Steve wrote:

Vandalism definitely came to mind as the exhaust pipe was flat black without a stain after I removed muffler, and the paper elements on the air cleaners were not damaged. I did not spend much time on it today but I did note a grey film around one of the rod journal's and that rod was sloppy. Saturday I be back at it.

The rear rod? next to the flywheel?

check the rod(s) bearing(s) furthest from the oil pump....almost always the first damaged and the worst...(small block and big block Chev again, sorry)

rain flaps are not always water tight and driving rain can blow in past them. that's why most old tractors had a drain hole drilled in the low parts of the manifold to stop that but the holes block with oil and soot need to be cleared regularly.
another spot can be past the nut on the air hat if the drain hole in the air cleaner is blocked clean regularly. vandals are also a possibility.

Today I removed the number 3 rod cap from the radiator and it is ugly, I think its time to make plans for engine removal and proper overhaul. I have a owners / maintenance manual on the way. Does anyone have a service manual they would sell. Can someone that has done this give me pointers or some guidance on pulling this engine.

It's been a few years since I had an engine out of a 943, if memory serves me right I could do it in a morning with the right tools and lifting equipment, a brief summary: jack the cab up and put the safety strut in place,
Remove batteries and battery boxes, exhaust and hood, disconnect rad hoses and oil cooler pipes , the radiator and oil cooler lift off as a unit (heavy), unbolt compressor (if fitted) and move to one side, unbolt hydraulic pump and tie back(no need to disconnect hoses) , disconnect wiring loom, unbolt bell housing and engine mounts and slide out.

Hope this helps

shovel man

those shells are knackered rebuild time. you may be able to do a in frame job since you've got the sump off and it does turn over? you should be able to remove the pistons etc from above after the head is off

Getting things ready to remove engine and I discovered where the water came from.

I noted the air intake pipe is routed through a rib in the hood that's about 2 inches thick, in that space the intake pipe is rusted through. I believe this rib is functioning as a drain directing water it into the air intake.

trainzkid88 wrote:

those shells are knackered rebuild time. you may be able to do a in frame job since you've got the sump off and it does turn over? you should be able to remove the pistons etc from above after the head is off

No in frame on the 3204 if cylinder bores need attention. Engine has to come out for rebore, there are no removable liners.

As Old Magnet has stated the 3204 is a parent metal block no liners, if needed you can either rebore and fit oversized Pistons or bore it out larger and sleeve it back to standard, I've always used 3 ring Pistons on a rebuild (IPD I think) , the other thing that is important on a 3204 is con rods, the small end is tapered and prone to failure, I've always fitted re-man con rods on a re-build I don't know if Caterpillar still offer that option , the other bit of advice I can offer is to fit Cat gaskets in the oil cooler, the pattern part gaskets don't last.

Update

Engine out, dissembled and cleaned, short block is out to have sleeves replaced, yes it has dry sleeves installed, Crank has damage from 2 spun rod bearings, I need to get it to a Crank shop to see if they can be ground or if I need to get the journals welded up. New Crank is just as much as the rest of a aftermarket OH kit. The head looks good just a typical valve grind, Guides are tight, will get it magnafluxed to be sure. Cam shaft and lifters are like new. Eager to make progress.