Usage:
NOTE: This instruction should be included in the 3306 DI Engine Tune-Up Kit. See the Engine Service Guide, Form No. SEBF2561.
The tune-up will need the following special tools:
1 Steam clean the engine. Obtain an SOS sample; be sure the oil is hot and well mixed before you take the sample. Disconnect the batteries.
| NOTICE |
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Do not let the tops of the fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzle turns in the body. |
2 Disconnect the fuel injection lines at the nozzles and fuel injection pumps. Install 2F2990 Plugs and 5F2807 Caps on the fuel line connections to keep them free of dirt.
3 Disconnect brackets (1) and (2) from the cylinder head and remove the fuel injection lines. Remove clamps (3).
4 Install 6V3129 Nozzle Puller (4). Move the screw out of the puller enough to engage the inside lip of the puller on the lower stepped diameter of the nozzle.
| NOTICE |
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Do not exceed a torque of 17 N·m (150 lb.in.) on the screw in tool (4) to remove the nozzle. Added force can cause the stem of the nozzle to bend or break off. |
5 With the nozzle bleed screw seen through the clearance hole in tool (4), turn the screw down until the lip of the button goes down into the threads in the hole for the nozzle clamp bolt. Remove each nozzle. If the nozzle cannot be removed with 6V3129 Puller (4), use FT1533 Nozzle Adapter (6) and 1P0074 Slide Hammer (5).
| NOTICE |
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Hold nozzle adapter (6) and slide hammer (5) so the centerline of the tools is the same as the extended centerline of fuel injection nozzle (7). This will prevent the fuel injection nozzle from bending or breaking off. |
6 Remove 5F2807 Caps and use slide hammer (5) and nozzle adapter (6) to remove fuel injection nozzle(s) (7). When these tools are used to remove the fuel injection nozzle, the nozzle is not reusable.
7 Use 6V4089 Reamer Assembly (8) to clean the bore for each fuel injection nozzle. Use an open end wrench or a tap driver to turn the reamer.
8 Make sure that seal (9) is in position on each nozzle (7). Put washer (10) in place on each nozzle.
9 Install each fuel injection nozzle. Position each nozzle with bleed screw (11) away from the valve cover. Install each clamp.
10 Remove 5F2807 Caps and 2F2990 Plugs from the fuel line connections. Connect the fuel injection lines to the nozzles and fuel injection pumps. Tighten the fuel line nuts finger tight only.
| NOTICE |
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Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will become damaged if the top of the nozzle turns in the body. |
11 Use 5P0144 Socket and a torque wrench to tighten the nuts to a torque of 40 ± 7 N·m (30 ± 5 lb.ft.). Make sure the fuel line clamps are tight. Install the bolts that hold the fuel line brackets to the cylinder head. Loosen clamps (12) and slide the hose on the tube assembly. Remove bolt and breather assembly (13) from the valve cover and remove the seal.
12 Remove bolts (15) that hold the valve cover in place. Remove valve cover (14) and gasket.
13 Put No. 1 piston at top center (TC) on the compression stroke. To find TC on the compression stroke for No. 1 piston, turn the flywheel clockwise (opposite the direction of engine rotation) approximately 30° This will ensure all play is removed from the timing gears when the engine is at TC.
14 Remove plug (16). Turn the flywheel counterclockwise until a 3/8" - 16 NC bolt can be installed through the hole in the flywheel housing. The No. 1 piston is at TC.
NOTE: If the flywheel is turned beyond the point at which the 3/8" - 16 NC bolt can be installed, turn the flywheel clockwise a minimum of 30° before turning it counterclockwise toward alignment again.
15 Look at the valves of cylinder 1 to see if No. 1 piston is on the compression stroke. If cylinder 1 is on the compression stroke, the valves will be closed. (You should be able to move the rocker arms up and down by hand.) If No. 1 piston is not on the compression stroke, turn the flywheel 360° counterclockwise. Install the 3/8" - 16 NC bolt as before. The No. 1 piston is now at TC on the compression stroke.
16 Make an adjustment to the valve clearance on the intake valves for cylinders 1, 2 and 4. Make an adjustment to the valve clearance on the exhaust valves for cylinders 1, 3 and 5.
17 Turn the flywheel 360° in the direction of engine rotation. This will put No. 6 piston at TC on the compression stroke. Make an adjustment to the valve clearance on the intake valves for cylinders 3, 5 and 6. Make an adjustment to the valve clearance on the exhaust valves for cylinders 2, 4 and 6.
18 After the valve adjustments are correct, tighten the nuts for the valve adjustment screws to 28 ± 4 N·m (22 ± 3 lb.ft.). Remove the timing bolt from the flywheel.
19 Put contact cement on the face of the valve cover and the top side of the valve cover gasket. Put the valve cover gasket in position in the valve cover. Put valve cover (14) in position on the cylinder head. Tighten the valve cover bolts in the sequence shown in the line drawing to a torque of 11 ± 3 N·m (8 ± 2 lb.ft.).
20 Install the hose to connect breather assembly (18) to the tube assembly. Install seal (19) and breather assembly (18) on the valve cover. Tighten the hose clamps.
21 Drain the cooling system to a level below the water temperature regulator housing. Disconnect the radiator hose from the top of the water temperature regulator housing.
22 Remove four bolts (20) and remove the water temperature regulator housing. Remove the regulator from the housing. Put the temperature regulator and gaskets in position. Install the water temperature regulator housing on the cylinder head.
23 Connect the radiator hose to the top of the housing. Fill the cooling system to the correct level. Connect the batteries and start the engine.
NOTE: It may be necessary to prime the fuel system if the engine fails to start.
24 Inspect for leaks. Stop the engine and allow the oil to drain. Check to see the oil and coolant are at their correct levels.