CARTRIDGE GROUP 3G2235 - Caterpillar

All Caterpillar 3406 Direct Injection Engines This instruction should be included in the 3406 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. 2 Loosen clamps (1), holding hose (3) to breather (2). Remove the hose. Loosen clamp (4) and remove the breather. Remove the valve covers from the valve cover bases. Remove the four bolts holding elbow (5) to the inlet manifold. Remove elbow and inlet pipe (6) as a unit. Remove the valve cover base bolts and the valve cover bases.3 Use 5P5195 Wrench to disconnect fuel line assemblies (7) from the cylinder head. Use 5P0144 Socket to disconnect the fuel line assemblies from the valve bodies. Remove the fuel lines. Install 2F2990 Plugs and 5F2807 Caps on the fuel line connections to keep them free of dirt. 4 Remove nut (8) that holds each body assembly in position. Use 5P6229 Extractor (9) to remove the body assemblies from the adapter assemblies. If the body assembly cannot be removed from the adapter assembly with 5P6229 Extractor, use 1P0074 Puller Assembly and FT1533 Adapter to remove it.5 Remove nozzle assembly (10) from each body (11). Remove seal (12) from each body.6 Use 5P4755 Guide to install the seal on each valve body. Install the nozzle assembly on each valve body. Tighten finger tight only. Put a small amount of clean diesel fuel on each seal.7 Install the body assemblies in the adapter assemblies. Install the nut that holds the body assembly and valve and tighten to a torque of 75 7 N m (55 5 lb.ft.). 8 Remove 2F2990 Caps and 5F2807 Plugs from the fuel line connections. Put fuel lines (13) in position on the engine. Use 5P5195 Wrench and 5P0144 Socket to tighten the fuel line nuts to a torque of 40 7 N m (30 5 lb.ft.).9 No. 1 piston at top center (TC) on the compression stroke is the starting point of all timing procedures. Timing bolt (14) is kept in storage at location (16) and can be installed in either the left side of the engine at location (15) or in the right side of the engine at location (17). There are two threaded holes in the flywheel. These holes are in alignment with the holes with plugs in the left and right front of the wheel housing. The two holes in the flywheel are at a different distance from the center of the flywheel so the timing bolt cannot be put in the wrong hole.10 Remove the bolts and cover from the flywheel housing. Install 9S9082 Turning Tool into the housing until the shoulder of the tool is against the housing. Attach a 1/2" drive ratchet to 9S9082 Turning Tool and turn the flywheel while holding the timing bolt