r
" 4. Remove compression seal (4) 4 d carbon dam seal
(8) from fuel injection nozzle ($
2. 5%
S 0 8 C & 3412C Marine Engines 143 ~isassembl$%Assembiy

5. Use Tool (A), and remove adapter (6) from the
cylinder head.
Precombustion Chambers
6. Remove gasket (7) and seal (5) from adapter (6). Remove Precombustion
Chambers 1106-011
NOTE: The following steps are for installation of the
fuel injection nozzles and adapters.
Tools Needed A 6
7. Use Tool (E) to clean the bore in adapter (6). Use an FT1322 Lever Assembly 1
open end wrench or tap driver to turn Tool (E). 880225 PrecombustionChamber Wrench 1
8. Inspect seal (5) for damage or wear. Replace the

seal if necessary. Start By:
9. Put washer (7) and seal (5) in position on adapter a. remove glow plugs
(6).
b. remove fuel injection valves.
10. Put liquid soap in the bores of the
and in seals (5) in the adapters.
11. Put 5P-3931 Anti-Seize Compound & the

threads of adapter (6), and install the adapter in 4
the cylinder head asspmbly.
.. tained during performance of inspection, mainte-
12. Use Tool (A), and tighten the adapter to a torque
Be prepared to collect the flu@ with suitable con-
of 205 +14 N-m (150 +10 Ib ft)
"TOOLS AND SHOP PRODUCT4GUIDE,NENG25001',
NOTICE for tools and supplies suitable to collect and contain
the correct compression seal washer (4) is fluids in Caterpillar machines. Dispose fluids
nozzle assembly is installed in the according to local regulations and-mandates. f-
copper washers are to be used with this?'
adagter.
- *
rain the coolant from the cylinder heads into a
13. Install compression seal washer (4) and use Tool uitable container for storage or disposal.
(F) to install carbon dam seal (8) on the fuel
injection nozzle.
14. Put fuel injection nozzle (3) in position in the

adapter, and install retainer (2).
15. Use ~ool'(6)

to tighten retainer (2) to a torque of
48 + +
7 N-m (35 5 Ib ft).
16. Install fuel line (1). Tighten the nuts on the fuel line
with Tool (A) to a torque of 40 2 7 N-m (30 +
5 Ib ft).
End By:

2. Make separation between the push rod rocker
arms with Tool (A). Move the rocker arms to one I
1
1
- ,
3. Remove valve bridges (1). 1. Put liquid soap on the bore of the cylinder head and
on seal (2).
4. Remove precombustion chambers with Tool (B).
2. Put 5P-3-1 Anti-Seize Compound on the-
threads-of precombustion chamber (1). Install
chamber (1) and gasket (3) in the chamber head.
- Tighten the precombustion chamber with Tool (B)
Install Precombustion to a torque of 205 2 14 N-m (150 & 10 Ib ft).
Chambers 1106-012
Tools Needed A B
FT1322 Lever Assembly 1
850225 PrecombustionChamber Wrench 1
s
-

sembling any component containing fluids. Refer to 3. Install bridges (4).
for tools and supplies suitable to collect and contain 4. ~ a k a
e connection between push rods and rockers
fluids in Caterpillar machines. Dispose fluids arms with Tool (A).
5. Check the level of the coolant in the engine.
End By:
a. install fuel injection lines
b. install glow plugs

Direct Injection Adapters
Remove Direct lnjection
Adapters 1106-011
Tools Needed A B C
5P0961 Fuel Valve Adapter Wrench 1
5P0125 Precombustion Chamber Wrench 1
Start By:
4. Loosen adapters (2) with the correct Tool (B) or (C).
a. remove fuel injection nozzles Remove the adapters from the cylinder head.
Care must be taken to ensure that fluids are con- Install Direct Injection
tained during performance of inspection, mainte- Adapters 1106-012
Be prepared to collect the fluid with suitable con- Tools Needed A B C
-
5P0961 Fuel Valve Adapter Wrench 1
for tools and supplies suitable to collect and contain 5P0125 Precombustion Chamber Wrench 1

1. Drain the coolant from the cylinder heads into a
suitable container for storage or disposal. Care must be taken to ensure that fluids are con-
"TOOLS AND SHOP PRODUCT GUIDE, NENG25001'
for tools and supplies suitable to collect and contail.,
2. Separate the push rods and rocker arms with Tool

(A). Move the rocker arms to one side.
3. Put identification marks on valve bridges (1) as to

their location on the head. Remove valve bridges
(11.

1. Put liquid soap on the bore of the cylinder head and 3. Install valve bridges (4) in their correct locations/
on seal (1).
4. Connect the push rods and rocker arms with Tool
(A)"
5. Check the level of the coolant in thb engine.
End By:
a. install fuel injection nozzles
2. Put 5P-3931 Anti-Seize Compound on the

threads of adapter (2). Install adapter (2) and gasket
(3) in the cylinder head. Tighten the adapters to the
correct torque as follows:
a. Use Tool (B) and tighten 2W-9757 Adapters to

+
a torque of 205 14 N-m (150 2 10 Ib ft) ,
4W-5733 Adapters to a torque of 135 +
L +
7 Nom (100 10 Ib ft).
b. Uee Tool (C) and tighten 7W-1902 Adapkrs to

a torque of 205 2 14 N-m (150 2 10 Ib ft).

Valve Lifters & Push Rods Install Valve Lifters & Push
Rods 1209 8~1208-012
Remove Valve Lifters & Push
Rods 1209 & 1208-011 C
Tools Needed
FT1322 Lever Assembly
5P2401 Tool Assembly
NOTE: Install a new guide spring on the valve lifter any

time the lifters are removed from the engine.
Start By:
1. Install a new guide spring on the valve lifter with
1. Turn the crankshaft with Tool (C) until there is no

Tool (A), Tool (B) and a Mft hammer.
C
pressure on rocker arm (2).
2. Make a separation between rocker arm (2) and

push rod (1) with Tool (A). Remove push rod (1).
NOTE: Put identification on each push rod as to its

location in the cylinder head.
3. Remove valve lifter (3) with Tool (B).
4. Remove spring (4) from lifter (3).
I
Rocker Shaft Assembly
Remove Rocker Shaft
Assembly 1102-011
Tools Needed A B
FT1~322 Lever Assembly 1
5P0144 Socket 1
Start By:,
. .
a. rernoiie 'valve 'kov6rs
I FLUID SPILLAGE CONTAINMENT

semblina anv com~onentcontainina fluids. Refer to
"TOOLS-AND SHOP PRODUCT GUIDE.NENG250OM,
for tools and supplies suitable t o colle,& and contain
fluids in Caterpillar machines. is pose fluids
2. Remove lifter from Tool (A). Put clean engine oil on

the lifter. Put lifter into position in the cylinder block
j with spring (2) in alignment with the hole in the
cylinder block. Push the lifter out of Tool (B) with
Tool (D).
3. Install the push rod for each lifter. Make a

connection between the rocker arms and push rods
with Tool (C).
End By:
-
. a. install valve covers
1. Remove fuel line (2) with Tool (B). Put protective

caps on all fuel openings.
2. Make a separation between rocker arm (1) and the

push rod with Tool (A). Put identification on each
valve bridge as to its location. Remove valve
bridges (3).
.---- - - -
---.-.- .-- - - - --
- -
-.- - --
--
3. Disconnect fuel lines (4) from fuel line adapters (5).
Remove locks (6). Remove adapters (5).
4. Remove bolts (8)that hold the rocker shaft

assembly (7) to the cylinder head. Remove rocker
shaft assembly (7).
Install Rocker Shaft

Assembly 1102-012
Tools Needed A B
5P0144 Socket 1
1. Put rocker shaft assembly (2) into position on the

head.
I FLUID SPILLAGE CONTAINMENT 1 2. Put clean engine oil on the threads of bolts (1) and
Care must be taken to ensure that fluids are con- install the bolts to hold rocker shaft assembly.
tained during performance of inspection, mainte- Tighten the bolts as follows:
Be prepared to collect the fluid with suitable con- a. Tighten bolts 1 through 6 in number sequence
tainers before opening any compartment or disas- shown to a torque of 270 + 25 N-m (200 & L
sembling any component containing fluids. Refer to 20 Ib ft).

for tools and supplies suitable to collect and contain b. Tighten bolts 1 through 6 in number sequence
fluids in Caterpillar machines. Dispose fluids shown again to a torque of 447 +
20 N-m
according to local regulations and mandates. (330 + 15 Ib ft).
c. Tighten bolts 1 through 6 in number sequence

shown again to a torque of 447 +
30 N-rn
(330 + 15 Ib ft).

Tools Needed A
5P0944 Puller Group 1
Start By:
a. remove rocker shaft assembly
3. Put clean engine oil on the O-ring for adapter (5).

Install adapters (5) and locks. A
e .
.* *
4. Connect fuel lines.(3) to adabters'(5). Tighten fuel
line nuts to 40 -t-. 7 Nm@l -c 5 Ib ft) ~ f i Tool
h
, (B)
i
5. ~ut':cleanengine oil Bj7 the vdve bridge dowels.

Install valve bridges (7) in their correct locations on
the cylinder head.
NOTE: Adjustment of the bridge is necessary only if

valve grinding or other reconditioning of the cylinder
head has been done. See the topic "Bridge 1. Remove retainer (1) from the shaft .
Adjustment" in the Systems Operation, Testing and
Adjusting Manual for this procedure. 2. Remove the washers and rocker arm (2).
6. Put clean engine oil on the valve bridges. Make

connection between the rocker arms (4) and push
rods with Tool (A).
7. Make an adjustment of the valve to have a

clearance of .038mm (.015 in) for intake and
-
I*.
0.76 mm (-030 in) for exhaust. See the topic "Valve
Clearance Settingnin the Systems Operation,
Testing & Adjusting Manual.
8. Install the fuel lines to fuel valves (6). Tighten the

fuel line nuts to 40 k 7 Nmm (30 k 5 Ib ft) with
Tool (B).
End By: ,
3. Use Tool (A) to m o v d ths pin t h d holds bracket
(3) to the rocker arm shaft.
4. Remove bracket (3), rocker a m (4) and the spring.
5. Remove the remainder d the rocker arms.
NOTE: The center brackets do not have pins.

Assemble Rocker Shaft Cylinder Head Asse-
Assembly 1102-016
NOTE: Make sure all parts of the rocket shaft
Remove Cylinder Head
assembly are clean before assembly. Assemblies 1100-011
Start By:
a. remove rocker shaft assembly
b. remove exhaust manifold
1. put olean engine oil on shaft (3).
2. Ihstall the center springs, ro"oakrarms and bracket.
3. Install spring (I), rocker arm (4) and bracket (2).
4. Put tape around the shaft on each side of bracket 1. Disconnect wires (2) from the valve cover bases.
(2) as shown. Put the hole in bracket (2) in Remove glow plug harnesses (1).
alignment with the hole in shaft (3)).
Put a mark on
each piece of tape in alignment with the hole in
bracket (2).
2. Remove valve cover bases (3).
C
5. Install pin (5) until it is Mended Ef.6 mm(s34in)
above the surface of bracket (2). Make sure pin (5)
is in alignment With the ma& ~FI tape b&cTre pin B
installed. Remove th@ t q ~ .
6. lnstall rocker arm (6), washers (7) and retainer (8).
NOTE: Install enough washers until the end play on each

end of the shaft is 0.12 to l.Olmm (.MEto .Oe0 in).
End By:
a. install rocker shaft assembly

.-
~ t 3 &23412C Man; ~ n ~ i n e s 152 Disassembly & Assembly

- -
NOTICE
Do not put the cylinder head down on a flat surface.
Direct injection nozzles extend out from the bottom
surface of the cylinder head and will be damaged by
the weight of the head.
NOTE: A new spacer plate gasket must be installed

when the cylinder head is removed. See Remove &
Install Spacer Plate.
Install Cylinder Head

Assemblies 1100-012
Tools Needed A 6
5P0144 Socket 1
1. Thoroughly clean the spacer plateand bottom

surface of the cylinder head. Install. a new head
gasket and water seals. Do not use any adhesives.
NOTE: A new spacer plate gasket must be used when

3. Disconnect elbow (4) to temperature regulator the cylinder head is installed. See Remove & lnstall
housing (7). Spacer Plate.
4. Remove bracket (5) and bracket (6). Remove

bracket (8). Remove the remainder of the (3/8in)
head bolts.~emovelifting bracket (9).
5. Install three 5/16 in-18 NC Forged Eyebolts in the

cylinder head. Fasten a hoist to the cylinder head.
2. Put the cylinder head into position on the spacer

plate. Be careful not to damage the head gasket or
water seals.
6. Remove cylinder head bolts (10). Remove the

cylinder head. The weight of the cylinder head is
approximately 90 kg (198 Ib) for the 3408 engine
and approximately 172 kg (380 Ib) for the 3412
engine.
-
-- - - -. - -
-. .- -
5. Put rocker shaft assembly (4) into position on the
cylinder head. Put 5P-3931 Anti-Seize
Compound on bolts (3). Install rocker shaft
assembly bolts and washers. Tighten the bolts as
follows:
i/
a. Tighten bolts 21 through 26 in number
sequence to 270 +. 25 N-m (200 & 20 Ib ft).
b. Tighten bolts 21 through 26 in number

sequence to 447 & 20 N-m (330 & 15 Ib ft).
c. Tighten bolts 21 through 26 in numbers

sequence to 447 + 20 N-m (330 +. 15 Ib ft).
3. Put 5P-3931 Anti-Seize Compound on the

threads of head bolts (1). Install the cylinder head
bolts and washers and tighten as follows:
a. Tighten bolts 1 through 20 in number sequence

to 270 & 25 N-m (200 +. 20 Ib ft).
b. Tighten bolts 1 through 20 in number sequence

to 447 & 20 N-m (330 & 15 Ib ft).
c. Tighten bolts 1 through 20 in number sequence

again to 447 +. 20 Nem (330 & 15 Ib ft.
4. Install glow plug harness (2).

6. lnstall bracket (6) and spacer (5) on the cylinder
head. Tighten bolts (9) finger tight. lnstall the bolt
) that holds bracket (6) to the automatic timing
advance housing and tighten to standard torque.
+
Tighten bolts (9) to 43 k 7 N-m (32 5 Ib ft). 13. lnstall valve cover base (21) on the cylinder head.
Tighten the bolts in the sequence shown.
7. lnstall bracket (8). Tighten bolts (11) finger tight.
Tighten bolts (7) to standard torque. Tighten bolts 14. Put clean engine oil or glycerin on the O-ring seal
(11) to43 & 7 N-m (32 + Ibft). for adapter (19). lnstall adapter (19) and lock (16).
8. Follow Step 6 for bracket (12). 15. Connect fuel line (17) to adapter (19). Tighten the
+
fuel line nut to 40 7 N-m (30 k 5 Ib ft) with
9. Put 5P-3931 Anti-Seize Compound on the Tool (B).
remainder of 3/8" head bolts (10) and tighten to
43 + 7 N-m (32 zk 5 Ib ft). 16. lnstall fuel line (20). Tighten the fuel line nuts to
+
40 2 7 N-m (30 5 Ib ft) with Tool (B).
10. lnstall lifting bracket (14).
17. Connect elbow (18) to the temperature regulator
11. Put clean engine oil on the bridge dowels and on housing
valve bridges (15).lnstall the valve bridges in their
correct locations on the cylinder head. End By:
12. Make a connection between rocker arms (13) and a. install exhaust manifold
the push rods with Tool (A). Make an adjustment
b. install rocker shaft assembly
of the valves to have a clearance of 0.38 mm
(.015 in) for inlet and 0.76 mm (.030 in) for
exhaust. See the topic "Valve Clearance Setting"
in the Systems Operation, Testing & Adjusting
Manual.

Valves
Remove Valves 1105-011
Tools Needed A 6
5S1330 Valve Spring Compressor 1
8S2263 Valve Spring Tester 1
Start By:
a. remove cylinder head assemblies
b. remove precombustion chambersldirect injection 4. Check the spring force with tool (B).Mah reference
adapters to the Specifications Manual to find the correct
-ling specificattons.
5. Do Steps 1 through 4 agein for the remainder of the

,-
valves. \
\J
Install Valves 1105-012
Tools Needed A
5S1330 Valve Spring Compressor 1
1. Put springs (1) in compression with Tool (A).
2. Remove locks from valves.
3. Remove Tool (A), rotocoil, spring and valve.
NOTE: If valves can be used again, put identification

on the valves for location at installation.
1. Put clean engine oil on the valve stem. Install spring

(2), rotocoil (1) and valve.

Valve Seat Inserts
Remove Valve Seat Inserts 1103-011
Tools Needed A
983095 Handle Assembly 1
953081 Extractor (Inlet) 1
983089 Extractor (Exhaust) 1
Start By:
a. remove valves
2. Put the springs in compression with Tool (A).
3. Install locks (3) with the thick end up.
Locks can be thrown from the valve when the spring

compressor is released if the locks are not in their
correct position.
4. Remove compressor and hit valve with a soft

hammer to be sure the locks are in their correct
position.
'j 1. Remove valve seat inserts with Tool (A).
'
5. Do Steps 1 through 4 again for the remainder of the
valves. 2. Clean and remove burns from the valve seat bore.
End By:
a. install precombustion chambersldirect injection

adapters
b. install cylinder head assemblies

d

Install Valve Seat Inserts 1103-012 Remove Valve Guides 1104-011
Tools Needed Tools Needed A

983095 Handle Assembly 9117349 Driver 1
953081 Extractor (Intake)
983089 Extractor (Exhaust)
Start By:
a. remove valves
1. Remove valve guides with Tool (A).

1. Lower the temperature of the valve and seat inserts
and install them with Tool (A).
NOTICE
Do not make the diameter of the extractor in valve
seat insert larger when theinsert is installed in the
cylinder head.
2. Grind vale seat insert according to the

specifications given in the Specifications Manual.
End By:
a. install valves

Install Valve Guides 1104-012 Bridge Dowels
Tools Needed A
Remove Bridge Dowels 1121-011
9U7349 Driver 1
5P2396 Bushing 1
Tools Needed A
5P0944 Dowel Puller Group 1
5P0942 Extractor 1
1. Put clean engine oil on the outside of the valve
guides.
Start By:
a. remove valves
2. Use Tool (A) to install valve guides. Guides must be

extended 32.3 2 0.8 mm (1.27 2 .03 in) from the
surface of the head. The inside diameter of the
guides must be 9.487 to 0.025 mm (.3735 2
.W10 in). The maximum diameter for used guides 1. Remove dowels (1) with Tool (A).
) is 9.545 mm (.3758 in).
End By:
a. install valves

Install Bridge Dowels 1121-012 Spacer Plates
Tools Needed A
Remove Spacer Plates 1221-011
5P2406 Dowel Driver 1
Start By:
a. remove cylinder head
1. Install dowels with Tool (Al. Dowels must be

+
extended 53.3 0.5 mm (2.10 & .02 in) above
the head surface. 1. Remove seals (1) from the spacer plate.
End Bv:
a. install valves
'
./
2. Install six 318"-16 NC Forcing Screws (3) in the

spacer plate. Tighten the screws evenly until the
plate is free of the dowels on the cylinder head.
NOTICE
Do not damage dowels (2) as the plate is removed.
3408C & 3412C Marine Engines 160 Disassembly & Assembly I

I'
-I
Install Spacer Plates 1221-012 Oil Pan
1. Make sure the spacer plate and the machined
surface (3) of the cylinder block are clean and free Remove<Oil Pan 1302-011
of dirt and foreign material.
2. lnstall O-ring seals (1).
3. Put a new gasket into position over dowels (2) on Care must be taken to ensure that fluids are con-
the cylinder block. tained during performance of inspection, mainte-
1. Drain the oil from the oil pan into a suitable

container for storage or disposal.
4. lnstall spacer plate (4).
NOTICE
) Both surfaces of the spacer plate, gasket and the top
of the cylinder block must be clean. Do not use a gas-
ket adhesive or other substances on these surfaces.
5. lnstall new water seals in the spacer plate.
6. Check the cylinder liner projection. See lnstall

Cylinder Liners.
2. Remove bolts (1) from around the oil pan. Use two
people to remove the oil pan. The weight of the oil
_- End By: pan is approximately 14 kg (31 Ib) for the 3408
engine and approximately 27 kg (60 Ib) for the
a. install cylinder head
3412 engine.

Install Oil Pan 1302-012 Oil Pump
Remove Oil Pump 1304-011
Start By:
a. remove oil pan
Be prepared t o collect the fluid with suitable con-
for tools and supplies suitable to collect and contain Care must be taken to ensure that fluids are con-
fluids in Caterpillar machines. Dispose fluids tained during performance of inspection, mainte-
according to local regulations and mandates. nance, testing, adjusting and repair of the machine.
fluids in Caterpillar machines. Dispose fluids,_
1.. Put a new 'qf~the oil pan. Use

into p ~ l t i o n
two people to put th@03 p a ' hta p m i o n on the
engine.
2. Install the bolts that hold pan (1) to the cylinder

block. 1. Remove four bolts (1). Remove bolt (3) and washer
Remove oil suction bell (5),bracket (4) and tube (2). -
2. Remove one bolt and washer that hold tube (8) to
oil pump (7).Removetube (8).
3. Remove three bolts (6). Remove oil pump (7).

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

tained during performance of inspection, rnainte-
for tools and supplies suitable to collect and contain Start By:
according to local regulations and mandates. a. rermle oil pump

1. Put pump (2) into position on the engine block.

Install bolts (1).
2. Put clean engine oil on the O-ring seals for the bell
tube and supply oil tube. Install the suction bell tube
and supply oil tube.
3. Install two bolts at locations (3)for the suction bell

bracket.
End By:
a. install oil pan
1. Remove the bolt and washer that hold gear (1) on

the pump shaft.
2. Remove drive gear (1) with Tool (A). Remove the

key from the shaft. Put marks on the pump bodies
so they can be assembled in the correct position.
3408C & 3412C Marine Engines Disassembly 81Assembly
-- - .- -. - -. - -- - - I
3. Remove retainer (3) for the bypass valve. Remove 6. Remove gears r).
Put marks on the gears so they
the spring- and bypzss valve. can be assembled in the same position.
5,' .%-' <,
4. &mbve Jx~lts %%it ka@ @Wi@ @$thyf2) ta the 7. Remove spacer (6) from the main pump body (5).
main pump body. Remuvefiep h p body. R6rnowa the baring8 from spacer (8)with Tool (C). .
5. Remove the bmrhgs from pump body (2)with Tool & Rmov8 the gmrs from main puiilp body (6). 'Ll
(El.
% Removethe be&ngs Worn the m i n pump body
with Tool1(C).
!
Assemble Oil Pump 1304-016

tained during performance of inspection, rnainte- 1. Use Tool (A) to install bearings (2) until they are
nance, testing, adjusting and repair of the machine. even with the outside surface of main pump body
Be prepared to collect the fluid with suitable con- (1). lnstall bearings (2) so the junctions in the
tainers before opening any compartment or disas- bearings are 30 -1- 15 degrees from the center line
- sembling any component containing fluids. Refer to

of the M q g bares and tgward the oil pump outlet
passage as shown.
2. lnstall bearings (3) in the spacer with Taol (A). lnstall

the bearings until they are in position the same
distance in from each side of the spacer. Install the
bearings with the oil holes in the bearing in
alignment with the oil holes in the spacer and the
junctions in the bearings in alignment with the cavity
in the spacer as shown. - .
%
3. Put clean engine oil small gears and bearings

before they are assembled in the oil pump. Install
the idler and drive gears (5) in the main pump body.
4. lnstall spacer (4) on the gear shafts with the smaller

cavity and the oil holes in spacer toward the pump
outlet passage as shown.
- - - -
BEARING JUNCTION
9. Install gear (13) on the shaft. lnstall the washer and

bolt that hold gear (13) on the ehaft. Be wre the
pump turns freely after assembly.
5. Use Tool (8)to install bearings (6) in the pump body
(7) until they are 1.52 f 0.25 mm (.060 f .001 in) End By:
from the inside edge of the bearing bores. Install
the bearings so the junctions in the he bearings are a. install oil pump
30 f 15 degrees from the center line of the
bearing bores and toward the outlet passage. The
outlet passage has a cavity between the bearing
bores.
6. lnstall pump gears (8) on the oil pump shafts in their

original position.
7. lnstall pump body (10). lnstall bypass valve (9),

spring (11) and retainer (12).
8. lnstall the key on the shaft.
I
Connecting Rod Bearings NOTICE
-
Be careful not to damage the crankshaft journals. Do
Remove 8 Install Connecting Rod not turn the crankshaft while any of the connecting
rod cam are removed.
Bearings 1219-010
Tools Needed A NOTE: The following steps are for the installation of
989082 Engine Turning Pinion 1 the connecting rod bearings.
Start By:
a. remove oil pump
NQTE: If the bearing.clearances are to be checked

with Plastiggge, do not put oil on the parts until the
bearing clearance has been checked.
5. Install the upper bearings in connecting rods. Put

clean engine oil on the bearings and on the
1. Check each connecting rod cap for its location on
) the crankshaft. Each cap must have a number (1)
crankshal? journals. Slowly pull the connecting rods
on the crankshaft.
which is the same as the number on the connecting
rod. Do not mix bearings. 6. Put clean oil on the lower bearings. Install the lower
bearings in the connecting rod c-aps.
2. Use Tool (A) to turn the crankshaft until two of the
pistons are at bottom center. NOTE: Be sure tab (3)on the back af the bearings fits
in the groove of the Caps and connecting rods.
3. Remove connecting rod caps (2). Remove the lower
bearing from the connecting rod caps. NOTE: When connecting rod caps are installed, make
--- 4. Push the connecting rods away from the crankshaft sure the number on the s i d of
~ the cap is next to, and
respective with, the number on the side of the
and remove the upper bearings from the connecting rod.
connecting rods.

NOTICE
Do not use an impact wrench to tighten the nuts the
additional 120 degrees (1/3of a turn).
8. Remove the cap and measures the Plastigage. The

C
rod bearing clearance for new bearings must be
0.071 to 0.168 mm (.0028 to .0066 in).The
maximum clearance for used bearings is 0.25 rnrn
(.010 in).
9. Put bearing cap (2) in position and tighten the bolts

as in Step 7.
10. Do steps 1 through 9 for the other connecting rod

bearings.
End By:
a. install oil pump
7. Make a check of the bearing clearance with

Plastigage (4). Put clean engine oil on bolt threads
(5). Put caps (2) in position on the connecting rods
and install the nuts. Tighten the nuts with the
procedure that follows:
a. Tighten each nut (6) to a torque of 80 2 9 N-m

(60 + 6 Ib ft).
b. Put a mark across the nuts and bolts. Tighten

the nuts 120 degrees (1/3 of a turn) more.

Piston cooling Tubes Install Piston Cooling Tube 1331-012
1. Put the cooling tube in position on the cylinder
] Remove Piston Cooling block and install the screw that holds the cooling
Tubes 1331-011 tube to the block.
Tools Needed A
2. Tighten the screw to a torque of 24 2 7 N*m (18 +-
5 Ib ft).
989082 Engine Turning Pinion 1
Start By:
a. remove oil pump
1. Use Tool (A) to tum the crankshaft until pistons are

clear of the cooling tube to be removed.
3. With the piston at the bottom of the bore, check

the clearance between piston and wlirrg tube with
a piece of wire (1) 0.62 mm (.025 in) thick. If the
clearance is less than 0.63 mm (.250 in) , make a
replacement of'the tube.
NOTICE
The cooling tubes must fit evenly against the cylinder
2. Remove screw (1) that holds the piston cooling block. If they do not, it will cause an oil loss in the
tube. Remove the piston cooling tube. engine oil system.
NOTICE End By.

Do not remove the adapters for No. 1 and No. 12 pis-
ton cooling tubes on engines with Serial Numbers a. install oil pump
V
38S1 through 383890. The engine cylinder blocks that
use the adapters are identified by a 10-24 threaded
screw hole next to the piston cooling tube mounting
hole.

Pistons
Remove Pistons 1214-01 1
Tools Needed A
989082 Engine Turning Pinion 1
Start By:
a. remove cylinder head assemblies
b. remove oil pump

4. Push the pistons up until the piston rings are clear
c. remove piston cooling tubes of the cylinder liner. Remove pietons (2).
NOTE: Keep each cap with the respective connecting

NOTICE rod.
If the piston cooling tubes are not removed, it is pos- L
sible for the connecting rod to hit the piston cooling
tubes. This can move the piston cooling tube out of NOTICE
alignment. A piston cooling tube that is not in align- Da m a t turn the crankshaft while any oF the connect-
ment will not direct the lubricant to the correct loca- ing r d a are in the engine wIthd* the Wips installed.
tion. The result can be piston seizure. LW mat; dm- the cb&tSngtubes v&h'&ntRe p~stcms
aua removed.
I.Remove the carbon from the top inside surface of
the cylinder liners. 5. Do Steps 1 through 4 for the remainder of the
pistons.
2. Turn the crankshaft with Tool (A) until two pistons (c
are at bottom center.
3. Remove bearing caps (1) from the two connecting

rods. Put pieces of rubber hose or tape on the
threads of the connecting rod bolts as protection
for the crankshaft.

Install Pistons 1214-012 S
+7&
F"--
",,
t
] -1
NOTICE
Do not use an impact wrench to tighten the nuts the
Tools Needed A additional 120 degrees (1/3of a turn) more.
)' 5P3526 Piston Ring Compressor 1
5. Check the side clearance between two connecting-

rods on the same crankshaft journal. Clearance
1. Put clean engine oil on the piston rings, connecting must be 0.28 0.84 mrn (.011 t o .033in) for new
rod bearings and cylinder liners.
rods.
6. Do Steps 1 through 5 for the remainder of the

pistons.
End by:
a. install piston cooling tubes
b. install oil pump
c. install cylinder head assemblies
Disassemble & Assemble Pistons

(Earlier - Rod Pin Bearing With Straight
Sides) 1214-017
2. Put two pistons in position opposite of each other

in the correct bore of the block. lnstall pistons (1)
-/ Start By:
with tool (A).
a. remove pistons
NOTICE 1. Remove the bearings from the connecting rod and

Be sure that the pistons are installed with flat surfaces connecting rod cap.
(2) of the connecting rods toward each other and the
chamfered sides (4) toward the crankshaft.
NOTE: For more detail about checking bearing

clearances and installation of connecting rod bearings,
see Remove & Install Connecting Rod Bearings.
3. Check the bearing clearances with Plastigage.
4. Put 2P-2506 Thread Lubricant on bolts (5). Install

caps (3) and nuts finger tight. Tighten each nut to a
9 torque of 80 & 8 N m (60 k Ib ft). Put a mark
across the nut and bolts. Tighten each nut
120 degrees (1/3 of a turn) more.

2. Remove retainer ring (1) with Tool (C). 8, Put cannecting rod (4) in position on the base plate
of Tool (fjr. Put a new rod pin bearing (5) on the
3. Remove pin (2) and the connecting rod (4) from the adapter part of Tool (B). Make sure that the joint in
piston (3). +
the rod pin bearing is a 10 degrees from a
cmwr line through the crankshaft and pin bearing
bores.
4. Remove the piston rinas from the piston with Tool

(A). Clean the piston ring grooves on the pistons
with an acceptable ring groove cleaning rod. 3. Instail the pusher adapter (7) and pusher (8), part of
Tool (B), on the adapter.
NOTE: See Use of Pistons Pin Bearing Removal & -
InstallationTools, Special Instruction, SMHS7295. NOTE: The old bearing is pushed out by Tool (B) as
the new bearing is installed. 0
5. Heat the connecting rod in an oven to a
temperature of 177" to 22O0C(350to 500F). 8. Use Tool (B) to push the new bearing into the
Never use a direct flame to heat a connecting rod. connecting rod until the push adapter of Tool (B)
makes full contact with the connecting rod surface.
9. . Use a pin boring machine to make the rod pin

bearing the correct size. The bore ih the new rod
pin bearing must be 58.830 + 0.008 mm
(2.0012 + .W03 in).
10. Check the clearance between the ends of piston

rings. See the topic "Pistons & Ringsnin the
Specificatians Manual.

pistons.
f-
11. Install the oil ring spring in the oil ring groove of
the piston.

NOTE: The oil ring is to be installed over the spring Disassemble & Assemble Pistons
with the oil ring end gap of 180 degrees from the oil (Later - Tapered Rod Pin
- ring spring joint.
Bearings) 1214-017
Start By:
--
12. lnstall the oil ring on the piston with Tool (A).
13. lnstall the second (intermediate) piston ring with

the side that has the identification "UP-2" toward
a. remove pistons
the top of the piston with Tool (A).
14. lnstall the first (top) piston ring with the side that
has the identification "UP-1" toward the top of the
piston with Tool (A).
NOTE: After the installation of all three piston rings,

put the piston rings in position so the end gaps are
) 120 degrees apart.
1. Remove bearinis (3)from the cannecting rod and

connecting r6d mp.
2. Remove retainer ring (lrwith Tool (A).
3. Remove pin (2) and connecting ~ o (4)

d from the
piston. i
15. Put piston (3) in position on connecting rod (4).

Put clean engine oil on pin (2) and install the pin.
lnstall retainer rings (1) with Tool (C). Make sure
the retainer rings are in grooves of the piston.
16. lnstall the bearings in the connecting rod and

connecting rod cap.
End By:
-3
-
a. install pistons
--
C ---
--
- -
- - --- - -.
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.

pistons.
10. Install the oil ring spring in the oil ring groove of
the piston.
4. Remove piston ring (5) from the piston with Tool (B). NOTE: The oil ring is to be installed over the spring
Clean the piston ring grooves on the pistons with with the oil ring end gap 180 degrees from the oil ring
an ircc~ptablering groove cleaning tool. spring joint.
NOTE: See U,se of Piston Pin searing Removal &

Installation Tools, Special Ir-structions, SMHS7295.
11. tne&ll the oil ring on the piston with taol (6).
12. Install the second [hterrnediate) pMan ring with

the side that has the identifieationUUP-2"twmd
ths tap of the piston with Tool (B).
13. IhsMr the firat (tap) piston ring with the side that
. -.
has the Idenflimtion "UP-1" toward the top of theu
piston with Toql (B). -.
NOTE ~ f k the
c installation of d l three piston rings,
put th& piston r i g s in positron so the end gaps are
5. Heat the connecting rod (4) in an oven to a 18Udeg~eesapart.
temperature of 177" to 260C (350to 500F).
Never use a direct flame to heat a connecting rod.
6. Put connecting rod (4) in position on the base plate

of Tool (C). Put a new rod pin bearing (6) on the
adapter part of Tool (C).
NOTE: The old bearing is pushed out by Tool (C) as

the new bearing is installed.
7. Use Tool (C) to push the new bearing into the

connecting rod until the push adapter of Tool (C)
makes full contact with the connecting rod surface.

Cylinder Liners
Remove Cylinder Liners 1216-011
Tools Needed A
5P8665 Cylinder Liner Puller 1
Start By:
a. remove spacer plates
b. remove pistons
14. Put the in position on connecting rod (4).
Put clean engine ail pin (2) and install the pin.
Install retainer rihgs (1)with Tool (A). Make sure
the retainer rings are in the grooves of the pistons.
15. ln&&ll bearings (3) in the connecting rod and

W connectind rod cap.
End By:
a. instan pistons
1. Make an adjustment of the legs on Tool (A) for the

length of the cylinder liner.
NOTE: Be careful not to damage cooling tube at the

bottom of the cylinder liner.
2. Turn the nut on Tool (A) until cylinder liner (1) is free
of the cylinder block.

3. Remove seals (3) and filler band (2) from the
cylinder liner.
a. lnstall four bolts (4) and eight seals (washers)
lnstall Cylinder Liners 1216-012

from Tool (A) around each cylinder liner as
shown. Tighten the bolts evenly, in four steps:
14 N-m (5 Ib ft) ,35 Nom (25 Ib ft) , 7 0 N-m
(50 Ib ft) and then to 95 N-m (70 Ib ft). './
-
NOTE: To keep from moving bolts and seals as each
liner is checked, install two bolts with seals on each
side to each cylinder liner, along the complete length of
the top plate.
b. lnstall plate (3),

crossbar (6), plates (5) from Tool
(A) and bolts (2) and washers from Tool (C). Be
sure the crossbar is in position at the center of
the liner and the liner surface is clean. Tighten
the bolts evenly, in four steps: 7 N-m (5 Ib ft) ,
20 N-m (15 Ib ft) ,35 N-m (25 lb ft) , and then
to 70 N-m (50 Ib ft).
C
c. Check the distance from the bottom edge of
1. lnstall the gasket and spacer plate. crossbar (6) to the top edge of the spacer
plate.The distance on each end of the crossbar
2. Clean the cylinder liners and liner bores in the must be the same.
cylinder block.
d. Check the liner projection with Tool (B) at four '-
locations around the liner flange. Liner projectio-
must be 0.03 to 0.15 mm (.DO1 to .006 in).
The difference between the four measurements
on the same liner must not be more than
0.05 mm (.022 in). The difference between
average liner projection for liners next to each
other must not be more than 0.05 mm (.002
in). The maximum difference in the average
projection of the cylinder liners under each
cylinder head must not be more than 0.10 mm
(.OM in).
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 within specifications, move the liner to a different
3. lnstall the cylinder liners (1) in the cylinder block bore in the cylinder block and check the projection
without seals or bands. again.
4. Check the cylinder liner projection as follows:

5. If a liner does not measure with the correct
projection specifications, the projection can be
> changed with a counterbore operation to the top

surface of the cylinder block. The counterbore
depth must be a range from a minimum of 0.76
mm (.030 in) to a maximum of 1.14 mrn(.045 in).
Shims are available to then adjust the liner to the
correct projection.
NOTE: See Special Instruction, FM055228 for

procedure to use the 8s-3140 Cylinder Block
Counterboring Tool Arrangement.See the topic
"Cylinder Liner Projectionnin the Systems Operation,
Testing &Adjusting Manual to find shim thickness, part
number and installation.
8. Put liquid soap on seals (8), grooves of the liner and
the bore of the block. Install the sears on the
cylinder liner.
ti.put a@r:
M(f3; in cban SAP ~ I 6il
J .For a sh~rt
.- frirre, &dl 'the niter b&ndbn the liner.
., -
fat
'
'
l&$M fke liner imMmdfately after the flller band is
i w ~ * - g a ksuree the mark on liner b in
@i&m3&twTfkthe ark on the blcuck. Use;Tdql
)(: t o . p ~ ~_ ~ & l f n
i net r~
pasition. .I-.As
% I '
,b . *.
1I,- .M &$is ?'thou& l&ftqr the u$ngTnder.b the e .
I&$r&.
.P"
< c
6. Put a mark (7) on the cylinder liners and block so

~ni:k~ ,
) the liners can be installed in same position. a. install pistons

7. Remove Tool (A) and Tool (B). Remove one liner. a. install spacer plates

Crankshaft Main Bearings
Remove & Install Crankshaft Main
Bearings 1203-010
Tools Needed A B C
2P5518 Bearing Tool 1
Plastigage
885467 Indicator Group 1
Start By:
a. remove oil pump
NOTICE
If the crankshaft is turned in the wrong direction, the (-
1. Check each main bearing cap (2) for its location on tab of the bearing will be pushed between the crank-
the engine. Each cap has an arrow (1) which points shaft and the cylinder block. This will cause damage
to the front of the block and a number (3) which to the crankshaft and block.
gives the location of that cap.
2. Remove No. 2 through NO. 6 main bearing caps 4. Turn the crankshaft until Tool (A) can be installed in
from the engine. Remove the lower bearings from oil hole (4).Turn the crankshaft in the direction which
the caps. will push the upper main bearing out, tab end first.
u
3. Remove the thrust plate from each side of the No. NOTE: The following steps are for the installation of
4 upper main bearing. the crankshaft main bearings.

NOTICE
Make sure the upper and lower halves of bbarings are
installed so bearing tabs (5) fit into the notch in cylin-
- der block and bearing caps.
w
NOTE: Do not put oil on the parts until the bearing
clearance has been checked.
5. Put clean enginb OH on the lower. Install lower

b&rings in the be&ng caps,
6. Put clean engine oil on the upper bearings. Install

upper bmings in the cflnder block with Tool (A).
-,
8. P,ulk @$be of the Plastigag&on the surface of

the Iowdr bearing half.
b. int&gdl ;the main bearing caps with arrow (6)

toward the front of the cylinder block. Each cap
has a number (7) on the bottom surface and
must be installed in the same position as the
correct number on the left side of the cylinder
block.
c, Put 28-2506 Thread ~ubricknton the threads

Of the cap bolts. Instdl the cap bolts finger tight.
d. Tighten the bolts on the tab end of the caps first

to a torque of 260 r 14 N-m (190 f 10 Ib ft).
e. Tighten the bolts on the other end of the caps to

atorque of 260 k 14 N-m (196 +
10 Ibft).
f. Put's mark across the bolt head and cap.

Tighten the bolts opposite the tab end
120 degrees (1/3of a turn). Tighten the bolts
on the tab end of the cap 120 degrees (1/3of
a turn).
7--
- -- - - - - ~~-
.
-k-- - - -.
s*,: 8-
NOTICE Crankshaft
Do not use an impact wrench to tighten the bolts the
additional 120 degrees (113 of a turn).
Remove Crankshaft 1202-011
8. Remove the caps and measure the Plastigage. The Tools Needed A 6
clearance for new bearings must be 0.091 to 1P2322 Puller Assembly 1
0.018 mm (.0036 to .0073 in). The maximum 5P4170 Step Plate 1
clearance for used bearings is 0.25 mm(.010 in).
5P0944 Puller Group 1
9. Install a thrust plate (8) on each side of the No. 4 5P0941 Extractor 1
upper bearing.lnstall the thrust plates with the side 5P0939 Extractor 1
marked "Block Side" toward the cylinder block.
10. Install again the No. 2 through No. 6 main bearing Start By:
caps. Follow the tightening procedure in Step 7.
a. remove oil pump
11. Do Steps, 2,4,5,6,7 and 8 for the No. 1 and No. 7
main bearing caps. b. remove front housing
c. remove flywheel housing
d. remove pistons
NOTE: For more detail about removal of main

bearings see the topic "Remove & Install Crankshaft
Main Bearings".
12. Check the crankshaft end play with Tool (C). The
end play is controlled by the thrust plates on the 1. Check each bearing cap (1) for its location on the
center main bearing. Make sure the dial indicator engine. Each cap has an arrow which is toward the
is against a machined surface. End play for new front of the block and a number which gives the
thrust plates must be 0.15 to 0.51 mm (.006 to location of that cap. Keep each bearing with the
.020 in). The maximum end play with used thrust correct cap.
plates is 0.89 mm (.035 in).
2. Remove bearing caps No. 2 through No. 6.
End By: Remove thrust plates from No. 4 upper bearing.
a. install oil pump 3. lnstall one of the flywheel bolts in each end of the
crankshaft.Fasten a hoist to the crankshaft as
shown. Remove No. 1 and No. 7 main bearing
caps. Remove the crankshaft. The weight of the
crankshaft is approximately 143 k g (315 Ib) for the
3408 engine and approximately 180 k g (400 Ib) for
the 3412 engine.
c
NOTICE
Be careful not to damage the crankshaft journals when
)' the crankshaft is removed.
--
3. Heat crankshaft gear (3) to a maximum temperature
of 232C [4WF). Install gear (3) on the crankshaft
with groove (4) in alignment with dowel (2).
4. Make sure the upper main bearings are clean. Put

clean oil on the upper main bearings and journals of
4. Remove crankshaft gear (2) with Tool (A). the crankshaft.
5. Remove dowel and pin from the crankshaft with

Tool (B).
lnstall Crankshaft 1202-012
Tools Needed A
885467 Dial Test Indicator Group 1
5. lnstall one of the flywheel bolts in each end of the

crankshaft. Fasten a hoist to the crankshaft and put
it in position in the block.
NOTICE
Use care to prevent damage to the crankshaft jour-
nals. Make sure the "V" mark on the crankshaft gear
is in alignment with the "V" mark on the idler gear.
NOTE: For more detail about installation of main

bearings, see the topic "Remove & lnstall Crankshaft
Main Bearings".
1. lnstall pin (1) in the crankshaft end until it is 6. Check the bearing clearances with Plastigage.
extended from the surface a distance of 6.4 +
0.5 mm (.25 f .02 in). 7. Put 2P-2506 Thread Lubricant on the bolts for
caps No. 1 and No. 7 , lnstall No. 1 and No. 7 caps
2. lnstall dowel (2) until it is extended from the surface with the bolts finger tight. Make sure the arrows on
. .3 a distance of 4.1 & 5.0 mm (.I6 + .02 in). the caps are toward the front of the block.

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CATERPILLAR" SENR1133

3408C & 3412C Marine Engines

3 Marine Auxiliary & Generator Set Engines

"WARNING" as shown below.

Operation that may cause product damage are identified by N

1- Series) ........................................................................................ 143

Generator ................................................................................. 118

3408C & 3412C Marine Engines 3 Index

3. Remove twenty two bolts and washers (3) and

NOTE: To install the fan guards, reverse the removal

3408C & 3412C Marine Engines 4 Disassembly & Assembly

\ Remove & Install Radiator 1353-010

a. remove fan guard

FLUID SPILLAGE CONTAINMENT

Care must be taken to ensure that fluids are con-

. for tools and supplies suitable to colle& and contain

1. Drain the radiator into a suitable container for

5. Loosen two hose clamps (5) on the water

6. Remove two radiator braces (4).

2. Loosen two hose clamps (1).

7. Attach .lifting slings and a suitable lifting device to

3408C & 3412C Marine Engines 5 Disassembly & Assembly

8. Remove four bolts (7) fastening radiator (6) to the

9. Remove radiator (6).

1. Attach a lifting sling and a suitable lifting device to

2. Remove six bolts and washers (2).

3. Remove fan (1).

NOTE: To install the fan, reverse the removal steps.

a. install fan guard

3408C & 3412C Marine Engines 6 Disassembly & Assembly

1. Loosen four nuts (1) fastening the fan drive bracket

2. Tighten bolt (3) until fan belts (2) are tightened.

2. Loosen bolt (3) to loosen fan belts (2).

3. Remove three fan belts (2).

5. Tighten four nuts (1)fastening the fan drive to the

3408C & 3412C Marine Engines 7 Disassembly & Assembly

1. Attach a lifting sling and a suitable lifting device to

2. Remove four nuts and washers (2).

3. Remove fan drive (1). Fan drive weighs 23 kg

1. Remove two bolts and bracket (4) from the fan

2. Remove six bolts (1) that fasten fan adapter (3) to

4. Remove bracket assembly (3).

5. If necessary, remove four studs (4) with Tool (A).

NOTE: To install the fan drive, reverse the removal

a. install fan belts

3408C & 3412C Marine Engines 8 Disassembly & Assembly

18. ~ e m o v epulley (2) from fan bracket assembly (12). '

5. Remove hub (7) from the fan drive.

9. Remove spacer (13) from fan bracket assembly

6. Remove bearing (8), spacer (9) and bearing (10)

3408C & 3412C Marine Engines 9 Disassembly & Assembly

1 11. If removed, install plug (14) inside fan adapter (3).

3408C & 3412C Marine Engines 10 Disassembly & Assembly

a. install fan drive

18. Instatl washer $ndbof b.~h

3408C & 3412C Marine Engines 11 Disassembly & Assembly

a. remove exhaust manifolds a. remove crankshaft pulley & damper

2. Attach two lifting slings and a suitable lifting device

a. install exhaust manifolds

, 3408C & 3412C Marine Engines 12 Disassembly & Assembly

4. Attach chains and a suitable lifting device to the

1. Loosen hose clamp (2).

2. Remove breather (1).