0314595 JOHNSON CASE, Owner card

Start By:a. remove fuel injection linesb. remove fuel filter and basec. remove fuel transfer pump FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates. The following illustrations are of a 3304 Engine. 1. Disconnect the governor control linkage from the governor.2. On 3304 Engines only: remove oil supply line (1), oil drain line (2) and heat shield (3). Cap and plug all openings immediately. Remove the O-ring seal from oil drain line (2) if it is damaged. Remove the gaskets and screen from the top of the turbocharger.3. Disconnect fuel drain lines (4) and (5) from the fuel injection pump housing and governor. Cap and plug all openings immediately. 4. Remove the nuts, washers and cover from the timing gear housing. Remove studs (6) if they are damaged or loose.5. Loosen bolt (7) enough to leave a gap of 3.18 mm (.125 in) between washer (8) and the fuel pump drive gear.6. Install Tooling (A) as shown. Tighten the stud to pull the fuel pump drive gear loose from the taper on the fuel injection pump camshaft.7. Remove Tooling (A), bolt (7) and washer (8) from the engine. 8. Fasten a nylon strap and hoist to the fuel injection pump housing and governor. The 3304 fuel injection pump housing and governor weighs 24 kg (53 lb). The 3306 fuel injection pump housing and governor weighs 29 kg (64 lb).9. Remove bolt (9), bolt (10), three nuts (11) and the fuel injection pump housing and governor. Remove the two O-ring seals from the bottom and the two O-ring seals from the front of the fuel injection pump housing and governor.Install Fuel Injection Pump Housing & Governor
The following illustrations are of a 3304 Engine. 1. Put clean engine oil on the O-ring seals. Install O-ring seals (1) in the bottom and O-ring seals (2) in the front of the fuel injection pump housing and governor. 2. Make sure O-ring seals (1) and (2) stay in position in the fuel injection pump housing and governor. Fasten a hoist to the fuel injection pump housing and governor, and put it in position on the engine. Install the two bolts at location (5) and the three nuts on studs (3) to hold the fuel injection pump housing and governor in position.3. Remove the bolts that hold cover (4) in position. Remove cover (4) and the gasket. 4. Put Tooling (A) in position as shown. Install the bolt that holds the fuel pump drive gear to the fuel injection pump camshaft without the washer. This will allow the camshaft in the fuel system to be turned.5. Put pressure on the end of Tool (A) and turn the camshaft slowly until the tool drops into the groove (slot) in the camshaft. Leave Tool (A) in position in the groove (slot). Remove the bolt from the end of the camshaft. 6. Install washer (6) with the large diameter toward the front of the engine. Install bolt (7) and tighten it to a torque of 6.8 N m (60 lb in).7. Install Tooling (B) as shown in the flywheel housing. Make sure bolt (7) does not loosen as the flywheel is turned.8. Use Tooling (B), and turn the flywheel in the direction of engine rotation until bolt (8) 3/8 [" - 16 NC x 4 in. (102 mm) Long] can be installed in the flywheel. Do not turn the crankshaft counterclockwise to get bolt hole alignment.9. If you go past the bolt hole in the flywheel, turn the crankshaft counterclockwise opposite the direction of engine rotation (as seen from the front of the engine) approximately 30 degrees. This procedure will permit the (backlash) gear clearance to be removed from the timing gears when the crankshaft is turned in the direction of engine rotation (clockwise).10. Loosen the clamp and bolt that hold the breather cap to the valve cover. Remove the breather cap and O-ring seal from the valve cover. The No. 1 piston is at top center on the compression stroke when the bolt can be put in the flywheel through the hole in the flywheel housing, and both rocker arms for the No. 1 piston can be moved by hand (have clearance with the valve stem).11. When both rocker arms are loose, tighten bolt (7) to a torque of 270 25 N m (199 18 lb ft).12. Remove Tooling (A) and (B) and bolt (8) from the engine. 13. Put the O-ring seal and breather cap (11) in position on the valve cover and the hose. Install hose clamp (10) and bolt (9). Tighten bolt (9) to a torque of 14 3 N m (10 2 lb ft).14. If studs (12) were removed, put 5P-3413 Pipe Sealant with Teflon on them, and install them in the timing gear cover. Put the gasket and cover (13) in position, and install the washers and nuts that hold them. Tighten the nuts to a torque of 27 7 N m (20 5 lb ft). 15. Install the gasket, cover (17) and the bolts that hold it.16. Connect fuel drain lines (16) and (18). Install heat shield (19).17. On 3304 Engines, install the strainer assembly in the turbocharger with the screen down. Install the gasket, oil inlet line and the bolts that hold them. Install the O-ring seal on oil drain line (15). Put clean engine oil on the O-ring seal and install the gasket, oil drain line and the bolts that hold them. Install the clamp that holds the oil lines together.18. Connect the governor control linkage to the fuel injection pump housing and governor.End By:a. install fuel