Installation Of The 0R-2554 Cylinder Block And The 0R-3258 Cylinder Block {1201} Caterpillar

Engines:

3306 (S/N: 66D; 67D; 76R)

Introduction

This Special Instruction should be used when you are replacing an original cylinder block that has a counterbore in the cylinder liner with a 0R-2554 Cylinder Block or a 0R-3258 Cylinder Block .

Note: The cylinder block in the remanufactured short block group may not have counterbores in the cylinder liners.

If both the original cylinder block and the remanufactured short block have counterbored cylinder liners, refer to the Parts Book in order to determine the correct cylinder head gasket and seals that are needed in order to make the installation.

If the remanufactured short block does not have counterbored cylinder liners and the original cylinder head is going to be used again, additional parts will be needed for the cylinder head installation. These parts are included with a short block group for engines with spacer plates.

Because of the oil supply that is needed for the cylinder head valve, only the spacer plate and the other additional parts should be used when the original cylinder head from the cylinder block with the counterbore in the cylinder liner is installed on the remanufactured short block. Refer to Table 1.

Remanufactured engines and remanufactured short blocks must have adequate lubrication during the first seconds of engine cranking and start-up.

An engine start without this lubrication can cause damage to the engine's components.

References

• Service Manual

• Parts Book

• Operation & Maintenance Manual

• Special Instruction, SEHS8914, "Pressure Lubrication Procedure For Remanufactured Engines And Short Blocks"

Engine Assembly

1. Clean the protective coating from all of the parts in the short block group. After the installation of the camshaft, put clean engine oil on the cylinder liner walls and the lifters. Turn the crankshaft several times in order to get a good distribution of lubricant on these parts.

2. Check the following items before further installation of parts on the new short block:

   1. Measure the crankshaft end clearance.

   2. Inspect the cylinder head for flatness.

      Reference: Consult the Specifications section in the Service Manual for more information.

3. The spacer plate gasket, the spacer plate and the head gasket must be clean and dry.

   Note: Do not use gasket sealant.

4. The 9Y-1798 Water Seals and the 7N-8018 Water Seals must be installed before the installation of the cylinder head.
   Show/hide table
   
   

   Illustration 1	g00334378
   Refer to location (A) on the original cylinder block. Drive the dowel to the dimension that is shown.

   1. The part numbers for the sleeve and dowel or the plug and dowel must be identified in order to ensure that the parts are replaced in the correct position.

   2. Some of the engines will have a 1S-1768 Sleeve and a 4L-3395 Dowel at location (A) .

   3. Some of the engines will have a 4B-3938 Cup Plug and a 2A-3798 Dowel .

   4. Install the correct parts after identification.

5. Install the remainder of the parts that are needed on the new remanufactured short block.

Note: Do NOT reuse gaskets and seals.

Reference: Consult the Service Manual for torque values, tightening procedures, special tools, special procedures and the specifications that are needed for the engine components' assembly.

9L-5797 Oil Pan (Front Sump)

Illustration 2	g00336178

For engines that have the 9L-5797 Oil Pan , the original three 2M-3403 Bolts (B) must be removed. The bolts should be replaced with three 0T-0065 Bolts .

The remaining bolts in the Oil Pan should be reused.

Engines That Are Equipped With An Air Compressor

Illustration 3	g00334419

Early engine models that are equipped with an air compressor must be drilled and tapped at location (C) in order to accept the oil drain line for the air compressor.

Ensure that the threads are the same size as the threads for the old block.

3N-2887 Front Housing Fastener Group

Illustration 4	g00339389

For engines that have the 3N-2887 Front Housing Fastener Group , the original 4K-4937 Bolt (D) must be removed. The bolt should be replaced by a 9S-1366 Bolt .

The remaining bolts in the Front Housing Fastener Group should be reused.

6N-5233 Flywheel Housing Group

Illustration 5	g00339390

For engines that have the 6N-5233 Flywheel Housing Group , the original 0S-1587 Bolts (E) must be removed. The bolts should be replaced with the 0S-1585 Bolts .

The remaining bolts in the Flywheel Housing Group should be reused.

2P-6122 Flywheel Housing Group

Illustration 6	g00339391

For engines that have the 2P-6122 Flywheel Housing Group , both the original 0S-1585 Bolt (F) and the original 0S-1587 Bolt (F) must be removed. The bolts should be replaced by two 032-3180 Bolts .

The remaining bolts in the Flywheel Housing Group should be reused.

2P-6131 Flywheel Housing Group

Illustration 7	g00339392

For engines that have the 2P-6131 Flywheel Housing Group , the original 1A-5822 Bolts (G) must be removed. The bolts should be replaced by two 4K-4937 Bolts .

The remaining bolts in the Flywheel Housing Group should be reused.

Flywheel Measurements

Measure the face runout (axial eccentricity) and the bore runout (radial eccentricity) of the flywheel and the flywheel housing.

Reference: Consult the Service Manual for more information.

Installation Of The Fuel System On Early Engines

When the interim scroll fuel system from an early model 3306 Engine is going to be installed on a remanufactured long block that does not have counterbores in the cylinder block (cylinder blocks with a spacer plate), the following Steps must be taken:

1. A 2P-8704 Fuel Pump Bracket must be used in order to fasten the fuel pump and the governor to the side of the short block groups that do not have counterbored cylinder blocks (blocks with spacer plates) if a 2P-8704 Fuel Pump Bracket or a 7S-6722 Fuel Pump Bracket is not available from the engine that is being replaced. The 5S-8981 Bracket that was used with the former cylinder block (cylinder blocks with a counterbore) can not be used on a remanufactured short block without a counterbore in the cylinder block.

   Note: Use new seals and new gaskets when you are installing the fuel pump's bracket.

2. If the engine is going to be pressure lubricated, refer to Special Instruction, SEHS8914, "Pressure Lubrication Procedure For Remanufactured Engines And Short Blocks" before adding any oil to the crankcase.

3. When the engine assembly and installation are complete, fill the engine crankcase with the correct amount and type of oil. Recommendations for the correct amount of oil and type of oil can be found in the Operation & Maintenance Manual.

4. Start the engine.

   1. Operate the engine at the low idle rpm.

      Reference: Consult the Fuel Setting And Related Information Library, SBFY1108 for more information.

   2. Ensure that the engine is running at the specified oil pressure.

   3. Ensure that the engine is running at the specified coolant temperature.

      Reference: Consult the Service Manual, Operation & Maintenance Manual, or the Fuel Setting And Related Information Library, SBFY1108 for more information.

   4. Inspect the engine for fuel, air, oil, and coolant leaks.

   5. Perform any repairs that may be required.