SENR1183-02

August 2004

3406E & C-15 Diesel Truck Engines Engine Design

Bore 137 mm (5.4 inch)
Stroke 165 mm (6.5 inch)
Number of Cylinders 6
Cylinder Arrangement *In-Line
Firing Order (Injection Sequence) 1, 5, 3, 6, 2, 4
Direction of Rotation Counterclockwise
(When viewed from flywheel end)
*No. 1 cylinder is opposite flywheel end.

In-Frame
Overhaul Procedure
Q – Denotes Critical Checkpoint
Literature References
Form No. Title Steps Procedures
SEBF8238 3400 Engines Reuse & Salvage Guides Reference Manual 27 Turn crankshaft until two connecting rods are at the bottom center.
Remove bolts and nuts. Remove connecting rod caps.
SELD0018 Core Acceptance Criteria-Cylinder Heads
28 Remove the cylinder liner, piston and connecting rod as a unit using
SENR5016 3406E Diesel Truck Engine D&A (1MM1-up, 2WS1-up) the cylinder pack removal and installation tooling.
SENR5017 3406E Diesel Truck Engine Systems Operation Testing & Note: When removing cylinder packs, watch the end of
Adjusting (1MM1-up, 2WS1-up)
connecting rod and prevent it from catching on cylinder block
SENR5018 3406E Diesel Truck Engine Specifications (1MM1-up, 2WS1-up) bore as the cylinder pack is removed.
RENR1277 3406E Diesel Truck Engine D&A (5DS1-up, 1LW1-up) 29 Repeat Steps 27 and 28 until all assemblies have been removed from
the cylinder block.
RENR1273 3406E Diesel Truck Engine Systems Operation Testing &
Adjusting (5EK, 5DS, 6TS, 1LW)
RENR1272 3406E Diesel Truck Engine Specifications (5DS1-up, 1LW1-up) Q – Main Bearings Cylinder Block
SENR6421 3406E Diesel Truck Engine D&A (5EK1-up, 6TS1-up)
SENR5577 3406E Diesel Truck Engine Specifications (5EK1-up, 6TS1-up)
SEHS9564 3400 Cylinder Head To Block Joint Repair Procedure
RENR2307 C-15, C-16 & C-18 On-Highway Engines - Systems Operations
Testing & Adjusting, 6NZ, 7CZ, W1A, CJP, MEP, MDP
RENR2308 C-15 & C-16 Truck Engines - Specifications, 6NZ, 7CZ, W1A,
MEP, MDP, CJP
RSNR2306 C-15 & C-16 Truck Engines - D&A, 6NZ1-Up, 7CZ1-Up
RSNR2307 C-15 & C-16 Truck Engines - Systems Operation Testing &
Adjusting, 6NZ1-Up, 7CZ1-Up
RSNR2308 C-15 & C-16 Truck Engines - Specifications, 6NZ, 7CZ
SENR9687 C-15 Truck Engine Specifications, MBN
Illustration 1
SENR9688 C-15 Truck Engine Systems Operation Testing & Adjusting, MBN Cylinder Block
Note: Refer to 3406E Diesel Truck Engine D&A, SENR6421 for detailed
30 Remove main bearing caps and main bearings from No. 2, 3, 4, 5, and
disassembly and assembly instructions.
6. Use a 2P-5518 Bearing Removal Tool to remove the upper main
Initial Disassembly bearing halves. Remove thrust bearings from the No. 4 main bearing
block area.
Note: EXTRA ATTENTION should be given to cleanliness, as Note: Do not remove No. 1 and 7. No. 1 and 7 will be used to
built in dirt is a major cause of engine failure following rebuild. support the crankshaft while replacing the other main bearings.
Steps Procedures NOTICE
1 Steam clean engine. If crankshaft is rotated in wrong direction, the tab of bearing will
2 Disconnect batteries. be pushed between crankshaft and cylinder block. This can
3 Drain engine oil.
cause damage to either or both crankshaft and cylinder block.
Q – 31 Clean cylinder block’s top surface and inspect cylinder liner surface for
4 Drain coolant.
signs that may require installation of inserts. Refer to Special
Instruction, SEHS9564 for inspection guidelines on cylinder block top
Disassembly surfaces.

5 Removal all necessary parts prior to cylinder head removal. Fuel lines, Q – 32 Clean the gasket area of the exhaust manifold and inspect the
inlet pipes, inlet manifold, etc. manifold for reuse.

6 Remove valve covers and valve cover bases. Q – 33 Clean the gasket sealing surface of the oil pan.

Note: If the front crankshaft seal is to be changed, the crankshaft
seal and wear sleeve come as a set and must not be separated
from each other at anytime.
Q–7 Remove valve rocker arms and injector rocker arms as a unit.
Remove rocker shaft assemblies.
8 Remove electronic unit injectors.
9 Remove water temperature regulator.
10 Remove inlet and exhaust manifold.
11 Remove fan drive.
Q – 12 When removing camshaft and idler access cover, remove allen head
screw first. The ten bolts holding cover will keep pressure on gasket,
which will allow the allen screw to be removed more easily. After the
allen head screw has been removed, remove remaining ten bolts.
13 Disconnect the wire and remove the speed/timing sensor.
14 Remove one bolt and install a 9U-6896 Guide Bolt. Remove the
remaining six bolts. Remove the gear using 1P-7405 Eye Bolt and a
strap attached to a hoist.
Camshaft must be held in place when removing or installing
cylinder head. Camshaft can slide forward resulting in
injury and/or damage to camshaft bearings. Use 132-3904
Camshaft Retaining Tool to prevent movement of camshaft.
Q – 15 Disconnect the fuel line from the back of the cylinder head.
16 Disconnect air compressor lines, fuel lines, or sensor wires that may
prevent removal of the cylinder head.
17 Remove the cylinder head bolts. Remove the cylinder head.
18 Remove gaskets, seals, and O-rings from the spacer plate.
19 Remove the spacer plate, gasket and O-rings.
Note: Some engines may be equipped with a sound suppression panel.
Q – 20 Remove the bolts that hold the sound suppression panel to the oil
pan. Remove the sound suppression panel.
21 Remove the bolts and oil pan.
22 If the engine is equipped with a plate between the oil pan and the
cylinder block, remove the plate.
23 Remove the oil supply tube, suction bell and tube, and the oil pump
from the cylinder block.
Q – 24 Remove the piston cooling tubes. Identify location of the tubes in the
cylinder block for installation.
Q – 25 Check and mark connecting rods, connecting rod caps, and main
bearing caps before removing. Connecting rods and main bearing
caps must be installed into the same location and direction as
removed from.
26 Remove the connecting rod bolts and connecting rod caps.
Q – 34 Clean oil pan gasket’s sealing surface on bottom of cylinder block.
Q – 35 Clean the crankshaft area of the cylinder block.
Q – 36 Clean all removed components being reinstalled.
Assembly
Q – 37 Clean No. 2, 3, 4, 5 and 6 main bearing journals and main bearing
caps.
Note: If the bearing clearances are being checked, do not apply
oil on the bearing or journal surfaces. Apply oil during final
assembly only.
Q – 38 Apply clean engine oil on the upper main bearing halves of No. 2, 3, 4,
5 and 6. DO NOT put oil on the back side of the bearing.
Q – 39 Making sure the tab on the bearing will engage with the groove in the
cylinder block, rotate the bearing halves into the cylinder block using
the 2P-5518 Bearing Removal Tool.
Note: Be sure the main bearing caps are installed so the
numbers on the side of the cylinder block are the same as the
numbers on the main bearing caps. If there are arrows on the
main bearing caps then they must face toward the front of the
cylinder block; else assemble bearing caps with the word ”front”
on the bearing cap toward front of block.
Q – 40 Install lower bearing halves in No. 2, 3, 4, 5 and 6 main bearing caps.
DO NOT put oil on the back side of the bearing.
Q – 41 Put engine oil on the bolt threads. Start with the tab end of the main
bearing cap. Install and tighten the main bearing cap bolts on No. 2,
3, 4, 5 and 6 to a torque of 260 ± 14 N·m (190 ± 10 lb ft). Put a mark
on each bolt and main bearing cap. Start with the bolt away from
(opposite) the tab end of the main bearing cap, and tighten each bolt
an additional 120 ± 5 degrees.
Illustration 2
Q – 42 Remove No. 1 and 7 main bearings from the cylinder block and main
bearing caps.
Q – 43 Repeat Steps 37 through 41 for No. 1 and 7 main bearing journals and
main bearing caps.
Q – 44 Install the thrust bearings for the No. 4 main bearing. Install the thrust
bearings with the identification “Block Side” toward the cylinder block.

Note: When removing cylinder liner, piston & connecting rod Q – 45 Check the end play of the crankshaft with a dial indicator. The end
play with new thrust bearings must be 0.15 to 0.55 mm (0.006 to 0.022
assemblies, identify location and direction of connecting rod caps inch).
for reinstallation. On some 3406E Engines, connecting rod cap
is attached with a bolt from the top & a nut. To protect
crankshaft journals from threaded portion of connecting rod
bolts, cut short pieces of rubber hose & install them over
connecting rod bolt threads during removal & installation.
Checking Cylinder Liner Projection
Steps Procedures
Q – 46 Clean the gasket surfaces of the cylinder block and spacer plate
before checking cylinder liner projection. Refer to Special Instruction,
SEHS9564. Use the 8T-0455 Liner Projection Tool Group for
checking cylinder liner projection.
Q – 47 Install clean cylinder packs (without the filler band or the rubber seals),
spacer plate gasket and clean spacer plate.
Q – 48 Check cylinder liner projection.
Q – 49 Do not exceed the maximum cylinder liner projection of 0.152 mm
(0.006 inch). Excessive cylinder line projection will contribute to Illustration 4
cylinder liner flange cracking. Also, minimum cylinder liner projection
Torque Sequence for Cylinder Head
is 0.03mm (0.001 inch).
Q – 50 With the correct cylinder liner projection, mark the cylinder liner packs Note: The bolts marked “X” are 216 mm (8.5 inch) long. The
in the proper position and set them aside. remainder of the bolts are 194 mm (7.6 inch) long.

Note: Apply liquid soap and/or clean engine oil immediately
before assembly. If applied too early, the seals may swell and
be pinched under the cylinder liners during installation.
Q – 51 When the engine is ready for final assembly, the O-rings, cylinder
block and upper filler band must be lubricated before installation. If
the lower O-rings are black in color, apply liquid soap on the lower O-
rings and the cylinder block. Use clean engine oil on the upper filler
band. If the lower O-rings are brown in color, apply engine oil on the
lower O-rings, cylinder block and upper filler band.
Steps Procedures
Q – 69 Install cylinder head bolts and washers.
Q – 70 Tighten bolts (by hand torque wrench) 1 thru 26 in a numerical
sequence shown to a torque of 270 ± 15 N·m (200 ± 11 lb ft).
Q – 71 Tighten bolts (by hand torque wrench) 1 thru 26 in a numerical
sequence shown to a torque of 450 ± 15 N·m (333 ± 11 lb ft).
Q – 72 Again, tighten bolts (by hand torque wrench) 1 thru 26 in a numerical
sequence to a torque of 450 ± 15 N·m (333 ± 11 lb ft).

Q – 52 Be sure cylinder numbers on the connecting rod caps and connecting 73
rod are the same and are on the same side of the connecting rod. Q – 74
Numbers are on the same side of the connecting rod and connecting
rod cap as are the bearing tab slots. If new connecting rods are Q – 75
installed, put the cylinder number on the connecting rod and
connecting rod cap. Be sure the number on the tab groove side of the
Q – 76
connecting rod is on the opposite side from the camshaft.
53 Install cylinder packs using 5P-3526 Piston Ring Compressor Tool.
Q – 54 Install the upper half of the connecting rod bearing. Be sure the
connecting rod bearing tab properly engages the slot in the connecting 77
rod. Lubricate the connecting rod bearing surface with clean engine
78
oil and tap the piston down with a rubber mallet until the connecting
rod and connecting rod bearing contacts the crankshaft journal. 79
Q – 55 With the connecting rod bearing in place and oil on the bearing 80
surface only, install the connecting rod cap.
81
Q – 56 Put 4C-5593 Anti-Seize Compound or 6V-4876 Molykote Paste
Lubricant on threads and seat surfaces of the connecting rod bolts. 82
Install guide bolt into one of threaded holes in the end of the camshaft.
Install camshaft gear, aligning timing mark with mark on the housing.
Install the 9U-7255 Adjustable Idler Assembly Tool and adjust the idler
stub shaft bracket.
Install idler gear and check backlash between the camshaft gear and
idler gear. The backlash between the two gears should be taken with
idler gear assembly held stationary, the backlash measurement should
be 0.216 ± 0.114 mm (0.0085 ± 0.0045 inch).
Install the camshaft gear cover and new gasket.
Install the fan drive.
Install the valve cover bases.
Install the electronic unit injectors.
Install the rocker and shaft assemblies.
Install the valve covers.

Q – 57 Install the two bolts and tighten each bolt to a torque of 90 ± 8 N·m (66 83 Install the water temperature regulator.
± 6 lb ft). Put a mark on the bolt head and cap, and tighten the bolts Q – 84 Adjust valve rocker arms and unit injector arms.
an additional 90 ± 5 degrees from the mark.

Valve Lash
Inlet 0.38 ± 0.08 mm (0.015 ± 0.003 inch)
Exhaust 0.76 ± 0.08 mm (0.030 ± 0.003 inch)
Note: After setting valve lash, tighten adjusting screw locknut 30 ± 7
N·m (22 ± 5 lb ft)
Adjust the following valves at No. 1 TC.
Valves Cylinder
Inlet 1, 2, 4
Exhaust 1, 3, 5
Illustration 3
Adjust the following valves at No. 6 TC.
Q – 58 Repeat Steps 55 through 58 for installing the remaining cylinder
packs. After installing all of the cylinder packs, rotate the engine to Valves Cylinder
top center for piston No. 1. Inlet 3, 5, 6
Q – 59 Check the piston cooling jets and then install them into the cylinder Exhaust 2, 4, 6
block correctly, in the same location as removed. Tighten the cooling
jet bolt to a torque of 40 ± 8 N·m (30 ± 6 lb ft). Note: Minimum
permissible clearance between the piston, the piston cooling jet and
the crankshaft is 0.63mm (0.025 inch).

Piston Cooling Jet Dimensions

a. 127.68 ± 0.25 mm (5.027 ± 0.010 inch)
b. 55.8 ± 0.25 mm (2.197 ± 0.010 inch)
c. 250 ± 0.25 mm (9.843 ± 0.010 inch)
d. 120.68 ± 0.25 mm (4.751 ± 0.010 inch)
e. 66.45 ± 0.25 mm (2.616 ± 0.010 inch)
f. 250 ± 0.25 mm (9.843 ± 0.010 inch) Illustration 5
Cylinder and Valve Location

85 Assemble the remaining components according to D&A Manual,

SENR6421.
86 Install the exhaust manifold. Follow exhaust manifold assembly
procedure.

NOTICE
The following procedure should be used during assembly of the
three piece exhaust manifold to the cylinder head. If 2P-2333
Manifold Sealer is left on the inside of the exhaust manifold after
assembly, it may cause damage to the turbocharger

Illustration 6
Exhaust manifold installed to cylinder head

Q – 60 Install oil pump, suction bell tubes and plate onto the bottom of the Q – 87 Apply a thin film of 2P-2333 Manifold Sealer to the outside diameter of
cylinder block. the male end of the manifold before assembly. Remove excess
manifold sealer from assembled joint.
Q – 61 Install the oil pan with a new gasket.
Q – 88 Put oil on the female ends of manifold and assemble the three
Q – 62 Install the oil pan sound suppression panel (if equipped). sections. Put 5P-3931 Anti-Seize Compound on the manifold studs
and install the exhaust gaskets. Install the assembled exhaust
Note: The following steps are for installation of cylinder head. If manifold onto the studs.
a Remanufactured cylinder head is used, transfer all related
components to new cylinder head. Refer to Special Instruction,
SEHS9564 for procedure to inspect cylinder head bolts.
Q – 63 Make sure spacer plate and machined surface of the cylinder block
are clean and free of dirt and foreign material. Both surfaces of the
spacer plate gasket and the top of the cylinder block must be clean.
DO NOT USE A GASKET ADHESIVE ON THESE SURFACES.
64 Install a new spacer plate gasket over the dowels in the cylinder block.

Note: Check to ensure that piston No. 1 is at top center.

65 Install new O-rings, seals and spacer plate.
66 Install new seals and new cylinder head gasket on the top side of the
spacer plate. Illustration 7
Torque Sequence for Exhaust Manifold

Q – 89 Tighten exhaust manifold nuts in number sequence shown in

illustration 7 to a torque of 38 ± 5 N·m (28 ± 4 lb ft).
Camshaft must be held in place when removing or installing
Q – 90 Use 5P-3931 Anti-Seize Compound on the turbocharger to exhaust
cylinder head. Camshaft can slide forward resulting in
manifold bolts and locknuts. Install the turbocharger to the exhaust
injury and/or damage to camshaft bearings. Use 132-3904 manifold using the bolts and locknuts . Tighten bolts and locknuts to
Camshaft Retaining Tool to prevent movement of camshaft. 55 ± 5 N·m (41 ± 4 lb ft).
Q – 91 Fill the engine with oil.
Q – 67 Fasten a hoist to the cylinder head. Position the cylinder head
assembly over the head gasket and spacer plate. Q – 92 Fill the cooling system.
Q – 68 Lower the cylinder head assembly slowly over the dowels to prevent 93 Connect the batteries.
damage to the dowels.
94 Start the engine and check all systems.
Q – 95 Check for fuel or oil leaks before road or dynamometer testing vehicle.

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