90004-ZZ3-000 Honda BOLT, STUD (8X32)

Introduction
This instruction lists the parts, tools, machining dimensions, and installation procedures to modify 3406 Engine water pumps, equipped with a 9N-5034 Housing, to install a 108-7930 Tapered Roller Bearing Assembly.The machining operations and parts installation, as outlined in this instruction, update the original water pump to current production design. Current Caterpillar Remanufactured 3406 Engine water pumps feature the 108-7930 Tapered Roller Bearing Assembly.If available, Caterpillar recommends using remanufactured water pumps.Parts and Tools Required
Disassembly
1. Remove the water pump from engine.2. Disassembly the water pump.Refer to the procedures in the Disassembly & Assembly module of the Service Manual.Component Cleaning
The water pump must be thoroughly cleaned before any machining operations.Machining Operation(s)
Modified 9N-5034 Housing1. Machine bearing bore to a semi-finish diameter (A) of 74.012 0.013 mm (2.910 0.0005 in) on the centerline of the pump shaft to a depth (B) of 15.00 0.13 mm (0.590 0.005 in) from the face of the housing.The new semi-finished bore should have a F (85-125 Ra, micro inches) surface finish.This operation will remove 2.00 mm (0.079 in) of material from the inside diameter of the original bore. The diameter of the new bore MUST be concentric with the coolant seal bore within 0.100 mm (0.0039 in).2. Press the 102-5944 Sleeve into the machined bore until it is flush with the face of the housing. Use an arbor press or appropriate tool to apply an EVEN force to seat the sleeve concentrically with the bore.3. Finish machine 102-5944 Sleeve to a diameter (C) of 69.075 0.013 mm (2.720 0.0005 in) on the centerline of the water pump shaft, to a depth (D) of 36.58 0.10 mm (1.440 0.0039 in).The new finish machined bore should have a F (85-125 Ra, micro inches) surface finish.This operation will remove 0.775 mm (0.0305 in) of material from the inside diameter of the original bore. The diameter of this finish bore MUST be concentric with the seal bore within 0.100 mm (0.0039 in).Assembly Procedures
3406 Water Pump With 9N-5034 Housing Use a new oil seal and coolant seal assembly.1. Use the 1P-0510 Driver Group to install new oil seal (1) into the pump housing.Install the seal with the lip toward the bearing bore of the housing.The edge of the seal shell should be flush with the housing surface.Inspect the seal after installation to ensure the seal is fully seated in the bore.2. Install shaft (2) in the pump housing, making sure the oil seal lip does not get cut or rolled.3. Install 108-7930 Bearing Assembly (3) over shaft (2).4. Position 103-1248 Spacer Plate (4) and 102-5945 Retainer (5) over shaft.Align the holes of 103-1248 Spacer Plate (4) and 102-5945 Retainer (5) with the mounting holes in the housing.5. Install four mounting bolts (6) and tighten to a torque of 25 6 N m (18.5 4.5 lb ft).6. Install drive gear (7) on the shaft.7. Install retainer (8) and bolt (9) and tighten to a torque of 215 40 N m (160 30 lb ft).8. Turn the housing over and remove the spring from the rotating portion of the coolant seal assembly (10).9. Use the flat (not counterbored) end of the 2W-9102 Seal Installation Tool to install the stationary seal and cup of the coolant seal assembly (10) in the bore of the housing. Use ONLY CLEAN water as a lubricate when installing the stationary and rotary parts of the coolant seal assembly. Do NOT touch the faces of the seal.10. Install the rotating part of the seal on the shaft with the counterbored end of the 2W-9102 Seal Installation Tool using hand pressure.11. Inspect to ensure the rotary seal face is in contact with the stationary seal face.12. Install the spring (removed in Step 8) on the seal.13. Install impeller (11), washer (12) and bolt (13) and tighten to a torque of 39 3 N m (29 2 lb ft).14. After assembly is complete be sure the impeller/shaft/gear rotate freely.