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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

When the words "use again" are in the description, the specification given can be used to determine if a part
can be used again. If the part is equal to or within the specification given, use the part again.

When the word "permissible" is in the description, the specification given is the "maximum or minimum"
tolerance permitted before adjustment, repair and/or new parts are needed.

A comparison can be made between the measurements of a worn part and the specifications of a new part to
find the amount of wear. A part that is worn can be safe to use if an estimate of the remainder of its service
life is good. If a short service life is expected, replace the part.

NOTE: For Systems Operation, Testing & Adjusting make reference to 3406C Generator Set Engine,
SENR1103.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

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Typical Example

(1) Put 4C5593 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque
of ... 270 ± 40 N·m (200 ± 29 lb ft)

(2) Maximum permissible temperature of the gear for installation on the flywheel (do not use a torch) ...
300°C (572°F)

NOTE: Refer to Flywheel Runout in Systems Operation, Testing and Adjusting for the correct method of
flywheel inspection.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

NOTE: Be sure the contact surfaces of the flywheel housing and the block are clean and free of any foreign
material. Clean the contact surfaces with 8T9011 or 4C4079 Component Cleaner. Put an application of
1U8846 Gasket Maker on the contact surface of the flywheel housing. Put a 1.5 mm (.06 in) bead of 1U8846
Gasket Maker down the middle of the contact surface and around each bolt hole. Spread the bead of gasket
maker into a thin even thickness over the contact surface.

(1) Tighten flywheel housing bolts with the procedure that follows:

a. Tighten bolts 1 through 24 in number sequence to a torque of ... 40 ± 10 N·m (29 ± 7 lb ft)

b. Retighten bolts 1 through 9 in number sequence to a torque of ... 135 ± 20 N·m (100 ± 15 lb ft)

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c. Retighten bolts 10 through 24 in number sequence to a torque of ... 55 ± 10 N·m (40 ± 7 lb ft)

(2) Maximum permissible change from an exact vertical face (face runout) at 4 points (total indicator reading)
... 0.38 mm (.015 in)

NOTE: Tighten the plug on the side of the flywheel housing to a torque of ... 55 ± 14 N·m (40 ± 10 lb ft)

NOTE: Refer to Flywheel Housing Runout and Flywheel Housing Bore in Systems Operation, Testing and
Adjusting for the correct methods of flywheel housing inspection.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Tighten bolts holding cover to a torque of ... 47 ± 7 N·m (35 ± 5 lb ft)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

NOTE: For procedure on how to measure for a bent crankshaft, See Guideline for Reusable Parts,
SEBF8030.

(1) Maximum length of pin out of crankshaft face ... 6.4 mm (.25 in)

(2) End play for the crankshaft (new) ... 0.15 to 0.51 mm (.006 to .020 in)

Maximum permissible end play with used bearings ... 0.89 mm (.035 in)

(3) Make reference to Main Bearing Journals.

(4) Make reference to Connecting Rod Bearing Journals.

(5) Maximum permissible temperature of the gear for installation on the crankshaft ... 205°C (401°F)

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Centerline of gear key way to be in alignment with centerline of dowel within ... 0.50 mm (.020 in)

NOTE: Install gear with timing "V" mark to the outside.

(6) Length of dowel out of the crankshaft ... 4.1 ± 0.5 mm (.16 ± .02 in)

(7) 2W1734 Seal Group (rear).

(8) Thrust plates for center main bearing only.

(9) 2W1733 Seal Group (front).

NOTE: Seals and wear sleeves can not be used again, after the seals and wear sleeves are separated.

a. Use the 1U7600 Puller Group to remove the seals.

b. Use the 5P7318 Distorter Group to remove the wear sleeves.

a. Clean the outer surface of the crankshaft with 6V1541 Quick Cure Primer.

b. Crankshaft seals must be installed with the lip of the seal toward the inside of the engine as shown. Make
sure the correct seal is installed on each end of the crankshaft. Use the 2W1733 Seal Group on the front and
the 2W1734 Seal Group on the rear.

NOTE: No lubrication is needed to install wear sleeves and seals.

c. Do not separate seals from sleeves. Install the seal groups as a unit on each end of the engine as shown
with the correct tools.

NOTE: See Special Instruction, SMHS8508 and SMHS8008 for the necessary tools and complete procedure
for installation of front and rear seal groups.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Make reference to Guidelines For Reusable Parts; Main Bearings And Connecting Rod Bearings, SEBF8009;
and Crankshaft Measurement, SEBF8041.

Clearance between bearing and journal (new) ... 0.062 to 0.160 mm (.0024 to .0063 in)

Maximum permissible clearance between bearing and journal ... 0.20 mm (.008 in)

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Clearance between bearing and journal (new) ... 0.091 to 0.186 mm (.0036 to .0073 in)

Maximum permissible clearance between bearing and journal ... 0.25 mm (.010 in)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Make reference to Special Instruction, GMG02394 & SMHS7366 for information to check and recondition
connecting rods. Also see, Guideline For Reusable Parts; Salvage Of Non-Serrated Connecting Rods,
SEBF8064.

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(1) Bore in connecting rod for piston pin bearing ... 55.436 ± 0.013 mm (2.1825 ± .0005 in)

NOTE: The connecting rod must be heated for installation of piston pin bearing. Do not use a torch.

(2) Distance rod may be heated to 175 to 260°C (347 to 500°F) to install the piston pin bearing ... 85.0 mm
(3.35 in)

(3) Bore in bearing for piston pin (new) ... 50.830 ± 0.008 mm (2.0012 ± .0003 in)

(3) Bore in bearing for piston pin (new) ... 50.830 ± 0.008 mm (2.0012 ± .0003 in)

Diameter of piston pin (new) ... 50.795 ± 0.005 mm (1.9998 ± .0002 in)

Thoroughly lubricate piston pin with clean engine oil prior to inserting into piston group and rod assembly.

Maximum permissible clearance between bearing and piston pin (worn) ... 0.25 mm (.010 in)

(4) Bearing joint must be assembled at either location on centerline through the connecting rod bore ... ± 5
degrees

Make reference to Special Instruction, SMHS7295 for use of pin bearing removal and installation tools and
procedures.

(5) Distance between center of bearings ... 261.62 ± 0.05 mm (10.300 ± .002 in)

(6) Bore in connecting rod for bearing with nuts tightened to specifications (8) ... 96.200 ± 0.013 mm (3.7874
± .0005 in)

(7) Location for etching cylinder number on connecting rod and cap. Rods and caps are to be marked with
numbers 1 through 6 on the same side of the rod as the bearing tab slots.

(8) Tighten connecting rod bolts as follows:

a. Before installing bolts, lubricate bolt threads and seating faces of the caps with 4C5593 Thread Lubricant.

b. Tighten each bolt to ... 90 ± 8 N·m (66 ± 6 lb ft)

c. Put an alignment mark on each cap and bolt.

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d. Tighten each bolt an additional ... 90 ± 5 degrees

(9) Bore in bearing for crankshaft rod journal ... 90.112 ± 0.028 mm (3.5477 ± .0011 in)

Clearance between bearing and crankshaft (new) ... 0.062 to 0.160 mm (.0024 to .0063 in)

Maximum permissible clearance between bearing and crankshaft (worn) ... 0.20 mm (.008 in)

NOTE: Bearings are available in 0.63 mm (.025 in) and 1.27 mm (.050 in) smaller than original size.

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(1) Bore in connecting rod for piston pin bearing ... 59.640 ± 0.013 mm (2.3480 ± .0005 in)

NOTE: The connecting rod must be heated for installation of piston pin bearing. Do not use a torch.

(2) Distance rod may be heated to 175 to 260°C (347 to 500°F) to install the piston pin bearing ... 85.0 mm
(3.35 in)

(3) Bore in bearing for piston pin (new) ... 55.035 ± 0.008 mm (2.1667 ± .0003 in)

Diameter of piston pin (new) ... 55.000 ± 0.005 mm (2.1654 ± .0002 in)

Thoroughly lubricate piston pin with clean engine oil prior to inserting into piston group and rod assembly.

Maximum permissible clearance between bearing and piston pin (worn) ... 0.25 mm (.010 in)

(4) Bearing joint must be assembled at either location on centerline through the connecting rod bore ... ± 5
degrees

Make reference to Special Instruction, SMHS7295 for use of pin bearing removal and installation tools and
procedures.

(5) Distance between center of bearings ... 261.62 ± 0.05 mm (10.300 ± .002 in)

(6) Bore in connecting rod for bearing with nuts tightened to specifications (8) ... 96.200 ± 0.013 mm (3.7874
± .0005 in)

(7) Location for etching cylinder number on connecting rod and cap. Rods and caps are to be marked with
numbers 1 through 6 on the same side of the rod as the bearing tab slots.

(8) Tighten connecting rod bolts as follows:

a. Before installing bolts, lubricate bolt threads and seating faces of the caps with 4C5593 Thread Lubricant.

b. Tighten each bolt to ... 90 ± 9 N· (66 ± 7 lb ft)

c. Put an alignment mark on each cap and bolt.

d. Tighten each bolt an additional ... 90 ± 5 degrees

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(9) Bore in bearing for crankshaft rod journal ... 90.112 ± 0.028 mm (3.5477 ± .0011 in)

Clearance between bearing and crankshaft (new) ... 0.062 to 0.160 mm (.0024 to .0063 in)

Maximum permissible clearance between bearing and crankshaft (worn) ... 0.20 mm (.008 in)

NOTE: Bearings are available in 0.63 mm (.025 in) and 1.27 mm (.050 in) smaller than original size.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Typical Example

Make reference to Guideline For Reusable Parts; Pistons, SEBF8049; Cylinder Liners, SEBF8068; and Piston
Pins And Retaining Rings, SEBF8051.

NOTE: For installation, number on tab groove side of connecting rod is to be positioned toward opposite side
of engine from camshaft.

The 1U6431 Keystone Piston Ring Groove Gauge is necessary for measuring ring grooves in keystone style

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pistons. For correct use of the gauge group, see the instruction card that is with the gauge group.

Install piston rings with "UP" side toward top of piston.

(1) Top Ring has the mark "UP-1".

(2) Intermediate ring has the mark "UP-2".

Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 137.16 mm (5.400
in):

Top ring ... 0.724 ± 0.190 mm (.0285 ± .0075 in)

Intermediate ring ... 1.080 ± 0.190 mm (.0425 ± .0075 in)

Increase in clearance between ends of piston rings for each 0.03 mm (.001 in) increase in cylinder liner bore
size ... 0.08 mm (.003 in)

(3) Install oil control ring with the gap in the spring 180 degrees away from the gap in the ring. White portion
of spring must be visible at the ring end gap.

Width of groove in piston for piston ring (new) ... 3.188 ± 0.013 mm (.1255 ± .0005 in)

Thickness of piston ring (new) ... 3.137 ± 0.013 mm (.1235 ± .0005 in)

Clearance between groove and piston ring (new) ... 0.051 ± 0.025 mm (.0020 ± .0010 in)

Maximum permissible clearance (worn) ... 0.15 mm (.006 in)

Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 137.16 mm (5.400
in) ... 0.572 ± 0.190 mm (.0225 ± .0075 in)

Increase in clearance between ends of piston ring for each 0.03 mm (.001 in) increase in cylinder liner bore
size ... 0.08 mm (.003 in)

(4) Bore in piston for pin ... 50.808 ± 0.005 mm (2.0003 ± .0002 in)

Clearance between pin and bore in piston ... 0.013 ± 0.010 mm (.0005 ± .0004 in)

Permissible clearance (worn) ... 0.05 mm (.002 in)

Pin diameter ... 50.795 ± 0.005 mm (1.9998 ± .0002 in)

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(1) Crown assembly.

(2) Connecting rod.

NOTE: Install connecting rod and piston group with number on tab groove side of connecting rod to be
positioned toward opposite side of engine from camshaft.

(3) Piston skirt.

The 1U6431 Keystone Piston Ring Groove Gauge is necessary for measuring ring grooves in keystone style
pistons. For correct use of the gauge group, see the instruction card that is with the gauge group.

Install piston rings with "UP" side toward top of piston.

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(4) Top Ring has the mark "UP-1".

(5) Intermediate ring has the mark "UP-2".

Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 137.16 mm (5.400
in):

Top ring ... 0.724 ± 0.190 mm (.0285 ± .0075 in)

Intermediate ring ... 1.080 ± 0.190 mm (.0425 ± .0075 in)

Increase in clearance between ends of piston rings for each 0.03 mm (.001 in) increase in cylinder liner bore
size ... 0.08 mm (.003 in)

(6) Install oil control ring with the gap in the spring 180 degrees away from the gap in the ring. White portion
of spring must be visible at the ring end gap.

Width of groove in piston for piston ring (new) ... 3.188 ± 0.013 mm (.1255 ± .0005 in)

Thickness of piston ring (new) ... 3.137 ± 0.013 mm (.1235 ± .0005 in)

Clearance between groove and piston ring (new) ... 0.051 ± 0.025 mm (.0020 ± .0010 in)

Maximum permissible clearance (worn) ... 0.15 mm (.006 in)

Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 137.16 mm (5.400
in) ... 0.572 ± 0.190 mm (.0225 ± .0075 in)

Increase in clearance between ends of piston ring for each 0.03 mm (.001 in) increase in cylinder liner bore
size ... 0.08 mm (.003 in)

(7) Pin bore diameter in piston crown bearing ... 55.047 ± 0.008 mm (2.1672 ± .0003 in)

Pin bore diameter in piston skirt ... 55.013 ± 0.004 mm (2.1659 ± .0002 in)

Pin diameter ... 55.000 ± 0.005 mm (2.1654 ± .0002 in)

Thoroughly lubricate pin with clean engine oil before assembling to piston group and connecting rod.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

NOTE: This procedure alleviates the need for the "H" bar to hold down liners during projection
measurements.

Liner Projection Components

(1) Bolt. (2) Washer. (3) Washer.

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Install clean liners or cylinder packs (without the filler band or the rubber seals), spacer plate gasket and clean
spacer plate.

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Install bolts and washers, as indicated previously, in the holes. Install all bolts or the six bolts around the liner.
Tighten the bolts to a torque of 95 N·m (70 lb ft).

Use the 8T0455 Liner Projection Tool Group to measure liner projection at positions indicated with an A, B,
C and D. Record measurements for each cylinder. Add the four readings for each cylinder and divide by four
to find the average.

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If the liner projections are out of specification, try rotating the liner or install the liner in another bore to see if
the measurements improve.

If the liner projections are all below the specifications or low in the range, 0.025 mm (0.0010 in) or 0.051 mm
(0.0020 in), try using a thinner spacer plate. These plates are 0.076 mm (0.0030 in) thinner than the regular
plate and they will increase the liner projection, thus increasing the fire ring crush. Use these spacer plates to
compensate for low liner projections that are less than 0.076 mm (0.0030 in) or if the inspection of the top
deck reveals no measurable damage directly under the liner flanges, but the average liner projection is less
than 0.076 mm (0.0030 in).

Do not exceed the maximum liner projection of 0.152 mm (0.0060 in). Excessive liner projection will
contribute to liner flange cracking.

With the proper liner projection, mark the liners in the proper position and set them aside.

When the engine is ready for final assembly, the O-ring seals, cylinder block and upper filler band must be
lubricated before installation.

NOTE: Apply clean engine oil immediately before assembly. If applied too early, the seals may swell and be
pinched under the liners during installation.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

For Installation:

a. Put clean engine oil on the liner bore surfaces of the cylinder block and on the rubber seals installed on the
lower part of the liner.

b. Put the filler band completely in clean engine oil for a moment.

c. Install filler band (1) in the groove under the liner flange, without delay.

d. Install the liner in the block immediately, before expansion of the filler band.

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(1) Filler Band.

(2) O-Ring Seals.

(3) Thickness of flange on liner ... 8.890 ± 0.020 mm (.3500 ± .0008 in)

"Use again" minimum thickness ... 8.870 mm (.3492 in)

(4) Bore in liner (new) ... 137.185 ± 0.025 mm (5.4010 ± .0010 in)

NOTE: Make reference to Guideline For Reusable Parts; Pistons And Cylinder Liners, SEBF8049 and
SEBF8068.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

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(1) Thickness of spacer plate ... 8.585 ± 0.025 mm (.3379 ± .0009 in)

Thickness of gasket that is placed between spacer plate and cylinder block ... 0.208 ± 0.025 mm (.0081 ±
.0009 in)

Height of liner over spacer plate, under installation pressure ... 0.13 ± 0.08 mm (.005 ± .003 in)

(2) Height of four dowels above top surface of cylinder block:

End dowels (Put 7M7456 Bearing Mount Compound on two end dowels at installation) ... 18.5 ± 0.5 mm (.73
± .02 in)

Middle dowels ... 16.0 ± 0.5 mm (.63 ± .02 in)

(3) Dimension (new) from centerline of crankshaft bearing bore to top of block (top deck) ... 425.45 ± 0.15
mm (16.750 ± .006 in)

Minimum dimension from centerline of crankshaft bearing bore to top of block (top deck) ... 425.02 mm
(16.733 in)

NOTE: The flatness across the whole contact surface of the block must be within 0.10 mm (.004 in) and
within 0.05 mm (.002 in) for any 177 mm (7.0 in) section of the surface. The surface finish specification is 3.2
micrometers (125 microinches) maximum.

(4) Bore in block for camshaft bearings ... 76.835 ± 0.018 mm (3.0250 ± .0007 in)

Install bearings with the oil holes in the bearings on the horizontal centerline. Make sure the bearing joint
position is above the oil holes.

(5) Bore in the block for the main bearings:

Standard, original size (new) ... 129.891 ± 0.013 mm (5.1138 ± .0005 in)

0.64 mm (.025 in) larger than original size ... 130.526 ± 0.013 mm (5.1388 ± .0005 in)

(6) Distance from front of rear face of cylinder block to end of dowels ... 19.1 ± 0.05 mm (.75 ± .02 in)

(7) Width of main bearing cap ... 215.900 ± 0.025 mm (8.5000 ± .0010 in)

Width of block for main bearing cap ... 215.900 ± 0.013 mm (8.5000 ± .0005 in)

Press fit between main bearing cap and cylinder block ... 0.038 mm (.0015 in) tight to 0.038 mm (.0015 in)
loose

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Tightening Procedure For Main Bearing Cap Bolts

(8) Torque for the bolts that hold the caps for the main bearings:

Install the main bearing caps with the marks (arrow) toward the front of the engine. Install each cap in the
correct position by putting the number stamped on the bottom of the cap toward the corresponding number
cast on left side of the cylinder block at the pan rail.

a. Put 4C5593 Thread Lubricant on the threads of the bolts.

b. Tighten the bolts first on the bearing tab side of the cap to ... 258 ± 14 N·m (190 ± 10 lb ft)

c. Tighten the bolts on the opposite side of the bearing tab side to ... 258 ± 14 N·m (190 ± 10 lb ft)

d. Put a mark on each bolt and cap.

e. Tighten the bolts on the opposite side of the bearing tab side, from the mark ... 120 ± 5 degrees

f. Tighten the bolts on the bearing tab side of the cap, from the mark ... 120 ± 5 degrees

(9) Dimension (new) from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 165.10 ±
0.10 mm (6.500 ± .004 in)

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View From Right Side Of Cylinder Block

(10) Put 5P3413 Pipe Sealant on threads of plugs before installation in the cylinder block.

(11) Torque for bolts holding oil jet cooling tubes ... 30 ± 7 N·m (22 ± 5 lb ft)

NOTE: Minimum permissible clearance between piston and oil jet cooling tube ... 0.64 mm (.025 in)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Typical Example

(1) Bolts that hold the cover and core support plate.

Tighten the bolts to a torque of ... 25 ± 6 N·m (18 ± 5 lb ft)

After the engine is operated, again tighten the bolts to a torque of ... 25 ± 6 N·m (18 ± 5 lb ft)

(2) Put clean engine oil or glycerin on all O-ring seals and in their bores at assembly.

NOTE: Tighten all bolts (1) through the core support plate before bolts (3), through the water line adapters,
are tightened.

(3) Tighten the bolts and nuts to a torque of ... 25 ± 6 N·m (18 ± 5 lb ft)

(4) Bolts that hold the water line adapters.

(5) Put 9S3263 Thread Lock on the bolt threads at assembly.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Temperature when completely open ... 92°C (197°F)

Minimum opening distance at 92°C (197°F) ... 10.4 mm (.41 in)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Typical Example

(1) Torque for bolt that holds the impeller ... 39 ± 3 N·m (28 ± 2 lb ft)

(2) Shaft diameter at carbon seal assembly seat area must be ... 19.10 ± 0.05 mm (.752 ± .002 in)

NOTE: Use 6V1541 Quick Cure Primer to clean the water pump shaft and the ceramic ring seal counterbore
in the pump housing.

(3) Ring and water seal.

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Use a 125-9622 Seal Installation Tool and hand pressure to install the rubber seal and ceramic ring as a unit in
the pump housing bore. Make sure the identification mark (holes or groove) on the ceramic ring face is
installed inside the rubber seal.

(4) Seal assembly.

a. Remove the spring from the seal.

b. Put clean water on the seal assembly as the only lubrication for assembly. Do not get any grease or oil on
the seal faces.

c. Do not stretch the rubber of the seal assembly at installation. If the seal is stretched, the service life is
shortened.

d. Use a 125-9622 Seal Installation Tool and hand pressure to install the seal assembly on the pump shaft until
the carbon face makes light contact with the smooth face of the ceramic ring.

NOTE: The carbon seal assembly must rotate with the water pump shaft. Do not use any lubricant (except
clean water) that will reduce the friction between the seal and the shaft.

e. Install the carbon seal assembly spring.

(5) Oil seal. Put a small amount of clean engine oil on the lip of the seal at assembly. Install it with the lip
toward the bearings as shown using a press.

(6) Torque for bolt that holds the gear ... 215 ± 40 N·m (160 ± 30 lb ft)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Typical Example

(1) Pipe plug. Put 9S3263 Thread Lock on the threads of all pipe plugs, and tighten to a torque of ... 80 ± 11
N·m (60 ± 8 lb ft)

(2) Magnetic plug. Install the gasket and/or O-ring for the magnetic drain plug with the seam against the oil
pan. Tighten magnetic drain plug to a torque of ... 70 ± 15 N·m (50 ± 11 lb ft)

(3) Tighten bolts to a torque of ... 55 ± 10 N·m (40 ± 7 lb ft)

NOTE: Retorque all drain plugs with gaskets and/or O-ring at each oil change.

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4P0519 Drain assembly

(1) Lubricate with oil and tighten to a torque of ... 70 ± 13 N·m (50 ± 10 lb ft)

7E4613 Oil Pan Group requires 4P0519 Drain Assembly to be tightened to a torque of ... 95 ± 15 N·m (70 ±
11 lb ft)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

NOTICE

Before operation, the pump must be lubricated with clean engine oil
and the pump must turn freely by hand or damage to parts can be the
result.

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Rotation (seen from the drive end) ... counterclockwise

Test on test stand, with SAE 10W oil at 49°C (120°F)

Output ... 272 liter/min (72 U.S. gpm)

At a pressure of ... 310 kPa (45 psi)

With pump at ... 2550 rpm

Output ... 144 liter/min (38 U.S. gpm)

At a pressure of ... 560 kPa (81 psi)

With pump at ... 2550 rpm

(1) Diameter of drive shaft ... 22.217 ± 0.005 mm (.8747 ± .0002 in)

Bore in bearings for drive shaft ... 22.258 ± 0.008 mm (.8763 ± .0003 in)

Diameter of idler shaft ... 22.217 ± 0.005 mm (.8747 ± .0002 in)

Bore in bearings for idler shaft ... 22.258 ± 0.008 mm (.8763 ± .0003 in)

(2) Length of gears ... 79.375 ± 0.025 mm (3.1250 ± .0010 in)

Depth of bores for gears ... 79.502 ± 0.020 mm (3.1300 ± .0008 in)

(3) 2S2760 Spring (oil pressure relief):

Length under test force ... 117.9 mm (4.64 in)

Test force ... 490 ± 27 N (110 ± 6 lb)

Free length after test ... 152.9 mm (6.02 in)

Outside diameter ... 27.00 mm (1.063 in)

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Pump Body

(4) Bearing junction.

(5) Position of bearing junction from the centerline through bearing bores ... 30 ± 15 degrees

Install bearings so they are even with outside of pump body.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) 4N8150 Spring for bypass valves for oil cooler and oil filter:

Length under test force ... 55.25 mm (2.175 in)

Test force ... 75 ± 5 N (17.0 ± 1.3 lb)

Free length after test ... 93.7 mm (3.69 in)

Outside diameter ... 20.6 mm (.81 in)

Filter and cooler bypass valves to open with a pressure difference of ... 255 ± 20 kPa (37 ± 3 psi)

(2) Tighten four plugs to a torque of ... 100 ± 15 N·m (75 ± 11 lb ft)

(3) Torque for stud:

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Put 9S3263 Thread Lock Compound on threads of the stud and tighten the stud to ... 68 ± 7 N·m (50 ± 5 lb ft)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Shield Position

(1) Manifold shield.

(2) Install shield as shown with short end toward front of engine, but behind manifold bolts by a dimension of
... 50 ± 3 mm (1.97 ± .12 in)

(3) Put 5P3931 Anti-Seize Compound on the threads of the bolts and tighten the nuts to a torque of ... 25 ± 7
N·m (18 ± 5 lb ft)

(4) Front face of block.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Put 5P3931 Anti-Seize Compound on threads of studs.

(1) Tighten nuts in number sequence shown to a torque of ... 38 ± 5 N·m (28 ± 4 lb ft)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) End play for shaft (new) ... 0.114 ± 0.038 mm (.0045 ± .0015 in)

Maximum permissible end play (worn) ... 0.20 mm (.008 in)

(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 5.36 ± 0.03 mm (.211 ± .001 in)

(3) Diameter of shaft (new) ... 15.997 to 16.005 mm (.6298 to .6301 in)

Bore in the bearing (new) ... 16.035 to 16.043 mm (.6313 to .6316 in)

Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002 in)

(4) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.25 mm (.010 in)

(5) Turbocharger impeller installation:

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a. Put impeller on shaft.

b. Put a small amount of clean oil on the threads and impeller face area that contacts the nut.

c. Install and tighten the nut to ... 15.5 ± 1.5 N·m (11 ± 1 lb ft)

NOTICE

Do not bend or add stress to the shaft when the nut is loosened or
tightened.

d. Remove the nut from the shaft.

e. Use 6V1541 Quick Cure Primer on the threads of the shaft and nut.

f. Put 9S3265 Retaining Compound on the threads of the shaft and nut.

g. Install and tighten the nut to ... 4 ± 2 N·m (35 ± 18 lb in)

h. Tighten the nut more ... 90 ± 5 degrees

(6) Thickness of each thrust ring ... 2.553 ± 0.013 mm (.1005 ± .0005 in)

(7) Bore in housing (new) ... 24.994 to 25.006 mm (.9840 to .9845 in)

Outside diameter of the bearing (new) ... 24.882 to 24.892 mm (.9796 to .9800 in)

Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)

Tighten both band clamps (that hold the compressor and turbine housings to the cartridge group) with
procedure that follows:

a. Tighten to ... 14.0 ± 1.1 N·m (10 ± 1 lb ft)

b. Tap (hit) clamp lightly all around.

c. Tighten again to ... 14.0 ± 1.1 N·m (10 ± 1 lb ft)

NOTICE

Do not over tighten the clamps.

Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger to
exhaust manifold ... 55 ± 5 N·m (40 ± 4 lb ft)

NOTE: Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation to provide
start up lubrication and/or storage protection.

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(1) End play for shaft (new) ... 0.114 ± 0.038 mm (.0045 ± .0015 in)

Maximum permissible end play (worn) ... 0.20 mm (.008 in)

(2) Tighten band clamps with procedure that follows:

a. Tighten to ... 13.6 ± 1.1 N·m (10 ± 1 lb ft)

b. Tap (hit) clamp lightly all around.

c. Tighten again to ... 13.6 ± 1.1 N·m (10 ± 1 lb ft)

(3) Thickness of thrust bearing ... 5.36 ± 0.03 mm (.211 ± .001 in)

(4) Diameter of shaft (new) ... 14.254 to 14.262 mm (.5612 to .5615 in)

Bore in the bearing (new) ... 14.293 to 14.300 mm (.5627 to .5630 in)

Maximum permissible clearance between bearing and shaft (worn) ... 0.08 mm (.003 in)

(5) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.23 mm (.009 in)

(6) Bore in housing (new) ... 22.255 to 22.268 mm (.8762 to .8767 in)

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Outside diameter of the bearing (new) ... 22.144 to 22.154 mm (.8718 to .8722 in)

Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)

(7) Turbocharger impeller installation at room temperature:

NOTICE

Do put side force on the shaft when tightening or removing the nut that
holds the compressor wheel in position. Use a universal drive socket
when tightening.

a. With the compressor wheel on the shaft, put a small amount of clean engine oil on the turbine shaft threads
and the compressor wheel face that contact with the nut.

b. Install the nut, and tighten it to a torque of 14 to 17 N·m (10 to 13 lb ft) to push the compressor wheel on to
the shaft.

c. Remove the nut from the shaft. Apply 6V1541 Quick Cure Primer on the threads of the shaft and the nut.

d. Put 9S3265 Retaining Compound on the threads of the shaft and the nut.

NOTICE

Do not let the retaining compound get into the compressor wheel bore
or on the shaft, because it can make removal of the compressor wheel
difficult during future turbocharger disassembly.

e. Install the nut, and tighten it to a torque of 4 N·m (30 lb in). Then tighten the nut an additional 75 degrees
of rotation.

(8) Thickness of each thrust ring ... 2.553 ± 0.013 mm (.1005 ± .0005 in)

(9) Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) ... 55 ± 5 N·m (40 ± 4 lb ft)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Large bolts (3/4 inch). Put 6V4876 Molykote Paste Lubricant on all bolt threads and under all bolt heads.
Tighten the bolts in the following step sequence:

1. Tighten bolts 1 through 14 in number sequence to ... 470 ± 25 N·m (200 ± 20 lb ft)

2. Tighten bolts 1 through 14 in number sequence to ... 470 ± 20 N·m (345 ± 15 lb ft)

3. Tighten bolts 1 through 14 in number sequence again to ... 470 ± 20 N·m (345 ± 15 lb ft)

4. Install the rocker arm shafts for the engine valves.

5. Tighten bolts 15 through 26 in number sequence to ... 270 ± 25 N·m (200 ± 20 lb ft)

6. Tighten bolts 15 through 26 in number sequence to ... 450 ± 20 N·m (330 ± 15 lb ft)

7. Tighten bolts 15 through 26 in number sequence again to ... 450 ± 20 N·m (330 ± 15 lb ft)

8. Tighten the twelve small bolts (2) to ... 45 ± 7 N·m (33 ± 5 lb ft)

(2) Small bolts (3/8 inch). See Step 8 above.

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(3) Torque for twelve studs in cylinder head ... 35 ± 5 N·m (26 ± 4 lb ft)

(4) Thickness of cylinder head (new) ... 112.78 ± 0.25 mm (4.440 ± .010 in)

Minimum permissible thickness of cylinder head ... 111.51 mm (4.390 in)

(5) Torque for six studs that hold fuel line adapter locks ... 17 ± 5 N·m (13 ± 4 lb ft)

NOTE: Flatness of the cylinder head should be within 0.13 mm (.005 in) total, and a maximum of 0.03 mm
(.001 in) for any 76.2 mm (3.00 in) span.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Bore in rocker arm for shaft ... 24.803 ± 0.013 mm (.9765 ± .0005 in)

Diameter of rocker arm shaft ... 24.752 ± 0.013 mm (.9745 ± .0005 in)

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(2) Put 6V4876 Molykote Paste Lubricant on all the threads of bolts that hold rocker arm shafts and tighten
the bolts in the step sequence that follows:

1. Tighten bolts from 1 through 6 in number sequence to ... 270 ± 25 N·m (200 ± 20 lb ft)

2. Tighten bolts from 1 through 6 in number sequence to ... 450 ± 20 N·m (330 ± 15 lb ft)

3. Tighten bolts from 1 through 6 in number sequence again to ... 450 ± 20 N·m (330 ± 15 lb ft)

(3) Torque for locknut for valve adjustment screw ... 30 ± 4 N·m (22 ± 3 lb ft)

(4) Torque for locknut for bridge adjustment screw ... 30 ± 4 N·m (22 ± 3 lb ft)

(5) Valve Lash:

Inlet valves ... 0.38 mm (.015 in)

Exhaust valves ... 0.76 mm (.030 in)

(6) Height to top of dowel ... 53.3 ± 0.5 mm (2.10 ± .02 in)

(7) Diameter of dowel ... 11.008 ± 0.003 mm (.4334 ± .0001 in)

Bore in bridge for dowel ... 11.13 ± 0.05 mm (.438 ± .002 in)

Bore in head for dowel ... 10.968 ± 0.020 mm (.4318 ± .0008 in)

(8) Diameter of valve lifter ... 27.896 ± 0.013 mm (1.0983 ± .0005 in)

Bore in block for valve lifter ... 27.953 ± 0.019 mm (1.1005 ± .0008 in)

NOTE: See Guideline For Reusable Parts; Salvage Of Lifter Bores In 3400 Series Engines, SEBF8069 for the
procedure, tooling and specifications needed to install 4W4588 Sleeves for salvage of the lifter bores in the
cylinder block.

(9) Guide springs must not be used again. Always install new guide springs.

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(10) 2N7229 Spring:

Length under test force ... 74.2 mm (2.92 in)

Test force ... 45 to 53 N (10 to 12 lb)

Free length after test ... 114.3 mm (4.50 in)

Outside diameter ... 29.7 mm (1.17 in)

(11) Dowel length above top surface of rocker shaft support to be ... 12.7 ± 1.0 mm (.50 ± .04 in)

(12) Clearance for rocker arms (both ends) ... 0.30 to 1.40 mm (.012 to .055 in)

(13) Use 2N7228 Washer as needed to get clearance (12).

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Typical Example

(A) Minimum dimension after reconditioning ... 16.51 mm (.650 in)

(B) Allowable wear before reconditioning ... 0.13 mm (.005 in)

Inspect the bridge seats for wear. Use the bridge again if the wear is 0.13 mm (.005 in) or less. When the wear
seat is worn more than the allowable limit, the worn surface of the seat can be ground flat. The maximum
amount of material that can be removed is 0.38 mm (.015 in). If the seat cannot be made flat, replace the
bridge. Reconditioning of the wear seat can only be done once.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Typical Example

NOTE: Guidelines For Reusable Parts; Valves And Valve Springs, SEBF8002 and SEBF8034 have the
procedure and specifications necessary for checking used valves and valve springs.

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(1) 4W2471 Spring for valves (outer) (new):

Length under test force ... 53.24 mm (2.096 in)

Test force ... 245 ± 24 N (55 ± 5 lb)

Length of spring at valve open position ... 39.0 mm (1.54 in)

Use again minimum load at valve open position ... 805 ± 40 N (181 ± 9 lb)

Free length after test ... 59.5 mm (2.34 in)

Outside diameter ... 37.31 mm (1.469 in)

(1) 4W2472 Spring for valves (inner) (new):

Length under test force ... 50.24 mm (1.978 in)

Test force ... 178 ± 18 N (40 ± 4 lb)

Length of spring at valve open position ... 36.0 mm (1.42 in)

Use again minimum load at valve open position ... 343 ± 17 N (77 ± 4 lb)

Free length after test ... 65.7 mm (2.60 in)

Outside diameter ... 25.13 mm (.989 in)

(2) Height to top of valve guide ... 27.2 ± 0.8 mm (1.07 ± .03 in)

(3) Diameter of valve stem (new) ... 9.441 ± 0.010 mm (.3717 ± .0004 in)

Use again minimum diameter of valve stems:

Exhaust ... 9.408 mm (.3704 in)

Inlet ... 9.408 mm (.3704 in)

Bore in valve guide with guide installed in the head (new) ... 9.487 ± 0.025 mm (.3735 ± .0010 in)

Use again dimension for valve guide bore (measured .750 from end of guide) ... 9.538 mm (.3755 in)

(4) Diameter of valve head:

Exhaust valve ... 41.81 ± 0.13 mm (1.646 ± .005 in)

Inlet valve ... 44.98 ± 0.13 mm (1.771 ± .005 in)

(5) Angle of inlet valve face ... 29 1/4 ± 1/4 degrees

Angle of exhaust valve face ... 44 1/4 ± 1/4 degrees

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(6) Depth of bore in head for valve seat insert ... 13.01 ± 0.35 mm (.512 ± .014 in)

(7) Diameter of valve seat insert for inlet valve ... 46.025 ± 0.013 mm (1.8120 ± .0005 in)

Bore in head for valve seat insert for inlet valve ... 45.949 ± 0.025 mm (1.8090 ± .0010 in)

Diameter of valve seat insert for exhaust valve ... 42.850 ± 0.013 mm (1.6870 ± .0005 in)

Bore in head for valve seat insert for exhaust valve ... 42.774 ± 0.025 mm (1.6840 ± .0010 in)

(8) Angle of face of inlet valve seat insert ... 30 ± 1 degrees

Angle of face of exhaust valve seat insert ... 45 ± 1 degrees

(9) Dimension from end of closed valve to machined face of head.

Maximum permissible dimension:

New inlet and exhaust valves.

Below (recessed from) machined face ... 1.22 mm (.048 in)

Above (extended from) machined face ... 0.04 mm (.0016 in)

Reconditioned inlet and exhaust valves.

Below (recessed from) machined face ... 1.70 mm (.067 in)

Above (extended from) machined face ... 0.04 mm (.0016 in)

(10) Outside diameter of the face of the valve seat insert:

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Exhaust seat ... 39.268 ± 0.013 mm (1.5460 ± .0005 in)

Inlet seat ... 40.894 ± 0.013 mm (1.6100 ± .0005 in)

(11) "Use again" thickness of valve lip:

Exhaust valve ... 2.06 mm (.081 in)

Inlet valve ... 2.51 mm (.099 in)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Typical Example

(1) Torque for the bolts that hold valve covers and cover bases in position ... 18 ± 3 N·m (13 ± 2 lb ft)

NOTE: Cut valve cover seals and cover base seals to fit at assembly. Coat joints with 3S6252 sealant.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Tighten clamp to a torque of ... 4.5 ± 0.5 N·m (40 ± 4 lb in)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Inside diameter of camshaft bearings 2 through 7 (after assembly) ... 69.982 ± 0.061 mm (2.7552 ± .0024
in)

(2) Centerline of No. 1 cylinder.

(3) Inside diameter of the front camshaft bearing (after assembly) ... 69.969 ± 0.048 (2.7547 ± .0019 in)

(4) Front surface of cylinder block.

Dimension from the front surface of the cylinder block to install the camshaft bearings.

(A) ... 1039.1 ± 0.5 mm (40.91 ± .02 in)

(B) ... 867.7 ± 0.5 mm (34.16 ± .02 in)

(C) ... 696.2 ± 0.5 mm (27.41 ± .02 in)

(D) ... 524.8 ± 0.5 mm (20.66 ± .02 in)

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(E) ... 353.3 ± 0.5 mm (13.91 ± .02 in)

(F) ... 181.9 ± 0.5 mm (7.16 ± .02 in)

(G) ... 2.8 ± 0.5 mm (.11 ± .02 in)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Gear. If new gear is required, replace camshaft assembly. The heat treatment of the gear is damaged if
heated.

(2) Diameter of the surfaces (journals) for the camshaft bearings (new) ... 69.850 ± 0.013 mm (2.7500 ± .0005
in)

Bore in front bearing for the camshaft (after assembly) ... 69.969 ± 0.048 mm (2.7547 ± .0019 in)

Bore in the other six bearings for the camshaft (after assembly) ... 69.982 ± 0.061 mm (2.7552 ± .0024 in)

(3) Thickness of thrust plate (new) ... 4.65 ± 0.03 mm (.183 ± .001 in)

Thickness of groove in camshaft for thrust plate (new) ... 4.83 ± 0.06 mm (.190 ± .002 in)

End play of the camshaft ... 0.10 to 0.26 mm (.004 to .010 in)

(4) Camshaft.

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(5) Height of camshaft lobes.

To find lobe height, use the procedure that follows:

A. Measure camshaft lobe height (5).

B. Measure base circle (7).

C. Subtract base circle (STEP B) from lobe height (STEP A). The difference is actual lobe lift (6).

D. Specified camshaft lobe lift (6) is:

a. Exhaust lobe ... 10.210 mm (.4019 in)

b. Inlet lobe ... 10.212 mm (.4021 in)

Maximum permissible difference between actual lobe lift (STEP C) and specified lobe lift (STEP D) is 0.13
mm (.005 in).

1. Check the No. 1 inlet valve lash with the engine stopped. The valve lash must be 0.30 to 0.46 mm (.012 to
.018 in). If the valve lash is not in this range, adjust the lash to 0.38 mm (.015 in).

2. Mark Top Center Position of the crankshaft of the vibration damper or pulley.

3. Use a dial indicator to measure the inlet valve movement.

4. Rotate the crankshaft in the direction of normal engine rotation. Stop when the inlet valve is 1.91 mm (.075

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in) off its seat in the opening sequence.

At this point the crankshaft Top Center Position Mark must be ... 1 ± 2 degrees After Top Center

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

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(1) Bore in bearing of gear (after assembly) ... 63.602 ± 0.038 mm (2.5040 ± .0015 in)

Diameter of bearing surface of the shaft ... 63.500 ± 0.013 mm (2.5000 ± .0005 in)

(2) Install bearing from face of gear to a depth of ... 1.5 ± 0.5 mm (.06 ± .02 in)

(3) Length of gear ... 50.75 ± 0.05 mm (1.996 ± .002 in)

Length of bearing surface of the shaft ... 51.00 ± 0.05 mm (2.008 ± .002 in)

(4) Front (spacer) plate between cylinder block and front housing.

(5) Rear face of front housing.

(6) Tighten adapter studs to a torque of ... 35 ± 5 N·m (26 ± 4 lb ft)

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(1) Tighten stud to a torque of ... 55 ± 10 N·m (40 ± 7 lb ft)

Typical Example

(1) When 4N3852 Cover from 1N3970 Accessory Drive Group is installed, tighten the bolts to a torque of ...
30 ± 3 N·m (22 ± 2 lb ft)

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(1) Accessory Drive.

(2) Tighten air compressor crankshaft nut to a torque of ... 150 ± 20 N·m (110 ± 15 lb ft)

Hit end of air compressor crankshaft with hammer and again tighten nut to a torque of ... 150 ± 20 N·m (110
± 15 lb ft)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Drive gear for water pump.

(2) Idler gear assembly. Idler gear for water pump.

(3) Idler gear for camshaft. Part of idler gear assembly (2).

(4) "K" marks must be seen from front of engine when gears are in alignment as shown. Top center for the
No. 1 cylinder.

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(5) Camshaft gear.

(6) Air compressor drive gear.

(7) Idler gear for air compressor drive.

(8) Drive gear for fuel pump.

(9) Crankshaft gear.

(10) Drive gear for oil pump.

(11) Torque for bolt ... 55 ± 10 N·m (40 ± 7 lb ft)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Typical Example

NOTE: Cut gaskets even with the bottom of front housing and front plate after the housing is installed on the
engine.

(1) Tighten two studs to a torque of ... 55 ± 5 N·m (40 ± 4 lb ft)

(2) Put 9S3263 Thread Lock on the threads of the studs. Two studs must be installed to extend above the
housing surface to a dimension of ... 28.5 ± 1.5 mm (1.12 ± .06 in)

(3) Put 9S3263 Thread Lock on the threads of the stud. The stud must be installed to extend above the

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housing surface to a dimension of ... 37.0 ± 1.5 mm (1.46 ± .06 in)

(4) Five studs marked "X" must be installed to extend above the housing surface to a dimension of ... 28.5 ±
1.5 mm (1.12 ± .06 in)

Tighten studs to a torque of ... 35 ± 5 N·m (26 ± 4 lb ft)

NOTE: Put 9S3263 Thread Lock on the stud serrations and each side of the gasket prior to assembly.

NOTE: Heads of studs must not be more than 4.5 mm (.18 in) above the surface of the timing gear plate after
installation.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Bore in bearing of gear (after assembly) ... 63.602 ± 0.038 mm (2.5040 ± .0015 in)

Diameter of bearing surface of the shaft ... 63.500 ± 0.013 mm (2.5000 ± .0005 in)

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(2) Install bearing from rear face of gear assembly to a depth of ... 1.5 ± 0.5 mm (.06 ± .02 in)

(3) Length of gear ... 47.60 ± 0.05 mm (1.874 ± .002 in)

Length of the bearing surface of the shaft ... 47.85 ± 0.05 mm (1.884 ± .002 in)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Distance from vertical centerline of dowel hole to vertical centerline of pilot bore ... 186.33 (7.336 in)

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(2) Bore in cylinder block for idler gear shaft pilot ... 31.750 ± 0.025 mm (1.2500 ± .0010 in)

Depth of bore from surface of cylinder block ... 11.9 ± 2.5 mm (.47 ± .10 in)

Diameter of idler gear shaft pilot ... 31.687 ± 0.025 mm (1.2475 ± .0010 in)

(3) Tighten bolts that hold idler gear shaft in position to ... 55 ± 10 N·m (40 ± 7 lb ft)

(4) Distance from horizontal centerline of dowel and crankshaft to horizontal centerline of pilot bore ...
247.02 mm (9.725 in)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Stud (two). Used when filter base is installed high on aftercooler housing. Install stud so end of stud
extends above surface of aftercooler housing boss to a dimension of ... 24.3 ± 1.5 mm (.96 ± .06 in)

(2) Put 9S3265 Retaining Compound on the tapered end of stud to a distance of ... 7.6 mm (.30 in)

(3) Sealing surface of stud.

NOTE: Do not damage this surface.

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(4) Distance from sealing surface of base to end of stud ... 24.6 ± 1.3 mm (.97 ± .05 in)

(5) Torque for stud ... 70 ± 15 N·m (50 ± 11 lb ft)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Torque for nut ... 25 ± 5 N·m (18 ± 3 lb ft)

(2) 7S9323 Spring:

Length under test force ... 27.9 mm (1.10 in)

Test force ... 125 to 145 N (28 to 33 lb)

Free length after test ... 42.7 mm (1.68 in)

Outside diameter ... 17.3 mm (.68 in)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

NOTE: For the correct timing specifications to use for adjustment of the automatic timing advance unit, see
the Engine Information Plate, TMI (Technical Marketing Information), or Fuel Setting And Related
Information Fiche.

(1) 1W5427 Spring:

Length under test force ... 62.0 mm (2.44 in)

Test force ... 391 ± 20 N (87.9 ± 4.5 lb)

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Free length after test ... 81.96 ± 1.31 mm (3.228 ± .052 in)

Outside diameter ... 97 mm (3.82 in)

(2) Torque for four bolts ... 12 ± 4 N·m (9 ± 3 lb ft)

(3) Torque for plug ... 70 ± 15 N·m (50 ± 11 lb ft)

(4) Torque for nut ... 4.5 ± 0.5 N·m (39.82 ± 4.43 lb in)

(5) Torque for nut ... 70 ± 15 N·m (50 ± 11 lb ft)

(6) 4P1358 Spring:

Length under test force ... 39.0 mm (1.54 in)

Test force ... 12.2 ± 0.6 N (2.74 ± .14 lb)

Free length after test ... 42.25 mm (1.66 in)

Outside diameter ... 15.4 mm (.61 in)

Color code (stripes) ... one yellow, one red

(7) Bolts that hold flyweight carriers.

(8) Torque for four bolts ... 55 ± 7 N·m (40 ± 5 lb ft)

(1) Torque for eight bolts ... 55 ± 10 N·m (40 ± 7 lb ft)

(2) Tighten hub on body (3) to a torque of ... 950 ± 95 N·m (700 ± 70 lb ft)

(3) Body.

(4) Torque for eight bolts ... 13 ± 3 N·m (10 ± 2 lb ft)

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NOTE: Lubricate all seals lightly with engine oil.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

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(1) Setscrew. Adjustment for fuel ratio control.

(2) Nut. Tighten to a torque of ... 1.70 ± 0.25 N·m (15 ± 2 lb in)

(3) Lever for manual shutoff.

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(4) Setscrew. Adjustment for dimension (6).

(5) Nut. Tighten to a torque of ... 1.70 ± 0.25 N·m (15 ± 2 lb in)

(6) Dimension at shutoff. With manual shutoff lever (3) at the maximum shutoff position, the distance from
the end of the lever assembly to the face of the rear governor housing must be ... 28.8 ± 0.5 mm (1.13 ± .02
in)

NOTE: Make sure setscrew (4) is adjusted to give dimension (6) at assembly.

(7) Setscrew. This setscrew is used for the adjustment of dimension (6) on engines that use a shutoff detent.

(8) Nut. Tighten to a torque of ... 1.70 ± 0.25 N·m (15 ± 2 lb in)

(9) Broken link spring. See the Miscellaneous Spring Chart.

(10) Torque for screws ... 3.4 ± 0.5 N·m (31 ± 4 lb in)

(11) Centering spring. See the Miscellaneous Spring Chart.

(12) Guide. The distance from the end of the guide to the housing gasket surface is dimension (14) ... 11.80 ±
0.25 mm (.464 ± .010 in)

(13) Dashpot spring. See the Miscellaneous Spring Chart.

(15) Governor spring. See the Governor Spring Chart.

(16) Tighten the insulated terminal in governor housing to a torque of ... 3.4 ± 0.5 N·m (31 ± 4 lb in)

(17) Setscrew. Adjustment for torque rise setting.

(18) Setscrew. Adjustment for fuel setting.

(19) Nut. Tighten the nut on setscrews (17) and (18) to a torque of ... 1.70 ± 0.25 N·m (15 ± 2 lb in)

(20) Bumper spring. See the Miscellaneous Spring Chart.

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(21) Lever. Install the shutoff lever as illustrated. Angle (A) and angle (B) from the vertical centerline must be
... 30 degrees

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

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(1) Distance from end of dowel to the opposite wall of the bore ... 40.40 ± 0.18 mm (1.591 ± .007 in)

(2) Dowel.

(3) Distance from flat surface of rack bearing to opposite wall of the bore ... 11.178 ± 0.050 mm (.4401 ±
.0020 in)

(4) Rack bearing in drive end of fuel pump housing.

(5) Install bearing with flat surface (as shown) to an angle of ... 15 degrees

NOTE: The 6V4824 Driver and 6V4825 Plate are available to install the rack bearing to the correct angle and
depth.

(6) Distance from the end of pin to the opposite wall of the bore ... 35.57 ± 0.10 mm (1.400 ± .004 in)

(7) Distance from the governor end of the housing to the end of the dowel ... 7.5 ± 0.5 mm (.30 ± .02 in)

(8) Distance from the drive end housing face to the drive end rack bearing ... 83.0 ± 0.5 mm (3.27 ± .02 in)

Inside diameter of bearing (after assembly) ... 12.767 ± 0.058 mm (.5026 ± .0023 in)

(9) Distance from the governor end housing face to the governor end rack bearing ... 6.50 ± 0.13 mm (.256 ±
.005 in)

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Inside diameter of the bearing (after assembly) ... 12.746 ± 0.045 mm (.5018 ± .0018 in)

(10) Position of oil supply hole for three camshaft bearings ... 30 ± 3 degrees

(11) Inside diameter of three fuel pump camshaft bearings (after assembly) ... 74.089 ± 0.039 mm (2.9169 ±
.0015 in)

(12) Distance from surface of bore to end of camshaft bearing ... 1.00 ± 0.50 mm (.039 ± .020 in)

(13) Distance from surface of bore to end of center camshaft bearing ... 218.0 ± 0.3 mm (8.58 ± .01 in)

(14) Distance from governor end of housing to the end of the camshaft bearing ... 1.00 ± 0.25 mm (.039 ±
.010 in)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

NOTE: For the correct timing specifications for the adjustment of the fuel injection pump, see Engine
Information Plate, TMI (Technical Marketing Information), or Fuel Setting And Related Information Fiche.

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Tighten the two 9S8007 Plugs in the engine side of the pump housing to a torque of ... 5 ± 1 N·m (44 ± 9 lb in)

(1) Torque for bushing ... 270 ± 13 N·m (200 ± 10 lb ft)

(2) 8N5993 Spring (reverse flow check valve):

Length under test force ... 11.50 mm (.453 in)

Test force ... 151 ± 8 N (34.2 ± 1.8 lb)

Free length after test ... 15.81 mm (.622 in)

Outside diameter ... 10.36 mm (.408 in)

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(3) Thickness of 7E9907 Spacer ... 6.761 ± 0.005 mm (.2662 ± .0002 in)

(4) Torque for cover bolts ... 14 ± 4 N·m (10 ± 3 lb ft)

(5) Length of pump plunger (new) ... 77.423 ± 0.013 mm (3.0481 ± .0005 in)

(6) 118-0540 Spring (lifter):

Length under test force ... 48.87 mm (1.924 in)

Test force ... 210 ± 10 N (47 ± 2 lb)

Free length after test ... 53.87 mm (2.121 in)

Outside diameter ... 34.21 mm (1.347 in)

(7) Bore for the rack and diameter of the rack:

Bore in bearing (after installation) in governor end of housing ... 12.746 ± 0.045 mm (.5018 ± .0018 in)

Bore in bearing (after installation) in drive end of housing ... 12.767 ± 0.058 mm (.5026 ± .0023 in)

Diameter of rack (new) ... 12.662 ± 0.005 mm (.4985 ± .0005 in)

(8) Bore in bearings for camshaft (after assembly) ... 74.089 ± 0.039 mm (2.9169 ± .0015 in)

Diameter of bearing surfaces of the camshaft ... 74.000 ± 0.013 mm (2.9134 ± .0005 in)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Clearance between guide and tappet ... 0.0025 to 0.0101 mm (.0001 to .0004 in)

NOTE: The guide and tappet are a matched set. If one part is worn, a new guide and tappet assembly must be
installed.

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(2) Bore in sleeve for the piston ... 34.000 ± 0.015 mm (1.3386 ± .0006 in)

Diameter of piston ... 33.972 ± 0.008 mm (1.3375 ± .0003 in)

(3) 7W0134 Spring:

Length under test force ... 33.67 mm (1.326 in)

Test force ... 221 ± 11 N (49.7 ± 2.5 lb)

Free length after test ... 56.1 mm (2.21 in)

Outside diameter ... 27.4 mm (1.08 in)

(4) Fuel inlet port.

(5) Check valves.

(6) Fuel outlet port.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Torque for fuel injection line nut ... 42 ± 7 N·m (31 ± 5 lb ft)

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(2) Torque for retainer ... 48 ± 7 N·m (35 ± 5 lb ft)

(3) Tighten bleed screw to a torque of ... 2.7 ± 0.8 N·m (24 ± 7 lb in)

Always use a new washer (seal) anytime the bleed screw is removed.

(4) Washer. Make sure the correct washer is used when the nozzle assembly is installed.

(5) Put liquid soap on the rubber O-ring seal and in the bore in the head before assembly.

(6) Put 5P3931 Anti-Seize Compound on the threads of the adapter before installation. Torque for the adapter
... 200 ± 14 N·m (150 ± 10 lb ft)

Torque for the nut on the adapter assembly ... 72 ± 7 N·m (53 ± 5 lb ft)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Fuel Injection Line With Support Bracket

Be sure the fuel injection line clamps are installed in the correct
locations. Incorrectly installed clamps may allow the fuel injection lines
to vibrate and become damaged. The damaged lines may leak and cause
a fire.

(1) Clamp location dimensions are in reference to a vertical line (1) through the center of the number one fuel
pump outlet.

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Align brackets in position to fuel lines such that when the fasteners are tightened no strain will be added to
the fuel lines while tightening fasteners.

(A) ... 35 ± 3 mm (1.38 ± .12 in)

(B) ... 165 ± 13 mm (6.50 ± .51 in)

(C) ... 187 ± 1 mm (7.36 ± .04 in)

(D) ... 187 ± 3 mm (7.36 ± .12 in)

(E) ... 282 ± 3 mm (11.10 ± .12 in)

(F) ... 286 ± 3 mm (11.26 ± .12 in)

(G) ... 529 ± 3 mm (17.99 ± .12 in)

Tighten metal-to-metal clamps to a torque of ... 2.3 N·m (20 lb in)

NOTE: The 6V4980 Torque Screwdriver Tool Group is available for applying the correct torque.

(2) Tighten fuel injection line nuts to ... 42 ± 7 N·m (31 ± 5 lb ft)

(3) Tighten nuts to ... 14 ± 3 N·m (10 ± 2 lb ft)

(4) Tighten retainer on adapter to ... 48 ± 7 N·m (35 ± 5 lb ft)

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

Cylinder and Valve Location

Bore ... 137 mm (5.4 in)

Stroke ... 165 mm (6.5 in)

Displacement ... 14.6 liter (893 cu in)

Number and Arrangement of Cylinders ... 6, Inline

Firing Order (Injection Sequence) ... 1,5,3,6,2,4

Rotation of Crankshaft (when viewed from flywheel end) ... Counterclockwise

Rotation of Fuel Pump Camshaft (when viewed from pump drive end) ... Counterclockwise

NOTE: Front end of engine is opposite to flywheel end. Left side and right side of engine are as seen from
flywheel end. No. 1 cylinder is the front cylinder.

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Product: GEN SET ENGINE

Model: 3406C GEN SET ENGINE 4ZR
Configuration: 3406C Generator Set 4ZR00001-UP

Specifications
3406C GENERATOR SET ENGINE
Media Number -SENR1102-00 Publication Date -13/02/1996 Date Updated -11/10/2001

(1) Lubricate seal with engine oil.

Shaft rotation (from shaft end of Service Meter) ... CCW

Engine rpm (1533 rpm for 60 minutes) ... one count

Engine rpm (1800 rpm for 60 minutes) ... one count

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