Usage:
This instruction is to be used with these new cylinder block service groups and the hardware kits, when it is necessary to make a replacement of a former cylinder block that has cylinder liner counterbores. These service cylinder block groups do not have a counterbore for the cylinder liners, but they do use a spacer plate between the cylinder block and cylinder head. Two hardware kits are needed to make the installation. One of these hardware kits has a special spacer plate that makes it possible to use the former cylinder head and valve mechanism with this new cylinder block, if desired, and if all components are usable. Because of the oil supply that is needed for the valve mechanism, use only the spacer plate from the hardware kit if a former cylinder head is to be installed on the new cylinder block. See the chart that follows for the parts that are needed.
3304 and 3306
(1) If the cylinder head from the former counterbored cylinder block is to be installed on the new cylinder block with a spacer plate, remove 1S9540 Dowel (1) (hollow). Install the two 3J5389 Plugs (2) from the parts kit, in the left side of the new cylinder block.
(2) The parts that follow must be removed from the former cylinder block and installed in the locations shown on the new cylinder block: 8M9307 Plug (3) and 6F7062 Gasket, 5M6213 Plugs (4), 7H3171 Plug (5) and 5M6214 Plug (6).
3304
If the former cylinder block has plugs in holes (A), install 7M4593 Plugs in the holes (A) of the new cylinder block. If the former cylinder block has orifices in holes (A), use orifice installation tool (1) to install 2S1541 Orifices in holes (A) of the new cylinder block.
3306
(1) Look in the holes at each location (A) (crankshaft bearing bore) of the former cylinder block, to see if it has plugs (1) or orifices (2). If plugs were in the former cylinder block at location (A), install the 7M4593 Plugs (1) in the new cylinder block. If orifices were in the former cylinder block at location (A), use the orifice installation tool to install 2S1541 Orifices (2) in the new cylinder block.
Look at location (B) of the former cylinder block. Some engines have a 1S1768 Sleeve (3) and 4L3395 Dowel (4) at location (B), and other engines will have a 4B3938 Plug (5) and 2A3798 Dowels (6). Install the correct parts at location (B) of the new cylinder block, so it will be exactly the same as the former cylinder block
*This thrust plate must be used if an earlier crankshaft, that has a wide rear main bearing journal, is to be installed in a spacer plate cylinder block.
Measure width (C) of the rear main bearing journal of the crankshaft that is to be installed in the new block. Make reference to the chart to find the correct thrust plate to install.
When the spacer plate gasket, spacer plate and head gasket are installed, they are to be clean and dry. Do not use sealant. Be sure to install the 7N8018 Seals and 7N8025 Seals before installation of the cylinder head. Install all other needed parts from the former cylinder block, on the new cylinder block. See SPECIAL PROCEDURES that follow for special information. See the Service Manual for specifications.
Special Procedures
Installation Of Fuel System (Early Counterbore Engines That Have Scroll Type Fuel System)
When the scroll type fuel system from a former 3304 counterbore cylinder block is to be installed on a replacement spacer plate cylinder block, it will be necessary to use a 2P3949 Fuel Pump Bracket to fasten the fuel pump and governor to the side of the new cylinder block. (The 7S6743 Bracket that was used on the former cylinder block can not be used on the new cylinder block.) Use new gaskets and seals as necessary.
For 3306 early counterbore engines, it will be necessary to use a 2P8704 Fuel Pump Bracket.
Oil Filter Base (Early 3304 Engines)
Some earlier 3304 Engines have a 7S6397 Oil Filter Base Assembly. To install this oil filter base on the new service block, it will be necessary to first grind away part of the boss shown at location (A) to get needed clearance. It is also permissible to install a 2P6475 Oil Filter Group as a replacement for the 7S6397 Oil Filter Base. If the 2P6475 Oil Filter Group is installed, it will not be necessary to do the grinding procedure at location (A).
Earlier Engines That Are Equipped With An Air Compressor
For those earlier engines that are equipped with an air compressor, it will be necessary to drill and tap a hole at boss (A) for installation of an oil drain line for the air compressor. Make the threads in the new hole the same size as those for the old cylinder block.
9L5797 Oil Pan Group (Front Sump)
For those 3306 Engines that have a 9L5797 Oil Pan Group, use three T65 Bolts (1) at the location shown, instead of the three former 2M3403 Bolts that were used with the former cylinder blocks. All other bolts used are the same as those used for the oil pan with the former cylinder block.
3N2887 Front Housing Fastener Group
For those 3304 or 3306 Engines that have a 3N2887 Front Housing Fastener Group, use a 9S1366 Bolt (1) at the location shown, instead of the former 4K4937 Bolt that was used with the former cylinder block. All other bolts are the same as those used with the former cylinder block.
6N5233 Flywheel Housing Group
For those 3304 or 3306 Engines that have a 6N5233 Flywheel Housing Group, use two S1585 Bolts (1) at the location shown, instead of the former S1587 Bolts that were used with the former cylinder block. All other bolts for the flywheel group are the same as those used with the former cylinder block.
2P6122 Flywheel Housing Group
For those 3306 Engines that have a 2P6122 Flywheel Housing Group, use two 323180 Bolts (1) at the location shown, instead of the former S1585 Bolt and S1587 Bolt that were used with the former cylinder block. All other bolts are the same as those used for the flywheel housing group with the former cylinder block.
2P6131 Flywheel Housing Group
For those 3306 Engines that have a 2P6131 Flywheel Housing Group, use two 4K4937 Bolts (1) at the location shown, instead of the two former 1A5822 Bolts that were used on the former cylinder block. All other bolts used are the same as those used for the flywheel housing group with the former cylinder block.