3406E On-Highway Engine Caterpillar

Removal Procedure

Start By:

1. Remove the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".

2. Remove the rocker arms and the rocker shafts. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Remove".

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Illustration 1	g01028806

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NOTICE
Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine.

1. Remove bolts (2) and thrust plate (1).
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   Illustration 2	g00576209

2. Remove seal assembly (3) and adapter (4).
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   Illustration 3	g00576240

3. Remove O-ring seals (5) and (6) from seal assembly (3).
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   NOTICE
   Care must be used when removing the camshaft to not damage the highly finshed surfaces of both the camshaft and camshaft bearings

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   Illustration 4	g00509797

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   Illustration 5	g00581441

4. Use the bolts for the rocker arm shaft assembly to install Tooling (A) at Location (Y).
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   Illustration 6	g00581442

5. Install Tooling (B) on front housing (7). Do not tighten the bolts for Tooling (B) at this time.
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   Illustration 7	g01074729

   Note: It is necessary to install Tooling (C) on the camshaft. Tooling (C) will support the rear of camshaft (8) as the camshaft is moved out of the cylinder head and into Tooling (B).

6. Move camshaft (8) forward and install one Tooling (C) in the end of camshaft (8). Again, move the camshaft forward and install remaining Tooling (C) into the back of first Tooling (C).

7. Position camshaft (8) into the bore of Tooling (B). Tighten the bolts that hold Tooling (B) to the front housing.
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   Illustration 8	g00581444

   Note: Avoid lifting camshaft (8) with Tooling (D). The camshaft should rest on Tooling (A). Lifting of the camshaft can cause misalignment as the camshaft is removed, resulting in damage to the camshaft bearings.

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   Illustration 9	g00581445

8. Remove camshaft (8), as follows:

   1. Use Tooling (D) to move camshaft (8) toward the front of the engine. Reposition Tooling (D), as needed.

   2. Move camshaft (8) far enough out of the cylinder head in order to attach a suitable lifting device.

   3. Keep the camshaft level while the camshaft is being removed from the cylinder head. The weight of the camshaft is approximately 39 kg (86 lb).

Alternative Removal Procedure

Start By:

1. Remove the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".

2. Remove the rocker arms and the rocker shafts. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Remove".

Note: This is an optional procedure to remove the camshaft. The preceding tool list shows the required tooling for removing the camshaft from the front of the engine or the rear of the engine.

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Illustration 10	g01028806

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NOTICE
Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine.

1. Remove bolts (2) and thrust plate (1).
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   Illustration 11	g00576209

2. Remove seal assembly (3) and adapter (4).
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   Illustration 12	g00576240

3. Remove O-ring seals (5) and (6) from seal assembly (3).
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   Illustration 13	g01043575

4. Remove screws (7) and cover (8).
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   NOTICE
   Care must be used when removing the camshaft to not damage the highly finshed surfaces of both the camshaft and camshaft bearings

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   Illustration 14	g01024825

   Note: Carefully align Tooling (F) with the end of the camshaft. If the adapter and the camshaft are not aligned, the camshaft may not be removed. The adapter and camshaft bearing will interfere.

5. To remove the camshaft from the rear of the engine, install Tooling (F) on the front of the camshaft with Tooling (G).

6. Install Tooling (E).
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   Illustration 15	g01043577

7. Carefully slide the camshaft to the rear of the engine for removal. Use two technicians to remove the camshaft. Keep the camshaft level while the camshaft is being removed from the cylinder head. The weight of the camshaft is approximately 39 kg (86 lb).
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   Illustration 16	g01024826

8. To remove the camshaft from the front of the engine, install Tooling (E) on the rear of the camshaft.

9. Carefully slide the camshaft to the front of the engine for removal. Use two technicians to remove the camshaft. Keep the camshaft level while the camshaft is being removed from the cylinder head. The weight of the camshaft is approximately 39 kg (86 lb).