SENR1169-03

Disassembly and
Assembly
3406E MARINE ENGINE
S/N 9WR00001-UP
CONTENT.

Use the bookmarks for navigation inside of the Manual.

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02733419

Fuel Priming Pump - Remove and Install

SMCS - 1258-010

Removal Procedure

Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electrical components can

cause a fire.

Clean up all leaked or spilled fuel. Do not smoke while working on the
fuel system.

Turn the disconnect switch OFF or disconnect the battery when

changing fuel filters.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

 Illustration 1 g01026874

1. Remove bolts (1), fuel priming pump (2), and the gasket.

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 2 g01026874

1. Position the gasket and fuel priming pump (2) on the fuel filter base. Install bolts (1).
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02713779

Fuel Filter Base - Remove and Install

SMCS - 1262-010

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 185-3630 Strap Wrench As 1

Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electrical components can

cause a fire.

Clean up all leaked or spilled fuel. Do not smoke while working on the
fuel system.

Turn the disconnect switch OFF or disconnect the battery when

changing fuel filters.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Turn the fuel supply to the "OFF" position.

2. Disconnect the harness assembly and remove the fuel pressure sensor. Remove the O-ring seal
from the fuel pressure sensor.

Illustration 1 g01026897

3. Use Tooling (A) to remove the fuel filter from fuel filter base (3) .

4. Disconnect hose assemblies (2) .

 5. Remove bolts (1) . Remove fuel filter base (3) .

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2 g01026897

1. Position fuel filter base (3) on the engine. Install bolts (1) .

2. Connect hose assemblies (2) .

3. Install the fuel filter on fuel filter base (3) .

4. Install the O-ring seal on the fuel pressure sensor. Install the fuel pressure sensor on the fuel
filter base and tighten to a torque of 10 ± 2 N·m (90 ± 18 lb in).

5. Connect the harness assembly for the fuel pressure sensor.

6. Turn the fuel supply to the "ON" position.

7. Remove the air from the system. Refer to Testing and Adjusting, "Fuel System - Prime".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02320359

Fuel Transfer Pump - Remove

SMCS - 1256-011

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

 Illustration 1 g00770238

1. Disconnect hose assemblies (1) and (2) . Plug and cap all openings in order to prevent debris
and contamination from entering the system.

2. Remove bolts (3) and fuel transfer pump (4) .

Illustration 2 g00488105

3. Check the condition of O-ring seal (5) on fuel transfer pump (4) . If the O-ring seal is worn or
damaged, use a new part for replacement.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02320363

Fuel Transfer Pump - Install

SMCS - 1256-012

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g00488105

1. Install O-ring seal (5) on fuel transfer pump (4) . Apply clean engine oil to O-ring seal (5) .
 Illustration 2 g00770238

2. Position fuel transfer pump (4) on the engine. Install bolts (3) .

3. Connect hose assemblies (1) and (2) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02320377

Fuel Manifold - Remove

SMCS - 1702-011

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a
suitable cover over disconnected fuel system component.

Note: Put identification marks on all hose assemblies, on all tube assemblies, and on all harness
assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This will help
prevent fluid loss, and this helps to keep contaminants from entering the system.

Illustration 1 g00948819

1. Disconnect the hose assemblies from fuel manifold (2) .

2. Disconnect harness assembly (1) .

3. Remove bolts (3) and fuel manifold (2) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02320387

Fuel Manifold - Install

SMCS - 1702-012

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a
suitable cover over disconnected fuel system component.
 Illustration 1 g00948819

1. Position fuel manifold (2) on the engine and install bolts (3) .

2. Connect harness assembly (1) .

3. Connect the hose assemblies to fuel manifold (2) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02097659

Electronic Unit Injector - Remove

SMCS - 1290-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 5F-4764 Pry Bar 1

Start By:

A. Remove the rocker arms and the rocker arm shaft. Refer to Disassembly and Assembly,
"Rocker Arm and Shaft - Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01026993

1. Disconnect harness assembly (1) from electronic unit injector (2) .

2. Remove bridge assemblies (3) .

NOTICE
Do not reuse the injector hold down bolts. New injector hold down
bolts must be used.

NOTICE
If the injector hold down bolt is loose during the removal procedure,
inspect the injector bore for wear and debris. Replace the clamp and
spacer.

3. Remove bolt (4), spacer (5), and clamp (6) .

4. Place an identification mark on the electronic unit injectors for installation purposes. Each
electronic unit injector must be reinstalled in the original electronic unit injector sleeve.
 Illustration 2 g00996395

5. Use Tooling (A) in order to pry beneath the base and free electronic unit injector (2) .

6. Remove electronic unit injector (2) from the cylinder head.

Illustration 3 g01039929

7. Remove O-ring seals (7) from electronic unit injector (2) .

 Illustration 4 g01054374

8. Inspect electronic unit injector seat (8) and electronic unit injector bore (9) .
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i03780254

Electronic Unit Injector - Install

SMCS - 1290-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
B 8T-2998 Lubricant -
1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle -
C
Tube
4C-4057 -
7.9 mm (0.31 inch) OD
D 4C-5552 Large Bore Brush 1
E 4C-6774 Vacuum Gun Kit 1
F 8T-7765 Surface Reconditioning Pad -

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Use Tooling (C) to remove the fuel and oil from the cylinder. Evacuate as much fuel and oil as
possible from the cylinder before installing the electronic unit injector. Several evacuations
may be necessary.

2. Use Tooling (D) to clean the carbon deposit from the inside of the electronic unit injector
 sleeve. Tooling (E) is available to clean loose material from the bore of the electronic unit
injector sleeve and the cylinder.

3. Use Tooling (F) to clean the carbon from the seat area that is inside of the electronic unit
injector sleeve.

4. Install the O-ring seals on the electronic unit injector. Lubricate the top two O-ring seals with a
50/50 mixture of clean engine oil and Tooling (B) .

Illustration 1 g01150587

NOTICE
When an electronic unit injector is replaced, the new electronic
injector code must be programmed into the engine's personality
module software by using the calibration menu on the Electronic
Service Tool. If the new electronic injector code is not entered, the
characteristics of the previous electronic unit injector is assumed.

If it is not possible to immediately reprogram the electronic injector

code into the personality module software, the engine will not be
severely harmed. The new electronic injector code should be
reprogrammed as quickly as possible in order to optimize engine
performance.

5. Install electronic unit injector (2) into the original location in the cylinder head.

Note: Use new bolt (4) .

6. Install spacer (5) , clamp (6) , and bolt (4) . Tighten bolt (4) to a torque of 55 ± 10 N·m (41 ± 7
lb ft).
 7. Install bridge assemblies (3) in the orientation that was noted during removal.

8. Connect harness assembly (1) on electronic unit injector (2) . Tighten the nuts to a torque of
2.5 ± 0.25 N·m (22 ± 2 lb in).

9. Remove the air from the fuel system. Refer to Testing and Adjusting, "Fuel System - Prime".

End By: Install the rocker arms and the rocker arm shaft. Refer to Disassembly and Assembly,
"Rocker Arm and Shaft - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02733293

Electronic Unit Injector Sleeve - Remove

SMCS - 1713-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
128-7889 Bridge Puller 1
221-9778 Puller Stud 1
A (1) 9U-6877 Thrust Bearing 1
5P-8247 Hard Washer 1
4K-0367 Nut 1
(1) Part of the 9U-6891 Injector Tool Group

Start By:

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

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
 Illustration 1 g01002969

2. Use Tooling (A) to remove unit injector sleeve (1) .

Illustration 2 g00948616

3. Remove O-ring seals (2) from unit injector sleeve (1) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02340816

Electronic Unit Injector Sleeve - Install

SMCS - 1713-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
9U-6862 Tapered Brush 1
9U-6863 Small Bore Brush 1
B 9U-7244 End Brush 1
9U-7237 Brush Extension 1
4C-5552 Large Bore Brush 1
C (1) 221-9778 Puller Stud 1
D (1) 9U-7258 Driver Cap 1
E 4C-9507 Retaining Compound -
(1) Part of the 9U-6891 Injector Tool Group

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Use Tooling (B) to clean the bore in the cylinder head for the unit injector sleeve.
 NOTICE
Before starting installation ensure that the unit injector sleeve and the
cylinder head bore for the unit injector sleeve are completely free of
oil, dirt, and sealant debris.

Illustration 1 g01003258

2. Install new O-ring seals (2) on unit injector sleeve (1) .

Note: Do not apply Tooling (E) to the cylinder head surfaces. Apply Tooling (E) on the unit
injector sleeve only.

3. Apply Tooling (E) to the contact surface at Mark (X) .

4. Lubricate O-ring seals (2) with clean engine oil.

5. Install Tooling (C) into the threads of unit injector sleeve (1) .

6. Position Tooling (C) and unit injector sleeve (1) in the cylinder head. Use care not to damage
the O-ring seals on the unit injector sleeve.

NOTICE
Ensure that the unit injector sleeve is properly seated in the cylinder
head. The tool and the unit injector sleeve will "RING" when the unit
injector sleeve is fully seated in the bore in the cylinder head.
 Illustration 2 g01027804

7. Use Tooling (D) and a hammer to install the unit injector sleeve.

8. Use a clean towel to remove any excessive retaining compound.

9. Fill the cooling system with coolant. Refer to Operation and Maintenance, "Refill Capacities"
for the cooling system capacity.

End By: Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit
Injector - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02320457

Turbocharger - Remove
SMCS - 1052-011

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

 Illustration 1 g00802225

1. Disconnect tube assembly (1) and tube assembly (3) .

2. Remove the plates and bolts (2) .

Illustration 2 g01160169

3. Remove tube assembly (4) .

4. Disconnect tube assembly (5) .

 Illustration 3 g01160170

5. Remove bolts (6) and the plates.

Illustration 4 g01160171

6. Attach a suitable lifting device to the turbocharger (8) . The weight of turbocharger (8) is
approximately 43 kg (95 lb). Remove nuts (7) and turbocharger (8) .

Illustration 5 g01160172

7. Remove elbow (9) from turbocharger (8) . Inspect the O-ring seals. If the O-ring seals are
worn or damaged, use new parts for replacement.

8. Inspect the gasket. If the gasket is worn or damaged, use a new part for replacement.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02326983

Turbocharger - Disassemble
SMCS - 1052-015

Disassembly Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01162399

1. Position the turbocharger on a bench.

2. Place alignment marks on compressor housing (1) , turbocharger cartridge (4) , and turbine
housing (3) .

3. Remove bolts (2) from compressor housing (1) .

4. Remove compressor housing (1) from turbocharger cartridge (4) .

5. Remove bolts (2) from turbine housing (3) .

6. Remove turbine housing (3) from turbocharger cartridge (4) .

NOTICE
Do not attempt to disassemble the turbocharger cartridge assembly or
wastegate. Do not remove the compressor wheel. The turbocharger
cartridge assembly and the wastegate are not field serviced, and should
be replaced only as a unit.

7. Check the condition of all the components. Use new components to replace worn components
or damaged components.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02326995

Turbocharger - Assemble
SMCS - 1052-016

Assembly Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
The compressor housing must remain straight with the turbocharger
cartridge during disassembly and assembly. Tilting may cause damage
to the tips of the compressor wheel and the compressor shaft.
 Illustration 1 g01162399

Note: Check the condition of the components. Use new components to replace worn
components or damaged components.

1. Place an alignment mark on new turbocharger cartridge (4) in the same location as the old
turbocharger cartridge.

2. Align the marks and install compressor housing (1) on turbocharger cartridge (4) . Install bolts
(2) and tighten bolts (2) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

3. Align the marks and install turbine housing (3) on turbocharger cartridge (4) . Install bolts (2)
and tighten bolts (2) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i04001716

Turbocharger - Install
SMCS - 1052-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 5P-3931 Anti-Seize Compound -

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.

Dispose of all fluids according to local regulations and mandates.

1. Install the new gasket and O-ring seals.

 Illustration 1 g01160172

2. Install elbow (9) on turbocharger (8) .

Illustration 2 g01160171

3. Attach a suitable lifting device to turbocharger (8) . The weight of turbocharger (8) is
approximately 43 kg (95 lb).

Note: Discard the nuts after use. Use new nuts for installation.

4. Apply Tooling (A) to the studs of the exhaust manifold. Place turbocharger (8) into position
and install nuts (7) . Tighten nuts (7) to a torque of 55 ± 9 N·m (41 ± 7 lb ft).
 Illustration 3 g01160170

5. Install the plates and bolts (6) .

Illustration 4 g01160169

6. Connect tube assembly (5) .

7. Install tube assembly (4) .

Illustration 5 g00802225
8. Install the plates and bolts (2) .

9. Connect tube assembly (3) and tube assembly (1) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i04001720

Exhaust Manifold - Remove and Install

SMCS - 1059-010

Removal Procedure
Start By:

A. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".

B. Remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove
and Install".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g00771347

1. Remove elbow (1) from exhaust manifold (2) .

 Illustration 2 g00771349

2. Remove the nuts and spacers from studs (3) . Remove exhaust manifold (2) .

Illustration 3 g00771403

3. Remove liners (4) and the gaskets.

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 5P-3931 Anti-Seize Compound -
B 2P-2333 High Temperature Sealer -

NOTICE
Keep all parts clean from contaminants.
 Contaminants may cause rapid wear and shortened component life.

Note: Before assembly, check the condition of the gaskets, the liners, the studs, and the nuts. If the
parts are worn or damaged, use new parts for replacement.

1. Apply Tooling (A) to the studs for the exhaust manifold. If the studs were removed from the
cylinder head, install the studs in the cylinder head. Tighten the studs to a torque of 35 ± 5
N·m (26 ± 4 lb ft).

Illustration 4 g00771403

2. Install the gaskets and liners (4) .

Illustration 5 g00771349
 Illustration 6 g00771353

3. Apply Tooling (B) to the outside diameter of the male ends of exhaust manifold (2) . Apply
clean engine oil to the female ends of exhaust manifold (2) .

Note: Discard the nuts after use. Use new nuts for installation.

4. Position exhaust manifold (2) on studs (3) . Install the spacers and nuts on studs (3) .

5. Tighten the nuts for the exhaust manifold in a numeric sequence to a torque of 38 ± 5 N·m (28
± 4 lb ft).

Illustration 7 g00771347

6. Install elbow (1) on exhaust manifold (2) .

End By:

a. Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove
and Install".
b. Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02329934

Inlet and Exhaust Valve Springs - Remove and Install

SMCS - 1108-010

S/N - 9WR1-9999

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
1U-8826 Thrust Bearing 1
9U-7242 Compressor Plate 1
9U-7548 Compressor Base 1
A (1)
2J-3506 Full Nut 1
5P-8248 Hard Washer 1
0L-1143 Bolt 1
B 8S-2263 Spring Tester 1
(1) Part of the 9U-7241 Valve Spring Compressor

Start By:

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

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Place the piston at the top of the Compression Stroke (TC). Remove the valve springs for that
cylinder. If the valves fall into the cylinder liner, then the cylinder head must be removed.

1. Place the piston at the top of the Compression Stroke (TC) of the cylinder.

Illustration 1 g01163160

Illustration 2 g01163164
 Personal injury can result from being struck by parts propelled by a
released spring force.

Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to

release the spring force.

2. Secure Tooling (A) with unit injector clamp (1) .

3. Tighten the full nut until valve spring retainers (3) are loose on valve (2) .

4. Remove valve spring retainers (3) from valve (2) .

5. Carefully remove Tooling (A) from valves (2) .

6. Remove valve rotator (4) .

7. Remove valve spring (5) from valve (2) .

8. Remove washer (6) from the valve guide.

9. Use Tooling (B) to check the valve springs (spring force). Refer to Specifications, "Cylinder
Head Valves".

Installation Procedure
Table 2

Required Tools
Tool Part Number Part Description Qty
1U-8826 Thrust Bearing 1
9U-7242 Compressor Plate 1
9U-7548 Compressor Base 1
A (1)
2J-3506 Full Nut 1
5P-8248 Hard Washer 1
0L-1143 Bolt 1
(1) Part of the 9U-7241 Valve Spring Compressor

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Lubricate the valve stems with clean engine oil.

Illustration 3 g01163164

Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

2. Ensure that washer (6) is installed on the valve guide.

3. Install valve spring (5) on valve (2) .

4. Install valve rotator (4) on valve (2) .

5. Secure Tooling (A) with unit injector clamp (1). Use Tooling (A) to compress the valve
springs. Install valve spring retainers (3) on each valve (2) .

The valve spring keepers can be thrown from the valve when the valve
spring compressor is released. Ensure that the valve spring keepers are
properly installed on the valve stem. To help prevent personal injury,
keep away from the front of the valve spring keepers and valve springs
during the installation of the valves.

6. Carefully remove Tooling (A). Strike the top of the valve with a soft faced hammer in order to
 ensure that valve spring retainers (3) are properly installed.

End By: Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit
Injector - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02330159

Inlet and Exhaust Valves - Remove and Install

SMCS - 1105-010

S/N - 9WR1-9999

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 5S-1330 Valve Spring Compressor 1
B 8S-2263 Spring Tester 1

Start By:

A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01163301

Personal injury can result from being struck by parts propelled by a

released spring force.

Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to

release the spring force.

1. Use Tooling (A) to compress the valve springs. Remove valve spring retainers (2) from valve
(1) .

2. Carefully remove Tooling (A) from valve (1) .

 3. Remove valve rotator (3) .

4. Remove valve spring (4) from valve (1) .

5. Remove washer (5) and valve (1) from the valve guide.

6. Use Tooling (B) to check the valve springs (spring force). Refer to Specifications, "Cylinder
Head Valves".

7. Inspect the inlet valves and the exhaust valves. Refer to Specifications, "Cylinder Head
Valves".

Installation Procedure
Table 2

Required Tools
Tool Part Number Part Description Qty
A 5S-1330 Valve Spring Compressor 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Lubricate the inlet valves and the exhaust valves with clean engine oil. Install the inlet valves
and the exhaust valves in the cylinder head.
 Illustration 2 g01163301

Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

2. Ensure that washer (5) is installed on the valve guide.

3. Install valve spring (4) on valve (1) .

4. Install valve rotator (3) on valve (1) .

5. Use Tooling (A) to compress valve spring (4). Install valve spring retainers (2) on valve (1) .
 The valve spring keepers can be thrown from the valve when the valve
spring compressor is released. Ensure that the valve spring keepers are
properly installed on the valve stem. To help prevent personal injury,
keep away from the front of the valve spring keepers and valve springs
during the installation of the valves.

6. Carefully remove Tooling (A). Strike the top of the valve with a soft faced hammer in order to
ensure that valve spring retainers (2) are properly installed.

End By: Install the cylinder head. Refer to Disassembly and Assembly, " Cylinder Head - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02015995

Inlet and Exhaust Valve Guides - Remove and Install

SMCS - 1104-010

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A (1) 9U-6895 Valve Guide Driver 1
(1) Part of 9U-7530 Engine Tool Group

Start By:

A. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust
Valves - Remove and Install".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01003942

1. Remove valve stem seal (1) from valve guide (2) .

2. Use Tooling (A) and a hammer to remove the valve guide from the cylinder head.

Installation Procedure
Table 2

Required Tools
Tool Part Number Part Description Qty
A (1) 9U-6895 Valve Guide Driver 1
B (1) 9U-6894 Guide Collar 1
(1) Part of 9U-7530 Engine Tool Group

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2 g01003943

1. Lubricate the bores for the valve guides with clean engine oil.

2. Install valve guide (2) in the cylinder head with Tooling (A) and Tooling (B), as shown.

Note: Tooling (B) must be used in order to install the valve guide to the correct height.

Height to top of valve guide from cylinder head surface ... 35.00 ± 0.50 mm (1.378 ± 0.020
inch)

Note: For more information, refer to Specifications, "Cylinder Head Valves".

3. Install valve stem seal (1) on the valve guide.

End By: Install the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust
Valves - Remove and Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02016026

Inlet and Exhaust Valve Seat Inserts - Remove and Install

SMCS - 1103-010

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 166-7441 Valve Seat Extractor Tool Group 1

Start By:

A. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust
Valves - Remove and Install".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01042314

1. Use Tooling (A) to remove the valve seat inserts from the cylinder head.

2. Clean the bores in the cylinder head for the valve seat inserts. Remove any rough areas from
the bores.

Installation Procedure
Table 2

Required Tools
Tool Part Number Part Description Qty
9U-6898 Valve Seat Driver (Exhaust) 1
B (1)
9U-6897 Valve Seat Driver (Inlet) 1
(1) Part of 9U-7530 Engine Tool Group

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 2 g01042315

1. Lower the temperature of new valve seat inserts (1) .

2. Use Tooling (B) to install the new valve seat inserts in the cylinder head.

Note: Do not machine the prefinished valve seat inserts in order to correct the valve
projection. Excessive valve projection indicates that the valve seat insert is not seated or
material was not cleaned from the bottom of the counterbore.

End By: Install the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust
Valves - Remove and Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02110458

Inlet and Exhaust Valve Seals - Remove and Install

SMCS - 1104-010-SA

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 5P-7414 Seal Pick 1
B (1) 9U-6890 Seal Installer 1
C (1) 9U-7216 Valve Seal Pin 1
(1) Part of the 9U-7226 Seal Installer

Start By:

A. Remove the inlet and exhaust valve springs. Refer to Disassembly and Assembly, "Inlet and
Exhaust Valve Springs - Remove and Install".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The valve seals can be replaced with the cylinder head on the engine or off the engine. The
valves do not need to be installed in the cylinder head in order to install the valve seals.
Illustration 1 g00516322

1. Use Tooling (A) to remove valve seals (2) from valves (1) and valve guides (3) .

Installation Procedure
Table 2

Required Tools
Tool Part Number Part Description Qty
A 5P-7414 Seal Pick 1
B (1) 9U-6890 Seal Installer 1
C (1) 9U-7216 Valve Seal Pin 1
(1) Part of the 9U-7226 Seal Installer

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2 g00516322

Illustration 3 g00516323

Note: Follow Steps 1 and 2 in order to install the valve seals with the valves in the cylinder head.

1. Apply a thin coat of clean engine oil on the valve stems. Position valve seals (2) on valves (1) .

2. Use Tooling (B) to press valve seals (2) onto valve guides (3) .

Note: Follow Steps 3 through 7 in order to install the valve seals when the valves are removed
from the cylinder head. Use Tooling (C) instead of the valve stem to correctly position the new
valve seal.

3. Position valve seal (2) on Tooling (B) .

4. Insert Tooling (C) through Tooling (B) and the new valve seal.

5. Position Tooling (C) in the valve guide bore.

6. Use Tooling (B) to push valve seal (2) in position on valve guide (3) .

7. Remove Tooling (B) and Tooling (C) from valve guide (3) .

8. Repeat Steps 3 through 7 in order to install the remaining valve seals.

End By: Install the inlet and exhaust valve springs. Refer to Disassembly and Assembly, "Inlet and
Exhaust Valve Spring - Remove and Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02330510

Engine Oil Filter Base - Remove

SMCS - 1306-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 185-3630 Strap Wrench As 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

 Illustration 1 g00776213

1. Use Tooling (A) to remove engine oil filter (1) .

Illustration 2 g01163398

2. Disconnect tube assembly (3) from engine oil filter base (4) .

3. Remove tube assembly (5) and the O-ring seal.

4. Remove bolts (2) and engine oil filter base (4) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02330633

Engine Oil Filter Base - Disassemble

SMCS - 1306-015

Disassembly Procedure
Start By:

A. Remove the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter
Base - Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g00776364

1. Remove tube (3) from engine oil filter base (1) . Remove the O-ring seal from tube (3) .

Note: Be careful not to damage the threads on stud (2) .

 Illustration 2 g00776366

Personal injury can result from parts and/or covers under spring
pressure.

Spring force will be released when covers are removed.

Be prepared to hold spring loaded covers as the bolts are loosened.

2. Remove the cover, spring (4) , and valve (5) from engine oil filter base (1) .

3. Check the condition of O-ring seal for wear or damage. If the O-ring seal is worn or damaged,
use a new part for replacement.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02330669

Engine Oil Filter Base - Assemble

SMCS - 1306-016

Assembly Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g00776364

Note: Be careful not to damage the threads of stud (2) .

Note: Check the condition of O-ring seal for wear or damage. If the O-ring seal is worn or
damaged, use a new part for replacement.

1. Install tube (3) in engine oil filter base (1) . Install the O-ring seal in tube (3) .
 Illustration 2 g00776366

Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

2. Install valve (5) , spring (4) , and the cover in engine oil filter base (1) .

End By: Install the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter
Base - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02330677

Engine Oil Filter Base - Install

SMCS - 1306-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 185-3630 Strap Wrench As 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

 Illustration 1 g01163398

1. Position engine oil filter base (4) on the engine and install bolts (2) .

2. Install the O-ring seal and tube assembly (5) .

3. Connect tube assembly (3) to engine oil filter base (4) .

Illustration 2 g00776213

4. Use Tooling (A) to install engine oil filter (1) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02330687

Engine Oil Cooler - Remove

SMCS - 1378-011

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Drain the oil from the engine oil cooler into a suitable container for storage or disposal. Refer
to Operation and Maintenance Manual, "Engine Oil and Filter - Change".

2. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
 Illustration 1 g00770450

3. Remove tube (1) from the engine.

4. Remove clip (3) and bolts (2) . Remove bonnet (4) and the adapter as an assembly.

Illustration 2 g00770451

5. Remove adapter (5) from bonnet (4) . Remove the O-ring seals from the adapter.

Illustration 3 g01163454
6. Remove clip (8) .

7. Remove elbow (6) , bypass valve body (7) , and engine oil cooler (9) as an assembly.

8. Check the condition of the gaskets and the O-ring seals. If the gaskets or the O-ring seals are
worn or damaged, use new parts for replacement.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02330920

Engine Oil Cooler - Disassemble

SMCS - 1378-015

Disassembly Procedure
Start By:

A. Remove the engine oil cooler. Refer to Disassembly and Assembly, "Engine Oil Cooler -
Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Use a rod of 3.17 mm (0.125 inch) diameter to clean each tube of the engine oil cooler.

Note: Place identification marks on the engine oil cooler and the bonnet for proper alignment
during assembly.

Illustration 1 g00770734
 Illustration 2 g00770920

Personal injury can result from parts and/or covers under spring
pressure.

Spring force will be released when covers are removed.

Be prepared to hold spring loaded covers as the bolts are loosened.

2. Remove cover (1) from oil cooler bypass body (3) .

3. Remove spring (2) and bypass valve (4) from oil cooler bypass body (3) .

Illustration 3 g00770809

4. Remove elbow (5) and tube (6) from oil cooler bypass body (3) .

5. Remove elbow (5) from tube (6) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02330949

Engine Oil Cooler - Assemble

SMCS - 1378-016

Assembly Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Use the identification marks on the engine oil cooler and the bonnet for proper alignment
during assembly.

Illustration 1 g00770809

1. Install elbow (5) on tube (6) .

2. Install elbow (5) and tube (6) on oil cooler bypass body (3) .

Note: Use clean engine oil to lubricate the O-ring seals.

 Illustration 2 g00770920

Illustration 3 g00770734

Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

3. Install spring (2) and bypass valve (4) in oil cooler bypass body (3) .

4. Install cover (1) on oil cooler bypass body (3) .

5. Lubricate the new O-ring seals with clean engine oil. Install the elbow and the oil cooler
bypass body on the engine oil cooler.

End By: Install the engine oil cooler. Refer to Disassembly and Assembly, "Engine Oil Cooler -
Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02330967

Engine Oil Cooler - Install

SMCS - 1378-012

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01163454

1. Install engine oil cooler (9) , bypass valve body (7) , and elbow (6) as an assembly on the
engine.

2. Install clip (8) .

 Illustration 2 g00770451

3. Install the O-ring seals on adapter (5) . Install adapter (5) on bonnet (4) .

Illustration 3 g00770450

4. Install bonnet (4) and the adapter as an assembly. Install clip (3) and bolts (2) .

5. Install tube (1) on the engine.

6. Refill the engine with oil. Refer to Operation and Maintenance Manual, "Engine Oil and Filter
- Change".

7. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02330996

Marine Transmission Oil Cooler Core - Remove and Install

SMCS - 3320-010-KO

S/N - 9WR1-9999

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".

2. Disconnect the tube assemblies from the marine transmission oil cooler.
 Illustration 1 g00771083

3. Remove bolts (1) and cover (2) .

4. Remove the O-ring seals from cover (2) .

Illustration 2 g00771084

5. Remove core assembly (3) and gasket (4) from the housing.

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 3 g00771084

1. Install gasket (4) and core assembly (3) in the housing.

Illustration 4 g00771083

2. Install the O-ring seals on cover (2) .

3. Install cover (2) and bolts (1) .

4. Connect the tube assemblies to the marine transmission oil cooler.

5. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02331026

Marine Transmission Oil Cooler - Remove and Install

SMCS - 3320-010

S/N - 9WR1-9999

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".

2. Disconnect the tube assemblies from the marine transmission oil cooler.
 Illustration 1 g00771160

3. Disconnect tube assembly (1) .

Illustration 2 g00771161

4. Remove clip (4) .

5. Remove bolts (2) and marine transmission oil cooler (3) .

6. Remove the gasket and the O-ring seal from the marine transmission oil cooler.

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 3 g00771161

1. Install the gasket and the O-ring seal on the marine transmission oil cooler.

2. Position marine transmission oil cooler (3) and install bolts (2) .

3. Install clip (4) .

Illustration 4 g00771160

4. Connect tube assembly (1) .

5. Connect the tube assemblies to the marine transmission oil cooler.

6. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i01984199

Engine Oil Pump - Remove

SMCS - 1304-011

Removal Procedure
Start By:

A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

 Illustration 1 g01001911

1. Remove oil supply tube assembly (1). Remove suction bell and tube assembly (4) .

2. Remove bolts (3) and remove engine oil pump (2) from the cylinder block.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02331069

Engine Oil Pump - Disassemble

SMCS - 1304-015

Disassembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 1P-2321 Combination Puller 1
B 1P-0510 Driver Group 1

Start By:

A. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01042320

1. Use Tooling (A) to remove drive gear (1) from the shaft of engine oil pump (2) . Remove the
key from the shaft.

Illustration 2 g01028300
 Personal injury can result from parts and/or covers under spring
pressure.

Spring force will be released when covers are removed.

Be prepared to hold spring loaded covers as the bolts are loosened.

2. Remove retainer (7) .

3. Remove spring (6) and bypass valve (5) from engine oil pump (2) .

4. Remove cover (4) .

5. Remove idler gear and drive gear (3) .

6. Use Tooling (B) to remove the bearings from engine oil pump (2) .
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02331114

Engine Oil Pump - Assemble

SMCS - 1304-016

Assembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
B 1P-0510 Driver Group 1

Illustration 1 g01038181

1. Use Tooling (B) to install bearings (8) in the engine oil pump. The bearing joint should be 30
± 15 degrees from the center line of the two bearing bores. Install the bearings so the bearings
are even with the outside of the engine oil pump.
2. Lubricate the bearings with clean engine oil.

Illustration 2 g01028300

3. Lubricate idler gear and drive gear (3) with clean engine oil. Install idler gear and drive gear
(3) .

4. Install cover (4) .

Note: The engine oil pump must turn freely after assembly. Turn the engine oil pump by hand.
Reposition cover (4) if the engine oil pump does not turn freely.

5. Install bypass valve (5) , spring (6) , and retainer (7) .

 Illustration 3 g01038184

6. Install drive gear (1) . Install bolt (9) . Tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb
ft).

End By: Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i01984303

Engine Oil Pump - Install

SMCS - 1304-012

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01001911

Note: Ensure that engine oil pump (2) is seated on the dowels before bolts (3) are tightened.

1. Position engine oil pump (2) on the dowels in the cylinder block. Install bolts (3) .

2. Install oil supply tube assembly (1). Install suction bell and tube assembly (4) .

End By: Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02331233

Water Pump - Remove

SMCS - 1361-011

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Note: Intermittent leakage of a small amount of coolant from the weep hole is not an
indication of water pump seal failure. Seepage is normal to ensure proper lubrication of the
face of the water pump seal. Replace the water pump if excessive leakage is observed from the
weep hole in the water pump housing.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
 Illustration 1 g01163689

2. Remove bolts (3) and the plate from elbow (1) . Remove tube (2) from the elbow.

3. Remove bonnet (5) from water pump (4) .

Illustration 2 g01163687

4. Remove hose (6) .

5. Remove cover (7) .

Note: Check the condition of the O-ring seals. If the O-ring seals are worn or damaged, use
new parts for replacement.
 Illustration 3 g01163691

6. Remove cover (8) and the water pump.

7. Remove the O-ring seal from the water pump.

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02331283

Water Pump - Disassemble

SMCS - 1361-015

Disassembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
8S-2264 Puller Group 1
4B-3903 Bolt 2
A
1P-0456 Plate 1
4B-4277 Washer 2
B 9S-9152 Bearing Puller Gp 1

Start By:

A. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The water pump seal can be replaced without removing the water pump from the engine.
 Illustration 1 g01163722

1. Remove O-ring seal (7) from adapter (1) . Remove adapter (1) from housing (4) . Remove the
O-ring seal from the outside of adapter (1) .

2. Remove bolt (11) and washer (9) . Use Tooling (A) to remove impeller (3) from shaft (10) .

3. Remove bolt (13) and washer (12) from shaft (10) . Remove gear (15) from shaft (10) .

4. Remove bolts (14) from bearing retainer (8) . Remove bearing retainer (8) . Remove bearing
cone (6) and shaft (10) from housing (4) by inverting the pump assembly.

5. Use a suitable press to remove seal (2) and oil seal (5) from the housing.

6. Use Tooling (B) and a suitable press to remove bearing assembly (6) from shaft (10) .

7. Remove O-ring seal (16) from housing (4) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i03657405

Water Pump - Assemble

SMCS - 1361-016

Assembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
C 1P-0510 Driver Group 1
D 138-9299 (1) Oil Seal Tool 1
E 139-0088 (1) Seal Tool 1
E 325-5756 (2) Seal Installer 1
F 4C-9500 Quick Cure Primer 1
(1) Use with a 19.1 mm (0.75 inch) shaft
(2) Use with a 25.4 mm (1.00 inch) shaft

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01163722

1. Use Tooling (F) to clean shaft (10) and the counterbore for oil seal (5) in housing (4) .

2. Use Tooling (C) to install a new oil seal (5) in housing (4) . Install the seal with the part
number on the metal face of the seal toward the housing. Ensure that the oil seal is flush with
the front edge of the counterbore of the housing. Do not lubricate the oil seal.

3. Install bearing cone (6) on shaft (10) .

4. Position bearing retainer (8) with "this side out" markings toward the gear end of shaft (10) .
Install gear (15) . Install washer (12) and bolt (13) on shaft (10) . Tighten bolt (13) to a torque
of 215 ± 40 N·m (159 ± 30 lb ft).

5. Slide Tooling (D) over shaft (10) . The tapered edge will be facing outward.

6. Install the gear and shaft assembly into housing (4) . Use care not to damage the oil seal.
Install bolts (14) that hold bearing retainer (8) to the housing.
 7. Remove Tooling (D) from shaft (10) .

8. Use Tooling (E) and a suitable press to install a new seal (2) over shaft (10) and into housing
(4) . Ensure that the outer shell of the seal is fully seated in the housing.

9. Position impeller (3) on shaft (10) . Install washer (9) and bolt (11) . Tighten the bolt to a
torque of 39 ± 3 N·m (29 ± 2 lb ft).

10. Install a new O-ring seal on the outside of adapter (1) . Lightly lubricate the seal with clean
engine oil.

11. Install a new O-ring seal (7) on adapter (1) .

12. Position adapter (1) on housing (4) .

13. Install a new O-ring seal (16) in housing (4) .

End By: Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02331364

Water Pump - Install

SMCS - 1361-012

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Check the condition of the O-ring seals. If the O-ring seals are worn or damaged, use
new parts for replacement.

1. Install the O-ring seal on the water pump.

Illustration 1 g01163691

2. Place the water pump in position and install cover (8) .

 Illustration 2 g01163687

3. Install cover (7) .

4. Install hose (6) .

Illustration 3 g01163689

5. Install bonnet (5) on water pump (4) .

6. Install the O-ring seal on elbow (1) . Lubricate the bore for the O-ring seal lightly with
glycerin.

7. Install tube (2) on elbow (1) .

8. Install bolts (3) and the plate on elbow (1) .

9. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02331442

Water Temperature Regulator - Remove and Install

SMCS - 1355-010

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
 Illustration 1 g00770364

2. Disconnect hose assembly (1) .

Illustration 2 g00770365

3. Disconnect tube assembly (3) from regulator housing (6) .

4. Remove bolts (4) . Remove bolts (5) and the plates. Remove elbow (2) .

Illustration 3 g00770366
 5. Remove bolts (8) and elbow (7) .

Illustration 4 g00770367

6. Loosen hose clamps (10) and disconnect harness assemblies (9) .

Illustration 5 g00770368

7. Remove bolts (11) .

8. Remove the regulator housing and the gasket.

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 6 g00770368

1. Place a new gasket and the regulator housing in position. Install bolts (11) .

Illustration 7 g00770367

2. Connect harness assemblies (9) and tighten hose clamps (10) .

Illustration 8 g00770366

3. Install elbow (7) and bolts (8) .

 Illustration 9 g00770365

4. Install elbow (2) . Install the plates and bolts (5) . Install bolts (4) .

5. Connect tube assembly (3) to regulator housing (6) .

Illustration 10 g00770364

6. Connect hose assembly (1) .

7. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02331533

Auxiliary Water Pump - Disassemble - Type 1

SMCS - 1371-015

Disassembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 1P-2321 Puller Group 1
B 1P-1861 Retaining Ring Pliers 1
C 1P-1859 Retaining Ring Pliers 1
D 8B-7554 Bearing Puller 1

Start By:

A. Remove the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water
Pump - Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g00778500

1. Remove nut (1) and washer (2) that fastens gear (3) on the water pump.

Illustration 2 g00778509

2. Use Tooling (A) to remove gear (3) from the water pump.
 Illustration 3 g00778513

3. Remove key (4) from the shaft.

Illustration 4 g00778769

4. Remove bolts (5) that fasten adapter (6) to housing (7) .

Illustration 5 g00778772

5. Remove cover (8) from body (9) .

 Illustration 6 g00778791

6. Remove O-ring seal (10) and impeller assembly (11) from body (9) .

Illustration 7 g00778799

Personal injury can result from parts and/or covers under spring
pressure.

Spring force will be released when covers are removed.

Be prepared to hold spring loaded covers as the bolts are loosened.

7. Remove plate (12) . Use Tooling (C) to remove retaining ring (13) . Remove washer (14) and
the spring.
 Illustration 8 g00778809

8. Remove bolts (15) and separate body (9) from housing (7) .

Note: Be careful not to damage the seal assembly when you separate housing (7) from body
(9) .

Illustration 9 g00778811

9. Remove the ceramic part of seal assembly (16) .

Illustration 10 g00778812
10. Remove O-ring seal (17) . Use Tooling (B) to remove retaining ring (19) from the housing.

11. Remove shaft assembly (18) from the housing.

Illustration 11 g01163895

12. Use a suitable press to remove bearing (20) from drive shaft (21) .

Illustration 12 g01163896

13. Use Tooling (D) to remove bearing (22) from the housing.
 Illustration 13 g01163855

14. Remove O-ring seal (23) and lip seal (24) from the housing.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02331530

Auxiliary Water Pump - Remove

SMCS - 1371-011

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Drain the raw water system.

 Illustration 1 g00943007

2. Disconnect tube assembly (1) from auxiliary water pump (4) .

3. Remove clamps (2) from each side of auxiliary water pump (4) .

4. Remove nuts (3) from auxiliary water pump (4) .

5. Remove auxiliary water pump (4) and the gasket from the front housing. The weight of
auxiliary water pump (4) is approximately 23 kg (50 lb).
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i01984858

Auxiliary Water Pump - Disassemble - Type 2

SMCS - 1371-015

Disassembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 1P-2321 Puller Group 1
B 1P-1861 Retaining Ring Pliers 1
C 1P-1859 Retaining Ring Pliers 1
D 1P-1855 Retaining Ring Pliers 1
E 8H-0663 Bearing Puller Gp 1

Start By:

A. Remove the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water
Pump - Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
 of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1 g01

1. Use Tooling (A) to remove drive gear (1) .

2. Use Tooling (C) to remove retaining ring (2) .

3. Remove spacer (3) .

4. Remove cover (20) .

5. Remove impeller (19) .

6. Remove cam liner (18) .

 7. Use Tooling (B) to remove retaining ring (16) .

8. Remove plate (17) .

9. Separate housing (4) from housing (15) .

10. Use a suitable press to remove shaft assembly (10) from housing (4) .

11. Use a suitable press and Tooling (E) to remove bearing (6) .

12. Use Tooling (D) to remove retaining ring (7) .

13. Use a suitable press and Tooling (E) to remove bearing (9) and spacer (8) from shaft assembly
(10) .

14. Remove washer (14) from shaft assembly (10) .

15. Remove seal (13) and seal (12) from shaft assembly (10) .

16. Remove washer (11) from shaft assembly (10) .

17. Remove seal (5) from housing (4) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02331601

Auxiliary Water Pump - Assemble - Type 1

SMCS - 1371-016

Assembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
B 1P-1861 Retaining Ring Pliers 1
C 1P-1859 Retaining Ring Pliers 1
E 1P-0150 Driver Group 1
F 135-7629 Seal Installer 1
G 1P-0808 Multipurpose Grease 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01163855

Illustration 2 g01163896

1. Use Tooling (E) to install lip seal (24) and bearing (22) in the housing. Install O-ring seal (23)
in the housing. Lubricate the lip seal with Tooling (G) .

Note: Ensure that lip seal (24) is facing toward the bearing bore.

Illustration 3 g01163907

2. Use a suitable press to install bearing race (25) on drive shaft (21) . Install bearing (20) .
 Illustration 4 g00778812

3. Install shaft assembly (18) in the housing. Use Tooling (B) to install retaining ring (19) .
Install O-ring seal (17) .

Illustration 5 g00778811

Note: Do not touch the mating surfaces of the ceramic ring or the carbon ring. The sealing
surface area will be damaged.

Note: Use only clean water in order to lubricate the seal. Do not use grease or oil to lubricate
the seal.

4. Insert seal assembly (16) .

Note: Use Tooling (F) in order to install the seal assembly in the body. Install the ceramic ring
with the smoothest face of the ring toward the carbon seal assembly.
 Illustration 6 g00778809

5. Assemble housing (7) and body (9) together. Install bolts (15) .

Illustration 7 g00778799

Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure

and wear protective equipment.

6. Install the spring and washer (14) . Use Tooling (C) to install retaining ring (13) . Install plate
(12) .
 Illustration 8 g00778791

7. Install impeller assembly (11) and O-ring seal (10) in body (9) .

Illustration 9 g00778772

8. Install cover (8) on body (9) .

Illustration 10 g00778769

9. Position adapter (6) on housing (7) . Install bolts (5) .

 Illustration 11 g00778513

10. Install key (4) in the shaft.

Illustration 12 g00778500

11. Position gear (3) on the water pump and install washer (2) and nut (1) .

End By: Install the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water
Pump - Install".
 Shutdown SIS

Previous Screen

Product: MARINE ENGINE

Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i03126494

Auxiliary Water Pump - Assemble - Type 2

SMCS - 1371-016

Assembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
B 1P-1861 Retaining Ring Pliers 1
C 1P-1859 Retaining Ring Pliers 1
D 1P-1855 Retaining Ring Pliers 1
F 1P-0150 Driver Group 1
G 135-7629 Seal Installer 1
H 1P-0808 Multipurpose Grease 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01

1. Install seal (5) into housing (4) .

2. Install washer (11) onto shaft assembly (10) .

3. Use Tooling (G) to install seal (13) onto shaft assembly (10) .

4. Use Tooling (F) to install seal (12) into housing (4) . Lubricate seal (12) with Tooling (H) .

5. Install washer (14) onto shaft assembly (10) .

6. Use Tooling (D) to install retaining ring (7) .

7. Raise the temperature of bearing (9) and spacer (8) . Install bearing (9) and spacer (8) onto
shaft assembly (10) .

8. Raise the temperature of bearing (6) . Install bearing (6) .

9. Install shaft assembly (10) into housing (4) .

10. Position housing (4) onto housing (15) .

11. Install plate (17) .

12. Use Tooling (B) to install retaining ring (16) .

 13. Install cam liner (18) .

14. Install impeller (19) .

15. Install cover (20) .

16. Install spacer (3) .

17. Use Tooling (C) to install retaining ring (2) .

18. Install drive gear (1) .

End By: Install the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water
Pump - Install".

Copyright 1993 - 2013 Caterpillar Inc. Wed Dec 18 11:11:04 UTC+0200 2013
All Rights Reserved.
Private Network For SIS Licensees.
 Shutdown SIS

Previous Screen

Product: MARINE ENGINE

Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02332112

Auxiliary Water Pump - Install

SMCS - 1371-012

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Position auxiliary water pump (4) and the gasket in the front housing. The weight of auxiliary
water pump (4) is approximately 23 kg (50 lb).

2. Install nuts (3) on auxiliary water pump (4) .

3. Install clamps (2) on each side of auxiliary water pump (4) .

4. Connect tube assembly (1) to auxiliary water pump (4) .

 5. Refill the raw water system.

Copyright 1993 - 2013 Caterpillar Inc. Wed Dec 18 11:11:19 UTC+0200 2013
All Rights Reserved.
Private Network For SIS Licensees.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02332138

Aftercooler - Remove
SMCS - 1063-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
 Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".

Illustration 1 g00779452

2. Remove bolts (1) from tube assembly (2) and tube assembly (3) .

3. Disconnect tube assembly (2) from the aftercooler. Inspect the O-ring seal.

Illustration 2 g00779466

4. Remove brackets (5) from base (4) .

 Illustration 3 g00779476

5. Remove bolts (6) from bracket (7) and base (4) .

6. Disconnect tube assemblies (8) .

Illustration 4 g00779478

7. Remove bolts (9) from base (4) and aftercooler housing (10) .

Illustration 5 g00779484
 8. Disconnect harness assemblies (11) and (12) .

Illustration 6 g00779486

9. Remove clamp (13) and tube assembly (3) from auxiliary water pump (14) . Inspect the O-ring
seal.

Illustration 7 g01164130

10. Remove bolts (15) and the plates.

 Illustration 8 g01164161

11. Remove harness assembly (16) .

Illustration 9 g01164131

12. Attach Tooling (A) and a suitable lifting device to aftercooler housing (10) . The weight of
aftercooler housing (10) and the aftercooler core is approximately 68 kg (150 lb).

13. Remove bolts (17) . Remove aftercooler housing (10) and the aftercooler core as an assembly.

Illustration 10 g01164167

14. Remove bolts (18) from bonnet (19) .

15. Remove bonnet (19) .

 Illustration 11 g01164168

16. Remove aftercooler core (20) from the aftercooler housing. Inspect O-ring seals (21) . Replace
the aftercooler gaskets.

Illustration 12 g01164169

17. Attach a suitable lifting device to base (4) .

18. Remove bolts (22) and base (4) . Inspect the O-ring seals.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02332987

Aftercooler - Install
SMCS - 1063-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01164169

1. Attach a suitable lifting device to base (4) .

2. Position base (4) on the engine.

3. Install bolts (22) .

Illustration 2 g01164168

4. Inspect O-ring seals (21) . Replace the aftercooler gaskets.

5. Install aftercooler core (20) in the aftercooler housing.

Illustration 3 g01164167

6. Install bonnet (19) and bolts (18) .

 Illustration 4 g01164131

7. Attach Tooling (A) and a suitable lifting device to aftercooler housing (10) . The weight of
aftercooler housing (10) and the aftercooler core is approximately 68 kg (150 lb).

8. Position aftercooler housing (10) and the aftercooler core on the engine. Install bolts (17) .

Illustration 5 g01164161

9. Install harness assembly (16) .

 Illustration 6 g01164130

10. Install the plates and bolts (15) .

Illustration 7 g00779486

11. Install tube assembly (3) and clamp (13) on auxiliary water pump (14) .

Illustration 8 g00779484

12. Connect harness assemblies (11) and (12) .

 Illustration 9 g00779478

13. Install bolts (9) in base (4) and aftercooler housing (10) .

Illustration 10 g00779476

14. Connect tube assemblies (8) .

15. Install bolts (6) in bracket (7) and base (4) .

Illustration 11 g00779466
16. Install brackets (5) on base (4) .

Illustration 12 g00779452

17. Connect tube assembly (2) and tube assembly (3) to the aftercooler.

18. Install bolts (1) .

19. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02333083

Heat Exchanger - Remove

SMCS - 1379-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 4

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

 Illustration 1 g00777947

1. Remove bolts (2) from elbows (3) and heat exchanger (1) .

Illustration 2 g00777960

2. Remove bolts (4) from elbows (5) and the heat exchanger.

Illustration 3 g01164520

3. Remove bolt (7) and the plate.

4. Remove clamp (8) .

5. Remove tube (6) . Inspect the O-ring seal for damage. Use a new seal for replacement.

Illustration 4 g01164521

6. Attach Tooling (A) and a suitable lifting device to heat exchanger (1) . The weight of heat
exchanger (1) is approximately 61 kg (135 lb).

7. Remove bolts (9) and nuts (10) from the base of heat exchanger (1) .

8. Remove heat exchanger (1) from the engine.

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02333217

Heat Exchanger - Disassemble

SMCS - 1379-015

Disassembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 125-5597 Mounting Bar 2
B - Scotch Brite 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".

Illustration 1 g00777238

2. Remove bolts (1) and the front spacers from the heat exchanger.

Illustration 2 g01164548

3. Remove middle bolts (5) from each side of the heat exchanger.

4. Remove spacers (4) .

5. Remove bolts (2) and bracket (3) .

 Illustration 3 g01164557

Illustration 4 g00537934

6. Install Tooling (A) .

7. Loosen bolts (7) for the front frame in a reverse numerical sequence in at least three
incremental steps. The plates for the heat exchanger will deflect approximately 30 percent
when the bolts for the frame are loosened. Remove front frame (6) .
 Illustration 5 g00777275

Illustration 6 g00777290

8. Remove plates (8) from the assembly and keep the plates in order. Remove gasket (9) from
each plate. Clean the plate with a coarse nylon brush or new Tooling (B) . Do not use a dirty
Tooling (B) , steel wool or a wire brush, which may scratch the titanium plate. Any iron
scratches in the titanium plate can lead to corrosion of the plate. The recommended cleaning
solution for scale buildup of (calcium carbonate buildup) and sediment (corrosion products) is
a maximum of 4 percent solution of nitric acid, citric acid, or sulfuric acid. The recommended
cleaning solution for cleaning biological growth is a 4 percent solution of sodium hydroxide
with the nylon brush. Rinse plates with water.
 Illustration 7 g01164559

9. While the plates are removed, inspect titanium collar (11) and rubber seal (10) . Clean any
deposits from the ports.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02333356

Heat Exchanger - Assemble

SMCS - 1379-016

Assembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 125-5597 Mounting Bar 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01164559
1. Install rubber seal (10) and titanium collar (11) in the rear frame.

2. Install Tooling (A) .

Illustration 2 g01

3. Position new gasket (9) on plates (8) . Install the tabs of the gasket into the slots of the plate.

Note: Do not use the old gasket.

Note: The gasket on the plate assemblies should face the engine during assembly.

Note: The Gasket for Heat Exchanger Plate (Y) and the Gasket for Heat Exchanger Plate (Z)
are identical. The orientation of the heat exchanger plates is critical during the assembly of the
heat exchanger plates. Heat Exchanger Plate (Y) and Heat Exchanger Plate (Z) are for the sea
water in the heat exchanger.

Note: Heat Exchanger Plate (M) identifies the ports that are blocked in order to prevent
coolant flow. Heat Exchanger Plate (M) is installed against the front frame. The orientation of
the heat exchanger plate is critical during the assembly of the heat exchanger plates. Heat
Exchanger Plate (M) is for the jacket water in the heat exchanger.

Note: Heat Exchanger Plate (W) does not block any of the ports in order to prevent coolant
flow. Heat Exchanger Plate (W) is installed against the engine. The orientation of the heat
 exchanger plate is critical during the assembly of the heat exchanger plates.

Note: Heat Exchanger Plate (X) does not block any of the ports in order to prevent coolant
flow. The orientation of the heat exchanger plate is critical during the assembly of the heat
exchanger plates. Heat Exchanger Plate (X) is for the jacket water in the heat exchanger.

4. Install plates (8) on the heat exchanger.

Illustration 3 g00777742

5. When plates (8) are installed correctly, the edges of the plates will form a honeycomb pattern.

Illustration 4 g01164557
 Illustration 5 g00537934

6. Position front frame (6) on Tooling (A) . Install bolts (7) in front frame (6) and hand tighten
the bolts. Tighten the bolts in the numerical sequence that is shown in at least three
incremental steps until the front frame is tight against the spacers. Tighten the bolts in equal
steps so plates will not bend. The plates for the heat exchanger will compress approximately
30 percent when the bolts for the frame are tightened.

7. Remove Tooling (A) .

Illustration 6 g01164548

8. Install bracket (3) and bolts (2) .

9. Install spacers (4) . Install middle bolts (5) on each side of the heat exchanger.
 Illustration 7 g00777238

10. Install the spacers and bolts (1) .

11. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02333435

Heat Exchanger - Install

SMCS - 1379-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 4

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01164521
1. Attach Tooling (A) and a suitable lifting device to heat exchanger (1) . The weight of heat
exchanger (1) is approximately 61 kg (135 lb).

2. Position heat exchanger (1) on the mounting bracket and install bolts (9) and nuts (10) .

3. Tighten nuts (10) to a torque of 65 ± 10 N·m (48 ± 7 lb ft).

Illustration 2 g01164520

4. Install tube (6) .

5. Install clamp (8) .

6. Install the plate and bolt (7) .

Illustration 3 g00777960

7. Install bolts (4) in elbows (5) and the heat exchanger.

 Illustration 4 g00777947

8. Install bolts (2) in elbows (3) and heat exchanger (1) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02333449

Engine Lifting Bracket - Remove and Install

SMCS - 1122-010

Removal Procedure
Start By:

A. Remove the heat exchanger. Refer to Disassembly and Assembly, "Heat Exchanger -
Remove".

Illustration 1 g00771452

1. Remove bolts (1) and front bracket (2) .

 Illustration 2 g00771578

2. Remove the bolts and rear bracket (3) .

Installation Procedure

Illustration 3 g00771578

1. Install rear bracket (3) and the bolts.

Illustration 4 g00771452
 2. Install front bracket (2) and bolts (1) .

End By: Install the heat exchanger. Refer to Disassembly and Assembly, "Heat Exchanger - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02348107

Engine Support (Front) - Remove and Install

SMCS - 1154-010-FR

Removal Procedure

Illustration 1 g01173051

1. Support the engine.

2. Attach a suitable lifting device to front engine support (5). The weight of front engine support
(5) is approximately 36 kg (80 lb). Remove setscrews (1) and bolts (4). Remove front engine
support (5) .

3. Remove bolts (3) and engine supports (2) .

Installation Procedure
 Illustration 2 g01173051

1. Position engine supports (2) against the cylinder block and install bolts (3) .

2. Attach a suitable lifting device to front engine support (5). The weight of front engine support
(5) is approximately 36 kg (80 lb). Position front engine support (5) and install bolts (4) and
setscrews (1) .

3. Tighten bolts (4) to a torque of 475 ± 60 N·m (350 ± 44 lb ft). Tighten the nuts on setscrews
(1) to a torque of 45 ± 7 N·m (33 ± 5 lb ft).
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02333473

Flywheel - Remove
SMCS - 1156-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 138-7573 Lifting Bracket 2
B - Guide Stud5/8 - 18 NF by 8 inch 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01091639

1. Attach Tooling (A) and a suitable lifting device to flywheel (2). The weight of flywheel (2) is
approximately 65 kg (143 lb).

2. Remove two bolts (1). Install Tooling (B) .

3. Remove remaining bolts (1). Remove flywheel (2) .

Illustration 2 g01091705

4. Use a hammer and a punch in order to remove ring gear (3) from flywheel (2) .
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02333510

Flywheel - Install
SMCS - 1156-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 138-7573 Lifting Bracket 2
B - Guide Stud5/8 - 18 NF by 8 inch 2

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01091705

Note: Ring gear (3) must be installed with the chamfered side of the teeth upward. The
chamfered side of the gear teeth will be facing toward the starting motor when the flywheel is
installed.

1. Raise the temperature of ring gear (3). Install ring gear (3) on flywheel (2) .

Illustration 2 g01091639

2. Install Tooling (B) in the crankshaft.

3. Attach Tooling (A) and a suitable lifting device to flywheel (2). The weight of flywheel (2) is
approximately 65 kg (143 lb). Position the flywheel on the crankshaft.
4. Apply clean engine oil to the threads of bolts (1) .

5. Install bolts (1). Remove Tooling (B). Install remaining bolts (1) .

6. Tighten bolts (1) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).

7. Remove Tooling (A) from the flywheel.

8. Check the flywheel runout. Refer to Testing and Adjusting, "Flywheel - Inspect".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02016240

Crankshaft Rear Seal - Remove

SMCS - 1161-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 1U-7600 Slide Hammer Puller 1

Start By:

A. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The rear seal and the wear sleeve must be replaced at the same time. Once the
crankshaft rear seal and the wear sleeve are separated, these components can not be used
again.
 Illustration 1 g01042446

1. Use Tooling (A) to remove wear sleeve (2) .

2. Use Tooling (A) to remove crankshaft rear seal (1) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i03845953

Crankshaft Rear Seal - Install

SMCS - 1161-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
5P-1733 Seal Locator 1
5P-1737 Bolt 3
B
9S-8858 Nut (Seal Installer) 1
6V-6143 Seal Installer 1

Note: Certain configurations may not require a crankshaft rear seal.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The crankshaft rear seal and the wear sleeve must be replaced at the same time. Once the
crankshaft rear seal and the wear sleeve are separated, these components cannot be used again.
 Illustration 1 g01115766

Note: Do not use any type of lubricant during the installation of the crankshaft seal and wear
sleeve.

1. Clean the outside diameter of the crankshaft.

Note: Install the crankshaft rear seal with the arrow that shows the direction of crankshaft
rotation toward the rear of the engine.

2. Use Tooling (B) to install wear sleeve (2) and crankshaft rear seal (1) .

End By: Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i03251082

Flywheel Housing - Remove and Install

SMCS - 1157-010

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1

Start By:

A. Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
B. Remove the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal -
Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01031179

1. Attach Tooling (A) and a suitable lifting device to flywheel housing (3) . The weight of
flywheel housing (3) is approximately 40 kg (88 lb).

2. Remove tube assembly (1) .

3. Remove bolts (2) . Remove flywheel housing (3) from the dowels in the cylinder block.

Installation Procedure
Table 2

Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1
B 8T-9022 Silicone Gasket -

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2 g01031179
 Illustration 3 g01031192

1. Apply a small amount of Tooling (B) at the joint of flywheel housing (3) , the engine oil pan,
and the cylinder block.

2. Attach Tooling (A) and a suitable lifting device to flywheel housing (3) . The weight of
flywheel housing (3) is approximately 40 kg (88 lb).

3. Position flywheel housing (3) on the cylinder block and install bolts (2) .

4. Torque bolts (2) according to the following procedure:

a. Tighten Bolt (1) through Bolt (9) in a numerical sequence to a torque of 100 ± 20 N·m
(75 ± 15 lb ft).

b. Tighten Bolt (10) through Bolt (24) in a numerical sequence to a torque of 40 ± 10 N·m
(30 ± 7 lb ft).

c. Torque Bolt (1) through Bolt (9) again in a numerical sequence to a torque of 135 ± 20
N·m (100 ± 15 lb ft).

d. Torque Bolt (10) through Bolt (24) again in a numerical sequence to a torque of 55 ± 10
N·m (40 ± 7 lb ft).

5. Install tube assembly (1) .

End By:
a. Install the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal -
Install".
b. Install the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02333764

Vibration Damper and Pulley - Remove and Install

SMCS - 1205-010

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A - Guide Stud (5/8 - 18 NF) 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Remove the fan drive belts. Refer to Operation and Maintenance Manual, "Belts -
Inspect/Adjust/Replace".
 Illustration 1 g00514084

2. Remove top bolt (1) from the vibration damper and pulley assembly. Install Tooling (A) in
place of the bolt.

3. Remove remaining bolts (1) .

4. Remove vibration damper (3) from the crankshaft.

5. Remove pulley (2) from the crankshaft.

Installation Procedure
Table 2

Required Tools
Tool Part Number Part Description Qty
A - Guide Stud (5/8 - 18 NF) 1
B 4C-5593 Anti-Seize Compound 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Thoroughly inspect the viscous damper for signs of leakage or for signs
of a dented (damaged) case. Either of these conditions can cause the
weight to make contact with the case. This can affect the viscous
damper's operation.
 Illustration 2 g00514084

1. Install Tooling (A) in the bolt hole at the top of the crankshaft.

2. Install pulley (2) and vibration damper (3) on the crankshaft.

3. Apply Tooling (B) to bolts (1) . Install bolts (1) .

4. Remove Tooling (A) . Install bolt (1) in place of Tooling (A) .

5. Install the fan drive belts. Refer to Operation and Maintenance Manual, "Belts -
Inspect/Adjust/Replace".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02016277

Crankshaft Front Seal - Remove

SMCS - 1160-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 1U-7600 Slide Hammer Puller 1

Start By:

A. Remove the vibration damper and the pulley. Refer to Disassembly and Assembly, "Vibration
Damper and Pulley - Remove and Install".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The crankshaft front seal and the wear sleeve must be replaced at the same time. Once the
crankshaft front seal and the wear sleeve are separated, these components can not be used again.
 Illustration 1 g01042474

1. Use Tooling (A) or a punch and hammer in order to puncture three or more holes in wear
sleeve (2) and crankshaft front seal (1) .

2. Use Tooling (A) to remove the wear sleeve and the crankshaft front seal.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02210423

Crankshaft Front Seal - Install

SMCS - 1160-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
5P-1733 Seal Locator 1
5P-1737 Bolt 3
B
9S-8858 Nut (Seal Installer) 1
6V-6142 Seal Installer 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The crankshaft front seal and the wear sleeve must be replaced at the same time. Once
the crankshaft front seal and the wear sleeve are separated, these components cannot be used
again.

Note: Do not use any type of lubricant during the installation of the crankshaft front seal and
the wear sleeve.

1. Clean the outside diameter of the crankshaft.

 Illustration 1 g01116116

2. Use Tooling (B) to install crankshaft front seal (1) and wear sleeve (2) .

Note: Install the crankshaft front seal with the arrow that shows the direction of crankshaft
rotation toward the front of the engine.

End By: Install the vibration damper and the pulley. Refer to Disassembly and Assembly, "Vibration
Damper and Pulley - Remove and Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02348199

Gear Group (Front) - Remove

SMCS - 1206-011

Removal Procedure
Start By:

A. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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.
 Illustration 1 g01037502

1. Remove bolts (4) and adjustable idler gear (3) .

2. Remove bolts (6) and idler gear (5) .

3. Remove bolts (2) and cluster gear assembly (1) .

 Illustration 2 g01037504

Note: Stub shaft (10) and stub shaft (12) must be removed in order to remove plate (13) .

Note: If the nuts for stub shaft (10) are loosened, or if stub shaft (10) is removed or moved in
any way, the backlash for the camshaft gear and the adjustable idler gear will need to be
readjusted at assembly. Refer to Testing and Adjusting, "Gear Group (Front) -Time".

4. Remove the nuts, bolt (9), and stub shaft (10) .

5. Remove nuts (11), the bolt, and stub shaft (12) .

6. Remove bolts (8) and stub shaft (7) .

7. Remove locking bolts (14) that fasten plate (13) to the cylinder block. Remove plate (13) and
the integral seal.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02348209

Gear Group (Front) - Install

SMCS - 1206-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 8T-9022 Silicone Gasket 1
B 9S-3263 Thread Lock Compound 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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.
Illustration 1 g01037562
 Illustration 2 g01037504

Illustration 3 g01037563

1. Apply Tooling (B) to the serrations of studs (15). Install the studs in plate (13) .

2. Install the integral seal on the dowel pins on the cylinder block.
 Note: Apply Tooling (A) to the bottom of the integral seal in order to fill the space at the
cylinder block, the front housing and the engine oil pan.

3. Install plate (13) on the dowel pins on the cylinder block. Install new locking bolts (14)
(Marked "X") in order to fasten the plate to the cylinder block. Tighten the locking bolts to a
torque of 55 N·m (41 lb ft).

Note: Apply Tooling (B) to the bolts.

4. Install stub shaft (12). Apply Tooling (B) to the studs and the bolt for stub shaft (12). Tighten
nuts (11) and the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

5. Install stub shaft (10). Do not tighten the nuts and bolt (9) for the stub shaft at this time. The
nuts and the bolt for stub shaft (10) will need to be tightened when the backlash is adjusted.

Note: If the stub shaft has been removed, loosened, or moved in any way, the backlash for the
camshaft gear and the adjustable idler gear will need to be readjusted. The camshaft gear must
be installed and the adjustable idler gear must be removed in order to perform the backlash
adjustment procedure.

6. Install stub shaft (7). Apply Tooling (B) to bolts (8). Tighten bolts (8) to a torque of 55 ± 10
N·m (41 ± 7 lb ft) in the following sequence: (1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1).

Illustration 4 g01037502
 7. Position cluster gear assembly (1) on the stub shaft. Ensure that Timing Marks (V) are aligned
on the cluster gear assembly and the crankshaft gear.

8. Apply Tooling (B) to bolts (2). Install bolts (2) .

9. Position idler gear (5) on the stub shaft. Apply Tooling (B) to bolts (6). Install bolts (6) .

Note: Skip Step 10 if the stub shaft has been removed, loosened, or moved in any way. The
backlash for the camshaft gear and the adjustable idler gear will need to be readjusted. The
camshaft gear must be installed and the adjustable idler gear must be removed in order to
perform the backlash adjustment procedure. Refer to Testing and Adjusting, "Gear Group
(Front) - Time".

10. Position adjustable idler gear (3) on the stub shaft. Apply Tooling (B) to bolts (4). Install bolts
(4) .

11. Adjust the backlash for the camshaft gear and the adjustable idler gear, if necessary. Refer to
Testing and Adjusting, "Gear Group (Front) - Time".

Note: The camshaft gear must be installed and the adjustable idler gear must be removed in
order to perform the backlash adjustment procedure.

End By: Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02333981

Housing (Front) - Remove

SMCS - 1151-011

Removal Procedure
Start By:

A. Remove the heat exchanger. Refer to Disassembly and Assembly, "Heat Exchanger -
Remove".
B. Remove the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove
and Install".
C. Remove the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal
- Remove".
D. Remove the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and
Install".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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.
 Illustration 1 g01032876

1. Remove strap (1) .

2. Remove nut (2) , studs (3) , and bolts (4) from front housing (6) .

3. Remove front engine support (5) .

4. Remove front housing (6) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02333983

Housing (Front) - Install

SMCS - 1151-012

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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.
 Illustration 1 g01032876

1. Position front housing (6) on the engine.

2. Install nut (2) , studs (3) , and bolts (4) .

3. Install front engine support (5) .

4. Install strap (1) .

End By:

a. Install the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and Install".
b. Install the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal -
Install".
c. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and
Install".
d. Install the heat exchanger. Refer to Disassembly and Assembly, "Heat Exchanger - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i01994409

Valve Mechanism Cover - Remove and Install

SMCS - 1107-010

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01033224

1. Remove bolts (1).

2. Remove valve mechanism cover (2) .

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 2 g01033224

Illustration 3 g00579295

1. Position valve mechanism cover (2) on the valve cover base. Tighten bolts (1) to a torque of
18 ± 3 N·m (13 ± 2 lb ft) in the numerical sequence that is shown in Illustration 3.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i01985327

Valve Mechanism Cover Base - Remove and Install

SMCS - 1120-010

Removal Procedure
Start By:

A. Remove the valve mechanism covers. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01028794

1. Disconnect harness assembly (3) from the electronic unit injector.

2. Disconnect harness assembly (1) from valve cover base (2) .

3. Remove bolts (4) .

4. Remove valve cover base (2) .

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Before assembly, check the condition of the seal. If the seal is worn or damaged, use a new
part for replacement.
 Illustration 2 g01028794

Illustration 3 g00579307

1. Position valve cover base (2) on the cylinder head and install bolts (4). Tighten bolts (4) to a
torque of 18 ± 3 N·m (13 ± 2 lb ft) in the numerical sequence that is shown in Illustration 3.

2. Connect harness assembly (1) .

 3. Position harness assembly (3) on the electronic unit injector. Tighten the cap nuts to a torque
of 2.5 ± 0.25 N·m (22 ± 2 lb in).

End By: Install the valve mechanism covers. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02346853

Rocker Arm and Shaft - Remove

SMCS - 1102-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 124-2946 Lifting Bracket 1

Start By:

A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
B. Remove the compression brake, if equipped. Refer to Disassembly and Assembly,
"Compression Brake - Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g00517442

Illustration 2 g00517462

Illustration 3 g00517457
 Valve rocker arms and unit injector rocker arms can move on the shaft
after the bolts have been removed. The shaft should be kept level when
removed from the cylinder head. To avoid possible personal injury,
keep fingers clear of the valve rocker arms and the unit injector rocker
arms when lifting the assembly from the cylinder head.

Note: If the engine is equipped with a compression brake, skip Step 1.

1. Remove bolts (2) .

2. Remove rocker shaft (3) , valve rocker arms (1) , and unit injector rocker arms (4) as a unit
with Tooling (A) .

3. Repeat Steps 1 and 2 for the remainder of the rocker arm assemblies.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02725865

Rocker Arm - Disassemble

SMCS - 1123-015

Disassembly Procedure
Start By:

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

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01038992

1. Remove valve rocker arms (7) and unit injector rocker arm (2) from rocker shaft (3) .

Note: Do not reuse the O-ring seals on the rocker arm adjustment screws if the buttons have
been removed from the adjustment screws.

2. Remove button (6) from adjustment screw (5) in valve rocker arm (7) .

3. Remove button (4) from adjustment screw (1) in unit injector rocker arm (2) .
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02005591

Rocker Arm - Assemble

SMCS - 1123-016

Assembly Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01038992

Note: Do not reuse the O-ring seals on the rocker arm adjustment screws if the buttons have
been removed from the adjustment screws.
 1. Install the O-ring seals in button (6) and button (4) .

2. Install the O-ring seals and the buttons on the valve rocker arms, as follows:

a. Support valve rocker arm (7) in a vise with soft jaws.

b. Position the O-ring seal and button (6) on the round end of adjustment screw (5) .

c. Use a soft hammer to seat button (6) on adjustment screw (5) .

3. Install the O-ring seals and the buttons on the unit injector rocker arms, as follows:

a. Support unit injector rocker arms (2) in a vise with soft jaws.

b. Position the O-ring seal and button (4) on the end of adjustment screw (1) .

c. Use a soft hammer to seat button (4) on adjustment screw (1) .

4. Lubricate rocker shaft (3) with clean engine oil and install the assembled rocker arms on
rocker shaft (3) .

End By: Install the rocker arms and the rocker shaft. Refer to Disassembly and Assembly, "Rocker
Arm and Shaft - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02110799

Rocker Arm and Shaft - Install

SMCS - 1102-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 124-2946 Lifting Bracket 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Valve rocker arms and unit injector rocker arms can move on the shaft
after the bolts have been removed. The shaft should be kept level when
removed from the cylinder head. To avoid possible personal injury,
keep fingers clear of the valve rocker arms and the unit injector rocker
arms when lifting the assembly from the cylinder head.
 Illustration 1 g00517457

Illustration 2 g00517462

Illustration 3 g00517442

1. Install rocker shaft (3), valve rocker arms (1), and unit injector rocker arms (4) as a unit with
Tooling (A) .
 Note: Install rocker shaft (3) with the flat side facing upward.

Note: If the engine is equipped with a compression brake, skip Step 2.

2. Install bolts (2). Tighten bolts (2) to a torque of 109 ± 15 N·m (80 ± 11 lb ft).

3. Repeat Steps 1 and 2 for the remainder of the rocker arm assemblies.

End By:

a. Install the compression brake, if equipped. Refer to Disassembly and Assembly, "Compression
Brake - Install".
b. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02334062

Cylinder Head - Remove

SMCS - 1100-011

Removal Procedure
Start By:

A. Remove the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove
and Install".
B. Remove the valve mechanism cover base. Refer to Disassembly and Assembly, "Valve
Mechanism Cover Base - Remove and Install".
C. Remove the rocker arms and shafts. Refer to Disassembly and Assembly, "Rocker Arm and
Shaft - Remove".
D. Remove the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit
Injector - Remove".
E. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE

Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
 Dispose of all fluids according to local regulations and mandates.

Illustration 1 g01165003

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) .

 Illustration 2 g01165004

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

Illustration 3 g01165005

3. Remove O-ring seal (5) and O-ring seal (6) from seal assembly (3) .
 Illustration 4 g01165006

4. Disconnect tube assemblies (7).

5. Disconnect hose assembly (8) and hose assemblies (9) .

Illustration 5 g01164991
 6. Remove strap (12) .

7. Attach a suitable lifting device to cylinder head (11). The weight of cylinder head (11) is
approximately 235 kg (518 lb).

8. Remove cylinder head bolts (10) .

9. Carefully remove cylinder head (11) .

Illustration 6 g01164996

10. Remove cylinder head gasket (13), spacer plate (14), the gasket, and the O-ring seals.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i03705320

Cylinder Head - Install

SMCS - 1100-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 6V-4876 Lubricant -
B 4C-9505 Gasket Sealant -

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01164996

1. Install the O-ring seals, the spacer plate gasket, spacer plate (14) , and cylinder head gasket
(13) . Install the spacer plate gasket with the following procedure.

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

Note: Apply a thin film of clean engine oil on the O-ring seals prior to installation.

a. For best results, clean all surfaces and dry all surfaces with a solvent that is free of
residue.

b. Apply Tooling (B) as a uniform film to the bottom side of the spacer plate gasket.
Position the spacer plate gasket.

c. Apply Tooling (B) as a uniform film to the top side of the spacer plate gasket. Formulas
that dry more slowly increase the time for the procedure.

d. Once the repairs are completed and the sealant has had adequate time to cure, the engine
can be run.

e. If necessary, Tooling (B) can be removed from metal surfaces with isopropyl alcohol.
 Illustration 2 g01164991

Illustration 3 g01

2. Attach a suitable lifting device to cylinder head (11) . The weight of cylinder head (11) is
approximately 235 kg (518 lb).

3. Carefully install the cylinder head on the dowel pins on the cylinder block.
 Note: The bolts that are Marked "X" are 216 mm (8.5 inch) long. The remainder of the bolts
are 194 mm (7.6 inch) in length.

Note: Apply Tooling (A) to the bolt threads and both sides of the washers. Install cylinder
head bolts (10) .

4. Tighten cylinder head bolts (10) according to the following procedure:

a. In a numerical sequence, tighten Bolts 1 through 26 to a torque of 270 ± 15 N·m (200 ±

11 lb ft).

b. In a numerical sequence, tighten Bolts 1 through 26 to a torque of 450 ± 15 N·m (330 ±

11 lb ft).

c. In a numerical sequence, again tighten Bolts 1 through 26 to a torque of 450 ± 15 N·m

(330 ± 11 lb ft).

5. Install strap (12) .

Illustration 4 g01165006

6. Connect hose assembly (8) and hose assemblies (9) .

7. Connect tube assemblies (7) .

 Illustration 5 g00994660

8. Install O-ring seal (5) and O-ring seal (6) on seal assembly (3) .
 Illustration 6 g00993714

9. Install adapter (4) and seal assembly (3) .

 Illustration 7 g00993711

10. Install thrust plate (1) and bolts (2) .

End By:

a. Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".

b. Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit
Injector - Install".
c. Install the rocker arms and shafts. Refer to Disassembly and Assembly, "Rocker Arm and
Shaft - Install".
d. Install the valve mechanism cover base. Refer to Disassembly and Assembly, "Valve
Mechanism Cover Base - Remove and Install".
e. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and
Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02342181

Camshaft - Remove
SMCS - 1210-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 9U-7257 Cradle 1
B 9U-7256 Guide 1
C 9U-7225 Camshaft Pilot 2
D 9U-7240 Camshaft Hook 2

Start By:

A. Remove the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove
and Install".
B. Remove the rocker arms and the rocker shafts. Refer to Disassembly and Assembly, "Rocker
Arm and Shaft - Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01167737

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) .

Illustration 2 g01167738

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

 Illustration 3 g01167739

3. Remove O-ring seal (5) and O-ring seal (6) from seal assembly (3) .

NOTICE
Care must be used when removing or installing the camshaft. Do not
damage the finshed surfaces of the camshaft or the camshaft bearings.

Illustration 4 g01167740

4. Use the bolts for the rocker arm shaft assembly to install Tooling (A) at Location (Y) .
 Illustration 5 g01167741

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

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

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

7. Position the camshaft into the bore of Tooling (B). Tighten the bolts that hold Tooling (B) to
front housing (7) .
 Illustration 6 g01167742

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.

Illustration 7 g01167743

8. Remove camshaft (8), as follows:

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

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

c. Keep the camshaft level while the camshaft is being removed from the cylinder head.
The weight of camshaft (8) is approximately 39 kg (86 lb).

Alternative Removal Procedure

Table 2

Required Tools
Tool Part Number Part Description Qty
E (1) 177-8001 Sleeve 1
F (1) 177-8002 Adapter 1
G 6L-4697 Bolts 3
(1) Part of 177-8003 Engine Tool Group
Start By:

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

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

 Illustration 8 g01167737

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) .

Illustration 9 g01167738

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

 Illustration 10 g01167739

3. Remove O-ring seal (5) and O-ring seal (6) from seal assembly (3) .

Illustration 11 g01167746

4. Remove bolts (9) and cover (10) .

NOTICE
Care must be used when removing or installing the camshaft. Do not
damage the finshed surfaces of the camshaft or the camshaft bearings.
 Illustration 12 g01167748

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) .

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).
 Illustration 13 g01167750

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).
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02342218

Camshaft - Install
SMCS - 1210-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 9U-7257 Cradle 1
B 9U-7256 Guide 1
C 9U-7225 Camshaft Pilot 2
D 9U-7240 Camshaft Hook 2
H 9U-7243 Alignment Sleeve 1
J 8T-2998 Lubricant 1
K 9S-3263 Thread Lock Compound 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the camshaft and camshaft bearings are thoroughly clean. Lubricate the camshaft
lobes with a 50/50 mixture of Tooling (J) and clean engine oil. Apply a thin coat of clean
engine oil on the camshaft bearings.
 Illustration 1 g01167740

2. Install Tooling (A) on the cylinder head at Location (Y) .

Illustration 2 g01167741

3. Install Tooling (B) on front housing (7). Do not tighten the bolts that hold Tooling (B) to front
housing (7) at this time.

4. Use Tooling (H) to align Tooling (B) with the camshaft bearings. Tighten the bolts that hold
Tooling (B) to front housing (7). Remove Tooling (H) .

Note: Tooling (H) should move freely from the bore of Tooling (B) .
 Illustration 3 g01167743

5. Install Tooling (C) in the end of camshaft (8) .

Note: Rotate the camshaft during installation. This will prevent the camshaft from binding in
the camshaft bearings.

6. Use a suitable lifting device in order to position camshaft (8) into Tooling (B) and the cylinder
head. The weight of camshaft (8) is approximately 39 kg (86 lb).

Illustration 4 g01167742

Note: Tooling (C) must be removed before the camshaft can be completely installed in the
cylinder head.
7. Remove the suitable lifting device. Rotate the camshaft during installation. Use care not to
allow the end of the camshaft and Tooling (C) to drop. Use Tooling (D) to assist in aligning
camshaft (8) with the camshaft bearings.

8. Remove Tooling (C) and finish installing camshaft (8) in the bore.

9. Remove Tooling (A) and Tooling (B) .

Illustration 5 g01167739

Illustration 6 g01167738
 Illustration 7 g01167737

10. Install O-ring seal (5) and O-ring seal (6) in seal assembly (3). Lubricate O-ring seal (6) with
Tooling (J) .

11. Install adapter (4) and seal assembly (3). Ensure that the dowel in adapter (4) engages the hole
in the camshaft.

12. Install thrust plate (1). Apply Tooling (K) to bolts (2). Hold the thrust plate 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 in order to ensure that O-ring seal (5) stays in the groove in seal assembly
(3) .

End By:

a. Install the rocker arms and the rocker shafts. Refer to Disassembly and Assembly, "Rocker
Arm and Shaft - Install".
b. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and
Install".

Alternative Installation Procedure

Table 2

Required Tools
Tool Part Number Part Description Qty
E (1) 177-8001 Sleeve 1
F (1) 177-8002 Adapter 1
G 6L-4697 Bolts 3
 J 8T-2998 Lubricant 1
K 9S-3263 Thread Lock Compound 1
(1) Part of 177-8003 Engine Tool Group

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Ensure that the camshaft and camshaft bearings are thoroughly clean. Lubricate the camshaft
lobes with a 50/50 mixture of Tooling (J) and clean engine oil. Apply a thin coat of clean
engine oil on the camshaft bearings.

Illustration 8 g01167748

2. Install Tooling (F) on the front of the camshaft with Tooling (G).

3. Install Tooling (E) .

4. Use two technicians to install the camshaft. Carefully slide the camshaft into the cylinder head
from the rear of the engine. Keep the camshaft level while the camshaft is being installed in
the cylinder head. The weight of the camshaft is approximately 39 kg (86 lb).

5. Remove Tooling (F) .

 Illustration 9 g01167750

6. Install Tooling (E) on the end of the camshaft.

7. Use two technicians to install the camshaft. Carefully slide the camshaft into the cylinder head
from the rear of the engine. Keep the camshaft level while the camshaft is being installed in
the cylinder head. The weight of the camshaft is approximately 39 kg (86 lb).

8. Remove Tooling (F) .

Illustration 10 g01167746

9. Position cover (10) on the rear of the cylinder head. Install bolts (9) .
Illustration 11 g01167739

Illustration 12 g01167738
 Illustration 13 g01167737

10. Install O-ring seal (5) and O-ring seal (6) in seal assembly (3). Lubricate O-ring seal (6) with
Tooling (J) .

11. Install adapter (4) and seal assembly (3). Ensure that the dowel in adapter (4) engages the hole
in the camshaft.

12. Install thrust plate (1). Apply Tooling (K) to bolts (2). Hold the thrust plate 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 in order to ensure that O-ring seal (5) stays in the groove in seal assembly
(3) .

End By:

a. Install the rocker arms and the rocker shafts. Refer to Disassembly and Assembly, "Rocker
Arm and Shaft - Install".
b. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and
Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i03898290

Camshaft Gear - Remove and Install

SMCS - 1210-010-GE

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 9U-6896 Guide Bolt 1

Start By:

A. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove".

Illustration 1 g00579965
 Illustration 2 g00579966

1. Position the No. 1 piston at the top center of the compression stroke. Refer to Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston".

2. Verify that the timing mark on camshaft gear (1) is aligned with Timing Mark (X) on front
housing (3) .

3. Remove top bolt (2) from camshaft gear (1) . Install Tooling (A) in place of the bolt.

4. Remove remaining bolts (2) and remove camshaft gear (1) .

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.

5. Remove Tooling (A) .

Installation Procedure
Table 2

Required Tools
Tool Part Number Part Description Qty
A 9U-6896 Guide Bolt 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 3 g00579966

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. Install Tooling (A) in the top hole in the camshaft.

2. Align the hole in the back of camshaft gear (1) with the dowel in the adapter. Install camshaft
gear (1) over Tooling (A) .

Illustration 4 g00579965

Note: Camshaft timing is critical. The timing mark on the camshaft gear must be aligned with
the timing mark on the front cover when the No. 1 piston is at the top center of the
compression stroke. Refer to Testing and Adjusting, "Gear Group (Front) - Time".

3. Verify that the timing mark on camshaft gear (1) is aligned with Timing Mark (X) on front
housing (3) .
 Note: If the timing marks are not aligned, remove camshaft gear (1) and rotate the camshaft
until the timing marks are aligned.

4. Install bolts (2) . Remove Tooling (A) and install remaining bolt (2) .

Illustration 5 g00593987

5. Tighten the bolts in a numeric sequence 1, 4, 2, 5, 3, 6, 1, 4 to a torque of 240 ± 40 N·m (175 ±

30 lb ft).

6. Check the backlash between the camshaft gear and the adjustable idler gear. The backlash
should be 0.216 ± 0.114 mm (0.0085 ± 0.0045 inch). Refer to Testing and Adjusting, "Gear
Group (Front) - Time" for the backlash adjustment procedure.

End By: Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i01995165

Camshaft Bearings - Remove

SMCS - 1211-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
8S-2241 Camshaft Bearing Tool Group 1
8S-8290 Nut 1
8S-8291 Threaded Shaft 1
A (1) 8S-8287 Thrust Bearing Assembly 1
8S-8288 Cone 1
8S-8292 Extension (Short) 2
8S-8293 Extension (Long) 1
9U-7222 Camshaft Bearing Pilot 1
B
8M-8778 Taperlock Stud (1/2 inch - 13 UNC by 1 9/16 inch) 1
C 9U-7223 Alignment Bushing 1
D 9U-7210 Puller Plate 1
(1) Part of the 8S-2241 Camshaft Bearing Tool Group

Start By:

A. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".

 NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01005315

1. Remove bolts (1) from rear cover (2). Inspect the O-ring seal and replace the O-ring seal if the
O-ring seal is worn or damaged.

Illustration 2 g01034895
2. Remove the No. 7 camshaft bearing (rear). Work from the rear of the engine to the front of the
engine.

3. Install the small end of Tooling (B) in the camshaft bearing.

4. Position Tooling (D) on Tooling (A). Install Tooling (A) on Tooling (B) .

Note: Tooling (D) is installed on the outside of the cylinder head. Tooling (D) is required in
order to remove the No. 7 camshaft bearing from the cylinder head.

5. Use Tooling (A) to remove camshaft bearing (3) from the cylinder head.

6. Remove Tooling (B) from Tooling (A) and remove the camshaft bearing.

7. Repeat Step 3 through Step 6 in order to remove the remaining camshaft bearings. Work from
the rear of the engine to the front of the engine.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i01995166

Camshaft Bearings - Install

SMCS - 1211-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
8S-2241 Camshaft Bearing Tool Group 1
8S-8290 Nut 1
8S-8291 Threaded Shaft 1
A (1) 8S-8287 Thrust Bearing Assembly 1
8S-8288 Cone 1
8S-8292 Extension (Short) 2
8S-8293 Extension (Long) 1
9U-7222 Camshaft Bearing Pilot 1
B
8M-8778 Taperlock Stud (1/2 inch - 13 UNC by 1 9/16 inch) 1
C 9U-7223 Alignment Bushing 1
D 9U-7210 Puller Plate 1
9U-7213 Backup Plate 1
E
0S-1621 Bolt (1/2 inch - 13 UNC by 1 inch) 1
F 9U-7214 Spacer Plate 1
(1) Part of the 8S-2241 Camshaft Bearing Tool Group
 NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Ensure that the inside of the cylinder head is clean. Inspect the camshaft bore for metal burrs.
Put a thin film of clean engine oil on the inside of the camshaft bearing bores and on each camshaft
bearing prior to installation.

Illustration 1 g01034920

1. Install the No. 7 camshaft bearing (rear), as follows:

a. Insert the large end of Tooling (B) into the No. 7 camshaft bore. Position camshaft
bearing (3) on Tooling (B) .

b. Position Tooling (D) on Tooling (A). Install Tooling (A) in Tooling (B) .

c. Position camshaft bearing (3) on Tooling (B). Install Tooling (E) on Tooling (B) .

Note: Refer to Specifications, "Cylinder Head" for appropriate information for the
orientation of the camshaft bearings in the cylinder head.

d. Use Tooling (A) in order to pull camshaft bearing (3) into the camshaft bore.

Note: When the chamfer of Tooling (E) contacts the face of the camshaft bore, the
camshaft bearing is properly installed.

e. Remove Tooling (E) from Tooling (B). Remove Tooling (A) from Tooling (B). Remove
Tooling (B) from the cylinder head.
 Illustration 2 g01034921

2. Install the No. 6 through No. 2 camshaft bearings, as follows:

a. Insert the large end of Tooling (B) into the camshaft bore.

Note: Use Tooling (C) to align Tooling (A) and Tooling (B) with the camshaft bearing
bores. Install Tooling (C) in the inside diameter of any installed camshaft bearing
between Tooling (A) and Tooling (B) .

b. Install Tooling (A) in Tooling (B). Position camshaft bearing (3) on Tooling (B). Install
Tooling (E) on Tooling (B) .

Note: Refer to Specifications, "Cylinder Head" for appropriate information for the
location and the orientation of the camshaft bearings in the cylinder head.

c. Use Tooling (A) in order to pull camshaft bearing (3) into the camshaft bore.

Note: When the chamfer of Tooling (E) contacts the face of the camshaft bore, the
camshaft bearing is properly installed.

d. Remove Tooling (E) from Tooling (B). Remove Tooling (A) from Tooling (B) .

e. Remove Tooling (B) and Tooling (C) from the cylinder head.

3. Repeat Step 2 in order to install the No. 6 through No. 2 camshaft bearings.
 Illustration 3 g01034922

4. Install the No. 1 camshaft bearing (front), as follows:

a. Insert the large end of Tooling (B) into the No. 1 camshaft bore. Assemble Tooling (A)
and Tooling (C) on Tooling (B) .

b. Position camshaft bearing (3) on Tooling (B). Install Tooling (E) and Tooling (F) on
Tooling (B) .

Note: Refer to Specifications, "Cylinder Head" for appropriate information for the
location and the orientation of the camshaft bearings in the cylinder head.

Note: Tooling (F) is used to seat the No. 1 camshaft bearing to the correct depth in the
camshaft bore.

c. Use Tooling (A) in order to pull the No. 1 camshaft bearing into the No. 1 camshaft
bore. When the chamfer of Tooling (E) contacts the face of the camshaft bore, the
camshaft bearing is properly installed.

d. Remove Tooling (E) and Tooling (F) from Tooling (B). Remove Tooling (A) from
Tooling (B) .

e. Remove Tooling (B) and Tooling (C) from the cylinder head.
 Illustration 4 g01005315

5. Inspect the O-ring seal. Replace the O-ring seal if the seal is worn or damaged. Position rear
cover (2). Install bolts (1). Tighten the bolts to a torque of 13 ± 3 N·m (10 ± 2 lb ft).

End By: Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02343583

Engine Oil Pan - Remove and Install

SMCS - 1302-010

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 1U-7505 Hydraulic Jack 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

 Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact the skin.

1. Drain the engine oil from the engine oil pan into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change".

Illustration 1 g01169509

2. Disconnect hose (1) from engine oil pan (2) .

3. Use Tooling (A) to support engine oil pan (2) .

Illustration 2 g01169511

4. Remove bolts (3) and engine oil pan (2) .

Installation Procedure
Table 2
 Required Tools
Tool Part Number Part Description Qty
A 1U-7505 Hydraulic Jack 1
B 8T-9022 Silicone Gasket -

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Apply Tooling (B) to the sealing surface of the engine oil pan and on the connecting joints of
the front plate, gasket for the engine oil pan, cylinder block, and the flywheel housing. Install a
new gasket on the engine oil pan.

Illustration 3 g01169511

2. Use Tooling (A) to place engine oil pan (2) in position. Install bolts (3) .

3. If the drain plug was removed, install the drain plug. Tighten the drain plug to a torque of 70 ±
15 N·m (52 ± 11 lb ft).

4. If the pipe plugs were removed, install the pipe plugs. Tighten the pipe plugs to a torque of 82
± 10 N·m (60 ± 7 lb ft).
 Illustration 4 g01169509

5. Connect hose (1) to engine oil pan (2) .

6. Refill the engine with engine oil. Refer to Operation and Maintenance Manual, "Engine Oil
and Filter - Change".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i03871869

Cylinder Liner - Remove

SMCS - 1216-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 5P-8665 (1) Cylinder Liner Puller Gp 1
(1) The 6V-9448 Cylinder Pack Puller is an optional Tool for 137 mm (5.4 inch) and 140 mm (5.5 inch) bore diameters.

Start By:

A. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and
Connecting Rods - Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01005579

1. Remove cylinder liner (1) with Tooling (A) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02110914

Cylinder Liner - Install

SMCS - 1216-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
B 2P-8260 Cylinder Liner Installer 1
C 5P-3975 Rubber Lubricant 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Check the cylinder liner projection. Refer to Testing and Adjusting, "Cylinder Liner Projection
- Inspect".
 Illustration 1 g01004993

2. Install liner seals (3) in the respective grooves.

3. Apply Tooling (C) on the cylinder block liner bore surfaces and liner seals (3) .

4. Dip filler band (2) in clean engine oil for a moment. Install filler band (2) and install cylinder
liner (1) immediately.

Illustration 2 g01005003

5. Use Tooling (B) to install cylinder liner (1) in the cylinder block. Ensure that any marks in
relation to the cylinder liner projection are in alignment.

Note: Refer to Special Instruction, SEHS9564 for more information about cylinder liner
 installation.

End By: Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and
Connecting Rods - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i03334880

Piston Cooling Jets - Remove and Install

SMCS - 1331-010

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 9S-9082 Engine Turning Tool 1

Start By:

A. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01004705

1. Use Tooling (A) to rotate the crankshaft in order to gain access to the piston cooling jet.

2. Remove bolt (1) and piston cooling jet (2) .

Installation Procedure
Table 2

Required Tools
Tool Part Number Part Description Qty
A 9S-9082 Engine Turning Tool 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 2 g01004705

1. Use Tooling (A) to rotate the crankshaft in order to gain access to the piston cooling jet.

2. Install piston cooling jet (2) and bolt (1) . Tighten bolt (1) to a torque of 25 ± 6 N·m (18 ± 4 lb
ft). If bolt (1) is a 7/16 inch bolt, tighten bolt (1) to a torque of 40 ± 8 N·m (30 ± 6 lb ft).

3. Check the clearance between the piston, the piston cooling jet, and the crankshaft.

Minimum permissible clearance between the piston, the piston cooling jet, and the
crankshaft ... 0.63 mm (0.025 inch)

End By: Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02347805

Pistons and Connecting Rods - Remove

SMCS - 1225-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 9S-9082 Engine Turning Tool 1

Start By:

A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove".
B. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Remove".
C. Remove the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets -
Remove and Install".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Remove the carbon ridge from the top inside surface of the cylinder liner.

2. Use Tooling (A) and turn the crankshaft until two pistons are at the bottom center.
 Illustration 1 g01032888

3. Remove bolts (1) and the bearing caps. Push the connecting rods and pistons until the piston
rings are out of the cylinder liners.

Note: Be careful not to damage the cylinder liners and/or the crankshaft journals during the
removal of the pistons and the connecting rods.

Illustration 2 g01032895

4. Remove pistons (2) and connecting rods from the cylinder liners.

5. Repeat Steps 1 through 4 in order to remove the remainder of the pistons and connecting rods.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02344536

Pistons and Connecting Rods - Disassemble

SMCS - 1225-015

Disassembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 139-9039 Retaining Ring Pliers 1
B 7M-3978 Piston Ring Expander Gp 1

Start By:

A. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and
Connecting Rods - Remove".

Note: Mark the components of each piston and connecting rod assembly. The components must be
reinstalled in the original location. Do not interchange components.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01171223

1. Remove connecting rod bearings (10) from connecting rod (6) and connecting rod cap (11).
Remove dowel (12) from connecting rod cap (11) .

2. Use Tooling (A) to remove retaining rings (8) .

3. Remove piston pin (9) and connecting rod (6) from the piston.

4. Use Tooling (B) to remove piston rings (1), (2), and (3) from the piston.

5. Separate piston crown (5) from piston skirt (7) .

Note: Piston pin bearing (4) will be pushed out of connecting rod (6) during installation of the
new bearing.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i03742934

Pistons and Connecting Rods - Assemble

SMCS - 1225-016

Assembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 139-9039 Retaining Ring Pliers 1
B 7M-3978 Piston Ring Expander Gp 1
5P-8639 Hydraulic Press (Connecting Rod Bearing) 1
8F-0024 Hose Assembly 1
1P-2375 Connecting Coupler 1
1P-2376 Connecting Coupler 1
C
5P-8651 Spacer 1
5P-8649 Adapter 1
5P-8650 Bushing Adapter 1
9U-6600 Hydraulic Pump 1

Note: Prior to removal from the engine, the pistons and connecting rod assemblies were marked. The
components must be reassembled together. The components must be installed in the original location
in the engine. Do not interchange any of the components.

NOTICE

Keep all parts clean from contaminants.

 Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01171404

1. Install a new piston pin bearing (4) in connecting rod (6) and remove the old piston pin
bearing, as follows:

NOTICE
The connecting rod must be heated for the installation of the piston pin
bearing. Do not use a torch.
 Illustration 2 g01171408

a. Raise the temperature of connecting rod (6) along Length (Y) .

(Y) Maximum Length ... 85 mm (3.4 inch)

b. Use Tooling (C) to remove the old bearing and install the new bearing at the same time.
The adapter of Tooling (C) should make full contact with the surfaces of the connecting
rod.

Note: Orient the bearing joint within ± 5 degrees of either Location (X) .

c. Allow the connecting rod and the bearing to cool to room temperature.

2. Use a pin boring machine to machine the bore of the piston pin bearing to the correct diameter.

Diameter of piston pin bore ... 55.035 ± 0.008 mm (2.1667 ± 0.0003 inch)
 Illustration 3 g01171223

3. Check the clearance between the ends of piston rings (1) , (2) , and (3) . Refer to
Specifications, "Piston and Rings".

4. Install the spring for oil control piston ring (3) in the oil ring groove of the piston.

5. Position oil control piston ring (3) over the spring. Position the oil control piston ring so that
the gap is 180 degrees from the joint in the spring. Install the oil control piston ring on the
piston with Tooling (B) .

6. Use Tooling (B) to install intermediate piston ring (2) with the side that has the identification
"UP-2" toward the top of the piston.

7. Use Tooling (B) to install top piston ring (1) with the side that has the identification "UP-1"
toward the top of the piston.

8. Position piston rings (1) , (2) , and (3) so the gaps are 120 degrees from each other.

9. Position piston crown (5) on piston skirt (7) .

Note: Ensure that piston pin bearing (4) is in the correct position in connecting rod (6) .

10. Position the piston on connecting rod (6) . Apply clean engine oil to piston pin (9) and install
the piston pin. Use Tooling (A) to install retainer rings (8) . Make sure that the retainer rings
are fully seated in the grooves of the piston.
 11. Install connecting rod bearings (10) in connecting rod (6) and connecting rod cap (11) . Make
sure that the bearings are installed so that the bearing tabs fit into the notches in the connecting
rod and in the connecting rod cap.

12. Install dowel (12) in connecting rod cap (11) .

End By: Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and
Connecting Rods - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i03184195

Pistons and Connecting Rods - Install

SMCS - 1225-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
5P-3526
B or Piston Ring Compressor 1
149-7180

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01032680

1. Apply clean engine oil to the cylinder liner bore, to the piston rings, and to the outer surface of
the piston.

Note: Be careful not to damage the cylinder liners and/or the crankshaft journals during the
installation of the pistons and the connecting rods.

2. Use Tooling (B) to install piston (2) and the connecting rod in the cylinder liner.

Illustration 2 g01096077
Typical Example of 8 and 12 Cylinder Engines

3. The connecting rod and the piston must be installed in the engine with Surface (X) toward the
crankshaft main bearing journal. Surface (Y) must be toward the connecting rod.

Note: Surface (X) is thicker than Surface (Y) .

Note: Surface (X) is chamfered in order to fit the crankshaft.

 Illustration 3 g01249552
Typical Example of 6 Cylinder Engines

4. Make sure that the piston crown, the piston skirt, and the piston rod are properly aligned for
the clearance that is required by oil jet tube (3) . This will prevent major engine failure. Refer
to Specifications, "Connecting Rod" and Specifications, "Piston and Rings".

Note: The markings on the connecting rod need to face the side of the cooling jet.

Illustration 4 g01032888
Typical Example of 6 Cylinder Engines

5. Install bolts (1) and the bearing caps. Refer to Specifications, "Connecting Rod" for the correct
 tightening procedure.

End By:

a. Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets -
Remove and Install".
b. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".
c. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i01995623

Connecting Rod Bearings - Remove

SMCS - 1219-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 9S-9082 Engine Turning Tool 1

Start By:

A. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
 Dispose of all fluids according to local regulations and mandates.

1. Check the connecting rod and the connecting rod bearing caps for identification and the
orientation on the crankshaft.

2. Use Tooling (A) and turn the crankshaft until the connecting rod bearing caps are accessible.

Illustration 1 g01032923

3. Remove bolts (1) and connecting rod bearing cap (2) from the connecting rod. Remove the
lower half of the connecting rod bearing from the connecting rod bearing cap.

4. Push the connecting rod away from the crankshaft. Remove the upper half of the connecting
rod bearing from the connecting rod.

5. Repeat this procedure for the removal of the remainder of the connecting rod bearings.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i01974969

Connecting Rod Bearings - Install

SMCS - 1219-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
B 185-3989 Anti-Seize Compound 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01029039

Note: Install the connecting rod bearings dry when clearance checks are performed. Apply
clean engine oil on the connecting rod bearings for final assembly.

1. Install a new lower half connecting rod bearing (3) in connecting rod bearing cap (2) .

2. Install a new upper half connecting rod bearing in the connecting rod.

3. Pull the connecting rod onto the crankshaft.

Illustration 2 g01032923

4. Check the connecting rod bearing clearances. Follow Steps 5 and 6 for the correct installation
procedures and tightening procedures for the connecting rod bearing caps when the clearance
check is performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check".

Bearing clearance (new bearings) ... 0.062 to 0.160 mm (0.0024 to 0.0063 inch)

Maximum permissible bearing clearance (used bearings) ... 0.20 mm (0.008 inch)
 5. Lubricate the threads of bolts (1) and the seating faces of connecting rod bearing cap (2) with
Tooling (B). Install connecting rod bearing cap (2) and bolts (1). Ensure that the number on
the side of the connecting rod bearing cap is on the same side as the number on the connecting
rod.

6. Tighten bolts (1), as follows:

a. Tighten the bolts to a torque of 90 ± 8 N·m (65 ± 6 lb ft).

b. Put a mark on each bolt and on each connecting rod bearing cap.

c. Tighten each bolt for an additional 90 ± 5 degrees (1/4 turn).

7. Repeat Steps 1 through 6 in order to install the remainder of the connecting rod bearings.

End By: Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i01810421

Crankshaft Main Bearings - Remove

SMCS - 1203-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 2P-5518 Bearing Tool 1

Start By:

A. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Remove".

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
 Dispose of all fluids according to local regulations and mandates.

1. Check the main bearing caps for identification of the location and check the direction of the
main bearing caps in relation to the cylinder block. The main bearing caps must be installed in
the original location and the original direction.

Illustration 1 g00503084

2. Remove No. 2 through No. 6 main bearing caps (1). Remove the thrust plates from the No. 4
main bearing.

Note: Remove No. 1 and No. 7 main bearing caps (1) after No. 2 through No. 6 main bearing
caps have been installed.

Illustration 2 g00503174

Note: If the crankshaft is turned in the wrong direction, the tab on the bearing will be pushed
between the crankshaft and the bearing area of the cylinder block. This can result in damage to
the cylinder block and/or the crankshaft. Turn the crankshaft so that the bearing tab is rotated
out of the crankshaft.

3. Remove the upper halves of the main bearings by putting Tooling (A) in oil hole (2) in the
 crankshaft. Turn the crankshaft in the direction which will remove the upper halves of the
main bearings.

4. Remove the lower halves of the main bearings from the main bearing caps.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i03706857

Crankshaft Main Bearings - Install

SMCS - 1203-012

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 2P-5518 Bearing Tool 1
B 8T-5096 Dial Indicator 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g00503174

Note: Install the crankshaft main bearings dry when clearance checks are made. Put clean
engine oil on the crankshaft main bearings for final assembly.

1. Install new upper main bearings by putting Tooling (A) in oil hole (2) and turning the
crankshaft in order to push the main bearing into the cylinder block. Insert the end of the
bearing that does not have the tab into the cylinder block first.

Note: The upper halves of the main bearings have the oil groove and the oil hole.

Note: Ensure that the main bearings are installed so that the bearing tabs fit into the notch in
the cylinder block and in the main bearing caps.

2. Install new crankshaft main bearings in the main bearing caps.

Note: Refer to Guideline For Reusable Parts, SEBV0544, "Engine Bearings and Crankshafts"
for complete details concerning measuring of bearing clearances.

3. Check the crankshaft main bearing clearances. Follow Step 4 and Step 5 for the correct
installation procedures and tightening procedures for the main bearing caps when the clearance
check is performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check".

Bearing clearance (new bearings) ... 0.091 to 0.186 mm (0.0036 to 0.0073 inch)

Maximum permissible bearing clearance (used bearings) ... 0.25 mm (0.010 inch)

Illustration 2 g00503084
 Illustration 3 g01029625

Note: Ensure that the numbers on main bearing caps (1) match the numbers on the cylinder
block. Also ensure that arrows (3) on the main bearing caps are toward the front of the
cylinder block.

4. Apply clean engine oil on the bolts. Install the thrust plates during installation of the No. 4
main bearing. Install the main bearing caps and the bolts.

Note: Install the thrust plates for the No. 4 main bearing with the words "Block Side" toward
the cylinder block.

5. Tighten the bolts for the main bearing caps, as follows:

a. Tighten the bolt first on the bearing tab side of the main bearing cap to a torque of 260 ±
14 N·m (190 ± 10 lb ft).

b. Tighten the bolt opposite the bearing tab side to a torque of 260 ± 14 N·m (190 ± 10 lb
ft).

c. Put a mark on each bolt and on each main bearing cap.

d. Tighten the bolt opposite the bearing tab side for an additional 120 ± 5 degrees (2 flats).

e. Tighten the bolt on the bearing tab side for an additional 120 ± 5 degrees (2 flats).

6. Use Tooling (B) to check the crankshaft end play. Ensure that Tooling (B) is against a
machined surface. The end play is controlled by the thrust plates of No. 4 main bearing
(center).

Crankshaft end play (new thrust plates) ... 0.15 to 0.55 mm (0.006 to 0.022 inch)

Maximum permissible crankshaft end play (used thrust plates) ... 0.89 mm (0.035 inch)

End By: Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02345057

Crankshaft - Remove
SMCS - 1202-011

Removal Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
1H-3110 Bearing Puller 1
8B-7560 Step Plate 1
9U-6600 Hand Hydraulic Pump 1
1H-3108 Push-Puller Leg 2
1H-3107 Bearing Puller 1
A
3H-0468 Puller Plate 5
3H-0465 Push-Puller Plate 2
1P-0820 Hydraulic Puller 1
5B-0637 Nut 1
8S-6586 Forcing Screw 1
5P-0944 Dowel Puller Group 1
B
5P-0939 Dowel Extractor 1

Start By:

A. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove".
B. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing -
Remove and Install".
 NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Check the main bearing caps for identification marks. Place identification marks on the main
bearing caps, if necessary.

Illustration 1 g01029693

2. Remove bolts (2) for the main bearing caps. Remove main bearing caps (1) .
 Illustration 2 g01029696

3. Remove the connecting rod caps.

4. Attach a suitable lifting device to crankshaft (3) . The weight of crankshaft (3) is
approximately 159 kg (350 lb). Remove crankshaft (3) from the cylinder block.

5. Use Tooling (A) to remove crankshaft gear (4) .

6. Use Tooling (B) to remove the dowel and the pin.

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02355303

Crankshaft - Install
SMCS - 1202-012

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01018180
 Illustration 2 g01029696

1. Install pin (5) in the crankshaft.

The maximum length of the dowel out of the crankshaft face ... 6.4 mm (0.25 inch)

2. Install dowel (6) in the crankshaft.

Protrusion of dowel (6) from the crankshaft face ... 4.1 ± 0.5 mm (0.16 ± 0.02 inch)

Note: Do not raise the temperature of crankshaft gear (4) above 205 °C (400 °F).

3. Raise the temperature of crankshaft gear (4) . Install crankshaft gear (4) on the crankshaft with
the keyway in alignment with dowel (6) . Timing Mark "V" should face away from the
crankshaft.

Note: Install the main bearings dry when clearance checks are made. Refer to Disassembly
and Assembly, "Bearing Clearance - Check". Put clean engine oil on the main bearings for
final assembly.

4. Install the upper halves of the main bearings in the cylinder block.

5. Attach a suitable lifting device to crankshaft (3) . The weight of crankshaft (3) is
approximately 159 kg (350 lb). Install crankshaft (3) with Mark "V" on the crankshaft gear in
alignment with Mark "V" on the cluster gear.

6. Install the connecting rod caps.

 Illustration 3 g01029693

7. Place main bearing caps (1) in position. Install bolts (2) for the main bearing caps.

End By:

a. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing -
Remove and Install".
b. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02717761

Bearing Clearance - Check

SMCS - 1203-535; 1219-535

Measurement Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty

Plastic Gauge (Green)

198-9142 0.025 to 0.076 mm 1
(0.001 to 0.003 inch)

Plastic Gauge (Red)

198-9143 0.051 to 0.152 mm 1
(0.002 to 0.006 inch)
A
Plastic Gauge (Blue)
198-9144 0.102 to 0.229 mm 1
(0.004 to 0.009 inch)

Plastic Gauge (Yellow)

198-9145 0.230 to 0.510 mm 1
(0.009 to 0.020 inch)

Note: Plastic gauge may not be necessary when the engine is in the chassis.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Caterpillar does not recommend the checking of the actual bearing clearances particularly on
small engines. This is because of the possibility of obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each Caterpillar engine bearing is quality checked for
specific wall thickness.

Note: The measurements should be within specifications and the correct bearings should be used. If
the crankshaft journals and the bores for the block and the rods were measured during disassembly,
no further checks are necessary. However, if the technician still wants to measure the bearing
clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small
diameters if clearances are less than 0.10 mm (0.004 inch).

NOTICE
Lead wire, shim stock or a dial bore gauge can damage the bearing
surfaces.

The technician must be very careful to use Tooling (A) correctly. The following points must be
remembered:

 Ensure that the backs of the bearings and the bores are clean and dry.

 Ensure that the bearing locking tabs are properly seated in the tab grooves.

 The crankshaft must be free of oil at the contact points of Tooling (A) .

1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.

Note: Do not allow Tooling (A) to extend over the edge of the bearing.

2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an
impact wrench. Be careful not to dislodge the bearing when the cap is installed.

Note: Do not turn the crankshaft when Tooling (A) is installed.

3. Carefully remove the cap, but do not remove Tooling (A) . Measure the width of Tooling (A)
while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.
 Illustration 1 g01152855
Typical Example

4. Remove all of Tooling (A) before you install the bearing cap.

Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all
parts of Tooling (A) are not the same width. Measure the major width in order to ensure that
the parts are within the specification range. Refer to Specifications Manual, "Connecting Rod
Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct
clearances.
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02345662

Camshaft Position Sensor - Remove and Install

SMCS - 1912-010

Removal Procedure

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01171816

1. Disconnect harness assembly (1).

2. Remove bolt (3) and camshaft position sensor (2) .

3. Remove the O-ring seal from camshaft position sensor (2) .

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 2 g01171816

1. Install a new O-ring seal on camshaft position sensor (2). Lubricate the O-ring seal with clean
engine oil.

2. Position camshaft position sensor (2) in the housing and install bolt (3) .

3. Connect harness assembly (1) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02345809

Crankshaft Position Sensor - Remove and Install

SMCS - 1912-010

Removal Procedure

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01172018

1. Disconnect harness assembly (3) .

2. Remove bolt (2) and crankshaft position sensor (1) .

3. Remove the O-ring seal from crankshaft position sensor (1) .

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 2 g01172018

1. Install a new O-ring seal on crankshaft position sensor (1). Lubricate the O-ring seal with
clean engine oil.

2. Install crankshaft position sensor (1) in the front housing and install bolt (2) .

3. Connect harness assembly (3) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02346012

Coolant Level Sensor - Remove and Install

SMCS - 7470

Removal Procedure

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Drain the coolant from the cooling system to a level below the coolant level sensor into a
suitable container for storage or disposal. Refer to Operation and Maintenance Manual,
"Cooling System Coolant - Change".
 Illustration 1 g01172170

2. Disconnect harness assembly (2) .

3. Remove coolant level sensor (1) from the heat exchanger.

Installation Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 9S-3263 Thread Lock Compound -

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 2 g01172170

1. Apply Tooling (A) to the threads of the coolant level sensor.

Note: Do not apply Tooling (A) to a new coolant level sensor.

2. Install coolant level sensor (1) and tighten to a torque of 22 ± 3 N·m (16 ± 2 lb ft).

3. Connect harness assembly (2) .

4. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02345996

Coolant Temperature Sensor - Remove and Install

SMCS - 1906-010

Removal Procedure

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: The coolant temperature sensor is located in the water temperature regulator housing.

1. Drain the coolant from the cooling system to a level below the coolant temperature sensor into
a suitable container for storage or disposal. Refer to Operation and Maintenance Manual,
"Cooling System Coolant - Change".
 Illustration 1 g01172156

2. Disconnect harness assembly (1) .

3. Remove coolant temperature sensor (2) from the water temperature regulator housing.

4. Remove the O-ring seal from coolant temperature sensor (2) .

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 2 g01172156

1. Install a new O-ring seal on coolant temperature sensor (2) .

2. Install coolant temperature sensor (2) and tighten to a torque of 20 ± 5 N·m (15 ± 4 lb ft).

3. Connect harness assembly (1) .

4. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling
System Coolant - Change".
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02345866

Engine Oil Pressure Sensor - Remove and Install

SMCS - 1924-010

Removal Procedure

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01172147

1. Disconnect harness assembly (1) .

2. Remove engine oil pressure sensor (2) from the adapter on the cylinder block.

3. Remove the O-ring seal from engine oil pressure sensor (2) .

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 2 g01172147

1. Install a new O-ring seal on engine oil pressure sensor (2) .

2. Install engine oil pressure sensor (2) and tighten to a torque of 10 ± 2 N·m (89 ± 18 lb in).

3. Connect harness assembly (1) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02345759

Fuel Pressure Sensor - Remove and Install

SMCS - 7414-010

Removal Procedure

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 1 g01171982

1. Disconnect harness assembly (1) .

2. Remove fuel pressure sensor (2) .

3. Remove the O-ring seal from fuel pressure sensor (2) .

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 2 g01171982

1. Install a new O-ring seal on fuel pressure sensor (2) .

2. Install fuel pressure sensor (2) and tighten to a torque of 10 ± 2 N·m (89 ± 18 lb in).

3. Connect harness assembly (1) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02345471

Fuel Temperature Sensor - Remove and Install

SMCS - 1922-010

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

 Illustration 1 g01171721

1. Disconnect harness assembly (1) .

2. Remove fuel temperature sensor (2) from the fuel manifold.

3. Remove the O-ring seal from fuel temperature sensor (2) .

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

 Illustration 2 g01171721

1. Install a new O-ring seal on fuel temperature sensor (2) .

2. Install fuel temperature sensor (2). Tighten the fuel temperature sensor to a torque of 20 ± 5
N·m (15 ± 4 lb ft).

3. Connect harness assembly (1) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02345624

Turbocharger Outlet Pressure Sensor - Remove and Install

SMCS - 1917-010

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01171783

1. Disconnect harness assembly (1) .

 2. Remove turbocharger outlet pressure sensor (2) from the cylinder head.

3. Remove the O-ring seal from turbocharger outlet pressure sensor (2) .

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2 g01171783

1. Install a new O-ring seal on turbocharger outlet pressure sensor (2) .

2. Install turbocharger outlet pressure sensor (2). Tighten the turbocharger outlet pressure sensor
to a torque of 10 ± 2 N·m (89 ± 18 lb in).

3. Connect harness assembly (1) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02345581

Inlet Air Temperature Sensor - Remove and Install

SMCS - 1921-010

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01171741

1. Disconnect harness assembly (1) .

 2. Remove inlet air temperature sensor (2) from the cylinder head.

3. Remove the O-ring seal from inlet air temperature sensor (2) .

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2 g01171741

1. Install a new O-ring seal on inlet air temperature sensor (2) .

2. Install inlet air temperature sensor (2). Tighten the inlet air temperature sensor to a torque of
20 ± 5 N·m (15± 4 lb ft).

3. Connect harness assembly (1) .

 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02346711

Electronic Control Module - Remove and Install

SMCS - 1901-010

Removal Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Illustration 1 g00770251

1. Remove allen head screws (3) from harness assembly (1) and harness assembly (2) .

2. Remove harness assembly (1) and harness assembly (2) from electronic control module (4) .

Illustration 2 g00770252

3. Disconnect hose assembly (5) and hose assembly (6) from electronic control module (4) .

Illustration 3 g00770253
 4. Remove nuts (8) and the electrical ground strap from electronic control module (4) .

5. Remove bolt (7) and electronic control module (4) .

Installation Procedure

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 4 g00770253

1. Position electronic control module (4) on the engine and install bolt (7) .

2. Install nuts (8) and the electrical ground strap on electronic control module (4) .

Illustration 5 g00770252

3. Connect hose assembly (5) and hose assembly (6) to electronic control module (4) .
 Illustration 6 g00770251

4. Install harness assembly (1) and harness assembly (2) on electronic control module (4) .

5. Install allen head screws (3) in harness assembly (1) and harness assembly (2) . Tighten the
allen head screws to a torque of 2.25 ± 0.25 N·m (20 ± 2.2 lb in).
 Product: MARINE ENGINE
Model: 3406E MARINE ENGINE 9WR
Configuration: 3406E Marine Engine 9WR00001-UP

Disassembly and Assembly

3406E Marine Engine
Media Number -SENR1169-03 Publication Date -01/10/2007 Date Updated -18/10/2007

i02346905

Electric Starting Motor - Remove and Install

SMCS - 1453-010

Removal Procedure

Accidental engine starting can cause injury or death to personnel

working on the equipment.

To avoid accidental engine starting, disconnect the battery cable from

the negative (-) battery terminal. Completely tape all metal surfaces of
the disconnected battery cable end in order to prevent contact with
other metal surfaces which could activate the engine electrical system.

Place a Do Not Operate tag at the Start/Stop switch location to inform

personnel that the equipment is being worked on.

1. Disconnect the batteries.

2. Disconnect the harness assemblies from the electric starting motor.

 Illustration 1 g01042714

3. Attach a suitable lifting device to electric starting motor (2) . The weight of electric starting
motor (2) is approximately 36 kg (80 lb). Remove bolts (1) that hold the electric starting motor
to the flywheel housing. Remove electric starting motor (2) .

Installation Procedure
 Illustration 2 g01042714

1. Attach a suitable lifting device to electric starting motor (2) . The weight of electric starting
motor (2) is approximately 36 kg (80 lb). Position electric starting motor (2) on the flywheel
housing. Install bolts (1) that hold the electric starting motor to the flywheel housing.

2. Connect the harness assemblies to the electric starting motor.

3. Connect the batteries.