3406E On-Highway Engine Caterpillar

Installation Procedure

Note: Thoroughly clean the spacer plate and the bottom surface of the cylinder head. A new spacer plate gasket must be installed when the cylinder head is removed.

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Illustration 1	g00632049

1. Apply a thin film of clean engine oil to O-ring seal (26). Install O-ring seal (26).
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   Illustration 2	g00632048

2. Install a new spacer plate gasket (25).

3. Install the spacer plate on the engine.
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   Illustration 3	g00632047

4. Apply a thin film of clean engine oil to O-ring seal (22). Install O-ring seal (22).

5. Install water seals (23) dry.

6. Install seal (24) in the spacer plate.
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   Illustration 4	g00580833

7. Install a new cylinder head gasket (21).
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   Illustration 5	g00580812

8. Attach a suitable lifting device to cylinder head (8). Carefully position cylinder head (8) on the spacer plate. The weight of the cylinder head is approximately 235 kg (518 lb).
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   Illustration 6	g00513934

   Note: The bolts that are Marked “X” are 216 mm (8.5 inch) long. The remainders of the bolts are 194 mm (7.6 inch) in length.

9. Apply a small amount of Tooling (A) to the bolt threads and both sides of the washers. Install the cylinder head bolts. Tighten the cylinder head bolts, as follows.

   1. In a numerical sequence, tighten bolts 1 through 26 to a torque of 270 ± 15 N·m (200 ± 11 lb ft).

   2. In a numerical sequence, tighten bolts 1 through 26 to a torque of 450 ± 15 N·m (330 ± 11 lb ft).

   3. In a numerical sequence, again tighten bolts 1 through 26 to a torque of 450 ± 15 N·m (330 ± 11 lb ft).
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   Illustration 7	g00580810

10. Install spacers (17) and bolts (18) that fasten bracket (19) to the cylinder head.
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    Illustration 8	g00580808

11. Connect the harness assembly to sensor (14), sensor (15), and ground stud (16).

12. Install the bolt and support clip (13) for the harness assembly.
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    Illustration 9	g00580807

13. Install hose assemblies (10). Install the bolt and clamp (9).

    Note: If the engine is not equipped with an air compressor, skip Step 14.

14. Connect hose assemblies (11) and hose assemblies (12) to the air compressor.
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    Illustration 10	g00580805

15. Connect hose assembly (7) to cylinder head (8).
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    Illustration 11	g00576240

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    Illustration 12	g00576839

16. Install O-ring seals (5) and (6) in seal assembly (3). Lubricate seal (6) with Tooling (B).

17. Assemble thrust plate (1) and seal assembly (3). Apply Tooling (C) to bolts (2). Hold the assembly in position and install bolts (2). Evenly tighten bolts (2) until seal assembly (3) and O-ring seal (5) are seated against the cylinder head.

    Note: Be careful to ensure that O-ring seal (5) stays in the groove in seal assembly (3).

18. Install adapter (4). Ensure that the dowel in adapter (4) engages the hole in the camshaft.

End By:

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

2. Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".

3. Install the valve mechanism cover base. Refer to Disassembly and Assembly, "Valve Mechanism Cover Base - Remove and Install".

4. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".

5. Install the water temperature regulator. Refer to Disassembly and Assembly, "Water Temperature Regulator - Remove and Install".